Euroboor RAIL.60S User manual

Serial number:
Date of purchase:
/ /
Don’t forget to register your machine at:
www.euroboor.com/register
[ only when registered you benefit from extended warranty ]
User manual
10-2019
For framenumbers:
60S1901xxx
Rail drilling machine
RAIL.60S

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Congratulations on purchasing this premium rail drilling machine. At Euroboor we strive to exceed
our customers’ expectations by developing and providing premium and innovative portable drilling
and cutting solutions. We believe that a professional like you must be able to rely on a professional
supplier. Which has led us to become a major player in the industrial world, with our own factory and
several offices worldwide. All because we have always listened to our customers and to the demands
from the market.
Our vision is focused on developing innovative portable tools that add value for our customers and
facilitate them in their daily work. We never lose sight of sustainability, time savings and cost savings.
Enjoy your new machine!
Before operating your new rail drilling machine, please first read all instructions. You find the
instructions in this manual and on the warning label on your machine. With proper use, care and
maintenance your machine will provide you with years of premium drilling performance.
TO REDUCE THE RISK OF INJURY USER MUST READ AND UNDERSTAND ALL INSTRUCTIONS
To view all our offices and their contact information please visit:
www.euroboor.com

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Table of contents
Inhoudsopgave
1. Safety........................................................................................................................................4
1.1 General safety instructions.............................................................................................................4
1.2 Specific safety information.............................................................................................................6
2. Description................................................................................................................................7
2.1 Intended use...................................................................................................................................7
2.2 Description and features ................................................................................................................7
2.3 Box contents...................................................................................................................................8
2.4 Serial number .................................................................................................................................8
2.5 Technical data.................................................................................................................................9
2.6 Rail adapter ....................................................................................................................................9
2.7 Symbols ........................................................................................................................................10
2.8 Environmental ..............................................................................................................................11
3. Preparation & adjustment .......................................................................................................12
3.1 Assembly.......................................................................................................................................12
3.2 Prior to use ...................................................................................................................................12
4. Using the machine ...................................................................................................................14
4.1 Control panel................................................................................................................................14
4.2 Morse Taper spindle.....................................................................................................................15
4.3 Gearbox ........................................................................................................................................16
4.4 Switching motor on and off..........................................................................................................17
4.5 Motor speed control ....................................................................................................................17
4.6 Temperature control ....................................................................................................................17
5. Working with operation tools ..................................................................................................18
5.1 Annular cutters.............................................................................................................................18
6. Maintenance ...........................................................................................................................20
7. Trouble shooting .....................................................................................................................22
8. Exploded view & spare parts list ..............................................................................................23
8.1 Exploded view...............................................................................................................................23
8.2 Spare part list................................................................................................................................26
8.3 Exploded view & spare parts rail adapter ....................................................................................28
8.4 Wiring diagram.............................................................................................................................31

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1. Safety
1.1 General safety instructions
Do not use this rail drilling machine before you have thoroughly read and completely understood this
manual, specifically the “General safety instructions” and ‘’Specific safety information’’ , including
the figures, specifications, safety regulations and the signs indicating DANGER, WARNING and
CAUTION.
WARNING: When using electrical tools basic safety precautions should always be followed to
reduce the risk of fire, electrical shock and personal injury.
Please also observe the relevant national industrial safety regulations. Non-observance of the safety
instructions can lead to an electric shock, burns and/or severe injuries.
This manual should be kept for later use and enclosed with the rail drilling machine, should it be
passed on or sold.
Work area
1. Keep your work area clean and well lit. Cluttered and dark work areas increase the change of
accidents.
2. Do not operate a rail drilling machine in explosive atmospheres, such as in the presence of
flammable liquids, gases or dust. A rail drilling machine may create sparks which could ignite
the dust or fumes.
3. Keep bystanders, children and visitors away while operating a rail drilling machine.
Distractions can cause you to lose control.
Electrical safety
1. A rail drilling machine plug must match the outlet. Never modify the plug in any way. Do not
us any adapter plugs.
2. Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators.
There is an increased risk of electric shock if your body is grounded.
3. Do not expose the rail drilling machine to rain or wet conditions. Water entering a machine
will increase the risk of electric shock.
4. Do not abuse the cord. Never use the cord to carry the rail drilling machine or pull the plug
from an outlet. Keep the cord away from heat, oil, sharp edges or moving parts. Replace
damaged cords immediately. Damaged cords increase the risk of electric shock.
5. When operating a rail drilling machine, use an extension cord suitable for outdoor use, this
reduces the risk of electric shock.
6. If operating a rail drilling machine in a damp location is unavoidable, use a residual current
device (RCD), this reduces the risk of electric shock.

