Norton DR620 User manual

OWNERS MANUAL
TBA & TBA CORE DRILLS
TBA & TBA CORE DRILL STAND
FORM <<7202005
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Important: Before placing equipment in operation, record the following
information.
MODEL:_________________ SERIAL NO.___________
PURCHASE FROM: _____________________________
ADDRESS: ____________________________________
CITY__________ STATE _________ ZIP ___________
TELEPHONE NO. _______________________________
Before using this equipment, make sure that person using it read and
understand the instructions in this owners manual.
TBA & TBA CORE DRILL
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CONTENTS PAGE
GENERAL INFORMATION
Warranty Infromation Inside
Cover
I. Preparation
A. Safety Precautions 4
B. General Information 5
C. Bit Installation 5
D. Water Supply 5
E. Electrical Supply 6
II. Operation
A. Core Drill Positioning 7
B. Drilling Technique 7
C. Vacuum Hold Down Operation (Optional) 8
D. Water Collector Operation (Optional) 8
III. Maintenance and Component Description
A. Motor Specifications (Cardi) 9
B. Motor Specifications (Milwaukee) 10
C. Vacuum Pump 11
D. Leveling Screws 11
E. Carriage 11
F. Gibs 12
G. Motor Spindle 12
H. Vacuum Seal 12
I. Electrical Wiring Diagram 13
IV. Parts List Section
A. Ordering Information 14
B. Optional Accessories 14
C. Assembly Drawings 16-19
D. Service Parts List 16-19
E. Operating & Maintance Instructions Gast Vaccum Pump 20
F. Cardi Authorized Repair 23-26
G. Milwaukee Authorized Distributors 27
H. Gast Pump Authorized Distributors 28
I. Machine Service Log
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I PREPARATION
A. Safety Precautions
IMPORTANT!THE FOLLOWING SAFETY PRECAUTIONS MUST BE OBSERVED.
1. Know your core drilling machine! Read the Operator’s manual carefully. Learn the operation,
application and limitations, as well as the specific potential hazards peculiar to this equipment.
2. Ground the machine! The core drill must be grounded while in use to protect the operator from
electric shock. The motor is equipped with a three prong grounding type plug to fit the proper type
receptacle. The green [or green & yellow] conductor in the cord is grounding wire.
3. NEVER connect the green [or green & yellow] wire to a live terminal.
4. Use only three-wire grounded extension cords suitable for use outdoors and of sufficient gage to
accommodate power requirements.
5. Replace frayed or damaged extension cords.
6. Keep the work area clean avoiding cluttered work areas.
7. Consider the work area environment!
¾Do not expose power tools to rain.
¾Wear rubber boots to further insulate yourself from the drill.
¾Mop up all excessive water around the work area before and after drilling.
¾Keep the work area well lit.
8. Use extreme caution when drilling through floors. Provide for protection of all personnel and material
below the area. Cores generally drop from the drill bit at the completion of the hole.
9. Keep visitors away. Do not let visitors contact tool or extension cord. All visitors should be kept at a
safe distance from the work area.
10. Do not force the bit into the drilling surface.
¾Use an anchor bolt , ceiling jack or vacuum hold-down attachment when drilling vertically
(ÐÏ) into floors.
¾Only use an anchor bolt or ceiling jack when drilling horizontally (ÕÖ) into a wall or any other
vertical surface.
11. Dress properly for the work being performed.
¾Do not wear loose clothing or jewelry which can get caught in moving or rotating parts.
¾Rubber gloves and non-skid footwear is recommended when working outside.
¾Wear protective covering to contain long hair.
12. Don’t abuse the cord. Never carry the tool by the cord or yank the cord to disconnect the plug
from the receptacle.
13. Secure the drill stand to the work surface. Use an anchor bolt, ceiling jack or vacuum
attachment to secure the drill stand to the work surface.
14. NEVER stand on the drill stand base as a method of securing the drill stand!
15. Don’t overreach! Keep proper footing and balance at all times. The slippery surface created
during the drilling operation results in unstable footing.
