JEI MAGBEAST 2 Operation and maintenance manual

JEI SOLUTIONS LTD
UNIT 30 NEWHALLHEY BUSINESS PARK, NEWHALLHEY RD, RAWTENSTALL, ROSSENDALE
LANCASHIRE, BB4 6HR, UK
Tel. [phone] Fax. [phone]
www.jeiuk.com e-mail. [email protected]
SAFETY INSTRUCTIONS
AND OPERATOR’S MANUAL
FOR
DRILLING MACHINE
M
MA AG GB BE EA AS ST T 2 2

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Operator’s manual for Drilling Machine MAGBEAST 2 - 1 -
CONTENT
I. SAFETY INSTRUCTION ................................................................................................................ 4
1.General information ..................................................................................................................... 4
2.General safety advice.................................................................................................................. 4
II.START UP AND OPERATION ...................................................................................................... .7
1.Cutters and optional equipment features.................................................................................... .7
2.Machine start up ........................................................................................................................ 10
3.Operating instructions................................................................................................................ 17
III.ADJUSTMENT, MAINTENANCE AND SERVICE ....................................................................... 18
IV.TECHNICAL DATA....................................................................................................................... 19
V. ELECTRICAL DIAGRAM.............................................................................................................. 22
VI. EC DECLARATION OF CONFORMITY....................................................................................... 23
VII. MACHINE TEST CERTYFICATE................................................................................................. 24
VIII. WARRANTY CARD...................................................................................................................... 25
BEFORE YOU START WORK WITH THE MACHINE,
PLEASE READ THESE INSTRUCTIONS CAREFULLY
AND USE ALL RECOMMENDATIONS.

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1. GENERAL INFORMATION
Portable drilling machines with electromagnetic bases are fast becoming very
universal power tools not only at steel fabricating workshops or steel building sites but also at
every factory maintenance workshop, truck manufacture & repair company, military
equipment service, onboard ship maintenance shop etc.
But full advantages of electromagnetic drilling machines can be achieved only with
optimal tooling. Milling cutters are designed and manufactured specifically for use with these
machines and offer a whole range of advantages in one pass and with precision not
otherwise attainable without heavy stationary equipment. The drill is equipped with
a powerful verified for many years of exploitation drive.
The MAGBEAST 2 machine is capable of drilling 50mm holes through 2 inch plate.

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2. GENERAL SAFETY ADVICE
Drilling machine must not be used when:
1. The operator has not read the Operator’s Manual.
2. The work to be done is not in agreement with the recommendations in this Manual.
3. Drilling machine is not complete or has been repaired with non-original parts.
4. Power supply parameters do not conform to those stated on the motor’s plate.
5. Machines operator has not checked condition of the drilling machine, condition of
power cable, control panel or cutter.
6. Power supply socket is not equipped with a protection circuit.
7. Machine is not secured with safety chain as a protection from falling down
especially when used at heights or in vertical or upside-down positions.
8. Bystanders are present in the immediate vicinity of machine.
Important rules of safe use of drilling machine
1) Before attempting to work with the machine check condition of electrics including power
cord and plug.
2) The drilling machine should be connected to an installation equipped with protection
circuit (neutral or ground) and protected with a 16 A fuse for 220V and 32 A fuse for
120V. When used on building sites, it must be supplied through a separation
transformer made in the second class of protection
3) Machine can be used outdoors, but is not weatherproof. Do not expose to rain, snow or
frost.
4) Machine should not be used on: rusty surfaces, steel plates with thick covered with
paint, uneven surfaces, next to a welding machine.
5) In all cases always use a safety chain/strap /see drawing 1/. The safety chain mustn't
be loose! To avoid this situation the safety chain should be wrapped around the
element it is hooked to.
6) Do not use the machine in explosion hazard zones.
7) Do not start work if the machine has excessive play on guide slides.
8) Always wear safety goggles and ear protection.
9) Do not remove metal chips with bare hands.

