Drill Master JOURNEYMAN 400 User manual

JOURNEYMAN 400
User’s Guide
Guía del usuario
Mode d’emploi
1. ALIGN BITS
3. SPLIT POINTS
2. SHARPEN BITS

Thank you...
for buying your Drill Doctor®400. It will become a valuable tool
because you will now have sharp drill bits before a project,
during a project, and after a project.
I am very proud of the quality of our products and I am equally
proud of the great people at Drill Doctor who design and produce
them. If you have questions or need help with your Drill Doctor,
please call 1-800-597-6170 and one of our customer
representatives will be there to help.We support what we build!
Use this User’s Guide to learn to operate your Drill Doctor. I also
want to invite you to visit our website at www.DrillDoctor.com.
There you will find:
•Demonstrations of all operations with the sights and sounds
leading to successful drill bit sharpening
•Downloadable copies of the User’s Guide
•Warranty registration
•Service and contact numbers
Again, thank you for buying a Drill Doctor. Now enjoy its
convenience and quality.
Hank O’Dougherty, President, Drill Doctor®

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Contents
English
Safety .......................................................................... 2
Getting to Know Your Drill Doctor®............................ 3
Identifying Basic Drill Bits ........................................... 4
Anatomy of a Drill Bit ................................................. 4
The Drill Doctor®Sharpening Process ......................... 5
Aligning the Drill Bit ................................................... 5
Grit Tube Attachment .................................................. 7
Sharpening the Drill Bit .............................................. 8
Identifying Correctly Sharpened Drill Bits ................... 9
Split Points ............................................................... 10
Creating or Replacing a Split Point .......................... 10
Identifying Correctly Split Bits ................................. 11
Sharpening Bits of Different Lengths
and Diameters ....................................................... 12
Aligning and Sharpening Masonry Drill Bits ............ 13
Questions and Answers ........................................... 14
Drill Doctor®Maintenance ....................................... 18
Accessories and User-Replaceable Parts .................. 20
Warranty .................................................................. 21
Español ........................................................... 22
Français .......................................................... 45
English

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WARNING: Some dust created by power sanding,
grinding, miscellaneous construction activities, as well
as contents from the machine including the molding,
wiring, grinding wheel, or any other parts may contain
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm and can
be hazardous to your health.
Safety
•Carefully read this User’s Guide before operating the Drill
Doctor.
•When using electric tools, basic safety precautions should
always be followed to prevent the risk of fire, electric shock
and personal injury.
•Always disconnect the Drill Doctor when cleaning or
inspecting. Make sure the switch is in the OFF position before
plugging in the power cord.
•Do not use in wet or damp locations.
•Do not abuse the cord.
•Wear eye protection when using or cleaning the Drill Doctor.
•Never touch internal parts of the sharpener when it is turned
on or plugged in.The rotating diamond wheel can cause injury.
•As with any power tool, the Drill Doctor should be kept out
of the reach of children.

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Getting to Know Your Drill Doctor®
Split
Point
Hole
Power Switch
(at cord end)
Alignment
Button
Wheel Access
Cover
Alignment
Hole
Sharpening
Hole
Cam Guide
Flat Spot
Flat Spot
Window
Cam
Chuck
Knob
Chuck
Grit Tube and Cap

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Identifying Basic Drill Bits
The Drill Doctor®is most efficient when used to resharpen a
drill bit’s original point angle.With its standard diamond grind-
ing wheel it will sharpen high-speed steel, cobalt, TiN-coated,
carbide and masonry drill bits.
It has been designed and engineered to sharpen three of the
most common drill bit types:
Standard Point
This general purpose point is used for
drilling softer materials like cold
rolled steel, aluminum, and wood.
Masonry bits have a carbide insert
at the point and are used for drilling
materials like cement, brick, and
ceramic.
Split point bits are self-centering
and are generally used for tempered
steels, hard alloys or hard cast
materials.
Anatomy of a Drill Bit
It is important to understand that
each bit has a Chisel Edge, a Cutting
Edge, and a Heel.
When viewing a well sharpened bit
from the end, the entire surface from
the Cutting Edge to the Heel will have
a finely ground surface without ridges
or indentations. And, the Heel will
always be lower than the Cutting Edge.
Heel
Chisel
Edge
Cutting
Edge
Heel Cutting
Edge

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The Drill Doctor®Sharpening Process
The sharpening process includes 3 easy procedures:
1. Align the bit in the Chuck.
2. Sharpen the bit.
3. Split the point (if you choose).
Be sure to complete all three of the procedures to sharpen
and split a bit and always sharpen the bit prior to splitting it.
Aligning the Drill Bit
(See page 13 to align and sharpen a Masonry drill bit.)
4.
1. Turn the Chuck Knob to the left
to open the Chuck and Insert
your drill bit into the Chuck
(about halfway in is fine for
now).
Turn the Chuck Knob to the right
to tighten.
Turn the Chuck Knob to the left
just until the bit will slide and
rotate in the Chuck.
With one hand, press in and
hold the Alignment Button on
the Drill Doctor (do not release
until Step 7).
2.
3.

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Flat Spots
5.
With your free hand, insert the
Chuck into theAlignment Hole—
make sure the flat spots on the
Chuck match the flat spots in
the hole.
At this point, the Chuck
should be inserted into the
Alignment Hole with the
flat spots hidden, and the
Chuck should be locked in the hole.
6.
8.
9.
With the Alignment Button held
in, push the drill bit forward until
it is against the Drill Stop.
Look at the drill bit through
the Window over the
Alignment Hole—it should be
against the Drill Stop.
Release the Alignment Button.
While looking in the Window,
turn the drill bit to the right until
you feel the Bit Clamps grip
the bit at its narrowest
point (the bit is now difficult
to turn either way).
Turn the Chuck Knob to the right
until it is tight but make sure that
the bit did not turn or the Chuck
did not back out of the Hole.
7.

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Press the Alignment Button in
and remove the Chuck from the
Alignment Hole. Tighten the
Chuck Knob firmly.
You are now ready to sharpen the
drill bit.
10.
Grit Tube Attachment
The grit tube attachment is not critical for the function of the
Drill Doctor; however using it offers the following benefits:
•Extends the life of your Drill Doctor by removing the grit
created when sharpening your drill bits.
•Keeps your Drill Doctor in better operating condition with
less maintenance
•Keeps your work area safe and clean
•Easily attaches to a vacuum to clean your Drill Doctor
Using the Grit Tube Attachment
11.
Insert the ribbed end of the grit tube into the split-point
hole. (The second rib will be flush with the split-point hole).
For Use with Grit Tube Only
•Adjust position of the grit tube
as shown in Illustration A.
•Place the cap on the open end
of the grit tube.
•Sharpen as usual.
•After sharpening, remove cap to
dispose of grit.
For Use with Shop Vac
•Adjust position of the grit tube
as shown in Illustration B.
•Place the 1 1/4" vacuum hose
attachment on the open end of
the grit tube.
•Turn on your vacuum before
sharpening. Sharpen as usual.
•Grit will be suctioned into shop
vac. Dispose of debris as usual.
A
B

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Sharpening the Drill Bit
Before sharpening you should know:
•Keep the Cam in contact with the Cam Guide as you
sharpen—push the Chuck straight into the hole.
•Only light pressure is required—let the diamond wheel do
its work.
•Turn the Chuck an even number of half-turns:
3/32 inch bits—use 2 to 4 half-turns,
1/8 inch bits—use 4 to 6 half-turns,
3/8 inch bits—use 6 or more half-turns.
•You will hear a grinding noise as you complete each half-
turn and each side of the bit face is ground. (zzzzzzzzz)
•The Chuck will rock as you turn it and the Cam rides on the
Guide.
13.
12.
Insert the Chuck into the
Sharpening Hole.
It will be easier to sharpen the
bit if you stand up.
Align one of the white marks on
the Cam with the Cam Guide,
and push the Power
Switch to the ON (I)
position.
14. Turn the Chuck in complete half-
turns to the right so the white
marks on the Chuck move to the
Cam Guide one after the other.
It is important that your half-
turns be continuous—do not
stop or hesitate in the middle.
Cam Guide White Mark
Cam

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Identifying Correctly-Sharpened Drill Bits
(And What to Do With Those That Aren’t!)
The entire surface from the Cutting
Edge to the Heel will have a finely
ground surface without ridges or
indentations. And, the Heel will
always be lower than the Cutting
Edge.
Correctly Sharpened
Cause
Bit Clamps did not grip drill bit at
narrowest point in the aligning process
(Page 6).
Solution
Realign the bit by carefully following
steps 1 through 10 on Pages 4 to 7.
Cause
Sharpening Hole not functioning
properly.
Solution
The Sharpening Hole is where you
rotate the Chuck when sharpening.
Locate the bump on the bottom of the
Hole and press down on it. If the tube
does not spring back, please call our
Technical Support group at 1-800-597-
6170 or 541-552-1301 for assistance.
Cause
Dirty Chuck.
Solution
Insert a drill bit into the Chuck, tighten
Misaligned
Heel
The Chisel Edge is
ground flat.
Heel
Same Height
or Higher
Than the
Cutting Edge
Chisel Point
Cutting Edge
it, then press the bit against a hard surface. Does the bit slide
in the Chuck? If so, clean the Chuck as described on Page 18.
Cutting Edge
Heel

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2.
3.
1. With the machine turned on,
match the white line on the
Chuck with the white line next
to the Splitting Hole.
Split Points
Split point drill bits prevent walk-around on the material before
they begin to cut.
This feature is described as self centering. The need to center
punch is effectively eliminated. A standard drill bit chisel point
has to wear an area in the middle of the hole to be drilled before
the cutting edges will remove material. Due to its additional
cutting lips along the chisel edge, a split point will begin cutting
immediately. Up to 70% less thrust (when compared to a non-
split or conventional point) is required to drill a hole with a split
point.
Creating or Replacing a Split Point
Always align and sharpen a bit before splitting it.With the
Splitting Hole facing you, notice that the Splitting Hole has flat
spots like the Alignment Hole and a white mark on the case
next to the Hole. When inserting the Chuck into the Hole, align
the white mark on the Chuck with the white mark on the case.
As you push the Chuck slowly into the Hole, the flat spots on
the Chuck and in the Hole should match.The Chuck will be tight
in the Hole.
Insert the Chuck into the Splitting
Hole so the flat spots match
(white line to white line) and
push slowly and firmly until
the Chuck stops (you will hear a
grinding sound). Push hard until
the Chuck stops.
Pull the Chuck out slightly until
the flat spots release, and turn it
a half-turn either way. With the
white lines and flat spots aligned,
push it in firmly and slowly
until it stops. The second side of
the bit is now split.
White Marks

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4. Check the tip of the bit
carefully to determine that
both sides of the bit are split
equally. Compare it to this
illustration. If it does not
match, study the information
below.
Identifying Correctly Split Drill Bits
(And What to Do With Those That Aren’t!)
Correctly Split
Solution
More grinding is needed for
larger drill bits. If one side of
the bit is undersplit, insert the
Chuck into the Splitting Hole
again and split both sides.
Push the Chuck into the Hole
until it stops. Repeat until the
split sides are equal and look
like the correctly split bit
shown above.
Undersplit
Solution
After splitting, do not remove
the bit from the Chuck.
Reinsert the chucked bit into
the Sharpening Hole and
remove enough of the tip
until the split tip looks like the
correctly split bit above.
Oversplit
Split line
Split lines are nearly straight
across.
Not enough material has been
removed from the heel of the
drill bit.
Too much material removed.
Split lines do not meet in the
center but Chisel Edge remains.
Split lines are joined in the
center and Chisel Edge has
been removed.

