MAB 455
Translation of the Original
Operating Instructions
GB
8
4
2
5
1
3
Fig. 1
21
23
22
6
9
11
7
1213
10
3MAB 455
GB
Table of Contents
General instructions ................3
Safety ............................5
Components / delivery contents .....10
Before using for the rst time .......11
Preparation. . . . . . . . . . . . . . . . . . . . . . .11
Using ............................14
Eliminating blockages. . . . . . . . . . . . . .16
Cleaning/maintenance .............17
Storage ..........................18
Troubleshooting ..................18
Technical data ....................19
EC Declaration of Conformity .......20
Dear Customer,
Before using the machine, please read the
operating instructions contained in these
operating instructions on startup, safety,
intended use as well as cleaning and care.
The links and illustrations in these instructions refer to the illustrations on the inside
of the cover.
Keep these operating instructions for later
use and pass them onto the next owner of
the machine.
General instructions
Copyright
This document is subject to copyright. Duplication or reprinting, even in part as well
as reproduction of the illustrations, even
if modied, is only permitted with written
consent of the manufacturer.
Liability disclaimer
All technical information, data and instructions contained in these operating
instructions for startup, operation and care
correspond to the latest requirements at the
time of printing.
The manufacturer assumes no liability for
damage or injury resulting from failure to
observe the operating instructions, use for
other than the intended purpose, unprofes-
sional repairs, unauthorised modications
or use of non-approved spare parts and
accessories, tools and lubricants.
Instructions on disposal
The packaging materials used can be
recycled. When no longer required,
dispose of the packing materials according
to local environmental regulations.
This product may not be disposed of
in the European Union via the normal
household refuse. Dispose of the
device via communal collection points.
The lubricant used can contain
substances dangerous to the
environment. Dispose of the lubricant
according to local regulations. Observe the
disposal instructions from the lubricant
manufacturer.
General instructions
4
MAB 455
GB
Safety warning structure
The following warnings are used in these
operating instructions:
DANGER
A warning of this category indicates
an impending dangerous situation.
If the dangerous situation is not avoided, it may lead to serious injury or even
death.
► Follow the instructions in this warning
to avoid possible danger of serious
injury or even death.
WARNING
A warning of this category indicates a
potentially dangerous situation.
If the dangerous situation is not avoided, it may lead to serious injury or even
death.
► Follow the instructions in this warning
to avoid the danger of serious injury
to persons.
ATTENTION
A warning of this category indicates
potential danger to property.
If the situation is not avoided, it may lead
to material damage.
► Follow the instructions in this warning
to avoid material damage.
NOTE
► A note indicates additional information
that simplies the use of the machine.
Intended use
The machine is intended solely for drilling
operations in magnetic and non-magnetic
metals within the limits specied in the
technical data.
Any use other than previously stated is
considered as improper use.
WARNING
Danger due to improper use!
If not used for its intended purpose and/
or used in any other way, the machine
may be or become a source of danger.
► Use the machine only for its intended
purpose.
► Observe the procedures described in
these operating instructions.
No claims of any kind will be accepted for
damage resulting from use of the system
for other than its intended purpose.
The risk must be borne solely by the user.
NOTE
► If used commercially, pay attention to
compliance with the accident prevention and occupational safety regulations.
General instructions
5MAB 455
GB
Safety
NOTE
When using electrical tools, the following
fundamental precautions must be taken
to protect against electric shock and the
risk of injury and re!
Fundamental safety instructions
■ Do not use the machine in potentially
ammable or explosive environments.
■ Persons, who are unable to safely op-
erate the machine due to their physical,
mental or motor abilities, my only use
the machine under the supervision or
instruction of a person responsible.
■ Persons with heart pacemakers or other
medical implants must not use this
machine.
■ Children are not permitted to use the
machine.
■ Inspect the machine for visible signs of
damage before use. Do not operate a
damaged machine.
■ Before beginning work, check the condi-
tion of the safety chain and the function
of the switches on the machine.
■ Repairs to the connecting cable may
only be performed by a qualied electrician.
■ Repairs to the machine may only be
performed by an authorised specialist
workshop or factory customer service.
Unqualied repairs can lead to considerable danger for the user.
