Roto Brute MEGABRUTE RB65 User manual

RB65 MEGABRUTE
MAGNETIC DRILL PRESS
PARTS & SCHEMATICS
SAFETY / USAGE GUIDELINES

INCLUDED WITH EVERY RB65
Carrying case, safety strap, RB634 3/4” arbor, cutting fluid, safety guard, drift key & hex keys
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SAFETY
Be sure to read and follow these important safety instructions:
When using your RB65 MegaBrute, be sure to follow these important safety precautions:
1. Before operating the machine, check supply voltage and general conditions, i.e. cable/cord
damage. A machine with damaged cable must be returned or repaired prior to use.
2. Always use the safety strap in all drilling applications.
4. Since cutting tools can shatter, eye and head protection should be worn
at all times.
5. After use, clean machine and cutters and keep in the case provided.
6. Store when not in use in a dry environment.
7. Always provide a method of catching slug, where the ejected slug may cause injury (slug
ejects at end of cut).
8. Should the cutter jam in the work-piece, stop the machine immediately. Isolate the
machine at the main supply. Loosen the cutter by rotating the arbor. Do not attempt to free
cutter by starting and stopping the motor.
9. Always use the safety guard provided.
Electrical Safety
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 adapter plugs. Check with a qualified 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.
Never use the cord to carry the tools or pull the plug from an outlet. Replace damaged cords
immediately.
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. Minimum gauge
external cord should be 12/3.
Use the RB-32 with 110 A/C voltage only. Not for use with generators, welders or any dc
power source. Do not use on any surface where welding is taking place.
Personal Safety
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 influence of drugs, alcohol, or medication.
Do not wear loose clothing or jewelry. Avoid accidental starting. Be sure switch is off before
plugging in. Carrying tools with your finger on the switch or plugging in tools that have the
switch on invites accidents.
Remove adjusting keys before turning the tool on.
Do not overreach. Keep proper footing and balance at all times.
Safety equipment (eye protection, dust mask, nonskid safety shoes, hard hat, hearing
protection) should be used for appropriate conditions.
RB65
IMPORTANT
Please read these operating and safety instructions carefully and completely. For your own safety, before using this equipment check that the voltage
is correct and that all handles and parts are firmly secured. If you are uncertain about any aspect of using this equipment, contact your distributor.
PLEASE KEEP THESE INSTRUCTIONS
Tool Use and Care
Use clamps or other practical ways to secure and support the work-piece to
a stable platform.
Do not force tool. Use the correct tool for the application.
Disconnect the plug from the power source before making any adjustments, changing
accessories, or storing the tool.
Storeidle tools out of reach of children and other untrained persons.
Maintain tools with care. Keep cutting tools sharp and clean.
Check for misalignment or binding of moving parts, breakage of parts and any other condi-
tion that may affect the tool’s operation. If damaged, have the tool serviced before using.
Service
Tool service must be performed only by qualified and authorized personnel, or
warranty is voided.
When servicing a tool, use only original replacement parts. Use of unauthorized parts will
void the warranty.
Use of unauthorized parts or failure to follow maintenance instructions may create a risk of
electric shock or injury.
Magnetic Drill Safety
The drill’s magnetic adhesion depends on the thickness of the work-piece. 1/2” (13mm) is
the minimum thickness for safe operation. Keep the magnet clean of metal chips and other
dirt and debris. These will seriously reduce the magnetic adhesion. The drill must be oper-
ated on its own electrical outlet. Always use the supplied safety strap or chain. An electri-
cal overload can result in loss of adhesion.
CAUTION: The slug ejects at end of cut and is very hot.
WARNING: Do not attempt to drill a work-piece, which is thicker than the maximum cutting
depth of the cutter being used. Never exceed 4” cutter diameter.
Maintenance and Troubleshooting
Keep the drill press and the cord clean. In case of electrical or mechanical
malfunction, immediately switch off the tool and disconnect the plug. Excessive sparking
generally indicates the presence of dirt in the motor or worn out carbon brushes.
Periodically check brushes for wear and replace when they reach 1/4” (6mm).
Also check that the machine is well lubricated.
For all other service and maintenance, please contact a Champion® authorized
service center.
COMPONENTS & SAFETY
2
MEGABRUTE
Visit www.championcuttingtool.com
for 3-D imaging, zoom and and rotate.
RB65

