Rotabroach RHINO 4 User manual

RHINO 4
Petrol Driven Rail Drilling Machine
Model RD074
OPERATOR'S MANUAL
Approved in accordance with GM/RT1310 (Issue 2) CEF Number 12280
This machine (Serial No ) is CE approved.
IN-301-01 / RLL222
SAFETRACK BAAVHAMMAR AB
L.Moelleberga
245 93 Staffanstorp, Sweden
Tel. [phone]
Fax. [phone]

Issue 3 July 2004
- -1
CONTENTS OF THE MANUAL
Page No
[1] Specification of machine 2
[2] Safety procedures 3
[3] Cutting fluid 4
[4] Coolant inducement 4
[5] Fuelling 5
[6] Motor operating instructions 6
[7] Machine operating instructions 8
[8] Cutters for rail drilling machines 9
[9] Maintenance - general 10-11
[10] Exploded view of arbor/spindle assembly/parts list 12-13
[11] Exploded view of arbor spindle drive/parts list 14-15
[12] Exploded view of arbor spindle feed/parts list 16-17
[13] Exploded view of base plate assembly. 18-19
[14] Exploded view of clamp assembly 20-21
List of contents with drill unit Check list
RA356 Pilot (18-65 dia. Long series cutters) YES/NO
RA359 Pilot (13-18 dia. Std. series cutters) YES/NO
RA3047 Pilot (19-52 dia. std. series cutters) YES/NO
RD4088 4mm A/F Tee handled hex key YES/NO
RY2001 Coolant Feed Dispenser YES/NO
RD40038 8mm Hex key YES/NO

Issue 3 July 2004
- -2
[1] ROTABROACH RAIL DRILLING MACHINE MODEL RD074
Maximum hole cutting capacity 36mm dia.
Arbor bore 19.05mm dia. (3/4")
Engine Engine Speed
HONDA GXV50
49cm³ displacement
On load torque 3.04Nm @ 4500rpm
Fuel tank capacity 0,5 litres
No load (engine)
No load (arbor/spindle)
Normal full load (arbor/spindle)
5,000rpm
167rpm
150rpm
Compression
Ratio 8.0:1
Overall dimensions Length
Width
Height
550mm
420mm
380mm
Net Weight 18,5kgs
Maximum hand/arm vibration magnitude
(measured at handle during operation in
accordance with ISO5349)
3.8 m/s²
Estimate of likely daily vibration exposure –
Operation on 2 rails (24 holes @ 1
minute/hole)
0.85 m/s² A(8)
Average noise level during cutting at
operator’s ear position. 81 dB(A)
Approved in accordance with GM/RT1310 (Issue 2) CEF Number 12280
Must only be used in a Green Zone.
Must NOT be used on live conductor rail.
EAR DEFENDERS MUST BE WORN WITHIN 3 METRES
WHEN THE MOTOR IS RUNNING.
ANY UNAUTHORISED MODIFICATIONS TO THIS MACHINE WILL INVALIDATE
THE GUARANTEE

Issue 3 July 2004
- -3
[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 changing cutters, working on the machine, or
removing swarf.
•Always ensure the cutter is securely fastened.
•Remove tie, rings, watches and loose adornments, which might entangle with the rotating
machinery.
•Should the cutter become fast in the workpiece, switch off the motor immediately to
prevent personal injury. Do not attempt to free the cutter by starting and stopping the
motor.
•If the machine is accidentally dropped, always thoroughly examine the machine for signs
of damage and check that it functions correctly before trying to cut a hole.
•Regularly inspect the machine and check that nuts and screws are tight.
•Before fuelling the tank, read section 5 (fuelling)
•Observe local and national Health & Safety requirements before operating the machine.
•Never leave the machine lying on its side. The motor sump oil may be lost at an
inclination greater than 20˚from the vertical. If this may have happened, check the sump
oil level before starting the engine.
•Always wear approved eye and ear protection when the equipment is in operation.
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.

