USER MANUAL DRILL SERGEANT - Angle-Drilling System MODEL: ADS4590 - Shopify
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USER MANUAL DRILL SERGEANT Angle-Drilling System Lumberjack Tools Inc. MODEL: ADS4590 PO Box 730 Chippewa Falls, WI 54729 www.lumberjacktools.com Email: info@lumberjacktools.com Phone: 715-720-4719 Rev: 1/18
TABLE OF CONTENTS General Information About Your Product.…………………………………………………………. … 3 Warnings and Safety…………….……………………..…….….……………… 3 What’s Included…..………………….……………………..…….….…………. 4 Required Tools……………….……………………..…….….…………….…… 4 Troubleshooting….………………………….……………………..…….……… 17 Assembly Swing Arm Attachment………………………………………………………. … 5 Slide Assembly..…………….…………………………………………………… 6 Slide Installation…………….…………………………………………………… 8 Brace Plate Installation………………………………………..….…………. … 9 Safety Pin Installation…………………………………………………………… 10 Drill Depth Stop Installation…………………………………………………. ….10 Test Slide Clearance………………………………………………………………. … 7 Adjustability…....…………….…………………………………………………… 10 Set Up Lock Slide………………………………………………………………………… 11 Align Log Lock…………………………………………………………………… 11 Install Self-Feed Bit.…………….………………………………………………. 11 Hook Up Drill……………….…………………………………………………. ….11 Mount To Work Station………………………………………..….…………. ….12 Operation Setting Angles……………………………………………………………………. 13 Set Hole Depth……………………………………………………………………13 Drilling Holes…………..………………………………………..….……………..14 Maintenance Cleaning, Inspection & Bearing Grease…..………………………………….. 15 Bushing Replacement……..………………………………………………… ….16 Adjust Drill Center……..……………………………………………………..…. 16 2
About Your Product Thank you for purchasing our Drill Sergeant! The Drill Sergeant is designed to produce consistent angled mortise holes for any project. The fixture is laser cut from structural steel and formed in a press brake in order to withstand the high torque of drilling angled mortise holes. Simply screw down the fixture to a stable work surface, hook up a single-speed 1/2” drill and you’re ready to go. Our lifetime guarantee covers the steel body parts, aluminum bearing block, and shank for manufacturing defects. Normal wear and tear is NOT covered under warranty. The nuts, bolts, washers and screw handle are covered for 90 days from the date of purchase for breakage under normal working conditions. Excessive log overhang, or side loading the fixture could cause failure to occur in the bolts. Over tightening of the screw handles may bend the bolts or strip threading as a result. This is valid only to the original buyer, and not for the tools sold secondhand, used, or sold “as is” to a second party. What Voids Warranty In order to keep our lifetime and 90 day warranty you must AVOID the following actions: ● Side loading the fixture ● Using a forstner bit larger than 2” ● Over tightening the screw handles ● Failure to follow maintenance schedule ● Altering or misusing the fixture ● Unsupported log overhang of 24” or more SAFETY Before beginning any project, carefully read and follow ALL safety and operational instructions for any tools or devices you will be using. Failure to do so may cause physical harm to yourself or those around you. If you feel uncomfortable using our Drill Sergeant, STOP immediately. Lumberjack Tools assumes no responsibility for injury caused to the operator, bystander, or tools used in conjunction with the use or misuse of our Drill Sergeant. NEVER OPERATE POWER TOOLS UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR ANY MEDICATIONS REPLACE THE WARNING LABELS IF THEY BECOME OBSCURED OR DAMAGED KEEP SPACE AROUND THE FIXTURE CLEAN