Rotabroach COMMANDO40/3 User manual

Issue 1 Original version Dec 2014
- 1 -
Magnetic drilling machine
Model Number COMMANDO40/1, COMMANDO40/3
This machine (Serial Number ...........................) is CE approved.
Rotabroach™Ltd
Imperial Works, Sheffield Road
Sheffield, South Yorkshire
United Kingdom
S9 2YL
Tel: [phone] Fax: [phone]
Email: [email protected].uk Web site: www.rotabroach.co.uk

Issue 1 Original Version October 2014
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Thank you for purchasing our Commando 40 magnetic drill.
We would really like your feedback on the machine.
Other Products by Rotabroach™:
Thank you for your purchase of our product.
For more information please visit our website at www.rotabroach.co.uk
Or contact our sales department on [phone]

Issue 1 Original Version October 2014
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CONTENTS OF THE MANUAL.
1) INTENDED USE ____________________________________________________________________ 4
2) GENERAL SAFETY RULES ____________________________________________________________ 4
3) OPERATIONAL SAFETY PROCEDURES __________________________________________________ 4
4) INFORMATION PLATE SYMBOLS ______________________________________________________ 6
5) SPECIFICATION____________________________________________________________________ 7
6) MAGNET DETECTION_______________________________________________________________ 8
7) EXTENSION CABLE SELECTION________________________________________________________ 9
8) MOUNTING OF CUTTERS ____________________________________________________________ 9
9) REMEDIES FOR HOLE MAKING PROBLEMS _____________________________________________ 10
10) WIRING DIAGRAM _______________________________________________________________ 11
11) EXPLODED VIEW OF MACHINE _____________________________________________________ 12
12) EXPLODED VIEW OF MOTOR AND GEARBOX __________________________________________ 13
13) PARTS LIST _____________________________________________________________________ 14
14) PIPE ADAPTOR KIT RD2311 ________________________________________________________ 15
15) FITTING THE CHUCK______________________________________________________________ 16
16) MAINTENANCE__________________________________________________________________ 16
17) TROUBLE SHOOTING _____________________________________________________________ 18
18) CUTTER SELECTION AND SPEEDS ___________________________________________________ 20
19) WARRANTY STATEMENT __________________________________________________________ 22
P/N
Drawing
number
List of Contents with Magnetic Dill Unit
Check list
(Y/N)
RD4329
64
Safety Strip
RD4088
65
Hexagon Spanner 4mm
RD4152
66
Hexagon Spanner 3mm
RD33154
67
Drill Chuck Key
RD43099
68
13mm Drill Chuck
RD33153
69
Drill Chuck Adaptor
RD35612
8.35
Replacement Carbon Brush

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1) INTENDED USE
The intended use of this magnetic drill, is to drill holes in ferrous metals. The magnet is used to hold
the drill in place whilst the drill is functioning.
Any deviation from its intended use will not be covered by warranty.
2) GENERAL SAFETY RULES
Read all these instructions before attempting to operate the machine.
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.
Remove the power supply before carrying out any adjustment, servicing or maintenance.
Follow instructions for lubricating and changing accessories.
All repairs to be carried out by an authorized Rotabroach service facility.
3) OPERATIONAL SAFETY PROCEDURES
OPERATING INSTRUCTIONS
READ BEFORE USING THE MACHINE
1. 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.
2. 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.
3. Avoid unintentional starting. Ensure the magnet is OFF before plugging the machine in.
4. Consider the toxicity of dust produced from the cutter and material being cut. Use approved
extraction and or Personal Protective Equipment (PPE).
5. Secure work where possible, use clamps or a vice to hold the work. It is safer than using your
hand.
6. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool
before turning it on.
7. Never operate the machine if parts are missing or damaged.
8. Never direct jets of water or flammable liquids over the drill.
9. Operator must be physically able to handle the weight of the machine.
10. Operator should be trained in the use of the machine.
11. If the machine is accidentally dropped, ALWAYS thoroughly examine the machine for signs of
damage and check that it functions correctly BEFORE resuming drilling.
12. 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.
13. Keep work area clear - cluttered areas and benches invite injuries.
14. Consider work area environment;
Do not expose tools to rain.
Do not use tools in damp or wet locations.