Issue 3 July 2004
- -4
[3] 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)
[4] COOLANT INDUCEMENT
•Constituent items:
Coolant bottle and hose assembly RY2001

Issue 3 July 2004
- -5
[5] FUELLING
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 machine in a well-ventilated area, outdoors only.
•Avoid direct contact with the skin and avoid inhaling fuel vapour
•Always shut off the engine and allow it to cool before refuelling.
•Before fuelling, clean the filler cap and the area around it to ensure that no dirt falls into
the tank.
•Petrol vapour pressure may build up inside the gas tank. In order to reduce the risk of
burns or other personal injury from escaping gas vapour and fumes, remove the gas cap
carefully so as to allow any pressure build-up in the tank to release slowly. Never
remove the fuel filler cap whilst the engine is running,
FUEL
•It is recommended that you always use unleaded petrol with a minimum octane number of
90 ROZ(USA)/Canada: pump octane min. 87.
•Inferior quality petrol may damage the engine, sealing rings, fuel lines or fuel tank.

Issue 3 July 2004
- -6
[6] MOTOR OPERATING INSTRUCTIONS
STARTING
•Observe safety precautions (see Section 2 – Safety Procedures)
•Ensure that the sump oil level is to the correct level.
•Ensure the machine is clamped firmly in position on the rail.
•Ensure on/off switch (RD4748) is set to 1.
•Unscrew petrol tank vent screw.
•If the motor is cold, position cold start indicator to 1 o 1.

Issue 3 July 2004
- -7
•Rotate the fuel cut off valve to the horizontal position.
•Position the cutter feed handle to the forward position.
•Repeatedly pull the engine start cord with a quick, progressive movement until the engine
starts, then release the cord handle.
•When the engine has reached it’s operating temperature, the cold start lever can be moved
from the cold start position.
•Moving the cutter feed handle anti-clockwise will increase the engine speed and feed the
cutter into the rail.

Issue 3 July 2004
- -8
[7] MACHINE OPERATING INSTRUCTIONS
•Keep the inside of the cutter clear of swarf. It restricts the operating depth of the cutter.
•Pressurise the coolant dispenser by pumping the handle until the relief valve extends and
then give a further 5 to 10 pumps of the handle.
•With the pressurised cutting fluid dispenser connected to the coolant feed tube, coolant is
“metered” out by the pilot and is applied directly to the cutting edge.
•To ensure cutting fluid is being correctly metered, depress the pilot by slowly moving the
cutter to touch the rail. Regulate the flow by adjusting the needle valve RD4217.
•As the cutter approaches the rail, the automatic throttle will increase the engine speed to
ensure maximum speed before cutting the hole. Once drilling is complete immediately
fully retract the cutter, this will return the machine to idle speed. DO NOT ALLOW
THE MACHINE TO RUN AT FULL SPEED IF NOT DRILLING.
•When commencing to cut a hole apply light pressure until the cutter is introduced into the
work surface. Pressure can then be increased slightly whilst cutting the hole. Excessive
pressure is undesirable when using the Rotabroach system, it does not necessarily
increase the speed of penetration and it may damage the cutter, greatly reducing its life.
•Cutter breakage is usually caused by insecure clamping.

Issue 3 July 2004
- -9
[8] ROTABROACH CUTTERS FOR RAIL DRILLING MACHINES
All cutters have a 3/4" dia. shank.
ALWAYS ENSURE THAT THE MACHINE IS SWITCHED OFF
Take the chosen cutter and insert into its shank the appropriate pilot. Place the assembly,
correctly aligning the drive flats, into the arbor bore and securely fasten the socket screws
with the hexagon key.
RCV SERIES
(High wear)
CRWC SERIES
(Carbide Tipped)
Dia. mm Part No Pilot No Part No Pilot No
18 RCV180 RA359 CRWC18 RA3047
19 RCV190 RA3047 CRWC19 RA3047
20 RCV200 RA3047 CRWC20 RA3047
21 RCV210 RA3047 CRWC21 RA3047
22 RCV220 RA3047 CRWC22 RA3047
23 RCV230 RA3047 CRWC23 RA3047
24 RCV240 RA3047 CRWC24 RA3047
25 RCV250 RA3047 CRWC25 RA3047
26 RCV260 RA3047 CRWC26 RA3047
27 RCV270 RA3047 CRWC27 RA3047
28 RCV280 RA3047 CRWC28 RA3047
29 RCV290 RA3047 CRWC29 RA3047
30 RCV300 RA3047 CRWC30 RA3047
31 RCV310 RA3047 CRWC31 RA3047
32 RCV320 RA3047 CRWC32 RA3047
33 RCV330 RA3047 CRWC33 RA3047
34 RCV340 RA3047 CRWC34 RA3047
35 RCV350 RA3047 CRWC35 RA3047
36 RCV360 RA3047 CRWC36 RA3047
WHEN ORDERING CUTTERS AND PILOTS ALWAYS QUOTE SERIES TYPE
AND PART NUMBER

