SteelMax D1 Operation Manual
Contents
1. The didrill must be plugged into a three prong outlet properly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in diagram If in doubt of proper grounding contact a qualified electrician WARNING A shock hazard can result from improperly connecting the grounding wire Do not modify the electrical plug provided with tool Never remove the grounding prong from the plug If the cord or plug is damaged have it Outlet repaired before using If the plug will not fit the outlet have a proper outlet installed by a qualified electrician 1 4 yaq j Socket Z WARNING ko ANA DO NOT USE STEELMAX DRILLING MACHINES ON SURFACES OR MATERIALS BEING WELDED DOING SO CAN RESULT IN PERSONAL INJURY AND OR DAMAGE TO THE DRILLING Plug Ground MACHINE Prong EE COD S Use only 3 wire extension cords that have 3 prong grounding type plugs and 3 pole receptacles Make sure extension cord is in good condition Replace or repair damaged cords When using an extension cord limit length to 50ft or less Only use a cord of 12 gage or larger diameter An undersized cord will cause a drop in line voltage resulting in loss of power and overheating If in doubt use the next heavier gauge The smaller the gauge number the heavier the cord Srl 1 Read and follow operator s manual thoroughly Instructions are intended as guide in safe operating proced2. 03 00 MOTOR ASSY 115V W ARMATURE C31272 030 00 03 1 03 02 03 ARMATURE 115V ASSY W BEARINGS HO1 11 1 200 01 02 1 03 04 SELF TAPPING SCREW 3 9X19 N18310 630 9 1 91 6 03 08 PROTECTIVE SPRING C32257 020 30 00 1 03 09 FIELD FRAME COVER C31272 030 10 30 1 03 10 BRUSH HOLDER C3 127 1 030 60 00 2 03 11 MOTOR BRUSH HO 1 1 11 200 01 08 2 03 12 MOTOR BRUSH PLATE 31271 030 7000 2 03 13 SELF TAPPING SCREW 2 9X5 N18310 620 90 90 2 04 00 CONTROL PANEL ASSY 115V C31272 040 00 04 04 01 PANEL PLATE C32257 040 10 00 04 03 ELECTRONIC CONTROLLER SW 31 115V 31257 041 0000 1 04 04 MOTOR ON OFF SWITCH 115 WLC 000005 04 05 MAGNET SWITCH 01115 168 01 01 04 06 LOCKING PILLAR 01262 00301 01 3 O5 SPOKE HANDLE INCL KNOB ASSY C3 1249 0 10 50 00 3 07 PLUG C31271 070 00 00 2 08 PLUG WITH THREAD C3127 1 080 00 00 2 BOTTLE ASSY C31272 100 00 00 CROSS RECESSED SCREW MAX16 N18221 204 16 00 2 CHIP GUARD C31272 120 00 00 3 POWER CORD 115V CO2180 750 05 10 4 STRAIN RELIEF PG1 1 HO1131 133 02 02 5 CROSS RECESSED SCREW M4X10 N18220 204 10 01 4 6 WASHER EXT METRIC 4 3DIN 6798 N18202 404 03 00 1 7 EX NUT M4 N18214 404 00 0 1 2 8 SPRING WASHER 4 1 N18200 804 0 1 01 9 EX SOCKET BOLT M6X35 N18230 206 35 0 4 20 SELF TAPPING SCREW 4 8X32 N18310 640 83 2 1 3 21 SELF TAPPING SCREW 4 8X50 N18310 640 85 01 22 METAL BOX C31272 220 00 00 24 HEX WRENCH 4 HO0643 504 0 1 00 13 SteelMax d Wiring Diagram SteelMax d1 Drilling
3. Machine wiring diagram YO LOW OV OLLAND VIA OLIO T TA LATOIA MOVITA MOVTE ania NAO SH ania dOLS LHVLS CMS Gade L AS 331 I LINOVN CIHNDVW LHNDVIN T LHNDVIN TS IS 101999 01g p o I2A Q HUOPAA YIM 9 NPOIN 101002 SOIId I AS L n HOLIMS NAJAD 14 BASIC TROUBLESAHOOTING Motor will not stay running Magnet circuitry is designed to prevent run cycle in the event material Hold by magnet is insufficient Clamp additional material beneath magnet to increase hold Run switch may be manually held in to bypass this safety circuit If operator chooses to use this bypass circuit extreme caution must be used Models manufactured after 11 2006 have an electronic overload feature If the drill experiences over current due to excessive cutter penetration speeds the circuit will stop the drill motor If this should occur simply reset the motor switch to the off position and then turn back on Proceed with a slower feed rate without forcing the cutter Magnetic base not holding securely Material is too thin to engage magnet The minimum necessary thickness is 3 16 5 mm Surface of material being drilled must be free of chips debris rust and mill scale Cutter exceeds machine s rated capacity Check magnet face for unevenness nicks and burrs Welding equipment connected to material being dril
