Kimball midwest Roto-kut 82-6627 User manual

Kimball Midwest Roto-Kut™

Magnetic Base Drilling & Tapping Machine

82-6627

Kimball Midwest

4800 Roberts Road

Columbus, Ohio 43228

800-233-1294 www.kimballmidwest.com

CONTENTS OF THE MANUAL

List of Contents Included with the Roto-Kut™ Drill

Stationary ring

Safety belt

1/8” Hex key

1/2” Chuck

Arbor assembly –15/64” Hex key included

Drift

Arbor shank

Safety glasses

Spare brush

Page

Intended use

General safety rules

Information plate symbols

Specifications

Operational safety procedures

Operating instructions

Control panel operation

Tapping function

Gear selection

10)

Magnet detection

11)

Extension cord selection

12)

Mounting of cutters

13)

Capstan operation

14)

Troubleshooting drilling problems

15)

Exploded view of machine

16)

Exploded view of motor and gearbox

17)

Control panel parts and list

18)

Fitting the chuck

19)

Maintenance

20)

Troubleshooting

21)

Cutter selection and speeds

22)

Warranty statement

1) INTENDED USE

The intended use of the Roto-Kut™ Drill is to drill holes in ferrous metals. The magnet is used to hold the drill in place

while the drill is operating. It is designed for use in fabrication, construction, railways, petrochemical and any other

applications when drilling ferrous metal. Any deviation from its intended use will not be covered by warranty.

2) GENERAL SAFETY RULES

WARNING! Please read these instructions before attempting to operate the machine. 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 -

1. Disconnect from the power supply before carrying out any adjustment, servicing or maintenance.

2. Keep the work area clear - cluttered areas and benches invite injuries.

3. Consider the work area environment;

•Do not expose tools to rain.

•Do not use tools in damp or wet locations.

•Keep the work area well lit.

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

•Ensure there is adequate space to gain access to the plug, outlets and motor on/off switches.

4. Guard against electric shock:

•Avoid body contact with grounded surfaces (e.g. pipes, radiators, etc.). Electric safety can be further

improved by using a Ground Fault Circuit Interrupter (GFCI).

5. Keep other persons away. Do not let untrained persons, especially children, touch the tool or the extension cord

and keep them away from the work area.

6. Store tools when not in use. All tools should be stored in a dry locked-up place, out of reach of children.

7. Do not apply too much force through the machine. It will do a better and safer job at the feeds for which it was

designed.

8. Use the right tool;

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

•Do not use this tool for purposes not intended.

9. Dress properly;

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

•Non-skid footwear is recommended when working outdoors.

•Wear a protective hair covering to contain long hair. This will reduce the risk of entanglement.

10. Use protective equipment when using this machine;

•Use safety glasses to prevent debris from damaging eyes.

•Use hearing protection.

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

•Use protective gloves to prevent debris from cutting the skin.

11. When using the drill, always ensure a safe operating distance from any cut material and do not reach into the

cutting area, or near the cutter, when the machine is running.

12. Connect dust extraction and collecting equipment, if devices are provided, ensuring these are properly connected

and used.

13. Do not abuse the cord; never pull the cord to disconnect it from the socket. Keep the cord away from heat, oil and

sharp edges.

14. Secure work where possible, use clamps or a vice to hold the work. It is safer than using your hand.

15. Do not overreach! Keep proper footing and balance at all times.

16. Maintain tools with care;

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

•Regularly check the machine for any wear or damage.

•Ensure the machine is clean and free from debris prior to use.

•Disconnect from power prior to any maintenance.

•Follow instructions for lubricating and changing accessories.

•Inspect tool cords periodically and if damaged have it repaired by an authorized Kimball Midwest service

facility.

•Inspect extension cords periodically and replace if damaged.

•Keep handles dry, clean and free from oil and grease.

17. Disconnect tools from the power supply when not in use, before servicing or when changing accessories such as

cutters.

