Rotabroach SMARTPUMA1 Operation instructions

Issue 5 Original version Nov 2014
1
PUMA MAGNETIC DRILLING MACHINE
Model No. SMARTPUMA1 & SMARTPUMA3
T is mac ine (Serial No ) is CE approved.
Rotabroach Ltd
Imperial Works, S effield Road
S effield, Sout Yorks ire
United Kingdom
S9 2YL
Tel: [phone] Fax: [phone]
Email: [e-mail] Web site: www.rotabroach.co.uk

Issue 5 Original version Nov 2014
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Thank you for purchasing our Smart Puma 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.rotabroac .co.uk
Or contact our sales department on [phone]

Issue 5 Original version Nov 2014
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CONTENTS
Page
) Intended Use 4
2) General Safety 4
3) Mac ine Specification 6
4) Operating Instructions 7
5) Cutsmart Feature 8
6) Mounting of cutters 9
7) Remedies for ole making problems 9
8) Wiring Diagram 10
9) Exploded diagram of mac ine 11
0) Exploded diagram of motor and gearbox 13
) Pipe adaptor Kit 15
2) C uck conversion 16
3) Maintenance 16
4) Trouble s ooting 18
5) Cutter Selection, Speeds and Feeds 19
6) Warranty 20

Issue 5 Original version Nov 2014
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) INTENDED USE
T e intended use of t is magnetic drill, is to drill oles in ferrous metals. T e magnet is used to old t e drill in
place w ilst t e drill is functioning. It is designed for use in fabrication, construction, railways, petroc emical
and any ot er applications w en drilling ferrous metal.
Any deviation from its intended use will not be covered by warranty.
2) GENERAL SAFETY RULES
WARNING! W en using electric tools basic safety precautions s ould always be followed to reduce t e risk of fire, electric
s ock and personal injury, including t e following.
Read all t ese instructions before attempting to operate t e mac ine.
Remove t e power supply before carrying out any adjustment, servicing or maintenance.
1. Keep work area clear - cluttered areas and benc es 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 (500 Lux recommended).
•Do not use tools in t e presence of flammable liquid or gases.
•Ensure t ere is adequate space to gain access to t e plug, mains and motor on/off switc es.
3. Guard against electric s ock:
Avoid body contact wit eart ed or ground surfaces (e.g. pipes, radiators, cookers and refrigerators). Electric safety
can be furt er improved by using a ig -sensitivity (30 m A/0.1s) residual current device (RCD).
4. Keep ot er persons away! DO NOT let untrained persons, especially c ildren, touc t e tool or t e extension cord and
keep t em away from t e work area.
5. Store idle tools w en not in use. All tools s ould be stored in a dry locked-up place, out of reac of c ildren.
6. Do not force t e mac ine. It will do t e job better and safer at t e rate for w ic it was intended.
7. Use t e rig t tool;
•Do not force small tools to do t e job of a eavy duty tool.
•Do not use t is tool for purposes not intended: e.g. do not use t e magnetic drill to cut tree logs.
8. Dress properly;
•Do not wear loose clot ing or jewellery; t ey can be caug t in moving parts.
•Non-skid footwear is recommended w en working outdoors.
•Wear a protective air covering to contain long air. T is will reduce t e risk of entanglement.
9. Use protective equipment w en using t is mac ine;
•Use safety glasses to prevent debris from damaging eyes.
•Use ear defenders or ear plugs for earing protection.
•Use face or dust masks if cutting operations create dust.
•Use protective gloves to prevent swarf or debris cutting t e skin.
10. W en using t e drill, always ensure a safe operating distance from any swarf and do not reac into t e cutting area,
or near t e cutter, w en t e mac ine is running.
11. Connect dust extraction and collecting equipment, if devices are provided, ensuring t ese are properly connected and
used.
12. Do not abuse t e cord; never pull t e cord to disconnect it from t e socket. Keep t e cord away from eat, oil and
s arp edges.
12. Secure work w ere possible, use clamps or a vice to old t e work. It is safer t an using your and.
13. Do not overreac ! Keep proper footing and balance at all times.
14. Maintain tools wit care;
•Keep cutting tools s arp and clean for better and safer performance.
•Regularly c eck t e mac ine for any wear or damage.