4. Troy Circle Suite 110 Centennial CO 80111 email gt sales steelmax com web gt steelmax com 2 SteelMax 91 Portable Magnetic Drilling Machine Congratulations on your purchase of a SteelMax portable magnetic drilling machine SteelMax drilling machines are designed to deliver fast efficient hole drilling performance in portable applications SteelMax drills are fast becoming the most cost effective and efficient way to drill holes not only at steel fabricating work shops or steel building sites but also at virtually every factory maintenance workshop truck manufacturer amp repair company military equipment service onboard ship maintenance shop etc The full advantages of your SteelMax electromagnetic drilling machine can only be achieved with opti mal tooling Milling cutters are designed and manufactured specifically for use with these machines and offer a wide range of advantages such as 1 5 inch diameter holes through 2 inch steel in one pass and with precision not otherwise attainable without heavy stationary equipment This performance advantage has been virtually impossible in a drill with the size and weight of the SteelMax d1 until now The SteelMax d1 provides the latest state of the art features in portable drilling equipment Among the features are a no maintenance rail system that eliminates older gib type systems which lowers maintenance and maximizes the life of your SteelMax annular cutters Energy saving and s
5. eject with significant force due to the pilot pin spring pressure Always be prepared for the ejected slug 2 Return motor to the full upright position depress motor OFF button and wait until motor fully stops Move 1 E magnet switch to the OFF position to release the magnetic base from the material Note If the slug does not eject after the cut disconnect the machine from the power source and remove the cutter from the arbor body then expel the slug Caution Do not use the pilot pin as damage can result NORMAL MAINTENANCE The SteelMax d1 drilling machine is equipped with new unique system for elimination of excess play in slide guides This rail guide system completely eliminates maintenance or adjustment After every 250 hours of operation check the condition of the carbon brushes 03 01 07 If their length is less than 5 mm they should be replaced with new ones Replacement of brushes is possible without removal of motor from the drill To replace the brushes remove the 4 screws 03 01 09 securing the motor field frame cover 03 01 03 Remove the 2 brush holder screws 03 01 10 and carefully remove the brushes Reverse the procedure to re install After replacement new brushes should be run in without load for about 20 min Other repair work should only be performed by authorized service centers Replacement of brushes is possible without removal of motor from the drill To prevent the machine from rusting especiall
6. for any costs incurred on such goods or consequential damages No officer employee or agent of SteelMax is authorized to make oral representations of fitness for any particular purpose or to waive any of the foregoing terms of sale and none shall be binding on SteelMax STEELMAX DRILLS AND CUTTERS LLC RESERVES THE RIGHT TO MAKE IMPROVEMENTS AND MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE 10 11 12 NWARNING WHEN USING ELECTRIC TOOLS BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE RISK OF FIRE ELECTRIC SHOCK AND PERSONAL INJURY READ AND SAVE ALL INSTRUCTIONS FOR FUTURE REFERENCE Never Remove Swarf With Bare Hands Use a tool designed for the job to avoid injuries Never Touch Spindle During Operation Cutters are extremely sharp and cause serious injuries Keep Work Area Clean Cluttered areas and benches invite injuries Consider Work Area Environment Do not expose power tools to rain Do not use power tools in damp or wet locations Keep work area well lit Do not use tool in presence of flammable liquids or gases Guard Against Electric Shock Prevent body contact with grounded surfaces For example pipes radiators ranges and refrigerator enclosures Keep Children Away Do not let visitors contact tool or extension cord All visitors should be kept away from work area Store Idle Tools When not in use tools should be stored in a dry
7. high and locked up place out of reach of children Do Not Force Tool It will do the job better and safer at the rate for which it was intended Use Right Tool Do not force a small tool or attachment to do the job of a heavy duty tool Do not use tool for unintended purpose Dress Properly Do not wear loose clothing or jewelry They can be caught in moving parts Rubber gloves and non skid footwear are recommended when working outdoors Never wear gloves near rotating machine parts Wear protective hair covering to contain long hair Use Safety Glasses and Hearing Protection Also use face or dust mask if cutting operation is dusty Do Not Abuse Electrical Cord Never carry tool by cord or yank it to disconnect from receptacle Keep cord from heat oil and sharp edges 13 14 15 16 17 18 19 20 21 22 IMPORTANT SAFETY INSTRUCTIONS CONT Secure Work Use clamps or a vise to hold work It s safer than using your hand and it frees both hands to operate tool Do Not Overreach Keep proper footing and balance at all times Maintain Tools With Care tools sharp and clean for better and safer performance Follow instructions for lubricating and changing accessories Inspect tool cords periodically and if damaged have repaired by authorized service facility e Inspect extension cords periodically and replace if damaged Keep handles dry clean and free from o
8. the power cord Total weight Noise level Surrounding temperature SteelMax 41 350 rpm 110 120V 60 Hz 5 920 W 1010 W 3 4 Weldon 19 mm 1 5 35 mm 2 50 mm 2135 165 9500 N 3 15 x 6 3 x 1 6 80x160x42 mm slide up 14 8 376 mm slide down 12 306 mm 2 3 4 70 mm 6 6 167 mm 9 4 240 mm 3 28 yd 3 m 23 lbs 10 5 kg 85 dBA 32 F 104 F 0 C 40 C AVAILABLE STEELMAX CUTTERS SteelMax m2Al ANNULAR CUTTERS Cutter Dia inch 1 D O C 2 D O C 7 16 SM4375 SM437L 1 2 SM5000 SMS500L 9 16 SM5625 SM562L 5 8 SM6250 SM625L 1 16 SM6875 SM687L 3 4 SM7500 SM750L 3 16 SM8125 SM812L 7 8 SM8750 SM875L 5 16 SM9375 SM937 SM1000 SM100L 1 16 SM1062 SM106L 1 8 SM1125 5 1121 2 16 SM1187 SM118L 1 4 SM1250 SM125L 5 16 SM1312 SM131L 3 8 SM1375 SM137L 7 16 SM1437 SM143L 1 2 SM1500 SM150L 9 16 SM1562 SM156L 5 8 SM1625 SM162L 11 16 SM1687 SM168L 3 4 SM1750 SM175L 13 16 541812 SM181L 7 8 SM1875 SM187L 15 16 SM1937 SM193L 2 SM2000 SM200L 21 16 SM2062 SM206L 2 1 8 SM2125 SM212L 2 3 16 SM2187 SM218L 2 1 4 SM2250 SM225L 2 5 16 SM2312 SM231L 2 3 8 SM2375 SM237L YOUR STEELMAX DISTRIBUTOR 18 LITO15 12 06
9. 1 ExPLODED VIEWS E 02 01 02 I 02 07 02 01 09 02 02 03 020202 4 9 A 02 02 04 7 19 Z 2 Esk 02 02 05 5 T 12 SteelMax d Parts List Description Part Number Qty 01 01 MAIN BODY ASSEMBLY C31272 010 10 01 01 02 PINION SHAFT ASSEMBLY C31271 010 20 01 01 03 D RING STRAP C3 1272 010 30 00 01 04 ELECTROMAGNETIC BASE 31271 0104001 01 05 STRAIN RELIEF PGZ HO1131 133 01 04 01 06 HEX SOCKET BOLT M6X25 N18230 206 20 02 3 01 07 SPRING WASHER 6 1 N18200 806 0 1 01 3 01 08 EXTERNAL RETAINING RING 28z N1851 1 1 10 28 00 02 00 GEARBOX ASSEMBLY C31272 020 00 03 02 01 GEARBOX HOUSING ASSY W SPINDLE C31272 020 10 01 02 01 02 GEAR RACK 31271 020 10 21 02 01 05 BEARING 608 27 00636 448 01 00 02 01 09 EX SOCKET BOLT M6X20 N18230 206 20 00 02 02 02 PLUNGER C0338 1 390 00 2 02 02 03 SPRING C3127 1 020 20 30 02 02 04 SEAL C3 1279 020 10 60 02 02 05 NTERNAL RETAINING RING 19VV N1851 1 120 19 00 02 02 06 EX SET SCREW M8X10 N6009 1 308 10 00 2 02 03 PINION SHAFT ASSEMBLY C3127 1 020 30 0 1 02 04 COOLANT VALVE C31272 020 40 00 02 07 GUIDE C31271 060 00 01 2 02 08 BRAKE C31271 090 10 01 2 02 09 BRAKE SPRING C31271 110 00 01
10. STEELMAX d Portable Magnetic Drilling Machine OPERATOR S MANUAL N WARNING BEFORE USE BE SURE EVERYONE USING THIS MACHINE READS AND UNDERSTANDS ALL SAFETY AND OPERATING INSTRUCTIONS IN THIS MANUAL s gt A EYE PROTECTION HEARING PROTECTION NEVER PIACE LINE VOLTAGE BEWARE OF REQUIRED REQUIRED FINGERS NEAR PRESENT ROTATING CUTTING AREA OR MACHINE PARTS MACHINE ARBOR MODEL SM D1 Serial Date of Purchase TABLE OF CONTENTS p m4 TC Inest Mae bee be Kee ete es uhi 522435556 ss ka au a Important Safety Instructions 5 6 Grounding Instructions and Extension Cords Special ImsliDeliens 25 255 uu eed eae EIS Contents of Package 222252554452 Sade E xe Uma EE Seti SIGHED 505223 a ee eee eee E ee Tae eee Ready for Cutting PUBL UI ax ss ences PUE ARES 2 Bo RAEE EE a Normal Maintenance _ Exploded Views 2555535 ees LEE TERT ee eyes eeneess pg TT MAVEN DIAGN RE Pr Machine RCM c c euer e old TE ETE TT Available SteelMax Cutters eee STEELMAX DRILLS AND CUTTERS LLC Tel 303 690 9146 or Fox 303 690 9172 6200 S
11. afety features are also provided through the use of a powerful new generation low heat electromagnet with Condensed Magnetic Flux CMF and magnetic field control system This new system provides safety energy saving maintenance weight and operational advantages over other brand drills Please take a moment to complete and mail your product warranty registration card Doing so will validate your machine s warranty period and ensure prompt service if needed LIMITED VVARRANTY SteelMax Drills and Cutters L L C SteelMax will within twelve 12 months from the original date of purchase repair or replace any goods found to be defective in materials or workmanship provided the product warranty registration card has been returned to SteelMax within thirty 30 days of purchase date This warranty is void if tool has been damaged by accident neglect improper service or other causes not arising out of defects in materials or workmanship This warranty does not apply to machines and or components which have been altered changed or modified in any way or subjected to use beyond recommended capacities and specifications All goods returned defective shall be returned prepaid freight to SteelMax which shall be the buyer s sole and exclusive remedy for defective goods In no event shall SteelMax be liable for loss or damage resulting directly or indirectly from the use of merchandise or from any other cause SteelMax is not liable
12. aterial where welding is also simultaneously being performed Drilling machine will be damaged Caution Powering drilling machine from generator without proper surge protection device A between generator and drilling machine may cause damage to the circuitry in machine 8 1 Depress motor ON switch to start drill If drill OD MOTOR TO c CUI Insert the annular cutter in to the machine arbor lining up the flats on the cutter shank drive with the set screws on the arbor Secure the set screws making sure the screws are recessed in arbor body Fill the coolant reservoir with a water soluble coolant Do not overfill If drilling horizontally or inverted use coolant paste Position the d1 drill on the work surface Always use safety strap to prevent injury Refer to the drawing below Lower cutter to surface of material Turn on coolant flow valve Coolant flow will start when pilot pin is depressed Lifting pilot pin off work surface will stop coolant flow Always remember to close valve when not in use Position chip guard toward work area before drilling Place the drilling machine on the work piece with pilot pin over the center of the hole to be cut Move the magnet ON switch to the ON position The switch will illuminate to indicate DC power is going to the magnet momentarily turns on but will not continue to run check to make certain material is thick e
13. em 05 to the pinion hub item 01 02 NOTE Pinion assembly is mounted on the left side of the machine frame If necessary it can be reversed to operate from the right side of the frame To do so remove the external retaining ring item 01 08 from the right edge of the pinion Using a 5mm wrench not supplied loosen the guide rail hex socket retaining bolts about 2 3 turn each item 19 just enough for the pinion shaft to slide out of the machine frame without hitting the gear rack item 02 01 02 Insert the pinion assembly from the opposite side of machine frame Reassemble in reverse order and tighten all fasteners securely WHAT YOU SHOULD KNOW BEFORE YOU DRILL 1 Type of material to be drilled Brinnell or Rockwell hardness material thickness and position should all be determined to ensure proper selection of SteelMax cutting tools 2 Remove any excessive scale or rust from surface to be drilled 3 When drilling thin materials SteelMax recommends placing a steel plate under the work piece and d1 magnet area to increase magnetic holding force Failure to do so may result in dangerous operation 4 Material that has been flame cut may become heat treated and therefore difficult to drill Avoid drilling near such areas whenever possible 5 Paste type cutter lubricant is available for using the d1 drill and annular cutters in the horizontal or inverted position Consult you distributor for more information A Caution Do not drill on m
14. il and grease Disconnect Tools Prior to Service Unplug when not in use before servicing and when changing accessories such as blades bits and cutters Remove Adjusting Keys And Wrenches Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on Avoid Unintentional Starting Do not carry a plugged in tool Always disconnect from power source before moving Be sure switches are off before connecting to a power source Outdoor Use Extension Cords When tool is used outdoors use only extension cords intended for use outdoors and so marked Stay Alert Watch what you are doing Use common sense Do not operate tool when you are tired Do not use when taking medications that may cause drowsiness Check For Damaged Parts Before further use of the tool a guard or other part that is damaged should be repaired and performance verified prior to operation Check alignment of moving parts binding of parts breakage of parts mounting and any other conditions that may affect its operation A guard or other part that is damaged should be properly repaired or replaced by an authorized service center Do not use this tool if switches do not turn it on and off Have defective switches replaced by authorized service center Never Operate Drill In An Explosive Environment Sparks are generated internally by the motor brushes during normal operation
15. led Motor slows when drilling Extension cord is too long or too thin Excessive downforce during drilling cycle will cause motor to slow and overheat Cutter dull Coolant not flowing Coolant system is gravity dependent machine must be in an upright position to operate properly Dirt or debris in coolant tank Incorrect pilot pin Vent hole in coolant tank cap blocked Slugs not ejecting from cutter Lack of coolant causing slugs to expand in cutter bore Incorrect coolant type Incorrect pilot pin Broken pilot pin Dull cutter Breaking cutters Coolant flow must be supplied to interior of cutter Excessive feed pressure being applied Excessive material hardness Drilling stacked materials with incorrect cutter Dull cutters dull or chipped cutting edges require excessive feed pressure Oversized or rough holes Insufficient coolant flow Excessive feed pressure Dull cutter 15 max 376 mm H min 306 mm 119 5 165 1 1 Dimensions SteelMax d Dimensions and specifications Type Machine speeds under load Supply voltage Tolerance of supply voltage Motor power Total power Arbor Capacities max milling cutter diameter max milling drilling depth Magnet Dead Lift on 1 plate Dimensions electromagnetic base heights Slide stroke Width Length Length of
