SteelMax D1 AUTO User manual

The tools of innovation.
15335 E. Fremont Drive, Centennial, CO 80112
1–87STEELMAX, FAX [phone]
www.steelmax.com [email protected]
OPERATOR’S MANUAL
D
D1 1 A AU UT TO O
DRILLING MACHINE
WITH ELECTROMAGNETIC BASE

Contents
1. GENERAL INFORMATION............................................................................................... 3
1.1. Application................................................................................................................. 3
1.2. Technical data............................................................................................................ 3
1.3. Design ....................................................................................................................... 4
1.4. Equipment included ................................................................................................... 5
2. SAFETY PRECAUTIONS.................................................................................................. 6
3. STARTUP AND OPERATION........................................................................................... 8
3.1. Installing and operating the annular cutter.................................................................. 8
3.2. Installing and removing the cooling system bottle .....................................................10
3.3. Control system of the electromagnetic base holding force ........................................10
3.4. Preparing..................................................................................................................11
3.5. Drilling.......................................................................................................................13
3.6. Replacing the motor brushes ....................................................................................14
4. WIRING DIAGRAM..........................................................................................................15
5. EXPLODED DRAWINGS AND PARTS LIST....................................................................16
6. DECLARATION OF CONFORMITY.................................................................................20
7. QUALITY CERTIFICATE..................................................................................................21
8. WARRANTY CARD..........................................................................................................22

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1. GENERAL INFORMATION
1.1. Application
The D1 AUTO is a drilling machine with electromagnetic base designed to drill holes
with diameters of 12–36 mm (0.47–1.42’’) to the maximum depth of 51 mm (2’’) through
the use of annular cutters.
The electromagnetic base allows the drilling machine to be fixed to ferromagnetic
surfaces with a force that ensures user safety and proper machine operation. A safety
strap protects the machine from dropping in case of a power loss.
1.2. Technical data
Voltage
1~ 110–120 V, 50–60 Hz
1~ 220–240 V, 50–60 Hz
Total power
1000 W
Motor power
920 W
Cutter holder
19 mm Weldon (0.75’’)
Maximum drilling diameter
36 mm (1.42’’)
Maximum drilling depth
51 mm (2’’)
Electromagnetic base holding force
(surface with the thickness of 22 mm and roughness Ra= 1.25)
9 000 N
Electromagnetic base dimensions
80 mm × 160 mm × 38 mm
3.1’’ × 6.3’’ × 1.5’’
Slider stroke
70 mm (2.8’’)
Rotational speed under load
350 rpm
Rotational speed without load
580 rpm
Minimum workpiece thickness
6 mm (0.23’’)
Protection class
I
Noise level
over 85 dB
Vibration level
under 2.5 m/s2(≤ 8.2 ft/s2)
Required ambient temperature
0–40°C (32–104°F)
Weight
13.5 kg (30 lbs)

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1.3. Design
Fig. 1. View of the D1 AUTO
317 mm (12.5’’)
307 mm (12.1’’)
221 mm (8.7’’)
Arbor
Spoke handle
Carrying handle
Control panel
Electromagnetic base
Chip guard
Bottle valve lever
Opening for
safety strap
Cooling system bottle
Motor START button
Motor STOP button
Electromagnetic base
ON/OFF switch

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1.4. Equipment included
The D1 AUTO is supplied in a metal box including the following elements.
Drilling machine
1 unit
Metal box
1 unit
Spoke handle
2 units
Cooling system bottle
1 unit
Chip guard
1 unit
Safety strap
1 unit
4 mm hex wrench
1 unit
Operator’s Manual
1 unit

