Full Text Searchable PDF User Manual
Handy-Mag
II
474 E. 105th Street
Cleveland, OH 44108-1378
(216) 681-7400
•
Fax (216) 681-7009
www.clevelandsteeltool.com
•
sales@clevelandsteeltool.com
800-446-4402
Table of Contents
Warranty ................................................................................................................ 1
Safety Precautions ................................................................................................ 2
General Information ............................................................................................... 3
Specifications
........................................................................................................ 3
Grounding Instructions/Extension Cords ............................................................... 4
Getting Started ...................................................................................................... 5
Before the Cut ....................................................................................................... 6
Gear Selection ....................................................................................................... 6
Changing the Arbor to Optional Drill Chuck ........................................................... 6
Making the Cut ...................................................................................................... 7
After the Cut .......................................................................................................... 7
Maintenance .......................................................................................................... 8
Troubleshooting ..................................................................................................... 9
Parts List.........................................................................................................10-12
Parts Breakdown ................................................................................................. 13
Handy-Mag
II
Handy-Mag
II
Warranty
The Cleveland Steel Tool Company will, within one (1) year of date of purchase, replace or repair
F.O.B. the factory, any goods, which are defective in materials and workmanship provided that the
buyer returns the defective goods, freight prepaid, to the seller, which shall be the buyer’s sole
and exclusive remedy for the defective goods. THIS WARRANTY IS VOID IF YOU ATTEMPT
REPAIRS YOURSELF. This warranty is void if the items have been damaged by accident, neglect,
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. Electrical components
are subject to respective manufacturer’s warranties. In no event shall The Cleveland Steel Tool
Co. be liable for loss or damage resulting directly or indirectly from the use of merchandise or
from any other cause. The Cleveland Steel Tool Co. is not liable for any costs incurred on such
goods or consequential damages. No officer, employee or agent of the Cleveland Steel Tool Co.
is authorized to make oral representations or warranty of fitness or to waive any of the foregoing
terms of sales and none shall be binding on The Cleveland Steel Tool Co.
Proof of purchase date required
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 seller recommended capacities and specifica
-
tions. In no event shall seller be liable for labor costs expended on such goods or consequential
damages. Seller shall not be liable to the purchaser or any other person for loss, downtime, or
damage directly or indirectly arising from the use of the goods from any other cause. The Cleve-
land Steel Tool Co. reserves the right to make improvements and design modifications to the
machine without prior notice.
_______________________________________________
Company Name
Date of Purchase_________Serial #___________________
1
1
2
Handy-Mag
II
SAFETY PRECAUTIONS
1. The operator of this machine should thoroughly understand this manual before starting
any operation.
2. The area around the machine should be well lit, dry, and free from obstructions.
3. Wear eye and ear protection at all times.
4. All maintenance and repair work should be performed by a person familiar with the
machine.
5. Do not use Handy-Mag
II
drilling machines on surfaces or materials being welded.
Doing so can damage the machine’s electrical components.
6. Disconnect the power from the machine before performing any maintenance or repair
work. Turn power switch to the OFF position when changing tooling.
7. Always disconnect from the power source before moving. Be sure switches are off
before connecting to a power source.
8. Magnet will not hold properly on thin materials (under 3/8”) or rough and dirty surfaces.
9. Always use safety chain and chip shield provided with machine.
10. Assure all tooling is properly held in position before starting any operation. Periodically
check all tooling for tightness.
11. Do not use dull or broken cutters.
12. Keep 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. Inspect extension cords periodically and
replace if damaged. Keep handles dry, clean and free from oil and grease.
13. Beware of slugs ejected at end of cut. They become HOT during the cut.
14. Keep bottom of magnet burr free and clear of chips and debris.
15. Drilling stacked material requires a special STACKED GEOMETRY cutter.
General Information
The Cleveland Steel Tool Handy-Mag
II
is a compact
magnetic base drilling system that features:
•
A capacity up to 2-1/16" diameter through 3" material
•
Drilling stacked material requires a special STACKED GEOMETRY cutter.
•
Positive slug ejection system
•
Internal cutter lubrication for increased tool life
•
Powerful 2 speed motor
•
Adjustable motor slide ways
•
Complete coolant system
•
Safety Chain
•
Chip shield
•
Rugged carrying case
SPECIFICATIONS:
•
Annular cutter range: 7/16" thru 2-1/16"
•
Annular cutter depth range: 3"
•
Twist drill capacity (with optional chuck & adapter): 5/8"
•
Weight: 48 lbs.
