Slugger 18066 User manual

Slugger USA5
Slugger Portable Magnetic Drilling Machine
OPERATOR’S MANUAL
HEARING PROTECTION
REQUIRED
EYE PROTECTION
REQUIRED
MODEL #18066 (120V) OR #18080 (240V)
Serial # Date of Purchase
BEWARE OF
ROTATING
MACHINE PARTS
LINE VOLTAGE
PRESENT
NEVER PLACE
FINGERS NEAR
CUTTING AREA OR
MACHINE ARBOR
WARNING!
before use, be sure everyone using this machine reads and understands
all safety and operating instructions in this manual.
ALPHA INDUSTRIAL TOOL &
EQUIPMENT
51 Tamarack Drive
Thornhill, Ont
L3T 4 W2
Canada
PH. 905-731-1310
FAX [phone]

Slugger Portable Magnetic Drilling Machine
Congratulations on your purchase of a Slugger portable magnetic drilling machine. Slugger drilling machines are
designed to deliver fast, efficient hole drilling performance in portable applications. Please take a moment to complete
and mail your product warranty registration card. Doing so will validate your machine’s warranty period and ensure
prompt service if needed. Thank you for selecting a Slugger product from Jancy Engineering Inc..
table of contents
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Guideline for Shift Lever Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SpecialInstructions......................................... 5
Grounding Instructions and Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . 6
ContentsofPackage........................................ 7
GettingStarted ........................................... 7
MachineOperation........................................ 8
BasicTroubleshooting....................................... 9
RegularMaintenance...................................... 10
ControlPanelandPartsList .................................. 11
Machine and Arbor Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Machine and Arbor Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MotorPartsList .......................................... 14
AvailableSluggerCutters ................................... 15
JANCY ENGINEERING RESERVES THE RIGHT TO MAKE
IMPROVEMENTS AND MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE.
limited warranty
Jancy Engineering Inc. will, within one (1) year from the original date of purchase, repair or replace any goods found to
be defective in materials or workmanship, provided the product warranty registration card has been returned to Jancy
Engineering Inc. within thirty (30) days of purchase date. This warranty is void if the item has been damaged by acci-
dent, neglect, improper service or other causes not arising out of defects in materials or workmanship. This warranty does
not apply to machines and/or components which have been altered, changed, or modified in any way, or subjected to
use beyond recommended capacities and specifications. Electrical components are subject to respective manufacturers’
warranties. All goods returned defective shall be returned prepaid freight to Jancy, which shall be the buyer’s sole and
exclusive remedy for defective goods. In no event shall Jancy Engineering be liable for loss or damage resulting directly or
indirectly from the use of merchandise or from any other cause. Jancy Engineering is not liable for any costs incurred on
such goods or consequential damages. No officer, employee or agent of Jancy is authorized to make oral representations
of fitness or to waive any of the foregoing terms of sale and none shall be binding on Jancy.
2
™

important safety instructions
WARNING!
when using electric tools, basic safety precautions should always be followed
to reduce risk of fire, electric shock and personal injury.
READ AND SAVE ALL INSTRUCTIONS FOR FUTURE REFERENCE.
1. Keep Work Area Clean
•Cluttered areas and benches invite injuries.
2. Consider Work Area Environment
•Do not expose power tools to rain.
•Do not use power tools in damp or wet locations.
•Keep work area well lit.
•Do not use tool in presence of flammable liquids or gases.
3. Guard Against Electric Shock
•Prevent body contact with grounded surfaces. For example: pipes, radiators, ranges and refrigerator enclosures.
4. Keep Children Away
•Do not let visitors contact tool or extension cord.
•All visitors should be kept away from work area.
5. Store Idle Tools
•When not in use, tools should be stored in a dry, high and locked-up place, out of reach of children.
6. Do Not Force Tool
•It will do the job better and safer at the rate for which it was intended.
7. Use Right Tool
•Do not force a small tool or attachment to do the job of a heavy-duty tool.
•Do not use tool for unintended purpose. For example: Do not use a circular saw for cutting tree limbs or logs.
8. Dress Properly
•Do not wear loose clothing or jewelry. They can be caught in moving parts.
•Non-skid footwear is recommended when working outdoors.
•Wear protective hair covering to contain long hair.
9. Use Safety Glasses
•Also use face or dust mask if cutting operation is dusty.
10. Do Not Abuse Electrical Cord
•Never carry tool by cord or yank it to disconnect from receptacle.
•Keep cord from heat, oil and sharp edges.
11. Secure Work
•Use clamps or a vise to hold work. It’s safer than using your hand and it frees both hands to operate tool.
12. Do Not Overreach
•Keep proper footing and balance at all times.
3

