RHINO Rotabroach CM/127/1 User manual

Issue 12 Original version March 2019
- 1 -
RHINO E RAIL DRILLING MACHINE
Model No. CM/127/1 CM/127/3
This machine (Serial No ) is CE approved.
Rotabroach Ltd
Burgess Road
Sheffield, South Yorkshire
United Kingdom
S9 3WD
Tel: [phone] Fax: [phone]
Email: [email protected] Web site: www.rotabroach.co.uk

Issue 12 Original version March 2019
- 2 -
Other products by Rotabroach.
For more information please visit our website at www.rotabroach.co.uk
Or contact our sales department on [phone]

Issue 12 Original version March 2019
- 3 -
Contents
Page
1) General safety 4
2) Machine Specification 5
3) Operating instructions 6
4) Cutting Fluid 7
5) Coolant Inducement 7
6) Mounting of cutters 7
7) Remedies for hole making problems 7
8) Speed Selection 8
9) Wiring Diagram 9
10) Exploded diagram of machine 10
11) Exploded diagram of motor 12
12) Exploded Diagram of clamp 14
13) Exploded diagram of quick clamp 16
14) Maintenance checks 18
15) Trouble shooting 20
16) Warranty 24

Issue 12 Original version March 2019
- 4 -
[1] GENERAL SAFETY RULES
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. Keep other persons away do not let persons, especially children, not involved in the work 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 containing long hair.
9. Use protective equipment when using this machine
•Use safety glasses.
•Use ear defenders.
•Use face or dust mask if cutting operations create dust.
•Use protective gloves
10. Connect dust extraction equipment if device are provided for the connection of dust extraction and collecting equipment, ensure these
are connected and properly 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 use 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 oil and grease.
15. Disconnect tools when not in use, before servicing and when changing accessories such as blades, bits and cutters, disconnect tools
from the power supply.
16. Remove adjusting keys and wrenches 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 ensure switch is in “off” position when plugging in.
18. Use outdoor extension leads when the tool is used outdoors, use only extension cords intended for outdoor use and so marked.
19. Stay alert watch what you are doing, use common sense and do not operate the tool when you are tired.
20. Check for damaged parts before further use of tool; it should be carefully checked to determine that it will operate property and 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 toll 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.

Issue 12 Original version March 2019
- 5 -
[2] Specification
Maximum hole cutting capacity in .2/.3C steel = 40mm dia. x 52mm deep
Arbor bore = 19.05mm (3/4”) dia.
Motor Unit
(Nominal values)
CM/125/1
110v
10A
1100W
CM/125/3
230v
5A
1100W
Overall
Dimensions
Maximum extension
640 mm
Minimum extension
620 mm
Width (including Hand wheel)
180 mm
Length Overall (including Guard)
320 mm
Nett Weight
16.2 kg
Stroke
85mm
No Load speed
All voltages
270-610 rpm
Maximum hand/arm vibration magnitude (measured at handle during
operation in accordance with ISO5349 using a 22mm dia. cutter through
13mm mild steel plate.
0.51 m/s²
Estimate of vibration exposure. Operation 30 holes @ 1 minute/hole.
0.13 m/s² A(8)
Average noise level during cutting at operators ear position.
89 dB(A)
Ear defenders must be 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 the 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!
NB: ANY MODIFICATIONS TO THIS MACHINE WILL INVALIDATE THE GUARANTEE.
List of Contents with Magnetic Dill Unit
Check List
RD4088
4mm A/F Tee Handled Hexagon Key
YES/NO
RD4152
3mm Hexagon key
YES/NO
RY2307
Coolant Feed Dispenser
YES/NO

