Falcon Magnetic Rotabroach CM/405/1, Rotabroach CM/405/3 Operator's Manual

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Page 1

Issue%3% Original%Version% JUNE%2014%

!"#$%&'(")&*+,$'-.,##,&)'("$/,&*'

% % % % % % % % % % % % % % %

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%<*."+%.=>'("&?"#'

This%machine%(Serial%No%% % %)%is%CE%approved.%

% %

.0@ABC0ADE'#@1'

Imperial%Works,%Sheffield%Road%

Sheffield,%South%Yorkshire%

United%Kingdom%

S9%2YL%

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*MAN3F'4A324OC0@ABC0ADEPD0PQR' ' S2B'4N@2F'TTTPC0@ABC0ADEPD0PQR'

Page 2

Issue 3 Original Version JUNE 2014

+EAUR'V0Q'W0C'XQCDEA4NUY'0QC'!A3D0U'MAYU2@ND'1CN33P' S2'T0Q31'C2A33V'3NR2'V0QC'W221BADR'0U'@E2'MADENU2P' '

Other&Products&by&Rotabroach™:&

+EAUR'V0Q'W0C'V0QC'XQCDEA42'0W'0QC'XC01QD@P'

Page 3

Issue 3 Original Version JUNE 2014

$%&+*&+>'

% Page%

9I %% % General%safety% % % % % % % % 4% JI %%%%%%%%%%Machine%Specification% % % % % % 5% ;I %% Operational%safety%procedures% % % % % 6% 6I %% Machine%Operation%instructions% % % % % 6% 8I %%%%%%%%% Speed%Selection%% % % % % % % 7% LI %%%%%%%%%%Arbor%Attachments% % % % % % % 7% ZI %% Mounting%of%cutters% % % % % % % 8% [I %% Remedies%for%hole%making%problems% % % % 8% \I %% Trouble%shooting% % % % % % % 9% 97I Exploded%diagram%of%machine% % % % % 10% 99I Exploded%diagram%of%motor% % % % % 11% 9JI % Maintenance%checks% % % % % % % 12% 9;I %% Cutter%selection%and%speed%and%feed%information%% 14% 96I % Warranty% % % % % % % % % 16%

% %

Page 4

Issue%3% Original%Version% JUNE%2014%

9I )*&*."#'>"!*+]'.?#*>'

% WARNING!%When%using%electric%tools%basic%safety%precautions%should%always%be%followed%to%reduce%the%risk%of%fire,%electric%shock%and%

personal%injury,%including%the%following.% % Read%all%these%instructions%before%attempting%to%operate%this%product% % Remove%the%power%supply%before%carrying%out%any%adjustment,%serving%or%maintenance.% %

1. Keep%work%area%clear%\%cluttered%areas%and%benches%invite%injuries.%

2. Consider%work%area%environment%

• Do%not%expose%tools%to%rain.%

• Do%not%use%tools%in%damp%or%wet%locations.%

• Keep%work%area%well%lit.%

• Do%not%use%tools%in%the%presence%of%flammable%liquid%or%gases.%

3. Guard%against%electric%shock% % Avoid%body%contact%with%earthed%or%ground%surfaces%(e.g.%pipes,%radiators,%cookers%and%refrigerators).%Electric%safety%can%be%further%

improved%by%using%a%high\sensitivity%(30%m%A/0.1s)%residual%current%device%(RCD).%

4. Do%not%let%people%not%involved%in%the%work,%especially%children,%touch%the%tool%or%the%extension%cord%and%keep%them%away%from%the%

work%area.%

5. Store%idle%tools%when%not%in%use,%tools%should%be%stored%in%a%dry%locked\up%place,%out%of%reach%of%children.%

6. Do%not%force%the%tool,%it%will%do%the%job%better%and%safer%at%the%rate%for%which%it%was%intended.%

7. Use%the%right%tool%

• Do%not%force%small%tools%to%do%the%job%of%a%heavy%duty%tool.%

• Do%not%use%tools%for%purposes%not%intended:%for%example%do%not%use%circular%saws%to%cut%tree%limbs%or%logs.%

8. Dress%properly%

• Do%not%wear%loose%clothing%or%jewellery;%they%can%be%caught%in%moving%parts.%

• Non\skid%footwear%is%recommended%when%working%outdoors.%

• Wear%protective%hair%covering%to%contain%long%hair.%

9. Use%protective%equipment%when%using%this%machine%

• Use%safety%glasses.%

• Use%ear%defenders.%

• Use%face%or%dust%masks%if%cutting%operations%create%dust.%

• Use%protective%gloves%

10. Connect%dust%extraction%and%collecting%equipment,%if%devices%are%provided,%and%ensure%these%are%properly%connected%and%used.%

11. Does%not%abuse%the%cord;%never%pull%the%cord%to%disconnect%it%from%socket.%Keep%the%cord%away%from%heat,%oil%and%sharp%edges.%

12.%% Secure%work%where%possible%by%using%clamps%or%a%vice%to%hold%the%work.%It%is%safer%than%using%your%hand.%

12. Do%not%overreach%\%keep%proper%footing%and%balance%at%all%times.%

13. Maintain%tools%with%care%

• Keep%cutting%tools%sharp%and%clean%for%better%and%safer%performance.%

• Follow%instruction%for%lubricating%and%changing%accessories.%

• Inspect%tool%cords%periodically%and%if%damaged%have%th em%repaired%by%an%authorized%service%facility.%