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Personal safety
1. Stay alert, watch what you are doing and use common sense when using a rail drilling
machine. Do not use the machine while tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating a rail drilling machine may result in
serious personal injury.
2. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves
away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.
3. Avoid accidental starting. Be sure the switch is off before plugging the machine in. Carrying a
rail drilling machine with your finger on the switch or plugging in a rail drilling machine that
has the switch on increases the change of accidents.
4. Never place hands, fingers, gloves or clothing near drilling area or rotating machine parts.
5. Remove adjusting keys or switches before turning the machine on. A wrench or a key that is
left attached to a rotating part of the machine may result in personal injury.
6. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance
enables better control of the rail drilling machine in unexpected situations.
7. Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard
hat and hearing protection must be used for optimal safety.
When using this machine, you MUST wear ear and eye protection.
Machine use and care
1. While operating the machine, the annular cutter must be cooled and lubricated
2. Always remove the slug from the annular cutter after each hole. Caution; the slug may be
hot!
3. Do not use the machine when the switch does not turn it on or off. Any machine that cannot
be controlled with the switch is dangerous and must be repaired.
4. Disconnect the plug from the power source before making any adjustments, changing
accessories or storing the tool. Such preventive safety measures reduce the risk of starting
the tool accidentally.
5. Store your rail drilling machine out of reach for children and other untrained persons. Tools
are dangerous in the hands of untrained users.
6. Maintain your machine with care. Keep cutting tools sharp and clean. Properly maintained
tools, with sharp cutting edges are less likely to break and are easier to control.
7. Check for misalignment of moving parts, breakage of parts and any other condition that may
affect the machine’s operation. If you detect damage have the machine serviced before use.
Many accidents are caused by poorly maintained tools.
8. Only use accessories that are recommended by Euroboor for your machine model.
Accessories that are suitable for one machine may become hazardous when used on another
machine.

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Service
1. Tool service must be performed only by qualified repair personnel. Service or maintenance
performed by unqualified personnel could result in risk of injury.
2. When servicing a tool, use only identical replacement parts. Follow instructions in the
maintenance section of this manual. Use of unauthorized parts or failure to follow
maintenance instructions may create a risk of electric shock or injury.
3. Euroboor offers Armature kits containing official Euroboor spare parts suitable for your rail
drilling machine.
1.2 Specific safety information
•Keep your fingers away from the drilling area;
•Avoid touching the slug that is automatically ejected by the pilot pin when the working
procedure is finished. Contact with the slug when it is hot, or if it falls, can cause personal
injuries;
•Do not switch on the machine before checking whether the stand has been tightened firmly
to the mounting surface;
•Adjust the machine so cutter does not extend into the workpiece before drilling. Do not
perform any design, assembly or construction activities on the workpiece while the machine is
switched on;
•Before switching on the machine, make sure all accessories have been mounted correctly;
•Do not switch on the machine until it has been mounted and installed according to all above
mentioned instructions;
•Always use the recommended speed for the accessories and material you are working with;
•Do not use the machine on the same workpiece on which electric welders are working;
•In case of a jammed cutter, turn of the machine, disconnect the machine from the power
supply and then remove the reason for the jam before turning on the machine again.
Residual risk
In spite of following the relevant safety regulations and their implementation, certain residual risks
cannot be avoided.
These are:
•Impairment of hearing
•Risk of personal injury from flying particles
•Risk of burns due to accessories becoming hot during operation
•Risk of personal injury due to prolonged use.
Always try to reduce these risks as much as possible.

