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Copyright © 2006 Champion Cutting Tool Corp. All Rights Reserved RB-LIT 0806/25M

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RotoBrute

Champion’s RotoBrute system deliversthe quickest method of drilling and sawingsteel for the professional.

Portable, powerful, andlightweight, this is a completemetal sawing system. Engineeredto cut the most difficult materials- angle iron, “C” channel pipe,steel plate and stainless steel.

• Steel fabrication• Bridge and highway maintenance• Truck and trailer manufacturing• Construction equipment• Mining equipment• Shipbuilding and railway industries• Refineries, offshore rigs and pipelines• Lift and elevator repair• Welding• General engineering

The RotoBrute drilling system includes a complete line of magnetic drill presses andannular cutters, engineered to drill large diameter holes in structural steel from 7/16” to4” diameter. Our heavy duty RB32, RB45 & RB65 models feature high power motors anda high vertical travel support system which gives the user the choice of using twist drillsor annular cutters. All three magnetic drill presses feature a cutting fluid reservoir builtinto the arbor, reversible handles for use in tight areas and a wide high density magnetfor greater stability.

The RotoBrute AC35 offers big power in a small package. This economical magnetic drillpress now features a quick-change arbor for fast cutter installation, without using tools.

Champion magnetic drill presses may be used in any position - vertical, horizontal or overhead. It allows you to take the drill to the workpiece, instead of trying to bring theworkpiece to the drill.

RotoBrute Magnetic Drill Presses

RotoBrute IndustrialApplication Examples

RS725 MetalCutting Saw

INTRODUCTION

Renowned as the most dependablehole-making machine in its class, the

RB32 is remarkably powerful, yet compactand lightweight. Champion’s RB32 is the

ideal portable drill for plant maintenance &steel erection. Available in a variable speed

and reverse option.P04

Champion’s answer to the marketsrequirement for a lightweight

machine that yields more cutting power.The 2 speed 1200 watt motor packs the

power of much heavier machines.The RB45 accommodates cutters up to 2”

and twist drills up to 1”.P04

One of the most powerful machines on themarket, Champion’s RB65 is highly reliablewith an Atlas Copco 1260 watt, four speedmotor at its heart. This machine is virtually

maintenance free, can cut holes up to 4”diameter and 3” deep and can be used with

taper shank drills and bridge reamers.Available in a variable

speed and reverse option.P05

Drill Press Hints & TipsAn informative section onthe use of Magnetic DrillPresses and annularcutters.P08-10

CT Series - Carbide Tipped Annular Cutters

For maximum performance specify RotoBruteCT150 and CT200 carbide tipped cutters.

Engineered for tough materials, these cutterscontinue to cut when others fail.

XL Series - Plus 20 H.S.S. Annular Cutters

At the core of the RotoBrute system is thebroadest range of annular cutters which feature

our exclusive Plus20 surface treatment.Providing cleaner cuts, positive slug

ejection and long tool life.P06-07

Magnetic Drill Press Range

RotoBrute Drilling and Cutting Accessories

Cutter SizesHints, Tips & Accessories

RB32MiniBrute

RB65MegaBrute

RB45MightiBrute

RotoBrute Cutters

Metal Cutting Saw

AC35A lightweight, powerful andeconomical magnetic drill presswith a high torque 1200 wattmotor and large 1-3/8”cutter capacity.P05

and Tungsten Carbide Tipped Saw BladesColor coded, material matched range of cuttingsaw blades that deliver more cuts per blade at a lower cost than any other brand.P11

RB32 MINIBRUTEMAGNETIC DRILL PRESS

MAG

NETI

C DR

ILL

PRES

SES

04

RB45 MIGHTIBRUTEMAGNETIC DRILL PRESS

FEATURES• Weighs only 44lbs

• 2”Dia. x 2” Depth "Ca pacity

• Built in fluid reservoir

• Reversible feed handle

• 8” Vertical travel

BENEFITS• Much lighter than machines with

less cutter capacity• Greater capacity than machines

weighing much more• Delivers the coolant to work

place and cutter• Left hand use and operating in

restrictive areas• Utilizes S&D drills up to 1”

FEATURES• Weighs only 28lbs

• 1-3/8” Dia. Cutter Capacity

• Built-in fluid reservoir

• Reversible feed handle

• 6” Vertical travel

BENEFITS• Lighter weight makes handling

and transport easier and safer• Same capacity as machines

weighing much more• Delivers the coolant to work

place and cutter• Left hand use and operating in

restrictive areas• Utilizes S&D drills up to 3/4”

RB32-VSRThe same features as the RB32but has variable speed control andreverse. It also features anisolating power relay for improvedhandling safety.

