Hougen HMD904 Manual

Welcome to Hougen

Your model is designed to produce superior holes quickly and effi ciently. Through constant innovation and development, Hougen is committed to provide you with hole-producing tools and products to help you be more productive. Before attempting to operate your new Portable Magnetic Drill, please read all instructions fi rst. These include the Operator's Manual and Warning Label on the unit itself. With proper use, care, and maintenance, your model will provide you with years of effective hole drilling performance. Once again, thank you for selecting our product and welcome to Hougen.

SAFETY FIRST

	Always wear eye protection while using cutting tools, or in the vicinity of cutting.		Cutters are sharp. Wear gloves when installing or removing cutter from arbor. Do not grab a rotating cutter.
	The slug is ejected at the end of the cut. Do not aim cutter or arbor so that ejected slug may hit someone around, or below you.		To prevent electric shock, do not use power tools near wet areas, or where power tool may become wet.

UNPACKING YOUR NEW MAGNETIC DRILL

1. Open shipping carton and remove the literature and hardware packages.
2. Read and Follow All Instructions before attempting to operate your new Magnetic Drill.
3. Complete and mail the Product Registration Card now. It is important that Hougen Manufacturing, Inc. have a record of product ownership.
4. Open hardware package and check contents.
   10565 1/8" Hex wrench for Gib Adjustment
   04558 Feed handles (3)
   04532 Feed handle knobs (3)
   10506 Set screw for cutter installation (2)
   10730 Safety chain
   02635 Hex wrench for cutter installation
   13013 5/32" Hex wrench for safety switch adjustment
5. Using the handle of Magnetic Drill, lift unit out of the shipping case.
6. Remove all packing and securing material from the drill unit.

7. Screw the three Knobs (04532) into the three Feed Handles (04558) and then screw Handles into the Hub Assembly (40254). Do not overtighten or may strip the knobs.
8. Your Magnetic Drill was factory adjusted prior to shipping. Check to make sure that all gib adjustment screws, motor mount screws, front support bracket screws, and magnet mounting screws are snug and have not vibrated loose in transit.
9. Your new Magnetic Drill comes complete with arbor mounted. The 3/4" diameter arbor bore fi ts all 3/4"-shank "12,000-Series" Hougen Cutters.

Reread Safety Warnings listed in the Operator's Manual and on the drill unit to avoid injury. Follow operating procedures.

IMPORTANT SAFETY INSTRUCTIONS

When using electric tools, basic safety precautions should always be followed to reduce the risk of fi re, electric shock, and personal injury, including the following:

1. Read All Instructions
2. Grounding Instructions
   This tool should be grounded while in use to protect the operator from electric shock. The tool is equipped with a 3-conductor cord and a 3-prong grounding type lug to fi t the proper grounding type receptacle. The green (or green and yellow) conductor in the cord is the grounding wire. Never connect the green (or green and yellow) wire to a live terminal. If your unit is for use on 115V, it has a plug that looks like that shown in sketch (A). If it is for use on 230V, it has a plug that looks like that shown in sketch (D). An adapter, see sketches (B) and (C), is available for connecting 115V type plugs to 2-prong receptacles. The green-colored rigid ear, lug, or the like, extending from the adapter must be connected to a permanent ground, such as a properly grounded outlet box. (See Table 2)
3. Extension Cords
   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 the conductor size is large enough to prevent excessive voltage drop which will cause loss of power and possible motor damage. (See Table 1)
4. Consider Work Area Environment
   Do not expose tool to rain. Do not use tool in damp or wet locations. Keep work area well lit. Do not use tool in presence of fl ammable liquids or gases.
5. Guard Against Electric Shock
   Prevent body contact with grounded surfaces. For example: pipes, radiators, ranges, refrigerator enclosures.
6. Safety Chains
   For Operator safety -Always use the provided safety chain every time you use the unit. Failure to use the safety chain can result in serious personal injury plus possible damage to your machine.
7. Keep Children Away
   Do not let visitors contact tool. All visitors should be kept away from work area.
8. Store Idle Tools When not in use, tools should be stored in a dry, land high or locked-up place — out of reach of children.
9. Use Right Tool
   Do not force small tool or attachment to do the job of a heavy duty tool. Do not use tool for purpose not intended — for example — do not use a circular saw for cutting tree limbs or logs. — for example — do not use a circular saw for cutting tree limbs or logs.
10. Secure Work
    Use clamps or a vise to hold work. It is safer than using your hand and it frees both hands to operate tool.

TABLE 1

TABLE 2

SAFETY SWITCH INDICATOR LIGHT

The Safety Switch Indicator Light is a New Standard Safety Feature on HMD904 magnetic drills. Its purpose is to inform the user that an unsafe condition exists or the safety switch needs adjusting.

If light is Green:
In normal operation the safety switch light will be green. Motor "On" and "Off" Switches function normally.