18. Check to verify that keys and adjusting wrenches are removed from the tool before turning it on.

19. Avoid unintentional starting. Ensure the magnet is off before plugging the machine in.

20. Use extension cords intended for outdoor use when the tool is used outdoors.

21. Watch what you are doing, use common sense and do not operate the tool when you are tired. Do not operate

the machine when under the influence of alcohol or any illegal substances.

22. Check for damaged or missing parts before using the tool; it should be carefully checked to determine that it will

operate properly for its intended function.

23. The use of any accessory or attachment, other than ones recommended in this instruction manual, may present a

risk of personal injury.

24. Have your machine repaired by the qualified Kimball Midwest authorized service facility. This electric tool

complies with the relevant safety rules. Only qualified persons using original replacement parts should carry out

repairs, otherwise this may result in considerable danger to the user.

25. Never operate the machine if parts are missing or damaged.

26. Never direct jets of water or flammable liquids over the drill.

27. Operator must be physically able to handle the weight of the machine.

28. Operator should be trained in the use of the machine.

3) INFORMATION PLATE SYMBOLS

1 2 3 4 5

1.Refer to the user manual for operational and safety issues with regards to this machine.

2.Dispose of the machine and electrical components correctly.

3.Eye protection must be worn when operating the machine.

4.Ear protection must be worn when operating the machine.

5. Hand protection must be worn when operating the machine.

4) SPECIFICATION

Maximum hole cutting capacity in steel = 2”dia. x 2”deep

Arbor bore = Morse Taper #2

Motor Unit

Voltages

120V 50-60Hz

Normal full load

14.0 A

Electro Magnet

0.53 A

Size

7-7/8” long

3-55/64”wide

Holding Force at 68°F (20°C) with 1” minimum plate thickness

The use on any material less than 1” thick will progressively

reduce the magnetic performance. If possible, substitute

material should be positioned under the magnet and work

piece to equate to a suitable material thickness. If this is not

possible, an alternative secure method of restraining the

machine must be used.

3,035 Lbs

Total Load (magnet + motor)

14.53A

Overall Dimensions

Height - maximum extended

22-¼”

Height - minimum

17-9/16”

Width (including capstan fitting)

7-43/64”

Length Overall (including guard)

12-13/32”

Net Weight

34.2 Lbs

Ear and eye protection must be worn when operating this machine. Wear gloves to protect hands when operating the

machine.

These tools are UK designed and manufactured with globally sourced components and conform with the requirements

of EEC Document HD.400.1 and BS.2769/84

Suitable only for a single phase 50-60Hz A.C. power supply

DO NOT USE ON D.C. VOLTAGE

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

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

WARNING: THIS APPLIANCE MUST BE GROUNDED!

ANY MODIFICATIONS TO THIS MACHINE WILL INVALIDATE THE WARRANTY

5) OPERATIONAL SAFETY PROCEDURES

READ BEFORE USING THE MACHINE

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

personal injury.

•Ensure the magnet is off before plugging in the machine.

•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, gases or in high risk environments. Failure to do so may result in personal

injury.

•Before operating the machine, inspect all electrical supply cables (including extension cords) and replace if damaged. Do not

use if there are any signs of damage.

•Only use extension cords approved for the site conditions.

•Before operating the machine, always check for the correct functioning of all operational systems, switches, magnet etc.

•Before operating, the machine must be securely restrained to a fixed object by using the safety strap and stationary rings.

Attach the stationary rings onto the magnets uppermost side holes 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 approved safety glasses, hearing protection and other recommended PPE when operating the machine.

•Disconnect from power source when changing cutters or working on the machine.

•Cutters and cuttings are sharp, always ensure that hands are adequately protected when changing cutters or removing

cuttings. Use a tool or brush where necessary to remove any cuttings from the arbor.

•Before operating the machine, always ensure cutter-retaining screws are secured tightly.

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

•Always remove ties, rings, watches and any loose adornments that might entangle with the rotating machinery before

operating.

•Always ensure that long hair is securely enclosed by an approved restraint before operating the machine.

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

power source and turn arbor back and forth. Do not attempt to free the cutter by switching the motor on and off. Wear safety

gloves to remove the cutter from the arbor.

•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 for any damaged or loose parts.