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2. SAFETY PRECAUTIONS
1. Before beginning, read this Operator’s Manual and complete proper occupational
safety and health training.
2. The machine must be used only in applications specified in this Operator’s Manual.
3. The machine must be complete and all parts must be genuine and fully operational.
4. Thespecifications of the power sourcemust conform tothose specifiedon therating
plate.
5. The machine must be plugged into a properly grounded power source. The power
source must be protected with a 16 A fuse for 230 V or a 32 A fuse for 115 V.
When used on building sites, supply the machine through an isolation transformer
made with class II protection only.
6. Never carry the machine by the power cord and never pull the cord because this
may damage it and result in electric shock.
7. Transport and position the machine using the carrying handle and only when the
magnet switch is set to the position ‘O’.
8. Untrained bystanders must not be present near the machine.
9. Before beginning, check the condition of the machine and the power source, including
the power cord, plug, control panel components, and cutters.
10. Keep the machine dry. Exposure to rain, snow, or frost is prohibited.
11. Never stay below the machine placed at heights.
12. Keep the work area well lit, clean, and free of obstacles.
13. Install the annular cutter securely using set screws. Remove adjusting keys and
wrenches from the work area before connecting the machine to the power source.
14. Never use cutters that are dull or damaged.
15. Install and remove cutters using protective gloves and only when the machine is
unplugged from the power source.
16. Never use annular cutters without the pilot pin except when drilling incomplete
through holes.
17. Install only annular cutters with the maximum drilling diameter of 36 mm (1.42’’)
and the maximum drilling depth of 55 mm (2.17’’).
18. Neveruse machine nearflammable liquids orgases, orin explosive environments.
19. Using the machine on surfaces that are rusty, covered with a thick paint layer,
uneven, or not rigid is prohibited.

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20. Use the safety strap in all operating positions. The strap must be tight and
fastened to a securely fixed element either through the opening in the machine
body or by catching the strap on the carrying handle. Never insert the strap into
the buckle from the front.
21. Before every use, inspect the machine to ensure it is not damaged. Check
whether any part is cracked or improperly fitted. Make sure to maintain proper
conditions that may affect the operation of the machine.
22. Always use eye and hearing protection and protective clothing during operation.
Do not wear loose clothing.
23. Proceed with caution when drilling plate with a thickness less than 10 mm (0.4’’)
because the adhesion force depends on material thickness and is significantly
lower for thin plate.
24. The entire surface of the electromagnetic base bottom must be in full contact with
the workpiece. Before every positioning, wipe the workpiece with coarse-grained
sandpaper.
25. Do not touch moving parts or chips formed during milling. Prevent objects from
being caught in moving parts.
26. After every use, remove metal chips and excess coolant from the machine. Do
not remove chips with bare hands.
27. Cover steel parts with a thin anti-corrosion coating to protect the machine from
rust when not in use for any extended period.
28. Maintain the machine and install/remove parts and tools only with the machine
unplugged from the power source.
29. Repair only in a service center appointed by the seller.
30. If the machine falls from any height, is wet, or has any other damage that could
affect the technical state of the machine, stop the operation and immediately
send the machine to the service center for inspection and repair.
31. Never leave the machine unattended during operation.
32. Remove from the worksite and store in a secure and dry location when not in
use, previously removing the cutter and pilot pin from the arbor.

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3. STARTUP AND OPERATION
3.1. Installing and operating the annular cutter
Unplug the machine from the power source, and then set both spoke handles to the
position 1(Fig. 2) and rotate them to the right (2), to raise the motor. Insert the proper
pilot pin into the annular cutter (3), and then wear protective gloves and place the
cutter into the arbor (4) in such a way to align the flats 5with the set screws 6.
Finally,tighten both setscrews with the4mm hexwrench.To remove the cutter, proceed
in reverse order.
Fig. 2. Installing the annular cutter
Adhere to all safety precautions.
2
3
4
6
5
1

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Fig. 3 shows how annular cutters operate. As the cutter penetrates the workpiece,
the pilot pin recesses into the arbor and tightens the spring. As a result, after the cutter
goes through the entire thickness, the slug core is expelled from the cutter. The pilot
pin also allows application of coolant to the inner surface of the annular cutter as it
is depressed.
Fig. 3. Annular cutters operation
Annular cutters are designed to make only through holes shown in Fig. 4. When
drilling incomplete through holes the pilot pin must not be used.
Fig. 4. Types of holes to make with annular cutters
Incomplete through holes
Complete through holes
Slug core
Spring
Pilot pin
Annular cutter
Arbor

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3.2. Installing and removing the cooling system bottle
Hang the cooling system bottle on the screws (1, Fig. 5), and attach the bottle hose
to the coupling (2). Remove in reverse order.
Fig. 5. Installing the cooling system bottle
3.3. Control system of the electromagnetic base holding force
The D1 AUTO drilling machine incorporates a holding force control system to monitor
the adhesion force of the electromagnetic base to the surface. The force value
depends on several factors, such as type, thickness, flatness, and roughness of the
surface, presence of paint, rust or other contaminants, supply voltage fluctuations,
and the wear of the electromagnetic base bottom.
If the holding force falls below a safe operating value, the control system will not
allow the machine to operate. Additionally, the system will prevent the startup of the
motor if the machine is placed on a surface thinner than 5 mm (0.2’’) because such
thickness does not provide sufficient holding force. In such a case, the adhesion force
will be only about 25% of the force attained on a standard 22 mm (0.87’’) flat plate.
If the motor does not continue operation after the green MOTOR button is
pushed and released, it means that the control circuit is operating properly and
preventing further drilling because of too low adhesion force.
1
2