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•Ensure t e mac ine is clean and free from debris prior to use.
•Remove from t e mains prior to any maintenance.
•Follow instructions for lubricating and c anging accessories.
•Inspect tool cords periodically and if damaged ave t em repaired by an aut orized Rotabroac service facility.
•Inspect extension cords periodically and replace if damaged.
•Keep andles dry, clean and free from oil and grease.
15. Disconnect tools w en not in use, before servicing and w en c anging accessories suc as cutters, disconnect tools
from t e power supply.
16. Form t e abit of c ecking to see t at keys and adjusting wrenc es are removed from t e tool before turning it on.
17. Avoid unintentional starting. Ensure t e magnet is OFF before plugging t e mac ine in.
18. Use extension leads only intended for outdoor use w en t e tool is used outdoors.
19. WARNING! T e vibration emissions during actual use can differ from t e declared total value depending on t e ways
in w ic t e tool is being used.
20. Stay alert! Watc w at you are doing, use common sense and do not operate t e tool w en you are tired. DO NOT
operate t e mac ine w en under t e influence of alco ol or ANY illegal substances.
21. C eck for damaged or missing parts before use of t e tool; it s ould be carefully c ecked to determine t at it will
operate properly for its intended function.
22. Warning! T e use of any accessory or attac ment, ot er t an ones recommended in t is instruction manual, may
present a risk of personal injury.
23. Have your mac ine repaired by a qualified Rotabroac tec nician.
T is electric tool complies wit t e relevant safety rules. Qualified persons using original spare parts s ould only carry
out repairs, ot erwise t is may result in considerable danger to t e user.
24. Never operate t e mac ine if parts are missing or damaged.
25. Never direct jets of water or flammable liquids over t e drill.
26. Operator must be p ysically able to andle t e weig t of t e mac ine.
27. Operator s ould be trained in t e use of t e mac ine.
Foreseeable Misuse
During operation, failure to keep t e cable away from t e mac ine body, will result in t e cable damaged by drill bit, causing
electric conduction and ot er accidental injury.
Before operation, w en plugging t e power source, failure to turn all t e switc es to position <off>, may result in accidental start-
up from t e mac ine, causing accidental injury.
During suspended operation, failure to tie t e safety belt to fasten t e magnetic drill, w en power failure or power down suddenly,
causing magnetic drill to get out of t e work surface and resulting in t e accident.
Other risks
During operation, wear loose clot ing or jewellery, failure to wear protective air covering to containing long air, t ey can be
caug t in moving parts, may present an accidental injury.
During operation ， put in effort to pus and press t e mac ine, will result t e magnet getting out of t e work surface suddenly,
causing accidental injury.
Before mounting or removing t e drill bit, failure to disconnect t e supply, will result t e accidental start-up, causing personal
injury.

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3) SPECIFICATION
Maximum ole cutting capacity in .2/.3C steel = 30mm dia. x 25mm deep
Arbor bore = 19.05mm (3/4”) dia.
Model Voltage (V)(AC) Normal Full Load
Watts (W)
SMARTPUMA1 110V 50-60Hz 800
SMARTPUMA3 230V 50-60Hz 800
Electro Magnet
Model Voltage (V)(DC) Normal Full Load
Amps (A) Watts (W)
SMARTPUMA1 110 0.45 45
SMARTPUMA3 230 0.225 45
Total Normal Full Load (magnet + motor) 845
Overall
Dimensions
Heig t (maximum extended) 410mm
Heig t (minimum) 360mm
Widt (including Hand w eel) 170mm
Lengt Overall (including Guard) 250mm
Magnet Footprint 165mm x 80mm
Net Weig t 11.20kgs
Stroke Wit Arbor
Wit Drill c uck
30mm max
65mm
No Load
Speed
All voltages 600rpm
Tractive Force of Magnet at 20º C (25mm min. plate t ickness)
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.
8000N
Maximum and/arm vibration magnitude (measured at andle during operation in
accordance wit ISO5349 using a 22mm dia. cutter t roug 13mm mild steel plate. 2.95 m/s²
Estimate of vibration exposure. Operation 30 oles @ 1 minute/ ole. 0.39 m/s² A(8)
Average noise level during cutting at operators ear position.
L
PA
Max. 88.3 dB(A)
L
WA
Max. 101.3dB(A)
Suitable only for a single p ase 50-60 Hz A.C. power supply
DO NOT USE ON D.C. SUPPLY
Do not use your magnetic drill on t e same structure w en arc welding is in progress.
D.C. current will eart back t roug t e magnet and cause irreparable damage.
WARNING: THIS APPLIANCE MUST BE EARTHED!
NB: ANY MODIFICATIONS TO THIS MACHINE WILL INVALIDATE THE GUARANTEE
List of Contents wit Magnetic Dill Unit
C eck
List
RD4329 Safety Strap YES/NO
RD4088 4mm A/F Tee Handled Hexagon Key YES/NO