This machine can run twist drillsat correct RPM and has optionaltapping attachments.

INCLUDED WITH EVERY RB32Carrying case, safety strap, RB334 3/4” arbor, RB3212 1/2” drill chuck(and safety screw), D-handle, cutting fluid, safety guard, chuck key, hexkeys and spanner wrenches

INCLUDED WITH EVERY RB45

Carrying case, RB433 #2MT arbor, safety strap, cutting fluid, safetyguard, drift key and hex keys

MAGNETIC DRILL PRESSES

05

RB65MEGABRUTEMAGNETIC DRILL PRESS

AC35AC35MAGNETIC DRILL PRESS

FEATURES• Weighs 23lbs• 1-3/8” Dia. X 2” Depth Capacity

• Standard external fluid reservoir

• Quick change cutter arbor

•No load speed of 600 RPM

BENEFITS• Easy to maneuver• Same capacity as machines

weighing much more• Convenient cooling and less fill

ups than arbor reservoir• Annular cutters changed quickly

with no tools• Great for use with carbide tipped

annular cutters

FEATURES• Weighs 61 lbs

• 4” x 3” Cutter Capacity

• Built in fluid reservoir

• Reversible feed handle

• 11-1/2” Vertical travel

• #3 Morse Taper Spindle

BENEFITS• Excellent machine for all fabrication shops

• Enables greatest selection of cutters available

• Delivers the coolant to work place and cutter

• Left hand use and operating in restrictive areas

• Allows the use of twist drills up to 1-1/2”• Allows the use of morse taper bits up to 1-

1/2” and #3 morse taper reamers

RB65-VSRAll the same features as the RB65

but has variable speed controland reverse It also features an

isolating power relay for improvedhandling safety.

This machine can run twist drillsat correct RPM and has optional

tapping attachments.

INCLUDED WITH EVERY RB65Carrying case, safety strap, RB634 3/4” arbor, cutting fluid, safety guard,drift key and hex keys

INCLUDED WITH EVERY AC35Carrying case, hex keys, safety chain, external coolant bottle,cutting fluid, safety guard. Quick release arbor enables cutterchange in seconds.Motor is mounted to the frame in 3 points for greater rigidity

CT150/CT200 CARBIDE TIPPED ANNULAR CUTTERS

Champion CT series of cutters maximizes the power and cutting performance ofany portable magnetic drill press. Their superior “Triple Edge” cutting actionoutperforms ordinary high speed steel annular cutters and twist drills 6:1.

ApplicationsCut holes in cast iron, steel and ultra hard or exotic alloys with the added abilityto produce overlapping and interrupted holes easily.

CT150for drilling holes 9/16” to 1-9/16” diameter

CT200for drilling holes 9/16” to 2” diameter with high precision and speed

Time Saving features• Ultra hard carbide teeth permit faster cutting even in tough materials and shapes• Cut clean, bur free holes• Precision pilot pins eject the center as a plug of steel• Features Weldon style flats for fast loading and better rigidity

Triple Edge cutting system The CT series feature two sets of threecutting tips each with differentgeometries. This unique systembalances the cutting forces enablinghigher feed rates and smoother drilling,with better control in structural steeland steel plate.