13. Maintain Tools With Care
•Keep tools sharp and clean for better and safer performance.
•Follow instructions for lubricating and changing accessories.
•Inspect tool cords periodically and if damaged, have repaired by authorized service facility.
•Inspect extension cords periodically and replace if damaged.
•Keep handles dry, clean, and free from oil and grease.
14. Disconnect Tools
•Unplug when not in use, before servicing, and when changing accessories, such as bits and cutters.
15. Remove Adjusting Keys And Wrenches
•Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on.
16. Avoid Unintentional Starting
•Do not carry a plugged-in tool. Always disconnect from power source before moving.
•Be sure switches are off before connecting to a power source.
17. Outdoor Use Extension Cords
•When tool is used outdoors, use only extension cords intended for use outdoors and so marked.
18. Stay Alert
•Watch what you are doing. Use common sense. Do not operate tool when you are tired.
•Do not use when taking medications that may cause drowsiness.
19. Check Damaged Parts
•Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine
that it will operate properly and perform its intended function.
•Check alignment of moving parts, binding of parts, breakage of parts, mounting, and any other conditions
that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced
by an authorized service center.
•Do not use this tool if switches do not turn it on and off. Have defective switches replaced by authorized
service center.
important safety instructions
4
guideline for usa5 shift lever position

1. If you require an additional manual, please contact Jancy Engineering at [phone] for a FREE copy.
2. Never place hands, fingers, gloves or clothing near cutting area or rotating machine parts.
3. Always disconnect machine from power source before changing cutters, clearing chips, refilling lubricant or
performing adjustments.
4. Keep all safety features functioning and working properly.
5. Never wear loose clothing, gloves or jewelry when working near cutting area or rotating machine parts.
6. Always use eye and hearing protection.
7. Always use safety strap and chip guard provided with machine.
8. Always use proper tooling. Keep cutters securely fastened.
9. Do not use dull or broken cutters.
10. Do not use Slugger drilling machines on surfaces or materials being welded. Doing so can damage the
machine’s electrical components.
11. Beware of slugs ejected at end of cut. They become HOT during the cut.
12. Magnet will not hold properly on thin materials or rough and dirty surfaces.
13. Keep bottom of magnet burr free and clear of chips and debris.
14. To reduce the risk of electrical shock, do not use machine in wet or damp areas.
15. Do not remove or alter electrical panels. Use only authorized service centers for repairs.
16. Motor will not start on non-ferrous materials.
WARNING!
do not operate machine if warning and/or instruction labels are missing or damaged.
contact jancy engineering for replacement labels.
special instructions
5

WARNING!
Improperly connecting the grounding wire can result in the risk of electrical shock.
Check with a qualified electrician if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug provided with tool. Never remove the
grounding prong from the plug. If the cord or plug is damaged, have it repaired
before using. If the plug will not fit the outlet, have a proper outlet installed by a
qualified electrician. The USA5 must be plugged into an appropriate outlet, prop-
erly installed and grounded in accordance with all codes and ordinances. The
plug and outlet should look like those in Figure A.
WARNING!
do not use slugger drilling machines on surfaces or materials being
welded. doing so can result in personal injury and/or damage to the
slugger drilling machine.
grounding instructions
6
DRIP LOOP: To help prevent cutting fluids from traveling
along power cord and contacting power source, tie a drip
loop in power cord as shown in Figure B.
Fig. B
Use only 3-wire extension cords that have 3-prong grounding-type plugs and 3-pole receptacles that accept the tool’s
plug. Replace or repair damaged cords. Make sure your extension cord is in good condition. When using an extension
cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop
in line voltage resulting in loss of power and overheating. Jancy recommends using a minimum 12 gauge extension cord
not to exceed 100 feet. The table below is supplied only as a guide to minimum gauge for extension cords, where the
smaller the gauge number, the heavier the cord.
extension cords
minimum gauge for extension cords
volts total length of cord in feet
120V 0-25 26-50 51-100 101-150
240V 0-50 51-100 101-200 201-300
amperage
0-6 18 16 16 14
6-10 18 16 14 12
10-12 16 16 14 12
12-16 14 12 not recommended
recommended wire gauge
* jancy recommends using aminimum 12 gauge extension
cord not to exceed 100 feet.