AND FREE OF DEBRIS ALWAYS WEAR SAFETY GLASSES, DUST MASK, AND ANY OTHER PERSONAL PROTECTION ITEMS AS NEEDED NEVER WEAR LOOSE ITEMS THAT COULD BE CAUGHT IN MOVING PARTS. SECURE LOOSE OR LONG HAIR AWAY FROM AREA WE STRONGLY RECOMMEND A SINGLE-SPEED, GEAR DRIVEN DRILL WITH RPMS OF 500 OR LESS. EXCEEDING THESE RPMS MAY RESULT IN DAMAGE TO THE DRILL SERGEANT ALWAYS LOCK SLIDE IN TOP POSITION WITH SAFETY PIN BEFORE MAKING ANY ADJUSTMENTS TO TOOLS, FIXTURE OR WORK PIECE NEVER USE FIXTURE WITHOUT BOLTING DOWN TO A LEVEL, SECURE SURFACE NEVER PLACE ANY BODY PART UNDER SLIDE OR DRILL BIT. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY ALWAYS DISCONNECT POWER AND ALLOW DRILL TO COME TO A COMPLETE STOP BEFORE INSTALLING, REMOVING, OR ADJUSTING THE FIXTURE NEVER APPLY BENDING FORCE (SIDE LOADING) TO THE FIXTURE. SIDE LOADING COULD CAUSE THE SHANK TO FAIL, OR MAY RESULT IN FIXTURE DAMAGE ALWAYS SECURE STOCK IN A VISE, CLAMP OR LOG LOCK PRIOR TO STARTING YOUR DRILL. FAILURE TO DO SO MAY RESULT IN INJURY 3
Note: Images not to scale What’s Included 1A 1B 1C 1D Alignment Plate Base Plate (Qty. 1) (Qty. 1) Slide Plate (Qty. 1) Swing Arm (Qty. 2) 1E 1F 1G 1H Brace Plate (Qty. 1) Drill Chuck (Qty. 1) Pillow Block (Qty. 1) Drill Shank (Qty. 1) Bag 1 2A 2B 2C 2D Ø1/2” Shoulder Screw (Qty. 2) Ø3/8” Shoulder Screw (Qty. 4) Ø3/8” Large Washer (Qty. 4) Handle (Qty. 2) 2F 2G 2H 2E Ø3/8” x 3-1/2” Socket Cap Screw (Qty. 2) Ø3/8” x 2-1/2” Carriage Bolt (Qty. 2) Ø3/8” Lock Nut (Qty. 4) Ø5/16” Lock Nut (Qty. 4) 2J 2K 2I Ø1/2” Gold Washer (Qty. 16) Ø3/8” Small Washer (Qty. 12) Ø3/8” Spacer (Qty. 3) 2L 2M 2N Retaining Ring (Qty. 2) Thrust Bushing (Qty. 2) Zerk (Qty. 1) Bag 2 3A 3B 3C 3D 3E 3F Ø3/8” x 1-3/4” Socket Ø1/4” x 1” Socket Cap #10 x 5/8” Socket Cap #10 Lock Nut Cap Screw (Qty. 1) Screw (Qty. 4) Screw (Qty. 1) Ø1/4” Washer (Qty. 8) (Qty. 1) 3G 3H 3I 3J 3K Ø3/8” Wing Ø1/4” Lock Nut Ø3/8” Lock Washer Base Spacer (Qty. 2) Nut (Qty. 1) (Qty. 4) (Qty. 1) Safety Pin (Qty. 1) Lanyard (Qty. 1) Required Tools Allen Wrench Wrench/Socket Optional ● 3/16” ● 1/4” ● 3/8” ● 1/2” ● 5/16” ● Crescent Wrench ● 5/32” ● 5/16” ● 7/16” ● 9/16” 4
Assembly Tools Needed: Parts Needed: 1 Open Hardware Bag 1 and gather the items to complete steps 1 through 4. ● 1/4” Allen Wrench ● 9/16” Wrench/Socket ● 1A ● 1D Base Plate (Qty. 1) Swing Arm (Qty. 2) 2G ● 2A Handle (Qty. 2) Tape Pinch Point stickers 1D ● 2B Ø1/2” Shoulder Screw (Qty. 2) this side ● 2G Ø3/8” x 2-1/2” Carriage Bolt (Qty. 2) ● 2H Ø3/8” Lock Nut (Qty. 2) 2B 2G ● 2I Ø3/8” Spacer (Qty. 2) 2x 2J ● 2J Ø1/2” Gold Washer (Qty. 12) ● 2K Ø3/8” Small Washer (Qty. 6) 2x 2J 1A 1A 2B Fig. 1 Fig. 2 a. Install the parts as shown in Fig. 1 ● Use tape to hold the bolt heads in place b. Align bolts with the two lower holes in Swing Arm as shown in Fig. 2 Note left vs. right arm (sticker) c. Install the parts in order as shown in Fig. 3 ● Tighten handle 2A 2A until snug 2I 2A ● Tighten lock nut 2H2H (loosen ¼ turn if arm 2G 2J 2K 2K too difficult to rotate) d. Repeat steps 1-3 for the other Swing Arm NOTE: Washers 2J 2J between swing arm and base plate 2B 2J 2J 2K 2H Fig. 3 IMPORTANT It is critical to make sure that the Swing Arm is fully engaged with the bolts. Failure to properly install will make the fixture unstable. ● If the gap is greater than the washer thickness the installation is WRONG Gap No Gap WRONG CORRECT 5