ANNU

LAR

CUTT

ERS

06

250

200

150

100

50

0

No. o

f hol

es d

rille

d

213

CT15013/16”

HS Cutter13/16”

256%83

CT150 versus Standard HS Annular Cutter Comparison

CT Advantage:

Material used - Construction Steel (25mm thick) AC35 Magnetic Drill Press used - 920 watts @ 560RPMComparison stopped when no more holescould be bored at the same force

Independent Test 1” diameter cutter in 1-1/4” thick construction steel produced

1005 holes

FRACTIONALDIAMETERS

LIST CT1501-3/8¨ DEPTH OF CUT

LIST CT2002¨ DEPTH OF CUT

9/16 l l

5/8 l l

11/16 l l

3/4 l l

13/16 l l

7/8 l l

15/16 l l

1 l l

1-1/16 l l

1-1/8 l l

1-3/16 l l

1-1/4 l l

1-5/16 l l

1-3/8 l l

1-7/16 l l

1-1/2 l l

1-9/16 l l

1-5/8 l

1-11/16 l

1-3/4 l

1-13/16 l

1-7/8 l

1-15/16 l

2 l

ANNULAR CUTTERS

HIGH SPEED ANNULAR CUTTERSXLSERIES

Before you Drill:• Frequently Clear Chips - Clear all chips from your cutter before starting the next

hole. As the cutter begins removing material, new chips flow out through the gulletsand up the flutes. If these pathways are not cleared before cutting a new hole, packingor binding may result, causing the cutter to fill with chips and possibly break.

• Always Use Lubricant - Ensure Champion BruteLube fluid or wax is used tolubricate the cutters. This is to maintain cutting performance and tool life.

• Material Identification - Identify material properties before cutting (e.g. tensilestrength and abrasion) and adjust feed rate to match. Refer to chart on page 9.

While Drilling:• Feed Rate - The #1 cause of broken cutters is excessive feed rate. Too slow a

feed rates will also reduce the life of your cutter. Throughout the cuttingprocedure, use firm and steady pressure. Take a healthy chip.

• Force Applied - Do not force cutting tool into the material. This causes excessivetorque to be generated, which will reduce the efficiency of the cutter and causetool breakage.

• Material Hard Spots - Do not" force the cutter through hard spots in ma terial.Ease off pressure and cut at a lower speed.

Cutter Change - Resharpen or replace your cutter if slug ejection becomes unreliable or the tool resists cutting.

High speed steel annular cutters (M2) whichfeature Champion’s exclusive PLUS20 surfacetreatment, providing cleaner cuts, positive slugejection and longer tool life.

Available in 3 cutting depths:• 1” XL100, XL100M (Metric)• 2” XL200, XL200M (Metric)• 3” XL300

XL Series cutters are recommended for materialswith a brinell hardness number (BHN) up to 275.

XLSERIESHS ANNULAR CUTTERS

Available in 2 cutting depths:• 1” XL100T• 2” XL200T

High speed steel annular cutters with Titanium Nitride coating for higher speeds and longer tool life.XLT Series cutters are recommended for materials with a Brinell hardness number (BHN) of up to 325.

XLTSERIESHS TITANIUM NITRIDE COATEDANNULAR CUTTERS

Stack cutting annular cutters available for drillingmultiple layers without stopping to remove center plugs• 2” XL200STKStack cut tooth geometry cutters will smoothly penetratemultiple layers where non-modified cutters cannot.

XLSTKSERIESCOBALT STACK CUT ANNULAR CUTTERS

RotoBrute pilot action

RotoBrute Pilot Pins Rotobrute pins slide through the center of the annular cutter to:

• Help the operator set the precise location to drill• Guide a steady flow of cutting fluid to the cutting edges• Eject the slug when the cutter has completed the hole

Rotobrute pins are available for all types of Champion annular cutters.

07

PLUS20The PLUS20 coating on

XLSERIES Champion Cutters

gives 20% more tool life

and 20% higher performance

than standard high speed

annular cutters!