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Safety chain can also secure the drill through
the handle.
10) Do not touch the spindle and cutter during work.
11) Tools must be fastened firmly. When a milling cutter is used, check before start of work
if tool holding screws are screwed tight.
12) It is not permitted to use blunt of damaged tools.
13) Do not use milling cutter without pilots, and arbors without ejection spring.
Do not touch or replace the tool with power source on –while
electromagnetic base is being used.
14) Use tools recommended in Operator’s Manual only.
15) After use, always clean drilling machine from metal chips and coolant.
16) Always unplug machine from power supply during any work on the machine.
17) In the case that the machine falls on a hard surface, from a height, is wet or is
subjected to other unfortunate events that could affect its technical state - work should
be terminated immediately and the machine should be sent to service for inspection as
soon as possible.
Drawing 1.
Examples how safety chain should be fastened.
.

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DO NOT use drill on steel thinner than (less than 3/8” (10 mm)). On thin
steel (less than 3/8” (10 mm)) magnet’s adhesive power would be significantly
reduced what can cause machines failure or individuals injury. The machine
should be located on the work piece with the entire surface of the
electromagnetic base! It is recommended that each time, before positioning
the machine surface under the electromagnetic base should be sanded down
with abrasive paper!
Please keep all recommendations.
II. START UP AND OPERATION
1. Cutters and optional equipment features
This drilling machine’s spindle has a socket with Morse taper 2 which make possible
to use twists drill (if it necessary with using drill sleeves) or milling cutters by using AMT
Arbor for fixing them in socket spindle taper [Drawing 2].
Milling cutter (2) is located inside arbor body (1) and is fastened with screws (3).
While fastening the cutter in the socket, be aware that screws should be screwed tight so
that they could not come unscrewed. It is important to position the cutter in relation to the
socket in such a way that fixing flats on the cutter shank are positioned opposite to the fixing
screws (3). Both fastening screws(3) should be used to fasten the cutter. Pilot (5) is located
inside the cutter. It makes it easier to position milling cutter over centre of a planned hole.
During drilling as the cutter goes deep into steel, the pilot moves back into the arbor body
and tightens discharge spring (4). That spring ejects slug which is a by-product of milling a
hole with a centre free cutter.
Basically milling cutters are designed to make through holes. On occasions when
there is a need for an overlapping hole pilot should not be used. [Drawing 3]
Drawing 3. A few types of holes that can be done with a milling cutter.
Drawing 2. Principle of milling cutter’s work

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1.1 Installing and uninstalling the arbor
The arbor installation and uninstallation should be carried out when the machine
is turned off and disconnected from the power grid!
Installing the arbor:
a) Rice the guard (2) to the maximum,
b) Clean the inside of the spindle using a cotton cloth,
c) Before mounting, clean off the lubricant from the new arbor (3),
d) Place the arbor with the fin on top, and place it in the spindle,
e) By turning the arbor, align the fin to the appropriate slot in the spindle,
f) Using a light impact from the bottom side, drive the arbor into the spindle.
Uninstalling the arbor:
a) Raise the guard, turn the spindle so that the wedge MT opening in the spindle (1) is lined
up with the wedge MT opening in the reducer body,
b) Place the wedge MT (included as standard equipment) into the uncovered spindle
opening (1),
c) Hold down the arbor (3) with one hand,
d) Strike the wedge MT with a hammer, taking care to not to damage the arbor,
e) Carefully remove the arbor from the socket in the spindle,
f) Remove the wedge MT.

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1.2 Installing and uninstalling the milling cutter
Milling cutter installation and uninstallation should be carried out when the
machine is turned off and disconnected from the power grid!
Installing the milling cutter:
1. Raise the drive and the slide (2) up using the lever (3);
2. Raise the guard (1) to the maximum in order to attain access to the arbor (4) screws (5);
3. Insert the appropriate type of pilot (6) into the milling cutter (7);
4. Position the milling cutter (7) with the cutter facing up, so that the flat sides of the milling
cutter are found facing the screws (5)
5. Put the milling cutter (7) into the arbor socket (4);
6. Tighten the screws securely (5).
Uninstalling the milling cutter:
1. Raise the drive and the slide (2) up using the lever (3);
2. Raise the guard (1) to the maximum in order to attain access to the arbor (4) screws (5).
3. Loosen the screws (5);
4. Remove the milling cutter (7) and the pilot (6) from the arbor socket (4).