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Sharpening Bits of Different Lengths
and Diameters
Drill Bits Of Different Sizes
Too many rotations of a small diameter bit may result in incorrect
sharpening and too few on a large bit may not sharpen enough.
3/32 inch bits—use 2 to 4 half-turns,
1/8 inch bits—use 4 to 6 half-turns,
3/8 inch bits—use 6 or more half-turns.
Large Drill Bits
Large drill bits (3/8" to 1/2") will require increased pressure
and more half-turns (20 or more) of the Chuck. A well sharpened
bit will have a smooth surface from cutting edge to heel. It may
take two or three complete sharpenings (repeat all steps) to
resharpen a very dull or chipped large drill bit.
Short Drill Bits
Often bits smaller than 1/8" in diameter are so short they will
not stick out of the back of the Chuck.After inserting a small bit
into the Chuck and while holding theAlignment Button in, insert
the Chuck into the Alignment Hole.Then, insert a finger into the
back of the Chuck Knob and push the bit forward against the
Drill Stop. Look through the Window and make sure the Bit
Clamps grasp the bit at the narrowest point when you release
the Alignment Button.
Tighten the Chuck Knob, but
before sharpening small bits,
look through the back of the
Chuck to be sure all Chuck Jaws
are straight against the drill bit.
If the Jaws appear to be out of
line, move the Chuck Knob
slightly to the left just until the
Jaws straighten—do not loosen
the Chuck Knob or the bit will
loosen and the alignment will be
lost. Now, sharpen the bit in the
usual manner.
Correct
Incorrect

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Aligning and Sharpening Masonry Drill Bits
1.
3.
5.
Note: The Drill Doctor will place a curved grind on the carbide
insert, altering the appearance of the factory point.
4.
Now, sharpen the bit in the
Sharpening Hole. Always use an
even number of half-turns when
sharpening. Start with four half-
turns and then add as many half-
turns as needed.
While looking through the win-
dow, start with the carbide tip of
the bit straight up and down, and
then turn it 1/8 turn to the right
(the carbide tip should point to
between the 1:00 and 2:00
o’clock position when looking at
a clock face).
Push the Alignment Button back
to the housing and hold it in
through Step 4. Insert the
chucked drill bit to the
stop. Bit Clamps are
not used when
aligning masonry
bits.
Insert your masonry bit in the
Chuck in the same manner as
other bits (See page 5).
Tighten the Chuck Knob and
remove the chuck from theAlign-
ment Hole. Release the Align-
ment Button and tighten the
Chuck.
12:00 1:00
2:00
3:00
6:00
9:00
2.

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Questions and Answers
1. Question:
When I aligned the drill bit and sharpened it, why was no
material removed?
Answer:
This happens when the bit is not protruding out of the Chuck
far enough. You may have allowed the Alignment Button to
knock the drill back into the Chuck when aligning the bit.
Carefully realign the bit in the Alignment Hole again. Make sure
the drill is pushed all the way against the Drill Stop before you
release the Alignment Button.
2. Question:
I sharpened the bit. Why will it not cut?
Answer:
This happens when the heel on the bit is higher than the cutting
edge (negative relief). Realign the drill and resharpen in the
Sharpening Hole.
Maintain consistent inward light pressure during the half-turns
of the Chuck.
You may have a specialty drill bit. Slow and Fast Spiral, Helix,
Turbo Flutes, and Raised Margin drill bits are considered specialty
bits. To sharpen them, align them in the
Chuck as you do standard bits. Check the
position of the two Flats on the
Chuck and draw an imaginary line
from the middle of the flat up
through the drill bit (3/32" to 1/2").
When aligning, start with the Bit
Clamps on the narrow part of the
bit, then turn the bit clockwise to
approximately the 1:00 o’clock position. Hold the bit so it will
not move and tighten the Chuck. You may have to move the
drill bit clockwise in the Chuck more than once until it sharpens
correctly.
If the chisel edge moves too far to the right, realign the bit and
adjust again.
Heel
Flat Spot

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3. Question:
Why is the drill point off center?
Answer:
If the tip of the drill bit appears to be sharpened off center,
check the following items:
•You may not have done an even number of half-turns when
you sharpened and one face of the bit was ground more than
the other. Always use an even number of half-turns when
you sharpen.
•Make sure that there are no particles between the chuck jaws
and the drill bit which could hold it off center.
•Make sure the bit is not loose in the Chuck.
•During the sharpening process be sure to keep the same
pressure on each half-turn.
4. Question:
What can I do about flat spots on the bit point between
the cutting edge and the heel?
Answer:
The flat spots on a sharpened bit are the result of an incomplete
or paused half-turn of the Chuck in the Sharpening Hole. To
correct, apply light, not firm inward pressure and rotate the
Chuck smoothly while sharpening. Be sure to complete the half-
turns.
5. Question:
Why is the chisel edge on my drill bit flat?
Answer:
During the alignment process the Bit Clamps were gripping the
high points of the drill bit. Realign the drill bit making sure that
the Bit Clamps are located in the narrowest section of the bit.

