Rotabroach RD07A User manual

RHINO 2 PETROL DRIVEN RAIL DRILLING MACHINE
Model No. RD07A
(STIHL BT130)
RAILTRACK CERTIFICATE NUMBER: NT/PT/0024/99
This m chine (Seri l No ) is CE pproved.
Rotabroach Ltd
Imperi l Works, Sheffield Ro d
Sheffield, South Yorkshire
United Kingdom
S9 2YL
Tel: [phone] Fax: [phone]
Email: [e-mail] Web site: www.rotabroach.co.uk

Issue 8 June 2014
2
Thank you for purchasing our Rhino RD07 petrol rail drill.
We would really like your feedback on this machine.
Other Products by Rotabroach:
Thank you for your purchase

Issue 8 June 2014
3
CONTENTS OF THE MANUAL
P ge No
[1] Specific tion of m chine 4
[2] S fety procedures 5
[3] Cutting fluid 5
[4] Cool nt inducement 5
[5] Fuelling nd mixture 6-7
[6] Motor oper ting instructions 8-10
[7] M chine oper ting instructions 11
[8] Cutters for r il drilling m chines 12
[9] M inten nce - gener l 13-14
[10] M inten nce - motor 15-19
[11] Exploded view of rbor/spindle ssembly 20-21
[12]
[13]
[14]
[15]
Exploded view of rbor/spindle drive
Exploded view of rbor/spindle feed
P rts list for r il cl mp
W rr nty
22-23
24-25
26-29
30
List of contents with drill unit Check list
RD439 3/16” Allen Key YES/NO
RD4088 4mm A/F Tee h ndled hex key YES/NO
RD40038
8mm Hex key YES/NO
RY2307 Cool nt Feed Dispenser YES/NO

Issue 8 June 2014
4
[1] ROTABROACH RAIL DRILLING MACHINE MODEL RD07A
M ximum hole cutting c p city 36mm di .
Arbor bore 19.05mm di . (3/4")
Engine Engine Speed
STIHL Model BT130
36.3cm³ displ cement
On lo d torque 74.4Nm @ 150rpm
Fuel t nk c p city 0.8 litres
No lo d (engine)
No lo d ( rbor/spindle)
Norm l full lo d ( rbor/spindle)
9560rpm
200rpm
150rpm
Petrol/oil mix 50:1 with Stihl
25:1 other br nds
Over ll dimensions Length
Width
Height
500mm
420mm
450mm
Net Weight 19.2kgs
M ximum h nd/ rm vibr tion m gnitude
(me sured t h ndle during oper tion in
ccord nce with ISO5349)
15.6 m/s²
Estim te of likely d ily vibr tion exposure –
Oper tion on 2 R ils (24 holes @ 1
minute/hole)
2.47 m/s² A(8)
Aver ge noise level during cutting t oper tors
e r position. 92dB(A)
EAR DEFENDERS MUST BE WORN WHEN THE MOTOR IS RUNNING.
ANY MODIFICATIONS TO THIS MACHINE WILL IN ALIDATE THE GUARANTEE

Issue 8 June 2014
5
[2] SAFETY PROCEDURES
READ BEFORE USING THE MACHINE
•ALWAYS WEAR SAFETY GOGGLES AND EAR DEFENDERS WHEN OPERATING THE
MACHINE.
• Ensure motor is switched off when ch nging cutters, working on the m chine, or
cle ring sw rf.
•Alw ys ensure cutter-ret ining screws re secure.
•Regul rly cle r the work re nd m chine of sw rf nd dirt.
•Re d section [5] p ge 5 before ttempting to fuel the m chine.
•Remove tie, rings, w tches nd loose dornments, which might ent ngle with the
rot ting m chinery.
•Should the cutter become fast in the work piece, switch off the motor immedi tely to
prevent person l injury nd turn the rbor to nd fro. Do not attempt to free the cutter
by starting and stopping the motor.
•If the m chine is ccident lly dropped, lw ys thoroughly ex mine the m chine for signs
of d m ge nd check th t it functions correctly before trying to drill hole.
•Regul rly inspect the m chine nd check th t nuts nd screws re tight.
[3] ROTABROACH CUTTING FLUID
•Rot bro ch cutting fluid h s been specific lly formul ted to signific ntly enh nce the
perform nce nd life of the cutting tool, nd improve the qu lity nd surf ce finish of
the hole.
•Rot bro ch cutting fluid is v il ble in 1 litre (RD208) nd 5 litre (RD229) bottles.
[4] COOLANT INDUCEMENT
•Constituent items:
Cool nt bottle nd hose ssembly RY2307