Issue 3 July 2004
- -10
[9] MAINTENANCE (General)
TO BE CONDUCTED ONLY BY AUTHORISED PERSONNEL
In order to ensure that the unit is used to its full efficiency there are a few basic maintenance
needs to observe. A regular check-out of the machine will also ensure a prolonged life for
the cutters and easier operation.
Before proceeding with any maintenance work, be certain that the motor control switch is
in the OFF position
Weekly:
Check the gearbox oil level. Remove the oil level plug (1) and check that the oil level is up
to the level of the bottom of the threaded hole. If not, remove the vent pipe plug (2) and fill
with Renogear V220EP (or equivalent) . The open end of the vent pipe is located within the
lifting handle and should always be replaced in this position after filling. Replace both plugs
before use.
THROTTLE ADJUSTMENT.
The machine is supplied pre-set to provide optimum/cutter speed, but may require adjustment
after prolonged use.
The throttle is connected by a wire cable to a dedicated cam and lever arrangement and
activated by the feed handle.
The screw adjuster on the throttle cable should be set with the cutter feed handle fully
forward (cutter fully back) to give maximum engine revolutions without engaging the clutch
and rotating the spindle. This will ensure maximum revolutions for hole cutting.
1
2

Issue 1 28/09/00
PAGE 11
REGULAR SERVICE PERIOD. Perform at indicated
month or hour interval, whichever comes first.
Before
starting work
First month or
10 hours.
Every 3
months or 25
hours
Ever 6 months
or 50 hours
Every 100
hours
Every 2 years
or 300 hours
Check X X
Engine oil Change X X
Check X
Air cleaner Clean X
Clean/adjust X
Spark plug Replace X
Fuel tank filter Clean X
Idle speed Check/adjust X
Valve clearance Check/adjust X
Combustion chamber. Clean X
Fuel tubes Check X
Technical specifications
Inlet 0,06-0,1mm
Valve clearance Exhaust 0,09-0,31
It is advisable that this service is conducted by an authorised Honda agent, or
local specialist distributor.
Idle speed 2500-2700 rpm Should be maximum speed possible without cutter spindle rotating.
Spark plug type NGK C5HSB Gap 0,6-0,7 (.024”-.028”)
Oil type SAE 10W-30

Issue 1 28/09/00
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[10] EXPLODED VIEW OF ARBOR SPINDLE ASSEMBLY