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3.4. Preparing
Before beginning, clean steel parts, especially the Weldon shank, from anti-corrosion
coating used to preserve the machine for storage and transport.
Install the annular cutter into the arbor in the manner described before.
Position the machine on a flat ferromagnetic surface (some types of stainless and
acid-proof steel do not conduct magnetic flux) with the thickness of at least 6 mm
(0.23’’). The workpiece must be clean, without rust or paint that decrease the holding
force of the electromagnetic base.
Connect the drilling machine to the power source, and enable the holding force of
the electromagnetic base by setting the MAGNET switch to the position ‘I’.
Protect the machine using the safety strap to prevent possible injury if the
machine loses magnetic adhesion in case of a power loss. To do this, either fasten the
strap through the opening in the machine body (Fig. 6a, 6b) or catch the strap on the
carrying handle when working in horizontal position (Fig. 6c). The strap must be tight,
not twisted, and must be replaced every single time the machine hangs on the strap
as a result of coming loose from steel. Never insert the strap into the buckle from the
front (Fig. 6d).
Fig. 6. Securing the drilling machine using the safety strap
When working in the position from Fig. 6a, install the cooling system bottle as
described before, and fill it with acutting fluid. Do not use pure water as the cutting
fluid. However, using emulsions formed from mixing water and drilling oil is satisfactory.
To check the operation of the cooling system, slightly loosen the bottle cap, open the
a)
b)
c)
d)
INCORRECT
CORRECT
Inverted
drilling
Vertical
drilling
Horizontal
drilling

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valve using the lever, and initially apply pressure on the pilot pin by rotating the spoke
handles to the left. The fluid should fill the system and begin flowing from the inside
of the cutter.
Enter into manual feed mode by positioning the spoke handles as shown in Fig. 7a,
and rotate them to the left to place the tip of the pilot pin above the drilling point.
Fig. 7. Configuration of the spoke handles: manual feed (a), automatic feed (b)
The cooling system works by means of gravitation, therefore use
a cooling paste when working in horizontal or inverted positions.
a)
b)

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3.5. Drilling
Start the motor by pressing the green MOTOR button. Slowly rotate the spoke handles
to the left to bring the cutter close to the workpiece. Then, gently begin drilling and
enter into the automatic feed mode by setting the spoke handles to the position shown
in Fig. 7b. The drilling machine will automatically detect the end of the drilling, causing
the feed to stop after the hole is made; however, the motor will still be rotating.
After the hole is made, set the spoke handles to the position corresponding to the
manual feed mode (Fig. 7a). Then, retract the cutter from the workpiece and stop the
motor using the red MOTOR button. To move the machine to another drilling spot, first
disable the electromagnetic base by setting the MAGNET switch to the position ‘O’.
After the work is finished, unplug the machine from the power source, clean chips
and excess coolant from the machine and the cutter, and then remove the machine
from the worksite.
Tighten the cap of the cooling system bottle, close the valve, and press the pilot
pin to expel the coolant remaining within the system. Before inserting the drilling
machine into the toolbox, remove the cooling system bottle, and then remove the
cutter and pilot pin from the arbor using protective gloves.
When the cutter goes through the material, the slug core is
expelled from the tool with a significant force.

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3.6. Replacing the motor brushes
Check the condition of the carbon brushes every 100 operational hours. To do this,
unplug the machine from the power source, and unscrew four fixing screws (1, Fig. 8)
to remove the motor cover (2). Next, unscrew the pressing plate 3, and then remove
the brush holder (4)and the brush (5). If the length of the brush is less than 5mm (0.2’’),
replace both brushes with new ones. To install brushes, proceed in reverse order.
After the replacement, run the motor without load for 20 minutes.
Fig. 8. Replacing the brushes
1
2
3
4
5