Assembly Tools Needed: Parts Needed: 2 2H 2K ● 5/16” Allen Wrench ● 5/16” Socket ● 1C ● 1F Slide Plate (Qty. 1) Drill Chuck (Qty. 1) ● 9/16” Wrench/Socket ● 1G Pillow Block (Qty. 1) 2N ● 1H Drill Shank (Qty. 1) 1G ● 2F Ø3/8” x 3-1/2” Socket Cap Screw (Qty. 2) a. Complete the slide assembly with the parts shown in Fig. 4 ● 2H Ø3/8” Lock Nut (Qty. 2) ● Note the direction the Zerk is fac- ● 2K Ø3/8” Small Washer (Qty. 4) ing ● 2L Retaining Ring (Qty. 2) 1C ● Snug Zerk lightly with a 5/16” Sock- ● 2M Thrust Bushing (Qty. 2) et 2K ● 2N Zerk (Qty. 1) b. Center the Pillow Block in the Slide Plate as shown in Fig. 5 2F ● This can be adjusted after installa- tion is finished Fig. 4 Adjustment Fig. 5 c. Screw the Chuck tight to the Shank and apply a thin layer of grease to Shank body before installing into the pillow block as shown. We recommend using a permanent thread locker on the Chuck threads. DO NOT allow thread locker to contact the Shank body! ● Secure in place using the Thrust bushings and retaining rings ● Refer to Fig. 6 & 7 IMPORTANT DO NOT force Shank. Shank must be installed perfectly straight into pillow block! If Shank binds, re- 2M align and re-install. 2L IMPORTANT 1H 2M Be extremely careful not to damage shank surface during 2L installation! 1F Fig. 6 Fig. 7 6
Assembly 3 Test Slide Clearance a. Set the Swing Arm position to 0o ● Make sure Shoulder Bolts and Handles are tight b. Check the slide-to-arm clearance at BOTTOM (near base plate) ● If more clearance is needed add washers 2J 2j between arm and Check Clearance base plate, refer to Fig. 9 ● If less clearance is needed remove washers 2J 2j between arm and base plate, refer to Fig. 10 Rule of Thumb Base Plate 2J ● 4 total washers must always be kept on the bottom shoulder bolt 2b2B 2B ● (i.e. if you remove washers from one side of 2b2B , you must add those to the other side) Fig. 8 ● Fig. 8 displays what happens to the clearance when Move Washers washers are moved Less Clearance More Clearance Washer movement Max Clearance Min Clearance 4x 2J 2J 2G 2G 2B 2B 3x 2J Fig. 9 Fig. 10 4x 2J 2J For maximum clearance place all four washers in- For minimum clearance leave one washer in-between between the base plate and swing arm on both the the base plate and swing arm, (this protects the shoulder bolt 2b 2B and carriage bolt 2g 2G . Angle Sticker) on both shoulder bolt 2b 2B and carriage ● Repeat for second swing arm bolt 2g 2G be sure to follow the Rule of Thumb (Fig. 8) ● Repeat for second swing arm 7
Assembly Tools Needed: Parts Needed: 4 **some parts hidden for clarity** ● 3/16” Allen Wrench ● 1/2” Wrench/Socket ● Slide Assembly (Qty. 1) ● 2C Ø3/8” Shoulder Screw (Qty. 4) ● 2D Ø3/8” Large Washer (Qty. 4) ● 2E Ø5/16” Lock Nut (Qty. 4) ER 2E ● Two sheets of office paper SPAC (not included) 2D 2C ER SPAC ~2” ER Handle C (not shown) SPA facing this Tip way Use a 1/2” Wrench with tape to hold the Ø5/16” Lock Nuts while installing. Fig. 12 Tape Together Fig. 11 a. Lay the Drill Sergeant Arms flat on a surface o b. Loosen both screw handles three turns and position the arms to 0 using the Peep Sight c. Install the slide assembly near the top of the Swing Arms (around 2”) and insert a paper spacer (sheet of paper folded once) on both sides of the slide between the slide and the arm as shown in Fig. 12 d. Make sure handle on slide assembly is facing up (see next page for orientation) and install the parts as shown in Fig. 11 e. Install lock nut 2E 2E on screw 2C 2C (use the wrench with tape method to hold the nut during installation) and tighten by turning screw 2C2C 8
