Falcon Magnetic Rotabroach CM/405/1 User manual

Issue%3%Original%Version%JUNE%2014%
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This%machine%(Serial%No%% % %)%is%CE%approved.%
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Imperial%Works,%Sheffield%Road%
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United%Kingdom%
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*MAN3F'4A324OC0@ABC0ADEPD0PQR' ' S2B'4N@2F'TTTPC0@ABC0ADEPD0PQR'

Issue 3 Original Version JUNE 2014
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+EAUR'V0Q'W0C'XQCDEA4NUY'0QC'!A3D0U'MAYU2@ND'1CN33P'
S2'T0Q31'C2A33V'3NR2'V0QC'W221BADR'0U'@E2'MADENU2P'
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Other&Products&by&Rotabroach™:&
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Issue 3 Original Version JUNE 2014
3
$%&+*&+>'
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%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%
% %

Issue%3%Original%Version%JUNE%2014%
4
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%them%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.%
%
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Issue 3 Original Version JUNE 2014
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JI ("$/,&*'><*$,!,$"+,%&'
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Maximum%hole%cutting%capacity%in%.2/.3C%steel%=%50mm%dia.%x%50mm%deep%
Arbor%bore%=%19.05mm%(3/4”)%dia.%
Motor%Unit%
CM/405/1%%%%%%%%110V%
11.5A,%1150W%
CM/405/3%%%%%%%%230V%
5.75A,%1150W%
Overall%
Dimensions%
Machine%
230%x%160%x%420mm%
Magnet%Footprint%
170mm%x%85mm%
Net%Weight%
%
13.0kgs%
No%Load%
Speed%
All%voltages%
280%min\1%max%low%gear%Max%
530%min\1%high%gear%Max%
%
%
Tractive%Force%of%Magnet%at%20º%C%(25mm%min.%plate%thickness)%
+E2'Q42'0U'AUV'MA@2CNA3'3244'@EAU'J8MM'@ENDR'TN33'XC0YC244N^23V'C21QD2'@E2'
MAYU2@ND'X2CW0CMAUD2P',W'X044NB32'A11N@N0UA3'MA@2CNA3'4E0Q31'B2'X04N@N0U21'QU12C'
@E2'MAYU2@'AU1'T0CR'XN2D2'@0'2_QA@2'@0'A'4QN@AB32'MA@2CNA3'@ENDRU244P',W'@EN4'N4'U0@'
X044NB32'AU'A3@2CUA@N^2'42DQC2'M2@E01'0W'C24@CANUNUY'@E2'MADENU2'(?>+'B2'Q421P%
1850kgs%
Maximum%machine%stroke%
150mm%
Twist%drill%diameter%capacity%
1\23mm%
Tap%diameter%capacity%(DIN376)%
M3\M16%
Maximum%cutter%diameter%(Annular%cutter)%
50mm%
Maximum%cutting%depth%(Annular%cutter)%
50mm%
%
It%is%recomended%that%ear%and%eye%protectors%are%worn%when%operating%this%machine.%
%
Suitable%only%for%a%single%phase%25\60%Hz%A.C.%power%supply%
%
DO%NOT%USE%ON%D.C.%SUPPLY%
%
Do%not%use%your%magnetic%drill%on%the%same%structure%when%arc%welding%is%in%progress.%
D.C.%current%will%earth%back%through%the%magnet%and%cause%irreparable%damage.%%
%
WARNING:%%THIS%APPLIANCE%MUST%BE%EARTHED!%
'
&`F''"&]'(%-,!,$"+,%&>'+%'+/,>'("$/,&*'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%
&

Issue 3 Original Version JUNE 2014
6
;I %<*."+,%&"#'>"!*+]'<.%$*-?.*>'
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.*"-'`*!%.*'?>,&)'+/*'("$/,&*'
%
All%safety%measures%must%be%observed%at%all%times%when%using%magnetic%core%drills.%
Improper%use%and%carelessness%increase%the%risk%of%accidents.%Read%and%carefully%follow%these%recommendations%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,%watches%and%any%loose%adornments%that%might%entangle%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%machine%is%accidentally%dropped,%ALWAYS%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%sticks%in%the%cutter,%move%the%machine%to%a%flat%surface,%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%anchorage,%a%loosely%fitting%slide,%or%a%worn%bearing%in%the%arbor%support%bracket%usually%causes%cutter%breakage.%%
%
*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%reduction%of%power%from%the%motor.%%
%
•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%%

