TAP30 User Manual.indd - Industrial Tool and Machinery Sales
Contents
1. NO PART NO PART NAME Q ty 10 HTAP30A10 NIDDLE BEARING KYK609Z 1 11 HTAP30A11 BEARING NTN6005LLU 1 12 HTAP30A12 SNAPRING STW 28 1 13 HTAP30A13 MAIN GEAR 1 14 HTAP30A14 SNAPRING RTW 18 1 15 HTAP30A15 KEY 8X8X13X1R 1 16 HTAP30A16 4 110 1 17 7 BEARING 600277 1 18 HTAP30A18 SECOND PINION 1 19 HTAP30A19 KEY 6X30X13X1R 1 20 HTAP30A20 SECOND GEAR 1 21 HTAP30A21 BEARING 912 1 22 HTAP30A22 INNER COVER 1 23 HTAP30A23 GEAR COUPLING A 1 24 HTAP30A24 BEARING NTN6002LLU 1 25 HTAP30A25 SNAPRING STW 15 1 26 HTAP30A26 BEARING HK1412V2 1 27 HTAP30A27 FIRST PINION 1 28 HTAP30A28 FIRST GEAR KEY 1 29 HTAP30A29 HK1412V2 FIRST GEAR 1 30 HTAP30A30 SNAPRING STW 15 1 31 HTAP30A31 BEARING KBC6000ZZ 1 32 HTAP30A32 GEAR COUPLING B 1 33 HTAP30A33 ARMATURE FAN 1 34 FAN BUSHING 1 35 HTAP30A35 ARMATURE ASS Y 1 36 HTAP30A36 ARMATURE BUSHING 1 37 HTAP30A37 BEARING NTN6300ZZC3 1 38 HTAP30A38 HEX SOCKET HEAD SCREW M5 L75 2 39 9 2 40 40 HOUSING 1 41 HTAP30A41 CARBON BRUSH HOLDER ASS Y 1 42 HTAP30A42 HOUSING CAP 1 43 HTAP30A43 HEX SOCKET HEAD SCREW M6 L65 4 44 HTAP30A44 HEX SOCKET HEAD SCREW 110 4 45 HTAP30A45 PG 13 5 COVER 1 46 HTAP30A46 MAGNET RING PCB 1 47 HTAP30A47 MAGNET RING 1 17 18 PARTS BREAKDOWN H TAP30 PART2 NO PART NO PART NAME Q ty 1 HTAP30B01 MOTOR amp GEARBOX AS2. 104 120 3rd 215 248 4th 384 425 2 4 Gear Selection Per Cutter Sizes In case of cutting normal mild steel with cutters under 35mm dia 2nd gear is recommendable And for cutters over 40mm dia 1st gear should be selected For cutters around 36 39 mm dia it depends on situation Specially the material to be cut is very important 10 2 5 Use Of Cutting Fluid The use of cutting fluids is absolutely necessary when drilling with steel cutters Always use the correct cutting oil intended for use Other oils may provide insufficient lubrication under different temperatures When cutting with hard and difficult materials and a deep hole it may be advantageous to provide cutting oil under pressure For it is recommended to use a pressure can instead of a regular oil tank The pressure canister has a hose with a quick coupling and the valve on the pressure canister can be used to regulate the oil supply Cutting oil or paste must always be supplied through the centre of the cutter so that the oil goes inside out during drilling Application of cutting oil outside the cutter will not provide the necessary lubrication inside the cutter and cause a faster heating of the plug formed in the cutter The heat will cause the plug to expand and often result in a broken cutter 2 6 Mounting Of Cutters The machine has been made to accept MT3 Arbor The following procedure is to be used when m
3. If this is not possible an alternative secure method of restraining the machine MUST Overall Dimensions Height maximum extended Height minimum Width including Hand wheel Length Overall Stroke Net Weight Maximum hand arm vibration magnitude measured at handle 0 82m s during operation in accordance with 505349 using a 22mm cutter through 13mm MS plate Estimate of likely daily vibration exposure Operation 30 holes 0 29m s A 8 2 minute hole Average noise level during cutting at operators ear position 89dB A 1 5 Package Contents Operators Manual Coolant Bottle Safety Chain Arbor MT3 3 4 bore Drill Drift 4mm Hexagon Key 3mm Hexagon Key 2 Operation 2 1 Operating Tips Keep the inside of the cutter clear of swarf It restricts the operating depth of the cutter Ensure that the coolant bottle contains sufficient cutting oil to complete the required operating duration Refill as required Occasionally depress the pilot to ensure cutting fluid is being correctly metered Apply light pressure when commencing to cut a hole until the cutter is introduced into the work surface Excessive pressure is undesirable it does not increase the speed of penetration Always ensure that the slug has been ejected from the previous hole before commencing to cut the next 1 Cut 2 Cut 3 Cut 1 Cut 3 Cut 2 Cut Right Wrong Always cut overlapping holes as illustrated ab
4. an illustration and therefore differ in appearance With regular use the armature should be checked at least once per month Look for visible damage or wear to the armature body and the commutator commutator are brass plates which the brushes are touching The brushes will naturally wear on the commutator This is normal Look for damages in plates that have lifted or loose brass boards Change the aramature if damage or excessive wear is found If much coal dust is found on the commutator use compressed air to low clean The armature on the left is just an illustration and therefore may differ in appearance 2 9 Extension Cable Selection The machines are factory fitted with a 2 metre length of cable having three conductors 1 5mm 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 230v supply 26metres of 3 core x 1 5mm or 17metres of 3 core x 1 0mm 3 0 Solutions For Drilling Problems 1 Magne Material being cut may be too thin Attach an additional piece of metal under work piece for efficient holding where magnet will be located or mechanically clamp ma