• Inspect%extension%cords%periodically%and%replace%if%damaged.%

• Keep%handles%dry,%clean%and%free%of%oil%and%grease.%

15.%% Disconnect%tools%from%the%power%supply%when%not%in%use,%before%servicing%and%when%changing%accessories%such%as%blades,%bits%and%

cutters.%

16.%% Remove%adjusting%keys%and%wrenches%and%form%the%habit%of%checking%to%see%that%keys%and%adjusting%wrenches%are%removed%from%the%

tool%before%turning%it%on.%

17.%% Avoid%unintentional%starting%%by%ensuring%the%switch%is%in%the%“off”%position%when%plugging%in%the%power%supply.%

18.%% Use%outdoor%extension%leads%when%the%tool%is%used%outdoors,%but%only%those%intended%for%outdoor%use%and%so%marked.%

19.%% Stay%alert%and%watch%what%you%are%doing,%use%common%sense%and%do%not%operate%the%tool%when%you%are%tired.%

20.% Check%for%damaged%parts%before%using%the%tool;%it%should%be%carefully%checked%to%determine%that%it%will%operate%properly%and%for%its%

intended%function.%

21.% %Warning!%The%use%of%any%accessory%or%attachment%other%than%one%recommended%in%this%instruction%manual%may%present%a%risk%of%

personal%injury.%

22.% Have%your%tool%repaired%by%a%qualified%person% %%%% %This%electric%tool%complies%with%the%relevant%safety%rules.%Qualified%persons%using%original%spare%parts%should%only%carry%out%repairs;%

otherwise%this%may%result%in%considerable%danger%to%the%user.%

Page 5

Issue 3 Original Version JUNE 2014

JI ("$/,&*'><*$,!,$"+,%&'

Maximum%hole%cutting%capacity%in%.2/.3C%steel%=%50mm%dia.%x%50mm%deep% Arbor%bore%=%19.05mm%(3/4”)%dia.%

Motor%Unit% CM/405/1%%%%%%%%110V%

11.5A,%1150W%

CM/405/3%%%%%%%%230V%

5.75A,%1150W%

Overall% Dimensions%

Machine%

230%x%160%x%420mm%

Magnet%Footprint%

170mm%x%85mm%

Net%Weight%%13.0kgs%

No%Load% Speed%

All%voltages%

280%min\1%max%low%gear%Max%

530%min\1%high%gear%Max%

Tractive%Force%of%Magnet%at%20º%C%(25mm%min.%plate%thickness)%

+E2'Q42'0U'AUV'MA@2CNA3'3244'@EAU'J8MM'@ENDR'TN33'XC0YC244N^23V'C21QD2'@E2' MAYU2@ND'X2CW0CMAUD2P',W'X044NB32'A11N@N0UA3'MA@2CNA3'4E0Q31'B2'X04N@N0U21'QU12C' @E2'MAYU2@'AU1'T0CR'XN2D2'@0'2_QA@2'@0'A'4QN@AB32'MA @2CNA3'@ENDR U2 44P',W'@EN4'N4'U0 @' X044NB32'AU'A3@2CUA@N^2'42DQC2'M2@E01'0W'C24@CANUNUY'@E2'MADENU2'(?>+'B2'Q421P%

1850kgs%

Maximum%machine%stroke%

150mm%

Twist%drill%diameter%capacity%

1\23mm%

Tap%diameter%capacity%(DIN376)%

M3\M16%

Maximum%cutter%diameter%(Annular%cutter)%

50mm%

Maximum%cutting%depth%(Annular%cutter)%

50mm%

It%is%recomended%that%ear%and%eye%protectors%are%worn%when%operating%this%machine.%

Suitable%only%for%a%single%phase%25\60%Hz%A.C.%power%supply%

DO%NOT%USE%ON%D.C.%SUPPLY%

Do%not%use%your%magnetic%drill%on%the%same%structure%when%arc%welding%is%in%progress.%

D.C.%current%will%earth%back%through%the%magnet%and%cause%irreparable%damage.%%

WARNING:%%THIS%APPLIANCE%MUST%BE%EARTHED!%

&`F''"&]'(%-,!,$"+,%&>'+%'+/,>'("$/,&*'S,##',&a"#,-"+*'+/*')?"."&+**%

List%of%Contents%with%Magnetic%Dill%Unit%

Check%List%

RD40070%

Carrying%case%

YES/NO%

RD4329%

Safety%chain%

YES/NO%

RD48171%

Chuck%&%key%

YES/NO%

RD48259%

2MT%to%B16%Chuck%attachment%

YES/NO%

RD40076%

M10%Tap%collet%(DIN376)%

YES/NO%

RD40077%

M12%Tap%collet%(DIN376)%

YES/NO%

RD40078%

M14%Tap%collet%(DIN376)%

YES/NO%

RD40079%

M16%Tap%collet%(DIN376)%

YES/NO%

RD40072%

Hearing%protectors%

YES/NO%

RD40073%

Safety%glasses%

YES/NO%

RD40074%

Safety%gloves%

YES/NO%

RD40080%

2.5mm%Hexagon%key%

YES/NO%

RD40081%

3mm%Hexagon%key%

YES/NO%

RD4088%

4mm%Hexagon%key%

YES/NO%

RD4153%

5mm%Hexagonal%key%

YES/NO%

RD40082%

Wrench%8%

YES/NO%

RD48158%

Machine%Guard%

YES/NO%

Page 6

Issue 3 Original Version JUNE 2014

;I %<*."+,%&"#'>"!*+]'<.%$*-?.*>'

