Brobo 3M User manual

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PRODUCT AND MAINTENANCE MANUAL
3M PRECISION DRILLING MACHINE
BROBO WALDOWN (AUST) PTY. LTD.
A.C.N. 098 264 316
A.B.N. 42 098 264 316
65-67 Williams Rd, Dandenong, 3175
PO BOX 4274 Dandenong Sth, 3164
Victoria, AUSTRALIA.
Tel: [phone] Email: [e-mail]
Fax: [phone] Website: www.brobo.com.au
Certified System
Quality
ISO 9001
YOUR NORTH AMERICAN BROBO DISTRIBUTOR IS:

OPERATING MANUAL FOR 3M PRECISION DRILLING MACHINE
TECHNICAL SPECIFICATION i
CHAPTER 1: Installation of the Machine
1.1 Unpacking and Handling the Machine 1
1.2 Parts Checklist 2
1.3 Minimum Requirements 2
1.4 Anchoring the Drill Unit 2
1.5 Connection to Power Source 3
CHAPTER 2: Safety and Accident Prevention
2.1 Operation of the Machine 4
2.1.1 Noise Level 4
2.1.2 Power Supply 5
2.2 General Requirements 5
2.3 Advice for the Operator 5
2.4 Machine Safety Devices 6
2.4.1 Reference Standards 6
CHAPTER 3: Main Functions and Operation of the Machine
3.1.1 Drill Head Pulley & Belt Assembly 7
3.1.2 Safety Eye Shields 7
3.1.3 Depth Adjustment 7
3.1.4 Racklift Assembly 7
3.1.5 Column Support 8
3.2 Preparation for Operation 8
3.3 Operation Recommendations 8
CHAPTER 4: Drawings, Layouts, Assembly and Spare Parts
4.1.1 Assembly Drawing (1 of 5) 9
4.1.2 Assembly Drawing (2 of 5) 10
4.1.3 Assembly Drawing (3 of 5) 11
4.1.4 Assembly Drawing (4 of 5) 12
4.1.5 Miscellaneous Part List 13
4.2 Switch Assembly 14
CHAPTER 5: Maintenance and Selection of Consumables
5.1 Role of the Operator 15
5.2 Maintenance Requirements 15
5.3 General Maintenance of Functioning Components 15
CHAPTER 6: Troubleshoot
6.1 Troubleshooting For Blade and Cutting Problems 17
APPENDIX
i. Hazard/Risk Assessment 1
ii. Warranty 20
9

TECHNICAL SPECIFICATION
MACHINE
SPECIFICATION
3M SERIES (BENCH MOUNTED)
3M SERIES (FLOOR MOUNTED)
DRILLING CAPACITY
32mm
32mm
SIZE OF TABLE
Standard Square
Optional Round
Optional T-Slots
-
-
305 305
-
350
305 305
SPINDLE TRAVEL
101
101
COLUMN DIAMETER
74.6
74.6
MAXIMUM DISTANCE
SPINDLE TO TABLE
340
714
MAXIMUM DISTANCE
SPINDLE TO BASE
530
1208
THROAT DEPTH
191
191
MOTOR kW
1.1
1.1
SPINDLE SPEEDS
(NOMINAL)
STRAIGHT DRIVE
INTERMEDIATE DRIVE
480, 850, 1450, 2500
150, 280, 320, 480, 570, 650, 1800,
2000, 3000
480, 850, 1450, 2500
150, 280, 320, 480, 570, 650, 1800,
2000, 3000
WEIGHT UNPACKED
130kg
145kg
WEIGHT PACKED
149kg
164kg
HEIGHT PACKED (mm)
985
1390
HEIGHT INSTALLED
(mm)
985
1690
BASE AREA (mm)
368 600
368 600
i

WARNING – HEAD HEAVY MACHINE
The 3M drill is heaviest where the drill head is fitted and as such, care must be taken while
relocating or moving the machine.
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CHAPTER 1 - Installation of the Machine
1.1 Unpacking and Handling the Machine
Upon receiving the Brobo Group 3M Drill, the machine should be sitting upright and bolted centrally on top of a
wooden pallet. While the machine is situated on the pallet, position the forklift arms under the pallet between the
runners, keeping in mind that the machine is head heavy and minimal force should be exerted on the electrical
box located beneath the machine (Figure 1). Move the entire unit to an accessible area as close as possible to
the final location.
Carefully remove the packaging surrounding the drill unit and the bolts restraining the drill to the pallet. Once
completed, proceed by elevating the machine away from the pallet base using a sling harness wrapped around
the entire unit ensuring that it is equally supported.Ensure that the floor is as level as possible and enough
clearance is allocated before finally positioning the machine to the desired location.
Once in position, verify that the electrical supply is connected. Attached the 3MT arbour and chuck set (not
provided) into the quill housing, while ensuring that the arbour step correctly mates into the quill housing slot.
Figure 1. Assembly of 3M Drill
PLEASE OBSERVE AND FOLLOW THE INSTALLATION INTRUCTIONS ON PAGE 2
1