Issue 5 Original version Nov 2014
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4) OPERATING INSTRUCTIONS
READ BEFORE USING THE MACHINE
•W en using electrical tools, basic safety precautions s ould always be followed to reduce t e risk of electric s ock, fire, and personal
injury.
•Ensure t e magnet is OFF before plugging in t e mac ine.
•Do NOT use in wet or damp conditions. Failure to do so may result in personal injury.
•Do NOT use in t e presence of flammable liquids, gases or in ig risk environments. Failure to do so may result in personal injury.
•BEFORE activating t e mac ine, inspect all electrical supply cables (including extension leads), and replace if damaged. DO NOT use if
t ere are any signs of damage.
•Only use extension cables approved for site conditions.
•BEFORE activating t e mac ine, ALWAYS c eck t e correct function of all operational systems, switc es, magnet etc.
•BEFORE operating, t e mac ine MUST be securely restrained to a fixed independent feature (by using safety strap RD4329, or ot er
means) to reduce t e potential free movement, s ould t e magnet become detac ed from t e work piece. Failure to do so may
result in personal injury.
•ALWAYS wear approved eye protectors, ear defenders and recommended PPE at ALL times w en operating t e mac ine.
•Disconnect from power source w en c anging cutters or working on t e mac ine.
•Cutters and swarf are s arp, ALWAYS ensure t at ands are adequately protected w en c anging cutters or removing swarf. Use a
tool or brus w ere necessary to remove any swarf or t e cutter from t e arbor.
•Before operating t e mac ine, ALWAYS ensure cutter-retaining screws are secured tig tly.
•Regularly clear t e work area and mac ine of swarf and dirt, paying particular attention to t e underside of t e magnet base.
•ALWAYS remove tie, rings, watc es and any loose adornments t at mig t entangle wit t e rotating mac inery before operating.
•ALWAYS ensure t at long air is securely enclosed by an approved restraint before operating t e mac ine.
•S ould t e cutter become stuck in t e work piece, stop t e 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. Wear safety
gloves to remove t e cutter from t e arbor.
•If t e mac ine is accidentally dropped, ALWAYS t oroug ly examine t e mac ine for signs of damage and c eck t at it functions
correctly BEFORE resuming drilling.
•Regularly inspect t e mac ine and c eck for any damaged or loose parts.
•ALWAYS ensure w en using t e mac ine in an inverted position t at only t e minimum amount of coolant is used and t at care is
taken to ensure t at coolant does not enter t e motor unit.
•Cutting tools may s atter, ALWAYS position t e guard over t e cutter before activating t e mac ine. Failure to do so may result in
personal injury.
• On completion of t e cut, a slug will be ejected. DO NOT operate t e mac ine as t e ejected slug may cause injury.
•W en not in use ALWAYS store t e mac ine in a safe and secure location.
•ALWAYS ensure t at approved ROTABROACH™ agents conduct repairs.
OPERATION
•Keep t e inside of t e cutter clear of swarf. It restricts t e operating dept of t e cutter.
•Ensure t at t e coolant bottle contains sufficient cutting oil to complete t e required operating duration. Refill as required.
•Occasionally depress t e pilot to ensure cutting fluid is being correctly metered.
•To start t e mac ine follow t e control panel operation instructions.
•ALWAYS switc off t e motor by depressing t e RED stop button. DO NOT switc off t e motor by turning t e magnet switc to
zero.
•Apply lig t pressure w en commencing t e cut of a ole until t e cutter is introduced into t e work surface. Pressure can t en be
increased sufficiently to load t e motor. Excessive pressure is undesirable, it does not increase t e speed of penetration and will
cause t e safety overload protection device to stop t e motor, (t e motor can be restarted by operating t e motor start button), and
may cause excessive eat w ic may result in inconsistent slug ejection
•Always ensure t at t e slug as been ejected from t e previous ole before commencing to cut t e next.
•If t e slug sticks in t e cutter, move t e mac ine to a flat surface, switc on t e magnet and gently bring t e cutter down to make
contact wit t e surface. T is will usually straig ten a cocked slug and allow it to eject normally.
•Apply a small amount of lig t oil lubricant regularly to t e slide and arbor support bearing.
•Cutter breakage is usually caused by insecure anc orage, a loosely fitting slide or a worn bearing in t e arbor support. (Refer to
routine maintenance instructions).
•Only use approved cutting fluid. Rotabroac cutting fluid as been specially formulated to maximise t e cutters performance. It is
available in 1 litre (RD208) and 5 litre (RD229).
EXTENSION CABLE SELECTION
T e mac ines are factory fitted wit a 3 metre lengt of cable aving t ree, 1.5mm² conductors, LIVE, NEUTRAL and EARTH. If it becomes
necessary to fit an extension cable from t e 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 t e magnet and a reduction of power from t e motor.
Assuming a normal AC supply of t e correct voltage, it is recommended t at t e following extension lengt s s all not be exceeded:
For 0v supply: 3.5metres of 3 core x .5mm²
For 230v supply: 26 metres of 3 core x .5mm² or 7metres of 3 core x .0mm²