.*"-'`*!%.*'?>,&)'+/*'("$/,&*'

% All%safety%measures%must%be%observed%at%all%times%when%using%magnetic%core%drills.% Improper%use%and%carelessness%increase%the%risk%of%acc id en ts .%R e ad %a nd %c ar ef ully %fo llo w %t h es e%r ec o m m e n d at ion s %in%order%to%improve%your% own%safety.%% % This%machine%is%specifically%designed%for%drilling%holes%in%steel,%expanded%by%the%possibility%of%tapping/reaming/countersinking,%and%must%not% be%adapted%and/or%used%for%applications%other%than%those%they%were%designed%for,%including%driving%other%apparatus.%% %

• When%using%electrical%tools,%basic%safety%precautions%should%always%be%followed%to%reduce%the%risk%of%electric%shock,%fire,%and%personal%

injury.%

• Do%NOT%use%in%wet%or%damp%conditions.%Failure%to%do%so%may%result%in%personal%injury.%

• Do%NOT%use%in%the%presence%of%flammable%liquids%or%gasses.%Failure%to%do%so%may%result%in%personal%injury.%

• BEFORE%operating,%the%machine%MUST%be%securely%restrained%to%a%fixed%independent%feature%(by%using%safety%strap%RD4329,%or%other%

means),%to%reduce%the%potential%free%movement%should%the%magnet%become%detached%from%the%work%piece.%Failure%to%do%so%may% result%in%personal%injury.%

• ALWAYS%wear%eye%and%ear%protectors%when%operating%the%machine.%%Failure%to%do%so%may%result%in%personal%injury.%

• Disconnect%from%power%source%when%changing%cutters%or%working%on%the%machine.%Failure%to%do%so%may%result%in%personal%injury.%

• Cutters%and%swarf%are%sharp,%ALWAYS%ensure%that%hands%are%adequately%protected%when%changing%cutters,%or%removing%swarf.%

• Before%operating,%ALWAYS%ensure%cutter%retaining%screws%are%secured.%%

• Regularly%clear%the%work%area%and%machine%of%swarf%and%dirt,%paying%particular%attention%to%the%underside%of%the%magnet%base.%%

• With%a%gloved%hand,%and%after%switching%off%the%machine,%remove%any%swarf%that%might%have%gathered%around%the%cutter%and%arbor%

before%proceeding%with%cutting.%%

• ALWAYS%remove%your%tie,%rings,%watche s %a n d %a ny%loose%adornments%that%might%entang le %with%the%rotating%machinery%before%

operating.%%

• Should%the%cutter%become%‘stuck’%in%the%work \piece,%stop%the%motor%immediately%to%prevent%personal%injury.%%Disconnect%from%power%

source%and%turn%arbor%to%and%fro.%%DO%NOT%ATTEMPT%TO%FREE%THE%CUTTER%BY%SWITCHING%THE%MOTOR%ON%AND%OFF.%

• If%the%ma ch in e %is%a cc id en ta lly %dr o pp e d ,%AL WAYS%thoroughly%examine%the%machine%for%signs%of%damage%and%check%that%it%functions%

correctly%BEFORE%resuming%drilling.%%

• Regularly%inspect%the%machine%and%check%that%nuts%and%screws%are%tight.%%

• ALWAYS%ensure%when%using%the%machine%in%an%inverted%position%that%the%machine%is%securely%restained%in%the%event%of%power%failure.%

Only%use%the%minimum%amount%of%coolant%and%ensure%that%care%is%taken%to%prevent%coolant%entering%the%motor%unit.%%

• Cutting%tools%may%shatter,%ALWAYS%position%the%guard%over%the%cutter%before%activating%the%machine.%Failure%to%do%so%may%result%in%

personal%injury.%

• On%completion%of%the%cut,%a%slug%will%eject.%DO%NOT%operate%the%machine%if%the%slug%has%not%ejected,%as%this%may%cause%injury.%If%

necessary,%use%barriers%to%prevent%unauthorised%access%to%work%area.%

6I ("$/,&*'%<*."+,&)',&>+.?$+,%&>'

• Keep%the%inside%of%the%cutter%clear%of%swarf.%%It%restricts%the%operating%depth%of%the%cutter.'

• Apply%the%cutting%fluid%to%the%internal%reservoir%via%the%inducement%holes%in%the%arbor.%%It%is%then %“metered%out”%by%the%pilot%during%the%

cutting%cycle%and%is%applied%directly%to%the%cutting%edge.%%Alternatively,%fluid%can%be%applied%directly%onto%the%work\piece%making% certain%that%it%floods%into%the%groove%formed%by%the%cutter.'

• Occasionally%depress%the%pilot%to%ensure%cutting%fluid%is%being%correctly%metered.'

• To%start%the%machine,%first%switch%on%the%magnet%by%depressing%the%single%red%button.%%Ensure%that%the%rotary%switch%is%set%to%R,%%then%

start%the%motor%by%depressing%the%GREEN%%(I)%start%button.'

• ALWAYS%switch%off%the%motor%by%depressing%the%RED%(O)%stop%button.%%DO%NOT%switch%off%the%motor%by%switching%the%magnet%off.'

• Apply%light%pressure%when%commencing%to%cut%a%hole%into%the%work%surface.%%Pressure%can%then%be%increased%sufficiently%to%load%the%

motor.%Excessive%pressure%is%undesirable%when%using%the%Rotabroach™%“FALCON”%machine.%It%does%not%increase%the%rate%of% penetration%and%may%result%in%damage%to%the%machine%and%cutter.'

