BLUEROCK GCD4 Quick start guide

OPERATIONAL MANUAL
MODEL: GCD4 CORE DRILL MACHINE PORTABLE
GAS DRILL USED BY HAND
by BLUEROCK ® Tools
Volume
1.0

MWS-
GDC4 CORE DRILL
UNPACKING THE ITEM
CAUTION: This machine is packed together with items that may be sharp, oily and overly
heavy objects. Remove the machine from the packaging in a safe manner. Check to ensure
all accessories are included with the item while unpacking. If any parts are found to be
missing, contact the retailer as soon as possible. Do not throw away the packaging until the
item is out of the guarantee period. Dispose of the packaging in an environmentally
responsible manner. Recycle if possible. Keep all plastic bags away from children due to risk
of suffocation.
WEEE - Waste Electrical & Electronic Equipment. Note that parts of this machine should be disposed of as electrical &
electronic waste.
SLURRY DISPOSAL
NOTE: It is recommended to dispose of the drilling slurry (the muddy/dusty water material) in
an environmentally responsible manner. The disposal of slurry directly into sewage
systems, sewers, lakes, rivers, or direct earth without treatment can be environmentally
harmful and possibly illegal. Ask your local public authorities about current regulations in
your area.
ãTHE NEWMAN TRADING COMPANY LLC DBA BLUEROCK® TOOLS 2020
1033 Andover Park East
Tukwila, WA 98188
Phone [phone] • Fax [phone]
www.bluerocktools.com

GDC4 CORE DRILL
Table of Contents
SAFETY' 1!
PRE-OPERATIONAL SAFETY CHECKS! 1!
OPERATIONAL SAFETY CHECKS! 2!
HEALTH WARNINGS! 3!
SPECIFICATIONS' 4!
INCLUDED'ACCESSORIES' 4!
ADDITIONAL'AVAILABLE'ACCESSORIES' 5!
ADDITIONAL ACCESSORIES FOR THIS MACHINE CAN BE FOUND IN BLUEROCK ® TOOLS ONLINE SHOP AT
WWW.BLUEROCKTOOLS.COM OR FROM YOUR LOCAL RETAILER.! 5!
OPERATIONS' 6!
PURPOSE! 6!
OPERATIONAL PRINCIPLES! 6!
MACHINE COMPONENTS! 6!
TRANSPORTING AND STORAGE OF THE MACHINE! 7!
RUNNING THE MACHINE USING THE HANDHELD DRILLING METHOD! 7!
INSTALLING CORING BITS! 9!
TROUBLESHOOTING'10!
GENERAL'MAINTENANCE'11!
OCCASIONAL'MAINTENANCE'11!
PARTS'LIST'12!
BREAKDOWN'VIEW'-'OVERVIEW'13!

GDC4 CORE DRILL
1
Safety
DO NOT USE THIS MACHINE UNLESS YOU HAVE READ THE OPERATING
INSTRUCTIONS!
Safety glasses must be worn at all
times in work areas.
Long and loose hair must be
contained.
Appropriate footwear must be worn.
Close fitting/protective
clothing must be worn.
Safety gloves should be worn at all
times and jewelry must not be worn.
Hearing protection should be
worn when using this
machine.
Hard-hat must be worn while using
machine.
Dust mask must be worn
while using this machine.
Read operational manual prior to use.
PRE-OPERATIONAL SAFETY CHECKS
Ø Examine the body of the machine and inspect for damage or defects.
Ø Inspect your core bit for damage, correct/tight connection to machine and no debris inside.
Ø Inspect the machine’s watering system to ensure it will deliver a smooth flow of water.
Ø Check to ensure the air filter is clean.
Ø Check the engine oil before starting the machine. Fill if needed with SAE 10W-30.
o NOTE: Always switch OFF the engine before checking the oil or
adding oil. Do not overfill with oil.
Chapter
1