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2. Machine start up
The machine is supplied in a metal box with complete standard equipment.
MAGBEAST 2 comes in a standard equipment set which consists of:
metal box
1pc
drilling machine
1pc
arbor AMT2-C-19/2-2
1pc
cooling system
1pc
chip guard
1pc
spoke handles
3pcs
hex wrench s=4
1pc
hex wrench s=5
1pc
wedge, MT2
1pc
safety chain with snap hook
1pc
operator’s manual
1pc
2.1 Before first drill:
Steel elements of the drilling machine are protected for transit and storing with grease
film. Before first start up of the machine all grease should be removed
Before each use all handles should be screwed into pinion.
2.2 Before you cut
Before positioning the machine on work piece always make sure that:
-Work piece is made of ferromagnetic steel (some grades of stainless or acid
resistant steel does not conduct magnetic flux)
-thickness of work piece is at least 3/8” (10 mm)
-surface of steel under the magnet is flat
-wipe, brush or sand down clean surface where you intended to place the drilling
machine, so that you remove rust, paint, dirt etc which would reduce adhesive power of the
electromagnetic base.
Install drill bit, milling cutter or other tooling such as tap or reamer in the machine before
plugging it into mains. Then plug it in (see paragraph 2) and position where you wish to use
it. Place the machine so that the tool is over the centre of the hole you intend to make and
turn the magnetic base ON.
Prior to use always make sure that the machine is secured from falling
down with original chain (as described in paragraph I no.2 “Important rules of
safe use of drilling machine”).

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2.3 Cutting
- Select the right speed for the tool you intend to use (see the speeds chart in this
manual –paragraph IV no.1).
Cooling and lubricant fluid commercially available in concentrated are recommended to use
for cooling twist drill and annular cutter.
Soluble cutting oil can be used, speak to a member of our sales team who can recommend
the best solution for your drilling application.
Do not use clean water as the liquid cooling and lubricant.
The cooling system is an integral part of the machine and should always be used. (see point
2.7)
Warning: The cooling system can only be used when drilling machine is in
vertical position. In other positions additional external source of cooling should be
used, for example: a coolant bottle with a long nozzle, or our Turbo Endurance +
spray/paste
-Check working of cooling system. Open coolant reservoir’s tap and apply pressure on
the pilot by turning spokes counter clockwise. As the pilot starts to sink into the cutter cutting
lubricant should start to run down cutters inner wall. If there is no liquid flowing down check if
the tap is fully opened. It may take a few seconds for the cutting lubricant to fill the whole
system.
-Turn the motor on.
Making a hole with a milling cutter should ideally be done in one pass. It makes the
cutter work better and easier to eject the slug after the hole is completed. If you experience
slugs getting stuck inside a cutter after hole is complete try to reduce pressure on the cutter
or use different coolant. Do not allow excessive swarf build up around the cutter and arbor.
WARNING: when the milling cutter goes through the material the
slug can be pushed out often with considerable strength.
Pay attention to avoid injury.
-After a hole is made the cutter should be withdrawn back and both the motor and the
electromagnet should be switched OFF.
-When work with the machine is finished the power cord should be disconnected from
the power source, the machine should be cleaned up from swarf, coolant etc and the cutter
should be removed and cleaned.
Please keep all recommendations.

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2.4 Types of a ground material
As shown on the graphs [Drawing 4] magnetic clamping force of the electromagnetic
base to the ferromagnetic ground depends on its magnetic properties. Steel with increased
carbon content and some other alloying ingredients has a lower magnetic permeability, what
causes a decrease in the clamping force. Also a thickness of a work piece, on which the drill
is placed, is significant.
Maximum clamping force of the electromagnetic base to a 5 mm thick work piece
surface is only about 25% of a clamping force obtained from a smooth, plane, 22 mm
thick standard plate.
If such thin ground material does not bow, one can try to carry out drilling of a
hole, although with keeping the strictest precautions. Particularly a magnitude of a
pushing force on a feed handle should be very limited.
Appropriate rpm should be adjusted depending on if drilling would be carried out with
a drill bit, or with trepan type metal cutter and a metal cutter’s diameter. A drive is equipped
in mechanical 2-step reducing gearbox. A general dependence between drilling diameter and
drilling speed is shown in graphs [Drawing 5], detailed guide is supplied by manufacturer of
used drilling tools. The graph is just a general guide and the shown dependence applies to
average structural steel.
Cooling agent is fed gravitationally from a coolant bottle through an arbor to an inside
of the metal cutter. For horizontal and overhead positions special cooling pastes have to be
used.
2.5 How to use the special functions
There are some factors affecting the value of the clamping force. They are as follows:
thickness of the base, presence of the paint coats, rust and other contamination, non-flat
surface, big roughness rate, extended wear out of the magnet lower surface, type of material
the surface is made of.
If after turning on the electromagnet there is a problem to turn the motor on, that
means the motor is working only when the green START “I” switch is on. After
releasing the button it turns off the motor that means that the system is working
properly and does not allow for operation with no suitable clamping force.
To operate this machine you should push on the main switch in position “I”. Then you
should turn on the green button „I” to turn on the motor. To stop the motor you should push
on red button “O” (It causes the motor off, the magnet still holds). To move on the machine to
drill in another place you should stop the motor and then push on the main switch in position
“I”.
2.6Working in difficult areas
While working in difficult access areas as well as left-handed operator, there’s a
possibility to change location of the pinion with spoke handles to the other side of drilling
machine.

