Rockies Global Marketing SteelMax D2 User manual

STEELMAX®d2
Portable Magnetic Drilling Machine
OPERATOR’S MANUAL
EYE PROTECTION
REQUIRED HEARING PROTECTION
REQUIRED
MODEL #SM-D2
Serial # Date of Purchase
WARNING!
BEFORE USE, BE SURE EVERYONE USING THIS MACHINE READS AND UNDERSTANDS
ALL SAFETY AND OPERATING INSTRUCTIONS IN THIS MANUAL.
NEVER PLACE
FINGERS NEAR
CUTTING AREA OR
MACHINE ARBOR
LINE VOLTAGE
PRESENT BEWARE OF ROTATING
MACHINE PARTS

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5--6
Grounding Instructions and Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . .7
Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Contents of Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Ready for Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
After Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Normal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Machine Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Jacobs Chuck Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Available SteelMax Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2
TABLE OF CONTENTS
R OCKIES G LOBAL M ARKETING , LLC.
Tel ·
·303.690.9146 or Fax · ·303.690.9172
6200 S. Troy Circle. Suite 110. Centennial, CO 80111
email
·
·
[email protected] / web
·
·
steelmax.com

Congratulations on your purchase of a SteelMax portable magnetic drilling machine. SteelMax drilling machines are
designed to deliver fast, efficient hole drilling performance in portable applications. SteelMax drills are
fast becoming the most cost effective and efficient way to drill holes not only at steel fabricating work-
shops or steel building sites, but also at virtually every factory maintenance workshop, truck manufacturer
& repair company, military equipment service, onboard ship maintenance shop, etc.
The full advantages of your SteelMax electromagnetic drilling machine can only be achieved with opti-
mal tooling. Milling cutters are designed and manufactured specifically for use with these machines and
offer a wide range of advantages, such as 2 inch diameter holes through 2 inch steel, in one pass and
with precision not otherwise attainable without heavy stationary equipment. This performance
advantage has been virtually impossible in a drill with the size and weight of the SteelMax d2 until now.
The SteelMax d2 provides the latest state of the art features in portable drilling equipment. Among the
features are a no-maintenance rail system that eliminates older gib type systems, which lowers
maintenance and maximizes the life of your SteelMax annular cutters. Energy saving and safety features
are also provided through the use of a powerful new generation, low heat electromagnet with
Condensed Magnetic Flux (CMF) and magnetic field control system. This new system provides safety,
energy saving, maintenance, weight and operational advantages over other brand drills.
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.
SteelMax®d2 Portable Magnetic Drilling Machine
3

LIMITED WARRANTY
RGM RESERVES THE RIGHT TO MAKE IMPROVEMENTS AND
MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE.
Rockies Global Marketing, L.L.C. will, within twelve (12) months 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 RGM within thirty (30) days of purchase date. This warranty is
void if the tool being returned has been used to drill materials beyond the
recommendations in the Owner’s Operating Manual or if the drill has been
damaged by accident, 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
RGM, which shall be the buyer’s sole and exclusive remedy for defective goods.
RGM reserves the right to optionally repair or replace it with the same or
equivalent item. There is no warranty – written or verbal - for annular cutters. In
no event shall RGM be liable for loss or damage resulting directly or indirectly
from the use of merchandise or from any other cause. RGM is not liable for any
costs incurred on such goods or consequential damages. No officer, employee
or agent of RGM is authorized to make oral representations of fitness or to
waive any of the foregoing terms of sale and none shall be binding on RGM.
Questions relating to this limited warranty should be directed to the company’s
head office in Centennial, CO or call toll free 1-877-284-2928.
LIMITED WARRANTY
4

IMPORTANT SAFETY INSTRUCTIONS
5
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. Never Remove Swarf With Bare Hands
• Use a tool designed for the job to avoid injuries.
2. Never Touch Spindle During Operation
• Cutters are extremely sharp and cause serious injuries.
3. Keep Work Area Clean
•Cluttered areas and benches invite injuries.
4. 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.
5. Guard Against Electric Shock
•Prevent body contact with grounded surfaces. For example: pipes, radiators, ranges and refrigerator enclosures.
6. Keep Children Away
• Do not let visitors contact tool or extension cord.
• All visitors should be kept away from work area.
7. Store Idle Tools
• When not in use, tools should be stored in a dry, high and locked-up place, out of reach of children.
8. Do Not Force Tool
•It will do the job better and safer at the rate for which it was intended.
9. 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.
10. Dress Properly
• Do not wear loose clothing or jewelry. They can be caught in moving parts.
• Rubber gloves and non-skid footwear are recommended when working outdoors. Never wear gloves near
rotating machine parts.
•Wear protective hair covering to contain long hair.
11. Use Safety Glasses and Hearing Protection
•Also use face or dust mask if cutting operation is dusty.
12. 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.