• Always%ensure%that%the%slug%has%been%ejected%from%the%previous%hole%before%commencing%to%cut%the%next.'

• If%the%slug %st ick s%in %th e %cu t ter ,%m o ve %th e %m a ch in e%t o %a%fla t%s u rfa ce ,%switch%on%the%magnet%only,%and%gently%bring%the%cutter%down%to%

make%contact%with%the%surface.%%This%will%usually%straighten%a%cocked%slug%and%allow%it%to%eject%normally.%

• Apply%a%small%amount%of%light%oil%lubricant%regularly%to%the%slide%and%arbor%support%bearing.%

• Insecure %a nc h o ra ge ,%a%lo o se ly%f ittin g %slid e ,%or %a%worn%bearing%in%the%arbor%support%bracket%usually%cause s%c u tte r%b re a ka ge .%

*b+*&>,%&'$"`#*'>*#*$+,%&'

• The% machines% are% factory% fitted% with% a%3%metre%length% of% cable% having% three,% 1.5mm²% conductors,% LIVE,% NEUTRAL% and% EARTH.% %%If% it%

becomes%necessary%to%fit%an%extension%cable%from%the%power%source,%care%must%be%taken%in%using%a%cable%of%adequate%capacity.%%Failure% to%do%so%will%result%in%a%loss%of%traction%by%the%magnet%and%a%reductio n %of %po w e r%fro m %th e %m o to r.%%

• Assuming%a%normal%AC%supply%of%the%correct%voltage,%it%is%recommended%that%the%following%extension%lengths%shall%not%be%exceeded:% %

!0C'997^'4QXX3VF' ;P8M2@C24'0W';'D0C2'K'9P8MMc'

% !0C'J;7^'4QXX3V:% JL'M2@C24'0W';'D0C2'K'9P8MM²%%

Page 7

Issue 3 Original Version JUNE 2014

8I ><**-'>*#*$+,%&'

The%machine%is%equipped%with%gear%ranges%which%can%produce%speeds%up%to%450rpm.%Do%not% change%the%gear%while%the%motor%is%in%motion.% The%speed%range%for%this%gear%is%changed%by%the%rotary%change%switch%located%on%the%gearbox% side.%%

The%speed%controller%is%adjusted%by%rotating%the%blue%disk%located%on%the%control%panel%of%the% motor.% Before%cutting%holes%in%the%work%piece%ensure%that%you%are%using%the%correct%speed%and%gear% for%your%material%and%cutter.%Site%conditions,%e.g.%diameter%and%condition%of%cutter,%material% condition,%material%thickness,%etc%must%also%be%taken%into%account%when%determining%the% suitable%cutting%speed.%The%speed%and%feed%rate%must%continuously%be%monitored%and% adjusted%to%ensure%optimum%cutting%conditions%prevail.%% In%general%the%faster%output%speeds%would%be%used%for%smaller%cutters%and%the%slower%more% torque%gears%for%larger%cutters.%

' )2AC'4232D@0C'NU''''''''''''<04N@N0U'W0C'4MA33'DQ@@2C4' ' )2AC'4232D@0C'NU''''''''''''<04N@N0U'W0C'3ACY2'DQ@@2C4' '

LI ".`%.'"++"$/(*&+>%

The%CM/405%has%been%design%so%that%a%number%of%2%morse%taper%attachments%can%be%used%with%this% machine.% %

"CB0C4'W0C'DQ@@2C4'

Currently%available%from%Rotabroach™%are%a%number%of%various%Arbors%for%fitting%our%range%of%cutters% that%are%available%with%the%standard%19.05m m %W eld on %sha nk%a ttach m en t%an d%also %are%av ailable %with % a%32mm%Weldon%shank.% %

+TN4@'1CN334'

It%is%possible%to%also%use %twist%drills%with%this%machine.%These%can%either%be%2MT%twist%drills%or%a%using%a% suitable%drill%chuck.%Please%contact%our%sale%department%for%further%details.%Max%size%twist%drill%that% can%be%used%with%this%machine%is%23mm.% %

+AX'AU1'+AX'E0312C4'

Again%as%with%the%Twist%drills%this%machine%can%also%allow%you%to%tap%through%holes.%Using%a%suitable% tap%or%tap%holder%they%can%be%connected %to%the %2MT%output%shaft.% The%machine%is%suitable%for%tapping%up%to%M20.%Please%contact%our%sales%depa rtment%for%further% details%and%our%available%products.%

Gear%Selection%

Page 8

Issue 3 Original Version JUNE 2014

ZI (%?&+,&)'%!'$?++*.>'

The%machine%has%been%made%to%accept%cutters%having%19.05mm%(3/4”)%dia.%shanks.% The%following%procedure%is%to%be%used%when%mounting%cutters.%

• Lay%the%machine%on%its%side%with%feed%handles%uppermost,%ensuring%arbor%is%wound%down%to%its%lowest%point%to%enable%access%to% socket%screws.%

• Take%appropriate%pilot%and%place%through%hole%in%shank%of%cutter.%%Insert%shank%of%cutter%into%¾”%dia.%bore%of%arbor,%ensuring% alignment%of%two%drive%flats%with%socket%screws%%

• Tighten%both%screws%using%hexagon%key%RD4088.%%

ALWAYS%DISCONNECT%MACHINE%FROM%POWER%SOURCE.%

[I .*(*-,*>'!%.'/%#*'("d,&)'<.%`#*(>'

