SteelMax D4X User manual

D4X
Steelmax Tools LLC
112 Inverness Circle East, Englewood, CO. 80112
1-87STEELMAX Fax [phone]
www.steelmax.com e-mail: [email protected]
SAFETY INSTRUCTIONS
AND OPERATOR’S MANUAL
FOR
DRILLING MACHINE
D
D4 4X X

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TABLE OF CONTENTS
I. SAFETY INSTRUCTION ................................................................................................................ 3
1. General information ........................................................................................................................ 3
2. Important safety instruction.............................................................................................................3
II. OPERATING INSTRUCTIONS.......................................................................................................6
1. Cutters and optional equipment features........................................................................................6
2. Magnetic drilling machine start up ..................................................................................................9
III. MAINTENANCE AND SERVICE...................................................................................................17
IV. TECHNICAL DATA ....................................................................................................................... 19
V. PARTS LIST/EXPLODED VIEW...................................................................................................22
VI. ELECTRICAL DIAGRAM..............................................................................................................35
VII. EC DECLARATION OF CONFORMITY....................................................................................... 37
VII. MACHINE TEST CERTIFICATE...................................................................................................38
VIII. WARRANTY CARD ...................................................................................................................... 39
IX. ANNULAR CUTTERS...................................................................................................................40

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BEFORE YOU START WORK WITH THE MACHINE,
PLEASE READ THESE INSTRUCTIONS CAREFULLY
AND USE ALL RECOMMENDATIONS.
I. SAFETY INSTRUCTION
Drilling machine on electromagnetic base should be used only for the purpose
described in this manual. Using the machine incorrectly or not for its intended use may result
in serious injury and/or death.
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 in one pass and with precision not
otherwise attainable without heavy stationary equipment. The drill is equipped with a
powerful motor and automatically adjustable slides.
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 the recommendations in this Manual.
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 the condition of the drilling machine, condition of
power cable, control panel or cutter.
6. Power supply connection is not equipped with a protection circuit (fuse or circuit breaker).
7. Machine is not secured with safety chain as a protection from dropping especially when
used at heights or in vertical or upside-down positions.
8. Bystanders are present in the immediate vicinity of machine.
Important rules of safe use of drilling machine
1) Before attempting to work with the machine check condition of 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

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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 with thick covering of 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 should
not be loose! To avoid this situation the safety chain should be wrapped around the
element it is drilling. Loss of electric power will cause a loss of electromagnetic
adherence to the metal and will cause the drill to fall which could cause serious injury or
death.
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.
Safety chain can also secure the drill through
the handle.
10) Do not touch the spindle and cutter during work.
11) Tools must be fastened firmly. When a milling cutter is used, check before the start of
work to assure that tool retaining screws are screwed tight.
Drawing 1.
Examples how safety chain should be fastened.
.

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12) The use of blunt of damaged tools can be hazardous.
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 (with gloves or tool) and coolant from the drilling
machine.
16) Always unplug the machine from the power supply during any work on the machine.
17) In the case that the machine falls on a hard surface, from a height, is wet or is
subjected to other unfortunate events that could affect its operation, work should be
terminated immediately and the machine should be sent to service for inspection as
soon as possible.
It is not advised to use drill 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 the machines failure to adhere to the
metal and individuals injury. The machine should be located on the work piece
with the entire surface of the electromagnetic base contacting the metal! It is
recommended that each time, before positioning the machine the metal surface
under the electromagnetic base should be sanded down with abrasive paper!
Please follow all recommendations.

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II. START UP AND OPERATION
1. Cutters and optional equipment features
This drilling machine’s spindle has a socket with a Morse taper which makes it
possible to use twists drills or milling cutters by using an AMT Arbor for fixing them in the
socket spindle taper [Drawing 2].
Milling cutter (2) is located inside the 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 could 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 opposite to the fixing screws (3).
Both fastening screws(3) must be used to fasten the cutter. Pilot (5) is located inside the
cutter. It makes it easier to position milling cutter over center of a planned hole. During drilling
as the cutter goes deep into steel, the pilot moves back into the arbor body and tightens the
discharge spring (4). That spring ejects the slug which is a by-product of milling a hole with a
center free cutter.
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 3]
Drawing 3. A few types of holes that can be done with a milling cutter.
Drawing 2. Principle of milling cutter’s work