Assembly Tools Needed: Parts Needed: 5 Open Hardware Bag 2 and gather the items to complete steps 5 through 7. ● 3/16” Allen Wrench ● 7/16” Wrench/Socket ● 1E ● 3B Brace Plate (Qty. 1) Ø1/4” x 1” Socket Cap Screw (Qty. 4) ● 3D Ø1/4” Washer (Qty. 8) 3D 3I 3I● Ø1/4” Lock Nut (Qty. 4) 3B 3B 3D 3D 1E 3D 3I 1E ~3” ER SPAC CER Handle SPA ER SPAC Fig. 13 Fig. 14 o a. Look through the Peep Sight to make sure the arms are positioned at 0. Tighten handles b. Make sure slide is set about 3” below the top of the arms (Fig. 13) c. Center the Brace Plate between the Swing Arms and install as shown in Fig. 14. Make sure Brace Plate 1E 1E is on the same side as the slide Slide handle. Be sure to tighten these four bolts very securely d. Once installed, stand the assembly upright. Remove the paper spacers and move the slide up and down the entire length (Fig. 15), if too loose/tight readjust before continuing (see step 3 & step 5) CAUTION Assembly is very unstable when Fig. 15 standing up. Use one hand to stabilize slide arms when upright. 9
Assembly Tools Needed: Parts Needed: 6 3E ● 5/32” Allen Wrench ● 3/8” Wrench/Socket ● 3C ● 3E #10 x 5/8” Socket Cap Screw (Qty. 1) #10 Lock Nut (Qty. 1) 3C ● 3F Lanyard (Qty. 1) ● 3K Safety Pin (Qty. 1) 3K 3F Fig. 16 a. Install the parts as shown in Fig. 16 b. Once installed, move the slide back to top of arms and lock in place using the Safety Pin 3K 3K (see next page) Parts Needed: 7 ● 2I 2K ● Ø3/8” Spacer (Qty. 1) Ø3/8” Small Washer (Qty. 2) 3A ● 3A Ø3/8” x 1-3/4” Socket Cap Screw (Qty. 1) 3J ● 3H Wing Nut (Qty. 1) ● 3J Ø3/8” Lock Washer (Qty. 1) 2K 2I 2K 3H a. Attach the drill depth stop as shown in Fig. 17 ● This can be attached to either arm, choose side you feel most comfortable with Fig. 17 Test Adjustability Once assembled test the fixture. Check that the Slide arms can be adjusted from 0o to 45.o Make sure that the slide can be moved up Rotate and down the full arm length. 10
Set Up Lock Slide 1 2 3 Lock the slide at the top of the arms. **Top bolt hidden for clarity** 1. Pull the slide up to top 2. Roll slide back into rest 3. Insert safety pin into slide Note: If pin-hole is not visible after step 2, slide is installed incorrectly (handle facing wrong way) Align Log Lock Align the Log Lock (not included) with the Drill Sergeant Base Plate. (See pg. 12 first for orientation) 1. Begin by securing a straight, 1 ½” diameter piece of round stock in the Log Lock 2. Place the Log Lock over the Drill Sergeant Base Plate 3. Reposition the Log Lock until the clamped piece of round stock is centered in the v-channel of the Drill Sergeant Base Plate Install Self-Feed Bit Hook Up Drill ● Make sure safety pin is installed correctly ● Make sure safety pin is installed correctly ● Install the bit into the chuck and secure tightly (we ● Place the drill on the shank and secure tightly recommend self-feed bits) ● DO NOT use spade bits with this fixture 11
Set Up Front Mount (straight holes, angled holes on 1st end of log) ● We do not recommend mounting this to a work The purpose of the Alignment Plate station with a height greater than 30” is to allow drilling holes in both ends of stock. The Alignment Plate can also be repositioned to allow Log Lock setup for left & right handed users. ● Note that the Alignment Plate may be flipped to change Log Lock orientation 1 3 5 7 ● Use all 8 bolt holes to secure 6 8 Fig. 18 2 4 1B Rear Mount (angled holes on 2nd end of log) Parts Needed: ● 3G Base Spacer (Qty. 2) When moving the Alignment Plate and Log Lock to the rear of the Drill Sergeant use the two Base Spacers 3G and mount log lock on 2ⁿ� set of slots on alignment plate as shown in Fig. 19. The Drill Sergeant will not be able to o reach 45 if the spacers are not used IMPORTANT Short Long ● Use all 8 bolt holes to secure ● The Long edge of the align plate is always where the handle of the Log Lock must be located 1B 2nd slot Fig. 19 2nd slot 3G 12