If light is Red:
A condition with the safety switch exists that needs to be corrected.

Possible causes:

• Safety Switch is out of adjustment.
• Safety Switch is defective. Have drill serviced.
• Uneven work surface or material. Check work surface for fl atness.
• Dirt or chips under magnet. Clean work surface.
• Too thin material. Make sure material is at least 3/8" thick.

HOUGEN MANUFACTURING RECOMMENDS THAT CONDITIONS ARE CORRECTED SO LIGHT TURNS GREEN. THIS ALLOWS FOR THE UNIT TO BE OPERATED IN A SAFE MANNER.
When light is Red the motor will still function, but "ON" switch becomes a momentary switch. (The switch must be held down to operate motor.)
For any questions please contact Hougen Manufacturing's Technical Service at (810) 635-7111.

CHECK OUT OPERATION OF CONTROLS BEFORE INSTALLING HOUGEN CUTTER
CONTROL PANEL SWITCH PLATE FIGURE 2


Before turning on the machine, it is important that the operator understands the interrelated functions of the SAFETY SWITCH, GLIDE POST, MAGNET SWITCHES, AND MOTOR SWITCHES.
READ SAFETY SWITCH INDICATOR LIGHT INSTRUCTIONS PREVIOUS PAGE.
SAFETY SWITCH — Located in base of drill. Enables motor operation only when magnet is properly seated on a clean and fl at work surface. Turns motor off if switch detects shift or lift or unit.
MAGNET ON SWITCH — Energizes the magnetic base and activates the safety switch. Motor can now be started by pushing the motor START switch.
MAGNET OFF SWITCH — De-energizes the magnetic base and deactivates motor START switch.
MOTOR START SWITCH — Starts the motor (will not function unless the magnetic base is energized and the safety switch is activated).
MOTOR STOP SWITCH — Deactivates motor. Magnetic base remains energized and safety switch activated.
GLIDE POST — Lifts magnet and breaks residual magnetic energy after magnet is turned off. It also acts as a glide point when drill is being moved from one position to another on the work surface, thus minimizing wear on magnet. It also permits CONTROL PANEL SWITCH PLATE easier repositioning and protects the safety switch.

1. Place Magnetic Drill on clean, fl at steel plate that is at least 3/8" thick.
2. Plug unit into proper AC power source.DO NOT use with DC Power.
3. Locate the MagnetON and OFF switches and the motor STOP and START switches (Fig. 2).
4. NOTE: A loss of power will de-energize the magnetic base and deactivate the motor. When power is restored, the magnet will reenergize, however, the motor START switch must be depressed before the motor will start.

1. Make sure workpiece and bottom of magnet are free of chips, oil, etc.
2. Position drill by sliding it and gently feeding Arbor so that pilot point is touching center of hole to be drilled.
3. Secure unit to workpiece with safety chain.
4. Turn magnet ON by pressing the magnet ON button.
5. Turn Feed Handle, raising the cutter until the pilot is above the work surface.
6. Make certain that cutter is clear of workpiece and turn motor ON by pressing the motor START button.
7. Feed Hougen Cutter slowly into workpiece. Only after cutting path is established to a depth of about 1/16" can full force be applied to feed handles.
8. Ease up on feed pressure as cutter starts breaking through.
9. At conclusion of cut, turn motor OFF by pressing motor STOP button. Turn Feed Handles to raise Arbor thereby ejecting the slug if it hasn't already fallen free.
10. Turn magnet OFF by pressing the magnet OFF button. As the magnet de-energizes, the rear of the magnet should lift up off the work surface.
11. Disconnect from power source.
12. If necessary, remove chips from cutter and magnet, preferably wearing leather work gloves and/or with pliers.
    Disconnect safety chain and you are ready to move unit to new drilling position.

1. Disconnect from power source.
2. Lay drill on its side with feed handles up or be sure Arbor clears table if unit is in normal operating position.
3. Turn Feed Handles until cutter mounting set screws are exposed and completely remove the set screw.
4. Insert proper pilot in shank end of Hougen Cutter.
5. Insert Hougen Cutter until fl at on cutter shank is aligned with set screw holes and is exactly perpendicular to axis of set screw holes. If 1/2" diameter shank cutter is used, slip (10851) Arbor Adapter over the cutter shank with adapter hole positioned exactly over fl at on cutter shank prior to inserting into Arbor bore.
6. Insert set screws and tighten. When mounting 1/2" diameter shank cutter with adapter, use longer set screw. (ordered separately) Check to be certain that cutter is secure.

1. With Magnetic Drill in operating position, turn the feed handles so that cutter and pilot are above the work surface.
2. With magnet turned ON and motor OFF, fi ll reservoir by introducing cutting fl uid through slots in Arbor. Cutting fl uid should not leak out.
3. Test metering capabilities of Arbor/Cutter/Pilot assembly (magnet ON-motor OFF) by feeding the Arbor gently toward work surface until pilot is pushed up into Cutter, thus allowing fl uid to fi lter down onto work surface through groove in pilot.
4. For proper lubrication, all cutting fl uid in reservoir should empty onto work surface in no less than 15 seconds and no longer than 30 seconds.

