SteelMax D4X User manual

The tools of innovation.
15335 E. Fremont, Centennial, CO 80112
1–87STEELMAX, FAX 303–690–9172
www.steelmax.com [email protected]
OPERATOR’S MANUAL
D
D4
4X
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 MT4 twist drill bit................................................ 8
3.2. Installing, removing, and operating the annular cutter...............................................10
3.3. Installing and removing the cooling system bottle .....................................................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.......................................................................................17
3.8. Replacing the motor brushes ....................................................................................19
4. ACCESSORIES...............................................................................................................20
4.1. Pressure cooling system...........................................................................................20
4.2. Arbor MT4 x 32 mm Weldon .....................................................................................20
4.3. Pipe attachment DMP 501 ........................................................................................21
5. WIRING DIAGRAM..........................................................................................................22
6. EXPLODED DRAWINGS AND PARTS LIST....................................................................23
7. DECLARATION OF CONFORMITY.................................................................................29
8. QUALITY CERTIFICATE..................................................................................................30
9. WARRANTY CARD..........................................................................................................31

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1. GENERAL INFORMATION
1.1. Application
The D4X is a drilling machine with electromagnetic base, designed to drill holes either
with diameters of 12–111 mm (1/2 –4-3/8’’) to a depth of up to 76 mm (3’’) by using
HSS and TCT annular cutters or with diameters of 16–47 mm (5/8 –1-7/8’’) to a depth
up to 76 mm (3’’) by 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 falling in case of a power loss.
An optional attachment allows you to drill in pipes.
1.2. Technical data
Voltage
1~ 110–120 V, 50–60 Hz
1~ 220–240 V, 50–60 Hz
Total power
1800 W
Motor power
1650 W
Spindle shank
MT4
Tool holder
19 mm Weldon (3/4’’)
Drilling diameter with annular cutter
12–111 mm (1/2 –4-3/8’’)*
Drilling diameter with twist drill bit
16–47 mm (5/8 –1-7/8’’)
Maximum drilling depth
76 mm (3’’)
Electromagnetic base holding force
(surface with the thickness of 22 mm and roughness Ra= 1.25)
22 000 N (4800 lbs)
Electromagnetic base dimensions
120 mm × 240 mm × 63 mm
4-3/4’’ × 9-7/16’’ × 2-1/2’’
Stroke
230 mm (9’’)
Rotational speed under load
85 rpm (gear I)
135 rpm (gear II)
160 rpm (gear III)
250 rpm (gear IV)
Minimum workpiece thickness
10 mm (3/8’’)
Protection class
I
Noise level
More than 85 dB
Required ambient temperature
0–40°C (32–104°F)
Weight
31 kg (68 lbs)
* If more than 60 mm (2-3/8’’), MT4 arbor with 32 mm Weldon tool holder (UCW-0191-02-00-00-0) is required

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566 mm (22-5/16’’)
440 mm (17-5/16’’)
312 mm (12-5/16’’)

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1.3. Design
1.4. Equipment included
The drilling machine is supplied including the following elements.
Drilling machine
1 unit
Metal box
1 unit
Spoke handle
3 units
MT4 arbor with 19 mm (3/4’’) Weldon tool holder
1 unit
Cooling system bottle
1 unit
1.5 m (5 ft) safety chain
1 unit
MT3 drift
1 unit
2.5 mm hex wrench
1 unit
4 mm hex wrench
1 unit
5 mm hex wrench with handle
1 unit
6 mm hex wrench
1 unit
8 mm combination wrench
1 unit
Tool can
1 unit
Operator’s Manual
1 unit
Chip guard
Cooling system bottle
Lug for safety chain
Electromagnetic base
Spoke handle
Carrying handle
Gear switch
(I / II / III / IV)
Arbor
MOTOR
start
button
MOTOR
stop
button
Electromagnetic base
(MAGNET) switch
Feed shaft
Bottle valve
lever
Overload lamp

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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 by 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, and do not 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 tools securely. Tighten the annular cutter by using the set screws, and
hammer in the drill bit into the spindle. 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 by 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. Never use the machine on surfaces that are rusty, covered with a thick paint layer,
uneven, or not rigid.

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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. Drilling in plates with a thickness less than 10 mm (3/8’’) is not recommended
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 and
tool. 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.

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3. STARTUP AND OPERATION
3.1. Installing and removing the arbor or MT4 twist drill bit
Unplug the machine from the power source, raise the chip guard as high as possible
(1, Fig. 1), and then rotate the spoke handles to the right (2) to raise the motor. Wear
protective gloves and use a clean and dry cloth to wipe the spindle and arbor (drill bit).
Next, 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, and hammer it in (5).
Fig. 1. Installing the arbor or the drill bit
2
1
3
5
4

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To remove the arbor (drill bit), raise the motor, and then rotate the spindle (1, Fig. 2) in
such a way to align the openings in the spindle and gearbox (2). Next, insert the MT3
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. 2. Removing the arbor or the drill bit
1
2
3
4

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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. 3). Use a clean and dry cloth to wipe
the arbor and 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 4with the 5 mm hex wrench.
Fig. 3. Installing the annular cutter
1
2
4
3