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4. WIRING DIAGRAM

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5. EXPLODED DRAWINGS AND PARTS LIST
3
1
2
ITEM
PART NUMBER
DESCRIPTION
Q-TY
1
SKR-0502-17-00-00-0
METAL BOX
1
2
KLC-000036
4 MM HEX WRENCH WITH HANDLE
1
3
PAS-000007
SAFETY STRAP 250
1

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1
5
3
2
30
50
39
58
7
6
62
15
9
86
27
61 69
71
76
78
77
81 80
84
83
25
68
12
44
43
40
18
41
11
59
22
13
35
42
65
45
67
20
47
46
8
91
88
24
23
66
60
87
90
22
37
63
31
64
36
49
16
21
32
52
57
89
38
17
48
51
29
34
33
53
55
74
56
54
4
72
82
19
70
14
26
73
10
79
28
75
85

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ITEM
PART NUMBER
DESCRIPTION
Q-TY
1
SZN-0212-10-02-00-2
POWER CORD 230V
1
1
SZN-0075-00-51-00-5
POWER CORD 120V
1
2
TLJ-0399-06-00-00-0
BOTTOM SLEEVE
2
3
RDK-0440-02-00-00-1
GEARBOX ASSY
1
4
SLN-0440-03-00-00-5
MOTOR ASSY 230V
1
4
SLN-0440-03-00-00-3
MOTOR ASSY 120V
1
5
OSL-0440-04-00-00-2
SWARF SHIELD ASSY
1
6
KRP-0502-01-01-00-0
MAIN BODY ASSY
1
7
PKR-0502-02-00-00-1
BODY COVER
1
8
MSK-0502-03-00-00-0
CONTROL PANEL ASSY 220V
1
8
MSK-0502-03-00-00-1
CONTROL PANEL ASSY 120V
1
9
ZSP-0502-04-00-00-0
MOTOREDUCER ASSY
1
10
ZSP-0502-06-00-00-1
COOLANT BOTTLE ASSY
1
11
MDL-0502-07-00-00-0
ELECTRONIC CONTROLLER 220V
1
11
MDL-0502-07-00-00-1
ELECTRONIC CONTROLLER 120V
1
12
NKR-000013
HEX NUT M4
2
13
PDK-000002
DISTANCE WASHER
4
14
PDK-000151
NYLON WASHER SR1940
4
15
PDK-000016
ROUND WASHER 4.3
1
16
PDK-000161
EXTERNAL TOOTH LOCK WASHER 3.7
4
17
PDK-000045
SPRING WASHER 5.1
3
18
DLW-000007
CABLE GLAND WITH STRAIN RELIEF PG11
1
19
SPR-000030
PUSH SPRING
2
20
TLJ-000042
SLEEVE M3x20
4
21
WKR-000415
CROSS RECESSED PAN HEAD SELF-TAPPING SCREW 3.5x13
4
22
WKR-000302
SELF-TAPPING SCREW 5x30
3
23
WKR-000237
SELF-TAPPING SCREW 5x50
1
24
WKR-000113
CROSS RECESSED OVAL COUNTERSUNK HEAD SCREW M4x16
1
25
WKR-000158
COUNTERSUNK HEAD SCREW M3x16
4
26
WKR-000183
CROSS RECESSED PAN HEAD SCREW M4x10
2
27
WKR-000093
HEX SOCKET BUTTON HEAD SCREW M4x12
4
28
WKR-000395
HEX SOCKET ROUND HEAD SCREW WITH FLANGE M5x20
2
29
SRB-000083
HEX SOCKET HEAD CAP SCREW M5x16
3
30
SRB-000115
HEX SOCKET HEAD CAP SCREW M6x25
4
31
KNC-0234-00-10-00-0
COOLANT COUPLING
1
32
WLK-0271-02-03-00-1
PINION ASSY
1
33*
KOL-0271-02-05-00-1
GEAR 52
1
34*
PRS-0271-02-06-00-0
DISTANCE RING
1
35*
WRZ-0272-02-02-00-0
SPINDLE ASSY
1
36
WLK-0502-10-00-00-0
IDLE GEAR
1
37
PRT-0440-02-02-00-1
GUIDE
2
38*
LOZ-000047
BALL BEARING 25x47x12
1
39
LOZ-000072
BALL BEARING 9x26x8
1
40
WYP-0139-00-02-00-1
PLUNGER
1
41
SPR-0271-02-02-03-0
SPRING
1
42
KRP-0272-02-02-01-0
SPINDLE BODY
1
43
USZ-0279-02-01-06-0
SEAL
1
44
PRS-000009
INTERNAL RETAINING RING 19w
1
45
WKR-000059
HEX SOCKET SET SCREW WITH FLAT POINT M8x10
2
46*
LOZ-000048
BALL BEARING 25x47x12
1
47
LST-0271-02-01-02-1
GEAR RACK
1

