Champion Roto Brute BD100 MEGABRUTE User manual

BD100
Operating Manual
championcuttingtool.com
MEGABRUTE
Magnetic
Drill Press
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INTENDED USE
The intended use of this magnetic drill is to drill holes in ferrous metals. The magnet is used to hold the drill in
place whilst the drill is functioning. It is designed for use in fabrication, construction, railways, petrochemical
and any other applications when drilling ferrous metal.
Any deviation from its intended use will not be covered by warranty.
GENERAL SAFETY RULES
WARNING! Follow all instructions listed below to prevent electric shock, re and/or serious personal injury.
Cancer & Reproductive Harm. See P65warnings.ca.gov for more info.
WORK AREA
1. Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
2. Do not operate power tools in explosive atmospheres, such as in the presence of ammable liquids,
gases or dust. Power tools create sparks which may ignite the dust or fumes.
3. Keep bystanders, children and visitors away while operating a power tool. Distractions can cause you
to lose control.
ELECTRICAL SAFETY
1. Grounded tools must be plugged into an outlet properly installed and grounded in accordance with
all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not
use any adaptor plugs. Check with a qualied electrician if you are in doubt as to whether the outlet is
properly grounded. If the tools should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the user.
2. Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is
an increased risk of electric shock if your body is grounded.
3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of
electric shock.
4. Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord
away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged
cords increase the risk of electric shock.
5. When operating a power tool outside, use an outdoor extension cord marked” W-A” or” W”. These
cords are rated for outdoor use and reduce the risk of electric shock.
6. Use With 110/120V Supply Only.
7. Do not use on DC Supply.
8. Do not use magnetic drill on same structure when arc welding is in progress.
POWER INPUT 1600 W (13.3A)
VOLTAGE 110 / 120V
MOTOR SPEEDS Speed 1: 50-140, Speed 2: 80-230
Speed 3: 120-330, Speed 4: 180-510 RPM
MAGNETIC
STRENGTH 3800 lb (1723 kg)
ANNULAR CUTTER CAPACITY* 4” DIAM X 4” DEPTH
TWIST DRILL CAPACITY* 1-1/4” DIAM
MACHINE DIMENSIONS HEIGHT: 20-1/16 to 27-15/16
WIDTH: 12-3/16"
OAL LENGTH: 13-3/8"
NET WEIGHT
CONTENTS
Hex Key 2.5mm, Hex Key 5.0mm, Safety Guard , Handles (3)
Safety Strap, 3MT Set Screw Arbor, 3MT Drift Key, Coolant Tank Assembly
ARBORS
Set Screw Arbor Accepts Standard ¾” Weldon Shank Annular Cutters.
Annular Cutter Depth Of Cut Capacity Is 2”. 4" Depth Of Cut Can Be Achieved By Using 2 Piece Pilot Pin.
*Additional Arbors and Drill/Chuck Adaptors available for purchase.
Contact Champion directly for information.
MAGNETIC DRILL PRESS SPECIFICATIONS
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61 lbs (28 kg)

PERSONAL SAFETY
1. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use
tool while tired or under the inuence of drugs, alcohol, or medication. A moment of inattention while
operating power tools may result in serious personal injury.
2. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and
gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.
3. Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with your nger on the
switch or plugging in tools that have the switch on invites accidents.
4. Remove adjusting keys or switches before turning the tool on. A wrench or a key that is left attached to
a rotating part of the tool may result in personal injury.
5. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enable
better control of the tool in unexpected situations.
6. Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hardhat, or
hearing protection must be used for appropriate conditions.
TOOL USE AND CARE
1. Use clamps or other practical way to secure and support the workpiece to a stable platform.
Holding the work by hand or against your body is unstable and may lead to loss of control.
2. Do not force tool. Use the correct tool for your application. The correct tool will do the job better and
safer at the rate for which it is designed.
3. Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the switch is
dangerous and must be repaired.
4. Disconnect the plug from the power source before making any adjustments, changing accessories, or
storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally.
5. Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands
of untrained users.
6. Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools, with sharp
cutting edges are less likely to bind and are easier to control.
7. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may
affect the tools operation. If damaged, have the tool serviced before using. Many accidents are caused
by poorly maintained tools.
8. Use only accessories that are recommended by the manufacturer or your model. Accessories that may
be suitable for one tool, may become hazardous when used on another tool.