16. ALWAYS disconnect the power before servicing or changing accessories or bits.
17. ALWAYS check, then make sure wrenches are removed from the motor spindle and bit adapter
before connecting power or starting the drill motor.
18. ALWAYS make sure power switch is in “off” position before connecting drill to power.
Caution: It is very important that the drilling machine is properly secured to the work surface. Movement
during drilling will cause bit chatter against work surface, fracturing diamonds or binding bit in the hole.
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I PREPARATION
B. General Information
The Dr520 & Dr620 core drills are available with different power units.
MANUFACTURER AMPS VOLTS PHASE HERTZ
MILWAUKEE 15 115
SINGLE 60
Cardi 20 115
SINGLE 60
MILWAUKEE 20 115
SINGLE 60
All motors are single phase with two-speed selector switches. The 115 volt motors will
operate within a power range of 110 to 120 volts.
C. Bit Installation
The threads on the output spindle of the core drill motors have dimensions of 1-1/4"-7.
Core bits are available in a variety of diameters. The spindle thread on the adapter nut of
the core bit is 5/8-11 on smaller diameter bits. The use of an adapter coupling part
number 400148 is required in order to run smaller diameter bits. The adapter provides a
coupling which has a female 1-1/4"-7 thread on one side and a 5/8"-11 spindle on the
other end.
Core Bit Adapter
Part Number 400148
1. Using a wrench to firmly hold the output shaft , screw the core bit onto the spindle until
snug.
2. Placing one wrench on the machined flats of the output shaft and one wrench on the
end adapter of the core bit tighten the bit on the spindle. Note: Attempting to turn the
bit by the barrel rather than by the adapter nut may break the weld between the
adapter nut plate and the barrel.
D. Water Supply
It is important when wet cutting to maintain an
adequate supply of clean water to the diamond
drill bits. The hose input adapter on the water
swivel at the base of the core drill motor is used
to connect the water supply hose to the core
drilling unit. Special precautions should be
taken to insure that the water supply will not be
interrupted during the drilling operation.
Hose Input Adaptor
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I PREPARATION
E. Electrical Supply
The DR520 & DM620 core drills are furnished with 115 volt, single phase motors. These
motors operate within a power range of 110 to 120 volts. Serious damage can result if the
supply line voltage does not fall within this range.
The following wire sizes are recommended when using an extension cord:
DISTANCE
FROM
SOURCE
115 volt
25
FEET
115 volt
50
FEET
115 volt
75
FEET
115 volt
100
FEET
Wire
Gauge # 14 # 12 # 10 # 08
The DR520 & DR620 core drills are manufactured with a three conductor connector cord
which attaches the motor to the electrical supply. The green wire provided is used to
connect to a permanent ground.
za. Before connecting the drill to the power source, make sure that the voltage and cycles
shown on the name plate of the motor are the same as the available electrical power
supplied.
zb. Always properly ground the core drill before attempting to start the motor. The
presence of water during the drilling operation requires that the drill always be
properly grounded.
zc. NEVER connect the green wire to a live terminal !
The use of 3-prong adapter is prohibited in Canada
by the Canadian Electrical Code.
An adapter, Fig. "B" is available for connecting Fig.
A plugs to two prong receptacles. The green
grounding ear extending from adapter must be
connected to a permanent ground such as to
properly grounded outlet box. No adapter is
available for fig "C" plugs.
To connect twist lock plugs like those shown in
figures D and E, insert the plug into a matching
outlet. When the plug is fully inserted, turn it
clockwise until it locks. This prevents the plug from
being pulled out accidentally. To remove the plug,
twist it counterclockwise to unlock it and remove it
from the outlet.