Problem(

Cause(

Remedy(

1)%Magnetic%base% won’t%hold% effectively%

Material%being%cut%may%be%too%thin%for%efficient%holding.% % % Swarf%or%dirt%under%magnet.% % Irregularity%on%magnet%contact%or%work\piece.% % Insufficient%current%going%to%magnet%during%drilling%cycles.%

Attach%an%additional%piece%of%metal%under%work\piece%where%magnet%will% be%located,%or%mechanically%clamp%magnetic%base%to%work\piece.% % Clean%magnet.% % Use%extreme%care;%file%any%imperfections%flush%to%surface.% % Confirm%power%supply%and%output%from%control%unit,%check%supply%cable.%

2)%Cutter%skips%out% of%centre\punch% mark%at%initiation%of% cut%

Magnetic%base%is%not%holding%effectively.% % Worn%arbor%bushing%and/or%ejector%collar.% % Too%much%feed%pressure%at%start%of%cut.% % % Cutter%is%dull,%worn,%chipped%or%incorrectly%sharpened.% % Poor%centre\punch%mark;%weak%pilot%spring;%pilot%not%centred% in%centre\punch%mark.% % Worn%or%bent%pilot,%worn%pilot%hole.% % Loose%bolts%on%motor%bushing%support%bracket,%main%casting% or%loose%gib%adjusting%set%screws.%

See%causes%and%remedies%above.% % Replace!%%Only%a%few%thousandths%wear%permissible.%%New%arbor%bushing% is%needed.% Light%pressure%only%is%needed%until%a%groove%is%cut.%%The%groove%then% serves%as%a%stabilizer.% % Replace%or%re\sharpen.%%Sharpening%service%is%available.% % % Improve%centre\punch%and/or%replace%worn%parts% % % Replace%part%or%parts% % Adjust%where%necessary%

3)%Excessive%%%%%%%%%%%%% drilling%pressure% required%

Incorrectly%re\sharpened,%worn%or%chipped%cutter.% % Coming%down%on%swarf%lying%on%surface%of%work\piece.% % Gibs%out%of%adjustment%or%lack%of%lubrication.% % Swarf%accumulated%(packed)%inside%cutter.%

%Re\sharpen%or%replace.% % Take%care%not%to%start%a%cut%on%swarf.% % % Adjust%setscrews,%and%lubricate.% % Clear%cutter.%

4)%Excessive%cutter% breakage%

Steel%swarf%or%dirt%under%cutter.% % Incorrectly%re\sharpened%or%worn%cutter.% % % Cutter%skipping.% % Slide\ways%need%adjustment.% % Cutter%not%attached%tightly%to%arbor.% % Insufficient%use%of%cutting%oil%or%unsuitable%type%of%oil.%

Remove%cutter,%clean%part%thoroughly%and%replace.% % Always%have%a%new%cutter%on%hand%to%refer%to%for%correct%tooth%geometry,% together%with%instruction%sheet.% % See%causes%and%remedies%(2).% % Tighten%sideway.% % Retighten.% % Inject%oil%of%light%viscosity%into%the%coolant\inducing%ring%and%check%that%oil% is%being%metered%into%cutter%when%pilot%is%depressed.%%If%not,%check%pilot% groove%and%arbor%internally%for%dirt%or%apply%oil%externally.%%(Even%a%small% amount%of%oil%is%very%effective).%%

5)%Excessive%cutter% wear%

See%cause%and%remedy%above% % Incorrectly%re\sharpened%cutter.% % % Insufficient%or%spasmodic%cutting%pressure.%

% % Refer%to%instructions%and%a%new%cutter%for%proper%tooth%geometry.% % Use%sufficient%steady%pressure%to%slow%the%drill%down.%%This%will%result%in% optimum%cutting%speed%and%chip%load.%%

' ' ' ' ' '

Page 9

Issue 3 Original Version JUNE 2014

\I +.%?`#*'>/%%+,&)'

Magnet%and%motor%do%not%function%

\%The%magnet%switch%is%not%connected%to%the%power%supply% \%Damaged%or%defective%wiring% \%Defective%fuse% \%Defective%magnet%switch% \%Defective%Control%Unit% \%Motor%forward/reverse%switch%set%to%O%%

Magnet%does%function,%the%motor%does%not%

\%Damaged%or%defective%wiring% \%Carbon%brushes%are%stuck%or%worn%out% \%Defective%magnet%switch%% \%Defective%On%/%off%switch% \%Defective%Control%Unit%% \%Defective%anchor%and/or%field%

Magnet%does%not%function,%the%motor%does%

\%Defective%magnet% \%Defective%Control%Unit%

Hole%cutters%break%quickly,%holes%are%bigger% than%the%hole%cutter%

\%Play%in%the%guide% \%Bent%spindle% \%Shaft%extending%from%the%motor%is%bent%

Motor%running%roughly%and/or%seizing%up%

\%Bent%spindle% \%Shaft%extending%from%the%motor%is%bent% \%Triangular%guide%not%mounted%straight% \%Dirt%between%spindle%and%triangular%guide%

Motor%making%a%rattling%sound%

\%Gear%ring%(bottom%of%the%anchor)%worn%out% \%Gear(s)%worn%out% \%No%grease%in%gear%box%

Motor%humming,%big%sparks%and%motor%has%no% force%

\%Anchor%burned% \%Field%burned% \%Carbon%brushes%worn%out%

Motor%does%not%start%or%fails.%% %

\%Damaged%or%defective%wiring% \%Dirt%in%sensor%Speed%Control%Unit% \%Defective%Speed%Control%Unit%% \%Defective%speed%control%or%its%wiring% \%Defective%or%loose%magnet%on%top%of%anchor%