MAGNETIC DRILL SAFETY
1. The drill’s magnetic adhesion depends on the thickness of the work-piece. 1/2” (13mm) is the minimum
thickness for safe operation.
2. Keep the magnet clean of metal chips and other dirt and debris. These will seriously reduce the
magnetic adhesion.
3. The drill must be operated on its own electrical outlet.
4. Always use the supplied safety strap or chain. An electrical overload can result in loss of adhesion.
CAUTION: The slug ejects at end of cut and is very hot.
SERVICE
1. Tool service must be performed only by qualied repair personnel. Service or maintenance performed
by unqualied personnel could result in a risk of injury.
2. When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance
section of this manual. Use of unauthorized parts or failure to follow Maintenance Instructions may
create a risk of electric shock or injury.
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OPERATIONAL SAFETY PROCEDURES
• When using electrical tools, basic safety precautions should always be followed to reduce the risk of
electric shock, re, and personal injury.
• Ensure the magnet is OFF before plugging in the machine.
• Do NOT use in wet or damp conditions. Failure to do so may result in personal injury.
• Do NOT use in the presence of ammable liquids, gases or in high risk environments. Failure to do so
may result in personal injury.
• BEFORE activating the machine, inspect all electrical supply cables (including extension leads), and
replace if damaged. DO NOT use if there are any signs of damage.
• Only use extension cables approved for site conditions.
• BEFORE activating the machine, ALWAYS check the correct function of all operational systems,
switches, magnet etc.
• BEFORE operating, the machine MUST be securely restrained to a xed independent feature (by using
a safety strap, or other means) to reduce the potential free movement, should the magnet become
detached from the work piece. Failure to do so may result in personal injury.
• ALWAYS wear approved eye protectors, ear defenders and recommended PPE at ALL times when
operating the machine.
• Disconnect from power source when changing cutters or working on the machine.
• Cutters and chips are sharp, ALWAYS ensure that hands are adequately protected when changing
cutters or removing chips. Use a tool or brush where necessary to remove any chips or the cutter from
the arbor.
• Before operating the machine, ALWAYS ensure cutter-retaining screws are secured tightly.
• Regularly clear the work area and machine of chips and dirt, paying particular attention to the
underside of the magnet base.
• ALWAYS remove tie, rings, watches and any loose adornments that might entangle with the rotating
machinery before operating.
• ALWAYS ensure that long hair is securely enclosed by an approved restraint before operating the
machine.
• Should the cutter become stuck in the work piece, stop the motor immediately to prevent personal
injury. Disconnect from power source and turn arbor to and from.
DO NOT ATTEMPT TO FREE THE CUTTER BY SWITCHING THE MOTOR ON AND OFF.
Wear safety gloves to remove the cutter from the arbor.
• If the machine is accidentally dropped, ALWAYS thoroughly examine the machine for signs of damage
and check that it functions correctly BEFORE resuming drilling.
• Regularly inspect the machine and check for any damaged or loose parts.
• ALWAYS ensure when using the machine in an inverted position that only the minimum amount of
coolant is used, and that care is taken to ensure that coolant does not enter the motor unit.
• Cutting tools may shatter, ALWAYS position the guard over the cutter before activating the machine.
Failure to do so may result in personal injury.
• On completion of the cut, a slug will be ejected. DO NOT operate the machine as the ejected slug may
cause injury.
• When not in use ALWAYS store the machine in a safe and secure location.
• ALWAYS ensure that approved CHAMPION authorized repair centers conduct repairs.
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3. INFORMATION PLATE SYMBOLS
1. Dispose of the machine and electrical components correctly.
2. Refer to the user manual for operational and safety issues with regard to this machine.
3. Eye protection and ear defenders must be worn when operating the machine.
4.
5..
OPERATIONAL INSTRUCTIONS
•Keep the inside of the cutter clear of chips. It restricts the operating depth of the cutter.
• Ensure that the coolant bottle contains sufcient cutting oil to complete the required operating duration.
Rell as required.
• Occasionally depress the pilot to ensure cutting uid is being correctly metered.
• To start the machine, follow the control panel operation instructions.
• ALWAYS switch off the motor by depressing the MOTOR stop button. DO NOT switch off the motor by
depressing the MAGNET switch.
• Apply light pressure when starting the cut of a hole until the cutter is introduced into the work
surface. Pressure can then be increased sufciently to load the motor. Excessive pressure is
undesirable, it does not increase the speed of penetration and will cause the safety overload protection
device to stop the motor, (the motor can be restarted by operating the motor start button), and may
cause excessive heat which may result in inconsistent slug ejection
• Always ensure that the slug has been ejected from the previous hole before commencing to cut the
next.