ANNU

LAR

CUTT

ERS

08

ANNULAR CUTTER SIZE CHART

FRACTIONALDIAMETERS

LIST XL1001¨ DEPTH OF CUT

LIST XL100T1¨ DEPTH OF CUT

LIST XL2002¨ DEPTH OF CUT

LIST XL200T2¨ DEPTH OF CUT

LIST XL200STK2¨ DEPTH OF CUT

LIST XL3003¨ DEPTH OF CUT

METRICDIAMETERS

LIST XL100M1¨ DEPTH OF CUT

LIST XL200M2¨ DEPTH OF CUT

7/16 l l l l l 13 l l

1/2 l l l l l 14 l l

17/32 l l 15 l l

9/16 l l l l l 16 l l

5/8 l l l l l 17 l l

21/32 l 18 l l

11/16 l l l l l 19 l l

23/32 l 20 l l

3/4 l l l l l l 21 l l

25/32 l 22 l l

13/16 l l l l l l 23 l l

7/8 l l l l l l 24 l l

15/16 l l l l l l 25 l l

1 l l l l l 26 l l

1-1/16 l l l l l 27 l l

1-1/8 l l l l l 28 l l

1-3/16 l l l l l 29 l l

1-1/4 l l l l l 30 l l

1-5/16 l l l l l 31 l l

1-3/8 l l l l l 32 l l

1-7/16 l l l l l 33 l l

1-1/2 l l l l l 34 l l

1-9/16 l l l l l 35 l l

1-5/8 l l l l l 36 l l

1-11/16 l l l l l 37 l l

1-3/4 l l l l l 38 l l

1-13/16 l l l l l 39 l l

1-7/8 l l l l l 40 l l

1-15/16 l l l l l 41 l l

2 l l l l l 42 l l

2-1/16 l l l l 43 l l

2-1/8 l l l 44 l l

2-3/16 l l l 45 l l

2-1/4 l l l 46 l l

2-5/16 l l l 47 l l

2-3/8 l l l 48 l l

2-7/16 l l l 49 l l

2-1/2 l l l 50 l l

2-9/16 l l l

2-5/8 l l l

2-11/16 l l l

2-3/4 l l l

2-13/16 l l l

2-7/8 l l l

2-15/16 l l l

3 l l l

3-1/16 l l l

3-1/8 l l l

3-3/16 l l l

3-1/4 l l l

3-5/16 l l l

3-3/8 l l l

3-7/16 l l l

3-1/2 l l l

3-9/16 l l l

3-5/8 l l l

3-11/16 l l l

3-3/4 l l l

3-13/16 l l l

3-7/8 l l l

3-15/16 l l

4 l

l

l

l

l

l

l

l

l

l

l

l

l

l

l l

XLSERIES

ANNULAR CUTTERS

ANNULAR CUTTER SPEEDS ANDTECHNICAL INFORMATIONHINTS & TIPS

09

Type of MaterialBrinell

HardnessCutting

Speed (sfm)

Aluminum Wrought & CastDie Cast 360.0, 380.0

383.0, 413.0390.0, 392.0

*30-150*40-125*40-125*40-125

500-1000450-600450-60075-100

Cast Iron SoftMediumChilled

120-150160-220230-300

75-12550-10030-50

10 20 30 40 50 60 70 80 90 100CutterDia.

