SteelMax D1 AUTO User manual

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

Contents
1. GENERAL INFORMATION............................................................................................... 3
1.1. Application................................................................................................................. 3
1.2. Technical data............................................................................................................ 3
1.3. Equipment included ................................................................................................... 4
1.4. Dimensions................................................................................................................ 5
1.5. Design ....................................................................................................................... 5
2. SAFETY PRECAUTIONS.................................................................................................. 6
3. STARTUP AND OPERATION........................................................................................... 8
3.1. Installing, removing, 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 ........................................11
3.4. Preparing..................................................................................................................11
3.5. Drilling.......................................................................................................................13
3.6. Replacing the motor brushes ....................................................................................14
4. ACCESSORIES...............................................................................................................15
4.1. Pressure cooling system...........................................................................................15
4.2. Pipe attachment DMP 251 ........................................................................................15
5. WIRING DIAGRAM..........................................................................................................16
6. EXPLODED DRAWINGS AND PARTS LIST....................................................................17
7. DECLARATION OF CONFORMITY.................................................................................21
8. QUALITY CERTIFICATE..................................................................................................22
9. WARRANTY CARD..........................................................................................................23

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1. GENERAL INFORMATION
1.1. Application
The D1 is a drilling machine with electromagnetic base, designed to drill holes with
diameters of up to 36 mm (1-7/16’’) to a depth of up to 51 mm (2’’) by using annular
cutters.
The electromagnetic base allows the drilling machine to be fixed to ferromagnetic
surfaces with a force that ensures operator safety and proper machine operation.
A safety strap protects the machine from falling 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
Tool holder
19 mm Weldon (3/4’’)
Maximum drilling diameter
36 mm (1-7/16’’)
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 (2000 lbs)
Electromagnetic base dimensions
80 mm × 160 mm × 38 mm
3-1/8’’ × 6-5/16’’ × 1-1/2’’
Stroke
70 mm (2-3/4’’)
Rotational speed under load
350 rpm
Minimum workpiece thickness
6 mm (1/4’’)
Protection class
I
Noise level
More than 85 dB
Required ambient temperature
0–40°C (32–104°F)
Weight
10 kg (22 lbs)

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1.3. Equipment included
1
Drilling machine with cooling
system bottle and chip guard
1 unit
2
Plastic box
1 unit
3
Handle
3 units
4
Safety strap
1 unit
5
4 mm hex wrench with handle
1 unit
–
Operator’s Manual
1 unit
1
2
3
4
5

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1.4. Dimensions
1.5. Design
330 mm (13’’)
314 mm (12-3/8’’)
179 mm (7-1/16’’)
Electromagnetic base
(MAGNET) switch
MOTOR start button
MOTOR stop button
Spindle
with arbor
Carrying handle
Electromagnetic base
Chip guard
Bottle valve lever
Opening for safety strap
Feed shaft
Cooling system bottle
Control panel

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2. SAFETY PRECAUTIONS
1. Before starting, read this Operator’s Manual and complete proper occupational
safety and health training.
2. Use the machine only in applications specified in this Operator’s Manual.
3. The machine must be complete and all parts must be genuine and fully functional.
4. The specifications of the power source must conform to those specified on the
ratingplate.
5. Connect the machine to 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 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 by using the carrying handle and only when the
MAGNET switch is set to ‘O’.
8. Untrained bystanders must not be present near the machine.
9. Before starting, ensure the correct condition of the machine, power source, power
cord, plug, control panel components, and cutters.
10. Keep the machine dry, and never expose it to rain, snow, or frost.
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 by tightening the set screws. Remove 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 tools by 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. Do not make holes which diameter or depth differ from those specified in the
technical data.
18. Never use near flammable liquids or gases, or in explosive environments.
19. Never use the machine on surfaces that are rusty, covered with paint, uneven, or
not rigid.

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20. Use the safety strap in all work positions. Attach the machine to a fixed structure
by fastening the strap through the opening in the machine body or to the carrying
handle when working in horizontal position. 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 work.
Do not wear loose clothing.
23. Proceed with caution when drilling in plates with a thickness less than 10 mm (3/8’’)
because the holding force depends on material thickness and is much lower for
thin plates.
24. The whole bottom of the electromagnetic base 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. Prevent anything from being caught in
moving parts.
26. After every use, remove chips and excess coolant from the machine and tool.
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 when the machine
is 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 work and promptly send the
machine to the service center for inspection and repair.
31. Never leave the machine unattended during work.
32. Remove from the worksite and store in a secure and dry place 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, removing, and operating the annular cutter
Unplug the machine from the power source, and then rotate the handles to the right
(1, Fig. 1) to raise the motor. Wear protective gloves, insert the proper pilot pin into
the annular cutter (2), and then use a clean and dry cloth to wipe the arbor and
cutter. Next, insert the cutter into the arbor (3) so that the flats 4are aligned with the
set screws 5, and then use the 4 mm hex wrench to tighten both set screws.
To remove the cutter, loosen the screws 5with the 4 mm hex wrench.
Fig. 1. Installing the annular cutter
2
1
3
5
4

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Fig. 2shows how annular cutters work. As the cutter drills into the workpiece, the pilot
pin retracts and tightens the spring. As a result, after the cutter drills through the
material, the slug core is expelled from the cutter. Also, when pressed, the pilot pin
allows application of coolant to the inside of the cutter.
Fig. 2. Annular cutters work
Annular cutters are designed to drill only through holes shown in Fig. 3. When drilling
incomplete through holes the pilot pin must not be used.
Fig. 3. Types of holes to drill 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
Rotate the handles (1, Fig. 4) to raise the motor, place the cooling system bottle on
the machine (2), and then attach the bottle hose to the hose fitting (3).
Before removing the bottle, detach the hose from the fitting, and raise the motor.
Fig. 4. Installing the cooling system bottle
1
2
3

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3.3. Control system of the electromagnetic base holding force
The drilling machine includes a holding force control system to monitor the clamping
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 dirt, fluctuations of supply voltage, and the wear of the electromagnetic
base bottom.
If the holding force falls below a safe work value, the control system will not allow
the machine to work. Also, the system will prevent the startup of the motor on a
surface thinner than 5mm (3/16’’) because such thickness does not provide enough
holding force. In such a case, the holding force will be only about 25% of the force
attained on a standard 22-mm (7/8’’) flat plate.
If the motor does not continue work after the green MOTOR button is pressed and
released, it means that the control circuit is working properly and preventing further
drilling because the holding force is too low. Drilling on thin plates is possible, but in
such cases the green MOTOR button must be continuously held.
3.4. Preparing
Before starting, clean steel parts, including the arbor, from anti-corrosion coating
used to preserve the machine for storage and transport.
Screw the handles into the feed shaft. To allow working in places hard to reach or
using the machine by a left-handed person, the feed shaft can be installed so that the
handles are on the opposite side of the machine.
Select the proper annular cutter based on the hole size desired. Next, use a clean
and dry cloth to wipe the arbor and cutter, and then install the cutter into the arbor as
described before.
Place the machine on a flat ferromagnetic workpiece with the thickness of at
least 6 mm (1/4’’). The workpiece must be clean, without rust, paint, or chips that
decrease the holding force. Then, connect the machine to the power source, and set
the MAGNET switch to ‘I’ to turn on the clamping. Some types of steel are non-
ferromagnetic (do not conduct magnetic flux) and the machine is not able to clamp
onto them.
Use the safety strap to prevent the machine from falling and avoid possible injury
to the operator if the machine loses the clamping. To protect the machine, attach it to

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a fixed structure by fastening the strap through the opening (Fig. 5a, 5b) or to the
carrying handle when working in horizontal position (Fig. 5c). 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. 5d).
Fig. 5. Protecting the machine from falling by using the safety strap
Rotate the handles to the left to place the tool above the workpiece.
When working in the position from Fig. 5a, fill the cooling system bottle with
coolant. Do not use only water as the coolant. However, using emulsions from water
and drilling oil is adequate. To check the operation of the cooling system, slightly
loosen the bottle cap, use the lever to open the valve, and then rotate the handles to
the left to initially apply pressure on the pilot pin. The coolant should fill the system
and start flowing from the inside of the cutter.
Because the cooling system works by gravity, when working in inverted or horizontal
positions (Fig. 5b, 5c) use coolants under pressure or in the form of spray or paste.
Inverted drilling
INCORRECT
CORRECT
✓
a)
b)
c)
d)
Vertical drilling
Horizontal
drilling

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3.5. Drilling
Start the motor with the green MOTOR button, slowly rotate the handles to the left to
lower the tool to the workpiece, and start drilling. Drill the hole in one pass.
If the work results in an overload caused by not enough cooling, dull cutter, or too
fast feed in relation to the cutter diameter, the machine will automatically stop. In such
a case, to restart the machine, retract the cutter from the workpiece, and then press the
green MOTOR button (the electromagnetic base must remain powered).
After the hole is made, retract the cutter from the workpiece and press the red
MOTOR button to stop the motor. Before moving the machine to another drilling spot,
set the MAGNET switch to ‘O’ to turn off the electromagnetic base.
After the work is finished, unplug the machine from the power source, clean chips
and excess coolant from the machine and cutter, and then remove the machine from
the worksite.
Tighten the bottle cap, close the valve, and then press the pilot pin to expel the
coolant remaining within the cooling system. Before inserting the machine into the box,
wear gloves to remove the cutter from the arbor.
After the annular cutter drills through the material, the slug
core is expelled with a large force.

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3.6. Replacing the motor brushes
Check the condition of the carbon brushes every 100 work hours. To do this, unplug the
machine from the power source, and unscrew the cover (1, Fig. 6). Next, unscrew the
pressing plate (2), and then remove the brush holder (3) and the brush (4). If the length
of the brush is less than 5 mm (3/16’’), 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. 6. Replacing the brushes
1
2
3
4

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4. ACCESSORIES
4.1. Pressure cooling system
Capacity of 2 liters.
4.2. Pipe attachment DMP 251
Designed for pipes with diameters of 80–250 mm (3–10’’). Internal dimensions: 95 mm
× 211 mm (3-3/4’’ × 8-5/16’’).
Part number:
UKL-0440-16-00-00-0
Part number:
PDS-0110-03-00-01-0

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5. WIRING DIAGRAM

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6. EXPLODED DRAWINGS AND PARTS LIST
1 3 2
ITEM
PART NUMBER
DESCRIPTION
Q-TY
1
SKR-000010
PLASTIC BOX
1
2
KLC-000036
4 MM HEX WRENCH WITH HANDLE
1
3
PAS-000007
SAFETY STRAP 250
1

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

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ITEM
PART NUMBER
DESCRIPTION
Q-TY
1
SZN-0212-10-02-00-2
POWER CORD 230V 3x1.5 WITH STRAIN RELIEF ASSY (EU)
1
1
SZN-0212-10-02-00-1
POWER CORD 230V 3x1 WITH STRAIN RELIEF ASSY (AU)
1
1
SZN-0075-00-51-00-5
POWER CORD 120V 3x2.08 WITH STRAIN RELIEF ASSY (US)
1
1
PWD-0212-10-02-00-6
POWER CORD 230V 3x1.5 WITH STRAIN RELIEF ASSY (INDIA)
1
2
DZW-0212-12-00-00-0
SPOKE HANDLE WITH KNOB ASSY
3
3
PNL-0300-04-00-08-1
CONTROL PANEL ASSY 230V
1
3
PNL-0300-04-00-08-0
CONTROL PANEL ASSY 120V
1
4
KRP-0440-01-01-00-3
BODY ASSY
1
5
RDK-0440-02-00-00-3
GEARBOX ASSY
1
6
SLN-0440-03-00-00-5
MOTOR ASSY 230V
1
6
SLN-0440-03-00-00-3
MOTOR ASSY 120V
1
7
UKL-0440-05-00-00-1
COOLANT BOTTLE ASSY
1
8
SCN-0440-07-00-00-0
BODY COVER
1
9
PDK-000161
EXTERNAL TOOTH LOCK WASHER 3.7
8
10
WKR-000415
CROSS RECESSED PAN HEAD SELF-TAPPING SCREW 3.5x13
8
11
WKR-000302
SELF-TAPPING SCREW 5x30
3
12
WKR-000237
SELF-TAPPING SCREW 5x50
1
13
WKR-000112
CROSS RECESSED OVAL COUNTERSUNK HEAD SCREW M4x16
1
14
NKR-000013
HEX NUT M4
2
15
PDK-000060
EXTERNAL TOOTH LOCK WASHER 4.3
1
16
PDK-000043
SPRING WASHER 4.1
1
17
SRB-000118
HEX SOCKET HEAD CAP SCREW M6x30
2
18
SRB-000123
HEX SOCKET HEAD CAP SCREW M6x35
2
19
STR-0257-04-10-00-5
ELECTRONIC CONTROLLER SW 31M-C 230V
1
19
STR-0257-04-10-00-4
ELECTRONIC CONTROLLER SW 31M-C 120V
1
20
FLT-0257-04-12-00-1
INTERFERENCE ELIMINATOR
1
21
PWD-0440-03-01-00-0
MOTOR CORD ASSY
1
22
PNK-000013
MAGNET SWITCH
1
23
WLC-000007
START-STOP SWITCH 230V
1
23
WLC-000005
START-STOP SWITCH 120V
1
24
WLK-0271-01-02-00-1
PINION SHAFT ASSY
1
25
MSK-0300-04-01-00-1
PANEL PLATE ASSY
1
26
PDS-0440-06-00-00-0
ELECTROMAGNETIC BASE
1
27
PRS-000019
EXTERNAL RETAINING RING 28z
1
28
PDK-000046
SPRING WASHER 6.1
2
29
SRB-000114
HEX SOCKET HEAD CAP SCREW M6x20
2
30*
WRZ-0272-02-02-00-0
SPINDLE ASSY
1
31
PRS-000259
SEAL
1
32
WLK-0271-02-03-00-1
PINION SHAFT ASSY
1
33*
KOL-0271-02-05-00-1
GEAR z52
1
34*
PRS-0271-02-06-00-0
DISTANCE RING
1
35
PLY-0271-03-07-00-0
BRUSH HOLDER PRESSURE PLATE
2
36
WKR-000326
CROSS RECESSED COUNTERSUNK HEAD SHEET METAL SCREW 2.9x13
2
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