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5) CUTSMART FEATURE
‘CutSmart’ is a new feature from Rotabroac .
Designed to elp you to get t e best out of your mac ine. It does t is by way of a visual indicator.
T e visual indicator s ows w en you are using t e drill correctly wit in its specification t is is done by way of a
Tri colour LED to t e Rig t of t e magnet on LED.
During operation if you are drilling correctly t is will stay GREEN. However as you put more pressure onto t e
drill increasing its workload above its correct operation t e LED will start to c ange colour to ORANGE. T is
indicates t at you are putting more wear on t e mac ine and t e cutter w ic will eventually cause damage to
your mac ine. If furt er pressure is put on t e mac ine t e LED will eventually turn RED and t e motor will cut
off and will not be allowed to be turned back on for approximately 5 seconds. T is is a safety feature to protect
you and t e mac ine from damage.
Ideally to get t e most out of your mac ine you need to keep t e LED green w en drilling. If it starts to turn
orange release some pressure.
T e panels are set to cut off w en t e mac ine reac es t e following currents.
110V panel – approximately 17 amps
230V panel – approximately 10 amps
T e magnet is also protected by a 2A fuse
Care must be taken w en andling t e PCB as t ey are static sensitive please ensure you are eart ed. As t e
PCB contains some delicate components please do not flas test t is equipment.
New Cutsmart
indicator
Indicator turns
orange w en too
muc pressure is
added on t e
cutter. Will turn
Red and cut
power to motor if
mac ine is given
too muc force
for t e motor to
cope wit .

Issue 5 Original version Nov 2014
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6) MOUNTING OF CUTTERS
(See exploded view of complete mac ine)
T e mac ine as been made to accept cutters aving 19.05mm (3/4”) dia. s anks.
T e following procedure is to be used w en mounting cutters.
•Lay t e mac ine on its side wit feed andles uppermost, ensuring arbor is wound down to its lowest point to enable access to
socket screws #12.5.
•Take appropriate pilot and place t roug ole in s ank of cutter. Insert s ank of cutter into ¾” dia. bore of arbor, ensuring
alignment of two drive flats wit socket screws #12.5.
•Tig ten bot screws using exagon key RD4088.
ALWAYS DISCONNECT MACHINE FROM POWER SOURCE.
7) REMEDIES FOR HOLE MAKING PROBLEMS
Problem Cause Remedy
1) Magnetic base won’t
old effectively
Material being cut may be too t in for efficient olding.
Swarf or dirt under magnet.
Irregularity on magnet contact or work-piece.
Insufficient current going to magnet during drilling cycles.
Attac an additional piece of metal under work-piece w ere magnet will be located,
or mec anically clamp magnetic base to work-piece.
Clean magnet.
Use extreme care; file any imperfections flus to surface.
Confirm power supply and output from control unit, c eck supply cable.
2) Cutter skips out of
centre-punc mark at
initiation of cut
Magnetic base is not olding effectively.
Worn arbor bus ing and/or ejector collar.
Too muc feed pressure at start of cut.
Cutter is dull, worn, c ipped or incorrectly s arpened.
Poor centre-punc mark; weak pilot spring; pilot not centred in centre-
punc mark.
Worn or bent pilot, worn pilot ole.
Loose bolts on motor bus ing support bracket, main casting or loose
gib adjusting set screws.
See causes and remedies above.
Replace! Only a few t ousandt s wear permissible. New arbor bus ing is needed.
Lig t pressure only is needed until a groove is cut. T e groove t en serves as a
stabilizer.
Replace or re-s arpen. S arpening service is available.
Improve centre-punc and/or replace worn parts
Replace part or parts
Adjust w ere necessary
3) Excessive
drilling pressure
required
Incorrectly re-s arpened, worn or c ipped 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-s arpen 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-s arpened or worn cutter.
Cutter skipping.
Slide-ways need adjustment.
Cutter not attac ed tig tly to arbor.
Insufficient use of cutting oil or unsuitable type of oil.
Remove cutter, clean part t oroug ly and replace.
Always ave a new cutter on and to refer to for correct toot geometry, toget er
wit instruction s eet.
See causes and remedies (2).
Tig ten sideway.
Retig ten.
Inject oil of lig t viscosity into t e coolant-inducing ring and c eck t at oil is being
metered into cutter w en pilot is depressed. If not, c eck 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-s arpened cutter.
Insufficient or spasmodic cutting pressure.
Refer to instructions and a new cutter for proper toot geometry.
Use sufficient steady pressure to slow t e drill down. T is will result in optimum
cutting speed and c ip load.