NOTE: RECEPTACLE MUST BE GROUNDED FOR SAFE USE OF
ADAPTER:
IF IN DOUBT CALL A QUALIFIED ELECTRICIAN AND HAVE THE
RECEPTACLE CHECKED FOR G
ROUND
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II OPERATION
A. Core Drill Positions
To position the core drill:
1. Roll the drill so that the spindle is positioned over the desired drilling location.
2. Using the leveling screws located on the four corners of the base, level the core drill to
insure that the bit will drill a straight, vertical hole.
ÖCEILING BRACING - can be used when the ceiling above the work area is strong
enough to provide solid bracing. A length of pipe may be used with the adjustable brace
on the top of the drill column to firmly secure the drill against the work piece.
ÖANCHOR BOLTING - is a method used quite often in both horizontal and vertical drilling.
The anchor is secured in the work surface and the core drill is placed over the anchor bolt
so that the bolt goes through the hole in the center of the drill base. A nut and washer is
the used to pull the base down as the nut is screwed onto the anchor bolt.
ÖVACUUM HOLD DOWN - requires that the surface of the intended drilling area be
smooth or of an even texture in order to achieve an effective bond to the drilling surface.
A large hold down base and vacuum pump are used to fasten the drill to the work
surface. Both the pump and large base are available as optional accessories for the
drills.
B. Drilling Technique
The performance of any diamond core bit
depends heavily on the use of proper drilling
technique. Although drilling conditions and
materials may vary, following specific guide
lines insures faster drilling speeds and
longer bit life.
1. Secure the core drill to the work surface
so that there is no movement in the drill
that would cause the core bit to bind in
the hole.
2. Insure that the hole is constantly flushed
of abrasive fines by supplying a sufficient flow of water.
3. Slowly lower the bit into the hole so that there is no skidding or lateral movement of the
drill. The entire circumference of the core bit should penetrate the drilling surface
before additional pressure is applied to the handle.
4. Exert steady downward pressure while drilling. NEVER force the bit into the material!
5. Do not stop the flow of water or rotation of the bit while the core bit is drilling.
6. Check the core bit if the drilling rate decreases noticeably. The slowing penetration
rate generally indicates that the bit is in need of reconditioning.
Vacuum Pump Attachment
PART NUMBER: 407000
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II OPERATION
C. Vacuum Hold Down Operation
The vacuum hold down base and pump work together to seal the drill to the work surface.
The vacuum pump requires 115 volt electrical supply. A 115 volt accessory outlet located
on the switch box is used to supply power to the vacuum pump. One outlet is consistently
supplied with power so that turning the motor off does not turn off the vacuum pump and
release the drill from the work surface.
1. Mount the column and carriage in the large vacuum hold down base.
2. Connect the vacuum pump to the vacuum base.
3. Wet the work area in order to achieve an effective seal.
4. Connect the vacuum pump cord into the top outlet of the receptacle in the switch box
above the motor. This will start the pump and create a seal between the base and the
work surface.
5. Adjust the leveling screws so that the core drill is level and resting lightly on the
vacuum seal.
6. Plug the vacuum pump cord into the live outlet of the receptacle in the switch box. This
will start the pump and create a seal between the base and the work surface.
7. Adjust the leveling screws so that the base is snug against the work surface. NOTE:
(Excessive tightening of the leveling screws will break the seal between the base and
the work surface).
8. To turn the vacuum pump off, unplug the power cord.
D. Water Collector Operation
The water collector unit (Part Number 402034) is designed to work with any core drill. It
can be used with any diameter core bit up to and including ten inch. The unit consists of a
tear dropped shaped ring with a rubber seal, a 115 volt electric water pump and a
drainage hose.
1. Place the pump in the small end of the tear-drop ring. Center the large area of the ring
over the area to be drilled.
2. Run the drainage hose from the pump to a drainage barrel and secure the hose to the
barrel with the hose hook.
3. PROPERLY GROUND THE PUMP, then plug it into the top outlet of the core drill
switch box.
