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

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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)

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