Issue 8 June 2014
6
[5] FUELLING
The Rot bro ch drilling m chine uses n oil-petrol mixture for fuel.
Warning
Petrol is an extremely flammable fuel.
Use extreme caution when handling petrol or fuel mix.
Do not smoke or bring any fire or flame near the fuel.
Ensure the fuel mix does not spill on to hot engine.
FUELLING INSTRUCTIONS
•Fuel your m chine in well-ventil ted re , outdoors only.
•Alw ys shut off the engine nd llow it to cool before refuelling.
•Petrol v pour pressure m y build up inside the g s t nk of two-cycle engine depending
on the fuel used, the we ther conditions nd the venting system of the t nk. In order to
reduce the risk of burns or other person l injury from esc ping g s v pour nd fumes,
remove the g s c p on the STIHL product c refully so s to llow ny pressure build-up
in the t nk to rele se slowly. Never remove the fuel filler c p whilst the engine is
running,
FUEL MIX
•Prep re the mixture of br nd n me petrol nd qu lity two-stroke engine oil in n
pproved s fety type c nister. Pour in the oil first nd then dd the petrol.
•STIHL two-stroke engine oil is recommended. It is formul ted speci lly for STIHL engines
nd gu r ntees long engine life.
•It is recommended th t you lw ys use unle ded petrol with minimum oct ne number
of 90 ROZ(USA)/C n d : pump oct ne min. 87.
•Inferior qu lity petrol or oils m y d m ge the engine, se ling rings, fuel lines or fuel
t nk.
MIX RATIO
•With STIHL 50:1 two-stroke engine oil: 50 p rts petrol to 1 p rt oil.
•With other br nded two-stroke ir cooled engine oils: 25 p rts petrol to 1 p rt oil.

Issue 8 June 2014
7
For ex mple:
Petrol STIHL Oil 50:1 Other branded 2-stroke oils 25:1
Litres Litres (cc) Litres (cc)
1 0.02 (20) 0.04 (40)
5 0.10 (100) 0.20 (200)
10 0.20 (200) 0.40 (400)
15 0.30 (300) 0.60 (600)
20 0.40 (400) 0.80 (800)
25 0.50 (500) 1.00 (1000)
US gal. US fl.oz. US fl. oz.
1 2½ 5
1
/
8
2½ 6½ 12¾
5 12¾ 25¾
FUEL MIXAGES
•Only mix sufficient fuel for few months work - store in pproved s fety type c nisters.
•Thoroughly sh ke the mixture in the c nister before fuelling your m chine.
•Caution: Pressure may build up in the canister! Open it slowly.
•Cle n the fuel t nk nd c nister from time to time.
•T ke c re when h ndling petrol. Avoid direct cont ct with the skin nd void inh ling
fuel v pour.
•Change the fuel pickup body every year.
•Before fuelling, clean the filler cap and
the area round it to ensure that no
dirt falls into the tank.

Issue 8 June 2014
8
[6] MOTOR OPERATING INSTRUCTIONS
STARTING
Observe s fety prec utions - see section «Safety Procedures»
•Press throttle trigger interlock (2) nd squeeze throttle trigger (3). Move slide control (4)
to START nd then rele se throttle trigger, slide control nd throttle trigger interlock in
th t order.
•For cold start: turn choke knob (5) to CHOKE.
•For warm start: (even if engine h s been running but is still cold) - turn choke knob (5)
w y from CHOKE.