•Always ensure when using the machine in an inverted position that only the minimum amount of coolant is used and that care

is taken to ensure that coolant does not enter 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 be ejected.

•When not in use always store the machine in a safe and secure location.

•Always ensure that an approved Kimball Midwest service center conducts repairs.

6) OPERATING INSTRUCTIONS

•Keep the inside of the cutter clear of cut material. It restricts the operating depth of the cutter.

•Ensure that the coolant bottle contains sufficient cutting oil to complete the required operations. Refill as required.

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

•To start the machine, follow the control panel operating instructions. The Kimball Midwest Roto-Kut™ machine is fitted with a

dual motor protection system to fully ensure safety and extend the life of the motor. The CutSmart™protection (found on the

control panel) gives a clear and visible indication to the user of torque being applied to the motor, if too much pressure is

applied the drill will shut off automatically. To re-start the machine, press the start button again. If the speed controller

protection is activated, press the start button twice to re-activate the machine.

•Always switch off the motor by depressing the green start/stop button (or blue button) depending upon operation. Do not

switch off the motor by pressing the magnet switch.

•Apply light pressure when starting the cut until the cutter is cutting into the work piece. Pressure can then be increased

sufficiently to load the motor. Excessive pressure is undesirable; it does not increase the speed of penetration and will cause

the safety overload protection device to stop the motor (the motor can be restarted by operating the motor start button) and

may cause excessive heat which may result in inconsistent slug ejection

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

•If the slug sticks in the cutter, move the machine to a flat surface, switch on the magnet and gently bring the cutter down to

contact 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.

•Cutter breakage is usually caused by insecure anchorage or a loosely fitting slide (Refer to routine maintenance instructions).

•Only use approved cutting fluid. Kimball Midwest offers several cutting fluids that have been formulated to maximize cutter

performance.

7) CONTROL PANEL OPERATION

CutSmart™ Technology

Green Zone

Perfect, try to keep in

the green zone for

the best cut and

optimum machine

performance.

Yellow Zone

A little too much

pressure on the drill

- ease off to get back

to the green zone.

Red Zone

Overload: Back off

immediately as too

much force will cause

the motor to cut off

if you continue.

CutSmart™ Technology

Designed for you to get the most out of your

machine and your cutters. CutSmart™has an

easy to read panel that indicates when you

are drilling with too much force, which will

damage the machine and the cutters.

Allow the cutter to do the work and you will

find that a much smoother hole and faster

drilling time is achieved.

2) Magnet ON

To turn the magnet ON or OFF, press the

large button on the control panel. The LED

will illuminate either GREEN or RED

depending on the material thickness –too

thin materials will indicate red.

1.Ensure power to the machine, red LED will illuminate (#1).

2.Press the magnet switch on (#2) to engage the magnet. The LED will light up in either green or

red (#3). Depending on the material thickness and magnetic adhesion, the green magnet LED will

indicate that optimum adhesion is achieved. Drilling operation is then available.

Warning if the red magnet LED is illuminated, this indicates optimum adhesion is not achieved.

The drilling operation is still available.

3. Use the speed controller on the top cap housing to dictate the speed, always use speeds that

are recommended for the cutter size being used (see page 24).

4. Turn the motor on in the forward direction (#4).

5. Drill the hole the recommended size for the thread to be cut.

6. Without disengaging the magnet replace the drill with the tap.

7. Set the spindle speed to the required tapping speed required.

8. Start the drill spindle in the forward direction (#4) and feed the tap into the hole until it begins

to cut. Once cutting the tap will feed itself through, only gentle pressure on the feed handles

should be necessary.

9. Once the tap has threaded the hole the drill should be stopped immediately (#4).

10. The drill spindle should then be switched to reverse (#5) and the tap can be fed back out of the

hole, then allowing the tap to be safely extracted from the hole at a reduced RPM.

8) TAPPING FUNCTION

9) GEAR SELECTION

The Roto-Kut™ magnetic base drill is fitted with a 2-speed gearbox. The gear is used to reduce the

output speed when using larger cutters.

Slide Selector Position

Speed Controller Setting

Level 1

Level 6

200 RPM

500 RPM

100 RPM

265 RPM

10) MAGNET DETECTION

It is advised that, when working on thin material, a backing piece should be used to increase the

material thickness under the magnet. Working on thin material without a backing piece will reduce

the magnet’s holding force.

It is advised that the drill is to be operated on ferrous material ½” thick and above. Damage to the

magnet base, such as pitting, will affect the strength of the magnet’s holding force.

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

3000

3250

3500

3750

4000

21 13/161 9/161 3/81 3/16113/169/163/83/160

Material Thickness in Inches

Magnet Holding force (lbs)

Slide Selector Position Up

Slide Selector Position Down

11) EXTENSION CORD SELECTION

The machines are factory fitted with a 9 ¾ foot length of cable having three 16AWG conductors,

LIVE, NEUTRAL and GROUND. If it becomes necessary to attach an extension cord, care must be

taken in using a cord 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 cord lengths not be exceeded:

For 120v supply: 11 ½ feet of 3 conductor 16AWG

ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE CHANGING CUTTERS.

12) MOUNTING OF CUTTERS

•The machine has been made to accept cutters having 3/4” dia. Weldon shanks.

The following procedure is to be used when mounting the cutters:

•With the machine in the upright position, ensure the Arbor Assembly (#56 on page 12) is

fully inserted into the Arbor Spindle (#8.3 on page 14).

•Take the appropriate pilot and place it through the hole in the cutter shank. Insert the

shank of the cutter into bore of the Arbor Assembly, ensuring alignment of the two drive

flats with the socket screws.

•Tighten both screws using the hex key.

13) CAPSTAN OPERATION

The quick release capstan is a feature that offers the user simple dual side operation.

To remove the capstan, simply do the following;

1: Press in the central button on the capstan hub, holding onto the capstan arms.

2: With the button pressed in, pull the capstan away from the main body, holding on to the

capstan arms.

3: Re-insert the hex shaft into the hex slot to attach the capstan.

14) TROUBLESHOOTING DRILLING PROBLEMS

Problem

Cause

Remedy

1) Magnetic base

won’t hold

effectively

Material being cut may be too thin for efficient holding.

Cuttings or dirt under magnet.

Irregularity on magnet contact or work surface.

Insufficient current going to magnet during drilling cycles.

Attach an additional piece of metal under the magnet, or

mechanically clamp magnetic base to the work surface.

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 centerpunch

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 centerpunch mark; weak pilot spring; pilot not

centered in centerpunch mark.

Worn or bent pilot, worn pilot hole.

Loose bolts on motor bushing support bracket, main

casting or loose slide adjusting set screws.

See causes and remedies above.

New arbor bushing is needed.

Light pressure only is needed until a groove is cut. The groove

then serves as a stabilizer.

Replace or resharpen.

Improve centerpunch and/or replace worn parts

Replace part or parts

Adjust where necessary

3) Excessive

drilling pressure

required

Incorrectly resharpened, worn or chipped cutter.

Coming down on cuttings lying on the surface of the

workpiece.

Slide strips out of adjustment or lack of lubrication.

Cuttings accumulated (packed) inside cutter.

Resharpen or replace.

Take care not to start a cut on cuttings.

Adjust set screws and lubricate.

Clear cutter.

4) Excessive cutter

breakage

Steel cuttings or dirt under cutter.

Incorrectly resharpened or worn cutter.

Cutter skipping.

Slide needs adjustment.

Cutter not attached tightly to arbor.

Insufficient use of cutting oil or unsuitable type of oil.

Incorrect speed

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 set screws supporting the slide.

Retighten.

Inject light viscosity oil into the coolant line 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).

Ensure correct gear is used for the cutter.

5) Excessive cutter

wear

See cause and remedy above

Incorrectly resharpened cutter.

Insufficient or irregular 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.