Inches

51 102 153 204 255 306 357 407 458 509.7500

44 87 131 175 218 262 306 349 393 437.8750

38 76 115 153 191 229 267 306 344 3821.0000

34 68 102 136 170 204 238 272 306 3401.1250

31 61 92 122 153 183 214 244 275 3061.2500

28 56 83 111 139 167 194 222 250 2781.3750

25 51 76 102 127 153 178 204 229 2551.5000

24 47 71 94 118 141 165 188 212 2351.6250

22 44 65 87 109 131 153 175 196 2181.7500

20 41 61 81 102 122 143 163 183 2041.8750

19 38 57 76 95 115 134 153 172 1912.0000

18 36 54 72 90 108 126 144 162 1802.1250

17 34 51 68 85 102 119 136 153 1702.2500

16 32 48 64 80 96 113 129 145 1612.3750

15 31 46 61 76 92 107 122 138 1532.5000

15 29 44 58 73 87 102 116 131 1462.6250

14 28 42 56 69 83 97 111 125 1392.7500

13 27 40 53 66 80 93 106 120 1332.8750

13 25 38 51 64 76 89 102 115 1273.0000

12 24 37 49 61 73 86 98 110 1223.1250

12 24 35 47 59 71 82 94 106 1183.2500

11 23 34 45 57 68 79 91 102 1133.3750

11 22 33 44 55 64 76 87 98 1093.5000

11 21 32 42 53 63 74 84 95 1053.6250

10 20 31 41 51 61 71 81 92 1023.7500

10 20 30 39 49 59 69 79 89 993.8750

10 19 29 38 48 57 67 76 86 954.0000

Malleable Iron FerreticPearliticTemperature Matensite

110-160160-220200-320

100-13075-10030-60

Nickel Alloys 200-230Monel 400-404Monel K500, 502

80-170115-240150-330

60-8035-5020-40

Stainless Steel PrecipitationHardening By Hardness Range

17-4 PH

150-200275-325325-375

45-5540-5035-45

Steel Resulphurized/LeadedFree Machining

- 105-130

Steel Alloys Hard 260-300325-400

35-5030-40

Armor Plate 200-250250-300

40-5530-45

Stainless Steel 430/405Ferritic 430F

135-185 90-125

Stainless Steel Lower BHNAustenitic Higher BHN

135-185225-275

55-7540-70

Brass & Bronze - 300-600

Carbon Steel 10xx, 12xx, xx10, xx20 125-160 90-110

Stell Alloys Soft 170-210 65-90

Steel Alloys Medium 220-250 55-75

Tool Steel 210-250 35-60

Forgings - 40-50

Stainless Steel Nitonic (Low Alloy) 275-325 25-35

Magnesium *50-90 400-800

Stainless SteelMatensitic By Hardness Range

501416/440F

135-185185-240275-325375-425

70-12545-11035-5530-55

Surface Feet per Minute

Revolutions per minute (RPM)

The following charts contain information for calculating speeds when using RotoBrute annular cutters

Arbor PreparationWhen using a drill press, ensure that a support system is in place for the arbor and that it is not worn out.Surface PreparationThe material must be at least 3/8” thick. The machines magnetic base must be clear of chips and debris and must be securely attached to a clean workpiece.The magnet will be prevented from obtaining optimal holding power if it is used on an uneven surface or there is a large debris buildup. Thismay cause the drill to shift or lift during operation.Pipe / Convex Surface DrillingChampion Magnetic Drill Presses can be used to drill such surfaces but you need a support system. Champion stocks the RB-Saddle for such circumstances.Machine MaintenanceFor the best performance, always maintain your drill as instructed in your Champion machine operator's manual. Champion magnetic drill presses feature a slide/gibway system that requires periodic adjustments to maintain rigidity and optimal performance. Worn or damaged parts should be replaced to reducethe possibility of injury. Champion stocks a full range of replacement parts.

Champion stocksa complete rangeof spare parts forall RotoBrutemagnetic drillpresses.

Champion hasa nationwidenetworkof RotoBruterepair centers.Please contactChampion foryour nearestservice center.

Access via the Internetor by telephone to Champion’sHead Office will open thedoor to full technical supportregarding all Champion’sproducts. From drilling tipsto service center locations,replacement instruction manualsand material application queries.

ACCESSORIESM

AGNE

TIC

DRIL

L PR

ESS

ACCE

SSOR

IES

10

MAGNETIC DRILL PRESS ACCESSORIESChampion stocks a wide range of drilling accessories for their leading rangeof magnetic drill presses.

RB334 1/2-20 thread mounted 3/4” arbor

for RB32 machine

RB433 #2MT 3/4” arbor for RB45

RB634 #3MT 3/4” arbor for RB65

RB635 #3MT 1-1/4” arbor for RB65

LONG LENGTH ANNULAR CUTTER CONVERSION ARBORSRB335 1/2-20 thread mounted 3/4” arbor for RB32 for using 2” depth cuttersRB632 #3MT to 1-1/4” arbor for RB65 for using 3” depth cutters RB633 #3MT to 3/4” arbor for RB65 for using 3” depth cutters

INDUSTRIAL ARBORS

Greatly reduce tool change over time with Champion RB Series Tappers andQuick-Change Tap Adaptors. Precision manufactured for rugged use. Tapscan be changed in seconds. The adaptors are engineered for use with theRB32 VSR and RB65 VSR (variable speed / reverse) variants. The adaptorsaccept a number of “quick-change” #2 tap collets that will accept tap sizes0-6 up to 7/8”, small and large shank NPT and also 1/4”, 3/8” & 1/2” NPT.