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Drawing 4. Clamping force depending on the thickness of the substrate and the value gap.

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2.7 Installing and uninstalling the cooling system
Installing the cooling system:
a) Place the machine in the vertical position,
b) Slide the drive and the slider (1) up using lever (2),
c) Coolant bracket (7) with cooling unit (6) on screws (8) located to the side of the slider,
d) Connect the cooling conduit ending (3) with the coolant coupling (4) found in the cooling
ring (5).
Before starting the machine:
Remove the bottle’s cap,
Fill it with cooling lubricant,
Replace bottle cap.
After fulfilling the above actions and making sure, that the system has been appropriately
fixed, and the cooling conduit (3) is placed correctly on the coolant coupling (4), the bottle
cap should be loosened by 1/3 of a turn in order to deaereate it, turn on the valve (9), so that
liquid travels to the hose, after which the machine can be started (see II pt. 3)
After ending work, one must remember to tighten the bottle cap and turn off the valve
(9) (to prevent liquid from leaking during the time that the machine is not being used) and
uninstall the cooling system (6) before placing the machine in the box.
Uninstalling the cooling system:
a) Place the machine in the vertical position,
b) Slide the drive and the slider (1) up using lever (2),
c) Disconnect the cooling conduit ending (3) and the coolant coupling (4) found in the
cooling ring (5).
d) Take off the cooling system.

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2.8Cancelling clearance
The drive and the slider can be slid up and down smoothly using the lever (1), making
the screws (2) fixing the strip to the drill body visible through the openings in the slider (5). To
loosen screws (2), the slider should be placed in such a position (using levers) so that the
openings make the screws visible. After loosening the screws slide the slider up and down
several times so that the pressure strip aligns itself and cancels clearance.
After carrying out these activities and cancelling clearance, tighten screws (2) starting
from the middle screw. The slider should be located symmetrically relative to the middle
screw. Next, tighten the neighbouring screws (2) moving the slider in the degree necessary
for making them visible.
Then, tighten screws (3) until any noticable resistance is felt. When the screw in this
position and blocked with a hexagonal key, tighten counter nut (4). The screws (3) counteract
the machining force and protect the pressure strip from shifting during operation.
Canceling clearance

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3. Operating instructions
The machine is supplied in a metal box. Steel elements of the drilling machine are
protected for transit and storing with grease film. Before first start up of the machine all
grease should be removed. Before each use all spoke handles should be screwed into
pinion.
Control panel includes below elements:
(01) - Main switch MAGNET,
(02) - START-STOP switch MOTOR.
a) In order to start the machine press the main switch MAGNET (01) on “I“ button. Now you
can start the motor by pressing green button MOTOR (02) on “I”.
b) Stopping the motor is executed with red button „O” (then the motor is switched
OFF but the electromagnetic base is still ON) (02).
c) To move machine into next drilling spot, stop the motor as described above and
push the mains switch (01) to the position “O”.
d) To change the speed use the gear box lever.
To move machine into next drilling spot, stop the motor as described above and
push the mains switch MAGNET to the position “O”. To change the speed use the
gear box lever.
. READ THE WHOLE INSTRUCTIONS MANUAL
BEFORE ATTEMPTING TO START UP
III. ADJUSTMENT, MAINTENANCE AND SERVICE
Every 50 hours of work, or as need arises, elimination of excess play in slide guides
should be performed. The screws are provided for that reason. Play in slide guides is
acceptable the slide goes up easily and does not slide down under its own weight. (see
paragraph II no.2.8)
After every day’s work position of gear lever (used for selection of gearbox speed) should
be changed. For example if machine ran at 150 rpm speed, it should be switched to
300rpm.
Regularly check condition of carbon brushes. (see paragraph IV –Technical data).
Regularly lubricate brass slide guide inserts with grease as well as the rack and pinion.
To prevent the machine from rusting (especially when used outdoors) all steel parts
should be covered with thin layer of grease film.
Damaged machine parts to be exchanged only to original parts.

