SteelMax D2X 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
D2 2X X
DRILLING MACHINE
WITH ELECTROMAGNETIC BASE

Contents
1. GENERAL INFORMATION............................................................................................... 3
1.1. Application................................................................................................................. 3
1.2. Technical data............................................................................................................ 3
1.3. Design ....................................................................................................................... 5
1.4. Equipment included ................................................................................................... 5
2. SAFETY PRECAUTIONS.................................................................................................. 6
3. STARTUP AND OPERATION........................................................................................... 8
3.1. Installing and removing the arbor or MT2 twist drill bit................................................ 8
3.2. Installing, removing, and operating the annular cutter...............................................10
3.3. Installing and removing the cooling system...............................................................12
3.4. Control system of the electromagnetic base holding force ........................................13
3.5. Preparing..................................................................................................................13
3.6. Drilling.......................................................................................................................15
3.7. Adjusting the gib clearance.......................................................................................16
3.8. Replacing the motor brushes ....................................................................................18
4. ACCESSORIES...............................................................................................................19
4.1. Pressure cooling system...........................................................................................19
4.2. Pipe attachment DMP 251 ........................................................................................19
4.3. Pipe attachment DMP 501 ........................................................................................20
4.4. Cooling attachment for twist drilling...........................................................................20
5. WIRING DIAGRAM..........................................................................................................21
6. EXPLODED DRAWINGS AND PARTS LIST....................................................................22
7. DECLARATION OF CONFORMITY.................................................................................28
8. QUALITY CERTIFICATE..................................................................................................29
9. WARRANTY CARD..........................................................................................................30

D2X
D2X Operator’s Manual
3
1. GENERAL INFORMATION
1.1. Application
The D2X is adrilling machine with electromagnetic base, designed to drill holes either
with diameters of 12–50 mm (0.47–1.97’’) to a depth of up to 51 mm (2’’) using annular
cutters or with diameters of 3.5–23 mm (0.14–0.91’’) to a depth of up to 51 mm (2’’)
using twist drill bits.
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 chain protects the machine from dropping in case of a power loss.
Accessories allow, for instance, quick changing of tools or drilling in pipes.
1.2. Technical data
Voltage
1~ 110–120 V, 50–60 Hz
1~ 220–240 V, 50–60 Hz
Total power
1300 W
Motor power
1260 W
Spindle shank
MT2
Tool holder
19 mm Weldon (3/4’’)
Drilling diameter with annular cutter
12–50 mm (0.47–1.97’’)
Drilling diameter with twist drill bit
3.5–23 mm (0.14–0.91’’)
Maximum drilling depth
51 mm (2’’)
Electromagnetic base holding force
(surface with the thickness of 22 mm and roughness Ra= 1.25)
12 000 N
Electromagnetic base dimensions
90 mm × 180 mm × 48 mm
3.5’’ × 7.1’’ × 1.9’’
Stroke
153 mm (6’’)
Rotational speed under load
200 rpm (gear I)
400 rpm (gear II)
Minimum workpiece thickness
8 mm (0.31’’)
Protection class
I
Noise level
More than 85 dB
Required ambient temperature
0–40°C (32–104°F)
Weight
16.5 kg (36 lbs)

D2X
D2X Operator’s Manual
4
427 mm (16.8’’)
353 mm (13.9’’)
268 mm (10.6’’)

D2X
D2X Operator’s Manual
5
1.3. Design
Fig. 1.View of the D2X
1.4. Equipment included
The D2X is supplied including the following elements.
Drilling machine
1 unit
Metal box
1 unit
Spoke handle
3 units
MT2 arbor with 19 mm (3/4’’) Weldon tool holder
1 unit
Cooling system
1 unit
Protective spring for cooling hose
1 unit
1.5 m (5 ft) safety chain
1 unit
MT2 drift
1 unit
2.5 mm hex wrench
1 unit
4 mm hex wrench
1 unit
5 mm hex wrench with handle
1 unit
8 mm combination wrench
1 unit
Tool can
1 unit
Operator’s Manual
1 unit
Gear switch (I / II)
Motor START button
Electromagnetic base
ON/OFF switch
Motor STOP
button
Arbor
Spoke handle
Carrying handle
Electromagnetic base
Chip guard
Bottle valve lever
Lug for safety chain
Feed shaft
Cooling system bottle
Control panel
Cooling hose with
a protective spring