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2. Description
2.1 Intended use
This rail drilling machine is intended for commercial use as a drilling machine for drilling. Use always
tools and accessories recommended by Euroboor.
2.2 Description and features
[image 1-1]
1 Gearbox guide
2 RPM dial
3 Output shaft
4 Morse Taper spindle
5 Feed Handle
6 Motor Switch
7 Fuse holder
8 Magnet switch
9 Rail adapter

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2.3 Case content
1 x RAIL.60S+ rail drilling machine
3 x handles
1 x hex key 2.5 mm
1 x hex key 4 mm
1 x hex key 5 mm
1 x arbor MT 3 –19,05 (3/4")
1 x morse taper ejector drift key
1 x user manual
1 x safety ear protection
1 x safety goggles
1 x safety gloves
2.4 Serial number
The serial number is mentioned on the machine two times: engraved on the frame and on the serial
no. sticker on the motor housing. Additional serial no. stickers are provided with the machine for
your administration.
The serial number will help you, your dealer and Euroboor to validate and identify the machine.
For example:
060S1909001
breaks down to:
060S 19 09 001
Machine series
Year of manufacture
Month of manufacture
Identification number

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2.5 Technical data
Metric
Imperial
Annular cutting
Ø 12 –36 mm
Ø 7/16" –1 7/16"
Length
262 mm
10 5/16"
Width
130mm
5 1/8"
Height
597 –747 mm
23 1/2" –29 7/16"
Stroke
170 mm
6 11/16"
Weight
14,5 kg
32 lbs
Motor power
1600 W
14.5 A
Total power
1700 W
15.5 A
Speed (no load)
Speed (load 1600 W)
[I] 60 –275 rpm
[II] 100 –500 rpm
[I] 60 –275 rpm
[II] 100 –500 rpm
Spindle (Weldon)
MT3 19,05 mm
MT3 3/4"
Voltage
110 –120 V / 60 Hz
220 –240 V / 50 –60 Hz
2.6 Rail Adapter
The rail drilling machine is specifically designed for drilling in rails. The rail drilling machine is
available in various versions, ensuring there is always the right rail adapter for the job. The rail
adapter versions that we offer are: S49, S54, TR68, UIC50, UIC54 and UIC60.

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2.7 Symbols
Symbol
Term, meaning
Explanation
Read documentation
Be absolutely sure to read the documentation in
this user manual and specifically the “General
safety instructions” and ‘’Specific safety
information’’.
Wear ear protection
Use ear protection during operation.
Wear eye protection
Use eye protection during operation.
Danger/warning/caution
Read and apply the information in the adjacent
text!
European conformity symbol
Confirms the conformity of the rail drilling machine
with the directives of the European Community.
Class of protection I
Product with basic insulation and exposed
(touchable) conductive parts additionally
connected to the protective earth conductor.
mm
Millimeter
Unit of measurement for length, width, height or
depth.
kg
Kilogram
Unit of measurement for the mass.
V
Volt
Unit of measurement for the electric voltage.
A
Ampere
Unit of measurement for the electric current
.intensity
W
Watt
Unit of measurement for the output.
rpm
Revolutions per minute
Unit of measurement for the revolutions.
no
No load speed
Revolution speed at no load.

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2.8 Environmental
Separate collection. This product must not be disposed of with normal household waste.
Separate collection of used products and packaging allows materials to be recycled and used
again. Re-use of recycled materials helps prevent environmental pollution and reduces the
demand for raw materials.
Local regulations may provide for separate collection of electrical products from the household, at
municipal waste sites or at the retailer when you purchase a new product.