Remove all contents from packaging and inspect to ensure no damage was incurred during shipping. Your USA5 package
should also include the following:
operating instructions (before you begin)
description part # qty
OPERATOR’S MANUAL LIT104B 1
MAGNET NOTICE WARNING 0107D0C 1
SHUNT AND SHUNT INSTRUCTIONS 06954 1
WARRANTY CARD 0070342 1
3/16" PILOT 1" DEPTH OF CUT 16001 1
3/16" PILOT 2" DEPTH OF CUT 16002 1
1/4" PILOT 1" DEPTH OF CUT 16003 1
1/4" PILOT 2" DEPTH OF CUT 16004 1
1/4" PILOT 3" DEPTH OF CUT 16005 1
3/8"-24" x5/16" SSS 10185 3
PIPE HANDLE 10217 1
SAFETY STRAP 06798 1
3/16" HEX KEY 70089 1
3/16" T-HANDLE HEX KEY 70090 1
4MM HEX KEY 70587 1
SPOKE HANDLE 0151333 3
SAFETY AND MAINTENANCE VIDEO 0151515 1
getting started
what you should know before you drill
CAUTION!
always disconnect usa5 from power source before making adjustments.
NOTE: The item numbers found below in parenthesis refer to the images on page 12.
Assemble three spoke handles (item #18) to feed hub (item #17). NOTE: Feed hub assembly is mounted on right side
of machine frame . If necessary, it can be reversed for lefthand operation by simply removing the fastener (item #29)
and sleeve (item #30) from frame. Remove hub pinion shaft from right side of frame and insert it into left side of frame.
Replace sleeve and fastener into frame and tighten securely. Thread pipe handle (item #2) into motor housing. The
control panel (item #27) may also be reversed from left to right side of machine if desired. Remove screws (item #19)
holding control panel and side cover plate (item #20); next, remove side cover plate and control panel, then discon-
nect magnet and motor pin connections when removing control panel. Move control panel to opposite side of frame.
Reconnect magnet and motor pin connectors and secure control panel assembly using four screws (item #19). Replace
side cover plate, making sure warning instructions are visible.
1. Type of material to be drilled, Brinnell or Rockwell hardness, material thickness and position should all be determined
to ensure proper selection of Slugger cutting tools, RPM, coolant and drilling time.
2. Remove any excessive mill scale or rust from surface to be drilled.
3. When drilling materials under 3/8" thick, an additional steel plate may be required to achieve proper magnet adhe-
sion.
4. Material that has been flame cut may have become heat-treated and therefore difficult to drill. Avoid drilling near
such areas whenever possible.
5. Drilling with the USA5 in horizontal positions requires a special lubrication for Slugger cutters.
7

1. Select correct pilot pin and place in cutter shank from the rear, align flats on cutter shank with arbor body set screws,
insert cutter in arbor body.
2. Tighten set screws securely on cutter shank flats. NOTE: Set screws should be recessed in arbor body when tight.
3. The surface you are working on should be clean and flat, and free from rust, scale, dirt and chips.
4. Determine correct cutting speed for application, move gear box shift lever by lifting outward then repositioning to
desired speed.
CAUTION!
never change gears with motor running. doing so can result in personal injury and/or damage to the machine.
5. Place Slugger machine on workpiece with pilot pin over the center of hole to be drilled.
6. Connect machine to power source.
7. Lower Slugger cutter to surface of material to be cut. Coolant will be released down the pilot into center of Slugger
cutter. Coolant flow can be stopped by lifting pilot pin off work surface. NOTE: Be sure coolant valve is open.
Regulate coolant flow by adjusting coolant valve on left side of mainframe.
CAUTION!
always use safety strap. failure to do so could result in personal injury
and/or damage to the slugger drilling machine.
8. The safety strap must be securely fastened to machine and around work being drilled. Loop strap around work piece
and connect strap ends by attaching to D-rings on drill. NOTE: Safety strap is intended only to restrain the drill to the
work piece in the event of a power failure to the magnetic base.
9. Position chip guard toward work area before drilling.
before the cut
ready to make the cut
CAUTION!
position chip guard toward work area before drilling.
1. Move magnet switch to “ON” position. Switch will illuminate to indicate power is present– magnetic base should be
firmly secured to workpiece at this time. Thin materials may require an additional steel plate to achieve proper
magnet adhesion.
2. Start drill motor by depressing green motor “ON” button.
3. Using the feed handles advance cutter into material until Slugger cutter has established an external groove in the
material, During the remainder of cut apply smooth constant pressure without overloading motor. NOTE: Slugger
cutters are designed for uninterrupted cutting. Chips are evacuated during the cut. Do not peck drill when using
Slugger cutters.
CAUTION!
if drill motor should stall or stop before acomplete cut is made, always remove cutter from hole before
attempting to restart motor. failure to do so could result in personal injury and/or damage to the slugger drilling
machine. note: this machine’scircuitry will automatically shut the drill motor off if magnetic base is separated from its
work surface. if your machine requires adjustment, contact jancy’sservice department.
1. After Slugger cutter has finished the cut, the “slug”, or uncut center portion of material, will be expelled when
motor is returned to the full up position.
2. Return machine into full upright position and depress red motor “OFF” button, wait until motor completely stops.
3. Move magnet switch to “OFF” position when ready to release magnetic base from work surface.
after the cut

