Champion RotoBrute AC42 User manual

AC42
VariBrute
Magnetic Drill Press
HEAVY DUTY
DRILLING & TAPPING
Variable Speed + Forward/Reverse
championcuttingtool.com

2
Tapping Collet /
Adaptor
Accessories
* Wrench (M8), T-Wrench
(M6), Hex Key (M2.5, M4),
Chip Guard, Coolant Tank,
Safety Strap, Drill Chuck /
Adaptor, Tapping Collet
TECHNICAL DATA
1. Coolant Tank
2. Coolant Feed Tap
3. Motor Switch
4. Fwd / Reverse Switch
5. Magnet Switch
6. Magnet Base
7. Pilot Pin (sold separately)
8. Annular Cutter (sold separately)
9. Quick-Release Cutter Holder
10. Arbor
11. Handle
12. Slide Height Lock
13. Speed Control Dial
Model AC42
Power Input 1100 W
Voltage 110 - 120 V
No Load Speed 225 ~ 450 RPM
Max. Capacity Cutters, Ø x Depth of Cut 1-1/2 x 2" (38 x 50 mm)
Twist Drills 1" Diameter (1/2" Shank)
Ø of Taps 3/4"
Magnetic Adhesion 3800 lb
Net Weight 29 lbs (13.15 kg)
2.
3.
4.
6.
7.
8.
9.
11.
12.
1.
1/2" 3-Jaw
Drill Chuck / Adaptor
13.
10.
5.

RotoBrute AC42 MAGNETIC DRILL PRESS SAFETY WARNINGS
WARNING Read all safety warnings, instructions, illustrations and specifications provided with
this magnetic drill press. Failure to follow all instructions listed below may result in electric shock,
fire and/or serious injury. Save all warnings and instructions for future reference.
For tools equipped with over load protection, when motor has shut down off due to over load, always
run machine with no load for at least 3 minutes to reduce temperature before returning to operation
to avoid burn out of the motor.
1) WORK AREA SAFETY
a. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b. Do not operate magnetic drill press in explosive atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
c. Keep children and bystanders away while operating a magnetic drill press. Distractions can cause
you to lose control.
d. Never leave the electric magnetic drill press unattended. Only leave the machine when the tool in
use has come to a complete standstill.
2) ELECTRICAL SAFETY
a. Magnetic drill press plugs must match the outlet. Never modify the plug in any way. Do not use
any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will
reduce risk of electric shock.
b. Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
c. Do not expose power tools to rain or wet conditions. Water entering a magnetic drill press will
increase the risk of electric shock.
d. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the magnetic drill
press. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords
increase the risk of electric shock.
e. When operating a magnetic drill press outdoors, use an extension cord suitable for outdoor
use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
f. If operating a magnetic drill press in a damp location is unavoidable, use a residual current device
(RCD) protected supply. Use of an RCD reduces the risk of electric shock.
3) PERSONAL SAFETY
a. Stay alert, watch what you are doing and use common sense when operating a magnetic drill
press. Do not use a magnetic drill press while you are tired or under the influence of drugs, alcohol
or medication. A moment of inattention while operating power tools may result in serious personal
injury.
b. Use personal protective equipment. Always wear eye protection. Protective equipment such as a
dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will
reduce personal injuries.
c. Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power
source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on
the switch or energizing power tools that have the switch on invites accidents.
d. Remove any adjusting key or wrench before turning the magnetic drill press on. A wrench or a key
left attached to a rotating part of the magnetic dr l press may result in personal injury.
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e. Do not overreach. Keep proper footing and balance at all times. This enables better control of the
magnetic drill press in unexpected situations.
f. Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from
moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
g. If devices are provided for the connection of dust extraction and collection facilities, ensure
these are connected and properly used. Use of dust collection can reduce dust-related hazards.
h. Do not let familiarity gained from frequent use of tools allow you to become complacent
and ignore tool safety principles. A careless action can cause severe injury within a fraction of a
second.
4) RotoBrute AC42 MAGNETIC DRILL PRESS USE AND CARE
a. Do not force the magnetic drill press. Use the correct magnetic drill press for your application. The
correct magnetic drill press will do the job better and safer at the rate for which it was designed.
b. Do not use the magnetic drill press if the switch does not turn it on and off. Any magnetic drill press
that cannot be controlled with the switch is dangerous and must be repaired.
c. Disconnect the plug from the power source and/or remove the battery pack, if detachable,
from the magnetic drill press before making any adjustments, changing accessories, or storing
power tools. Such preventive safety measures reduce the risk of starting the magnetic drill press
accidentally.