D2X
D2X Operator’s Manual
6
2. SAFETY PRECAUTIONS
1. Before beginning, 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 operational.
4. The specifications of the power source must conform to those specified on the
rating plate.
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 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, make sure that the correct is the condition of the machine, power
source, power cord, plug, control panel components, and tools.
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 tools securely. Tighten the annular cutter using set screws. Hammer in
the drill bit into the spindle using a mallet. 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. Do not make holes whose diameter or depth differ from those specified in the
technical data.
16. Install and remove tools using protective gloves and only when the power cord is
unplugged from the power source.
17. Never use annular cutters without a pilot pin except when drilling incomplete
through holes. Never use arbors without a spring.
18. Never use near flammable liquids or gases, or in explosive environments.
19. Using the machine on surfaces that are rusty, covered with a thick paint layer,
uneven, or not rigid is prohibited.

D2X
D2X Operator’s Manual
7
20. Do not start operation if the gib clearance is excessive.
21. Use the safety chain in all operating positions. Attach the machine to a fixed
structure by fastening the chain to the lugs or the carrying handle. The chain
must not be loose. Wrap the chain around the workpiece if possible.
22. 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.
23. Always use eye and hearing protection and protective clothing during operation.
Do not wear loose clothing.
24. Proceed with caution when drilling plates with a thickness less than 10 mm (0.4’’)
because the holding force depends on material thickness and is significantly lower
for thin plates.
25. The entire bottom of the electromagnetic base must be in full contact with the
workpiece. Before every positioning, wipe the workpiece with coarse-grained
sandpaper.
26. Do not touch moving parts or chips formed during milling. Prevent objects from
being caught in moving parts.
27. After every use, remove metal chips and excess coolant from the machine. Do
not remove chips with bare hands.
28. Cover steel parts with a thin anti-corrosion coating to protect the machine from
rust when not in use for any extended period.
29. Maintain the machine and install/remove parts and tools only when the machine
is unplugged from the power source.
30. Repair only in a service center appointed by the seller.
31. 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.
32. Never leave the machine unattended during operation.
33. Remove from the worksite and store in a secure and dry location when not in
use, previously removing the tool from the holder.

D2X
D2X Operator’s Manual
8
3. STARTUP AND OPERATION
3.1. Installing and removing the arbor or MT2 twist drill bit
Unplug the machine from the power source, raise the chip guard as high as possible
(1, Fig. 2), and then rotate the spoke handles to the right (2) to raise the motor. Use a
clean and dry cloth to wipe the spindle and arbor (drill bit). Next, wear protective gloves
and insert the arbor (drill bit) into the spindle (3), and then rotate the arbor (drill bit) to
the right (4)until it slips into place. When installing the arbor, make sure that the vertical
rod is located between the hose fitting and the horizontal rod (5). Finally, firmly tap the
arbor (drill bit) into place using a mallet (6).
Fig. 2.Installing the arbor or drill bit
2
1
3
5
6
4

D2X
D2X Operator’s Manual
9
To remove the arbor (drill bit), raise the motor, and then rotate the spindle (1,
Fig. 3) in such a way to align the openings in the spindle and gearbox (2). Next, insert
the MT2 drift (3) into the opening above the arbor (drill bit), hold the carrying handle
with one hand, and then tap the drift using a mallet (4).
Fig. 3.Removing the arbor (twist drill bit)
1
2
3
4