Guiding%takes%a%great%deal%of%effort%

\%Guide%is%set%too%tight% \%Guide%is%dry% \%Guide/gear\%rack/rotation%system%dirty%or%damaged%

Insufficient%magnetic%force%

\%Damaged%or%defective%wiring% \%Bottom%of%magnet%not%clean%and%dry% \%Bottom%of%magnet%not%flat% \%Work%piece%is%not%bare%metal% \%Defective%Control%Unit% \%Defective%magnet%

Motor%only%runs%at%maximum%rpm%%

\%Defective%speed%switch%% \%Damaged%/%defective%wiring% \%Defective%Control%Unit%

Frame%under%voltage%

\%Damaged%/%defective%wiring% \%Defective%magnet% \%Motor%seriously%dirty%

Fuse%blows%when%magnet%switch%is%turned%on%

\%Damaged%or%defective%wiring% \%Wrong%value%fuse% \%Defective%magnet%switch% \%Defective%Control%Unit% \%Defective%magnet%

Fuse%blows%when%motor%is%started%up%

\%Damaged%or%defective%wiring% \%Wrong%value%fuse% \%Motor%running%roughly%% \%Defective%Anchor%and%/%or%Field% \%Carbon%brushes%worn%out% \%Defective%Control%Unit%

Rotation%system%free%stroke%too%long%

\%Loose%or%defective%gear\rack% \%Defective%rotation%system%

Page 10

Issue 3 Original Version JUNE 2014

97I *b<#%-*-'-,")."('%!'("$/,&*'

$0MX0U2U@'N12U@NWNDA@N0U'W0C'$(567859e;'!"#$%&'

,@2M'&0'

<AC@'&0'

-24DCNX@N0UP'

,@2M'&0'

<AC@'&0'

-24DCNX@N0UP'

RD48153%

Frame%

24%

RD48196%

Screw+washer+nut%

RD48174%

Screw%SSM6x16%

25%

RD38001%

Info%Plate%

RD48175%

Washer%M6%

26%

RD48198%

Panel%screw%M4x8%(rearplate)%

RD48176%

Setting%Nut%

RD48199%

Panel%screw%long%M4x20% (frontplate)%

RD48177%

Setting%Screw%

27%

RD38010%

Front%plate%110V%

RD48178%

Magnet%Hi/Lo%

27%

RD38011%

Front%Plate%230V%

RD48179%

Sensor%

28%

RD48201%

Sensor%LED+cable%

RD48180%

Slide%

29%

RD48202%

On/Off%switch%

RD48181%

Rack%

30%

RD48203%

Fuse%holder%

10%

RD48182%

Screw%SSM6x20%

31%

RD48204%

Fuse%F2A%

11%

RD48183%

Motorholder%

32%

RD4643%

Magnet%switch%

12%

RD48184%

Screw%SSM6x25%

34%

RD48206%

Potentiometer%

13%

RD48185%

Top%fixing%plate%110mm%

35%

RD48207%

L/R%switch%

14%

RD48186%

Brass%rail%set%(stick)%

36%

RD48208%

Control%Unit%Hi/Lo%220v%

15%

RD48187%

Pressing%Strip%4%holes%

36%

RD48209%

Control%Unit%Hi/Lo%110v%

16%

RD48188%

Capstan%hub%assembly%

37%

RD48210%

Cable%clamp%

17%

RD48189%

End%plate%

38%

RD48211%

Motorunit%220v%

18%

RD48190%

End%screw%

38%

RD48212%

Motorunit%110v%

19%

RD48191%

Arm%for%Capstan%

39%

RD38009%

Name%plate%

20%

RD48192%

Motorcable%

40%

RD48256%

Complete%control%unit%

21%

RD48193%

Coupling%nut%for%motorcable%

41%

RD48213%

Cable%housing%

22%

RD48194%

Coupling%nut%for%maincable%

42%

RD48214%

Screw%8%x%35%

23%

RD48195%

Main%Cable%

Page 11

Issue 3 Original Version JUNE 2014

99I *b<#%-*-'-,")."('%!'(%+%.'

$0MX0U2U@'N12U@NWNDA@N0U'W0C'$(567859e;'!"#$%&'

,@2M'&0'

<AC@'&0'

-24DCNX@N0UP'

,@2M'&0'

<AC@'&0'

-24DCNX@N0UP'