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3. Preparation & adjustment
3.1 Assembly
WARNING: To reduce the risk of injury, turn machine off and disconnect from power source
before installing and removing accessories, before adjusting or changing set- ups or when
making repairs. Be sure all switches are in the OFF position. An accidental start-up can cause
injury.
Fitting the feed handles
1. Fit each of the three feed handles by screwing them into the hub in clockwise direction.
2. Tighten firmly by hand.
The handles are supposed to face slightly outward. Be careful not to cross-thread any of the
components.
3.2 Prior to use
Check the machine for possible damage; Before using the machine, you must carefully check the
protective components or slightly damaged components to ensure they are operating perfectly and
as intended.
Check that moving parts are in perfect working order, do not jam and check whether the parts are
damaged. All parts must be correctly installed and fulfill all conditions necessary to ensure perfect
operation of the machine.
Damaged protective components must be repaired or replaced according to specifications by
Euroboor or any authorized Euroboor dealer.
DO NOT use under wet conditions or in presence of flammable liquids or gases.
DO NOT let children come into contact with the machine. Supervision is required when
inexperienced operators use this machine.
Electrical safety
The electric motor has been designed for one voltage only. Always check that the power supply
corresponds to the voltage on the rating plate.
Your Euroboor rail drilling machine is designed in class I (grounded) according to EN 61029-1. Earth
wire is required.
If the supply cord is damaged, it must be replaced by a specially prepared cord available at Euroboor
or your Euroboor dealer.
Extension cable
If an extension cable is required, use an approved 3-core extension cable suitable for the power input
of this machine (see technical data).The minimum conductor size is 1.5 mm²; the maximum length is
30 meter. When using a cable reel, always unwind the cable completely.

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Useful tips
–Try a few simple projects using old rails until you develop a ‘feel’for the rail drilling machine
–Let the machine run in for a period of eight to ten hours before starting with big operations
Do not load the machine too much during this run-in period.
–Never use the machine with serious overload
–Keep the machine clear from moisture at all times to protect the machine, yourself and
others

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4. Using the machine
WARNING: Always observe the safety instructions and applicable regulations.
WARNING: To reduce the risk of serious personal injury, turn the machine off and disconnect
the machine from power source before making any adjustments or removing/installing
attachments or accessories.
4.1 Control panel
The control panel on your rail drilling machine is designed for maximum ease of use and safety.
1. Motot Switch.
2. Magnet LED Indicator
3. Fuse Holder
4. RPM Dial
5. Magnet Switch
[image 2-2]

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4.2 Morse taper spindle
[image 2-3] [image 2-4]
1. Make sure the inside of the output shaft and the Morse Taper spindle are clean and free of
grease;
2. Align the coolant ring rotation limiter with the recess in the gearbox (A);
3. Firmly slide the Morse Taper spindle into the output shaft by hand (B). Make sure the spindle
is properly positioned. You should not be able to pull it out by hand;
4. To remove the Morse Taper spindle:
-Switch of the motor;
-Rotate the mechanical gear switch to neutral (see chapter Gearbox 4.3);
-Rotate the output shaft until the slots on the shaft align with the slots on the gearbox;
-Gently tap the supplied drift into the slots to push the Morse Taper arbor out.

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4.3 Gearbox
1. To select the correct gear from neutral (horizontal) position:
a. Rotate the switch counter clockwise to position o, this is gear 1.
b. Rotate the switch clockwise to position oo, this is gear 2.
2. A gear is only correctly selected when the gearbox switch is aligned with the indicators on
the gearbox.
In case you have trouble fully and correctly selecting a gear, the gears in the gearbox might be
misaligned. Slightly rotating the output shaft by hand will help you align the gears correctly and fully
select the intended gear.
3. Speed selection for annular cutters (also see plate on gearbox):
oØ 27-60 mm Rotating speed 60-275 rpm
oo Ø 12-26 mm Rotating speed 100-500 rpm
[image 2-5]
WARNING: never touch moving machine parts!

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4.4 Switching motor on and off
The motor unit can only be switched ON when the magnet switch is activated. Although it is a rail
drilling machine, there is a magnet switch. The machine is in fact a converted magnetic drilling
machine. To switch the motor ON, press the green button with marking “I”. To switch the motor OFF,
press the red button with marking “O”.
4.5 Motor speed control
The RPM dial allows you to electronically control the speed of the motor (in both clockwise and
counter clockwise direction).
-The indicator of the RPM dial in bottom left corner is minimum speed.
-The indicator of the RPM dial in bottom right corner is maximum speed.
The electronic motor speed control works for both mechanical gears. Be careful not to overturn the
dial.
4.6 Temperature control
This machine is equipped with an all-time electronic temperature protection. If the temperature of
the motor unit runs up to 70 Degree Celsius the motor unit will stop. After a few minutes it can be
started again. When it is possible to start the motor again, let the motor run idle at full speed for a
couple of minutes to let the motor cool down more in an efficient way.