1. Magnetic base not holding securely
•Material is too thin to engage magnet.
•Surface of material being drilled must be free of chips, debris, rust and mill scale.
•Does size of cutter exceed machine’s rated capacity?
•Check magnet face for unevenness, nicks and burrs.
•Is welding equipment connected to material being drilled?
2. Drill motor running, arbor and spindle not turning
•Possible sheared spindle key.
3. Motor slows when drilling
•Is an extension cord being used? If so, see page 6 for recommended wire gages and cord lengths.
•Excessive downfeed pressure during drilling cycle will cause motor to slow and overheat.
•Does cutting tool need to be resharpened?
4. Coolant system not working
•Coolant system is gravity dependent, machine must be in a upright position to operate properly.
•Check operation of coolant valve. Valve must turn freely.
•Check coolant lines for blockage.
•Dirt or debris in coolant tank.
•Consistency of coolant mixture too thick.
•Is correct pilot pin being used?
•Vent hole in coolant tank lid blocked.
5. Slugs not ejecting from cutter
•Lack of coolant causing slugs to expand in cutter bore.
•Is correct pilot pin being used?
•Possible broken internal arbor parts.
6. Breaking cutters
•How is coolant being applied? Coolant must be supplied to interior of cutter.
•Excessive feed pressure being applied when cutter initially contacts work surface.
•Confirm material hardness.
•Drilling stacked materials with incorrect cutter.
•Dull cutters; dull or chipped cutting edges require excessive feed pressure, resulting in breakage.
•Excessive arbor runout – see regular maintenance on page 10.
•Possible bent motor spindle or worn arbor sleeve.
•Improperly adjusted motor slide – see page 10.
7. Oversized or rough holes
•Insufficient coolant.
•Excessive feed pressure.
•Dull cutter.
•Worn support bracket roller bearing or arbor body sleeve.
•Bent motor spindle.
•Motor slide improperly adjusted.
basic troubleshooting
9

1. The motor slide may become loose and require adjustment after the machine has been in service. Refer to
parts breakdown and become familiar with the USA5 parts, locate motor slide cover plate #0151113
and adjustment screw #0151505. Using the 3 spoke feed handles, position motor and slide assembly in the
full up position. Insert supplied 5mm hex key through slide cover plate access hole, using the hex key turn
adjustment screw #0151505 clockwise to increase slide tension or counter clockwise to decrease slide tension.
Do not over tighten adjustment screw. Excessive slide tension can damage the USA5. Properly adjusted, the
motor and slide assembly should have no side to side movement and remain in position without drifting down.
2. Keep bottom of magnet clean, free of chips, burrs, nicks, oil and other contaminants. Inspect magnet face
to ensure surface is flat and square. A worn magnet surface dramatically reduces magnetic holding force.
3. Periodically lubricate motor slide ways with lithium base grease.
4. Routinely fill grease zerk (item #23) on arbor support bracket.
5. Visually inspect arbor, sleeve and support bracket for wear.
6. Arbor runout should not exceed .0035 inches per revolution. This is most accurately measured by placing a dial
indicator needle inside of arbor bore and rotating arbor while observing indicator.
7. Inspect coolant system, reservoir, o-rings, lip seals and coolant collar for wear.
8. Inspect motor brushes and replace as needed during extended periods of heavy machine usage.
9. Replace any worn parts and regularly tighten fasteners that have become loose during usage.
10.Regularly test machine by placing machine on non-ferrous material. Engage magnet switch.
Motor should not start.
regular maintenance
dimensions and specifications
Height 23-3/4"
Width 7-1/2"
Length 11"
Weight 51 lbs.
Motor 1.8 HP 1400W (single phase)
120V / 11.7A ~ 240V / 5.8A
270 / 520 RPM (no load)
Arbor Bore 3/4"
Drill Point Breakaway 950 lbs. on 1" plate
Magnet Base Dimensions 4" x 7-1/2"
Magnet Dead Lift 2320 lbs. on 1" plate
Slugger Cutter Diameter (Maximum) 2-3/8"
Slugger Depth of Cut (Maximum) 3"
10
note: magnetic base requires 1" minimum material thickness when drill-
ing 2-1/16" and larger diameter holes