Issue 12 Original version March 2019
- 6 -
[3]Operating instructions
Operational safety
READ BEFORE USING THE MACHINE
•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 activating the machine, inspect all electrical supply cables (including extension leads), and replace if damaged.
•Only use extension cables approved for site conditions.
•BEFORE activating the machine, ALWAYS check the correct function of all operational systems, switches, magnet etc.
•BEFORE operating, the machine MUST be securely restrained failure to do so may result in personal injury.
•ALWAYS wear approved eye and ear protectors when operating the machine.
•Disconnect from power source when changing cutters or working on the machine.
•Cutters and swarf are sharp, ALWAYS ensure that hands are adequately protected when changing cutters, or removing
swarf.
•Before operating the machine, ALWAYS ensure cutter-retaining screws are secured tightly.
•Regularly clear the work area and machine of swarf and dirt, paying particular attention to the underside of the magnet
base.
•ALWAYS remove tie, ring, 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 ‘fast’ 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 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. DO NOT operate the machine if the ejected slug may cause injury.
•When not in use ALLWAYS store the machine in a safe and secure location when not in use.
•ALLWAYS ensure that approved ROTABROACH™ agents conduct repairs.
OPERATING INSTRUCTIONS
•Keep the inside of the cutter clear of swarf. It restricts the operating depth of the cutter.
•Ensure that the coolant bottle contains sufficient cutting oil to complete the required operating duration. Refill as required.
•Occasionally depress the pilot to ensure cutting fluid is being correctly metered.
•To start the machine, first switch on the magnet by turning the rotary switch to position <I>. Then start the motor by
depressing the GREEN start button.
•ALWAYS switch off the motor by depressing the RED stop button. DO NOT switch off the motor by turning the magnet
switch off.
•Apply light pressure when commencing to cut a hole until the cutter is introduced into the work surface. 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 could result in inconsistent slug ejection
•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 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 slide and arbor support bearing.
•Insecure anchorage, a loosely fitting slide or a worn bearing in the arbor support usually causes cutter breakage.
SPEED SELECTION
•The machine is equipped with a step-less variation of speed range.
•The step-less variation is adjusted by rotating the disk (which is graduated into six numerically designated segments) and
is located on top of the motor.
•Before cutting holes the work piece material specification must be determined to facilitate the correct cutting speed
selection (See section Cutting speeds). 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 that optimum cutting conditions prevail.
EXTENSION CABLE SELECTION
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 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:
For 110v supply: 3.5metres of 3 core x 1.5mm²
For 230v supply: 26 meters of 3 core x 1.5mm²

Issue 12 Original version March 2019
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[4] ROTABROACH CUTTING FLUID
•Rotabroach cutting fluid has been specifically formulated to significantly enhance the performance and life of the cutting
tool, and improve the quality and surface finish of the hole.
•Avialable in
1 litre (RD208)
5 litre (RD229)
25 litre (RD220)
•
[5] COOLANT INDUCEMENT
•Coolant is induced into the system via a pressurised coolant bottle. Connect the coolant bottle to the machine via the
connector and then pressurise the bottle by pumping the coolant bottle’s pump several times. Regulate the flow using
the stop tap a quarter turn is usually sufficient.
•Constituent items:
Coolant bottle and hose assembly RY2307
ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE CHANGING CUTTERS.
[6] MOUNTING OF CUTTERS
•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 RD4066.
•Take appropriate pilot and place through the hole in cutter shank. Insert shank of cutter into bore of arbor, ensuring
alignment of two drive flats with socket screws.
•Tighten both screws using hexagon key.
[7] REMEDIES FOR HOLE MAKING PROBLEMS
Problem
Cause
Remedy
2) Cutter skips
out of centre-
punch mark at
initiation of cut
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.
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).