RB65 OPERATING INSTRUCTIONS
Operating Instructions
1. Place a pilot pin in the cutter at the shank end. Insert the cutter into the special
arbor, aligning the flats to the set screws on the arbor. Secure the set screws to the
cutter with the supplied hex wrench.
2. Position the machine on a clean, dry, ferrous surface at least 1/2” thick. Switch on
the magnet.
3. Cutting fluid must be used at all times to enhance the quality of cut and prolong
the cutting tool life. Cutting fluid is applied through small holes located at the
top/shank end of the arbor and feeds via gravity.
4. Switch on the drill. Always proceed with caution at the start of drilling operations.
When using RotoBrute annular cutters apply pressure gradually at first until a depth
of 1/8” is reached. Normal cutting pressure can then be applied.
5. On completion of cut, withdraw the cutter from hole, switch off the drill, then the
magnet. Ensure the magnet base is clear of chips. Locate the next hole using the
above procedures.
Adjusting Dovetail Slides
Slowly adjust the hex screws while moving the handle up and down. Adjust so there
is no free play or no binding anywhere through its range of travel. Periodically check,
lubricate, and adjust as necessary.
Repositioning of Handles
1. Elevate the slide upward to its full extent.
2. Remove the pinion cap screw and pinion cap from the shaft end
(opposite side to handles).
3. Slide the pinion with the handles on outward, approximately 1/3rd distance.
4. Disengage the rack by means of raising the slide up by another 3/4”.
5. Remove pinion, reposition through opposite side of body casting and reverse pro-
cedure as above.
Assembly of Traverse Handles
1. To assemble traverse handle, place each of the three (3) handles into the threaded
holes on the pinion rack, turning clockwise to tighten.
2. To remove handles, turn counter-clockwise.
Assembly of Arbor for use with Annular Cutters
1. Machine spindle must be clean and free of debris.
2. Push the arbor firmly up into the internal spindle to lock into place.
3. To remove cutter arbor, insert drift key through keyhole located on side of motor until
arbor ejects.
4. To prepare for cutters, loosen set screws with hex keys (provided). INSERT PILOT INTO
CUTTER HOLE AT SHANK END. Place shank of cutter into bottom of arbor. Align flats on
shank with set screws and tighten until cutter locks into place.
5. To remove cutter, loosen set screws and pull.
Assembly of Drill Chuck for use with Straight Shank Tools
Drill chuck is optional: RB6512 (1/2” capacity) or RB6534 (3/4” capacity)
1. Place the drill chuck into the internal spindle, give a firm push to be sure it locks into
place.
2. To remove, push drift key through drift keyhole located on side of motor until drill
chuck ejects.
3. To prepare drill chuck for drills, place chuck key into chuck key hole and turn counter
clockwise. Place drill bit into drill chuck and turn chuck key clockwise until drill bit locks
into place.
4. To remove drill bit, turn chuck key counter clockwise.
To use Taper Shank Drills and Reamers
1. Insert taper shank drill or reamer into internal #3MT spindle.
2. Make sure the tang on the taper shank drill or reamer is aligned correctly and locked
into place.
3. To remove, insert drift key into slot located on side of motor and push through until
drill or reamer is ejected.
4. If drill or reamer is not seated correctly, the tang will break off and may cause damage
to internal spindle.
Assembly of Safety Guard
• Loosen screw from underneath the arbor support (front/center). Align the bracket slot
with the screw, and tighten screw until safety guard locks into place.
• To remove safety guard, loosen screw and remove safety guard.
RB65 ELECTRICAL CONNECTION DIAGRAM
5
MEGABRUTE