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Keep work area well lit (500 Lux recommended).
Do not use tools in the presence of flammable liquid or gases
Ensure there is adequate space to gain access to the plug, mains and motor on/off switches.
Regularly clear the work area and machine of swarf and dirt, paying particular attention to
the underside of the magnet base.
15. Do not force the machine. It will do the job better and safer at the rate for which it was intended.
16. Use the right tool;
Do not force small tools to do the job of a heavy duty tool.
17. When using the drill, always ensure a safe operating distance from any swarf and do not reach
into the cutting area, or near the cutter, when the machine is running.
18. Do not overreach! Keep proper footing and balance at all times.
19. Cutting tools may shatter, ALWAYS position the guard over the cutter before activating the
machine. Failure to do so may result in personal injury.
20. 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.
21. Use Personal Protective Equipment (PPE) when using this machine;
Use safety glasses to prevent debris from damaging eyes.
Use ear defenders or ear plugs for hearing protection.
Use face or dust masks if cutting operations create dust.
Use protective gloves to prevent swarf or debris cutting the skin.
22. 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 a protective hair covering to contain long hair. This will reduce the risk of
entanglement.
23. 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.
Remove from the mains prior to any maintenance.
Follow instructions for lubricating and changing accessories.
24. On completion of the cut, a slug will be ejected. DO NOT operate the machine if the slug has not
ejected as it may cause injury.
25. 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.
26. Store idle tools when not in use. All tools should be stored in a dry locked-up place, out of reach
of children
27. WARNING! The vibration emissions during actual use can differ from the declared total value
depending on the ways in which the tool is being used.

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28. Stay alert! 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.
29. Warning! The use of any accessory or attachment, other than ones recommended in this
instruction manual, may present a risk of personal injury.
30. Insecure anchorage, a loosely fitting slide or a worn bearing in the arbor support usually causes
cutter breakage.
31. Guard against electric shock: Avoid body contact with earthed or ground surfaces (e.g. pipes,
radiators, cookers and refrigerators).
32. Electric safety can be further improved by using a high-sensitivity (30 m A/0.1s) residual current
device (RCD).
33. 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.
34. Inspect tool cords periodically and if damaged have it repaired by an authorized Rotabroach
service facility.
35. Only use extension cables approved for site conditions.
4) INFORMATION PLATE SYMBOLS
1 2 3 4
1Refer to the user manual for operational and safety issues with regard to this machine.
2Dispose of the machine and electrical components correctly.
3Eye protection must be worn when operating the machine.
4Ear defenders must be worn when operating the machine.

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5) SPECIFICATION
Maximum hole cutting capacity in .2/.3C steel = 40mm dia. x 50mm deep
Arbor bore = 19.05mm (3/4”) dia.
Motor Unit
(Nominal values)
COMMANDO40/1
110V 50-60Hz
1100W (10A)
COMMANDO40/3
230V 50-60Hz
1100W
Electro Magnet
COMMANDO40/1
110V 50-60Hz
45W
COMMANDO40/3
230V 50-60Hz
45W
Total Normal Full Load (magnet + motor)
1145
Overall
Dimensions
Height (maximum extended)
510 mm
Width (including Hand Wheel)
180 mm
Length Overall (including Guard)
265 mm
Magnet Footprint
165mm x 80mm
Nett Weight
14.6 kg
Stroke
85mm
No Load speed
All voltages
270-610 rpm
Tractive Force of Magnet at 20º C (25mm min. plate thickness)
The use on any material less than 25mm 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.
Failure to do so may result in personal injury.
8000N
Maximum hand/arm vibration magnitude (measured at handle during operation in
accordance with ISO5349, using a 22mm dia cutter through a 13mm mild steel plate).
2.892 m/s²
Estimate of vibration exposure. Operation 30 holes @ 1 minute/hole.
0.13 m/s² A(8)
Average noise level during cutting at operator’s ear position.
LPA Max. 88.4 dB(A)
LWA Max. 101.4dB(A)
Ear and eye defenders 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. 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!
NB: ANY MODIFICATIONS TO THIS MACHINE WILL INVALIDATE THE GUARANTEE

