Jancy Engineering Slugger USA5 Bedienungsanleitung

Slugger®USA5

Slugger

Portable Magnetic Drilling Machine

OPERATOR’S MANUAL

HEARING PROTECTION

REQUIRED

EYE PROTECTION

REQUIRED

MODEL #18066 (120V) OR #18080 (220V)

Serial # Date of Purchase

BEWARE OF

ROTATING

MACHINE PARTS

LINE VOLTAGE

PRESENT

NEVER PLACE

FINGERS NEAR

CUTTING AREA OR

MACHINE ARBOR

WARNING!

before use, be sure everyone using this machine reads and understands

all safety and operating instructions in this manual.

United States Patent #5,415,503 other patents pending.

Slugger

Portable Magnetic Drilling Machine

Congratulations on your purchase of a Slugger® portable magnetic drilling machine. Slugger® drilling machines are

designed to deliver fast, efficient hole drilling performance in portable applications. Please take a moment to complete

and mail your product warranty registration card. Doing so will validate your machine’s warranty period and ensure

prompt service if needed. Thank you for selecting a Slugger® product from Jancy Engineering Inc.™

table of contents

Important Safety Instructions ...................................3-4

Special Instructions ......................................... 5

Grounding Instructions, Extension Cords, Guideline For Shift Lever Position .... 6

Contents Of Package ....................................... 7

Getting Started, Before You Drill ................................ 7

Before The Cut, Ready To Cut, After The Cut........................ 8

Basic Troubleshooting ....................................... 9

Regular Maintenance ...................................... 10

Control Panel And Parts List .................................. 11

Machine And Arbor Breakdown ............................... 12

Machine And Arbor Parts Lists ................................ 13

Motor Breakdown And Parts List ............................... 14

Dimensions And Specifications ................................ 15

JANCY ENGINEERING RESERVES THE RIGHT TO MAKE

IMPROVEMENTS AND MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE.

limited warranty

Jancy Engineering Inc.™will, within one (1) year from the original date of purchase, repair or replace any goods found

to be defective in materials or workmanship, provided the product warranty registration card has been returned to Jancy

Engineering Inc.™ within thirty (30) days of purchase date. This warranty is void if the item has been damaged by acci-

dent, neglect, improper service or other causes not arising out of defects in materials or workmanship. This warranty does

not apply to machines and/or components which have been altered, changed, or modified in any way, or subjected to

use beyond recommended capacities and specifications. Electrical components are subject to respective manufacturers’

warranties. All goods returned defective shall be returned prepaid freight to Jancy, which shall be the buyer’s sole and

exclusive remedy for defective goods. In no event shall Jancy Engineering be liable for loss or damage resulting directly or

indirectly from the use of merchandise or from any other cause. Jancy Engineering is not liable for any costs incurred on

such goods or consequential damages. No officer, employee or agent of Jancy is authorized to make oral representations

of fitness or to waive any of the foregoing terms of sale and none shall be binding on Jancy.

™

important safety instructions

WARNING!

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.

1. Work Area Safety

a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.

b) 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.

c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

d) Secure work. Use clamps or a vise to hold work. It’s safer than using your hand and it frees both hands to

operate tool.

2. Electrical safety

a) 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.

b) 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.

c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of

electric shock.

d) 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.

e) 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.

f) If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) or

residual current device (RCD) protected supply. Use of a GFCI or RCD reduces the risk of electric shock.

3. Personal safety

a) 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.

b) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust masks,

non-skid safety shoes, hard hats or hearing protection used for appropriate conditions will reduce personal

injuries.

important safety instructions

c) 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

energizing power tools that have the switch on invites accidents.

d) Remove any adjusting key or wrench before turning the power tool on. A wrench or key left attached to

a rotating part of the power tool may result in personal injury.

e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power

tool in unexpected situations.

f) 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.

g) 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.