RB65 MOTOR PARTS
No. List/Size Description (Qty per Machine)
1 RB65-6680 Tapping Screws (1)
2 RB65-1957 Gear Cover (1)
3 RB65-1850 Gasket (1)
4 RB65-6640 Rear Inner Cover (1)
5 RB65-2046 Front Inner Cover (1)
6 RB65-3605 Internal Gear Change Piston (1)
7 RB65-1799 Plastic Gear Change Switch (1)
8 RB65-8821 Washer for Gear Switch (1)
9 RB65-6742 Gear Screw (1)
10 RB65-8031 Fan Guide (1)
11 RB65-2476 Bottom Cover (1)
12 RB65-2582 Plastic Brush Holder (2)
13 RB65-2529 Copper Brush Holder (internal) (2)
14 RB65-2532 Plastic Brush Cover (2)
15 RB65-2556 Set (2) Carbon Brushes (2)
16 RB65-HAB4 Housing Assembly (1)
17 RB65-3071 Stator (Field Coil) (1)
18 RB65-3055 Armature (1)
No. List/Size Description (Qty per Machine)
19 RB65-1712 Inner Gear Atlas Copco
20 RB65-1713 Inner Gear Atlas Copco
21 RB65-1714 Inner Gear Atlas Copco
22 RB65-1717 Inner Gear Atlas Copco
23 RB65-1722 Inner Gear Atlas Copco
24 RB65-3058 Spiral Gear for Armature
25 RB65-5267 Ring
26 RB65-5728 Inner Bushing Atlas Copco
27 RB65-7301 Locking ring
28 RB65-8177 Needle Bearing
29 RB65-8530 Needle Bearing
30 RB65-8593 Inner Bearing Assembly Atl Copco
31 RB65-9634 Washer
3
MEGABRUTE

RB65 STAND SCHEMATIC
No. List/Size Description (Qty per Machine)
1 RB601 Main Body Casting (1)
2 RB602 Magnetic Base (1)
3 RB613 Brass Guides (2)
4 RB625 Machine Rack (1)
5 RB604 Dovetail Slide (1)
6 RB605 Lower Drill Support (1)
7 RB634 #3MT to 3/4 Arbor (1)
11 RB623 Side Fixing Casting (1)
12 RB611 Safety Guard (1)
13 RB612 Retaining Bracket (1)
14 RB524 Pinion Cap (1)
15 RB221 Cap Head Screw for Pinion M5x15 (1)
16 RB614 Pinion Shaft (1)
17 RB615 Handle (3)
18 RB520 Handle Knob (3)
19 RB519 Cable Gland for Power Cord (1)
19A RB519A Cable Gland for Conduit Lead (2)
20 RB506 Counduit Lead (1)
21 RB503 Mains Cable (1)
23 RB617 Side Panel (1)
24 RB515 Rectifier Unit (1)
25 RB616 Switch Panel (1)
26 RB509 Stop/Start Switch (1)
27 RB513 Power Relay 110V (1)
29 RB505 Mag Switch 110V (1)
List/Size Description (Qty per Machine)
RB243 Clamps for RB65ECS Coolant Tube
RB516 Cutting Fluid Bottle
RB638 Relay Bracket 523 Clip
RB65-CASE-MT Empty Metal Case
RB65-MOTOR B4-32 Atlas Copco Motor
RB65-252 Panel Screws
SPANNER 7/16 & 17mm Wrench Set
RB-STRAP Ratchet Safety Strap
RB-POUCH Tool Pouch
4
MEGABRUTE
Exploded diagram of the RB65 safety guard
schematic and included RB634 3/4” arbor..
INCLUDED WITH EVERY RB65:
Carrying case, safety strap, RB634 3/4”
arbor, cutting fluid, drift key and hex keys,
safety guard.
19
19a
No. List/Size Description (Qty per Machine)
31 RB511 Fuse Holder (1)
32 RB512 2A Fuse (1)
33 RB626 Speed Switch (1)
34 RB637 Complete Motherboard (1)
35 RB61325 M5x25 Screw/Nut Guide (1) (not pictured)
36 RB502 Pinion Bushings (2)
36
25
12
36

Champion Cutting Tool Corp
P.O.Box 368, Rockville Centre, NY 11571-0368
Tel: [phone] Fax: [phone]
www.championcuttingtool.com
MAGNETIC DRILL PRESS RANGE
RB32 MINIBRUTE RB45 MIGHTIBRUTE RB65 MEGABRUTE AC35
CT SERIES
CARBIDE TIPPED ANNULAR CUTTERS
CT150 /CT200 /CT300 /CT400
XLSERIES
HIGH SPEED ANNULAR CUTTERS
XL /XLT /XLSTK
ANNULAR CUTTER RANGES
PORTABLE METAL
DRILLING SYSTEMS
CT150
1-3/8”
Depth of cut
CT200
2” Depth of cut
CT300
3” Depth of cut
CT400
4” Depth of cut
XL
HS ANNULAR
CUTTER
XL100/XL200/XL300
1” / 2” / 3”
Depth of cut
XLT
HS TITANIUM
COATED
XL100T / XL200T
1” / 2” Depth of cut
XLSTK
COBALT STACK CUT
XL200STK
2” Depth of cut