•
Height: Rack fully raised- 24"; Rack lowered- 20"
•
Voltage: 110v AC, 15 amps, 1800 watts, grounded & double insulated
•
Frequency: 50-60 HZ
•
RPM No Load: 380 & 500 RPM
•
Magnetic Holding Deadlift: 3500 lbs.
•
Magnet dimensions: 3" x 8" base
3
Handy-Mag
II
Warning:
Improperly connecting the grounding wire can result in the
risk of electrical shock. Check with a qualified electrician if
you are in doubt as to whether the outlet is properly ground-
ed. Do not modify the plug provided with tool. Never remove
the grounding prong from the plug. Do not use tool if the
cord or plug is damaged. Have it repaired before using. If the
plug will not fit the outlet, have a proper outlet installed by
a qualified electrician. The Handy-Mag
II
must be plugged
into an appropriate outlet, properly installed and grounded
in accordance with all codes and ordinances. The rigid ear
or lug extending from the adapter must be connected to a
permanent ground such as a properly grounded outlet box or
receptacle. Simply remove the center screw from the outlet,
insert the adapter and reattach the screw through the green
grounding ear to the outlet. If in doubt of proper grounding,
call a qualified electrician.
Handy-Mag
II
Grounding Instructions
Use only 3-wire extension cords that have 3-prong ground-
ing type plugs and 3-pole receptacles that accept the tool’s
plug. Replace or repair damaged cords. Make sure your
extension cord is in good condition. When using an exten-
sion cord, be sure to use one heavy enough to carry the
current your product will draw. An undersized cord will cause
a drop in line voltage resulting in loss of power and overheat-
ing. See table for the correct size to use depending on cord
length and nameplate amperage rating. If in doubt, use the
next heavier gage. The smaller the gage number, the heavi-
er the cord.
Extension Cords
Drip Loop:
To help prevent fluids from travel
-
ing the power cord and contacting the power
source, tie a drip loop in the power cord.
4
Getting Started
Your Handy-Mag
II
package should contain the following parts:
QTY
Part#
Description
1
HM
II
Handy-Mag
II
1
Carrying Case
1
Owners Manual
2
ME5091
Flat Washer
2
ME5092
Butterfly Bolt (M6 x 10)
1
ME5098
Coolant Tank
1
ME5046
Coolant Tube
1
ME5096
Chip Guard
1
ME5093
Wrench (M8)
1
ME5094
Hex Wrench (M2.5)
1
ME5095
Hex Wrench (M4)
3
ME5071
Crank Handle
1
ME5097
Safety Chain
Attach 3 crank handles (ME5071) to the crank spindle (ME5072). Attach the coolant tube
(ME5046) to the coolant tank (ME5098). Attach the coolant tank to the Handy-Mag
II
to the
top of the slide with screw provided. Attach open end of the coolant tube to the coolant con-
nector (ME5010).
Handy-Mag
II
What You Need To Know
Type of material to be drilled, Brinell or Rockwell hardness, material thickness and position
should all be determined to ensure proper selection of Handy-Mag
II
cutting tools, RPM, coolant
and drilling time.
Remove any excessive mill scale or rust from the surface to be drilled.
When drilling materials under 3/8" thick, an additional steel plate may be required to achieve
proper magnetic adhesion.
Drilling stacked material requires a special STACKED GEOMETRY cutter.
Material that has been flame cut may have become heat treated and therefore difficult to drill.
Avoid drilling near such areas whenever possible.
Drilling with the Handy-Mag
II
in horizontal positions requires a special lubrication for Handy-Mag
II
cutters. Consult The Cleveland Steel Tool Co. for details.
5
Handy-Mag
II
Before the Cut
1. Select the correct pilot pin and place it in the cutter shank from the rear.
Align the flats on the cutter shank with the arbor body set screws.
Insert cutter shank into the arbor body.
2. Tighten the set screws securely on the cutter shank flats. Note: The set screws should be recessed in
the arbor body when tight.
3. Attach chip guard (
ME
5096) to machine with butterfly bolts (
ME
5092).
4. Fill coolant tank with a water soluble coolant.
5. Place Handy-Mag
II
machine on work piece with pilot pin over the center of the hole to be drilled.
6. Safety chain must be securely fastened to machine and around the work being drilled.
NOTE:
Safety chain is intended to secure drill to work piece in case of emergency, such as a loss
of power to the magnetic base.