Issue 8 June 2014
9
•Ensure m chine is cl mped firmly in position on r il. Pull the st rter grip slowly with
your right h nd until you feel it eng ge - then give the grip brisk, strong pull - do not
pull out st rter rope more th n 60cm ( bout 2ft) - it might otherwise bre k.
•Do not let the st rter grip sn p b ck - guide it slowly into the housing so th t the st rter
rope c n rewind properly.
•If the engine is new, pull st rter grip sever l times to prime the fuel line.
•When the engine begins to fire, move the choke knob w y from CHOKE nd continue
cr nking - as soon as the engine runs, IMMEDIATELY blip the throttle trigger (3) - the
slide control (4) springs b ck to RUN position (I) nd the engine settles down to idling
speed.
•The rbor should not rot te whilst the engine is idling. If it does, check c rburettor
setting.
•Your m chine is now re dy for oper tion.
•To shut down engine - move slide control to STOP.
At very low outside temperatures allow the engine to warm up.
If the engine doesn't start:
•The combustion ch mber m y h ve flooded if you didn't move the choke knob w y
from CHOKE quickly enough fter the engine beg n to fire.
•Pull off the sp rk plug termin l. Unscrew nd dry off the sp rk plug. Set the slide
control to STOP. Squeeze the throttle trigger fully. Cr nk the engine sever l times with
the st rter to cle r the combustion ch mber. Refit the sp rk plug nd connect the sp rk
plug termin l. Move the slide control to START position nd choke knob w y from
CHOKE - even if the engine is cold. Now st rt the engine.
Fuel tank run until dry and then refuelled:
•Pull the st rter rope sever l times until the fuel line is primed.
During break-in period:
•A f ctory new m chine should not be run t high revs (full throttle off lo d) for the first
three t nk fillings. This voids the unnecess rily high lo ds during the bre k-in period.
•As ll moving p rts h ve to bed in during the bre k-in period, the friction l resist nces in
the engine re gre ter during this period. The engine develops its m ximum power fter
bout 5 to 15 t nk fillings.

Issue 8 June 2014
10
During operation:
•After long period of full throttle oper tion, llow the engine to run for short while t
idling speed so th t the engine he t c n be dissip ted by the flow of cooling ir. This
protects engine mounted components (ignition, c rburettor) from therm l overlo d.
•Check sp rk plug electrode g p bout every 50 oper ting hours - it should be 0.5mm
(0.020ins) - nd djust if necess ry.
After finishing work:
•Storing the machine for a short period: Fill the fuel t nk nd keep the m chine in dry
pl ce until you need it g in.
•Storing the machine for a long period: Dr in nd cle n the fuel t nk. Run the engine
until the c rburettor is dry.
•Check tightness of nuts nd screws (except djusting screws) t regul r interv ls nd
retighten if necess ry.

Issue 8 June 2014
11
[7] MACHINE OPERATING INSTRUCTIONS
•Keep the inside of the cutter cle r of sw rf. It restricts the oper ting depth of the cutter.
•Pressurise the cool nt dispenser by pumping the h ndle until the relief v lve extends
nd then give further 5 to 10 pumps of the h ndle.
•With the pressurised cutting fluid dispenser connected to the cool nt feed tube, cool nt
is “metered” out by the pilot nd is pplied directly to the cutting edge.
•To ensure cutting fluid is being correctly metered, depress the pilot by slowly moving the
cutter to touch the r il. Regul te the flow by djusting the needle v lve RD4217.
•Move the cutter 3-4mm w y from the r il nd run the engine to full throttle by pressing
throttle trigger (3) nd interlock (2) together (see p ge 7) to chieve m ximum RPM.
Once drilling is complete immedi tely rele se the throttle trigger (3), this will return the
m chine to idle speed. DO NOT ALLOW THE MACHINE TO RUN AT FULL SPEED IF NOT
DRILLING.
•When commencing to cut hole pply light pressure until the cutter is introduced into
the work surf ce. Pressure c n then be incre sed slightly whilst cutting the hole.
Excessive pressure is undesir ble when using the Rot bro ch system, it does not
necess rily incre se the speed of penetr tion, it m y d m ge the cutter gre tly reducing
its life.
•Cutter bre k ge is usu lly c used by insecure cl mping.
CAPSTAN AND THROTTLE CONTROL
The Rot bro ch RD07 m chine is provided with vers tile c pst n nd throttle control.
Both c n be djusted to suit your person l preference.
ROTATING THROTTLE CONTROL.
•Remove the Stihl screw (Item 13, see di gr m on p ge 24) from the c pst n h ndle
using the Stihl sp nner provided.
•Rot te the throttle h ndle through 180
0
.
•Repl ce the Stihl screw.
ADJUSTING ANGULAR POSITION OF CAPSTAN HANDLE.
(See di gr m on p ge 24)
•Remove the c pst n spindle (Item 8) from the m in housing.
•Remove the c pst n spindle housings (Item 3).
•Reposition the feed ge r (Item 6) nd the c pst n spindle to give the desired orient tion
of the c pst n.
•Repl ce the c pst n spindle housings.