51%

RD48215%

Screw%3,9x60%

72%

RD48236%

End%cover%

52%

RD48216%

Adaptor%ring%22x0,2%

73%

RD48237%

Housing%

53%

RD48217%

Needle%bearing%

74%

RD48238%

Circlip%471/10%

54%

RD48218%

Bearing%8x22x7%

75%

RD48239%

Circlip%471/15%

55%

RD48219%

Bearing%12x28x8%

76%

RD48240%

Circlip%472/28%

56%

RD48220%

First%gear%

77%

RD48241%

Inner%gear%plate%

57%

RD48221%

Axle%

77.1%

RD48242%

Gasket%for%gearcasing%

58%

RD48222%

Gear%shaft%

78%

RD48243%

Armature%220v%

59%

RD48223%

Spindle%drive%shaft%

RD48244%

Armature%110v%

60%

RD48224%

Carbon%brush%holder%

79%

RD48245%

Field%220v%

61%

RD48225%

Carbon%brush%set%

RD48246%

Field%110v%

62%

RD48226%

Ringmagnet%

80%

RD48247%

Gear%casing%

63%

RD48227%

Screw%4,8x45%

81%

RD48248%

Key%for%spindle%

64%

RD48228%

Screw%4,8x50%

82%

RD48249%

Key%

65%

RD48229%

Screw%2,8x12%

83%

RD48250%

Casing%pin%

66%

RD48230%

Adaptor%ring%rubber%22x2,5%

84%

RD48251%

Clutch%shaft%

67%

RD48231%

Bearing%20x37x9%

85%

RD48252%

Gear%switch%

68%

RD48232%

Bearing%17x40x12%

86%

RD48253%

Speed%Control%Unit%220v%

69%

RD48233%

Spindle%gear%

RD48254%

Speed%Control%Unit%110v%

70%

RD48234%

Gear%34/40%

87%

RD48255%

Plate%for%gear%casing%

71%

RD48235%

Baffle%

88%

RD38009%

Name%Plate%

Page 12

Issue 3 Original Version JUNE 2014

9JI (",&+*&"&$*'$/*$d>'

In%order%to%‘get%the%best%life’%out%of%your%Rotabroach™%machine%always%keep%it%in%good% working%order.%% A%number%of%items%must%always%be%checked%on%Rotabroach™%machines.% Always%before%starting%any%job%make%sure%the%machine%is%in%good%working%order%and%that% there%are%no%damaged%or%loose%parts.%Any%loose%parts%must%be%tightened.%

`2W0C2'XC0D221NUY'TN@E'AUV'MANU@2UAUD2'T0CR'B2'D2C@ANU'@EA@'@E2'X0T2C'4QXX3V'N4' 1N4D0UU2D@21P'

-24DCNX@N0U'

*^2CV'0X2CA@N0U''

9'T22R'

9'(0U@E'

aN4QA3'DE2DR'0W' MADENU2'W0C'1AMAY2'

%X2CA@N0U'0W'MADENU2'

$E2DR'BCQ4E'T2AC'

$E2DR'MAYU2@ND'BA42'

$E2DR'A3NYUM2U@'0W' @E2'MADENU2'

$E2DR'YC2A42'

$E2DR'"CMA@QC2'

aN4QA33V'DE2DR'@E2'MADENU2'W0C'1AMAY2P'

Machine%must%be%checked%before%operation%for%any%signs%of%damage%that%will%affect%the% operation%of%the%machine.%Particular%notice%must%be%taken%of%the%mains%cable,%if%the%machine% appears%to%be%damaged%it%should%not%be%used%failure%to%do%so%may%cause%injury%or%death.%

' $E2DR'0X2CA@N0U'0W'@E2'MADENU2P'

The%machines%operation%must%be%checked%to%ensure%that%all%components%are%working% correctly.%% % (ADENU2'`CQ4E24'\%should%be%checked%to%make%sure%there%is%no%abnormal%wear%present%this% should%be%checked%at%least%once%a%week%if%used%frequently.%If%the%brush%has%worn%more%than% 2/3%the%original%length%the%brushes%should%be%changed.%Failure%to%do%so%may%cause%damage% to%the%machine.% % (AYU2@ND'BA42%–%before%every%operation%the%magnetic%base%should%be%checked%to%make%sure% that%the%base%is%flat%and%there%is%no%damage%present.%An%uneven%magnet%base%will%cause%the% magnet%not%to%hold%as%efficiently%and%may%cause%injury%to%the%operator.%'

' "1fQ4@M2U@'0W'43N12'AU1'B2ACNUY'BCADR2@'A3NYUM2U@P'

An%essential%requirement%of%the%machine%is%that%the%slide%can%move%in%a%smooth%and% controlled%manner,%free%of%lateral%movement%and%vibration.% This%situation%can%be%maintained%by%periodic%adjustment%of%the%slide%and%is%accomplished%in% the%following%manner:%

1. Place%the%machine%in%an%upright%position%and,%by%means%of%the%capstan,%raise%the%slide% to%its%highest%position.%Clean%the%brass%gib%strips%and%apply%a%small%amount%of%light% machine%oil%to%the%wear%surfaces.%%

Page 13

Issue 3 Original Version JUNE 2014

2. Now%lower%the%slide%back%to%its%lowest%position.%Bring%the%slide%into%the%center%of%the% dovetail%slide%housing%and%loosen%screws%thus%allowing%free%movement%of%the%arbor% support%bracket.%

3. Commencing%with%the%middle%screws,%gently%feed%in%all%the%screws%until%slight% resistance%is%encountered.%

4. Operate%the%slide%up%and%down%a%few%times%to%test%the%movement%and%make%any% further%necessary%adjustments.%Try%to%ensure%that%all%the%screws%are%exerting%a% uniform%pressure%on%the%slide%from%top%to%bottom.%A%perfectly%adjusted%slide%will% operate%freely%up%and%down%without%any%sideways%movement.%

5. Now%raise%the%slide%to%its%highest%position.%%

6. Place%the%machine%on%a%steel%plate,%connect%to%supply%and%switch%on%magnet.%Start%up% the%motor.%If%the%arbor%is%incorrectly%aligned,%the%arbor%support%bracket%will%be%seen% to%oscillate.%Make%any%necessary%further%adjustments%to%the%bracket%to%ensure% correct%alignment%of%the%spindle%and%finally%tighten%the%screws%using%a%spanner.%%