4. Turn the pump off by unplugging the pump power cord at the cord drill switch box.
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III. MAINTENANCE AND COMPONENT DESCRIPTION
A. Motor Specifications Cardi
Specifications
MOTOR RPM BIT CAPACITY IN
MFR MODEL VOLT AMP LOW
GEAR HIGH GEAR LOW GEAR HIGH GEAR
Cardi D3-250 120 20 420 860 8"-10" 4"-7"
*Refer to motor owners manual supplied with drill for required motor maintenance.
The Cardi motor is designed to operate at two
speeds. Changing speeds is accomplished by
using the speed shift knob built into the gear
case of the unit.
Changing the rpm of the motor is
accomplished as follows:
1. Turn off switch, wait for spindle to stop then
rotate the shift knob to go from the
HIGH(••) to LOW(•) speed.
2. Move the shift knob until the clutch teeth
are fully engaged. Moving the knob toward
the single dot engages the LOW rpm while
moving the knob toward the two dots
engages the HIGH rpm.
3. Attempting to shift with the motor off may
require turning the spindle by hand to
engage the clutch.
Changing the rpm while the motor is running
will damge gears and void warranty.
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III. MAINTENANCE AND COMPONENT DESCRIPTION
The vacuum pump is used with the large vacuum hold down
base to secure the core drill on smooth evenly textured
surfaces. The
pump is powered
by a 115 volt, 4.2
amp, 60 hertz
electric motor. The
power cord of the
pump is plugged
into the live outlet
of the receptacle in
the switch box of
the core drill. The
switch box on the
drill allows the motor on the drilling unit to be turned
on and off without shutting down the vacuum pump
and breaking the seal between the drill base and the
work surface.
The required maintenance procedure for the vacuum pump is listed in the "Parts List and
Operating and Maintenance Instructions" pamphlet. Parts for the vacuum pump are
available from local distributors of Gast products. A listing of Gast distributors is available in
this drill manual and in the vacuum pump pamphlet.
B. Leveling Screws
The four leveling screws on the base should cleaned with a mild solvent
and lubricated with a lightweight machine oil each time the machine is
used. Allowing the slurry to accumulate on the threads may cause damage
to the threads in the base.
C. Carriage
The carriage or head assembly should be cleaned and lubed with a
lightweight machine oil each time the machine is put away. Allowing slurry
to build on the column and inside the carriage will prematurely wear the
pinion gear and gibs.
GAST VACUUM PUMP
OPTIONAL
COMBINATION BASE
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III. MAINTENANCE AND COMPONENT DESCRIPTION
D. Gibs
The gibs are brass wear shims used on the inside of the carriage which
allow the carriage to slide freely and rigidly on the column. The gibs require
periodic replacement. Replacing the gibs is necessary when the carriage is
no longer rigid on the column. Keeping the column free of excess debris
and burrs will maximize the service life of the gibs.
E. Motor Spindle
The motor spindle on all core drill motors is equipped with 1-1/4"-7 thread
dimensions. The end adapter of the core bit is also threaded 1-1/4"-7 on
core bits of 2 inches and larger diameter. Core bits with a diameter less
than 1-5/8 inches have 5/8”-11 threads and require the use of an adapter.
The motor spindle maintenance should be performed each time the
machine is stored for the day. Leaving the core bit on the motor spindle
may cause the threads on the spindle to rust making removal of the core bit
very difficult. After removing the core bit check the threads for any nicks or
burrs. The spindle should then be cleaned with a mild solvent and
lubricated with a lightweight machine oil.
Removing the core bit from the motor spindle by turning the core bit barrel
is not recommended. The core bit barrel may break the weld between the
adapter plate and barrel if excessive side pressure is applied. The best
results are achieved using two wrenches. One of the wrenches placed on
the machined flats on the motor spindle and the other wrench on the core
bit end adapter.
F. Vacuum Seal
The vacuum seal is the sponge rubber gasket which lines the bottom of the
large vacuum base. The material prevents air from entering the area under
the base. Thus allowing the vacuum to pull against the work surface. In
order for the seal to work properly the seal material must remain pliable and
in one piece with no gaps or inconsistencies on the surface. The vacuum
seal should be rinsed at the completion of each operation. Allowing the
slurry to accumulate on the gasket will cause the material to deteriorate
prematurely. The vacuum seal should be checked on a regular basis and
replaced if it has been damaged or started to deteriorate.