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Fig. 4shows 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. 4. Annular cutters operation
Annular cutters are designed to make only through holes shown in Fig. 5. When
drilling incomplete through holes the pilot pin must not be used.
Fig. 5. Types of holes to make with annular cutters
Slug core
Spring
Pilot pin
Annular cutter
Arbor
Incomplete through holes
Complete through holes

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3.3. Installing and removing the cooling system bottle
Hang the cooling system bottle on the screws (1, Fig. 6), and then attach the bottle
hose to the hose fitting (2).
To remove the bottle, first detach the bottle hose from the fitting.
Fig. 6. Installing the cooling system bottle
1
2

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3.4. Control system of the electromagnetic base holding force
The 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 (3/16’’) 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 (7/8’’) 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, including the spindle, 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 from
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 with a thickness of at least
10 mm (3/8’’). The workpiece must be clean, without rust or paint that decrease the
holding force. Some types of steel are non-ferromagnetic (do not conduct magnetic
flux) and the machine is not capable to clamp onto them.
Connect the 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 falling 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

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(Fig. 7a, 7b, 7c) or to the carrying handle (Fig. 7d). The chain must not be loose.
Wrap the chain around the workpiece if possible.
Fig. 7. Protecting the machine from falling by using the safety chain
Rotate the spoke handles to the left to place the tool above the workpiece.
When working with an annular cutter in the position from Fig. 7a, install the cooling
system bottle 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 by using the lever, and then rotate the spoke handles to the left
to initially apply pressure on the pilot pin. The coolant should fill the system and begin
flowing from the inside of the cutter.
Because the cooling system works by gravity, when working in inverted or
horizontal positions (Fig. 7b, 7c, 7d) use coolants under pressure or in the form of
spray or paste.
a)
b)
c)
Vertical drilling
Horizontal drilling
Horizontal drilling
(chain fastened to the
carrying handle)
d)
Inverted drilling

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3.6. Drilling
Use the gear switches to set the speed based on the following table.
Tool
Hole diameter
Rotational speed*
[rpm]
[mm]
[in]
HSS annular cutter
12–25
1/2 –1
250
25–44
1 –1-3/4
160
44–64
1-3/4 –2-1/2
135
64–111
2-1/2 –4-3/8
85
TCT annular cutter
12–30
1/2 –1-3/16
250
30–50
1-3/16 –2
160
50–76
2 –3
135
76–111
3 –4-3/8
85
Twist drill bit
16–22
5/8 –7/8
250
19–25
3/4 –1
160
22–30
7/8 –1-3/16
135
30–47
1-3/16 –1-7/8
85
* for sharp tool and mild steel with a shear strength Rm< 500 N/mm2(70,000 psi), such as for
example 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
example St5 (E295), 18G2A (S355N), or 45 (C45), requires lower rotational speed.
If the speed is selected too high or too 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 with the green MOTOR button, and slowly rotate the spoke
handles to the left to lower the tool to the workpiece, and begin drilling. Next, use the
speed adjustment knob to set a speed suitable for given process conditions.
When using annular cutters, drill holes in one pass.
When using drill bits, drill holes with diameters of 18–32 mm (11/16 –1-1/4’’) in two
passes. Drill afirst hole by using adrill bit with the 70% diameter of the hole size desired,
and then drill again by using a bit with diameter equal to the hole size desired. Drill
holes with diameters of 21–47 mm (13/16 –1-7/8’’) in three passes. Drill a first hole by
using adrill bit with diameter of 18 mm (11/16’’), drill again by using a bit with the 80%
diameter of the hole size desired, and then drill again by using a bit with diameter
equal to the hole size desired.
When the annular cutter goes through the workpiece, the slug
core is expelled from the cutter with a significant force.

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When drilling holes deeper than 50 mm (2’’), retract the tool above the workpiece
as often as possible to allow chips to be removed from the hole. If the grooves of the
tool are clogged, stop the motor and use a brush to clean them. After the drilling depth
exceeds 40 mm (1-9/16’’), apply the cutting fluid manually into the drilling area.
If the operation results in an overload, caused by insufficient cooling, dull tool, or
too fast feed in relation to the tool diameter, the machine will automatically stop.
In such a case, to restart the machine, press the red MOTOR button, retract the tool
from the workpiece, and then press the green MOTOR button (the electromagnetic
base must remain powered).
Operating near the overload (with the lamp flashing) is allowed; however, if the
lamp is lit continually and you increase the load, the motor will be shut off.
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 the gear switches to
the opposite position (for example from 250 rpm to 85 rpm or from 160 to 135), 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 box,
remove the bottle, and then wear gloves to remove the tool from the holder.

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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 falls under its own weight.
To remove the excessive clearance, use the 8 mm combination wrench to loosen
the nuts (1, Fig. 8), 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 falls 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 with the 2.5 mm hex wrench (8).

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Fig. 8. Adjusting the gib clearance
1
2
3
4
5
6
7
8

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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 4 mm hex wrench to unscrew four screws
(1,Fig. 9), 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 (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. 9. Replacing the brushes
2
1
3
5
6
7
4

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4. ACCESSORIES
4.1. Pressure cooling system
Capacity of 2 liters.
4.2. Arbor MT4 x 32 mm Weldon
Required when drilling diameter is more than 60 mm (2-3/8’’).
Part number:
UKL-0440-16-00-00-0
Part number:
UCW-0191-02-00-00-0
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