Issue 5 Original version Nov 2014
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8) WIRING DIAGRAM
No
Function
Wire Colour
1
Magnet 1
-
(110v & 230v Magnet)
Black
2
Magnet 2+ (110v & 230v Magnet)
Red
3
Motor
Blue
4
Magnet reed switc
Black
5
Motor
Brown
6
N/C
7
Mains (
Neutral
)
Blue
8
Magnet reed switc
Red
9
Mains (
Live
)
Brown

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9) EXPLODED DIAGRAM OF MACHINE

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Component parts list for Rotabroach Puma CM/300/1 & CM/300/3 From serial number 107621
Item Part number Discription Quantity Item Part number Discription Quantity
1 RD23094 Control panel assembly 110v. 1 8.6 RD43093 Screw. 1
1 RD23095 Control panel assembly 230v. 1 8.7 RD43116 Spacer block 1
2 RD23081 Magnet assembly 110v. 1 9 RD23014 Bearing bracket assembly. 1
2 RD23083 Magnet assembly 230v. 1 9.1 RD33099 Bearing bracket. 1
2.1 RD45606 Protection Switch 1 9.2 RD4518 Bearing 1
3 RD23008 Capstan assembly. 1 10 RD23015 Arbor sleeve assembly. 1
3.1 RD33088 Capstan spindle. 1 9 RD23014 Bearing bracket assembly. 1
3.2 RD43091 Capstan ball. 3 10.1 RD33100 Ejector sleeve. 1
3.3 RD33089 Capstan arm. 3 10.2 RA353 Pin. 1
3.4 RD33090 Capstan pinion sleeve. 1 10.3 RD4519 Thrust washer. 2
3.5 RD33092 Bearing. 2 10.4 RD43084 Circlip. 2
3.6 RD4098 M6 Socket head cap screw. 1 11 RD23016 Guard assembly. 1
3.7 RD4207 M6 Spring washer. 1 11.1 RD33101 Guard. 1
4 RD23064 Motor & Gearbox assy 110v. 1 11.2 RD33102 Guard bracket 1
4 RD23065 Motor & Gearbox assy 230v. 1 11.3 RD43092 Screw. 2
5 RD23009 Mains cable assembly 110v. 1 11.4 RD43096 Screw. 2
5 RD23012 Mains cable assembly 230v. 1 11.5 RD43097 Ball plunger 2
6 RD23003 Housing assembly. 1 11.6 RD43098 Shakeproof washer. 1
6.1 RD33094 Housing. 1 11.7 RD4252 M3 screw 1
6.2 RD4102 Tension pin. 2 12 RD23019 Arbor assembly. 1
6.3 RD33077 Logo plate. 1 12.1 RD33137 Arbor spindle. 1
6.4 RD4077 Screw. 4 12.2 RD4056 Circlip. 1
6.5 RD43093 Screw. 1 12.3 RA354 Button. 1
6.6 RD4069 Shakeproof washer. 1 12.4 RD3319 Spring. 1
6.7 RD4068 Nut. 2 12.5 RD4066 M8 Socket screw. 4
6.8 RD43094 Earth tag. 1 13 RD23018 Gib strip assembly 1
6.9 RD4070 Washer. 1 13.1 RD33103 Fixed gib strip 1
6.10 RD4312 Screw. 4 13.2 RD33104 Adjustable gib strip 1
6.11 RD4302 Information plate. 1 13.3 RD33105 Gib support strip 1
6.13 RD4077 M4 x 8 Pan head 1 14 RD33106 Motor support bracket. 1
6.14 RD43113 M4 spring washer 1 15 RD4157 M6 Socket head screw. 2
6.15 RD43117 Mains cable clamp 1 16 RD4096 M6 Shakeproof washer. 2
6.16 RD33145 Depth Guage 1 17 RD4091 M5 Socket head screw. 4
6.17 RD33146 Rivet 1 18 RD4092 M5 Shakeproof washer. 4
6.18 RD33144 Rubber Handle 1 19 RD33107 Bearing spacer. 1
6.19 RD43093 Screw 2 20 RD4319 M8 Bolt 2
7 RD23010 Motor supply cable assembly. 1 21 RD4079 M8 Shakeproof washer 2
7.1 RD33095 Cable assembly. 1 22 RD4078 M8 Washer 2
7.2 RD43095 cable clip. 2 23 RD4098 M6 Socket head cap screw. 2
7.3 RD43346 Motor cable elbow 1 24 RD4095 M6 Washer. 2
7.4 RD43112 Connector 1 25 RD4329 Safety Strap 1
8 RD23004 Slide assembly 1 26 RD4088 4mm Allen Key 1
8.1 RD33096 Slide. 1 27 RD43099 13mm Drill Chuck 1
8.2 RD33097 Rack. 1 28 RD33153 Drill Chuck Adaptor 1
8.3 RD4325 M5 socket head screw. 2 29 RD33154 Drill Chuck Key 1
8.4 RD4092 M5 Shakeproof washer. 2
8.5 RD4069 Shakeproof washer. 1