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III. MAINTENANCE AND COMPONENT DESCRIPTION
G Electrical Wiring Diagram
BEFORE CONNECTING DRILL TO THE POWER SOURCE, MAKE SURE THE
VOLTAGE AND CYCLES SHOWN ON THE NAME PLATE AGREE WITH THE
AVAILABLE ELECTRICAL SUPPLY!
ALWAYS PROPERLY GROUND THE CORE DRILL!
NEVER CONNECT THE GREEN WIRE TO A LIVE TERMINAL!
INTERNAL WIRING DIAGRAM
See Page 19 For Switch Box Parts Breakdown
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IV. PARTS LIST SECTION
A. Ordering Information
1. List model number of machine.
2. List part number and description of part (not item number).
3. Wherever alternate parts are shown due to product improvement, inspect the part
you have and provide additional description as necessary.
4. Specify mode of shipping desired, such as, parcel post, truck, air freight, U.P.S.,
best way, etc.
B. Optional Accessories
1. Vacuum Hold Down: Part Number 407000 Provides a means of securing the core
drill on smooth evenly textured surfaces without using anchors.
2. Water Collector Kit: Part Number 402034 recovers the excess water used during
the drilling operation and pumps it into a drum. The ring is used to limit the amount
of area that is exposed to water. The ring is best used in areas where the surface
texture is smooth and even.
3. Shaft Couplings: The couplings are used as adapters which decrease or increase
the spindle diameter and thread dimension.
Part Number Spindle Thread Adapter Thread
400145 1/2"--20 5/8"--11
400146 5/8"--11 1/2"--20
400147 5/8"--11 1-1/4"--7
400148 1-1/4"--7 5/8"--11
4. Shaft Extensions: Extend the depth to which a core bit will drill when the carriage
has reached the maximum travel distance of the column.
Part Number Spindle Thread Length
402754 1-1/4"--7 9"
402755 1-1/4"--7 3.5"
402756 1-1/4"--7 12"
402757 5/8"--11 12"
402758 5/8"--11 6"
402759 5/8"--11 3"
5. Motor Spacer Plate Kit: Part Number: 408002 Moves the motor away from the
column so that the drill will accept up to a fourteen inch bit.
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B. Optional Accessories
Part
Number
408003
UPC: 70184600938
The Bit Slider
Helps prevent the core bit from
“sticking” on threads of spindle.
No more need for wrench and
hammer to remove core bits.
Part
Number
403126
UPC: 70184675539
Water Pressure Tank
4 Gallon capacity
Metal Construction
Fittings included
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ASSEMBLY DRAWINGS
TBA & TBA
CORE DRILLS
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IV. PARTS LIST SECTION
Product Breakdown:
Model UPC Description
DS5 70184600922 Rental Drill Stand Only
DR520 70184600924 DS5, Milwaukee 20A Drill Motor,
Vacuum Pump
DS6 70184600923 Professional Drill Stand Only
DR620 70184600925 DS6, Milwaukee 20A Drill Motor,
Vacuum Pump
DR620C 70184600926 DS6, Cardi 20A Drill Motor,
Vacuum Pump