15) EXPLODED VIEW OF MACHINE

Item#

Description

Qty/pcs

Screw

M5 CSK Washer

Guard support

Slide channel

Screw M4×14 Button Head

Guard

Screw M4×8 Button Head

Magnet

Spring washer

Screw

Cable bush

Screw

Nut

Screw M4×8 Button Head

Right side plate

Screw M6×20 CAP HD

Screw M6×16 CAP HD

Spring washer

Bush

Capstan Washer

Circlip

Screw

Guide bar

Slide

Rack

Screw

Chain

M3 Nut

Chain

Screw M3×8 CSK HD

Screw

Coolant bottle assembly

Item#

Description

Qty/pcs

Screw M4×12 Button

Head

Screw

Housing

Handle insert

M4 nut

Earth label

Cable clamp

Screw M6×16 CAP HD

Capstan arm

Capstan Hub

Capstan spindle

Left side panel

Washer

Screw

Cable plug assembly

Control panel assembly-

PB50/1T

Tapping screw ST2.9×12

Clamp

Stationary ring

Safety belt

3mm hexagonal spanner

13mm Chuck

Arbor assembly

Drift

Arbor shank

Safety Glasses

Spare brush

1pair

PARTS LIST

16) EXPLODED VIEW OF MOTOR AND GEARBOX

PARTS LIST

Item#

Description

Qty/pcs

Motor assembly

8.1

Circlip

8.2

Oil seal washer

8.3

Arbor spindle

8.4

Roll Bearing

8.5

Flat Key

8.6

Tapping Screw

8.7

Spring

8.8

Gear lever

8.9

screw

8.10

Gear box

8.11

Needle bearing

8.12

Gear shaft washer

10mm ID

8.13

Key steel

8.14

Gear axel

8.15

Gear lever shaft

8.16

Dual gear

8.17

Washer

8.18

Needle bearing

8.19

Circlip

8.20

Big gear

8.21

Roll Bearing

8.22

Oil seal

8.23

Straight Pin

8.24

Rolling bearing 608

8.25

Shaft gear

8.26

Flat Key

8.27

Gear

8.28

Oil baffle plate

8.29

Inner gear plate

8.30

Seal washer

8.31

Rolling bearing 6001

8.32

Armature

8.33

Rolling bearing 629

8.34

Bearing Sleeve

8.35

Inductor

Item#

Description

Qty/pcs

8.36

Baffle plate

8.37

Tapping Screw

8.38

Field coil

8.39

Lead wire

8.40

Lead wire

8.41

Motor casing

8.42

Lead wire

8.43

Brush cap

8.44

Carbon brush

8.45

Brush holder

8.46

Lead wire

8.47

Terminal

8.48

Screw M3×6 Button Head

8.49

Speed controller module

8.50

Tapping Screw

8.51

Top Cap

8.52

Tapping Screw

8.53

Tapping Screw ST2.9×8

8.54

Outlet clamp

8.55

Plastic tube

8.56

Lead wire(green)

8.57

Lead wire(brown)

8.58

Lead wire(black)

8.59

Lead wire(blue)

8.60

Lead wire(red)

8.61

Lead wire(white)

17) CONTROL PANEL AND PARTS LIST

Item#

Description

Qty/pcs

Green Motor Switch

Blue Motor Switch-Tapping

Magnet Switch

Red LED

Green LED

Screw M3×12 Button Head

Control Panel Cover

Control Plate

Nylon Spacer

Array Board

M3 Nut

Connection line

E50PCBA

18) FITTING THE CHUCK

•The machine comes supplied with an Arbor Shank & ½” Chuck.

•Insert the arbor shank into the Arbor Spindle, ensure a good and tight fit is achieved.

•Insert the ½” chuck into the arbor shank, ensure a good and tight fit is achieved.

•Replacing the chuck is the reverse sequence, by utilizing the supplied drift.

19) MAINTENANCE

In order to obtain the best performance and life from your Kimball Midwest Roto-Kut™

machine always keep it in good working order.

A number of items must always be checked before use.

Before starting any job, always make sure the machine is in good working order and that

there are no damaged or loose parts. Any loose parts must be tightened.

Before proceeding with any maintenance work be certain that the power supply is

disconnected.

Description

Every operation

1 week

1 Month

Visual check of

machine for damage

Operation of machine

Check brush wear

Check magnetic base

Check alignment of

the machine

Check grease

Check armature

Visually check the machine for damage.