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20
ITEM
PART NUMBER
DESCRIPTION
Q-TY
45
WKR-000059
HEX SOCKET SET SCREW WITH FLAT POINT M8x10
2
46*
LOZ-000048
BALL BEARING 25x47x12
1
47
KNC-0234-00-10-00-0
HOSE FITTING
1
48
WKR-000241
SELF-TAPPING SCREW 4x20
4
49
SCZ-000008
MOTOR BRUSH 6x9x17
2
50
SCT-0271-03-06-00-0
BRUSH HOLDER
2
51
WZK-0242-04-00-00-0
REED RELAY WIRES SET ASSY
1
52
LOZ-000053
BALL BEARING 8x22x7
1
53
PKR-0440-03-02-00-1
MOTOR COVER
1
54*
PRS-000070
SEAL 25x37x7
2
55
LST-0271-02-01-02-1
GEAR RACK
1
56
SRB-000111
HEX SOCKET HEAD CAP SCREW M6x18
1
57
TLJ-0399-06-00-00-0
BOTTOM SLEEVE
2
58
DLW-000007
CABLE GLAND WITH STRAIN RELIEF PG11
1
59
OSL-0440-04-00-00-2
CHIP GUARD ASSY
1
60
PDK-000151
NYLON WASHER 8.1x14x3
4
61
SPR-000030
PUSH SPRING
2
62
WKR-000395
HEX SOCKET ROUND HEAD SCREW WITH FLANGE M5x20
2
63
PDK-000176
EXTERNAL TOOTH LOCK WASHER 6.3
1
64
SRB-000113
HEX SOCKET HEAD CAP SCREW M6x20
1
65
USZ-000055
SEAL
1
66
OBD-0272-03-01-01-1
FILED FRAME
1
68
WKL-000001
BEARING INSERT 19x7.5
1
69
STN-000004
STATOR 220V
1
69
STN-000002
STATOR 120V
1
70
OSL-0271-03-01-02-0
FAN GUARD
1
71
WKR-000241
SCREW FOR PLASTIC 4x20
1
72
WRN-000017
ROTOR 220V
1
72
WRN-000016
ROTOR 120V
1
73
PRS-0271-03-02-02-1
GEARBOX COVER RING
1
74
PKR-0272-03-02-01-2
GEARBOX COVER
1
75
WKR-000083
CROSS RECESSED PAN HEAD TAPPING SCREW
1
76
WKR-000081
CROSS RECESSED PAN HEAD SELF-TAPPING SCREW 4.8x19
2
77
PDK-000042
SPRING WASHER 4.1
2
78
SRB-000062
HEX SOCKET HEAD CAP SCREW M4x12
2
–
SMR-000001
GREASE
0.055
kg
(2 oz)
* before you order read the service manual