Issue 1 28/09/00
PAGE 13
[10] PARTS LIST FOR ARBOR SPINDLE ASSEMBLY
Item Description Part No Quantity Item Description Part No Quantity
1* MAIN HOUSING RD3747 1 22 COOLANT FEED HOUSING RD3709 1
2 M4 SHAKEPROOF WASHER RD4069 4 23* REAR BRONZE BEARING RD3719 1
3 M8 DOG POINT SOCKET SCREW RD4719 1 24 CIRCLIP RD4056 1
4 CIRCLIP RM22876 1 25 FEED TUBE WEAR CAP RD3714 1
5 ARBOR/SPINDLE STOP RING RD3722 1 26 HOUSING REAR ENDCAP RD3745 1
6 COMBINED NEEDLE THRUST RACE RD4700 2 27 BUTTON RA354 1
7 BEARING RD4701 2 28 VENT PIPE RD3770 1
8 COOLANT FEED TUBE RD3710 1 29 OILSEAL RD4704 1
9 ‘O’ RING RD4702 1 30* OILSEAL PROTECTION RING RD3718 1
10 COOLANT TUBE CLAMP SCREW RD3713 1 31 M4 C/SUNK SKT HD SCREW RD4721 4
11 ‘O’ RING RD4703 1 32 ‘O’ RING RD4736 1
12 CIRCLIP RD4713 1 33* FRONT BRONZE BEARING RD4711 1
13 OIL SEAL RD4712 1 34 M4 SCKT HEAD CAP SCREW RD4728 4
14 FINAL DRIVE KEY RD4705 2 35 M8 x 15 CAPSCREW RD4184 1
15 FINAL DRIVE SPINDLE RD3707 1 36 M8 WASHER RD4078 1
16 ARBOR/SPINDLE RD3704 1 37 1/8” BSPT PLUG RD4745 1
17 GEAR SET RD4742 1 38 M8 HEX NUT RD4192 1
18 ‘O’ RING RD4706 1 39 ROLL PIN RD4740 1
19 ‘O’ RING RD4707 1 40 1/8” BSP ELBOW RD4754 1
20 FEED TUBE RD3701 1 41 FLEXIBLE HOSE ASSEMBLY RD2709 1
21 SPRING RA355 1
* SUPPLIED AS ASSEMBLY RD2708

Issue1
28/09/00
PAGE 14
[11]EXPLODED VIEW OF ARBOR/SPINDLE DRIVE

Issue 1 28/09/00
PAGE 15
[11] PARTS LIST FOR ARBOR/SPINDLE DRIVE
Item Description Part No Quantity Item Description Part No Quantity
1 M4 SHCS RD4728 4 9 M4 SHAKEPROOF WASHER RD4069 4
2 SHAFT COVER RD3746 1 10 KEY RD3771 1
3 O’RING RD4737 1 11 M6 WASHER RD4207 4
4 MAIN HOUSING RD3747 1 12 M6 NYLOC NUT RD4223 4
5 GEAR SET RD4742 1 13 HONDA PETROL MOTOR RD4743 1
6 M6 STUD RD4340 4 14 M6 SHCS RD4156 1
7 CLUTCH ASSEMBLY RD4741 1 15 M6 WASHER RD4095 1
8 BEARING RD4082 2

Issue 1 28/09/00
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[12] EXPLODED VIEW OF ARBOR SPINDLE FEED

Issue 1 28/09/00
PAGE 17
[12] PARTS LIST FOR ARBOR/SPINDLE FEED
Item Description Part No Quantity Item Description Part No Quantity
1 M4 CSINK SET SCREW RD4721 3 12 CAPSTAN ARM RD3759 1
2 O’ RING RD4726 2 13 HAND GRIP RD4752 1
3 CAPSTAN SPINDLE HOUSING RD3712 1 14 O’ RING RD4727 2
4 FLANGED OILITE BUSH RD4724 2
5 MAIN HOUSING RD3747 1 16 CAPSTAN SPINDLE HOUSING RD3757 1
6 FEED GEAR RD3705 1 17 THROTTLE LINK RD3755 1
7 FEED GEAR KEY RD4708 1 18 THROTTLE LINK PIVOT RD3756 1
8 CAPSTAN SPINDLE RD3758 1 19 THROTTLE CAM RD3754 1
9 CIRCLIP RD4730 2 21 SHCS M5 RD4325 1
10 CAPSTAN HUB RD3725 1 22 3 DIA ROLL PIN RD4744 1
11 M8 SOCKET SCREW RD4066 2

Issue 1 28/09/00
PAGE 18
[13] EXPLODE VIEW OF BASE PLATE ASSEMBLY

Issue 1 28/09/00
PAGE 19
[13] PARTS LIST FOR BASE PLATE ASSEMBLY
Item Description Part No Quantity Item Description Part No Quantity
1 M6 C/SNK SET SCREW RD4722 4 4 CLAMP BLOCK RD3715 1
2 6MM DOWEL RD4242 4 5 SIDE PLATE (RH) RD3732 1
3 SIDE PLATE (LH) RD3731 1