WARNING – OPERATING VOLTAGE VARIATION
The drill unit has an inbuilt safety electrical system to protect it against voltage variations. However,
for the machine to operate efficiently, ensure that the drill operates within ± 10% limits of the
recommended voltage on the motor.
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WARNING – EXCEEDING MAXIMUM HEIGHT
Do not extend the height of the machine past the maximum ‘height installed’ indicated (Page i).
Exceeding past this limit will cause the column to extend out of the column support, which might
subsequently cause damage to the machine, as well as causing injury to any person in the vicinity.
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1.2 Parts Checklist
Along with the drill unit, check that the following accessories, packed "loose", are included as follows:
A. ACCESSORIES
i. 1 Operation Manual
1.3 Minimum Requirements
For the machine to function correctly, the room in which the drill unit is to be installed must be in the vicinity of,
and satisfy the following conditions:
415/240V Power Supply
Ambient Temperature:From -10 to + 50 degrees C.
Relative Humidity: Not more than 90%.
Lighting: More than 500 LUX.
1.4 Anchoring the Drill Unit
Prior to anchoring the saw unit, take into considerations the requirements mentioned in Section 1.3 and Section
2.2, and other aspects regarding the usage of the machine such as accessibility to drilled parts and safe access
for the operator.
The drill unit arrives fastened to the shipping pallet using 3 M16bolts provided. When positioning and fastening
the drill, please refer to the hole locations shown in Figure 2.
Figure 2. Anchoring Hole Location
2
FLOOR MOUNT
BENCH MOUNT

VOLTAGE MAIN VOLTAGE
415/240V 3 PH 240V
1.5 Connection to Power Source
Before connecting the machine to the power supply, check that the socket is not connected in series with other
machines. This condition is critical for the ideal operation of the drill (Referring to Figure 3for wiring of “4-CORE”
power supply cable from the machine to a power plug. Check that the spindle rotary direction and change the
phasing if required; clockwise rotation observing top-down on top of the motor pulley.)
Note that single-phase machines are supplied in Australia with 15-amp plug).Furthermore, ensure that all the
electrical leads and cables (including supply leads) are well maintained and should be immediately replaced if cut,
sliced or damaged in any manner.
Figure 3. Connection for “4-CORE” Wire System with Neutral
To connect the machine to the power supply, proceed as follows:
1) Insert the power plug into the socket, while
ensuring that the mains voltage is compatible for
which the drill is operating at.
2) Inspect that the power switch on the main box is
closed and set to OFF position.
3) To prepare the machine for operation, release the STOP/EMERGENCY STOP button by twisting the red
mushroom button. To activate the drill, engage the green START button.
4) If all of the above procedures have been carried out correctly, the drill should now be operational
The Brobo Group 3M Drillis now ready for use. Chapter 3 provides a detailed description of the various
functional features of the drill and its operating cycle.
3

WARNING – UNAUTHORISED MODIFICATIONS/REPLACEMENTS/USE
The manufacturer declines any responsibility whatsoever, either civil of criminal, in the case of
unauthorised interference or replacement of one or more parts or assemblies on the machine, or if
accessories, tools and consumable materials are used that are different from those recommended
by the manufacturer himself or if the machine is inserted in a plant system and its proper function is
altered.
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CHAPTER 2 - Safety and Accident Prevention
The Brobo Group 3M Drill has been designed and manufactured in accordance to Australian Standards. It is
HIGHLY RECOMMENDED that the instructions and warnings contained in this chapter be carefully followed for
correct usage of the machine.
2.1 Operation of the Machine
The Brobo Group 3M Drill is specifically design to drill through ferrous metal cross sections with thin-walled or
‘plate’ profiles. Other types of material and machining are not compatible for use with the specifications of the
drill. This machine involves high-speed revolutions; therefore extreme caution is required when operating
the device.
The employer is responsible for instructing the personnel who, in turn, are obliged to inform the operator of any
accident risks, safety devices, noise emission and accident prevention regulations provided for by national and
international laws governing the use of the machine. The operator must be perfectly aware of the position
and functions of all the machine’s controls.
All those concerned must strictly adhere to ALL instructions, warnings and accident prevention
standards in this manual.
The following definitions are those provided for by the EEC DIRECTIVE ON MACHINERY No. 98/37/CE:
Danger Zone - any zone in and/or around a machine in which the presence of a person constitutes a risk
for the safety and health of that person.
Person Exposed - any person finding him or herself, either completely or partly in a danger zone.
Operator -the person or persons given the responsibility of installing, operating, adjusting, maintaining,
cleaning, repairing and transporting the machine.
2.1.1 Noise Level
The noise level of an idling drill unit has been measured to be below 85 dBA.This complies with the Australian
Occupational Health and Safety (Noise) Regulations 1992.
Please note that peak impulse noise levels will be experienced due to variables including drill characteristics,
type, and condition. This will also vary accordingly depending on the size and type of sample being drilled.
Under these circumstances, management should make available to the operator(s) the appropriate hearing
protection equipment as prescribed under the above stated act.
4

2.1.2 Power Supply
The 415/240V power supply requirements for this machine are of a high level and unauthorised interference and
or inadequate maintenance could result in a situation that could put the operator at risk. A qualified electrical
engineer should be assigned to maintain and repair the system.
2.2 General Requirements
Lighting
Insufficient lighting during the operation of the drill unit would constitute a safety hazard for the people concerned.
For this reason, the user of the machine must provide adequate lighting in the working area to eliminate areas in
shadow, whilst also preventing dazzling illumination sources (reference standard ISO 8995 - 2002 ‘Lighting of
Indoor Workplaces’).
Connections
Check that the power supply cables, compressed air supply and/or coolant system complies with, and are
operating within the acceptable range of the drill capabilities. Faulty, damaged or worn components must be
replaced immediately.
Earthing Systems
The installation of the earthing system must comply with the requirements stated in the IEC Standards Part 195:
Earthing and Protection Against Electric Shocks 1998.
2.3 Advice for the Operator
Protective eyewear or goggles must be worn at all times while attending and operating the
drill.
Ensure that hands and arms are kept clear of the drilling zone when the machine is
operating.
Do not wear oversize clothing with long sleeves and oversize gloves, bracelets, necklaces or
any other loose object that may become entangled in the machine’s tooling bit during drilling.
Long hair must be tied back or placed in a hair net.
Always disconnect the power supply to the machine before carrying out any maintenance
work or adjustments. This includes cases of abnormal operations of the machine.
The operator MUST NOT conduct any risky operations or those not required for the drilling in
course (eg. remove swarf shavings from the machine while drilling). Never move the 3M drill
while the machine is operating.
Always keep the workplace areaas clean as possible. Remove equipment, tools or any other
objects from the drilling zone.
5

Support the work piece on both sides of the machine to prevent it falling or jamming during
the drilling cycle.
If the drill bit is jammed, press the emergency stop push button immediately. Do not
continue forcing the bit through. This could damage the drill, the specimen or be a cause for
potential injury to the operator.
Always turn off the machine before carrying out any repair work. Consult the Brobo Group
Engineering Department in the country in which the machine was initially purchased.
2.4 Machine Safety Devices
This product and maintenance manual is not purely intended as a guide for the usage, operation and
maintenance of the drill unit in a strictly production environment; it is instead an instrument to providing
information on how to use the machine correctly and safely. The following standards listed in section 2.4.1, which
are applicable to the Brobo Group 3M Drill,are those specified by the EEC Committee that governs safety of
machinery, health and safety at work, personal protection and safeguarding of the work environment. In addition,
the saw also complies with the Australian Standards regarding the safeguarding and general requirements for
electrical equipment.
2.4.1 Reference Standards
MACHINE SAFETY
EEC Directive No. 98/37/CE -Machines Directive
EEC Directive No. 91/368 -94/68 - Amends sections of EEC Directive No. 98/37/CE relating to machine
safety
EEC Directive No. 73/23 - Low Voltage Directive
AS4024.1 -1996 - Safeguarding of Machinery
HEALTH AND SAFETY AT WORK
AS3100 -2002 - General Requirements for Electrical Equipment
Operational Health and Safety (OHS) 1995.81/1995 - Compliance References
EEC Directive No. 80/1107; 83/477; 86/188; 88/188; 88/642 - Protection of Workers against risks caused
by exposure to physical, chemical and biological agents in workplace
EEC Directive No. 73/23 and Special EEC Directives No. 89/654;89/655 -Improvements in health and
safety at work
6

CHAPTER 3 - Main Functions and Operation of the Machine
3.1.1 Drill Head – Pulley & Belt Assembly
The full set of motor drive, intermediate and quill pulleys are all housed within the protective drill guard cover.
Facing the front of the drill unit, the spindle speed setting is located on the right hand side of the cover, beneath
the locking mechanism. To change the spindle speed settings, the user must manually change the V-belt
positions as shown in the black panel.
3.1.2 Safety Eye Shields
As the name suggests, the safety eye shield should be lowered into position prior to drilling to prevent any swarf
dislodging in the direction of the user.
3.1.3 Depth Adjustment
Situated beneath the 3-pronged handle boss is the depth adjustment gauge. Using the gauge and the scale
indicator shown on the left hand side of the drill, the operator can manually set the desired depth for a drill hole
and lock its position.
3.1.4 Racklift Assembly
Available in round or rectangular profile, all workpiece is
fastened to the racklift table using a standard mechanical vie
(not provided). The racklift can be adjusted up or down via
the rack handle, to obtain optimum user working height.
2
4
5
KEY:
1. Drill Head –Pulleys and Belt Assembly
2. Safety Eye Shields
3. Depth Adjustment
4. Racklift Assembly
5. Column Support
7
1
3
Figure 4. Electrical Unit

3.1.5 Column Support
Prior to usage, ensure that the column support is securely fastened to the ground using the 3 x M16 bolt holes
provided (see Figure 2).
3.2 Preparation for Operation
The following procedure is recommended for the correct drilling using the Brobo Group 3M Drill.
PROCEDURE
i) Clean the workpiece to ensure it is free of any grit, swarf or flammable substances. It is highly
recommended that a solvent be used to remove any residue, while ensuring the solvent is inflammable and
non-toxic.
ii) Prior to drilling, clear the drill and the work area around the work piece of any swarf or/and tools to
minimise the likelihood of the user getting injured during the drilling operation.
iii) Load the workpiece into the mechanical vice (sold separately), located on the racklift, and fastened
workpiece securely. Loosen the racklift and adjust the height and horizontal position. Once you have
position the workpiece into the desired location, relock the racklift assembly.
iv) Check that the correct speed drill speed setting is selected, and the safety eye shield is directly positioned
to deflect swarf and any dislodged particles.
v) Turn the machine on. Proceed by slowly drilling into the workpiece until a guide indent is created. Steadily
increase the feed rate of drilling by applying a constant yet steady force on the feed handle until the desired
hole depth is reached.
vi) Reverse the direction of the drill fed until it come to rest in its start position and turn the drill machine off.
3.3 Operation Recommendations
To reduce the amount of frictional contact between the drill bit and work piece, a light coating of oil or
lubricant can be applied onto the drill bit price to drilling.
Do not force the drill bit through the workpiece as this significantly reduces the lifespan of the bit, as well as
increasing the risk of the bit bending and/or breaking and injuring the operator.
When drilling through larger hole diameters through thick materials, its is advisable to split the drilling
operation into two or three stages, starting from drilling a smaller hole size and increasing it until the
desired final hole size.
8

CHAPTER 4 - Drawings, Layouts, Assembly and Spare Parts
4.1.1 Assembly Drawing (Sheet 1 of 5)
9

4.1.2 Assembly Drawing (Sheet 2 of 5)
10

4.1.3 Assembly Drawing (Sheet 3 of 5)
11

4.1.4 Assembly Drawing (Sheet 4 of 5)
12

4.1.5 Miscellaneous Part List
Please find below of most commonly replaced spare parts, aside from those specified on pages 9 -12. These
listed parts draw reference to components found predominantly on the rack lift assembly and drill column support.
Should you require a spare part that you are not familiar with, or not shown in Chapter 4, please contact Brobo
Group Engineering department.
PART NUMBER
SPARE PART DESCRIPTION
1132010
BASE, FLOOR TYPE
2112010
COLUMN SUPPORT ( use with Floor Base)
2114060
COLUMN, FLOOR (Solid, 1220mm)
1035190
COLUMN, BENCH (Solid, 767mm)
2122020
COLUMN CLAMP (includes 1042000 & 2124050)
2121310
RACKLIFT ASSEMBLY, COMPLETE (Floor Type)
1041080
RACKLIFT ASSEMBLY, COMPLETE (Bench Type)
2114010
RACK
2111140
WORMWHEEL & BUSH ASSEMBLY
2114020
WORM
2114040
SPINDLE WORMWHEEL
2111170
SPINDLE & EXTENSION ASSEMBLY
2111300
QUILL ASSEMBLY
2125200
MOTOR (0.75kW, 1HP, 1PH, TEFC)
2125180
MOTOR (0.75kW, 1HP, 3PH, TEFC)
13

4.2 Switch Assembly
14

CHAPTER 5 – Maintenance and Selection of Consumables
5.1 Role of the Operator
The person operating and maintaining the Brobo Group 3M Drill must familiarise themselves with these
instructions for their own safety and that of others, in addition to safeguarding the production of the machine.
Responsibility must be taken by the user on the general maintenance and up keeping of the unit as specified in
this chapter, with particular emphasis on:
Check to ensure that other operators of the machine always aware of and comply with the relevant safety
instructions and standards as specified in Chapter 2 -Safety and Accident Prevention. Therefore, check
that the safety devices are operational and work perfectly and that personal safety requirements are
complied with.
Ensure that the working cycle is efficient and guarantees maximum productivity, inspect the:
-Functions of the main components of the machine
-Sharpness of the drill bits and lubricating fluid
-Correct working parameters for the type of material being drilled
Verify that the quality of each drilled hole meets the requirements and that the final product is free from
any machining defects.
5.2 Maintenance Requirements
All maintenance must be carried out with the power switched off and the machine in emergency stop
condition.
To guarantee perfection operation, all spare parts must be Brobo Group originals.
On completion of maintenance works, ensure that the replaced parts or any tools used have been
removed from the machines before starting it up.
Any behaviour not in accordance with the instructions for using the machine specified in this manual may
create hazards and/or safety risks for the operator.
Therefore, read and follow all the instructions for use and maintenance of the machine and those on the
product itself.
5.3 General Maintenance of Functioning Components
The general maintenance operations that should be carried out regularly are as follows:
i) Keep the rack lift table, overall machine and path of the drilling free of any offcuts, accumulated swarf and
lubricants by using compressed air or preferably thread-free cloth.
ii) Lubricate the drill shaft and rotary chuck regularly with an NLGI 2 extreme pressure grease, Shell Alvania
No.1 grease or equivalent.
iii) Check the belt condition and tension regularly. Do not over tighten belts, as this will inadvertently exert
tension on the spindle and motor bearings. To provide the right tension, follow the belt manufacturer’s
recommendations and specifications.
15

iv) Clean and lubricate any moving joints or sliding surfaces with good quality oil.
v) Clean the drill machine regularly and keep any unpainted surfaces lightly oiled to protect from rust and
corrosion.
vi) Ensure that the machine performs drill perpendicular to the work surface. If not, contact Brobo Group
engineering department.
16

CHAPTER 6 - Troubleshoot
6.1 General Troubleshooting
Below lists of some of the most common problems associated with the Brobo Group 3M Drill and the
recommended troubleshooting procedures to undertake to rectify the situation. If the solutions provided do not
resolve the problems, or the problem identified differs from those listed, immediately contact Brobo Group
engineering department.
PROBLEM IDENTIFIED
DIAGNOSIS
SOLUTIONS
Drilling is not at 90 ° , or is
angled to the rack lift table
Drill bit not turning
penetrating the material
Work piece not held firmly in vice
clamp
Excessively fast feed rate forcing the
drill bit through the material
Drill bit is not locked properly inside
the chuck unit
Work piece exceeds the
recommended drilling capacity
V-Belt slipping
Blunt drill bit
Excessive swarf trapped in the drill
hole
Ensure that the vice clamps is
securely fastened to the work piece
prior to drilling.
Slow down the drill feed rate, else it
might cause the drill bit to break and
cause harm to the operator.
Check that no swarf is lodged in the
chuck unit. Remove aggregate using
an air gun. Also check that the
chuck teeth are not worn. If so, the
chuck unit might need to be
replaced.
Please ensure that the work piece
required drilling area does not
exceed the recommended drilling
capacity.
Check that the motor/pulley belts are
not worn and if so, promptly replace
them. The V-belts are available for
purchase from Brobo Group.
Replace or resharpen the drill bit to
continue with the drilling process. To
reduce the amount of friction
between the drill bit and parent
material, apply a light coating or
grease/lubricant onto the drill bit prior
to drilling.
Back off the feed rate on the drill.
Use an airgun to clean out any
remaining swarf in the hole. Reapply
lubricant on the drill bit and continue
with the drilling process.
17
X"