Issue 8 June 2014
12
[8] ROTABROACH CUTTERS FOR RAIL DRILLING MACHINES
All cutters h ve 3/4" di . sh nk.
ALWAYS ENSURE THAT THE MACHINE IS SWITCHED OFF
T ke the chosen cutter nd insert into its sh nk the ppropri te pilot. Pl ce the ssembly,
correctly ligning the drive fl ts, into the rbor bore nd securely f sten the socket screws
with the hex gon key.
SRCV SERIES
(High wear)
SCRWC SERIES
(Carbide Tipped)
Dia. mm
Part No
Pilot No
Part No Pilot No
18
SRCV180 SRA25
SCRWC18 SRA25
19
SRCV190 SRA25
SCRWC19 SRA25
20
SRCV200 SRA25
SCRWC20 SRA25
21
SRCV210 SRA25
SCRWC21 SRA25
22
SRCV220 SRA25
SCRWC22 SRA25
23
SRCV230 SRA25
SCRWC23 SRA25
24
SRCV240 SRA25
SCRWC24 SRA25
25
SRCV250 SRA25
SCRWC25 SRA25
26
SRCV260 SRA25
SCRWC26 SRA25
27
SRCV270 SRA25
SCRWC27 SRA25
28
SRCV280 SRA25
SCRWC28 SRA25
29
SRCV290 SRA25
SCRWC29 SRA25
30
SRCV300 SRA25
SCRWC30 SRA25
31
SRCV310 SRA25
SCRWC31 SRA25
32
SRCV320 SRA25
SCRWC32 SRA25
33
SRCV330 SRA25
SCRWC33 SRA25
34
SRCV340 SRA25
SCRWC34 SRA25
35
SRCV350 SRA25
SCRWC35 SRA25
36
SRCV360 SRA25
SCRWC36 SRA25
WHEN ORDERING CUTTERS AND PILOTS ALWAYS QUOTE SERIES TYPE AND PART NUMBER

Issue 8 June 2014
13
[9] MAINTENANCE (General)
TO BE CONDUCTED ONLY BY AUTHORISED PERSONNEL
In order to ensure th t the unit is used to its full efficiency there re few b sic
m inten nce needs to observe. A regul r check-out of the m chine will lso ensure
prolonged life for the cutters nd e sier oper tion.
Before proceeding with any maintenance work, be certain that the motor control switch is
in the OFF position.
Weekly:
Check the ge rbox oil level. Remove plugs A nd B nd check th t the oil level is up to the
level of the bottom of the thre ded hole B. If not fill with Renoge r V220EP through hole A
until it flows from hole B. Repl ce plugs A nd B.

Issue 8 June 2014
14
Before
After
finishing
work or
daily
After
each
refuelling
stop
Weekly
Monthly
If
faulty
If damaged
As required
See
page
starting
work
Complete
machine
Visual inspection
(condition, leaks)
X
X
Clean
X
Throttle trigger,
stop switch
Check operation
X
X
7
Filter in fuel
tank
Clean wire mesh
filter
X
Replace foam
element
X
Fuel tank
Clean
X
Air filter
Clean
X
17
Replace
X
17
Cooling inlets
Clean
X
Cylinder fins
Clean
X
Carburettor
Check idle
adjustment
X
16
(drilli
ng spindle
must not turn)
Readjust idle
X
16
Spark plug
Readjust electrode
gap
X
17
All accessible
screws and nuts
(not adjusting
screws)
Retighten
X
Drilling gear
Relubricate
X
Drilling spindle
Clean
X

Issue 8 June 2014
15
[10] MAINTENANCE (Motor)
TO BE CONDUCTED ONLY BY AUTHORISED PERSONNEL
ADJUSTING CARBURETTOR
The c rburettor is set on the production line to obt in optimum perform nce t the
b rometric pressure nd clim tic conditions t the f ctory.
•Check the ir filter - cle n it if necess ry
•W rm up the engine.
•Use t chometer - do not exceed m ximum permissible engine RPM - the engine could
be d m ged by insufficient lubric tion nd overhe ting. M ximum engine speed is
12,000 rpm.
If you h ve to re djust the c rburettor from scr tch, first c rry out the b sic setting s
described below:
Basic setting
•B ck off high speed djusting screw (H) one full turn.
•B ck off low speed djusting screw(L) one full turn.
•If you don't h ve t chometer, do not set the high speed
djusting screw ny le ner by turning it beyond this b sic
setting.
Minor corrections m y be necess ry when oper ting t high ltitude (mount ins) or se
level
•Turn high speed djusting screw (H) nd low speed djusting screw (L) clockwise (le ner)
for oper tion t high ltitude or counter-clockwise (richer) for oper tion t se level.