13. 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.
14. Do Not Overreach
• Keep proper footing and balance at all times.
15. 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.
16. Disconnect Tools Prior to Service
• Unplug when not in use, before servicing, and when changing accessories, such as blades, bits and cutters.
17. Remove Adjusting Keys And Wrenches
• Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on.
18. 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.
19. Outdoor Use Extension Cords
•When tool is used outdoors, use only extension cords intended for use outdoors and so marked.
20. 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.
21. Check For Damaged Parts
• Before further use of the tool, a guard or other part that is damaged should be repaired and performance
verified prior to operation.
• 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.
22. Never Operate Drill In An Explosive Environment
• Sparks are generated internally by the motor brushes during normal operation.
IMPORTANT SAFETY INSTRUCTIONS (CONT.)
6

Use only 3-wire extension cords that have 3-prong grounding-type plugs and 3-pole receptacles. Make sure
extension cord is in good condition. Replace or repair damaged cords.When using an extension cord, limit
length to 50ft. or less. Only use a cord of 12 guage or larger diameter. An undersized cord will cause a drop in line
voltage resulting in loss of power and overheating. If in doubt, use the next heavier gauge. The smaller the guage
number, the heavier the cord.
The d2 drill must be plugged into a three prong outlet, properly installed and
grounded in accordance with all codes and ordinances. The plug and outlet
should look like those in diagram. If in doubt of proper grounding, contact a
qualified electrician. WARNING!
A shock hazard can result from improperly connecting the grounding wire.
Do not modify the electrical 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.
WARNING!
DO NOT USE STEELMAX DRILLING MACHINES ON SURFACES OR MATERIALS BEING
WELDED. DOING SO CAN RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THE DRILLING
MACHINE.
GROUNDING INSTRUCTIONS
EXTENSION CORDS
7
1. Read and follow operator’s manual thoroughly. Instructions are intended as a guide in safe operating
procedures and practices. Always contact SteelMax in the event any instruction is not clearly understood.
2. Never wear loose clothing or gloves when working near cutting area or machine arbor.
3. DO NOT touch rotating cutter or machine parts.
4. DO NOT use dull or broken cutters.
5. To reduce the risk of electrical shock, DO NOT remove or alter electrical panels or use machine in damp
areas.
6. Always stop machine completely and unplug from power source before changing cutters, clearing swarf,
filling coolant reservoir or performing maintenance.
7. Always wear eye protection. Any tool can shatter.
8. Always use safety strap provided with machine.
9. Always use proper tooling. Keep cutters securely fastened.
10. Beware of ejected slugs core at end of cut. They become HOT during the cut.
11. Keep all safety features functioning and working properly.
12. Use only authorized service centers for repairs.
SPECIAL INSTRUCTIONS

Remove all contents from packaging and inspect to ensure no damage was incurred during shipping.
Your SM-d2 package should include the following:
OPERATING INSTRUCTIONS (BEFORE YOU BEGIN)
DESCRIPTION PART #QTY
METAL TOOL SHIPPING BOX C31300-130-00-00 1
SAFETY STRAP C31272-130-00-00 1
HEX WRENCH 5 H00643-505-01-00 1
HEX WRENCH 6 H00643-506-01-00 1
D2 OPERATORS MANUAL LIT- 016 1
SPOKE HANDLE WITH KNOBS C3281-290-70-01 3
CHIP GUARD C31300-120-00-00 1
REPLACEMENT BRUSHES H01111-200-01-13 2
DRIFT PIN WEDGE C31300-130-00-00 1
COOLANT BOTTLE C31300-060-00-00 1
DRILLING MACHINE SM--D2 1
WHAT YOU SHOULD KNOW BEFORE YOU DRILL
CAUTION!
BESURE YOUR SM-D2IS DISCONNECTED FROM THE POWER SOURCE BEFORE MAKING ADJUSTMENTS.
1. Assemble (3) spoke handles (item 11) to the pinion hub (item 01.03) NOTE: Pinion assembly is mounted on
the left side of the machine frame. If necessary, it can be reversed to operate from the right side of the
frame. To do so, remove the external retaining ring (item 01.07) from the right edge of the pinion. Using a
5mm wrench, loosen the (8) guide rail hex socket retaining bolts about 2-3 turn each (item 23-24) just
enough for the pinion shaft to slide out of the machine frame without hitting the gear rack (item
02.01.02). Insert the pinion assembly from the opposite side of machine frame. Reassemble in reverse
order and tighten all fasteners securely. Note: Coolant line will be in the way and may need to be moved
and secured.
8
1. Type of material to be drilled, Brinnell or Rockwell hardness, material thickness and position should all be
determined to ensure proper selection of SteelMax cutting tools.
2. Remove any excessive scale or rust from surface to be drilled.
3. When drilling thin materials, SteelMax recommends placing a steel plate under the work piece and d2
magnet area to increase magnetic holding force. Failure to do so may result in dangerous operation.
4. Material that has been flame cut may become heat treated and therefore difficult to drill. Avoid drilling near such
areas whenever possible.
5. Paste type cutter lubricant is available for using the d2 drill and annular cutters in the horizontal or inverted
position. Consult you distributor for more information.
Caution: Do not drill on material where welding is also simultaneously being performed. Drilling
machine will be damaged.
Caution: Powering drilling machine from generator without proper surge protection device
between generator and drilling machine may cause damage to the circuitry in machine.