1. Loosen all Gib Screws (40237).
2. Feed the drill in and out a few times and then, with top of motor slide fl ush with top of housing, tighten the Gib Screws until you feel them touch the Steel Gib (02431).
3. Feed the drill in and out again.
4. Adjust Gib Screws so that there is uniform pressure from top to bottom. (Top of motor slide fl ush with top of housing.)
5. Turn each Gib Screw in about 1/8 to 1/4 turn, depending upon your preference.
6. Gibs should be tight enough so that slide moves up and down smoothly with no wobble or shaking.
   (Looseness will cause cutter breakage.)
   NOTE: Gibs should be lubricated regularly.

1. Loosen Arbor Support Bracket Bolts.
2. Be sure top of arbor is fl ush with the shoulder on motor output shaft. Also make certain arbor is securely fastened.
3. Turn feed handle until motor and spindle are at the bottom of their travel.
4. Tighten Arbor Support Bolts.
5. Feed slide up and down a few times, checking for free and uniform movement.
   NOTE: Check Arbor support bolts regularly to make certain they are tight. Tighten as required.

1. Unplug unit from power source and place it on a fl at sheet of steel that is at least 3/8" thick. Only magnet portion should be on steel plate. Rear support block (Glide posts should hang over the edge of the steel plate.
2. Remove Access Hole Screw (10977) from the bottom of the panel assembly.
3. Insert 5/32" Allen Wrench into access hole and back off (counterclockwise) Microswitch Adjusting Screw (10969) about three full turns.
4. Turn adjusting screw in (clockwise) about 1/8 turn at a time (removing wrench, plugging motor to power source, and turning magnet and motor ON each time) until you fi nd exactly where motor starts.
   
   Turn switches OFF and unplug motor from power source prior to each adjustment.
5. After determining point where motor starts, turn adjustment screw clockwise one and a half turns.
6. Plug unit to power source. Turn Magnet and Motor switches ON. Strike side of magnet at rear with rubber hammer. Motor should shut off before the magnet moves 1/2" in any direction.
   NOTE: Safety Switch adjustment should be checked regularly following the procedure outlined in Step 6 above.

MOTOR PARTS DIAGRAM

04503 MOTOR ASSEMBLY

11053 BOLT TORQUE SPECIFICATIONS - TIGHTEN TO 18 IN-LBS
75289 BOLT TORQUE SPECIFICATIONS - TIGHTEN TO 25 IN-LBS

MOTOR PARTS LIST

CONTROL PANEL HOOKUP

CONTROL PANEL PARTS LIST

Panel Assembly P/N: 05188

MODEL HMD904 EXPLODED DIAGRAM

HMD904 PARTS LIST W / ASSEMBLIES

In order to minimize wear on moving parts and to insure smoother operation and longer life for your magnetic drill, the following maintenance should be done periodically, based on use.

1. Regularly tighten all fasteners and replace all worn parts.
2. Check motor brushes and replace if worn. (Break in period - 30 minutes at no load speed)
3. Check power cord and cord from panel to motor and, if cracked or frayed, return to an authorized repair center for replacement.
4. Apply grease to the slide dovetails, brass gibs, and the feed gear rack. For best results use Shell Cyprina-RA or equivalent.
5. Remove arbor and pack the bearing in the front support bracket with grease. Use Shell Cyprina-RA or equivalent.

1. Keep insides of Hougen Cutter clear of chips. Chips will interfere with cutting to maximum depth, may impede the free oil fl ow and can cause cutter breakage.
2. Keep work, machine, arbor and Hougen Cutter free of chips and dirt.
3. Tighten all bolts and fasteners regularly.
4. We highly recommend using a light viscosity cutting fl uid (preferably Hougen Cutting Fluid - Part No. 11742-4)
5. Occasionally check metering of cutting fl uid fl ow. Lack of cutting fl uid may cause Hougen Cutter to freeze in cut, slug to stick and may result in poor cutter life.
6. Always start cut with light feed pressure and then increase suffi ciently to achieve maximum cutting rate.
7. Ease off on pressure as cutter begins to break through at the end of the cut.
8. Keep slide dovetails, brass gibs and feed rack lubricated and free of chips and dirt.
9. When slug hangs up in cutter, turn off motor and bring cutter down on a fl at surface. This will normally straighten a cocked slug, allowing it to be ejected.
10. When cutting large diameter or deep holes it may be necessary to stop in the middle of the cut to add cutting fl uid and remove the chips from around the arbor. (When doing this DO NOT raise the cutter out of the hole.
    Doing so can allow chips to get under the teeth of the cutter and make it diffi cult to restart the cut.)

Documents / Resources

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