■ Repairs to the machine during the guar-
antee period may only be performed by
a customer service authorised by the
manufacturer, otherwise the guarantee
is invalid.
■ Defective parts may only be replaced
with original spare parts. Only these
parts ensure that the safety requirements are met.
■ Do not leave the machine unsupervised
during operation.
■ Store the machine in a dry, temperate
location out of the reach of children.
■ Do not allow the machine to stand out-
side and do not expose to moisture.
■ Make sure that your work area is su-
ciently lit (>300 Lux).
■ Do not use low-power machines for
heavy working.
■ Pay attention to cleanliness at the
workplace.
■ Keep the machine clean, dry and free of
oil and grease.
■ Follow the instructions on lubricating
and cooling the tool.
Safety
6
MAB 455
GB
Danger from electric current!
DANGER
Danger to life from electrical current!
Contact with live wires or components
can lead to serious injury or even
death!
Observe the following safety precautions
to avoid any danger from electric current:
► Do not open the housing of the
machine. Risk of electric shock from
touching live connections.
► Never immerse the machine or mains
plug in water or other liquids.
► Only use extension cables or cable
drums with a cable cross-section of at
least 1.5 mm².
► Only use extension cables that are
approved for the location of use.
► Check the condition of the extension
cable regularly and replace if damaged.
► Avoid bodily contact with grounded
parts (e.g., pipes, radiators, steel
girders) to reduce the risk of electric
shock in the event of a defect.
► When using the machine outside or in
a humid environment, an RCD (residual circuit device) must be used.
Risk of injury!
WARNING
Risk of injury from engine starting
unintentionally!
Pay attention to the following safety
notes to avoid danger from motor starting
unintentionally:
For safe stopping of the motor:
► Press the red button (O) of the motor
switch (21).
► Switch o the machine with the ON/
OFF switch (main switch) (23).
► Disconnect the voltage supply (pull
out the mains plug).
WARNING
Improper handling of the machine
increases the risk of injury!
Pay attention to the following safety
instructions in order not to injure others
or yourself:
► Operate the machine only with the
protective equipment specied in
these instructions (see section “Personal protective equipment”).
► Do not wear protective gloves when
the machine is running. A glove can
be caught by the drilling machine and
torn o the hand. Risk of losing one
or more ngers.
► Remove loose jewellery before begin-
ning work.
► Wear a hair net if you have long hair.
Safety
7MAB 455
GB
WARNING
► Always switch o the machine before
changing tools, performing maintenance or cleaning. Wait until the
machine has come to a complete
standstill.
► Always remove the plug from the
mains socket before changing tools,
cleaning or performing maintenance
work in order to avoid unintentional
starting of the machine.
► Do not put your hand into the ma-
chine while it is in operation. Remove
swarf only when the machine is at
a standstill. Wear protective gloves
when removing swarf.
► When working on scaolding, the op-
erator must be secured with a safety
belt as the machine can oscillate dangerously in the event of interruption to
the power supply.
► Check for secure clamping of the
electromagnets on the substrate before every use (see section “Prepa-
ration”).
► Secure the machine with the safety
chain (D) supplied when working in
an inclined or vertical position and
during overhead work. The machine
could fall down if the magnet is loosened or the power fails.
► Check that the tool is tightened
securely before using (see section
“Inserting the tool”).
► Do not allow the connecting cable to
hang over edges (trip eect).
Preventing damage
ATTENTION
Potential damage to property if the
machine is improperly used!
Observe the following instructions to
avoid damage to property:
► Before connecting the machine, com-
pare the connection data (voltage and
frequency) on the rating plate with
those of your mains power supply.
The data must correspond in order to
avoid damage to the machine.
► Always use the handle to carry the
machine and not the connecting
cable.
► Do not pull the mains cable to remove
the plug from the mains socket.
Safety
8
MAB 455
GB
ATTENTION
► Do not crush the connecting cable.
► Do not subject the connecting cable
to heat or chemical liquids.
► Do not pull the connecting cable
across sharp edges or hot surfaces.
► Lay the connecting cable in such
a way that it cannot be caught and
wound up in the rotating part of the
machine.
Safety equipment
Restart protection
NOTE
► The machine stops automatically
when the magnetic clamp is switched
o or if the power supply is interrupted.