Operation o o Setting Angles The Drill Sergeant can drill any angle between 0 and 45 1. Loosen both screw handles 1-2 turns 0o 22.5o WARNING Very heavy, be careful 45o when adjusting n lo o se lo o sen 2. Keep one hand on Peep Sight 3. Tighten both screw handles so the angle holds the top of fixture and adjust to desired angle setting by n looking through the ht e t ig ht e t ig Peep Sight n Set Hole Depth If you want to set a specific hole depth, you will need to use the drill stop and a ruler/tape measure. 1. With the self-feed bit installed, move the slide 2. Set the Drill Stop X inches away from the bottom of down until the face of the bit comes into contact the slide to set your hole depth at X inches, tighten with the log wing nut to secure X 13
Operation Drilling Holes Shank must be greased BEFORE use (pg. 15) NEVER use anything larger than a 2” forstner bit in this fixture NEVER use a spade bit in this fixture Always make sure the log is secure and the screw handles are tight before drilling. We strongly recommend using self-feed bits with this fixture. 1. Start drill before contacting log and slowly move the self-feed bit into the log IMPORTANT Tip Advance Drill very slowly with light If wood is splintering (tear out), pressure until bit enters the log use some scotch tape on the log where the bit enters the wood completely! Failure to do so may cause damage to the bit or fixture DO NOT Push this direction sh sh Pu 2. Hold steady pressure and Pu lean onto the slide handle to aid the drill ● DO NOT apply cross- force to the drill or fixture WRONG CORRECT t k Ou c Ba 3. Once you have reached your desired hole depth, stop running the drill, switch to reverse and slowly back the drill out of the hole 14
Maintenance ● Fixture - Cleaning ○ Keep the swing arms, base plate & slide plate clear of sap, wood chips and other build-up ○ Always remove drill & bit before cleaning ○ Always lock the slide plate with the safety pin before cleaning ○ Clean the plates with a solvent (such as mineral spirits) - Oiling ○ Once cleaned apply grease or oil to slide arm rail track, to improve slide action USE CAUTION WHILE MANEUVERING AROUND DRILL SERGEANT. DRILL SLIDE WILL CRUSH EXTREMITIES IF NOT SECURED IN PLACE WITH SAFETY PIN. ● Fasteners - Inspection ○ Check for visible thread damage ○ Do any of the bolts appear bent or deformed? ○ Replace any damaged nut, bolt or washer to reduce risk of damage - Oiling ○ Apply oil to the shoulder bolts on a monthly basis ● Mounting - Inspection ○ Make sure the screws securing the fixture to the workbench are still holding properly ○ Remove any debris between the workbench and fixture ○ Is the workbench still level and stable? ○ Replace any broken screws ○ Tighten any loose screws ● Bearing Grease - Application Re-greasing required every 250 holes. We recommend a high-quality synthetic grease with moly. Lumberjack Tools cannot guarantee reliability/function if using GREASE different grease. Attach the grease gun fitting over the zerk located on the back of the slide. Grease gun can Zerk be found at most hardware stores. - Wipe excess grease from ends of shank TASK EACH USE MONTHLY Clean Fixture Plates X X Inspect Shoulder Bolts X X Inspect Mounting Bolts X X Oil Shoulder Bolts X X 15