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1.1 Installing and uninstalling the arbor
The arbor installation and uninstallation should be carried out when the machine
is turned off and disconnected from the power grid!
Installing the arbor:
a) Raise the guard (2) to the maximum,
b) Clean the inside of the spindle using a cotton cloth,
c) Before mounting, clean off the lubricant from the new arbor (3),
d) Place the arbor with the fin on top, and place it in the spindle,
e) By turning the arbor, align the fin to the appropriate slot in the spindle,
f) Using a light impact from the bottom side, drive the arbor into the spindle.
Uninstalling the arbor:
a) Raise the guard, turn the spindle so that the wedge MT opening in the spindle (1) is lined
up with the wedge MT opening in the reducer body,
b) Place the wedge MT (included as standard equipment) into the uncovered spindle
opening (1),
c) Hold down the arbor (3) with one hand,
d) Strike the wedge MT lightly with a hammer, taking care to not to damage the arbor,
e) Carefully remove the arbor from the socket in the spindle,
f) Remove the wedge MT.

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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 (2) up using the lever (3);
2. Raise the guard (1) to the maximum in order to attain access to the arbor (4) screws (5);
3. Insert the appropriate type of pilot (6) into the milling cutter (7);
4. Position the milling cutter (7) with the Weldon shank facing up, so that the flat sides of the
milling cutter are aligned with the screws (5)
5. Put the milling cutter (7) into the arbor socket (4);
6. Tighten the screws securely (5).
Uninstalling the milling cutter:
1. Raise the drive and the slide (2) up using the lever (3);
2. Raise the guard (1) to the maximum in order to attain access to the arbor (4) screws (5).
3. Loosen the screws (5);
4. Remove the milling cutter (7) and the pilot (6) from the arbor socket (4).

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2. Magnetic drilling machine start up
The machine is supplied in a metal box with complete standard equipment.
D4X comes in a standard equipment set which consists of:
metal box
1pc
drilling machine
1pc
arbor SM-AMT4-U-19 4-3
1pc
cooling system
1pc
chip guard
1pc
spoke handles
3pcs
Hex. Wrench s=2,5
1pc
Hex. Wrench s=4
1pc
Hex. Wrench s=5
1pc
Hex. Wrench s=6
1pc
8 mm flat wrench
1pc
wedge, MT4
1pc
safety chain with snap hook
1pc
operator’s manual
1pc
2.1 Before first drill:
The 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 handles should be screwed into pinion.
2.2 Before you cut
Before positioning the machine on work piece always make sure that:
-Work piece is made of ferromagnetic steel (some grades of stainless or acid
resistant steel do not readily conduct magnetic flux)
-thickness of work piece is at least 3/8” (10 mm)
-surface of steel under the magnet is flat
-wipe, brush or sand down to clean the surface where you intend 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 electric power. Then plug it in (see paragraph 2) 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 drill
and turn the magnetic base ON.

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Prior to use always make sure that the machine is secured from dropping
with original chain (as described in paragraph I no. 5 “Important rules of safe
use of drilling machine”).
2.3 Cutting
- Select the right speed for the tool you intend to use (see the speeds chart in this
manual –paragraph IV no.1).
Cooling and lubricant fluid commercially available in concentrated form are recommended for
cooling twist drills and annular cutters.
The use of emulsions formed from a mixture of water and drilling oil are acceptable.
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
2.7)
Warning: The cooling system can only be used when drilling machine is in
vertical position. In other positions an additional external source of cooling should be
used, for example: a coolant bottle with a long nozzle or a pressurized system.
-Check the operation of the 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.
Making a hole with a milling cutter should ideally be done in one pass. The proper
method is to put the motor under load in which it experiences about a 10% reduction in
speed by listening to the sound it emits. It makes the cutter work better and more easily
ejects the slug after the hole is completed. If you experience slugs getting stuck inside a
cutter after the hole is complete try to reduce pressure on the cutter or use a 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.
When drilling holes deeper than 50 mm (2’’), retract the tool above the workpiece as
often as possible to allow the chips to be expelled from the hole. Additionally, once the tool is
retracted, clean the grooves of the tool using a small brush if they are clogged. After
exceeding 40 mm of the drilling depth, introduce the cutting fluid into the milling area
manually (from the bottle).