Issue 12 Original version March 2019
- 8 -
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.
[8] CUTTING SPEEDS.
CUTTING SPEEDS.
For CRWC or SCRWC cutters.
Speed selector
Position.
Cutter diameter
Rail specification
N/mm²
5
18
700
3
1200
4
22
700
2
1200
1
30
700
2
1200
This data is presented for guidance only, and should be adjusted to suit site and material conditions
Material
Surface speed
(M/min)
Aluminium
60-90
Cast iron
Soft
30-50
Hard alloy
15-21
Malleable
15-30
Steel
Mild (460 N/mm²)
24-30
(460-770 N/mm²)
15-27
(770-1070 N/mm²)
9-15
1070-1230 N/mm²)
6-9
Stainless steel
Ferritic
15-18
Austenitic
12-15
Martensitic
9-15
Typical cutting speeds (RPM) for various materials
Cutter Surface speed. Cutter Surface speed.
dia 915 30 45 dia 915 30 45
12 239 398 796 1194 39 73 122 245 367
13 220 367 734 1102 40 72 119 239 358
14 205 341 682 1023 41 70 116 233 349
15 191 318 637 955 42 68 114 227 341
16 179 298 597 895 43 67 111 222 333
17 168 281 562 842 44 65 109 217 326
18 159 265 530 796 45 64 106 212 318
19 151 251 503 754 46 62 104 208 311
20 143 239 477 716 47 61 102 203 305
21 136 227 455 682 48 60 99 199 298
22 130 217 434 651 49 58 97 195 292
23 125 208 415 623 50 57 95 191 286
24 119 199 398 597 51 56 94 187 281
25 115 191 382 573 52 55 92 184 275
26 110 184 367 551 53 54 90 180 270
27 106 177 354 530 54 53 88 177 265
28 102 171 341 512 55 52 87 174 260
29 99 165 329 494 56 51 85 171 256
30 95 159 318 477 57 50 84 168 251
31 92 154 308 462 58 49 82 165 247
32 90 149 298 448 59 49 81 162 243
33 87 145 289 434 60 48 80 159 239
34 84 140 281 421 61 47 78 157 235
35 82 136 273 409 62 46 77 154 231
36 80 133 265 398 63 45 76 152 227
37 77 129 258 387 64 45 75 149 224
38 75 126 251 377 65 44 73 147 220
These speeds should be viewed as a suggested starting point only.
The machine speed may require adjustment to suit the application conditions.

Issue 10 Original Version December 2011
- 9 -
[9] WIRING DIAGRAM

Issue 10 Original Version December 2011
- 10 -
[10] Exploded view of complete machine.

Issue 10 Original Version December 2011
- 11 -
Component parts for CM/127/1 and CM/127/3
Item
Component
Part No.
Item
Component
Part No.
1
Protection plate assembly
7
Capstan arm assembly
RD23604
1.1
Protection plate
RY3386
7.1
Capstan arm
RD33642
1.2
Countersunk screw
RD4347
7.2
Capstan knob
RD43602
1.3
Washer
RD45607
8
Capstan assembly
RD23610
2
Bearing bracket assembly
RD23605
8.2
Nyliner bearing
RD4313
2.1
Bearing bracket
RD33635
8.3
Pinion shaft sleeve
RD3303
2.2
Arbor bearing
RD45624
8.4
M6 shakeproof washer
RD4096
3
Motor & gearbox assembly (230v)
RD23663
8.5
M6 socket head screw
RD4098
3.1
Cable connector
RD43600
8.6
Capstan pinion shaft
RD33643
3.2
M5 socket head screw
RD4091
9
Gib strip assembly
RD23612
3.3
M5 shakeproof washer
RD4092
9.1
Gib support strip
RD33644
3.4
Cutter retaining screw
RD4066
9.2
Adjustable gib strap
RD33645
3.5
Coolant connector
RD4087/RD4280
9.3
Fixed jib strip
RD33646
4
Slide assembly
RD23608
10
Base plate assembly
RY2258
4.1
Slide
RD33630
10.1
Base plate
RY3384
4.2
Key
RD33341
10.2
Handle plate
RY3385
4.3
Rack
RD33600
10.3
Handle
RY33117
4.4
M5 socket head screw
RD4325
10.4
Screw
RD4209
4.5
M5 shakeproof washer
RD4092
10.5
Washer
RD4092
5
Housing sub assembly
RD23619
10.6
6mm socket head screw
RD4156
5.1
Housing
RD33632
10.7
6mm washer
RD4096
5.2
Tension pin
RD45622
10.8
Dowel
RD4228
6
Housing assembly
RD23609
10.9
M10 socket head screw
RD40033
5
Housing sub assembly
RD23619
10.10
M12 socket head screw
RD4229
6.2
M4 screw
RD45621
10.11
Dowel
RD4242
6.3
M4 shakeproof washer
RD4069
11
Control unit assembly (230v)
RD2767
6.4
M4 washer
RD4070
11
Control unit assembly (110v)
RD2766
6.5
M4 hexagon nut
RD4068
12
Pan head screw
RD4077
6.6
M4 pan head screw
RD4077
13
Mains cable assembly (230v)
RD25620
6.7
Logo plate
RD43083
14
Arbor bracket spacer assembly
RD23620
6.8
Information plate
RD4302
15
Arbor bracket bolt
RD43619
6.9
M6 tuflock screw
RD4312
16
Shakeproof washer
RD4079
6.10
Cable clip
RD4210
17
Plain washer
RD4078
6.11
Eath tag
RD45604
18
Socket set screw
RD4098
19
Shakeproof washer
RD4096