D2X
D2X Operator’s Manual
10
3.2. Installing, removing, and operating the annular cutter
Install the arbor as described before, wear protective gloves, and then insert the proper
pilot pin into the annular cutter (1, Fig. 4). Use a clean and dry cloth to wipe the cutter.
Next, place the cutter into the arbor (2) in such a way to align the flats 3with the set
screws 4, and then use the 5 mm hex wrench to tighten both set screws.
To remove the cutter, loosen the screws 4using the 5 mm hex wrench.
Fig. 4.Installing the annular cutter
1
2
3
4

D2X
D2X Operator’s Manual
11
Fig. 5shows 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. When
pressed, the pilot pin also allows application of coolant to the inner surface of the
annular cutter.
Fig. 5.Annular cutters operation
Annular cutters are designed to make only through holes shown in Fig. 6. When
drilling incomplete through holes the pilot pin must not be used.
Fig. 6.Types of holes to make with annular cutters
Incomplete through holes
Complete through holes
Slug core
Spring
Pilot pin
Annular cutter
Arbor

D2X
D2X Operator’s Manual
12
3.3. Installing and removing the cooling system
Hang the cooling system bottle on the screws (1,Fig. 7),lower the chip guard (2),
and then insert the hose with the protective spring positioned as in the figure below,
between the vertical rod and the arbor (3). Next, attach the bottle hose to the hose
fitting (4)and slide the spring to the hose end (5) to rest the spring on the arbor (6).
To remove the bottle, proceed in reverse order.
Fig. 7.Installing the cooling system bottle
1
2
3
4
spring
6
5

D2X
D2X Operator’s Manual
13
3.4. Control system of the electromagnetic base holding force
The D2X drilling machine incorporates 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 other contaminants, fluctuations of supply voltage, 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 on asurface thinner than 5mm (0.2’’) because such thickness does not provide
sufficient holding force. In such a case, the holding 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 pressed
and released, it means that the control circuit is operating properly and preventing
further drilling because the holding force is too low.
3.5. Preparing
Before beginning, clean steel parts, especially the MT2 shank, from anti-corrosion
coating used to preserve the machine for storage and transport.
Screw the spoke handles into the feed shaft. The feed shaft can be installed at
the opposite side of the drilling machine to allow working in places hard to reach or
using the machine by a left-handed person.
Select the proper annular cutter or drill bit based on the hole size desired. Next,
use a clean and dry cloth to wipe the spindle, arbor (drill bit), and cutter, and then
install the arbor (and then the cutter) or the drill bit as described before.
Position the machine on a flat ferromagnetic surface (some types of stainless and
acid-proof steel do not conduct magnetic flux) with a thickness of at least 8 mm (0.3’’).
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 set the MAGNET switch to
the position ‘I’ to turn on the clamping of the electromagnetic base.
Use the safety chain to prevent the machine from dropping and avoid possible
injury to the operator if the machine loses magnetic clamping in case of a power loss.
To protect the machine, attach it to a fixed structure by fastening the chain to the lugs

D2X
D2X Operator’s Manual
14
or the carrying handle (Fig. 8). The chain must not be loose. Wrap the chain around
the workpiece if possible.
Fig. 8.Protecting the machine from dropping using the safety chain
Rotate the spoke handles to the left to place the tool above the workpiece.
When using the annular cutter and working in the positon from Fig. 8a, install the
cooling system as described before, and fill it with a cutting 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 valve using the lever, and then rotate the spoke handles to
the left to initially apply pressure on the pilot pin. The fluid should fill the system and
begin flowing from the inside of the cutter.
Because the cooling system works by means of gravitation, use a cooling paste
when working in horizontal or inverted positions.
a)
b)
c)
Vertical drilling
Inverted drilling
Horizontal drilling
Horizontal drilling
(chain fastened to the
carrying handle)
d)