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6) MAGNET DETECTION
It is advised that when working on thin material a packing piece should be used to increase the
material thickness under the magnet. Working on thin material without a packing piece will reduce
the magnet holding force.
It is advised that the drill is to be operated on ferrous material 6mm thick and above. Damage to the
magnet base, such as pitting, will affect the strength of the magnet holding force.

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7) EXTENSION CABLE SELECTION
The machines are factory fitted with a 3 meter length cable, having three conductors 1.5mm² 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:
For 110v supply: 3.5metres of 3 core x 1.5mm² For 230v supply: 26metres of 3 core x
1.5mm²
ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE
CHANGING CUTTERS.
8) MOUNTING OF CUTTERS
The machine has been made to accept cutters having 19.05mm (3/4”) dia. Weldon shanks.
The following procedure is to be used when mounting cutters:
oLay 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.
oTake appropriate pilot and place through the hole in the cutter shank. Insert shank
of cutter into bore of arbor, ensuring alignment of two drive flats with socket
screws.
oTighten both screws using hexagon key.

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9) REMEDIES FOR HOLE MAKING PROBLEMS
Problem
Cause
Remedy
1) Magnetic base
won’t hold
effectively
Material being cut may be too thin for efficient
holding.
Attach an additional piece of metal under work-piece where
magnet will be located, or mechanically clamp magnetic base
to work-piece.
Swarf or dirt under magnet.
Clean magnet.
Irregularity on magnet contact or work-piece.
Use extreme care; file any imperfections flush to surface.
Insufficient current going to magnet during drilling
cycles.
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.
See causes and remedies above.
Worn arbor bushing and/or ejector collar.
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 stabiliser.
Too much feed pressure at start of cut.
Replace or re-sharpen. Sharpening service is available.
Cutter is dull, worn, chipped or incorrectly
sharpened.
Improve centre-punch and/or replace worn parts
Poor centre-punch mark; weak pilot spring; pilot not
centred in centre-punch mark.
Replace part or parts
Worn or bent pilot, worn pilot hole.
Replace part or parts
Loose bolts on motor bushing support bracket, main
casting or loose gib adjusting set screws.
Adjust where necessary
3) Excessive
drilling pressure
required
Incorrectly re-sharpened, worn or chipped cutter.
Re-sharpen or replace.
Coming down on swarf lying on surface of work-
piece.
Take care not to start a cut on swarf.
Gibs out of adjustment or lack of lubrication.
Adjust setscrews, and lubricate.
Swarf accumulated (packed) inside cutter.
Clear cutter.
4) Cutter
breakage
Steel swarf or dirt under cutter.
Remove cutter, clean part thoroughly and replace.
Incorrectly re-sharpened or worn cutter.
Always have a new cutter on hand to refer to for correct tooth
geometry, together with instruction sheet.
Cutter skipping.
See causes and remedies (2).
Gib Strip need adjustment.
Tighten Gib Strip.
Cutter not attached tightly to arbor.
Retighten.
Insufficient use of cutting oil or unsuitable type of oil.
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.
Do not use. Refer to instructions and a new cutter for proper
tooth geometry.
Exercise, insufficient or spasmodic cutting pressure.
Use sufficient steady pressure to slow the drill down. This will
result in optimum cutting speed and chip load.