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-After a hole is made the cutter should be withdrawn back and both the motor and the
electromagnet should be switched OFF in that order.
-When work with the machine is finished the power cord should be disconnected from
the power source, the swarf and coolant should be cleaned from the machine and the cutter
should be removed and cleaned.
Please follow all recommendations.
2.4Cutting
1. 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. (see point 2.8)
2. Turn the motor on.
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
pressurized system.
3. Start the engine by button ”on the control panel (see II point 3). Drilling in the material
must be conducted with sensitivity.
4. Some of magnetic drilling machines have a built-in overload system. Overload is
indicated by red LED diode on the control panel. Further increasing the engine load
causes the activation of the overload system and power source loss. It’s possible to
continue the drilling operation by pressing the “O” MOTOR switch to reset the system and
restart the engine. Periodic, uncommon illumination of LED’s diode during the drilling
process is normal. This means that the drilling process is used to the maximum extent of
the permissible engine capacity.
5. Making a hole with a milling cutter should ideally be done in one pass. It makes the cutter
work better and easier to eject the slug after the hole is completed.
WARNING: when the milling cutter goes through the material the slug can be
pushed out often with considerable strength. Pay attention to avoid injury.
6. Do not allow excessively long chips (swarf) to accumulate that could interfere with the
handles as this could be a safety hazard.
7. After a hole is made the cutter should be withdrawn back and both the motor and the
electromagnet should be switched OFF in that order.

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8. When work with the machine is finished the power cord should be disconnected from the
power source, the machine should be cleaned of swarf and coolant etc. The cutter should
be removed and cleaned.
9. The tool should be removed from drill chuck before returning to the toolbox.
2.5 Types of a ground material
As shown on the graphs [Drawing 4] 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 have lower magnetic permeability, which
causes a decrease in the clamping force. Also the thickness of the 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 22 (0.87”)
mm thick standard plate.
If such thin ground material does not exist, one can try to carry out drilling of a
hole, although with keeping the strictest precautions. The magnitude of force on the
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 annular type metal cutter. The drill is equipped with a mechanical 2-step
reducing gearbox. The general relationship between drilling diameter and drilling speed is
shown in graphs [Drawing 5], and a detailed guide is supplied by the manufacturer of drilling
tools. The graph is just a general guide and the shown relationship applies to average
structural steel.
Cooling agent is fed gravitationally from a coolant bottle through an arbor to the inside of
the metal cutter. For on-a-wall and on-a-ceiling positions special cooling pastes or aerosol
sprays or pressurized coolant dispersal agents should be used.
2.6Electromagnetic 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. In the
case of a reduction in the force value below safety limits to guarantee safe operation of the
machine, the system automatically switches off the drive drill. It also does not allow the drive
to be started when there is no guarantee of the proper clamping 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 and excessive wear of the lower part of the electromagnetic base.
If the moto will not start after the magnetic base is clamped it means that the safety
system is working properly. The system will not allow drilling without sufficient clamping force
for personnel safety reasons.
2.7 Working in difficult areas

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While working in difficult access areas as well as left-handed operator the pinions can be
moved to the opposite side.
Drawing 4. Clamping force depending on the thickness of the substrate and the value gap.

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2.8 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) 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 (2) is placed correctly on the coolant coupling (4), the bottle
cap should be loosened by 1/3 of a turn in order to depressurize it, turn on the valve (3), so
that liquid travels to the hose, after which the machine can be started (see II pt. 3)
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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2.9 Semiautomatic gib adjustment
Turn the spoke handles (1), so the screws (2) in the face plate are visible through
the openings in the slider (5).. After loosening all the screws, slide the slider up and
down several times so that the pressure strip aligns itself and automatically adjusts
the gib to the proper clearance. This is only necessary in case the drill drops to the
bottom by itself (too loose) or binds during operation (too tight or out of straight
alignment).
After resetting the gib clearance, tighten screws (2) starting from the middle screw. The
slider should be located symmetrically relative to the middle screw. Next, tighten the
neighboring screws (2) moving the slider, as necessary, to make the screws accessible.
Then, tighten screws (3) until any noticeable resistance is felt. When the screw is in this
position and held with an allen key, tighten counter nut (4). The screws (3) counteract the
machining force and protect the pressure strip from shifting during operation.
Canceling clearance