5. keep in good working order A well maintained machine is a happy machine A number of items must always be checked on magnetic drilling 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 po Everyday Once a Month a damage Operation of machine Check of magnetic base X Check of brushwear J O Check Alignmentofmachine x Checkofgrease Jo o X Check armature T x Visually check the machine for damage Machine must be checked before operation for any signs of damage that will affect the operation of the machine Particular notice must be taken of the mains cable if the machine appears to be damaged it should not be used failure to do so may cause injury or death Check operation of the machine The machines operation must be checked to ensure that all components are working correctly Machines Carbon Brushes The Machines Brushes should be checked to make sure there is no abnormal wear present This should be checked at least once a week if used frequently If the brush has worn more than 2 3 the original length the brushes should be changed Failure to do so may cause damage to the machine Machines Magnetic base Before every operation the magnetic base sho
6. use of the tool a guard or other part that is damaged should be carefully checked to determine that it operates properly and perform its intended function Check for alignment of moving parts binding of moving parts breakage of parts mounting and any other conditions that may effect its operation A guard or other part that is damaged should be properly repaired or replaced by an authorized service centre Do not use this tool if switches do not turn it on and off Have defective switches replaced by authorized service centre N WARNING SAFETY RULES MUST BE CLOSELY OBSERVED SAFETY INSTRUCTIONS 1 3 Special Safety Requirements Read and follow operator s manual thoroughly If you cannot locate your operator s manual contact ITM www industrialtool com au for an additional FREE copy DO NOT touch rotating cutter or parts Always stop machine completely and unplug from power source before changing cutters cleaning clips refilling lubrication or performing adjustments Never wear loose clothing or gloves when working near cutting area or machine arbor Always wear eye protection Any tool can shatter Always use safety chain or strap provided with machine Always use proper tooling keep cutters securely fastened DO NOT use dull or broken cutters Beware of ejected slugs at end of cut they become HOT during the cut Magnet will not hold properly on thin materials under 3 8 9 5mm rough or dirty surfaces Keep all safety fe
7. QUALITY EUROPEAN MADE MAGNETIC DRILLING MACHINES TAP 30 DRILLING MACHINE OPERATOR S MANUAL BEFORE USE ENSURE EVERYONE USING THIS MACHINE READS AND UNDERSTANDS ALL SAFETY AND OPERATING INSTRUCTIONS IN THIS MANUAL senal Heche ere ee oc cece eee eee Date of HOLEMAKER TAP 30 DRILLING MACHINE IMPORTED amp DISTRIBUTED BY ea INDUSTRIAL TOOL amp MACHINERY SALES 18 BUSINESS ST mE EH EN m mS YATALA QLD 4207 AUSTRALIA T 07 3287 1114 F 07 3287 1115 E sales industrialtool com au Ww www industrialtool com au WARRANTY TERMS In addition to any warranties or conditions implied by applicable Statute or Regulations Industrial Tool amp Machinery Sales warrants all of it s products against defective workmanship and faulty materials for a period of twelve 12 months from the date of purchase unless otherwise stated At our option we will repair or replace free of charge any item on the condition that The complete machine or tool is returned freight prepaid to ITM or one of it s authorised service agents as directed by ITM and is found to have a material or constructional defect The machine or tool has not been subject to misuse neglect or damage by accident The fault is not a result of normal wear and tear Written permission has been received from ITM prior to commencement of repair Repairs tampering or modification carried out by unauthorised p
8. S Y 2 2 HTAP30B02 HEX SOCKET HEAD SCREW M4 L6 4 3 HTAP30B03 HEX SOCKET HEAD SCREW M6 L15 4 HTAP30B04 GIB STRIP 4 5 HTAP30B05 NUT M6 6 6 HTAP30B06 O RING ASSEMBLED STOP BOLT 6 7 HTAP30B07 SLIDE 1 8 HTAP30B08 SOCKET SET SCREW M6 L16 6 9 HTAP30B09 PG 13 5 COVER 1 10 HTAP30B10 WIRE HOSE 1 11 HTAP30B11 RACK GEAR 1 12 HTAP30B12 SLIDE BAR 2 PARTS BREAKDOWN 13 HTAP30B13 COOLANT HANGER 1 14 HTAP30B14 HEX SOCKET HEAD SCREW 125 2 15 HTAP30B15 COOLANT TANK ASS Y 1 16 HTAP30B16 HANDLE ASS Y 1 14 HTAP30B17 HANDLE PINION 2 18 HTAP30B18 BUSHING 1 19 HTAP30B19 HANDLE_COLLAR 2 20 HTAP30B20 HEX SOCKET HEAD SCREW M6 L30 4 21 HTAP30B21 PAN HEADED SCREW M4 L10 1 22 HTAP30B22 WARNING PANEL 1 23 HTAP30B23 MAIN PCB 5 24 HTAP30B24 SCREW M3 L5 1 25 HTAP30B25 CABTYLE CABLE ASS Y 6 26 HTAP30B26 HEX SOCKET HEAD SCREW M5 L30 4 27 HTAP30B27 HEX SOCKET HEAD SCREW M6 L30 1 28 HTAP30B28 CABLE GRAND ASS Y 1 29 HTAP30B29 ELECTROMAGNET 4 30 HTAP30B30 PAN HEADED SCREW M4 L10 1 31 HTAP30B31 CONTROL PANEL 1 32 HTAP30B32 MAIN FRAME 1 33 HTAP30B33 ARBOR SUPPORTER 1 34 HTAP30B34 HEX SOCKET HEAD SCREW M4 L6 2 19 20 ELECTRICAL CIRCUIT WARNING THIS APPLIANCE MUST BE EARTHED Insulation Resistance Test With the magnet switch in the ON position apply a voltage of 1 5kv between the live connection on the mains plug and
9. atures functioning and working properly Keep bottom of magnet burr free and clear of chips and debris To reduce the risk of electrical shock DO NOT remove or alter electrical panels or use machine in damp areas Use only authorized service centres for repairs drilling machine must be connected to protected power source which is properly grounded Improperly connecting the grounding wire can result in the risk of electrical shock Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded Do not modify the plug provided with the tool Never remove the grounding prong from the plug Do not use tool if the cord or plug is damaged have it repaired before using If the plug will not fit the outlet have a proper outlet installed by a qualified electrician The TAP30 must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances If in doubt of proper grounding call a qualified electrician SAFETY INSTRUCTIONS 1 4 Specifications Motor Unit Voltages 230V 60Hz Normal Full Load Output 2000W Magnet Size 210 x 105 x 70 mm be used Magnet Force At 20 C With 25mm Plate Thickness 1850kgf 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
10. ersonnel will void all warranty Consumable items such as cutting tools pilot pins saw blades grinding wheels etc are NOT covered by warranty Our goods come with guarantees which cannot be excluded under the Australian Consumer Law You are entitled to replacement or refund for a major failure and to compensation for other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure ll HOLEMAKER TAP 30 DRILLING MACHINE TABLE OF CONTENTS Safety Instructions Read And Save All Instructions For Future Reference Safety Requirements Special Safety Requirements Specifications Package Contents Operation Operating Tips Stopping and Starting the Machine Speed Control Gear Selection Per Cutter Sizes Use Of Cutting Fluid Mounting Of Cutters Adjustment Of The Slide Tips For Keeping Your Machine In Correct Working Order Extension Cable Selection Solutions For Drilling Problems Trouble Shooting Parts Breakdown Electrical Circuit 4 s s 0 ee Ts oe 9 zd a10 adds 3 245 5x lt 16 20 SAFETY INSTRUCTIONS READ OPERATOR S MANUAL BEFORE YOU START TO WORK WITH THE MACHINE 1 Safety Instructions The HMTAP30 Magnetic Base Drilling Machine should be used only to applications stated in the manual Using in other applica
11. gnetic base to work piece Swart or dirt under magnet Irregularity on magnet contact or Use extreme care file any imperfections flush to work piece surtace Insufficient current going to magnet Confirm power supply and output from control unit during drilling cycles check supply cable Magnetic base is not holding ef See causes and remedies above vere bushing and or ejector Replace Only a few thousandths wear permissible New arbor bushing is needed e Light pressure only is needed until a groove is cut The groove then serves as a stabilizer Cutter is dull worn chipped or Replace or re sharpen Sharpening service is availa incorrectly sharpened ble Poor centre punch mark weak pilot Improve centre punch and or replace wom parts spring pilot not centred in centre punch mark Loose bolts on motor bushing sup Adjust where necessary port bracket main casting or loose gib adjusting set screws 13 14 SOLUTIONS FOR DRILLING PROBLEMS down swarf lying on Take care not to start a cut on swarf surface of work piece Gibs out of adjustment or lack of lubrica chipped cutter Coming ji tion 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 Refer to instructions and a new cutter for proper tooth geometry Insufficient or spasmodic cu
12. ounting cutters Take appropriate pilot and place through hole in shank of cutter Insert shank of cutter into 3 4 dia bore of arbor ensuring alignment of two drive flats with socket screws Arbor Selection For cutters of 11mm 60mm dia 3 4 dia bore of arbor For cutters over 60mm dia 1 1 4 dia bore of arbor e Tighten both screws using hexagon key 2 7 Adjustment Of The Slide For the machine to work well it is essential that the slide that controls the core feeding movements can be moved in an easy and controlled way without lateral movement or vibration Periodic adjustment of the slide is performed as follows Stand the machine upwards on a steel plate in a vertical position and raise the slide up to the highest possible position by turning the capastan arm Clean the slide and apply thin machine oil on the sliding surfaces Loosen the 2 screws that hold the bearing bracket and lower the slide to the lowest position Starting by adjusting the middle screws Then adjust all the screws gently until slight resistance is achieved Move the slide up and down a few times to test the movement Make the necessary adjustments Make sure all screws are equally tightened and ensure that the slide moves up and down without any sideways movement 2 8 Tips For Keeping Your Machine In Correct Working Order In order to get the best life out of your magnetic drill machine always
13. ove do not use excessive pressure and ensure cutting fluid is reaching teeth of the cutter 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 Cutter breakage is usually caused by insecure anchorage and a loosely fitting slide Refer to routine maintenance instructions 2 2 Stopping amp Starting The Machine Before starting the motor always make sure to turn on the magnetic switch first When the magnet is activated the motor can be started with start button Stopping the motor must always be done with the stop switch Never stop the machine with the main current magnetic switch It is dangerous and can also cause damage to the electronics of the machine 2 3 Speed Control The machines are equipped with a mechanical four speed gearbox Select the required speed by pressing in shifting and engaging Change the speed only when the machine is not running and support the gear changing by slightly rotating the spindle RPM no load 45 90 rpm 90 160 rpm 125 400 rpm 4 300 570 In load condition each gear has 2nd 20160 CN 65 75 efficiency defendant on rel fs working situations So following RPM A S is expected per each gear Ke re YY YY 151 58 68 1st 2 nd 3 rd 4 th 2nd
14. rbox Low amount of grease in the gearbox Damaged Armature Damaged Field Damaged or Worn Brushes Damaged or defective wiring Contaminated reader Defective or loose magnet in reader for speed control Damaged or defective brushes Slide adjustments are tightened too hard The slides sliding surfaces are too dry Shaft Rack are contaminated Damaged or deceptive wiring The work area surface is not clean and or dry The work area surface has poor magnetic ability The work area surface is not flat The work area surface is too thin thinner than 10mm Damaged or defective wiring Faulty control box Damaged or defective wiring Faulty magnet The motor is heavily polluted Damaged or defective wiring Faulty magnet switch Defective control box Faulty magnet Damaged or defective wiring Defective armature and or field Motors running too fast Worn brushes Defective control box 15 16 PARTS BREAKDOWN H TAP30 PART1 NO PART NO PART NAME Q ty 1 HTAP30A01 SNAPRING RTW 52 1 2 HTAP30A02 BEARING KYK6907ZZ 1 3 HTAP30A03 SPINDLE 1 4 HTAP30A04 HEX SOCKET HEAD SCREW M6 L35 4 5 HTAP30A05 GEAR BOX 1 6 HTAP30A06 GEAR CHANGER ASS Y 2 7 HTAP30A07 NIDDLE BEARING KYK609Z 1 8 HTAP30A08 THIRD PINION 1 9 HTAP30A09 THIRD GEAR 1 PARTS BREAKDOWN
15. the frame of the machine for a duration of 7 seconds The reading obtained should not fall below infinity Should a fault be indicated it must be found and rectified