d. Store idle tool out of the reach of children and do not allow persons unfamiliar with the
magnetic drill press or these instructions to operate the magnetic drill press. Power tools are
dangerous in the hands of untrained users.
e. Maintain magnetic drill press and accessories. Check for misalignment or binding of moving
parts, breakage of parts and any other condition that may affect thetool’s operation. If
damaged, have the magnetic drill press repaired before use. Many accidents are caused by poorly
maintained power tools.
f. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less
likely to bind and are easier to control.
g. Use the magnetic drill press, accessories and tools in accordance with these instructions, taking
into account the working conditions and the work to be performed. Use of the magnetic drill
press for operations different from those intended could result in a hazardous situation.
h. Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles
and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
5) SERVICE
Have your magnetic drill press serviced at a qualified Champion Cutting Tool authorized repair center
using only identical replacement parts. This will ensure that the safety of the magnetic drill press is
maintained.
TERMINOLOGY USED IN THE MANUAL
1. Warning: This term means that there is a risk of physical harm or death to the operator or people
nearby.
2. Caution: This term means that there is a risk of damage to the machine, cutting tool or other
equipment.
3. Note: These terms offer useful information relating to the operation of the machine or its
maintenance.
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RotoBrute AC42 MAGNETIC DRILL SAFETY WARNINGS
a. The magnetic drill press must be secured. A drill that is not properly secured may move or tip over
and may result in personal injury.
b. The workpiece must be clamped or secured to the workpiece support. Do not drill pieces that are
too small to be clamped securely. Holding the workpiece by hand during operation may result in
personal injury.
c. Do not wear loose gloves. Gloves may be entangled by the rotating parts or chips, leading to personal
injury.
d. Keep your hands out of the drilling area while the tool is running. Contact with rotating parts or
chips may result in personal injury.
e. Make sure the accessory is rotating before feeding into the workpiece. Otherwise the accessory may
become jammed in the workpiece, causing unexpected movement of the workpiece and personal injury.
f. When the accessory is jammed, stop applying downward pressure and switch off the tool.
Investigate and take corrective actions to eliminate the cause of the jam. Jamming can cause
unexpected movement of the workpiece and personal injury.
g. Avoid generating long chips by regularly interrupting downward pressure. Sharp metal chips may
cause entanglement and personal injuries.
h. Never remove chips from the drilling area while the tool is running. To remove chips, move the
accessory away from the workpiece, switch off the tool, and wait for the accessory to stop moving.
Use tools such as a brush or hook to remove chips. Contact with rotating parts or chips may result in
personal injury.
i. Accessories with speed ratings must be rated at least equal to the maximum speed marked on the
magnetic drill press. Accessories running faster than their rated speed can break and fly apart.
MAGNETIC DRILL SPECIFIC SAFETY WARNINGS AND CAUTIONS
a. Always use safety strap. Mounting can release.
b. WARNING: While operating, only hold the crank handles, not any other part of the machine.
Placing the hand on the machine may result in an electric shock in the event of a voltage leak or if the
machine cuts its own power supply cable.
Symbols used in this manual
V…….......volts
A…….......amperes
Hz……......hertz
W……......watt
~………....alternating current
n
0
………..no load speed
min-1….....revolutions or reciprocation
per minute
......warning of general danger
.…with electrical earth
.......read these instructions
......always wear eye protection
......always wear a dust mask.
.....always wear hearing protection
.....wear safety-approved hard hat
do not dispose of electric tools,
accessories and packaging together
with household waste material
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c. Always ensure that the work piece is a minimum of 13mm (1/2in.) thick. If it is not, then use a
piece of steel plate at least 12mm thick and larger than the magnet, below the work piece, to
supplement the magnetic adhesion. The magnet’s adhesion depends on the thickness of the work
piece.
d. Do not operate the machine on a workpiece while it is being welded. This may lead to damage to the
machine and/or personal injury.
e. Never position machine on a work piece between the electrode and the ground of any arc type
welder. The welder’s current will ground through the earth wire in the machine’s power supply cable,
causing it damage.
f. Do not exceed 90 degrees from horizontal. It is hazardous to use the drill upside-down.
g. Always ensure that the magnet is clean and free of rust and scale. Metal chips and other debris will
hamper magnetic adhesion.
h. Always use the tool alone on the receptacle. Other units used on the same receptacle could cause
uneven voltage that could lead to the magnet releasing.
i. Ensure that the magnet has properly adhered to the work piece before beginning drilling. Proper
magnet adhesion is essential for safe drilling.
j. Do not operate with dull or damaged cutting tools. This may overload the motor.
k. Avoid operating annular cutters without cutting fluid. Always check fluid level before operating.