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0) EXPLODED DIAGRAM OF MOTOR AND GEARBOX
(From serial No 0699 and greater)

Issue 5 Original version Nov 2014
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Item
Part
Number Description Qty Item
Part
Number Description Qty
1 RD23020 Output shaft assembly. 1 6.2 RD33111 Field coil 110v. 1
1.1* RD33139 Output shaft. 1 6.3 RD33085/B Motor casing. 1
1.2 RM304210 Bearing. 1 6.4 RD33086 Brush end cap. 1
1.3 RM22876 Circlip. 1 6.5 RM297640 Carbon Brush assy 110v. 2
2 RD23024/B Gearbox Housing assembly. 1 6.6 RD43089 Screw. 2
2.1 RD33081/B Gearbox Housing. 1 6.7 RD43118 Capacitor 1
2.2 RM22876 Circlip. 1 6.8 RD43119 Terminal 1
3 RD23001/B Gearbox assembly. 1 6.9 RD43120 Screw. 4
1 RD23020 Output shaft assembly. 1 6.10 RD43121 Brush cover spring 1
2 RD23006/B Gearbox Housing assembly. 1 6 RD23023/B Motor case assembly 230v 1
3.1 RD43085 Screw. 4 6.1 RD33084 Field coil baffle. 1
3.3* RD33128 Key 1 6.2 RD33113 Field coil 230v. 1
3.4 RD33082 Final drive gear. 1 6.3 RD33085/B Motor casing. 1
3.5 RD43087 Circlip 1 6.4 RD33086 Brush end cap. 2
3.6 RD33083 Intermediate gear. 1 6.5 RM297630 Carbon Brush assy 230v. 2
4 RD23007/B Inner Gear plate assembly. 1 6.6 RD43089 Screw. 2
4.1 RD23007 Inner Gear plate. 1 6.7 RD43118 Capacitor 1
4.2 RD43088 Ph Bz Bearing. 1 6.8 RD43119 Terminal 1
4.4 RM22880 Needle Bearing. 2 6.9 RD43120 Screw. 4
5 RD23011 Armature assembly 110v 1 6.10 RD43121 Brush cover spring 2
5.1 RD33091 Armature 110v 1 7 RD23031 Motor assembly 110v 1
5.2 RM17134 Bearing. 2 5 RD23011 Armature assembly 110v 1
5.3 RD43122 Washer 3 6 RD23021/B Motor case assembly 110v 1
5.4 RD43123 Dust proof Ring 1 9 RD33087/B Motor end cap 1
5 RD23013 Armature assembly 230v 1 8 RD43090 Screw. 2
5.1 RD33093 Armature 230v 1 7 RD23033 Motor assembly 230v 1
5.2 RM17134 Bearing. 2 5 RD23013 Armature assembly 230v 1
5.3 RD43122 Washer 3 6 RD33113 Field coil 230v. 1
5.4 RD43123 Dust proof ring 1 8 RD43090 Screw. 2
6 RD23021/B Motor case assembly 110v 1 9 RD33087 Motor End Cap 1
6.1 RD33084 Field coil baffle. 1 10 RD43346 Motor Cable elbow 1

Issue 5 Original version Nov 2014
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) PIPE ADAPTOR KIT RD23
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 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
2) CHUCK CONVERSION
•To remove t e arbour lay t e mac ine on its side.
•Unscrew t e two grub screws at t e top of t e arbor
•Some early mac ines will only ave spanner flats on t e arbor.
•W en t e arbor as become detac ed from t e spindle t is can t en be removed
•Remove t e arbour support bracket and guard wit t e arbour retained.
•Mount t e c uck using t e c uck adaptor RD33153.
•Replacing t e c uck is t e reverse sequence.
3) MAINTENANCE
In order to ‘get t e best life’ out of your Rotabroac ™ mac ine always keep in good working
order.
A number of items must always be c ecked on Rotabroac ™ mac ines.
Always before starting any job make sure t e mac ine is in good working order and t at t ere
are no damaged or loose parts. Any loose parts must be tig tened.
Before proceeding with any maintenance work be certain that the power supply is
disconnected.
Description
Every operation
week
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 grea
se
X
Check Armature
X
Visually check the machine for damage.
Mac ine must be c ecked before operation for any signs of damage t at will affect t e
operation of t e mac ine. Particular notice must be taken of t e mains cable, if t e mac ine
appears to be damaged it s ould not be used failure to do so may cause injury or deat .
Check operation of the machine.
T e mac ines operation must be c ecked to ensure t at all components are working correctly.

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17
Machine Brushes - s ould be c ecked to make sure t ere is no abnormal wear present t is
s ould be c ecked at least once a week if used frequently. If t e brus as worn more t an 2/3
t e original lengt t e brus es s ould be c anged. Failure to do so may cause damage to t e
mac ine.
Magnetic base – before every operation t e magnetic base s ould be c ecked to make sure
t at t e base is flat and t ere is no damage present. An uneven magnet base will cause t e
magnet not to old as efficiently and may cause injury to t e operator.
Adjustment of slide and bearing bracket Alignment.
An essential requirement of t e mac ine is t at t e slide can move in a smoot and controlled
manner, free of lateral movement and vibration.
T is situation can be maintained by periodic adjustment of t e slide and is accomplis ed in t e
following manner:
1. Place t e mac ine in an uprig t position and, by means of t e capstan, raise t e slide to
its ig est position. Clean t e brass gib strips and apply a small amount of lig t mac ine
oil to t e wear surfaces.
2. Now lower t e slide back to its lowest position. Bring t e slide into t e centre of t e
dovetail slide ousing and loosen screws t us allowing free movement of t e arbor
support bracket.
3. Commencing wit t e middle screws, gently feed in all t e screws until slig t resistance
is encountered.
4. Operate t e slide up and down a few times to test t e movement and make any furt er
necessary adjustments. Try to ensure t at all t e screws are exerting a uniform pressure
on t e slide from top to bottom. A perfectly adjusted slide will operate freely up and
down wit out any sideways movement.
5. Now raise t e slide to its ig est position. Slig tly undo t e arbor bearing bracket and,
using fingers only, tig ten t e screws.
6. Place t e mac ine on a steel plate, connect to supply and switc on magnet. Start up t e
motor. If t e arbor is incorrectly aligned, t e arbor support bracket will be seen to
oscillate. Make any necessary furt er adjustments to t e bracket to ensure correct
alignment of t e spindle and finally tig ten t e screws using a spanner. Lastly tig ten
t e arbor bearing bracket.
Check machines grease.
T e gearbox grease s ould be c ecked once a mont to ensure all moving components are
covered to prevent wear. T e grease s ould be c anged at least once a year to ensure you gain
t e best from t e mac ine.
Check Armature of the machine.
T is s ould be c ecked at least 1 per mont to c eck t at t ere are visual signs of damage to
t e body or to t e commutator. Some signs of wear will be seen on t e commutator over a
period of time t is is normal as t is is t e part t at comes in contact wit t e brus es but any
signs of abnormal damage and t e part s ould be replaced.