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6. Question:
Why are my small drill bits grinding off-center?
Answer:
After aligning the small bit, look into the back of the chuck and
determine if the jaws are straight against the bit. If the jaws
appear to be out of line, move the Chuck Knob slightly to the
left just until the Jaws straighten. Do not loosen the Chuck Knob
or the bit will loosen and the alignment will be lost. If that
happens, you will need to align the bit again.
7. Question:
Why was my drill bit sharpened improperly?
Answer:
The most common cause of improper sharpening is improper
drill bit alignment.
Key causes are:
1. Drill point not pushed all the way to the Drill Stop.
2. Chuck not pushed all the way into the Alignment Hole.
3. Drill not aligned in the Bit Clamps correctly.
In order to correct these problems be sure the Chuck is all the
way in the Alignment Hole with the flats entirely hidden. The
drill point must be against the Drill Stop and the Bit Clamps
must be at the narrowest part of the drill bit.
8. Question:
Why is my split point uneven?
Answer:
Page 11 shows a drill point that is undersplit and a drill point
that is correctly split.To correct an uneven point split, insert the
Chuck into the Splitting Hole and split both sides again. Push
the Chuck into the Hole until it stops. Repeat until the split sides
are equal and look like the correctly split bit shown above.

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9. Question:
Why does the drill bit back up into the Chuck during the
sharpening procedure?
Answer:
Make sure the bit is tight in the Chuck before sharpening.
Your Chuck may be dirty. Follow the steps for cleaning the Chuck
on page 18.
10. Question:
When splitting, why don’t I hear a grinding sound?
Answer:
The Chuck is not seated properly in the flat spots of the Splitting
Hole.
When inserting the Chuck into the Splitting Hole (with the
Splitting Hole facing you), align the flat spots and move the
Chuck either way until the flat spots mesh. Firmly and slowly
push the Chuck into the hole until the grinding sound stops.
11. Question:
Can I change a 135-degree drill bit into a 118-degree drill
bit?
Answer:
You can change the degree angle of any drill bit from 135 degrees
to 118 degrees.
The alignment and sharpening procedure will need to be
performed three or more times to remove the old angle and
produce the new angle desired.

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Drill Doctor®Maintenance
After sharpening 20 to 25 drill bits, the drill bit grinding dust
will accumulate in the grinding compartment. Grinding particles
will promote wear in the Alignment, Sharpening, and Splitting
Holes and Chucks, so cleaning on a consistent basis can add life
to your machine. Before any maintenance or cleaning is
performed, be sure to unplug your Drill Doctor.®
Removing the Wheel Cover
Unplug the Drill Doctor.®Using the narrow end of the wrench
provided (or a flat head screwdriver), insert it into the slot of
the clear Wheel Cover on the front of the machine and use a
twisting motion to pry the cover off.
Cleaning Your Drill Doctor
®
Unplug the Drill Doctor.®Shake accumulated drill bit grinding
dust from behind the Wheel Cover into a disposable container.
Remove dust particles around the wheel with a small dry brush.
Dispose of the container and drill bit dust in a safe and
environmentally approved manner. With a dry cloth wipe the
inside and outside of the three Holes to remove any grinding
dust that may have accumulated. A standard 1" vacuum hose
works equally well.
Jaw Alignment
Grooves
Jaws
Chuck
Knob
Cleaning the Chuck
With compressed air, blow out the
Chuck from the Knob end. After 20 to
25 sharpenings, you may need to
disassemble the Chuck for cleaning:
•Keep the Chuck upright (vertical)
and remove the Chuck Knob.
•Do not remove the springs or Jaws.
•Use a small brush or rag to remove
all grinding particles.
•Reassemble with all of the Jaws in
their respective grooves. If some
Jaws do not slip into their grooves
on the inside of the Chuck, reach
through the hole in the bottom of
the Chuck Knob (or use a paper clip
or small bit) and align them.