GDC4 CORE DRILL
2
Ø Check to ensure the machine has fuel before starting.
o NOTE: This machine takes unleaded fuel with octane 86 or above.
o NOTE: Always switch OFF the engine before checking the fuel or
re-fueling. DO NOT overfill with fuel.
OPERATIONAL SAFETY CHECKS
Ø ONLY to be operated by qualified personal who have read instructions.
o NOTE: Failure to read and follow instructions could result in electrical shock, fire,
property damage and/or serious injury!
Ø DO ensure all non-essential people are clear of the immediate work area.
Ø DO be attentive at all times. Keep your eye on the work piece. Always be in a sensible state
of mind and do not use the machine if you cannot fully concentrate.
Ø DO keep body parts, clothing & power cords clear of turning/cutting pieces. Stay alert and
use common since when using this tool.
Ø DO allow machine to reach operating speed before starting a hole.
Ø DO shut down machine while changing or adjusting cutting bits so as not to accidentally turn
machine on.
Ø DO remove adjusting wrenches prior to turning the machine on.
Ø DO be mindful that power tools can expose an operator to vibrations transmitted trough
contact with the machine. Prolonged exposure can lead to medical issues which should be
discussed with a medical professional.
Ø DO use a dust extraction system for cutting materials that create dust. The operator should
also wear a protective respiratory device.
Ø DO keep the engine at least 3 feet away from buildings or flammable objects during operation
as the engines exhaust can become very hot during operation.
Ø DO NOT make adjustments to machine while the machine is running.
Ø DO NOT switch off the machine when it is under load, except in an emergency.
Ø DO NOT leave the machine running when not in use.
Ø NO NOT touch the motor or motor parts while hot as burns may occur.
Ø DO NOT hold the work piece by hand or using body. Always mechanically clamp or secure
work piece.
Ø DO NOT allow liquids to enter the machine’s ventilation system.
Ø DO NOT operate machine outside of machine specifications.

GDC4 CORE DRILL
3
Ø DO NOT touch moving parts while the machine is running as death or dismemberment could
occur.
Ø DO NOT operate machine overhead (Inverted) when drilling “wet” type cores.
Ø DO NOT allow children or untrained personal to operate machine.
Ø DO NOT use this machine in the rain or a wet environment.
Ø DO NOT operate in the presence of explosive materials as power tools create sparks which
may ignite dust or fumes.
Ø DO NOT place anything on the motor while running.
Ø DO NOT drill into an area that may contain a live electrical wire/circuit.
Ø DO NOT use full water pressure when drilling with “wet” type bits! You need minimal water to
drill with these machines. Extreme water pressure can damage machine and cutting bits.
Ø DO NOT depress throttle engaging clutch when starting the motor as you do not want the core
bit to spin quickly while not held securely.
Ø DO NOT use this gas machine indoors.
Ø DO NOT smoke or allow flames around this gas machine.
HEALTH WARNINGS
Ø Certain dust created by drilling contains chemicals known to cause cancer, birth defects or
other reproductive harm. The examples of these chemicals are below:
o Lead from lead based paint.
o Crystalline silica from bricks, cement and assorted masonry products.
§ TO REDUCE RISK OF EXPOSURE TO THESE CHEMICALS, WORK IN A WELL
VENTILATED AREA WITH VACUUM SYSTEMS, RESPIRATORS AND WITH
ALL SUITABLE SAFETY EQUIPMENT.
Ø This machine’s exhaust contains poisonous carbon monoxide. Breathing in carbon
monoxide can lead to unconsciousness, injury or death.
o DO NOT run the engine without adequate ventilation and never run indoors.

GDC4 CORE DRILL
4
Specifications
MOTOR DATA
Motor Type
4 Stroke Gas Driven (Unleaded Fuel)
Motor Model
Honda GX35 EPA Certified
Motor Oil Type
10W-30
Maximum Power
1.5KW/350RPM
Maximum Torque
40N/m
Cooling System
Forced Air Cooling
Spark Plug
CMR5H (NGK)
MECHANICAL DATA
Cutter Range
1” to 4” Max Diameter by Hand
Cutting Speed of Core Bits
700 RPM
Tool Holder
Direct Arbor 1-1/4” 7 UNC Spindle
Clutch
Yes, Clutch Drum Type Assembly
Water hose and Valve
Yes
Hand held capable
Yes
Item Weight
22 Lbs
Included Accessories
DESCRIPTION
QTY
Instruction Manual
1
Water Hose and Valve
1
Note
UPON RECEIPT, CHECK CAREFULLY TO ENSURE THAT THE
MACHINE IS IN GOOD CONDITION AND HAS ALL ACCESSORIES
LISTED ABOVE.
Chapter
2

GDC4 CORE DRILL
5
Additional Available Accessories
Additional accessories for this machine can be found in BLUEROCK ® Tools
online shop at www.bluerocktools.com or from your local retailer.
DESCRIPTION
1” Wet Coring Bit
1.25” Wet Coring Bit
1.5” Wet Coring Bit
1.75” Wet Coring Bit
2” Wet Coring Bit
2.5” Wet Coring Bit
3” Wet Coring Bit
3.5” Wet Coring Bit
4” Wet Coring Bit
1” Dry Coring Bit
1.25” Dry Coring Bit
1.5” Dry Coring Bit
1.75” Dry Coring Bit
2” Dry Coring Bit
2.5” Dry Coring Bit
2.75” Dry Coring Bit
3” Dry Coring Bit
3.5” Dry Coring Bit
4” Dry Coring Bit
1-1/4” 7 UNC to 5/8” 11 UNC Core Bit Adapter
10” Extension Rod
12” Extension Rod
18” Extension Rod

GDC4 CORE DRILL
6
Operations
Note
THOROUGHLY READ THROUGH THE ENTIRE MANUAL BEFORE
OPERATING THIS MACHINE!
PURPOSE
Ø The purpose of the GCD4 core drill is to drill through masonry, concrete or other
mineral rock types using annular coring bits.
Ø These drills are designed to be used by hand.
Ø These machines can be used vertically, horizontally or overhead (inverted) provided
an acceptable work environment.
o CAUTION: If drilling overhead you are only permitted to use dry type core bits
with a vacuum system. “Wet” type holes overhead would allow water into the
motor and create an extremely dangerous situation.
OPERATIONAL PRINCIPLES
Ø The main drilling shaft rotates in a forward clockwise direction. The main drilling
motor connects to the tool spindle to make contact with a surface and slowly bore a
hole.
Ø These drills are ONLY to be used with diamond impregnated coring bits.
o When drilling with “wet” type bits, the bit ends pulverizes the material and the
water brings the material out of the cut.
o When drilling with “dry” type bits, the bit end pulverizes the material and dust
brings the material out of the cut.
MACHINE COMPONENTS
Ø The main components of the GDC4 are the spindle, gearbox and motor. The spindle
is driven by the transfer case and the motor. There is a centrifugal clutch that
engages and drives the spindle once the motor begins to turn.
Chapter
3

GDC4 CORE DRILL
7
TRANSPORTING AND STORAGE OF THE MACHINE
Ø CAUTION: GAS FUMES ARE HIGLY FLAMABLE! GAS FUMES CAN CAUSE
DIZZINESS, VOMITING, AND A COMBUSTIBLE ENVIRONEMENT THAT CAN CAUSE
INJURY OR DEATH!
Ø When transporting the machine, always use two hands.
Ø DO NOT transport the machine with bits attached.
Ø As this is machine has a gas storage tank attached to the motor, it is NOT
recommended that this machine be transported inside of a vehicle. It is only
recommended to transport in a clean, dry, ventilated environment. ALWAYS secure
the machine when transporting with any vehicle so it does not move or bounce.
Ø The machine should be stored in a clean, dry, ventilated environment.
Ø “Winterizing” - It is recommended to run the machine dry (no gas in the fuel tank or in
the carburetor) if storing for more than 2 months as fuel can decay.
RUNNING THE MACHINE USING THE HANDHELD DRILLING METHOD
Ø Do all pre-operational and operational safety checks from Chapter 1.
Ø Consider your security and stability as well as the orientation of the machine in the
work area.
o DO NOT use this item in an unstable position (such as on a ladder, leaning
outside of center of gravity, etc). When using by hand, these drills could bind
up and personal injury could occur if not taking into account a very stable
body position.
o Consider the work surface material, condition, strength, density and rigidity.
These factors directly affect the tool’s efficiency.
Ø Ensure the work surface is free of debris, oil, etc.
Ø If using “wet” type bits, set up your drilling templates or other professional methods
for starting your hole.
Ø Select and set up fluid delivery method or dust collection system.
Ø If using the machine with the water system, connect hose to the side of the machine
using the connector.
o This connector takes standard ¾” US garden hose or quick disconnect
hookup depending on the model.
o Make sure the water valve is in the off position.
§ This is generally at a 90 degree angle from the valve hose.
o Partially turn the water spigot on (usually half a turn).
§ CAUTION: DO NOT turn the hose on fully! You need sufficient water
when using wet type bits. Using too much water pressure can cause
the bits to not cut properly as well as water entering the gearbox.

GDC4 CORE DRILL
8
Ø Select appropriate size cutting bit and install by screwing the bit onto the spindle.
See section below for details on securing bit.
Ø Open the water valve to allow water to come out to the work surface.
Ø If the engine is cold, shift the choke lever to the CLOSED position.
Ø If restarting a warm engine, the choke lever should be set the OPEN position.
Ø Press the priming bulb several times until there is fuel in the fuel-return tube.
Ø Turn the on/off switch into the “on” position.
Ø Adjust the throttle valve to the appropriate start position.
Ø Adjust the machine location to ensure the core bit do not contact any object in the
event it may accidentally rotate during the starting procedure.
Ø Pull starter handle lightly until resistance is felt once. Then pull the starter handle all
the way until the engine starts.
Ø Adjust the throttle valve to enable the engine to idle.
Ø As the engine temperature increases, gradually adjust the choke lever to the OPEN
position.
Ø Adjust the throttle valve to enable the engine to reach desired operating speed.
Ø ATTENTION: BE AWARE THESE MACHINES ARE EXTREMELY POWERFUL. THEY
HAVE A TREMENDOUS AMOUNT OF TORQUE WHICH MIGHT NOT BE SUITABLE
FOR ALL POTENTIAL USERS. ESPECIALLY WITH LARGER BITS. DESPITE THE
SAFETY CLUTCH, THESE DRILLS CAN STILL INJURE THE USER. IF IN DOUBT,
CONTACT A PROFESSIONAL FOR ADVICE.
Ø Very slowly engage the cutting bit with the material surface by lightly engaging the
bit with the material.
o NOTE: During the initial stages of contact the bit may wander.
o NOTE: If drilling and not using a guide, a common way to start the hole uses a
30 degree angle to slightly cut into the material. Once the bit has bored
slightly into the material, the user will slowly level the machine out straightly.
If unsure, it is recommended to contact a coring professional.
Ø After about 1/8” of cutting has been achieved in the work surface, slightly more force
can be applied. This will be the normal amount of force the rest of the hole.
o NOTE: Do not force the hole. Let the machine do most of the work.
Excessive physical effort should be avoided as it can cause damage to the
machine or cause injury to the user.
o If the unit jams in a hole, stop the drill immediately by quickly disengaging the
throttle switch to prevent injury. Loosen the cutter by turning drill spindle
counterclockwise. Never attempt to free a stuck bit by starting motor!
§ After an interruption in drilling, make sure the drill bit is free and turns
before restarting the hole. Be very careful at this point to make certain
the drill does not bind when restarting.
Ø Make sure to keep the cutting material lubricated when “wet” drilling.
Ø Ease up on pressure as the cutter starts breaking through the backside of the
material (if cutting completely through the material)
o Be certain all is clear on the output side of this core to prevent injury to
persons or property.

GDC4 CORE DRILL
9
o If drilling completely through the material, stop drilling after breaking through
the bottom, stop bit rotation and slowly pull out the bit and the core.
Ø If drilling to a specified depth (and not breaking all the way through the material)
leave the drill bit rotating until you reach your desired depth. Continue to leave the
drill bit rotating as you pull the bit completely out of the material.
Ø Once the drill is safely back to the non-drilling position, adjust the throttle valve to
enable the engine back to the idle state.
Ø Switch engine to “off” position.
Ø Turn water valve off. Turn off main water supply as well.
INSTALLING CORING BITS
Ø WARNING: Core bits can be sharp and should only be handled with gloves so as not
to cut the user during installation or removal.
Ø Check that the bits are not damaged.
o NOTE: Coring bits that are damaged should not be used.
Ø Make certain the machine is turned off.
Ø Apply grease to the spindle thread to prevent corrosion and allow easier core bit
removal.
Ø Insert the coring bit and screw it onto the drill spindle.
Ø Tighten the bit until fully tightened.
o Use wrenches that fit the spindle and coring bit to fully tighten.

