SteelMax D1PRO User manual

Steelmax Tools LLC
112 Inverness Circle East, Englewood, CO. 80112
1-87STEELMAX Fax [phone]
www.steelmax.com e-mail: [e-mail]
SAFETY INSTRUCTIONS
AND OPERATORS MANUAL
FOR
DRILLING MACHINE
D
D1 1P PR RO O

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CONTENT
1. GENERAL INFORMATION ...................................................................................................... - 4 -
2. GENERAL SAFETY ADVICE ................................................................................................... - 5 -
3. STANDARD EQUIPMENT ....................................................................................................... - 7 -
4. START UP AND OPERATION ................................................................................................. - 8 -
5. TECHNICAL DATA ................................................................................................................ - 19 -
6. MAINTENANCE AND SERVICE ............................................................................................ - 22 -
7. PARTS LIST AND EXPLODED PARTS DRAWINGS............. .............................................- 23 -
8. ELECTRICAL DIAGRAM ....................................................................................................... - 33 -
9. CE DECLARATION OF CONFORMITY................................................................................. - 34 -
10 MACHINE TEST CERTIFICATE ............................................................................................ - 35 -
11. WARRANTY CARD................................................................................................................ - 36 -

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BEFORE YOU START WORK WITH THE MACHINE,
PLEASE READ THESE INSTRUCTIONS CAREFULLY
AND USE ALL RECOMMENDATIONS.
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 such as 3 inch
diameter holes through more than 2 inch steel, in one pass and with precision not
otherwise attainable without heavy stationary equipment.
The D1 PRO machine is capable of milling 40 mm (1-9/16") holes trough 2
inch plate what is totally unique for an electromagnetic drill of this size and weight.
The D1 PRO is equipped with a powerful verified for many years of exploitation drive
and electromagnet with field control system.
Before you start work with the machine, please read these instructions
carefully. Take special note of safety recommendations.

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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 these recommendations.
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 dropping from
power loss especially when used at heights or in vertical or upside-down
positions.
8. Bystanders are present in the immediate vicinity of machine.
Warning!
Read and save all instruction for future reference!
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 covered with thick
paint, uneven surfaces or next to a welding machine. When the machine is
attached to any metal surface, that surface should not be welded. Remove the
drill from the steel before beginning welding. This can cause damage to the
machine and will void the warranty
.
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.

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Safety chain can also secure the drill through
the handle.
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.
10) Do not touch the spindle and the 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 fastened tightly.
12) Do not use dull or damaged cutters.
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 metal chips and coolant from drilling machine.
16) Always unplug machine from power supply during any work on the machine.
17) Before each use the machine should be checked for the presence of damage
and the proper and consistent use. Check whether any of the parts are broken
and that all the parts are fastened properly.
Drawing 1.
E
x
am
p
les how
s
a
f
et
y
chain
s
hould be
f
astened..

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18) If 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.
The drill should not be used on steel thinner than (less than 3/8” (10
mm)). On thin steel (less than 3/8” (10 mm)) the magnet’s adhesive power
would be significantly reduced which can cause machine 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 the electromagnetic base should be
cleaned with a rag or sanded down with abrasive paper!
Please keep all recommendations.
3. STANDARD EQUIPMENT
D1 PRO comes in a standard equipment set which consists of:
metal box - 1 pc
drilling machine - 1 pc
cooling system - 1 pc
2.5 Allen Key - 1 pc
3 Allen Key - 1 pc
4 Allen Key - 1 pc
8 mm flat wrench - 1 pc
spoke handles - 3 pcs
safety chain with snap hook - 1 pc
operator’s manual - 1 pc
plastic box - 1 pc

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4. START UP AND OPERATION
4.1 Cutters and optional equipment features.
This drilling machine’s spindle has a Weldon Shank type socket 3/4” or
19.05 mm and is specifically designed for use with milling cutters.
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 do not come loose. It is important to position the cutter in relation to
the socket in such a way that the flats on the cutter shank are positioned under the
fixing screws (3). Both fastening screws(3) should be used to secure the cutter. Pilot
(5) is located inside the cutter. It makes it easier to position milling cutter over the
center 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 center free cutter. The pilot also
allows cutting fluid to cool and lubricate the cutter from the inside.
Basically milling cutters are designed to make through holes. On occasions when
there is a need for an overlapping hole the pilot should not be used.
Drawing 2.
Principle of milling cutter’s work
Drawing 3.
A few types of holes that can be done with a milling cutter