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10) WIRING DIAGRAM

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11) EXPLODED VIEW OF MACHINE

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12) EXPLODED VIEW OF MOTOR AND GEARBOX

Commando 40 Manual Original instructions June 2014
14
13) PARTS LIST
Item
Rotabroach P/N
Description
Qty/pcs
Item
Rotabroach P/N
Description
Qty/pcs
1
RD4347
M5×16 Cross Sunk Screw
2
13
RD33148
Spacer For Bearing Bracket
1
2
RD45607
M5 Lock Washer
2
14
RD23626/RD23625
Magnet Base Assembly
230v/110v
1
3
RD4103
M3×6 Cross Panhead Screw
1
15
RD4078
M8 Flat Washer
2
4
RD33647
Guard Bracket
1
16
RD4079
M8 Elastic Washer
2
5
RD4077
M4×8 Cross Panhead Screw
7
17
RD43619
M8×88 Hex Head Tap Bolt
2
6
RD33640
Guard
1
18
RD33632
Housing Assembly
1
7
RD4066
M8×8 Lock Screw
2
19
RD4312
M6×12 Lock Screw
4
8
RD23114/RD23115
Motor Assembly 110V/230V
1
20
RD45622
Pin 3×8
2
8.1
RD4056
Circlip 19-Hole
1
21
RD4313
Sleeve
2
8.2
RA354
Button
1
22
RD3303
Pinion Shaft Sleeve
1
8.3
RA3118
Spring
1
23
RD4096
M6 Elastic Washer
5
8.4
RD33155
Arbor
1
24
RD4098
M6×20 Socket Cap Screw
5
8.5
RD4066
Screw M8×8
2
25
RD4077
M4×6 Cross Panhead Screw
4
8.6
RD33156
Arbor Spindle
1
26
RD4302
Warning Label
1
8.7
RD43304
Oil Seal
2
27
RD4325
M5×16 Socket Cap Screw
2
8.8
RD33602
Gearbox
1
28
RD4092
M5 Elastic Washer
6
8.9
RD43305
Ball Bearing 6003
2
29
RD33338
Dirigible Wheel
1
8.10
RD43306
Circlip 35-Hole
1
30
RD4414
M4×10 Socket Cap Screw
2
8.11
RD43607
Lock Assembly
1
31
RD33320
Clamp Assembly
1
8.12
RD43626
Dishing Washer
1
32
RD4269
M6×25 Socket Cap Screw
1
8.13
RD43608
Washer
1
33
RD45605
Coolant Elbow
1
8.14
RD33603
Brass Washer
2
34
RD23603
Cooling Bottle Assembly
1
8.15
RD33604
Big Gear
1
35
RD33644
Gib Support Strip
1
8.16
RD43609
Gear Bushing
1
36
RD33645
Adjustable Gib Strip
1
8.17
RD33606
Internal Tooth Bushing
1
37
RD33630
Slide
1
8.18
RD43310
Circlip 14-Shaft
1
38
RD33600
Rack
1
8.19
RM17134
Ball Bearing 608
3
39
RD33646
Fixed Gib Strip
1
8.20
RD33607
Gear-Shaft
1
40
RD4091
M5×25 Socket Cap Screw
4
8.21
RD33608
Small Gear
1
41
RD4210
Coil Pipe Clamp
1
8.22
RD33609
Inner Gearplate
1
43
RD43357
Spring Washer M4
2
8.23
RD45614
Bearing Pin
1
44
RD43600
Connector
1
8.24
RD45522
Ball Bearing 6001
1
45
RD23110/RD23109
Control Panel Assembly
230v/110v 230v/110v
1
8.25
RD33623/RD33610
Armature 230V/110V
1
46
RD25620/RD25619
Cable Assembly 230v/110v
1
8.26
RD43603
Ball Bearing 629
1
47
RD33643
Capstan Spindle
1
8.27
RD35639
Inductor
1
48
RD33642
Capstan Arm
3
8.28
RD33611
Fan Baffle
1
49
RD43091
Capstan Ball
3
8.29
RD43625
Tapping Screw St4.8×60
2
50
RD33178
Brand Label
1
8.30
RD33633/
RD33631
Field Leadwire Sa 230v/110v
1
51
RD45621
M4×22 Cross Panhead Screw
1
8.31
RDB3069
Bearing Sleeve
1
52
RD4069
M4 External Tooth Washer
1
8.32
RD33186
Commando 40 Motor Housing
1
53
RD45604
Earth Tag
1
8.33
RD43624
Screw SA M5×42
4
54
RD4070
M4 Flat Washer
2
8.34
RD33616
Brush Cover
2
55
RD4068
M4 Hexagon Nut
2
8.35
RD35612
Brush
2
56
RD33341
Flat Key
1
8.36
RD33614
Brush Holder
2
57
RD4095
M6 Flat Washer
4
8.37
RD23643/RD23630
Speed Controller 230v/110v
1
58
RD45606
Protecting Switch
1
8.38
RD45610
Tapping Screw St3.9×16
2
59
RD43117
Cable Gland
1
8.39
RD35617
Terminal
2
60
RD43093
M4×14 Cross Panhead Screw
2
8.40
RD45613
Screw M3×6
4
61
RD33145
Depth Gauge
1
8.41
RD35619
Protector
1
62
RD33146
Label-Plate Rivet
2
8.42
RD45612
Tapping Screw St3.9×12
4
63
RD33144
Handle Sheath
1
8.43
RD23623
Motor Cable Assembly
1
64
RD4329
Safety Strip
1
8.45
RD35615
End Cap
1
65
RD4088
Hexagon Spanner 4mm
1
8.46
RD43618
Tapping Screw St3.9×32
4
66
RD4152
Hexagon Spanner 3mm
1
9
RD33070
Information Plate
1
67
RD33154
Drill Chuck Key
1
10
RD45624
Needle Bearing Hk354216
1
68
RD43099
13mm Drill Chuck
1
11
RD45620
Spring Plunger
2
69
RD33153
Drill Chuck Adaptor
1

Commando 40 Manual Original instructions June 2014
15
14) PIPE ADAPTOR KIT RD2311
FITTING INSTRUCTIONS
Dependent upon the size of the pipe to be cut (see illustrations) attach adjustable angle plates RD3328 with cap screws
RD4325 and washers RD4205 (4 off each) to the magnet sides. Do not tighten.
Locate the machine on the centreline of the pipe taking care that the magnet is in line with the longitudinal axis of the
pipe.
Switch on the magnet and move the sliding plates down to the outside diameter of the pipe. Tighten the screws on both
sides by hand then check once again that the full length of the moving plates is touching the pipe at the front and back,
fasten the plate securely. Feed the safety strap through the lugs at the front of the housing, around the pipe and pull
tight.
When cutting the hole DO NOT use excessive pressure but rather let the cutter ease into the cutting surface.

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16
15) FITTING THE CHUCK
To remove the arbor lay the machine on its side.
Unscrew the two grub screws at the top of the arbor.
When the arbor has become detached from the spindle this can then be removed.
Remove the arbor support bracket and guard with the arbor retained.
Mount the chuck using the chuck adaptor RD33153.
Replacing the chuck is the reverse sequence.
16) MAINTENANCE
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.
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.
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 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
3the 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:

Issue 1 Original Version October 2014
17
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 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 power supply and switch on the 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 your machine.
Check Armature of the machine.
This should be checked at least once a month to check 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 a period of 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.

Issue 1 Original Version October 2014
18
17) TROUBLE SHOOTING
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
- Defective power supply
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 armature and/or field
- Defective magnet protective switch
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
- Defective magnet causing movement
- 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
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
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

Issue 1 Original Version October 2014
19
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 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

Issue 1 Original Version October 2014
20
18) CUTTER SELECTION AND SPEEDS
Possible speed selection for mild steel with ideal conditions at 30 M/min.
Speed selector
position.
Cutter diameter
Nominal RPM
1
40
270
2
32
330
3
24
400
4
19
470
5
16
570
6
14
610
This data is presented for guidance only, and should be adjusted to suit site and material
condition.
Material
Material Hardness
Cutter
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