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ITEM
PART NUMBER
DESCRIPTION
Q-TY
48*
PRS-000070
SEAL 25x37x7
2
49
LOZ-000053
BALL BEARING 8x22x7
1
50
SRB-000111
HEX SOCKET HEAD CAP SCREW M6x18
1
51
SCZ-000008
MOTOR BRUSH 6x9x17
2
52
SCT-0271-03-06-00-0
BRUSH HOLDER
2
53
PLY-0271-03-07-00-0
BRUSH HOLDER PRESSURE PLATE
2
54
PKR-0440-03-02-00-1
MOTOR COVER
1
55
WKR-000326
CROSS RECESSED COUNTERSUNK HEAD SHEET METAL SCREW 2.9x13
2
56
WKR-000241
SELF-TAPPING SCREW 4x20
4
57
PWD-0440-03-01-00-0
MOTOR CORD
1
58
PDS-0440-06-00-00-0
ELECTROMAGNETIC BASE
1
59
PLY-0277-00-02-00-1
INSULATION PLATE
1
60
KOL-0502-01-02-00-0
GEAR z=60
1
61
ZSP-0502-05-00-00-0
LEVERS ASSY
1
62
PDK-000166
EXTERNAL TOOTH LOCK WASHER 4.3
1
63
KUL-000003
BEARING BALL 5
8
64
PRS-000021
EXTERNAL RETAINING RING 30z
1
65
PDK-000046
SPRING WASHER 6.1
3
66
LOZ-000080
BALL BEARING 45x58x7
1
67
SRB-000115
HEX SOCKET HEAD CAP SCREW M6x25
3
68
WZK-0242-04-00-00-0
REED WIRES SET
1
69
SPR-0203-03-09-00-0
LATCH SPRING
2
70
KRP-0502-05-01-00-1
LEVER BODY
1
71
PKR-0502-05-02-00-0
COVER
1
72
DZW-0502-05-03-00-0
SPOKE HANDLE INCLUDING KNOB (ASSY)
2
73
WLK-0502-05-04-00-0
DRIVEN SHAFT
1
74
WLK-0502-05-05-00-1
SWITCHING SHAFT
1
75
TLJ-0502-05-06-00-0
CLUTCH SLEEVE
1
76
KLK-000015
SPRING DOWEL PIN 4x26
2
77
KUL-000003
BEARING BALL 5
2
78
NKR-000035
SHORT NUT M6
2
79
PRS-000259
SEAL
1
80
PDK-000017
ROUND WASHER 5.3
1
81
PDK-000045
SPRING WASHER 5.1
1
82
WKR-000019
HEX SOCKET SET SCREW WITH DOG POINT M5x6
2
83
WKR-000069
HEX SOCKET SET SCREW WITH CONE POINT M8x12
3
84
WKR-000092
HEX SOCKET BUTTON HEAD SCREW M4x10
2
85
SRB-000075
HEX SOCKET HEAD CAP SCREW M5x10
1
86
KOL-0502-04-02-00-0
GEAR z=16
1
87
KLK-000005
SPRING DOWEL PIN 3x14
1
88
SLN-000056
MOTOREDUCER 12V
1
89
PNK-000013
MAGNET SWITCH
1
90
WLC-000007
SWITCH START-STOP 230V
1
90
WLC-000005
SWITCH START-STOP 115V
1
91
PWD-0277-09-04-00-0
PANEL PLATE WIRE
1
–
SMR-000001
GREASE
0.055 kg
* before you order read the service manual

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6. DECLARATION OF CONFORMITY
EC Declaration of Conformity
We
PROMOTECH sp. z o.o.
ul. Elewatorska 23/1
15-620 Bialystok
Poland
declare with full responsibility that product:
D1 AUTO Drilling Machine with Electromagnetic Base
which the declaration applies to is in accordance with the following standards:
•EN 60745-1
•EN 55014
•EN ISO 12100-1
•EN ISO 12100-2
and satisfies safety regulations of the guidelines:2004/108/EC, 2006/95/EC, 2006/42/EC.
Bialystok, 6 September 2013 ___________________________
Marek Siergiej
Chair