D2X
D2X Operator’s Manual
15
3.6. Drilling
Use the gear switch to set the speed based on the following table.
Tool
Hole diameter
Rotational speed*
[rpm]
[mm]
[in.]
Annular cutter
12–35
0.47–1.38
400 (gear II)
36–50
1.38–1.97
200 (gear I)
Twist drill bit
3.5–13
0.14–0.51
400 (gear II)
14–23
0.55–0.91
200 (gear I)
* for sharp tool and mild steel with a shear strength Rm< 500 N/mm2(70,000 psi),
such as for instance St0 (S185), St3S (S235JR), or St4W (S275JO)
Steel with a shear strength Rm= 500–700 N/mm2(70,000–100,000 psi), such as
for instance St5 (E295), 18G2A (S355N), or 45 (C45), requires lower rotational speed.
If the speed is selected too high or low for the shear strength and the type/diameter of
the tool, the tool will wear faster or be unable to drill the hole.
Start the motor using the green MOTOR button and slowly rotate the spoke
handles to the left to lower the tool to the workpiece, and begin drilling.
When using annular cutters, drill holes in one pass.
When using drill bits, drill holes with diameters of 18–23mm (0.71–0.91’’) in two
passes. Drill a first hole using a drill bit with the 70% diameter of the hole size desired,
and then drill again using the bit with diameter equal to the hole size desired.
After the drilling depth exceeds 40 mm (1.6’’), apply the cutting fluid manually into
the drilling area.
After the hole is made, retract the tool 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 the position ‘O’ to turn off the electromagnetic base.
After the work is finished and the motor is stopped, switch to the opposite gear
(for instance from gear I to II), and then run the machine for awhile without load,
which will improve lubricity. Next, turn off the motor and the electromagnetic base,
unplug the machine from the power source, clean chips and excess coolant from the
machine and tool, 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 tool
box, remove the bottle, and then wear gloves to remove the tool from the holder.
When the annular cutter goes through the workpiece, the slug
core is expelled from the cutter with a significant force.

D2X
D2X Operator’s Manual
16
3.7. Adjusting the gib clearance
Every 50 operation hours, or more often, check the gib clearance because it greatly
influences the quality of drilled holes. The clearance is appropriate if the motor slides
smoothly and not drops under its own weight.
To remove the excessive clearance, use the 8 mm combination wrench to loosen
the nuts (1, Fig. 9), and then use the 2.5 mm hex wrench to loosen the set screws (2).
Next, rotate the spoke handles to set the motor on such a level to access the gib
screws through the holes, use the 4 mm hex wrench to loosen these screws (3), and
then tighten (4) with a force enough to prevent the gib from being pushed out by the
springs located inside.
Use the 2.5 hex wrench to tighten the set screws (5) to such an extent that the
motor moves smoothly through the entire stroke and not drops under its own weight.
Next, use the 4 mm hex wrench to tighten the gib screws: central screw (6), adjacent
screws, and then top and bottom screws. Finally, use the 8 mm combination wrench to
tighten the nuts (7), while countering the set screws using the 2.5 mm hex wrench (8).

D2X
D2X Operator’s Manual
17
Fig. 9.Adjusting the gib clearance
1
2
3
4
5
6
7
8

D2X
D2X Operator’s Manual
18
3.8. Replacing the motor brushes
Check the condition of the carbon brushes every 100 operation hours. To do this, unplug
the machine from the power source, use the 4mm hex wrench to unscrew four screws
(1,Fig. 10), and then remove the motor cover (2), paying attention to the ground wire 3
attached. Next, pry off the spring that holds the brush and rest the spring on the top
of the brush holder (4). Unlock the connector by pressing it in the center (5), and then
remove the connector (6) and the brush (7). If the length of the brush is less than
5 mm (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. 10.Replacing the brushes
2
1
3
5
6
7
4

D2X
D2X Operator’s Manual
19
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’’).
Part number:
UKL-0440-16-00-00-0
Part number:
PDS-0110-03-00-01-0

D2X
D2X Operator’s Manual
20
4.3. Pipe attachment DMP 501
Designed for pipes with diameters of 150–500 mm (6–20’’).
4.4. Cooling attachment for twist drilling
Part number:
PDS-0111-03-00-01-0
Part number:
KNC-0399-09-00-00-0