Issue 8 June 2014
16
•Turn screws very c refully - even very slight ch nges h ve notice ble effect on engine
running beh viour.
Corrections to high speed adjusting screw:
•M ximum off-lo d engine speed is ltered with high speed djusting screw (H). The
engine's m ximum permissible rpm will be exceeded if the setting is too le n - this could
d m ge the engine.
•Do not set the c rburettor le ner to obt in n pp rent incre se in power - you might
exceed the engine's m ximum permissible rpm.
Setting the idling speed (2,000 rpm):
•It is usu lly necess ry to ch nge the setting of the idle speed djusting screw (I) fter
every correction to the low speed djusting screw (L).
Engine stops whilst idling:
•Turn the idle speed djusting screw (I) clockwise until drilling spindle begins to rot te -
then b ck off the screw one h lf turn.
Drilling spindle rotates when engine is idling
•Turn the idle speed djusting screw (I) counter-clockwise until the drilling spindle stops
rot ting - then turn the screw pproxim tely one h lf turn in the s me direction.
Erratic idling behaviour - poor acceleration
•Idle setting is too le n. Turn the low speed djusting screw (L) counter-clockwise until
the engine runs nd cceler tes smoothly.
Exhaust smokes at idling speed
•Idle setting is too rich. Turn the low speed djusting screw (L) clockwise until engine
speed drops, then turn screw b ck one qu rter turn nd check th t the engine
cceler tes smoothly when the throttle is opened.

Issue 8 June 2014
17
CLEANING THE AIR FILTER
All day operation
•Cle n filter d ily. If the work re is very dusty, cle n more often.
•Turn choke knob to CHOKE. T ke out screws (1), remove filter cover (2). Cle n w y dirt
from round filter. Remove fo m (3) nd felt elements (4).
•W sh filter in cle n, non-infl mm ble cle ning solution (e.g. w rm so py w ter) nd
then dry.
•Alw ys repl ce d m ged filter element. Reinst ll the filter.
CHECKING THE SPARK PLUG
•If the engine is down on power, difficult to st rt or runs poorly t idling speed, first check
the sp rk plug.
•Fit new sp rk plug fter pproxim tely 100 oper ting hours - or e rlier if the
electrodes re b dly eroded.
•Remove the sp rk plug - see "If engine doesn't start" Cle n dirty sp rk plug. Check
electrode g p - it should be 0.5mm (0.020ins) - correct if necess ry.
•Rectify f ults which h ve c used fouling of sp rk plug - incorrect c rburettor setting;
too much oil in fuel mix; dirty ir filter; unf vour ble running conditions, e.g. oper ting
t p rt lo d.

Issue 8 June 2014
18
REPLACING THE STARTER ROPE AND REWIND SPRING
•Remove four screws nd st rter cover
•T ke out screw (1) nd pull off rope rotor with w sher (2).
•Remove rem ining rope from rotor, thre d new rope Ø3.5mm (9/64") nd 850mm
(33½") long into the rotor nd secure it with simple overh nd knot. Thre d the other
end from inside, through the rope guide bush nd underside of the st rter grip nd
secure with speci l knot - do not wind rope onto rotor.
•Co t rope rotor be ring bore with non-resinous oil, slide rotor onto st rter post, turn it
b ck nd forth so th t the nchor loop (3) of the rewind spring eng ges.
•Fit the w sher nd screw nd tighten down firmly.
Tensioning the rewind spring
•M ke loop in the st rter rope nd use it to turn the rope rotor six full revolutions
counter-clockwise. Hold the rotor ste dy, str ighten the twisted rope, rele se the rotor,
then let go of the rope slowly so th t it winds onto the rotor.
•The st rter grip must loc te firmly in the rope guide bush. If the grip droops to one side,
dd one more turn on the rope rotor to incre se spring tension.
•When the st rter rope is fully extended it must be possible to rot te the rotor t le st
nother h lf turn. If this is not the c se, the spring is over-tensioned nd could bre k.
T ke off one turn of the rope.

Issue 8 June 2014
19
Replacing a broken rewind spring
•Lubric te the new spring with few drops of non-resinous oil. Do not open the wire
ret iner.
•Remove the rope rotor. Remove the bits of the old spring nd fit the new rewind spring
with the outer spring loop in the recess t the bottom of the st rter cover. The wire
ret iner slips off during this process.
•Reinst ll the rope rotor, tension nd rewind spring nd secure the st rter cover in
position.
•If the spring pops out during inst ll tion, refit it in the counter-clockwise direction
st rting outside nd working inw rds.

Issue 8 June 2014
20
[11] EXPLODED VIEW OF ARBOR SPINDLE ASSEMBLY
From seri l number 65820 onw rds