Annular cutters require cutting fluid for proper operation and long life.
l. Protect the motor. Never allow cutting fluid, water, or other contaminants to enter the motor. This
could lead to electric shock or motor damage.
m. When drilling stacked work materials, always stop to clear the slug after the first layer is drilled.
The loose slug will interfere with proper drilling.
n. CAUTION: Never attempt to use machine with incorrect current or abnormally low voltage.
Incorrect voltage could lead to motor damage.
o. This machine is not intended for production-line type use.
MAGNET BASE DUTY CYCLE
Do not leave the magnet base activated continuously for more than 60 minutes. If the magnet base is
overheated, allow it to cool for 30 minutes before continuing.
CAUTION: Turn the magnet base off when not in use. Leaving the magnet base on continuously will
damage it.
ASSEMBLY
Coolant tank assembly required. First attach clear tube to the bottom of the coolant tank. To do this, first loosen
the nut and slide nut onto the tube. Then slide tube onto the nipple. Then tighten the nut. Slide tank hanger
over the screw on the upper right hand side of slide and tighten. Finally insert the other end of the tube into
the quick-release connector in the gearbox. Just directly push in to install. (To remove, first firmly push the
red collar of the connector and pull the tube out.) Cutting coolant fluid is always required when using
annular cutters. Open tank cover and fill. Check coolant fluid level often. Keep coolant tap closed when not in
use.
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Chip guard must be used. To attach the chip guard, use the supplied butterfly bolts to bolt to the magnet. It is
not necessary to remove guard to clean chips. Simply raise guard to its upper position.
Safety Strap must be used. Loop strap around the workpiece, feed strap throught the power tool's handle,
and tighten strap using the ratchet mechanism.
ADJUSTING THE SLIDE HEIGHT
Adjustable slide height allows the operator to quickly change the height
position of the motor head on the slide. This is useful when switching
between twist drills and annular cutters, for example. For annular cutters,
use the lowest position possible for best stability. For twist drills, raise the
motor head to allow enough clearance for the twist drill to be mounted.
To adjust:
1. Using the T-handle hex wrench, loosen the socket cap screw on the
Slide Height Lock. (It's helpful to give it tap to allow it to release).
2. Slide the motor head to the desired position.
3. Tighten the Slide Height Lock.
MOUNTING ANNULAR CUTTERS
CAUTION: Never use a cutting tool that is larger than the maximum
rated capacity of the machine.
Push up on the quick-release collar. Insert the cutter with pilot pin and turn
until the flat meets the locking pin. When the flat meets the locking pin, the
collar will snap down. Double check to ensure that it is fully locked.
TWIST DRILLS
1. Push up on the Quick-Release Collar. Insert the Drill / Chuck
Adaptor into the Tool Holder and turn until the Quick-Release Collar
snaps down.
2. Always double check to ensure that the Quick-Release Tool Holder
is fully locked.
3. Insert the twist drill into the Chuck and tighten with the chuck key.
Quick-release
collar
Slide height lock
Quick-release
collar
Chuck
adaptor
Chuck
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TAPPING
CAUTION: Never use a cutting toolwhich is larger than the maximum
rated capacity of the machine.
CAUTION: Always follow the tap manufacturer’srecommendation for
selecting the correct size hole for tapping.
1. For tapping, use the universal tap chuck.
2. To insert the universal tap chuck, push up on the Quick-Release Collar
and insert the shank into the coupling.
3. Use the key to turn it to open its jaws enough to fit the square of the
tap. Ensure that the corners of the square are properly located in the
jaws. Then use the key to securely tighten the chuck.
NOTE: Make sure that the tap is inserted as deeply as possible into the
jaws. An improperly seated tap will run off center and could result in
damage to the jaws or tap.
SPEED CONTROL DIAL
The Speed Control Dial is used to reduce the speed and power of the motor
for tapping operations. Only use the speed control when tapping. For
drilling operations, always keep the Speed Control Dial at its maximum
setting.
CAUTION: Do not use the Speed Control Dial to reduce speed when
drilling. The reduced speed may lead to motor overheating and
insufficient torque.
REVERSING SWITCH
The Reversing Switch has 3 positions:
1. The position marked (F) is for forward rotation, which is the standard
direction for all drilling operations. Always leave the switch in this
position when not tapping.
2. The position marked (R) is for reverse rotation, which is only used for removing the tap from the hole.
3. The central position between (F) and (R), which is unmarked, is for neutral. In the neutral position the
motor will not turn, even though its switch is still turned on. This is only used to allow the spindle to stop
rotating before reversing the rotation direction.