% $E2DR'MADENU24'YC2A42P% The%gearbox%grease%should%be%checked%once%a%month%to%ensure%all%moving%components%are% covered%to%prevent%wear.%The%grease%should%be%changed%at%least%once%a%year%to%ensure%you% gain%the%best%from%the%machine.%

$E2DR'"CMA@QC2'0W'@E2'MADENU2P'

This%should%be%checked%at%least%1%per%month%to%check%that%there%are%visual%signs%of%damage% to%the%body%or%to%the%commutator.%Some%signs%of%wear%will%be%seen%on%the%commutator%over% a%period%of%time%this%is%normal%as%this%is%the%part%that%comes%in%contact%with%the%brushes%but% any%signs%of%abnormal%damage%and%the%part%should%be%replaced.%

Page 14

Issue 3 Original Version JUNE 2014

9;I $?++*.'>*#*$+,%&'"&-'><**->'

(A@2CNA3'

(A@2CNA3'/AC1U244'

$Q@@2C'

Mild%and%free%cutting%steels%

<700N/mm²%

RAP%or%RAPL%

Mild%and%free%cutting%steels%

<850N/mm²%

SRCV%or%SRCVL%

Steel%angle%and%joists%

<700N/mm²%

RAP%or%RAPL%

Steel%angle%and%joists%

<850N/mm²%

SRCV%or%SRCVL%

Plate%and%sheet%steel%

<700N/mm²%

RAP%or%RAPL%

Plate%and%sheet%steel%

<850N/mm²%

SRCV%or%SRCVL%

Aluminium%

<750Nmm²%

RAP%or%RAPL%

Aluminium%

<850N/mm²%

SRCV%or%SRCVL%

Brass%

<700N/mm²%

RAP%or%RAPL%

Brass%

<850N/mm²%

SRCV%or%SRCVL%

Cast%iron%

<700N/mm²%

RAP%or%RAPL%

Cast%iron%

<850N/mm²%

SRCV%or%SRCVL%

Stainless%steel%

<700N/mm²%

RAP%or%RAPL%

Stainless%steel%

<850N/mm²%

SRCV%or%SRCVL%

Stainless%steel%

>850N/mm²%

CWC%to%CWCX%

Rail%track%

>850N/mm²%

SCRWC%or%SCRWCL%

Tool%steel%

>850N/mm²%

CWC%to%CWCX%%

Die%Steel%

>850N/mm²%

CWC%to%CWCX%

Page 15

Issue 3 Original Version JUNE 2014

&%+*>

Page 16

Issue 3 Original Version JUNE 2014

96I''S".."&+]'>+"+*(*&+'

Rotabroach™%warrants%its%machines%to%be%free%from%faulty%materials,%or%workmanship%under%normal%use%for%a%period%of%12%months%from% initial%date%of%purchase%and%90%days%for%all%other%parts%(excluding %cu tt ers) ,%pro vid ed %t ha t%th e %w arra n ty%re gist ratio n %ca rd %(or%online% registration)%has%been%completed%and%returned%to%Rotabroach™,%or%its%de s ig n a t e d %d i st ributor%within%a%period%of%(30)%days%from%the% purchase%date,%failure%to%do%so%will%void%the%warranty.%If%the%stated%is%adhered%to,%Rotabroach™%will%repair%or%replace%(at%its%option)% without%charge%any%faulty%items%returned.% %

This%Warranty%does%not%cover:%

1. Components%that%are%subject%to%natural%wear%and%tear%caused%by%the%use%in%accordance%with%the%operators%instructions%

2. Defects%in%the%tool%caused%by%non\compliance%with%the%operating%instructions,%improper%use,%abnormal%environment%conditions,%

inappropriate%operating%conditions%overload%or%insufficient%serv icin g%o r%m a in ten a nc e.%

3. Defects%caused%by%using%accessories,%components%or%spare%parts%other%than%original%Rotabroach™%parts.%

4. Tools%to%which%changes%or%additions%have%been%made.%

5. Electrical%components%are%subject%to%manufacturer’s%warranty.%

Your%online%registration%can%be%submitted%on%www.rotabroach.co.uk% % The%warranty%claim%must%be%lodged%within%the%warranty%period.%This%requires%the% submission%or%sending%of%the%D0MX32@2%tool%in%question%with%the%original%sales%receipt% which%must%indicate%the%purchase%date%of%the%product.%A%complaint%form%must%also%be% submitted%prior%to%the%return.% This%can%be%found%online%at%www.rotabroach.co.uk.%Failure%to%complete%this%form%will% result%in%the%delay%of%your%claim.% All%goods%returned%defective%must%be%returned%pre\paid%to%Rotabroach™,%in%no%event%shall% Rotabroach™%be%liable%for%subsequent%direct,%or%indirect%loss%or%damage.%

THIS%WARRANTY%IS%IN%LIEU%OF%ANY%OTHER%WARRANTY,%(EXPRESSED%OR% IMPLIED)%INCLUDING%ANY%WARRANTY%OF %MECHANTABLITY%OR%FITNESS%FOR% A%PARTICULAR%PURPOSE.%ROTABROACH™%RESERVE%THE%RIGHT%TO%MAKE% IMPROVEMENTS%AND%MODIFICATIO N S %TO%DESIGN%WITHOUT%PRIOR%NOTICE%

% % % % % %

% % %

dU0TU'AU1'+CQ4@21'S0C31TN12'W0C'gQA3N@Vh'<2CW0CMAUD2'AU1'.23NABN3N@V'