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4) TROUBLE SHOOTING
Magnet and motor do not function
-
T e magnet switc is not connected to t e power supply
- Damaged or defective wiring
- Defective fuse
- Defective magnet switc
- Defective Control Unit
- Defective power supply
Magnet does function, t e motor does not
-
Damaged or defective wiring
- Carbon brus es are stuck or worn out
- Defective magnet switc
- Defective On / off switc
- Defective Control Unit
- Defective armature and/or field
- Defective magnet protective switc
Magnet does not function, t e motor does
-
Defective magnet
- Defective Control Unit
Hole cutters break quickly, oles are bigger
t an t e ole cutter
-
Play in t e guide
- Bent spindle
- Defective Magnet causing movement
- S aft extending from t e motor is bent
- Uneven work surface causing lack of magnetic ad esion.
- Bent pilot
Motor running roug ly and/or seizing up
-
Bent spindle
- S aft extending from t e motor is bent
- Triangular guide not mounted straig t
- Dirt between spindle and triangular guide
Motor making a rattling sound
-
Gear bearing (bottom of t e armature) worn out
- Gear(s) worn out
- No grease in gear box
Motor
umming, big sparks and motor as no
force
-
Armature burned
- Field burned
- Carbon brus es 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 brus es
Guiding takes a great deal of effort
-
Guide is set too tig t
- Guide is dry
- Guide/gear- rack/rotation system dirty or damaged
Insufficient magnetic forc
e
-
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 t in less t an 10mm
- Defective Control Unit
- Defective magnet
Motor only runs at
maximum rpm
-
Defective speed switc
- Damaged / defective wiring
- Defective Control Unit
Frame under voltage
-
Damaged / defective wiring
- Defective magnet
- Motor seriously dirty
Fuse blows w en magnet switc is turned on
-
Damaged or defective wi
ring
- Wrong value fuse
- Defective magnet switc
- Defective Control Unit
- Defective magnet
Fuse blows w en motor is started up
-
Damaged or defective wiring
- Wrong value fuse
- Motor running roug ly
- Defective Armature and / or Field
- Carbon brus es worn out
- Defective Control Unit
Rotation system free stroke too long
-
Loose or defective gear
-
rack
- Defective rotation system

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19
5) CUTTER SELECTION, SPEEDS AND FEEDS

Issue 5 Original version Nov 2014
20
WARRANTY STATEMENT
Rotabroac ™ warrants its mac ines to be free from faulty materials, or workmans ip under normal use for a period of 6
mont s from initial date of purc ase and 90 days for all ot er parts (excluding cutters), provided t at t e warranty
registration card (or online registration) as been completed and returned to Rotabroac ™, or its designated distributor
wit in a period of (30) days from t e purc ase date, failure to do so will void t e warranty. If t e stated is ad ered to
Rotabroac ™ will repair or replace (at its option) wit out c arge any faulty items returned.
T is Warranty does not cover:
1. Components t at are subject to natural wear and tear caused by t e use in accordance wit t e operators instructions
2. Defects in t e tool caused by non-compliance wit t e operating instructions, improper use, abnormal environment conditions, inappropriate
operating conditions overload or insufficient servicing or maintenance.
3. Defects caused by using accessories, components or spare parts ot er t an original Rotabroac ™ parts.
4. Tools to w ic c anges or additions ave been made.
5. Electrical components are subject to manufacturer’s warranty.
Your online registration can be submitted on www.rotabroac .co.uk
T e warranty claim must be lodged wit in t e warranty period. T is requires t e submission or sending of t e complete
tool in question wit t e original sales receipt w ic must indicate t e purc ase date of t e product. A complaint form
must also be submitted prior to t e return.
T is can be found online at www.rotabroac .co.uk Failure to complete t is form will result in t e delay of your claim.
All goods returned defective must be returned pre-paid to Rotabroac ™, in no event s all Rotabroac ™ be liable for
subsequent direct, or indirect loss or damage.
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, (EXPRESSED OR IMPLIED) INCLUDING ANY WARRANTY OF
MECHANTABLITY OR FITNESS FOR A PARTICULAR PURPOSE. ROTABROACH™ RESERVE THE RIGHT TO MAKE
IMPROVEMENTS AND MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE
Known and Trusted Worldwide for Quality, Performance and Reliability