TAPPING ATTACHMENTS

DRILL CHUCKS AND KEYS

1/2-20 Thread mounted drill chuck for RB32#2 Morse taper mounted 1/2” drill chuck for RB45Chuck adaptor RB32 3/4” shank#3 Morse Taper mounted 1/2” drill chuck for RB65#3 Morse Taper mounted 3/4” drill chuck for RB65

PIPE SADDLE

Champion’s RotoBrute pipesaddle enables Rotobrutemagnetic drill presses to beused on convex surfaces, steelpipe and tubing. Providing nonslip positioning and centered holelocation. Easily assembled bysliding the machine onto thesaddle and tightening withadjustable ratchet straps.

BRUTELUBE CUTTING FLUID

EDP No Tap Sizes EDP No Tap Sizes EDP No Tap Sizes

RB-925 0-6 RB-933 1/2” RB-940 1/8” Small Shank NPT

1/8” Large Shank NPT

RB-926 #8 RB-934 9/16”

RB-927 #10 RB-935 5/8” RB-941

RB-928 #12 RB-936 11/16”

RB-929 #14 & 1/4” RB-937 3/4” RB-942 1/4” NPT

RB-930 5/16” RB-938 13/16” RB-943 3/8” NPT

RB-931 3/8” RB-939 7/8” RB-944 1/2” NPT

RB-932 7/16”

Tapping attachmentfor RB32

Tapping attachment for RB65

Quick Change Collet

FOR CHAMPION MAGNETICDRILL PRESSES

Champion BruteLube is amultipurpose cutting andtapping fluid speciallyformulated to extend tool lifeand reduce chip welding.Complies with OSHA regulationsand contains no.1,1,1Trichloroethane.

Available in 4 oz, 16 oz and 1 gallon.

ROTOMAG MAGNETIC CLEAN-UP TOOLRMX7Clean up has never been easier thanwith the RotoMag magnetic wand.Simply wave it over steel chips or othermagnetic objects and safely dipose ofthem by pulling back the handle. Nomechanic or machinist should be withoutthis handy tool.

BruteLube Wax is speciallyformulated to extend toolperformance, reduce chipwelding, and to cling to yourcutting tools for a continuousshield against friction and heat.Wax eliminates dripping so it isperfect for overhead operations.Highly recommended for usewith RS754NF saw blades.

Wax available in 2 oz and 16 oz.

STEEL CUTTING SAW AND SAW

BLADES

11

RotoBrute blades are engineered to handle withease, difficult to cut materials such as steel plate,pipe flanges, rebar, angle iron, flat stock and nailembedded wood. Each blade is hand tensioned andhardened to 40Rc to withstand heavy loads anddeliver predictable performance, cut after cut.

Features:

Micrograin carbide tips for long life and bur-free cutting

Color coded for easy identification

Hand tensioned for distortion free operation

Alternative top bevel grind delivers fast,cold cuts without scorching the wood

Triple-chip grind produces faster cleaner cuts

FEATURESBlade Size: 7-1/4”

Arbor Size: 20mm

No Load Speed: 3500rpm

Max. Cutting Depth: 2-1/4” tubing

Cutting Thickness: 3/8” (soild plate)

ROTOBRUTE CARBIDE TIPPED BLADES BLADE SELECTION CHART

450400350300250200150100

0

Num

ber o

f Cut

s

Plate Steel1/4” x 6”

Round Pipe2”

Square Tube2” x 2”

Angle Steel2” x 2”

RS740FExpected Blade Life

Actual results may vary with material and care.

245

151

292

388

RS725

A complete metalcutting system engineeredto cut the most difficultmaterials: angle iron, "C" Channel,pipe, steel plate andstainless steel.

Improved SafetyPortable, powerful, lightweight circular saw - specially designed to cut copper, brass,aluminum, steel and wood without sparks, burs or flying chips.

Lower CostErgonomically designed saw and material matched blades deliver more cuts per bladeand at a lower cost per cut than any other brand.

METAL CUTTINGSAW

Type RS740F RS736F RS754NF RS748SS RS736W

Materials Ferrous Ferrous Non-Ferrous Stainless Steel Wood

Color Black Black Blue Yellow Green

Teeth 40 36 54 48 36

Geometry Extra Heavy Heavy Duty/ For aluminum, Triple chip AlternativeDuty/Alternative Alternative brass & plastics grind top bevel grindtop bevel grind top bevel grind Triple chip grind

INCLUDED WITH EVERY RS725Carrying case, RS736F Blade & extra set of brushes