WARNING: When the motor is switched on with the Reversing Switch in its neutral position, the machine
will not turn but will be “live”, and as soon as either forward or reverse is selected, the arbor will begin
turning! Take due care to avoid unexpected or unintentional starts.
Speed Control Dial
Quick-release
collar
Universal
Tapping
chuck
adaptor
Universal
Tapping
chuck
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Tapping Operations:
1. Once the correctly sized hole is drilled, mount the tap in the arbor and
lubricate the tap with a suitable cutting fluid.
2. Turn the Speed Control Dial down to a low setting. (This will reduce the
torque applied to the tap and will make the tapping operation more
controllable at the same time).
3. Ensure that the Reversing Switch is set to the forward (F) position.
4. Carefully center the tap on the hole and turn the magnet on.
5. Start the motor and feed the tap into the hole, allowing the tap to feed at
its own pace, a light guiding hand on the handle is sufficient.
CAUTION: Do not allow the tap to bottom out.
6. As soon as the hole is tapped, turn the Reversing Switch to its central (neutral) position and wait long
enough to allow the spindle to come to a complete stop.
CAUTION: Always allow the spindle to stop completely before changing its direction of rotation.
Immediately reversing rotation, without stopping first, will cause damage to the motor.
7. Once the spindle has completely stopped, turn the Reversing Switch to the Reverse (R) position to
remove the tap from the hole.
8. After shutting off the motor, remember to return the Reversing Switch back to the forward (F) position.
OPERATION-GENERAL
WARNING: Always ensure that the magnet is adhered properly to the work piece before beginning
drilling.
NOTE: If mounting to a curved surface beam, mount the machine parallel to the curve in the work piece.
WARNING: Avoid operating at more than 90 degrees from horizontal. When drilling at such an angle
take precautions to prevent cutting coolant from entering the motor. Brutelube wax lubricant should
be used.
CAUTION: Machine is equipped with a reversing switch. Always ensure that direction of rotation is
correct before operating. Operating in the wrong direction could result in damage to the cutter.
1. First fit tool into arbor and line up with intended center of cut. Then switch magnet on.
2. Press green motor on button to start motor. Use the crank handle to feed to work. Always use very
light pressure when beginning the cut and just as the tool is breaking through. The crank handle offers
tremendous leverage; so do not use too much force. Allow the cutting tool to determine the pace.
With experience, the operator will be able to determine the best pace to feed to the work. There should
be some degree of audible slowing of the motor but not bogging in the cut. Correct cutting speed
with a properly sharp annular cutter will produce long unbroken chips, which produce a birds nest
shaped bundle of chips around the cut.
Magnet Switch
On/O Switch
Forward / Reverse
Switch
NOTE: Always ensure that the cutting tool is sharp. A dull cutter will produce finer / smaller chips.
9

WARNING: ALWAYS clear chips when there is too much build-up. Excessive chip build-up could result in
a jammed cutter or other hazardous situation.
WARNING: The slug ejects at end of cut and is very hot. Always provide a method of catching the slug,
since the ejected slug may cause injury to people below.
Note: Lock the slide lock on the side of the machine in the fully raised position when at rest to prevent
the slide from accidentally slamming down - remember to unlock it again before commencing drilling.
CAUTION: Never attempt to cut half-circles or to stitch drill (drill overlapping holes) with a Carbide
Tipped cutter. This may destroy the cutter.
CAUTION: Never attempt to re enter a half-finished cut if the magnet has been turned off and the
machine shifted in the interim. This may destroy the cutter.
MAINTENANCE
WARNING: All repairs must be entrusted to an authorized service center. Incorrectly performed repairs
could lead to injury or death.
Every 50 hours of operation blow compressed air through the motor while running at no load to clean out
accumulated dust. (If operating in especially dusty conditions, perform this operation more often.)
1. Keep the machine clean and free of chips.
2. Check for loose fittings and tighten as needed.
3. Ensure that the ventilation slots are clear so that motor can be cooled normally. Blow low-pressure
compressed air through the ventilation slots with the motor running to keep motor clean.
THE GIBS (DOVETAIL SLIDES)
The gibs require adjustment if too loose. To adjust, loosen the lock nuts and
adjust the adjustor screws evenly while moving the handle up and down.
Adjust so that there is no free play, without any binding anywhere in its
range of travel. Then retighten the lock nuts. Periodically check, lubricate,
and adjust as needed.
CARBON BRUSHES
Carbon brushes are a normal wear parts and must be replaced when they reach their wear limit.
Caution: Always replace the brushes as a pair.
To replace:
1. Remove the 4 screws and remove the motor tail cover.
2. Using pliers rotate the brush spring out of the way and slide the old
carbon brush out of the brush holder.
L-hex key
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