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Every repair work should be done only by authorised service points, appointed by
distributor.
New spare parts order: required to enter the code or send the damage part with
information about type of drilling machine and power supply.
Caution: In the case that the machine falls on a hard surface,
from a height, is wet or is subjected to other unfortunate events
that could affect its technical state - work should be terminated
immediately and the machine should be sent to service for
inspection as soon as possible.

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IV. TECHNICAL DATA
Power supply
□ 110÷120V AC / 50-60 Hz
□220÷240V AC / 50-60 Hz
Power required
1300 W
Motor power
1260 W
Tool holder
19 mm (3/4") Weldon
Max. twist drill diameter
23 mm
Max. annular drilling diameter
50 mm
Max. milling depth
51 mm (2”)
Insulation Class
I
Standard adhesive force of electromagnet
(for steel 7/8” (22 mm) thick and Ra< 1,25)
12 000 N
Slide stroke
153 mm
Machine speeds /under load/
I bieg –200 rpm
II bieg –400 rpm
Electromagnetic base
90x180x48 mm
Length of the power cord
3,0 m
Total weight
16,5 kg
Noise level
85 dB
Surrounding temperature
0 ÷ 40° C
Detailed PARTS LIST of Drilling Machine MAGBEAST 2
is available at www.jeiuk.com or e-mail
[e-mail]

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Operator’s manual for Drilling Machine MAGBEAST 2 - 18 -
Replacement of motor brushes:
For the MAGBEAST 2 drill, the condition of the carbon brushes should be monitored
every 100 working hours.
Replacement of motor brushes should take place when the machine is turned off and
the power cable is disconnected from the power grid!
1. Unscrew 4 M5x40 engine cover screws (1), using a 6-kt s=4 wrench.
2. Carefully take off the engine cover (3). Remember that it is connected with the motor by a
grounding lead (4).
3. Take off the motor brushes from the connector (6) using the flat ending (5) of the lead.
The ending has a safeguard against its sliding down –first, press the protruding element
at the middle of the ending, then carefully slide off the ending from the connector.
4. Push aside the spring arm (7) pressing down the brush and rest it on the surface of the
brush holder (8) and remove the brush (9).
5. Inspect brush length - if the length is less than 5mm, the brush should be replaced with
an original brush.
6. Carry out all actions in reverse, in order to install the engine.
After replacement, new brushes should be Grinded in for about 20 minutes on idle gear.
Replacement of engine brushes is possible without removing the drive from the drill.

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1. Relationship between machine speed and cutter diameter –parameters
After work position of gear lever (used for selection of gearbox speed) should be
changed. For example if machine worked with 200 rpm speed, it should be switched to
400rpm.
Relationship between machine speed and cutter diameter
The cutter diameter
Rotary speed
[rpm]
[inch]
[mm]
1,00÷1,50
12÷35
400
1,51÷2,00
36÷50
200
Relationship between machine speed and twist drill diameter
The twist drill diameter
Rotary speed
[rpm]
[inch]
[mm]
0,04÷0,43
3,5÷13
400
0,44÷0,67
14÷22
200
The above rate on ordinary quality steel <500N/mm2, such as S185, S235JR,
S275JO and use a sharp tool.
For steel <700N/mm2 like E295, S355N,C45, speed should be reduced by about
35%.
2. Guidelines for grading diameters of twist drills when drilling
holes.
Drilling holes of a diameters greater than 18mm should be carried out by preliminary
drilling where a diameter of a first hole should be 0,7 of a final hole diameter.
For example: When drilling a 23mm diameter hole it is recommended to initially drill it using a
drill bit of 16mm in diameter and to increase a size of a tool gradually to reach a diameter of
the desired hole.
Holes diameter
[mm]
Drills diameter [mm]
Number
of passes
Drilling
Expanding the
hole by driling
for 18
for 18
1
18,1 - 23
0,7 final hole
diameter
final hole diameter
2