Issue 3 Original Version JUNE 2014
7
8I ><**-'>*#*$+,%&'
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The%machine%is%equipped%with%gear%ranges%which%can%produce%speeds%up%to%450rpm.%Do%not%
change%the%gear%while%the%motor%is%in%motion.%
The%speed%range%for%this%gear%is%changed%by%the%rotary%change%switch%located%on%the%gearbox%
side.%%
The%speed%controller%is%adjusted%by%rotating%the%blue%disk%located%on%the%control%panel%of%the%
motor.%
Before%cutting%holes%in%the%work%piece%ensure%that%you%are%using%the%correct%speed%and%gear%
for%your%material%and%cutter.%Site%conditions,%e.g.%diameter%and%condition%of%cutter,%material%
condition,%material%thickness,%etc%must%also%be%taken%into%account%when%determining%the%
suitable%cutting%speed.%The%speed%and%feed%rate%must%continuously%be%monitored%and%
adjusted%to%ensure%optimum%cutting%conditions%prevail.%%
In%general%the%faster%output%speeds%would%be%used%for%smaller%cutters%and%the%slower%more%
torque%gears%for%larger%cutters.%
'
)2AC'4232D@0C'NU''''''''''''<04N@N0U'W0C'4MA33'DQ@@2C4'
'
)2AC'4232D@0C'NU''''''''''''<04N@N0U'W0C'3ACY2'DQ@@2C4'
'
LI ".`%.'"++"$/(*&+>%
'
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%19.05mm%Weldon%shank%attachment%and%also%are%available%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%department%for%further%
details%and%our%available%products.%
Gear%Selection%

Issue 3 Original Version JUNE 2014
8
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.%%
'
'
'
'
'
'

Issue 3 Original Version JUNE 2014
9
\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%

Issue 3 Original Version JUNE 2014
10
97I *b<#%-*-'-,")."('%!'("$/,&*'
$0MX0U2U@'N12U@NWNDA@N0U'W0C'$(567859e;'!"#$%&'
%
%
%
,@2M'&0'
<AC@'&0'
-24DCNX@N0UP'
,@2M'&0'
<AC@'&0'
-24DCNX@N0UP'
1%
RD48153%
Frame%
24%
RD48196%
Screw+washer+nut%
2%
RD48174%
Screw%SSM6x16%
25%
RD38001%
Info%Plate%
3%
RD48175%
Washer%M6%
26%
RD48198%
Panel%screw%M4x8%(rearplate)%
4%
RD48176%
Setting%Nut%
%
RD48199%
Panel%screw%long%M4x20%
(frontplate)%
5%
RD48177%
Setting%Screw%
27%
RD38010%
Front%plate%110V%
6%
RD48178%
Magnet%Hi/Lo%
27%
RD38011%
Front%Plate%230V%
7%
RD48179%
Sensor%
28%
RD48201%
Sensor%LED+cable%
8%
RD48180%
Slide%
29%
RD48202%
On/Off%switch%
9%
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%
%
%
%

Issue 3 Original Version JUNE 2014
11
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%
%

Issue 3 Original Version JUNE 2014
12
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'
'
b'
'
'
%X2CA@N0U'0W'MADENU2'
'
b'
'
'
$E2DR'BCQ4E'T2AC'
'
b'
'
$E2DR'MAYU2@ND'BA42'
b'
'
'
$E2DR'A3NYUM2U@'0W'
@E2'MADENU2'
'
'
b'
$E2DR'YC2A42'
'
'
b'
$E2DR'"CMA@QC2'
'
'
b'
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.%%

Issue 3 Original Version JUNE 2014
13
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.%
%
%
%
%
%
%
%
%
%
%
%
%
%
%

Issue 3 Original Version JUNE 2014
14
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%

Issue 3 Original Version JUNE 2014
15
&%+*>

Issue 3 Original Version JUNE 2014
16
'
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%cutters),%provided%that%the%warranty%registration%card%(or%online%
registration)%has%been%completed%and%returned%to%Rotabroach™,%or%its%designated%distributor%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%servicing%or%maintenance.%
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%MODIFICATIONS%TO%DESIGN%WITHOUT%PRIOR%NOTICE%
%
%
%
%
%
%
%
%
%
dU0TU'AU1'+CQ4@21'S0C31TN12'W0C'gQA3N@Vh'<2CW0CMAUD2'AU1'.23NABN3N@V'