7. Connect machine to power source.
8. Open coolant tap (
ME
5045) to release coolant. NOTE: Coolant flow starts when pilot pin contacts the
work surface. Coolant flow can be stopped by lifting pin off work surface.
Caution!
Do not use the Handy-Mag
II
for work other than it’s intended use.
The Handy-Mag
II
is designed to work only with the tooling provided.
Use of other tooling may cause damage to the drill,
cause personal injury and void the warranty.
CAUTION:
Always use safety chain.
Failure to do so could result in personal
injury and/or damage to the Handy-Mag
II
drilling machine.
6
Gear Selection
Gear
No Load RPM
Cutter Size
1
380
1-9/16
"
to 2-1/16
"
2
500
7/16
"
to 1-1/2
"
Changing the Arbor to Optional Drill Chuck
To convert the Handy-Mag
II
from annular cutters to twist drill chuck:
1. Loosen the 2 hex screws located at the top of the arbor (ME5002) with hex wrench
supplied and release the arbor.
2. Use the included hex wrench to remove the 3 arbor support screws and remove the arbor
support bracket (ME5088)
3. Fit chuck adapter (MEHTA46) and drill chuck (MEHTA51) to Handy-Mag
II
in place of the
arbor.
NOTE: Store arbor and arbor support bracket in the carrying case. To convert back to
annular cutters, reverse the process.
7
Handy-Mag
II
Making the Cut
CAUTION: Always use chip shield.
1. Move magnet switch to “On” position, panel lamp should illuminate indicating
power is on. Magnetic base should be firmly secured to work piece at this time.
2. Start drill motor by depressing green motor “On” button.
3. Using the feed handles, advance cutter into material until Handy-Mag
II
cutter has
established an external groove in the material, during the remainder of cut apply,
smooth constant pressure without overloading motor.
NOTE: Handy-Mag
II
cutters are designed for uninterrupted
cutting, chips are evacuated during the cut. Do not
peck drill when using Handy-Mag
II
cutters.
CAUTION: If drill motor should stall or stop before a complete cut is made,
always shut the motor off and remove the cutter from the hole before attempt-
ing to restart the motor. Failure to do so could result in personal injury and/or
damage to the Handy-Mag
II
drilling machine or cutter.
After the Cut
1. After the Handy-Mag
II
cutter has finished the cut, the “slug” or uncut center
portion of material will be expelled when motor is returned to the full up position.
Beware of slugs ejected at end of cut. They become HOT during the cut.
2. Return the machine to a full upright position and depress red motor “OFF “
button. Wait until motor completely stops.
3. Move magnet switch to “OFF” position when ready to release magnetic base
from work surface.
8
Handy-Mag
II
Maintenance
Keep tool and electrical cord clean. In case of electrical or mechanical malfunction,
immediately turn off tool and disconnect power supply.
1. Adjusting motor slide tension:
The motor slide assembly may become loose and require adjustment after the machine has been in service.
Wrenches are provided in the tool kit for performing adjustments.
•
Using the feed handles, position motor and slide assembly in the full up position.
•
Loosen 6 jam nuts (
ME
5055) and equally tighten 6 adjustment screws (
ME
5056) using 2.5mm and
8mm combination wrench and hex key.
•
Do not over tighten adjustment screws. Excessive slide tension can damage the machine. Properly
adjusted, the motor/slide assembly should have no side to side movement and remain positioned
without drifting down.
2. Inspecting magnet base:
Keep bottom of magnet clean, free of chips, burrs, nicks, oil and other contaminants. Inspect magnet face to
insure surface is flat and square. A worn magnet surface dramatically reduces magnetic holding force.
3. Lubricating motor slideways:
Periodically clean and lubricate motor slide ways with lithium base grease.
4. Inspecting arbor support system:
Visually inspect arbor, sleeve and support bracket for wear.
Caution: Always remove cutter from arbor body before measuring runout, never use hands or
fingers to rotate arbor or motor spindle.
5. Checking arbor runout:
Arbor runout should not exceed .0035 per revolution. This is most accurately measured by placing a dial indi-
cator needle inside of arbor bore and rotating arbor while observing indicator.
6. Motor brush inspection:
Excessive sparking may indicate the presence of dirt in the motor or worn out carbon brushes. Periodically
check brushes for wear and replace (
ME
5041) when they reach 1/4
”
.
CAUTION: Never operate machine with worn or missing parts.
9
Handy-Mag
II
Troubleshooting
1. Magnetic base is not holding securely:
•
Material being drilled must be a minimum of 3/8" thick for proper magnetic adhesion.
•
Surface of material should be free of chips, debris, rust and mill scale.
•
Verify size of cutter. It should not exceed machines capacity.
•
Check magnet face for unevenness, nicks and burrs.
•
Welding equipment should not be connected to material being drilled.
2. Drill motor is running, arbor and spindle is not turning:
•
Woodruff key (
ME
5006) could be sheared.
3. Motor slows when drilling:
•
Check extension cord requirements if one is being used. (pg. 4)
•
Excessive downfeed pressure during drilling cycle will cause motor to slow and overheat.
•
The cutting tool may need to be resharpened.
4. Coolant system not working:
•
Coolant system is gravity dependent. Machine must be in an upright position to operate properly.
•
Consistency of coolant mixture is too thick.
•
Check for the correct pilot pin.
5. Slugs not ejecting from cutter:
•
Lack of coolant can cause slugs to expand in cutter bore.
•
Check for correct pilot pin.
•
Check for broken internal arbor parts.
* Drilling stacked material requires a special STACKED GEOMETRY cutter.
6. Breaking cutters:
•
Coolant must be applied to the interior of the cutter.
•
Excessive downfeed pressure when cutter contacts work surface can cause breaks.
•
Confirm material hardness.
•
Drilling stacked material with improper cutter. (Drilling stacked material requires special cutters)
•
Dull cutters and dull or chipped cutting edges require excessive feed pressure resulting in breakage.
•
Excessive arbor runout. (see pg.8 for maintenance)
•
Motor spindle is bent or there is a worn arbor sleeve.
•
Motor slide is improperly adjusted. (see pg.8)
7. Oversized or rough holes:
•
Insufficient coolant.
•
Excessive feed pressure.
•
Dull cutter.
•
Worn support bracket roller bearing or arbor body sleeve.
•
Bent motor spindle.
•
Motor slide improperly adjusted.
10
Handy-Mag
II
Parts List
Item Description
Part No. Qty Req.
1 Set Screw M5x6
MEX5001
2
1.05
2 Arbor Shaft-
Complete (inc 104-110)
MEX5002
1
82.45
3 Water Seal
MEX5003
1
6.60
4 Spring
MEX5004
1
6.60
5 Main Drive Spindle
MEX5005
1
51.65
6 Woodruff Key M5x5x16 MEX5006
1
2.15
7 Oil Seal 22x32x7
MEX5007
2
2.15
8 Screw M5x80
MEX5008
4
2.15
9 Gear Case
MEX5009
1
49.45
10 Coolant Connector
MEX5010
1
5.45
11 Selector Spring
MEX5011
1
3.25
12 Selector Slider
MEX5012
1
5.45
13 Screw
MEX5013
1
2.70
14 Selector Fork
MEX5014
1
5.34
15 Bearing 6003ZZ
MEX5015
2
16.45
16 Snap Ring R-35
MEX5016
1
3.14
17 Circlip S-17
MEX5017
1
3.14
18 Driven Gear 39T
MEX5018
1
32.95
19 Circlip S-14
MEX5019
1
2.70
20 Bearing HK0810
MEX5020
3
16.45
21 Woodruff Key M5x5x50 MEX5021
1
2.15
22 Idler Gear Pinion
MEX5022
1
32.95
23 Idler Gear 30x33T
MEX5023
1
38.45
24 Bearing HK1010
MEX5024
1
16.45
25 First Gear Pinion 10x13T MEX5025
1
32.95
26 Woodruff Key M4x4x10 MEX5026
1
2.15
27 First Gear 29T
MEX5027
2
32.95
28 Gear Plate
MEX5028
1
36.25
29 Bearing 609ZZ
MEX5029
1
13.15
30 Armature 110V
MEX5030
1
148.34
31 Screw M5x60
MEX5031
2
2.15
32 Spring Washer M5
MEX5032
2
1.05
33 Bearing 6200ZZ
MEX5033
1
13.15
34 Field Coil 110V
MEX5034
1
68.70
35 Motor Housing
MEX5035
1
54.40
36 Cord Clip
MEX5036
2
1.05
37 Screw M4x14
MEX5037
2
1.05
38 Motor Cable
MEX5038
1
7.65
39 Cable Protector Sheath MEX5039
1
10.62
11
Handy-Mag
II
Parts List
Item Description
Part No. Qty Req.
40 Brush Holder
MEX5040
2
14.03
41 Carbon Brush
MEX5041
2
21.95
42 Brush Cap
MEX5042
2
2.15
43 Motor Tail Cover
MEX5043
1
20.74
44 Screw M5x45
MEX5044
4
2.15
45 Coolant Tap
MEX5045
1
9.85
46 Coolant Tube
MEX5046
1
3.14
47 Motor Switch 110V
MEX5047
1
53.85
48 Magnet Switch
MEX5048
1
31.85
49 Guard Bar
MEX5049
2
5.45
50 Switch Panel
MEX5050
1
31.85
51 Hex Bolt M8x16
MEX5051
5
1.05
52 Spring Washer M8
MEX5052
5
1.05
53 Flat Washer 40x8x2.5
MEX5053
1
1.05
54 Bushing 32x38x12
MEX5054
2
16.45
55 Nut M5
MEX5055
6
1.05
56 Set Screw M5x25
MEX5056
6
1.05
57 Body Assy.
MEX5057
1
136.90
58 Hex Bolt M4x16
MEX5058
4
1.05
59 Spring Washer M4
MEX5059
4
1.05
60 Flat Washer M4
MEX5060
4
1.05
61 Gib Tensioner
MEX5061
1
14.80
62 Gib Strip Left
MEX5062
1
18.65
63 Gib Strip Right
MEX5063
1
18.65
64 Screw M4x20
MEX5064
1
1.05
65 Hex Bolt M6x20
MEX5065
3
2.15
66 Spring Washer M6
MEX5066
3
1.05
67 Electro-Magent
MEX5067
1
130.30
68 Screw M4x8
MEX5068
4
1.05
69 Side Panel
MEX5069
1
27.34
70 Handle Grip
MEX5070
3
5.34
71 Crank Handle
MEX5071
3
12.60
72 Crank Spindle
MEX5072
1
49.45
73 Star Washer M4
MEX5073
1
1.05
74 Screw M4x6
MEX5074
1
1.05
75 Bridge Rectifier
MEX5075
1
31.85
76 Nut M4
MEX5076
3
1.05
77 Screw M4x25
MEX5077
2
1.05
78 Cord Armor
MEX5078
1
2.15
12
Handy-Mag
II
Parts List
Item Description
Part No. Qty Req.
79 Power Supply Cord
MEX5079
1
10.62
80 Conduit Gland
MEX5080
1
5.12
81 Hex Bolt M8x20
MEX5081
2
2.15
82 Gear Rack
MEX5082
1
47.25
83 Slide Plate
MEX5083
1
58.25
84 Screw M5x15
MEX5084
1
1.05
85 Coolant Tank Bracket
MEX5085
1
7.10
86 Flat Washer M8
MEX5086
2
1.05
87 Motor Fixing Plate
MEX5087
1
8.42
88 Arbor Support Bracket
MEX5088
1
36.25
89 Bearing HK3516
MEX5089
1
21.95
90 Hex Bolt M8x70
MEX5090
2
2.15
91 Flat Washer M6x13x1
MEX5091
2
1.05
92 Butterfly Bolt M6x10
MEX5092
2
2.15
93 Wrench M8
MEX5093
1
4.35
94 Hex Wrench M2.5
MEX5094
1
2.15
95 Hex Wrench M4
MEX5095
1
2.15
96 Chip Guard
MEX5096
1
20.85
97 Safety Chain
MEX5097
1
10.95
98 Coolant Tank
MEX5098
1
10.95
99 O-Ring 7.5x1.5
MEX5099
1
1.05
100 Flat Washer 12x24x2.5
MEX50100
1
1.05
101 Nut
MEX50101
1
2.15
102 Screw M4x10
MEX50102
2
1.05
103 Hex Bolt M8x60
MEX50103
3
2.15
104 Circlip
MEX50104
1
5.45
105 Collar
MEX50105
1
20.85
106 Return Spring
MEX50106
1
9.85
107 Spring Retainer Ring
MEX50107
1
16.45
108 Set Screw M3x12
MEX50108
1
1.05
109 Lock Pin
MEX50109
1
3.14
110 Flat Spring
MEX50110
1
3.25
111 Screw M3x6
MEX50111
1
1.05
112 Chuck Adaptor
MEXHTA46
1
27.45
113 Electrical Connector
MEX50113
2
1.05
114 Motor Back Cover Plate MEX50114
1
6.55
115 Flat Head Screw
MEX50115
4
1.05
Parts Breakdown
Handy-Mag
II