GDC4 CORE DRILL
10
Troubleshooting
Note
SERVICING SHOULD ONLY BE DONE BY A QUALIFIED TECHNICIAN.
DON’T FORGET TO POWER DOWN UNIT PRIOR TO SERVICE!
PROBLEM
SOLUTION
Motor does not
turn on.
1) Check fuel level.
2) Fuel Filter is clogged. Replace filter.
3) Check oil level.
4) Check air filter is clean.
5) Motor carburetor needs cleaning.
6) Loose internal wire. Check and secure if necessary.
7) Spark plug issue. Inspect/replace if necessary.
8) Check to ensure the motor on/off switch is operable. Replace if
necessary.
Hole is not
cutting.
1) Cutting bit is dull. Replace bit.
2) Work area material is not appropriate for bit type.
Bit is jammed
while coring.
1) Debris is lodged between core hole and bit. Rotate bit in both
directions to and inspect bit for debris.
Coring speed has
reduced.
1) Bit has hit rebar. Adjust feed pressure to prevent motor overload while
cutting through rebar.
2) Diamonds on bit have glazed over. Deglaze bit or dress diamond rim on
bit and check water flow rate.
3) Diamonds on bit have worn away. Replace core bit.
4) New core bit. Core at slow rate with new bits for 2-3 coring cycles.
5) The safety clutch is slipping. Inspect and assess clutch condition.
6) DRY type drilling progress is prevented by an accumulation of dust.
Use suitable vacuum cleaner.
7) Water flow rate is too low. Increase water flow.
8) Core is stuck in the core bit. Remove core.
Core bit appears
to wobble.
1) Spindle is damaged. Replace spindle and check bearings.
2) Bit is bent or damaged. Replace bit.
3) The core bit is not screwed securely onto the spindle.
4) Coring material is attaching to the bit. Inspect bit and increase water
flow rate.
Water escapes at
the water swivel
or gear housing.
1) The water pressure is too high. Turn down water flow.
2) The shaft seal is defective. Replace seal
3) The water hose is damaged. Replace hose.
Chapter
4

GDC4 CORE DRILL
11
General Maintenance
Ø Inspect machine and machine body connections.
Ø Keep machine clean and free of debris. Do not forget to grease the drill spindle.
Ø Check for misalignment, binding and breakage of all moving parts. If damaged, repair tool
before use.
Ø Keep cutting tools sharp and clean. Sharp bits are less likely to bind and are easier to
control.
Occasional Maintenance
Ø Have the tool serviced by a qualified service technician using identical replacement parts.
o Inspect/Change Spark Plug:
o After 100hrs of use, inspect and remove the carbon build up
on the spark plugs.
o Check and adjust the spark plug gap to 0.6mm.
o Replace spark plug if necessary. Ensure the 0.6mm gap is
correct for a new plug.
o Change Gear Oil:
1) Change engine oil after 10 hours for a new machine (for engine break
in). After initial break in period, change oil at the 50 hour service
mark.
Chapter
5

GDC4 CORE DRILL
12
Parts List
NO.
Description
Item No.
Qty
1
Engine
Honda GX35
1
2
Handle
BKQYJ2018090101
2
3
Switch block
1
4
Inner hexagon screw
M6x20
2
5
Support plate
BKQYJ2018090102
2
6
Inner hexagon screw
M8x40
4
7
Mounting sleeve for handle
BKQYJ2018090103
2
8
Connecting plate
BKQYJ2018090104
1
9
Inner hexagon screw
M6x20
4
10
Inner hexagon screw
M6x20
2
11
Gearbox
BKQYJ2018090105
1
12
Baffle hexagon screw
BKQYJ2018090106
1
13
Inner hexagon screw
M6x15
2
14
O ring
16x3.1
1
15
1/4 Quick coupling
BKQYJ2018090108
1
16
1/4 valve
1
17
1/4 water tube connector
1
18
Water collecting ring
BKQYJ2018090109
1
19
TC Framework oil seal
35x50x8
2
20
Connection axle
BKQYJ2018090110
1
21
Cylindrical pin
8x35
1
22
Inner hexagon screw
M6x55
4
23
Handle cover
BKQYJ2018090111
1
Chapter
6

GDC4 CORE DRILL
13
Breakdown View - Overview