• If the slug sticks in the cutter, move the machine to a at 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.
• Apply a small amount of light oil lubricant regularly to the slide and arbor support bearing.
• Cutter breakage is usually caused by insecure anchorage, a loosely tting slide or a worn bearing in the
arbor support. (Refer to routine maintenance instructions).
• Only use approved cutting uid.
CUTTER INSTALLATION
This mag drill accepts annular cutters with 3/4” (19.05mm) diam. Weldon shanks.
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The pilot pin is used to both center the cutter and to eject the slug on completion of the cut. It has a at
side to allow coolant to run down to reach the center of the cut where the heat is greatest. Slide the pin
through the hole in the center of the cutter shank.
Lay the machine on its side with feed handles uppermost, ensuring arbor is wound down to its lowest
point to enable access to socket screws.
Take appropriate pilot and place through the hole in cutter shank. Insert shank of cutter into bore of
arbor, ensuring alignment of two drive flats with socket screws.Tighten both screws using hexagon key.
ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOURCE BEFORE CHANGING CUTTERS.
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EXTENSION CABLE SELECTION
• The machines are factory fitted with a 3 meter length of cable having three conductors 1.5 mm² 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.
•If the replacement of the supply cord is necessary, this must be done by the manufacturer or an
approved agent in order to avoid a safety hazard.
•Assuming a normal AC supply of the correct voltage, it is recommended that the following extension
lengths shall not be exceeded: For 110v supply: 3.5 meters of 3 core x1.5mm²
REPLACEMENT PARTS
•Contact Champion directly for information regarding replacement parts.
•It is highly suggested that all repairs to this magnetic drill press are competed by one of Champion's
authorized repair centers.

In order to ‘get the best life’ out of your Champion machine always keep it in good working order.
Several items must always be checked on Champion 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.
VISUAL CHECK OF MACHINE FOR DAMAGE X
OPERATION OF MACHINE X
CHECK BRUSH WEAR X
CHECK MAGNETIC BASE X
CHECK GREASE X
CHECK ARMATURE X
DESCRIPTION EVERY OPERATION WEEKLY MONTHLY
Visually check the machine for damage.
The machine must be checked before operation for any signs of damage that will affect the operation of the
machine. Particular notice must be taken to 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.
Machine 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.
Magnetic base – before every operation the magnetic base should be checked to make sure that the base is
at and there is no damage present. An uneven magnet base will cause the magnet not to hold as efciently
and may cause injury to the operator.
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 your
machine.
Check Armature of the machine.
This should be checked at least once a month to check that there are no 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, but this is normal
(this is the part that comes into contact with the brushes) however, if there are any signs of abnormal damage
the part should be replaced.
MAINTENANCE
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MEGABRUTE
REMEDIES FOR HOLE MAKING PROBLEMS
1) Magnetic base will not
hold effectively
Material being cut may be too thin for
efcient holding.
Attach an additional piece of metal
under the magnet, or mechanically
clamp magnetic base to workpiece.
Chips or dirt under magnet. Clean magnet.
Irregularity on magnet contact or
workpiece.
Use extreme care; le any
imperfections ush to surface.
Insufcient current going to magnet
during drilling cycles.
Conrm power supply and output from
control unit, check supply cable.
PROBLEM CAUSE REMEDY
2) Cutter skips out of center-punch
mark at initiation of cut
Magnetic base is not holding
effectively.
See causes and remedies above.
Worn arbor bushing and/or ejector
collar.
New arbor bushing is needed.
Too much feed pressure at start of cut. Light pressure only is needed until a
groove is cut. The groove then serves
as a stabilizer.
Cutter is dull, worn, chipped or
incorrectly sharpened.
Replace or re-sharpen. Sharpening
service is available.
Poor center-punch mark; weak
pilot spring; pilot not centerd in
centre-punch mark.
Improve center-punch and/or replace
worn parts Worn or bent pilot, worn
pilot hole.
Worn or bent pilot, worn pilot hole. Replace part or parts
3) Excessive drilling pressure
required
Incorrectly re-sharpened, worn or
chipped cutter.
Re-sharpen or replace.
Coming down on chips lying on
surface of workpiece.
Take care not to start a cut on chips.
Chips accumulated (packed) inside
cutter.
Clear cutter.
4) Excessive cutter breakage Steel chips or dirt under cutter. Remove cutter, clean part thoroughly
and replace.
Incorrectly re-sharpened or worn
cutter.
Always have a new cutter on hand
to refer to for correct tooth geometry,
together with instruction sheet.
Cutter skipping. See causes and remedies (2).
Cutter not attached tightly to arbor. Retighten.
Insufcient use of cutting oil or
unsuitable type of oil.
Inject oil of light viscosity into the
coolant-inducing 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).
Incorrect speed Ensure correct speed is use for the
cutter.
5) Excessive cutter wear See cause and remedy above
Incorrectly re-sharpened cutter. Refer to instructions and a new cutter
for proper tooth geometry.
Insufcient or spasmodic cutting
pressure.
Use sufcient steady pressure to
slow the drill down. This will result in
optimum cutting speed and chip load.
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MEGABRUTE
Magnet and motor do not function - The magnet switch is not connected to the power supply
- Damaged or defective wiring
- Defective magnet switch
- Defective control unit
- Defective power supply
Magnet does function, the motor does not - Damaged or defective wiring
- Carbon brushes are stuck or worn out
- Defective magnet switch
- Defective on / off switch
- Defective control unit
- Defective armature and/or eld
Magnet does not function, the motor does - Defective magnet
- Defective control unit
Hole cutters break quickly, holes are bigger than the hole
cutter
- Play in the guide
- Bent spindle
- Shaft extending from the motor is bent
- Pilot bent
Motor running roughly and/or seizing up - Bent spindle
- Shaft extending from the motor is bent
- Triangular guide not mounted straight
Motor making a rattling sound - Gear ring (bottom of the armature) worn out
- Gear(s) worn out
- No grease in gear box
Motor humming, big sparks and motor has no force - Armature damaged
- Field burned
- Carbon brushes worn out
Motor does not start or fails. - Damaged or defective wiring
- Damage to armature or eld coil
- Damaged or defective brushes
Insufcient magnetic force - Damaged or defective wiring
- Bottom of magnet not clean and dry
- Bottom of magnet not at
- Work piece is not bare metal
- Work piece is not at
- Work piece is too thin less than 10mm
- Defective control unit
- Defective magnet
Frame under voltage - Damaged / defective wiring
- Defective magnet
- Motor seriously dirty
Fuse blows when magnet switch is turned on - Damaged or defective wiring
- Wrong value fuse
- Defective magnet switch
- Defective control unit
- Defective magnet
Fuse blows when motor is started up - Damaged or defective wiring
- Motor running roughly
- Defective armature and / or eld
- Carbon brushes worn out
- Defective control unit
Rotation system free stroke too long - Loose or defective gear-rack
- Defective rotation system
TROUBLESHOOTING
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MEGABRUTE
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RECOMMENDED SPEED GUIDELINES
WARRANTY
Champion warrants its magnetic drill presses to be free from faulty parts, under normal usage of machines, for a period of 12
months from initial date of purchase. All other parts (excluding cutters) are under warranty for 90 days, provided that the warranty
online registration has been completed and returned to Champion or its designated distributor within a period of (30) days from the
purchase date. Failure to do so will void the warranty. If the stated is adhered to, Champion will repair or replace (at its option)
without charge any faulty items returned.
This Warranty does not cover:
1. Components that are subject to natural wear and tear caused by the use is not in accordance with the
operator’s instructions
2. Defects in the tool caused by non-compliance with the operating instructions, improper use, abnormal
environment conditions, inappropriate operating conditions overload or insufcient servicing or
maintenance.
3. Defects caused by using accessories, components or spare parts other than original Champion parts.
4. Tools to which changes or additions have been made.
5. Electrical components are subject to manufacturer’s warranty.
Optimize Performance Of Your Tools
Use BruteLube Fluid or Wax
Champion Offers A Complete Range Of
HSS & Carbide Tipped Annular Cutters
The warranty claim must be logged within the warranty period. This requires the submission or sending of the complete tool in question
with the original sales receipt which must indicate the purchase date of the product.
A complaint form must also be submitted prior to the return.
All goods returned defective must be returned pre-paid to Champion, in no event shall Champion 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
MERCHANTABLITY OR FITNESS FOR A PURPOSE. CHAMPION RESERVES THE RIGHT TO MAKE IMPROVEMENTS AND
MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE
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Phone: [phone]
PO BOX 368 Rockville Centre, NY 11571
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