Issue 10 Original Version December 2011
- 12 -
[11] EXPLODED VIEW-MOTOR AND GEARBOX

Issue 10 Original Version December 2011
- 13 -
Component parts of motor and gearbox RD23661 (110v) & RD23663 (230v)
Item
Part No.
Component
Qty
Item
Part No.
Component
Qty
1
RD23651
Motor assembly (110v)
1
4
RD23616
Motor housing assembly
1
1
RD23653
Motor assembly (230v)
1
4.1
RD33613
Motor housing
1
2
RD23631
Armature assembly (110v)
1
4.2
RD33614
Brush holder
2
2
RD23633
Armature assembly (230v)
1
5
RD23614
Gearbox housing assembly
1
3
RD23671
Field coil & motor housing assembly (110v)
1
5.1
RD33602
Gearbox
1
3
RD23673
Field coil & motor housing assembly (230v)
1
5.2
RD43304
Seal
2
1.1
RD43624
Screw
4
5.3
RD43305
Bearing
2
1.2
RD33611
Fan guide
1
5.4
RD43306
Circlip
1
2
RD23631
Armature assembly (110v)
1
6
RD23615
Inner gearplate assembly
1
2
RD23633
Armature assembly (230v)
1
6.1
RD33609
Inner gearplate
1
2.1
RD45522
Bearing
1
6.2
RM17134
Bearing
1
2.2
RD33610
Armature 110v
1
6.3
RD45614
Bearing pin
1
2.2
RD33623
Armature 230v
1
7
RD23607
Clutch assembly
1
2.3
RD43603
Bearing
1
7.1
RD43607
Locknut
1
2.4
RD35639
Speed sensor
1
7.2
RD43608
Washer
1
3
RD23671
Field coil & motor housing assembly (110v)
1
7.3
RD33603
Brass washer
1
3
RD23673
Field coil & motor housing assembly (230v)
1
7.4
RD33604
Gear
1
4
RD23616
Motor housing assembly
1
7.5
RD43609
Clutch bush
1
3.1
RD33631
Field coil (110v)
1
7.6
RD43626
Dish washer
1
3.1
RD33633
Field coil (230v)
1
7.7
RD33606
Clutch base
1
3.2
RD43625
Screw
2
8
RD23319
Gearbox assembly
1
3.3
RD23623
Motor cable assembly
1
5
RD23614
Gearbox housing assembly
1
3.4
RD35612
Carbon brush
2
6
RD23615
Inner gearplate assembly
1
3.5
RD33616
Brush cap
2
7
RD23607
Clutch assembly
1
3.6
RD23630
Speed controller assembly (110v)
1
8.1
RD33156
Arbor spindle
1
3.6
RD23643
Speed controller assembly (230v)
1
8.2
RD33155
Arbor
1
3.7
RD45610
Screw
2
8.3
RM17134
Bearing
1
3.8
RD35615
End cap
1
8.4
RD33607
Interpinion shaft
1
3.9
RD43618
Screw
4
8.5
RD33608
Gear
1
3.10
RD35617
Terminal
2
8.6
RD43310
Circlip
1
3.11
RD45613
Screw
4
9
RA3118
Spring
1
3.12
RD35619
Terminal cover plate
1
10
RA354
Button
1
3.13
RD45612
Screw
4
11
RD4056
Circlip
1

Issue 10 Original Version December 2011
- 14 -
[12] EXPLODED VIEW OF RAIL CLAMP ASSEMBLY

Issue 10 Original Version December 2011
- 15 -
[12] PARTS LIST FOR RAIL CLAMP ASSEMBLY
Item
No
Description
Part No
Quantity
1
CAPSTAN KNOB
RY4060
2
2
CAPSTAN SPINDLE
RY4061
1
3
CAPSTAN
RY4062
1
4
PIN
RY4063
1
5
COLLAR
RY4064
1
6
WORM
RY4065
1
7
THRUST WASHER
RY4066
1
8
BEARING BUSH
RY4067
1
9
ROLLER PIN
RY4068
1
10
ROLLER
RY4069
2
11
DISTANCE PIECE
RY4070
2
12
CLAMP ARM
RY4071
1
13
COLLAR
RY4072
1
14
SCREW
RD4325
1
15
RIVET
RY4074
4
16
GUARD PLATE
RY4075
1
17
PIVOT PIN
RY4076
1
18
LUBRICATION NIPPLE
RY4077
1
19
ROLL PIN
RY4078
1
20
CLAMP BODY
RY4079
1
21
LOCK SCREW
RY4368
1

Issue 10 Original Version December 2011
- 16 -
[13] EXPLODED VIEW OF QUICK RELEASE RAIL CLAMP
ASSEMBLY

Issue 10 Original Version December 2011
- 17 -
[13] PARTS LIST FOR QUICK RELEASE RAIL CLAMP
ASSEMBLY
Item
No
Description
Part No
Quantity
1
CAPSTAN KNOB
RY4060
2
2
CAPSTAN SPINDLE
RY4061
1
3
CAPSTAN
RY4062
1
4
PIN
RY4063
1
5
COLLAR
RY4064
1
6
WORM
RY4065
1
7
THRUST WASHER
RY4066
1
8
BEARING BUSH
RY4067
1
9
ROLLER PIN
RY4068
1
10
ROLLER
RY4069
2
11
DISTANCE PIECE
RY4070
2
12
CLAMP ARM
RY4071
1
13
COLLAR
RY4072
1
14
SCREW
RY4325
1
15
RIVET
RY4074
4
16
GUARD PLATE
RY4075
1
17
ROLL PIN
RY4078
1
18
CLAMP BODY
RY33125
1
19
LOCK SCREW
RY4368
1
20
CONNECTING ROD
RY33126
1
21
SLIDE BAR
RY33127
1
22
COUNTERSUNK M5
RD4347
1
23
WASHER
RY33138
1
24
CLAMP CONNECTOR
RY33128
1
25
BALL PLUNGER
RY4095
1
26
M5 X 16 SOCKETHEAD
RD4325
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Issue 10 Original Version December 2011
- 18 -
[14] Tips for keeping your machine in correct working
order.
In order to ‘get the best life’ out of your Rotabroach machine always keep in good
working order. A well maintained machine is a happy machine.
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.
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
X
Operation of machine
X
Check brush wear
X
Check magnetic base
X
Check alignment of
the machine
X
Check grease
X
Check Armature
X
Visually check the machine for damage.
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.
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 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.

Issue 10 Original Version December 2011
- 19 -
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 centre 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. Slightly undo the arbor bearing bracket
and, using fingers only, tighten the screws.
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.
Lastly tighten the arbor bearing bracket.
Check machines 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
gain the best from the machine.
Check Armature of the machine.
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 10 Original Version December 2011
- 20 -
[15] TROUBLE SHOOTING
Hole cutters break quickly, holes are bigger
than the hole cutter
- Play in the guide
- Bent spindle
- Shaft extending from the motor is bent
- Uneven work surface causing lack of magnetic adhesion.
- Bent pilot
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 bearing (bottom of the armature) worn out
- Gear(s) worn out
- No grease in gear box
Motor humming, big sparks and motor has
no force
- Armature burned
- Field burned
- Carbon brushes worn out
Motor does not start or fails.
- Damaged or defective wiring
- Dirt in sensor of Speed Control Unit
- Defective Speed Control Unit
- Defective speed control or its wiring
- Defective or loose magnet on top of armature
- Damaged or defective brushes
Guiding takes a great deal of effort
- Guide is set too tight
- Guide is dry
- Guide/gear- rack/rotation system dirty or damaged
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 Power switch is turned
on
- Damaged or defective wiring
- Wrong value fuse
- Defective magnet switch
- Defective Control Unit
Fuse blows when motor is started up
- Damaged or defective wiring
- Wrong value fuse
- Motor running roughly
- Defective Armature and / or Field
- Carbon brushes worn out
- Defective Control Unit
Rotation system free stroke too long
- Loose or defective gear-rack
- Defective rotation system