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4.1.1 Installing and uninstalling the arbor
The arbor installation and removal should be carried out when the
machine is turned off and disconnected from the power grid!
Installing the arbor:
a) Raise the drive and the slide (1) up using the lever (3);
b) Raise the guard,
c) Clean the spindle (2) using a cotton cloth,
d) Before mounting, clean off the lubricant from the new arbor (4),
e) Place the arbor on the spindle, so that the flat sides of the spindle are under the screws
(5)
f) Tighten the screws securely (5)
Uninstalling the arbor:
a) Raise the drive and the slide (1) up using the lever (3);
b) Raise the guard in order to attain access to the arbor (4) screws (5).
c) Loosen the screws (5);
d) Remove the arbor (4).

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4.1.2 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 (1) up using the lever (2);
2. Raise the guard in order to attain access to the arbor (4) screws (3);
3. Insert the appropriate type of pilot (5) into the milling cutter (6);
4. Position the milling cutter (6) with the cutter facing up, so that the flat sides of the
milling cutter are under the screws (3)
5. Put the milling cutter (6) into the arbor socket (4);
6. Tighten the screws securely (3).
Uninstalling the milling cutter:
1. Raise the drive and the slide (1) up using the lever (2);
2. Raise the guard in order to attain access to the arbor (4) screws (3).
3. Loosen the screws (3);
4. Remove the milling cutter (6) and the pilot (5) from the arbor socket (4).

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4.2 Operating instructions
The machine is supplied in a metal box. Check if all parts listed in paragraph 3 are
included. 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,
Control elements include:
- 2-position main switch Magnet (01),
- START-STOP switch (02),
a) In order to start the machine press the main switch (01) on “I“ button. Now you
can start the motor by pressing green button “I” (02).
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 magnet switch (01) to the position “O”.
CAUTION: READ THE WHOLE INSTRUCTIONS MANUAL
BEFORE ATTEMPTING TO START UP
Drawing 5. Control panel
D
rawin
g
4. View of the machine D1 PRO

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4.3 Before you cut
Before positioning the machine on work piece always make sure that:
-work piece is made of steel;
-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 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 dropping
with original chain (as described in paragraph 4 “Important rules of safe use of
drilling machine”).
4.4 Cutting
- Cooling and lubricant fluid commercially available in concentrated form are
recommended for use for cooling twist drill and annular cutter. The fluid will extend
the life of the cutting device. Use of emulsions formed from a mixture of water and
drilling oil are also satisfactory.
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 4.9)
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 a 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 cooling liquid 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
cooling liquid to fill the whole system.
-Turn the motor on.

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Bring the cutter gently into contact with the work piece and slowly start to
apply pressure on the cutter.
Making a hole with a milling cutter should ideally be done in one pass. It
makes the cutter work better and it is 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 of swarf,
coolant etc and the cutter should be removed and cleaned.
-The tool should be removed from drill chuck before inserting into the toolbox.
4.5. Types of a ground material
As shown on the graphs [Drawing 6] 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 lower magnetic permeability, what causes a decrease in the clamping force. Also
the thickness of a work piece, on which the drill is placed, is significant.
Maximum clamping force of the electromagnetic base to a 5 mm (0.2") thick
work piece surface is only about 25% of a clamping force obtained from a
smooth, plane, 22 mm (0.86") 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 the
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 1-step reducing gearbox of a motor rpm. A general
dependence between drilling diameter and drilling speed is shown in drawing 7,
detailed guide is supplied by manufacturer of drilling tools. The graph is just a general
guide and the shown dependence applies to average structural steel. One should
remember that during the drilling a cooling fluid should be used.