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3. Machine start-up
In order to start the machine press the main switch MAGNET (01) on “I” button. By
pressing green button (02) MOTOR on “I” start the motor.
a) Stopping the motor is executed with red button „O” (02) (the motor is switched OFF but
the electromagnetic base is still ON) (02).
b) Blinking of the red LED overload indicator (03) means that the machine is working at the
limit of the overload. The machine can be automatically turned off at any time.
c) To change the rpm speeds machine use the shift lever (04)
To move machine into next drilling spot, stop the motor as described above then
push switch MAGNET into the position “O”.
III. MAINTENANCE AND SERVICE
To avoid accidents the drill stand, power cable, wiring, plug connectors, switches
must be regularly inspected for damage.
Perform adjustment of the machine play guides every 50 hours or as necessary
performed by the regulation screws. Slide guide tension is correct if the drive can be
moved smoothly by using the lever. The slide should not slide down under it’s own
weight. (see II point 2.9)
T facilitate the proper distribution of lubricant after every days work the position of the
gear lever (used for selection of gearbox speed) should be changed. For example if
the machine worked with 150 rpm speed, it should be switched to 300rpm. (see IV
point.1).
Drawing No.6 Control Panel
Drawing No.7 View of the machine D4X

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After every 250 hours of work check the condition of carbon brushes. If their length is
less than 5 mm they should be replaced with original new ones. After replacement
new brushes should be run-in without load for about 20 min. Other repair work should
be done only by authorized service points, appointed by distributor. Replacement of
brushes is possible without removal the of the motor unit from the unit. (see IV)
Regularly lubricate brass slide guide inserts with grease as well as the rack and
pinion.
To prevent the machine from rusting (especially when used outdoors) all steel parts
should be covered with thin layer of grease film
Damaged machine parts will be exchanged only with original parts.
Caution:
In the case that the machine falls on a hard surface,
from a height, is wet or is subjected to other adverse 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.

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IV. TECHNICAL DATA
Power supply
□ 110-120V AC / 50-60 Hz
□220-240V AC / 50-60 Hz
Power required
□ 110-120V - 1700 W
□220-240V - 1800 W
Motor power
□ 110-120V - 1550 W
□220-240V - 1650 W
Tool holder
Morse Taper No 4
Max. twist drill diameter
16-47 mm (5/8” - 1 7/8”)
Max. annular drill diameter
12-110 mm (1/2” - 4 5/16”)*
Max. milling depth
76 mm (3”)
Insulation Class
I
Standard adhesive force of electromagnet
(for steel 7/8” (22 mm) thick and Ra < 1,25)
22 000 N
Slide stroke
230 mm (9”)
Machine speeds /under load/
I –85 rpm , II –135 rpm
III –160 rpm , IV –250 rpm
Minimum workpiece thickness
10 mm (0.4’’)
Electromagnetic base
120x240x63 mm (4.7x9.4x2.5”)
Length of the power cord
3 m (10 ft)
Total weight
31 kg (68 lbs)
Noise level
85 dB
Surrounding temperature
0 –40 °C (32-104 ° F)
* above 60 mm (2-3/8’’) the UCW-0191-02-00-00-0 arbor is required

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Using the drill on the electromagnetic base D4X with special annular cutters we are
capable of drilling and reaming holes up to 110mm (4-5/16”) diameter and 76mm (3”) depth
with a precision achievable previously only in a workshop.
Replacement of motor brushes:
For the D4X drill, the state of the carbon brushes should be monitored every 100 working
hours.
Replacement of motor brushes should take place when the machine is turned off and
the power cable is disconnected from the power grid!
1. Unscrew 4 M5x40 engine cover screws (1), using a 6-kt s=4 wrench.
2. Carefully take off the engine cover (3). Remember that it is connected with the motor by a
grounding lead (4).
3. Unplug the connector (6) from the motor brushes using the flat ending (5) of the lead. The
ending has a safeguard against its sliding down –first, press the protruding element at
the middle of the ending, then carefully slide off the ending from the connector.
4. Push aside the spring arm (7) pressing down the brush and rest it on the surface of the
brush holder (8) and remove the brush (9).
5. Inspect brush length - if the length is less than 5mm, the brush should be replaced with
an original brush.
6. Carry out all actions in reverse, in order to install the engine.
After replacement, new brushes should be run without load for about 20 minutes on idle
gear in order to seat properly. Replacement of engine brushes is possible without removing
the drive from the drill.