The machine must be checked before operation for any signs of damage that will affect the

operation of the machine. Particular notice must be taken to the power cord, if the machine

appears to be damaged it should not be used, failure to do so may cause injury or death.

Check operation of the machine.

The machines operation must be checked to ensure that all components are working

correctly.

Machine Brushes

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 of the original

length, the brushes should be changed. Failure to do so may cause damage to the machine.

Magnetic base

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.

Adjustment of slide and bearing bracket alignment.

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.

2. Now lower the slide back to its lowest position. Bring the slide into the center of the

dovetail slide housing and loosen the screws to allow free movement of the arbor

support bracket.

3. Starting with the middle screws, gently tighten 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.

Check machine grease.

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

obtain maximum performance from your machine.

Check Armature of the machine.

This should be checked at least once a month to verify that there are no visual signs of

damage to the body or to the commutator. Some signs of wear will be seen on the

commutator over time, but this is normal (this is the part that comes into contact with the

brushes) however, if there are any signs of abnormal damage the part should be replaced.

20) TROUBLESHOOTING

Magnet and motor do not function

- The magnet switch is not connected to the power supply

- Damaged or defective wiring

- Blown fuse*

- Defective magnet switch

- Defective control unit

- Defective power supply

Magnet does function, the motor does not

- Damaged or defective wiring

- Carbon brushes are stuck or worn out

- Defective on / off switch

- Defective control unit

- Defective armature and/or field

- Defective protective reed switch

Magnet does not function, the motor does

- Defective magnet

- Blown fuse*

- 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

- Pilot bent

Motor running roughly and/or seizing up

- Bent spindle

- Shaft extending from the motor is bent

Motor making a rattling sound

- Gear ring (bottom of the armature) worn out

- Gear(s) worn out

- No grease in gear box

Motor humming, sparks and motor has no

force

- Armature damaged

- Field coil burned

- Carbon brushes worn out

Motor does not start or fails.

- Damaged or defective wiring

- Damage to armature or field coil

- Damaged or defective brushes

Guiding takes a great deal of effort

- Slide is set too tight

- Slide is dry

- Slide /gear - rack/rotation system is 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

- Work piece is not flat

- Work piece is too thin less than 10mm

- Defective control unit

- Defective magnet

Fuse blows when magnet switch is turned on

- Damaged or defective wiring

- Wrong amperage fuse*

- Defective magnet switch

- Defective control unit

- Defective magnet

Fuse blows when motor is started

- Damaged or defective wiring

- Wrong amperage fuse*

- Motor running roughly

- Defective armature and / or field

- Carbon brushes worn out

- Defective control unit

*The fuse can be accessed by removing the rear panel of the drill. Replace only with a 5x20mm fast acting power fuse with

a 250V rating [K-M No. 28-1199].

Worn out or defective parts must be replaced by an authorized Kimball Midwest service

center, return to Kimball Midwest for evaluation.

21) CUTTER SELECTION AND SPEEDS

The data listed below is for reference purposes only and indicates potential starting

conditions. It is the responsibility of the user to determine correct application requirements.

These are only starting points, they will vary with application and work piece condition.

Difficult-to-machine materials will require reduced feed rates.

Material to be cut

Minimum/Maximum Min Max Min Max Min Max Min Max Min Max Min Max

Iron: cast (soft) 360 480 280 300 200 240 140 180 100 120 75 93

Iron: cast (hard) 250 320 200 230 160 200 110 147 80 105 60 81

Iron: cast (malleable) 250 660 200 420 160 380 110 290 80 160 60 130

Steel: mild 440 660 340 420 310 380 220 290 140 160 110 130

Steel: high tensile 265 340 190 250 150 185 125 145 90 100 65 80

Steel: stainless (free

cutting)

280 320 150 200 110 140 90 120 60 85 50 65

Steel: stainless (heat

resisting)

250 210 180 150 100 130 80 105 55 70 35 55

2-9/16"

Cutter Diameter/Material/RPM relationship

9/16"

3/4"

7/8"

1-1/4"

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