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5. Working with drilling accessories
5.1 Annular cutters
Annular cutters only cut material at the periphery of the hole, rather than converting the entire hole
to shavings. As a result, the energy required to make a hole is lower than for a twist drill.
When drilling with an annular cutter, it is not necessary to drill a pilot hole.
WARNING: Do not touch the cutter or the parts close to the cutter immediately after
operation, as they may be extremely hot and cause burns to the skin. Ensure nobody is in the
work area where the metal core (slug) is ejected.
Drilling conditions
The ease with which material can be drilled depends on several factors including tensile strength and
abrasion resistance. Whilst hardness and/or strength is the usual criterion, wide variations in
machinability can exist among material showing similar physical properties.
The drilling conditions are dependent on requirements for tool life and surface finish. These
conditions are further restricted by the rigidity of the tool and the workpiece, lubrication and
machine power available. The harder the material, the lower the cutting speed.
Some materials of low hardness contain abrasive substances leading to rapid cutting edge wear at
high speeds. Feed rates are governed by rigidity of set-up, volume of material to be removed, surface
finish and available machine power.
Drilling a hole
Now that you have read the information and safety recommendations above, you are ready to
actually start drilling. Follow these 12 steps for best drilling result :
1. Install the annular cutter.
-Place the pilot pin into the cutter;
-Align the flat faces on the cutter shank with the screws in the tool holder;
-Make sure the cutter shank is entered fully and correctly;
-Tighten the screws;
[image 3-1]

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2. Precisely mark the center of the hole.
3. Use the pilot pin to position the machine in the correct position, with the tip of the pilot pin
to meet the marked center of the hole.
4. Switch on the machine and verify that the drill is in the right position and that the machine is
pushed tight against the work piece.
5. Switch the motor on and allow it to run at the required speed.
6. Turn the feed handles to start drilling. Apply only a slight pressure when the annular cutter
touches the metal. Do not push the annular cutter with force into the metal.
7. Apply a regular pressure while drilling. The drilling performance does not improve by putting
more pressure on the machine. Too much pressure will overload the motor and your annular
cutter will be worn sooner.
A continuous, non-discoloured iron swarf is a sign of correct drilling speed and a well-
cooled, sharp cutter. Let the cutter do the job and give it time to cut the metal!
8. Apply less pressure when the drill cuts through the material. The slug will be pushed out of
the cutter by the pilot pin.
9. Turn the feed handles to put the motor in highest position and switch off the motor unit.
10. Remove the burrs, metal chips and clean the cutter and surface without getting injuries.
Caution: The slug can be sharp and very hot!

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6. Maintenance
Your Euroboor rail drilling machine has been designed to operate over a long period of time.
Continuous satisfactory operation depends upon proper tool care and regular cleaning.
CAUTION: To reduce the risk of injury, turn the machine off and disconnect machine from
power source before installing and removing accessories, before adjusting or changing set-
ups or when making repairs. Be sure the switch is in the OFF position. An accidental start-
up can cause injury.
Just as every rail drilling machine with moving parts, your Euroboor rail drilling machine also needs
regular maintenance service. A few recommendations follow :
Visually check the machine for damage
The machine must be checked before operating for any signs of damage that will affect the operation
of the machine. Particular notice must be taken of the main cable, if the machine appears to be
damaged it should not be used. Failure to do so may cause injury or death.
Cleaning
-Clean all dirt, dust, metal chips and burrs of your rail drilling machine;
-Blow dirt and dust out of the main housing with dry air as often as dirt is seen collecting in and
around the air vents. Wear approved eye protection and an approved dust mask;
-Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool.
These chemicals may weaken the materials used in these parts. Use a cloth dampened only with
water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool
into a liquid.
Operation of the machine
The machines operation must be checked to ensure that all components are working correctly.
Replace any defective parts immediately. This prevents properly functioning parts from being
damaged.
Check machine oil
The gearbox oil should be checked and replaced at least once a year to ensure maximum lubrication
and cooling, and thus the best performance of the machine.
Check armature
This should be checked at least once a month to check if 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
means the part should be replaced.
Adjustment of slide
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 can be accomplished in the
following manner: