ROTHENBERGER ROMAX 4000

Product Overview

The ROMAX 4000 is a handheld electric machine designed for pressing fittings onto pipes. It operates using ROTHENBERGER or CAS (Cordless Alliance System) battery packs and accessories. The machine is intended for professional use and should not be used for stationary applications. It can perform up to 4 crimps per minute.

Key Components:

• A: Battery compartment
• B-1: EMERGENCY-OFF Button
• B-2: ON-Switch
• B-3: Press Jaw Rotation mechanism
• C: LED indicator
• D: Press Jaw insertion point

Safety Instructions

Danger!

This sign warns against the danger of personal injuries.

Caution!

This sign warns against the danger of property damage and damage to the environment.

1.1 Intended Use

The ROMAX 4000 is designed exclusively for use with ROTHENBERGER pressing jaws or those declared suitable by ROTHENBERGER. It is intended for crimp fittings for which the corresponding pressing jaws are designed. Any other use is considered improper. ROTHENBERGER is not liable for damages resulting from improper use, use of non-approved pressing jaws, or failure to comply with operating instructions and safety regulations.

Only original ROTHENBERGER or CAS battery packs and accessories should be used.

1.2 General Power Tool Safety Warnings

Always read all safety warnings, instructions, illustrations, and specifications provided with the power tool. Failure to follow instructions may result in electric shock, fire, and/or serious injury.

Work Area Safety

• Keep the work area clean and well-lit.
• Do not operate in explosive atmospheres.
• Keep children and bystanders away.

Electrical Safety

• Ensure plugs match outlets; do not modify plugs.
• Avoid contact with earthed surfaces.
• Do not expose to rain or wet conditions.
• Do not abuse the cord; keep it away from heat and sharp edges.
• Use outdoor extension cords for outdoor use.
• Use a residual current device (RCD) in damp locations.

Personal Safety

• Stay alert and use common sense.
• Use personal protective equipment, including eye protection.
• Prevent unintentional starting by ensuring the switch is off before connecting power or battery.
• Remove adjusting keys or wrenches before operation.
• Maintain proper footing and balance; do not overreach.
• Dress properly; avoid loose clothing or jewelry.
• Ensure dust extraction facilities are connected and used.
• Do not become complacent with tool safety.

Power Tool Use and Care

• Do not force the tool; use the correct tool for the application.
• Do not use if the switch is faulty.
• Disconnect power/battery before making adjustments or storing.
• Store idle tools out of reach of children.
• Maintain tools and accessories; check for misalignment or damage.
• Keep cutting tools sharp and clean.
• Use tools and accessories according to instructions and working conditions.
• Keep handles and grasping surfaces dry and clean.

Battery Tool Use and Care

• Recharge only with the specified charger.
• Use only with designated battery packs.
• Keep battery packs away from metal objects to prevent short circuits.
• Avoid contact with liquid ejected from damaged batteries.
• Do not use damaged or modified battery packs or tools.
• Do not expose battery packs or tools to fire or excessive temperature.
• Follow all charging instructions and charge within the specified temperature range.

Service

• Have power tools serviced by qualified personnel using identical replacement parts.
• Never service damaged battery packs; only the manufacturer or authorized service providers should do so.

ROMAX 4000 Specific Safety

The term 'press jaw' includes the main jaw, press ring, and press chain.

• Never place fingers or body parts in the working area of the cylinder or press jaws.
• Remove the battery before performing any work on the machine.
• If the device is damaged exposing cables or drive parts, disconnect the mains plug immediately and contact service. Unauthorized repairs can lead to severe injury or death.
• Only personnel trained in using the device may make crimp pipe joints.
• The machine must only be used with an inserted press jaw in perfect technical condition.
• Only start the machine if it is in perfect working order.
• Servicing and repair work must be carried out by ROTHENBERGER-authorized workshops.
• Use only suitable press jaws and press fitting systems approved by ROTHENBERGER.
• After inserting the press jaw, check that the bolt is securely locked.
• In case of problems during the pressing process, press the EMERGENCY STOP button.
• Check that the pipe joint is secure after completing the pressing process. Imperfect joints must be re-compressed with a new fitting.
• Follow the installation instructions from fitting and pipe manufacturers.
• Ensure no moisture or water reaches the inside of the machine when pressing leaky fittings.
• After work, check the installation for leaks using appropriate testing equipment.
• The machine uses hydraulic oil. Avoid contact with oil leaks; clean skin with soap and water, flush eyes with plenty of water for at least 10 minutes if contact occurs.

Charger and Battery Safety

• Chargers are not intended for use by children or persons with limited physical, sensory, or mental capabilities, or lack of experience, unless supervised or instructed by a responsible person.
• Supervise children during use, cleaning, and maintenance.
• Do not charge non-rechargeable batteries.
• Danger - electrical voltage! Only use the charger indoors.
• Protect the charger from moisture.
• Never allow children to use the machine.
• Pull the mains plug immediately if the charger smokes or emits flames.
• Do not insert objects into ventilation slots; risk of electric shock and short circuits.
• Do not recharge a fully charged battery pack.
• Protect battery packs from water and moisture.
• Do not expose battery packs to naked flame.
• Do not use faulty or deformed battery packs.
• Do not load battery packs with AIR COOLED chargers in areas with high metal dust exposure.
• Do not open battery packs.
• Do not touch or short-circuit battery packs.
• Slightly acidic, flammable fluid may leak from defective Li-ion battery packs. If contact occurs, rinse skin immediately with water or wash eyes with clean water and seek medical attention.
• Transporting Li-ion battery packs: Observe Dangerous Goods Legislation requirements for third-party transport. Consult an expert for hazardous materials. Send battery packs only with intact housing and no leaking fluid. Protect contacts from short-circuiting.

2 Technical Data ROMAX 4000

Note: Wear hearing protection as the noise level can exceed 85 dB(A). Measured values are in accordance with EN 62841-1. Vibration and noise emissions can vary during actual use.

3 Technical Data Charger and Battery

Battery:

• U: Voltage
• C: Capacity
• W: Weight
• I_c: Charge current
• t: Approx. charging time (90% full)
• Charging voltage: 20,75 V DC
• Charging temperature: 0° - 50°C / 32° - 122°F
• Max. discharging temperature: 5° - 50°C / 41° - 122°F

Recharge battery pack before first use!

Charger:

• U1: Input voltage
• f1: Input frequency
• P1: Input power
• U2: Charging voltage
• I2: Max. charge current
• Nc: No. of battery cells
• W: Weight

Pay attention to the electrical outlet voltage! Check the label on the bottom of the charger.

Battery Specifications Table:

Charger Specifications Table:

Figure: Charger and battery similar.

4 Function of the Unit

4.1 Changing the Battery

Insert the battery until the catch clicks into place. A brief flash of the LED indicates contact. To remove, press the catch and pull out the battery.

If the battery does not deliver the required voltage, the LED will flash and a tone sequence will sound upon restart. Charge the battery.

4.2 EMERGENCY STOP Button

If there is any danger to personnel or the machine during pressing, press the EMERGENCY STOP button immediately and release the ON switch. The valve will open, and the piston will return to its initial position.

4.3 To Switch On

Press the ON button until the pressing process is complete. The motor cut-out indicates the end of the cycle.

4.4 To Turn the Press Jaw

The press jaw can be rotated up to 270° depending on the application.

4.5 LED

The white LED lights up when starting the press cycle and remains lit for up to 30 seconds after the cycle ends. The LEDs flash after 40,000 pressing processes, indicating the need for the next inspection. An internal counter tracks pressing processes.

4.6 To Insert the Press Jaw

1. Remove the battery.
2. Open the bolt [unlock-symbol].
3. Insert the appropriate press jaw for the job.
4. Lock the bolt [lock-symbol].

After changing the press jaw, ensure it matches the profile and nominal width of the fitting. Visually confirm the press jaw is fully closed at the end of the press cycle.

4.7 Operation

Use only system-compatible press fittings and press jaws. The nominal size of the press jaw must match the nominal size of the press fitting.

Caution: Risk of crush injuries to fingers or other body parts near the press jaw when inserting the pipe/fitting system.

1. Push the press fitting onto the pipe. Pull the press jaw apart and insert the pipe with the press fitting at a right angle. Ensure no foreign bodies are between the press contour and the fitting, as this will prevent a perfect joint.
2. Press the ON button until the pressing process is complete. The motor cut-out indicates the end of the cycle.
3. Push the press jaw apart and remove the machine from the joint.

Do not start the machine while the piston retracts or the emergency shutdown is pressed.

4.8 Charger and Battery Overview

• 1: Battery pack
• 2: Sliding seat
• 3: Operation display
• 4: Warning display
• 5: Capacity indicator button
• 6: Capacity and signal indicator

Start of Operation

Caution: Before plugging in, check that the rated mains voltage and frequency match your power supply. Devices generating DC may affect residual-current circuit breakers; use Type F or better (max. 30 mA release current).

Caution: Ensure air slots are clear before commissioning the charger (minimum 5 cm / 2 inches distance to other objects).

Self-test:

Insert the mains supply plug. The warning display and operating indicator light up sequentially for approx. 1 second, and the fan runs for approx. 5 seconds.

Battery Pack:

Charge the battery pack before use. Recharge if performance diminishes. Ideal storage temperature: 10°C to 30°C (50°F to 86°F). Permissible storage temperature: 0°C to 50°C (32°F to 122°F).

Li-ion battery packs have a capacity and signal indicator. Press button (5); LEDs indicate charge level. If one LED flashes, the battery pack is nearly empty and needs recharging.

Handling

Charging Battery Pack:

Push the battery pack completely onto the sliding seat (2) until it stops.

The operating indicator (3) flashes during charging.

Conservation Charge:

After charging, the charger automatically switches to conservation mode. The battery pack can remain in the charger and is always ready for use.

The operating display (3) lights up continuously when fully charged.

Faults:

• Warning display (4) lights up continuously: Battery pack not charging. Temperature too high/too low. Charging begins automatically when the battery pack temperature is between 0°C and 50°C (32°F - 122°F).
• Warning display (4) flashes: Battery pack is defective. Remove the battery pack from the charger immediately. The battery pack was not correctly seated on the sliding seat (2).

5 Care and Maintenance

ROMAX 4000:

• Remove the battery before performing any work on the machine.
• Check press jaws for full functionality. Damaged press jaws must not be used and must be sent to an authorized ROTHENBERGER repair shop.
• Check that the press jaw and drive rolls move freely.
• Regularly check the bolt for damage. Have damaged bolts replaced by an authorized ROTHENBERGER repair shop.
• Clean and grease drive rolls, bolt, and press jaws after work. Use only high-quality pressing or ball bearing grease.
• Keep the pressing contour free of grease.
• All other servicing, maintenance, and repair work must be carried out by an authorized ROTHENBERGER repair shop.
• The warranty is void if the seal is damaged.
• The machine requires servicing by an authorized ROTHENBERGER workshop after 40,000 pressing cycles or 2 years.
• When dispatching the machine, pack it in its carrying case with the battery and charger.
• Electro-hydraulic machines should not be stored for more than 3 hours at -5°C / 23°F.
• Disconnect the battery from the machine before storing.

Charger:

• Repairs to the charger must only be carried out by qualified electricians.
• If the mains connection cable is damaged, it must be replaced by the manufacturer, customer service, or a similarly qualified person to prevent hazards.

6 Accessories

Suitable accessories can be found in the main catalog or at www.rothenberger.com.

7 Customer Service

ROTHENBERGER service locations offer assistance, replacement parts, and service. Order accessories and spare parts from your specialist retailer or via RO SERVICE+ online:

• Phone: +49 (0) 61 95/ 8008200
• Fax: +49 (0) 61 95/ 8007491
• Email: service@rothenberger.com
• Website: www.rothenberger.com

8 Disposal

Components are recyclable. Contact certified recycling companies. For environmentally friendly disposal of non-recyclable parts (e.g., electronic waste), contact your local waste disposal authority.

The appliance contains oils and greases; dispose of in accordance with all local, regional, national, and international laws.

Do not dispose of power tools and batteries/rechargeable batteries into household waste.

For EU countries: According to Directive 2012/19/EU (WEEE) and Directive 2006/66/EC (Batteries), unusable power tools and defective/drained batteries must be collected separately and disposed of in an environmentally correct manner.

Only for United Kingdom: According to The Waste Electrical and Electronic Equipment Regulations 2013 and the Waste Batteries and Accumulators Regulations 2009, unusable products and batteries must be collected separately and disposed of in an environmentally friendly manner.

FCC Statement (Class A, Group 1)

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

NOTE: This equipment has been tested and found to comply with the limits for a Class A, Group 1 digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in an industrial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation.

Class A, Group 1 Note: Warning - This is a Class A, Group 1 product. In a domestic environment, this product may cause radio interference, in which case the user may be required to take adequate measures.

ROTHENBERGER Contact Information

ROTHENBERGER Werkzeuge GmbH
Industriestraße 7
D-65779 Kelkheim / Germany
Phone: +49 61 95 / 800 - 0
Fax: +49 61 95 / 800 - 3500
Email: info@rothenberger.com