4. Power tool use and care

a) 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.

b) 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.

c) 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 preventative safety measures reduce the

risk of starting the power tool accidentally.

d) 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 power tool. Power tools are dangerous in the hands of untrained users.

e) 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.

f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less

likely to bind and are easier to control.

g) Use the power tool, accessories and tools 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.

h) Check for 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 alignment

of moving parts, binding of 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 by an authorized

service center.

5. Service

a) 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.

1. If you require an additional manual, please contact Jancy Engineering at (563) 391-1300 for a FREE copy.

2. Never place hands, fingers, gloves or clothing near cutting area or rotating machine parts.

3. Always disconnect machine from power source before changing cutters, clearing chips, refilling lubricant or

performing adjustments.

4. Keep all safety features functioning and working properly.

5. Never wear loose clothing, gloves or jewelry when working near cutting area or rotating machine parts.

6. Always use eye and hearing protection.

7. Always use safety strap and chip guard provided with machine.

8. Always use proper tooling. Keep cutters securely fastened.

9. Do not use dull or broken cutters.

10. Do not use Slugger® drilling machines on surfaces or materials being welded. Doing so can damage the

machine’s electrical components.

11. Beware of slugs ejected at end of cut. They become HOT during the cut.

12. Magnet will not hold properly on thin materials or rough and dirty surfaces.

13. Keep bottom of magnet burr free and clear of chips and debris.

14. To reduce the risk of electrical shock, do not use machine in wet or damp areas.

15. Do not remove or alter electrical panels. Use only authorized service centers for repairs.

16. Motor will not start on non-ferrous materials.

WARNING!

do not operate machine if warning and/or instruction labels are missing or damaged.

contact jancy engineering for replacement labels.

special instructions

WARNING!

Improperly connecting the grounding wire can result in the risk of electrical 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 tool. Never remove the

grounding prong from the plug. If the cord or plug is damaged, have it repaired

before using. If the plug will not fit the outlet, have a proper outlet installed by a

qualified electrician. The USA5 must be plugged into an appropriate outlet, prop-

erly installed and grounded in accordance with all codes and ordinances. The

plug and outlet should look like those in Figure A.

WARNING!

do not use slugger® drilling machines on surfaces or materials being

welded. doing so can result in personal injury and/or damage to the

slugger® drilling machine.

grounding instructions

DRIP LOOP: To help prevent cutting fluids from traveling

along power cord and contacting power source, tie a drip

loop in power cord as shown in Figure B.

Fig. B

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

plug. Replace or repair damaged cords. 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. Jancy recommends using a minimum 12 gauge extension cord

not to exceed 100 feet. The table below is supplied only as a guide to minimum gauge for extension cords, where the

smaller the gauge number, the heavier the cord.

extension cords

minimum gauge for extension cords

volts total length of cord in feet

120V 0-25 26-50 51-100 101-150

240V 0-50 51-100 101-200 201-300

amperage

0-6 18 16 16 14

6-10 18 16 14 12

10-12 16 16 14 12

12-16 14 12 not recommended

recommended wire gauge

note:

jancy recommends using aminimum 12 gauge

extension cord not to exceed 100 feet.

guideline for usa5 shift lever position

Remove all contents from packaging and inspect to ensure no damage was incurred during shipping. Your USA5 package

should also include the following:

contents of package

description part # qty

OPERATOR'S MANUAL LIT104 1

PRODUCT DVD LIT032 1

WARRANTY CARD 0070342 1

3/16" PILOT, 1" DEPTH OF CUT 16001 1

3/16" PILOT, 2" DEPTH OF CUT 16002 1

1/4" PILOT, 1" DEPTH OF CUT 16003 1

1/4" PILOT, 2" DEPTH OF CUT 16004 1

1/4" PILOT, 3" DEPTH OF CUT 16005 1

3/8-24 X 5/16" FPSSS UH1474 3

3/16" HEX WRENCH UH8013 1

3/16" T-HANDLE HEX WRENCH UH8014 1

4MM HEX WRENCH UH8002 1

SPOKE HANDLE 0151333 3

SAFETY STRAP U11005 1

PIPE HANDLE 0010224 1

PIPE HANDLE ADAPTER 0010225 1

MAGNET WARNING NOTICE 0107D0C 1

SHUNT (ATTACHED TO HANDLE) UH5335 1

SHUNT INSTRUCTIONS U14102 1

getting started

what you should know before you drill

CAUTION!

always disconnect usa5 from power source before making adjustments.