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DS5 & DR520
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DS5 & DR520
Item No. Part# UPC# Description Qty
-NA- 407000 70184679912 PUMP VAC ASSY W/FITTINGS Opt
-NA- 403064 70184657985 MOT 20A 115V MILW ASSY Opt
-NA- 403061 70184657976 MOT 15A 115V MILW ASSY Opt
-NA- 408001 70184600916 MOT 20A 115V CARDI D3-250 Opt
-NA- 408002 70184600927 SPACER BLOCK DS5-DS6 Opt
-NA- 408003 70184600938 QUICK DISCONNECT BIT SLIDER Opt
1 408004 70184600985 GIBB BRASS 3X16X215MM 2
2 408005 70184600986 GIBB BRASS 3X38X215MM LS 1
3 408006 70184600987 GIBB BRASS 3X38X215MM 2
4 407062 70184679998 SWITCH BOX 1
5 27006 70184681615 NUT M10 1.5 DIN934 2
6 408007 70184600988 BUSHING THREADED 3/8X5/8 1
7 8177012 70184650149 WASHER 3/8 SPRING LOCK ZN 1
8 9048126 70184600989 SCR 3/8-16 X 1 SOC HD CP 1
9 408008 70184600990 TUBE 3/8ID X 1/2OD X 1L 1
10 408009 70184600991 WRENCH ALLEN 8MM T HANDLE 1
11 8041048 70184649898 SCR 3/8-16 X 3/4 HEXHDCAP 3
12 8041146 70184649936 SCR 5/8-11 X 3 HEXHDCAP 4
13 227146 70184674553 PIN COTTER 1/8 X 1-1/2 4
14 27505 70184681623 WASHER M20 DIN125 4
15 408010 70184600992 WHEEL 6 X 1-3/8 X 3/4 (2) 2
16 408011 70184600993 WHEEL DOLLY BRACKET DS5 1
17 8042136 70184600994 SCR 5/8-11 X 1 HEXHDCAP 2
8177016 70184650156 WASHER 5/8 SPRING LOCK 2
8172013 70184650127 WASHER 5/8 SAE 2
18 408012 70184600983 GASKET VACUUM BASE DS5- DS6 1
19 408013 70184600995 SCR 1/4-20 X 1/2 FHCP BRASS 9
20 8041008 70184649881 SCR 1/4-20X1 1/2 HEXHDC 1
21 408014 70184600996 BUBBLE LEVELING 1
22 9048092 70184650195 SCR 1/4-20X1 SOC HD CAP 6
23 9048090 70184600997 SCR 1/4-20X3/4 SOC HD CAP 4
24 408015 70184600998 DOVETAIL MOUNT 30 X 125MM 1
25 408016 70184600999 MOTOR MOUNT PLATE DS5- DS6 1
26 P110294 70184680687 KEY 3/8 X 3/8 X 2 1
27 408017 70184601000 KNOB HANDLE DS5-DS6 2
28 408018 70184601001 HANDLE BAR DS5-DS6 1
29 408019 70184601002 HANDLE CARRYING DS5-DS6 1
30 8041002 70184649875 SCR 1/4-20X1/2 HEXHDCAP 2
31 408020 70184601003 CARRIAGE LOCK 7/16-14 DS5- DS6 1
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DS5 & DR520
Item No. Part# UPC# Description Qty
32 408021 70184601004 CARRIAGE DS5-DS6 1
33 9083143 70184601005 SCR 7/16-14 X 1/2 SOC SET SCR 3
34 408022 70184601006 PINION GEAR DS5-DS6 1
35 8041095 70184649919 SCR 1/2-13 X4 1/2 FULL TH 2
36 8172011 70184650124 WASHER 1/2 SAE 4
37 408023 70184601007 COLUMN SUPPORT BRACKET DS5-DS6 2
38 408024 70184601008 SLOT PLUG ONLY DS5-DS6 1
39 408025 70184601009 CEILING JACK DS5-DS6 1
40 408026 70184601010 COLUMN DS5-DS6 1
41 408027 70184600984 GASKET SLOT PLUG DS5-DS6 1
42 408028 70184601011 VACUUM MOUNT DS5-DS6 1
43 408029 70184601012 BASE DR5-DR6 1
44 8041107 70184649929 SCR 1/2-13X4 1/2 HEXHDCAP 2
8172011 70184650124 WASHER 1/2 SAE 4
8177014 70184650154 WASHER 1/2 SPRING LOCK 2
8143005 70184650358 NUT 1/2-13 HEX JAM 2
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