16. nough Insufficient thickness can cause magnet to loose hold causing an operator hazard If necessary clamp an additional section of steel to the work piece to increase magnetic adhesion If material thickness is I less than 3 16 Smm the magnetic field control d1 system will not allow motor to start This system will turn OFF the motor after even minor movement of magnetic base If holes must be made regularly in thin less than 3 8 material the magnetic field control system can be disabled permanently Consult Factory www steelmax com Operational Note Models manufactured after 11 2006 have an electronic overload feature If the drill experiences over current due to excessive cutter penetration speeds the circuit will stop the drill motor If this should occur simply reset the motor switch to the off position and then turn back on Proceed with a slower feed rate without forcing the cutter A CAUTION AN ALTERNATE MEANS MUST BE USED TO SECURELY HOLD THE DRILL IN PLACE FAILURE TO DO SO CAN RESULT IN SERIOUS INJURIES 9 To start a cut apply pressure until the cutter has established an external grove Continue with steady pressure through the remainder of the cut Note Do not peck drill when using annular cutters The tools are designed to evacuate chips when drilling AFTER THE CUT AN CAUTION SLUG IS EXTREMELY HOT 1 After the cut has finished the slug should automatically eject from the cutter Slug can
17. ures and practices Always contact SteelMax in the event any instruction is not clearly understood Never wear loose clothing or gloves when working near cutting area or machine arbor DO NOT touch rotating cutter or machine parts DO NOT use dull or broken cutters To reduce the risk of electrical shock DO NOT remove or alter electrical panels or use machine in damp areas Always stop machine completely and unplug from power source before changing cutters clearing swarf filling coolant reservoir or performing maintenance Always wear eye protection Any tool can shatter Always use safety strap provided with machine Always use proper tooling Keep cutters securely fastened 0 Beware of ejected slugs core at end of cut They become HOT during the cut 11 Keep all safety features functioning and working properly 12 Use only authorized service centers for repairs 9 m RON Se o OPERATING INSTRUCTIONS BEFORE YOU BEGIN Remove all contents from packaging and inspect to ensure no damage was incurred during shipping Your SM d1 package should include the following DESCRIPTION QTY METAL TOOL BOX C31272 220 00 00 1 SAFETY 5 SS D1 27 1 HEX WRENCH 4 HO0643 504 0 1 00 1 OPERATORS MANUAL 015 1 SPOKE HANDLE WITH KNOBS C31249 010 50 00 3 CHIP GUARD C31272 120 00 00 1 CAUTION BE SURE YOUR SM D1 IS DISCONNECTED FROM THE POWER SOURCE BEFORE MAKING ADJUSTMENTS b Assemble 3 spoke handles it
18. y when used outdoors all steel parts should be covered with thin layer of grease film Keep the magnet clean and free of chips oil or other contaminant s Occasionally check the magnet base for flatness to ensure proper magnetic holding force Replace any worn parts and tighten fasteners that become loose during normal usage 10 SteelMax d Portable Magnetic Drilling Machine Labels The figure below shows all labels included on the d1 drilling machine As a required item for machine safety contact the factory for replacement labels if they become damaged 03 06 Serial Number 03 03 920 Watt x z a S 2 120 Volt 60 Hz 2 2 3 o 01 09 04 02 WARNING Read the Operation Manual before starting Keep your hands away from rotating machine s parts Always stop machine completely and disconnect from power source before changing cutters clearing chips refilling lubricant and servicing electrical components Always use the safety strap and chip guard Beware of ejected slug at end of cut Do not remove chips with bare hands Use special hook or hand brushes Always use personal protection dress protection glasses protection gloves and ear protectors Do not use altered dull or broken cutters Protect the power cord from fire oil and sharp edges Use only authorized service centers for repairs SD d MAGNET Stee Ji www steelmax com 1
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