NOTE: The item numbers found below in parentheses refer to the images on page 12.

Assemble three spoke handles (item #18) to hub pinion shaft (item #17). NOTE: Feed hub assembly is mounted on

right side of machine frame. If necessary, it can be reversed for lefthand operation by simply removing the fastener (item

#29) and sleeve (item #30) from frame. Remove hub pinion shaft from right side of frame and insert it into left side of

frame. Replace sleeve and fastener into frame and tighten securely. Thread pipe handle (item #2) into motor housing.

The control panel (item #27) may also be reversed from left to right side of machine if desired. Remove screws (item

#19) holding control panel and side cover plate (item #20) next. Remove side cover plate and control panel, then

disconnect magnet and motor pin connections when removing control panel. Move control panel to opposite side of

frame. Reconnect magnet and motor pin connectors and secure control panel assembly using four screws (item #19).

Replace side cover plate, making sure warning instructions are visible.

1. Type of material to be drilled, Brinnell or Rockwell hardness, material thickness and position should all be determined

to ensure proper selection of Slugger® cutting tools, RPM, coolant and drilling time.

2. Remove any excessive mill scale or rust from surface to be drilled.

3. When drilling materials under 3/8" thick, an additional steel plate may be required to achieve proper magnet

adhesion.

4. Material that has been flame cut may have become heat-treated and therefore difficult to drill. Avoid drilling near

such areas whenever possible.

5. Drilling with the USA5 in horizontal positions requires a special lubrication for Slugger® cutters.

Consult Jancy Engineering for details.

1. Select correct pilot pin and place in cutter shank from the rear. Align flats on cutter shank with arbor body set screws.

Insert cutter in arbor body.

2. Tighten set screws securely on cutter shank flats. NOTE: Set screws should be recessed in arbor body when tight.

3. The surface you are working on should be clean, flat and free from rust, scale, dirt and chips.

4. Determine correct cutting speed for application. Move gear box shift lever by lifting outward then repositioning to

desired speed.

CAUTION!

never change gears with motor running. doing so can result in personal injury and/or damage to the machine.

5. Place Slugger® machine on workpiece with pilot pin over the center of hole to be drilled.

6. Connect machine to power source.

7. Lower Slugger® cutter to surface of material to be cut. Coolant will be released down the pilot into center of

Slugger® cutter. Coolant flow can be stopped by lifting pilot pin off work surface or by using coolant valve. NOTE:

Be sure coolant valve is open. Regulate coolant flow by adjusting coolant valve on left side of mainframe.

CAUTION!

always use safety strap. failure to do so could result in personal injury

and/or damage to the slugger® drilling machine.

8. The safety strap must be securely fastened to machine and around work being drilled. Loop strap around work piece

and connect strap ends by attaching to D-rings on drill. NOTE: Safety strap is intended only to restrain the drill to the

work piece in the event of a power failure to the magnetic base.

9. Position chip guard toward work area before drilling.

before the cut

ready to make the cut

CAUTION!

position chip guard toward work area before drilling.

1. Move magnet switch to “ON” position. Switch will illuminate to indicate power is present–magnetic base should be

firmly secured to workpiece at this time. Thin materials may require an additional steel plate to achieve proper

magnet adhesion.

2. Start drill motor by depressing green motor “ON” button.

3. Advance cutter into material using the feed handles until Slugger® cutter has established an external groove in the

material. During the remainder of cut apply smooth constant pressure without overloading motor. NOTE: Slugger®

cutters are designed for uninterrupted cutting. Chips are evacuated during the cut. Do not peck drill when using

Slugger® cutters.