16. tions may lead to personal injury and machine damage 1 1 Read And Save All Instructions For Future Reference When using electric tools basic safety precautions should always be followed to reduce risk of fire electric shock and personal injury 1 2 Safety Requirements Keep Work Area Clean Consider Work Area Environment Do not expose power tools to rain Do not use power tools in damp or wet locations Keep work areas well lit Do not use tool in presence of flammable liquids or gases Guard against Electric Shock Prevent body contact with grounded surfaces For example pipes radiators ranges refrigerator enclosures Keep Children Away Do not let visitors contact tool or extension cord Store Idle Tools When not in use tools should be stored in dry and high or locked up place out of reach of children Do Not Force Tool It will do the job better and safer at the rate for which it was intended Use Right Tool Do not force small tool or attachment to do the job of a heavy duty tool Do not use tool for purpose not intended for example do not use a circular saw for cutting tree limbs or logs Dress Properly Do not wear loose clothing or jewellery they can be caught in moving parts Rubber gloves and non skid footwear are recommended when working outdoors Wear protective hair covering to contain long hair Use Safety Glasses Also use face or dust mask if cutting operation is dusty Do Not Abuse Elec
17. trical Cord Never carry tool by cord or yank it to disconnect from receptacle Keep cord from heat oil and sharp edges Secure Work 12 13 14 15 16 17 18 19 SAFETY INSTRUCTIONS Use clamps or a vice to hold work Itis safer than using your hand and it frees both hands to operate tool Do Not Overreach Keep proper footing and balance at all times Maintain Tools with Care Keep tools sharp and clean for better and safer performance Follow instructions for lubricating and changing accessories Inspect tool cords periodically and if damaged have repaired by authorized service facility Inspect extension cords periodically and replace if damaged Keep handles dry clean and free from oil and grease Disconnect Tools Unplug when not in use before servicing and when changing accessories such as blades bits and cutters Remove Adjusting Keys and Wrenches Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on Avoid Unintentional Starting Do not carry plugged in tool with fingers on switches Be sure switches are off when plugging in Outdoor Use Extension Cords When tool is used outdoors use only extension cords intended for use outdoors and so marked Stay Alert Do not use when taking medications that may cause drowsiness Watch what you are doing Use common sense Do not operate tool when you are tired Check Damaged Parts Before further
18. tting Use sufficient steady pressure to slow the drill down pressure This will result in optimum cutting speed and chip load Neither Magnet or Motor is working Magnet is active but motor does not turn Motor runs but magnet is not getting activated The cutter breaks and or making holes larger than the size of the cutter The motor is pulling heavily and or stops Noise in the motor gearbox The motor scores brush fires and little or no power The motor does not start or stop Heavy feed motion Magnetic holding power is too low Motor only runs at maximum RPM The operator receives an electric shock Fuse blows when magnet is activated Fuse blows when starting the motor TROUBLE SHOOTING The magnetic switch is not powered Damaged or defective wiring Damaged or defective fuse Faulty magnetic switch Defective control box Faulty power supply Damaged or defective wiring Brushes are stuck or too worn Faulty magnetic switch Defective stop start switch Defective control box Defective armature or field Faulty magnet Defective control box Clearance in the machines controls and or slide function Bent or sprung shaft Curved centre point Faulty or insufficient magnetic holding power Contact between the magnet and workpiece Bent or warped shaft Bearing bracket adjusted incorrectly Contamination between spindle and bearing bracket Worn bearing between gearbox and motor Damaged drives in the gea
19. uld 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 11 12 Check machines grease The gearbox grease should be checked once a month to ensure all moving components are covered to prevent wear The grease should be changed at least once a year to ensure you gain the best from the machine Check Armature of the machine This should be checked at least 1 per month to see that there are visual signs of damage to the body or to the commutator Some signs of wear will be seen on the commutator over a period of time This is normal as this is the part that comes in contact with the brushes but any signs of abnormal damage and the part should be replaced The motor on this machine has brushes The brushes should be checked regularly to detect any abnormal wear With regular use brushes should be checked at least once per week Brushes that are worn more than 2 3 of its normal length should be replaced Failure to do so may cause motor damage or repairs of larger scope The brushes on the left is just
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