Maintenance Bushing Replacement 1 Follow Step 2 (Page 6) in reverse to remove the Pillow Block from the Slide Plate Press Out Press out the old sleeve bushing ● Local auto shops can do this if you do not have the proper equipment It is EXTREMELY IMPORTANT 2 Press In Press in the new sleeve bushing to line up hole in replacement bushing and hole in pillow Hole ● Local auto shops can do block (where zerk fitting is) this if you do not have the proper equipment ● Follow step 2 (pg. 6) to re-install pillow block and chuck ● CRITICAL: bearing must be greased (pg. 16) BEFORE use Zerk Bearing Specs Sleeve Bushing: SAE 660 material, Thrust Bushing: SAE 841 material, Ø1" I.D. x Ø1-1/4" O.D. x 2-1/2" Length Ø1" I.D. x Ø1-1/2" O.D. x 1/8" Thickness McMaster Carr Part Number: 7965K41 McMaster Carr Part Number: 5906K523 Adjusting Drill Center Loosen If drill sergeant is not drilling on-center, adjust the pillow block. 1. Loosen the nuts and bolts holding the pillow block in place using a 9/16” Wrench and 5/16” Allen Wrench. ● Shift the pillow block either direction as-needed ● The pillow block can be adjusted ±3/16” to account for off-center drilling Adjust 2. Tighten the nuts and bolts securely Loosen 16
Troubleshooting Clamping (Log Lock) PROBLEM CAUSE SOLUTION • Clamp is not applying enough pressure • Tighten handle until log is secured • Log/Timber spins inside clamp • Adjust top in ladder to properly fit • Top not oriented properly over log • Re-orient the log if needed • Log sticking out too far from clamp • Position log with no more than 24” of overhang • Wobbling or Vibrating log in fixture • Fixture loose on base • Re-tighten screws securing base • Workbench not stable • Move fixture to more stable workbench • Adjust top so that the handle end is higher • Top not oriented over log properly • Top not staying locked into than the ladder end ladder • Re-orient the log and adjust the top as • Log orientation making it difficult to secure needed Drilling PROBLEM CAUSE SOLUTION • Not applying enough pressure to the slide • Position yourself so that you can lean onto the slide with your bodyweight • Drill not cutting hole • Using forstner bit larger than 2” • DO NOT use a forstner bit larger than 2” • Dull forstner bit • Use a sharp forstner bit • Bushing block not aligned with log • Loosen screws holding bushing block to • Not cutting hole in center of center drill chuck (pg. 16) log • Log not straight enough • Rotate log until as straight as possible • Not holding angle while • Screw handles not tight enough • Secure screw handles very tight cutting • Slide arms too tight against side • Re-do steps 3 and 4 (pages 7 and 8) with • Slide assembly not sliding paper folded two times well • Ø3/8" Shoulder screws are secured too tight • Loosen each Ø3/8" shoulder screw ¼ turn until desired resistance reached • Drill does not fit onto shank • Drill does not have a large enough capacity • Use drill with a 1/2” capacity chuck (or chuck larger) • Drill stops while cutting • Drill does not have enough power • Switch your drill to low speed (gear 1) • Use a high-power, low rpm 1/2” drill • Cannot install safety pin • Slide assembly installed backwards • Unbolt side assembly, rotate 180°, and install per step 2 • Drill Sergeant shank has too • Sleeve bushing worn-out • Replace sleeve bushing (page 16) much play (wobbles) • Very difficult to adjust angle • Bottom shoulder bolts too tight • Loosen bottom, 1/2” shoulder bolts ¼ turn • Drill bit not installed in drill chuck straight • Re-align drill bit in chuck • Drill bit wobbles when • Drill bit bent • Replace drill bit spinning • Sleeve bushing worn-out • Replace sleeve bushing (page 16) 17
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