CAUTION!

if drill motor should stall or stop before acomplete cut is made, always remove cutter from hole before

attempting to restart motor. failure to do so could result in personal injury and/or damage to the slugger® drilling

machine and cutter. note: this machine’scircuitry will automatically shut the drill motor off if magnetic base is sepa-

rated from its work surface. if your machine requires adjustment, contact jancy’sservice department.

1. After Slugger® cutter has finished the cut, the “slug”, or uncut center portion of material, will be expelled when

motor is returned to the full up position.

2. Return machine into full upright position and depress red motor “OFF” button, wait until motor completely stops.

3. Move magnet switch to “OFF” position when ready to release magnetic base from work surface.

after the cut

1. Magnetic base not holding securely

•Material is too thin to engage magnet.

•Surface of material being drilled must be free of chips, debris, rust and mill scale.

•Size of cutter exceeds machine’s rated capacity.

•Check magnet face for unevenness, nicks and burrs.

•Welding equipment connected to material being drilled.

2. Drill motor running, arbor and spindle not turning

•Possible sheared spindle key.

3. Motor slows when drilling

•If an extension cord is being used, see page 6 for recommended wire gauges and cord lengths.

•Excessive downfeed pressure during drilling cycle will cause motor to slow and overheat.

•Cutting tool needs to be resharpened.

4. Coolant system not working

•Coolant system is gravity dependent. Machine must be in an upright position to operate properly.

•Check operation of coolant valve. Valve must turn freely.

•Check coolant lines for blockage.

•Dirt or debris in coolant tank.

•Consistency of coolant mixture too thick.

•Incorrect pilot pin being used.

•Vent hole in coolant tank lid blocked.

5. Slugs not ejecting from cutter

•Lack of coolant causing slugs to expand in cutter bore.

•Incorrect pilot pin being used.

•Possible broken internal arbor parts.

6. Breaking cutters

•Coolant must be supplied to interior of cutter.

•Excessive feed pressure being applied when cutter initially contacts work surface.

•Confirm material hardness.

•Drilling stacked materials with incorrect cutter.

•Dull cutters; dull or chipped cutting edges require excessive feed pressure, resulting in breakage.

•Excessive arbor runout–see regular maintenance on page 10.

•Possible bent motor spindle or worn arbor sleeve.

•Improperly adjusted motor slide–see page 10.

7. Oversized or rough holes

•Insufficient coolant.

•Excessive feed pressure.

•Dull cutter.

•Worn support bracket roller bearing or arbor body sleeve.

•Bent motor spindle.

•Motor slide improperly adjusted.

basic troubleshooting

1. The motor slide may become loose and require adjustment after the machine has been in service. Refer to parts

breakdown and become familiar with the USA5 parts. Locate motor slide cover plate (item #31 on page 13)

and adjustment screw (item #8 on page 14). Using the 3 spoke feed handles, position motor and

slide assembly in the full up position. Insert supplied 5mm hex key through slide cover plate access hole. Using the

hex key turn adjustment screw (item #8) clockwise to increase slide tension or counter-clockwise to decrease slide

tension. Do not over tighten adjustment screw. Excessive slide tension can damage the USA5. Properly adjusted, the

motor and slide assembly should have no side to side movement and remain in position without drifting down.

2. Keep bottom of magnet clean, free of chips, burrs, nicks, oil and other contaminants. Inspect magnet face

to ensure surface is flat and square. A worn magnet surface dramatically reduces magnetic holding force.

3. Periodically lubricate motor slide ways with lithium base grease.

4. Routinely grease zerk (item #23) on arbor support bracket.

5. Visually inspect arbor, sleeve and support bracket for wear.

6. Arbor runout should not exceed .0035 inches per revolution. This is most accurately measured by placing a dial

indicator needle inside of arbor bore and rotating arbor while observing indicator.

7. Inspect coolant system, reservoir, o-rings, lip seals and coolant collar for wear.

8. Inspect motor brushes and replace as needed.

9. Replace any worn parts and regularly tighten fasteners that have become loose during usage.

10.Regularly test machine by placing machine on non-ferrous material. Engage magnet switch.

Motor should not start.

regular maintenance

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