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Cooling agent is fed gravitationally from a coolant bottle through an arbor to
the inside of the metal cutter via the pilot pin. For vertical and upside down positions
special cooling pastes have to be used.
4.6 Electromagnetic base clamping force control system
This system for security reasons is an integral part of each drill type. It works
by constant monitoring of the electromagnetic force base adhesion value to the
substrate. When the clamping force falls below a safe operating value the control
system will not allow the drill to operate. If the metal to be drilled is too thin it is
possible to clamp a thicker piece of metal to the workpiece in order to obtain the
proper electromagnetic force.
Clamping force depends on: type and thickness of substrate, thick coatings on
the substrate, rust or other contaminants, lack of flatness of the substrate, excessive
roughness of the surface, excessive wear of the lower part of the electromagnetic
base.
If the motor does not continue operation after the start switch is pushed and let
go it means that the control circuit is operating properly. Make adjustments as
suggested above in order to safely operate the machine.
4.7 How to use the special functions
There are many causes which can reduce magnet holding force. These can be:
insufficient work piece thickness, paint coating, rust or dirt, uneven and rough
surfaces, extensive wear of the magnets bottom surface etc.
If after turning drills electromagnet ON the motor will not start it can be
caused by machines safety system which has detected insufficient magnet
holding power. Motors operation can then be executed by holding the green
Start “I” button pressed continuously. After release of the Start button the
motor will stop. To eliminate this situation it is necessary to improve magnetic
properties of the work piece or recondition the magnetic base.
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 turns the motor off but the magnet still holds). To
move the machine to drill in another place you should stop the motor and then turn
off the main switch in position “O”.

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4.8 Working in difficult areas
While working in difficult access areas as well as left-handed operator, one can
change location of the pinion with spoke handles to the other side of drilling machine.
Drawing 6. Clamping force depending on the thickness of the substrate and the value gap.

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Drawing 7. Dependence of rotational speed on drilling diameter.

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4.9 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) Place 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 valve ending (4), the bottle cap
should be loosened by 1/3 of a turn in order to avoid a vacuum, turn on the valve (9), so that
liquid travels to the hose, after which the machine can be started (see point 4.2)
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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4.10 Adjusting gib clearance
The gib should not need to be adjusted often. However if the slide sticks or becomes
somewhat loose it can be adjusted as follows:
The drive and the slider (1) can be slid up and down smoothly using the lever (3),
uncovering strip (2) and the drill body.
.
Clearance adjustment should be carried out as follows:
1. loosen screws (4) after undoing the nuts (5),
2. slide the slider up and down several times,
3. slide the slider to its lowermost position
4. tighten the screws located at the height of the slider,
5. slide the slider up,
6. tighten the remaining screws,
7. slide the slider up and down and if necessary, tighten or loosen screws at the height where
problems with moving the slider occur,
8. tighten counter nuts (5) when screw has been put into position (using a hexagonal key)
Please keep all recommendation.

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5. TECHNICAL DATA
Power supply 110-120 V 50/60 Hz~ or
220-240 V 50/60 Hz~
Power required 1100 W
Motor power 1020 W
Tool holder 3/4” Weldon /19.05 mm/
Max. milling cutter diameter 40 mm - 1-9/16"
Max. drilling diameter 16 mm - 5/8"
Max. milling depth 2” - 51 mm
Insulation Class I
Standard adhesive force of
electromagnet 9 800 N - 2200 lbs.
Slide stroke 124 mm - 4.9"
Machine speeds /under load/ 440 rpm
Electromagnetic base 84x168x41.5 mm - 3.3x6.6x1.6"
Length of the power cord 3.0 m - 9.8'
Total weight 12.7 kg - 30 lbs.
Noise level above 85 dB
Surrounding temperature 0C to 40C - 32°F to 104°F

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5.1 Parameters depending on spindle speed(drilling)
Relationship between machine speed and cutter diameter
The cutter diameter Rotary speed
[rpm]
[inch] [mm]
0,47-1,38 12-40 440
Relationship between machine speed and twist drill diameter
The twist drill diameter
Rotary speed
[rpm]
[inch] [mm]
0.20-0,63 5-16 440