1.Insert the annular cutter in to the machine arbor, lining up the flats on the cutter shank with the set
screws on the arbor. Secure the set screws making sure the screws are recessed in arbor body.
2. Fill the coolant reservoir with a water-soluble coolant. Do not overfill! If drilling horizontally or inverted, use coolant
paste.
3. Position the d2 drill on the work surface. Always use safety strap to prevent injury. Refer to the drawing
below.
4. If necessary, adjust the gearbox speed by turning the gear selector to the appropriate position.
Position one (1) is used for cutters 1 1/8” or larger, and turns at 180 RPM. Position two (2) is used for
cutters smaller than 1 1/8” and turns at 360 RPM. The arbor may need to be turned slightly to shift the gear
selector.
5. Lower cutter to surface of material. Turn on coolant flow valve. Coolant flow will start when pilot pin is
depressed. Lifting pilot pin off work surface will stop coolant flow. Always remember to close valve when not
in use.
6. Position chip guard toward work area before drilling.
7. Place the drilling machine on the work piece, with pilot pin
over the center of the hole to be cut.
8. Move the magnet “ON” switch to the ON position. The switch
will illuminate to indicate DC power is going to the magnet.
9. Depress motor “ON” switch to start drill. If drill momentarily
turns on but will not continue to run, check to make certain
material is thick enough. Insufficient thickness can cause
magnet to loose hold, causing an operator hazard. If
necessary, clamp an additional section of steel to the
work-piece to increase magnetic adhesion. If material
thickness is less than 3/16” (5mm), the magnetic field control system will not allow motor to start. This
system will turn OFF the motor after even minor movement of magnetic base. If holes must be made
regularly in thin (less than 3/8”) material, the magnetic field control system can be disabled permanently.
(Consult Factory) *Operational Note: Models manufactured after 11-2006 have an electronic overload
feature. If the drill experiences over-current due to excessive cutter penetration speeds, the circuit will stop
the drill motor. If this should occur, simply reset the motor switch to the off position and then turn back on.
Proceed with a slower feed rate without forcing the cutter.
READY TO MAKE THE CUT
9
d2
Position 1 / Low Speed Position 2 / High Speed

11. The SteelMax d2 drilling machine is equipped with new unique system for elimination of excess play in
slide guides.This rail guide system completely eliminates maintenance or adjustment.
22. After every 250 hours of operation, check the condition of the (2) carbon brushes (03.16). If their length is
less than 10 mm they should be replaced with new ones. Replacement of brushes is possible without
removal of motor from the drill. Refer to Brush Replacement page for detailed instructions. Other repair work
should only be performed by authorized service centers.
33. To prevent the machine from rusting (especially when used outdoors) all steel parts should be covered
with thin layer of grease film.
44..Keep the magnet clean and free of chips, oil or other contaminant's.
55..Occasionally check the magnet base for flatness to ensure proper magnetic holding force.
6. Replace any worn parts and tighten fasteners that become loose during normal usage.
NORMAL MAINTENANCE
10
CAUTION! SLUG IS EXTREMELY HOT!
1. After the cut has finished, the slug should automatically eject from the cutter*. Slug can eject with significant
force due to the pilot pin spring pressure. Always be prepared for the ejected slug.
2. Return motor to the full upright position, depress motor OFF button and wait until motor fully stops. Move
magnet switch to the OFF position to release the magnetic base from the material.
*Note: If the slug does not eject after the cut, disconnect the machine from the power source and remove
the cutter from the arbor body, then expel the slug. (Caution: Do not use the pilot pin as damage can result).
AFTER THE CUT
CCAAUUTTIIOONN!!
AANNAALLTTEERRNNAATTEEMMEEAANNSSMMUUSSTTBBEEUUSSEEDDTTOOSSEECCUURREELLYYHHOOLLDDTTHHEEDDRRIILLLLIINNPPLLAACCEE..
FFAAIILLUURREETTOODDOOSSOOCCAANNRREESSUULLTTIINNSSEERRIIOOUUSSIINNJJUURRIIEESS!!
9. To start a cut, apply pressure until the cutter has established an external grove. Continue with steady
pressure through the remainder of the cut (Note: Do not peck drill when using annular cutters). The tools
are designed to evacuate chips when drilling.