In order to prevent the machine from
starting unexpectedly after switching on the
magnetic clamp again or after reconnection
following interruption to the power supply
("restart protection"), the machine must be
switched on using the ON/OFF switch.
Magnet indicator
The magnet indicator (22) provides visual
indication of the magnetic clamping force.
■ Magnet indicator (22) lights up GREEN:
The magnetic clamping force satises
the minimum requirements.
Processing can take place.
■ Magnet indicator (22) lights up RED:
Insucient magnetic clamping force.
Do not process with the machine. This
can be the case if the material is too
thin, the surface is uneven or if coated
with paint, scale or zinc.
Safety
9MAB 455
GB
Symbols on the machine
The symbols on the machine have the
following meaning:
Symbol Meaning
Electric shock hazard!
Read the operating instructions
before beginning work!
Wear protective goggles and
ear protection!
Personal protective equipment
Wear the following protective equipment at
all times when operating the machine:
Symbol Meaning
Close-tting work protection
clothing with a low tear strength
Goggles for protecting eyes
against ying parts and liquids
and ear protection in areas with
noise emission >80 dB(A)
Safety shoes for protecting feet
against falling objects.
Also wear the following protective equipment during special work:
Symbol Meaning
Helmet for protecting your head
against falling objects
Wear a harness where there is
a danger of falling.
Gloves for protection against
injuries
Safety
10
MAB 455
GB
Components / delivery con-
tents
Machine overview
1 Core drill
(not supplied as standard)
2 Tool mounting
KEYLESS quick-change drill chuck
system
3 MK2 spindle taper
4 Opening for ejector pin
5 2-speed gearbox with selector
6 Engine drive
7 Filler neck for cutting oil
8 Cutting oil tank
9 Handle
10 Hand lever
11 Operating panel (see g. 1)
12 Magnetic foot
13 Machine slide and guide
Operating panel
(see g. 1)
21 Motor ON/OFF switch
22 Magnet indicator (Magnet Power)
23 Magnet ON/OFF switch
(main switch)
Scope of supply
Machine MAB 455
A KEYLESS quick-change drill chuck
system
B ZAK 075 ejector pin
C ZAK 100 ejector pin
D Safety chain
e) MK2 ejector pin
Transport case (not illustrated)
Operating instructions/guarantee card
(not illustrated)
Components / delivery contents
11MAB 455
GB
Before using for the rst time
Transport inspection
As standard, the machine is supplied with
the components indicated in the “Scope of
supply” section.
NOTE
► Check for visible signs of damage or
missing items on delivery. Report an
incomplete or damaged delivery to
your dealer/supplier immediately.
Preparation
This section contains important instructions
on the required preparation before beginning any work.
Additional safety measures for
certain work
Additional safety precautions must be
taken for the following operations with the
machine:
Non-horizontal work position
WARNING
Risk of injury from a falling machine.
When working in inclined or vertical
position and during overhead work, the
machine must be secured to prevent it
from falling using the safety chain (D)
supplied.
► Check the safety chain for proper
function before every use. A damaged safety chain must not be used.
Replace a damaged safety chain
immediately.
WARNING
► Attach the safety chain in such a way
that the machine moves away from
the operator in the event of slipping.
► Lay the safety chain as tightly as
possible around the handle of the
machine.
► Check the secure tting of the safety
chain and lock before starting work.
► Use the protective equipment stipulat-
ed in the section “Personal protec-
tive equipment”.
Work on scaolding
WARNING
Risk of falling from sudden oscillating
movements of the machine.
When working on scaolding, the
machine can make a sudden oscillating
movement on starting or in the event of
interruption to the power supply.
► Secure the machine with the safety
chain (D) supplied.
► Wear a safety harness to protect
yourself against falling.
Before using for the rst time
12
MAB 455
GB
Check the condition
of the substrate
The magnetic clamping force is dependent on the condition of the substrate. The
clamping force is signicantly reduced by
paint, zinc and scale coatings and rust.
The substrate must satisfy the following
conditions in order to achieve sucient
magnetic clamping force:
■ The substrate must be magnetic.
■ The clamping surface and the magnetic
foot (12) must be clean and greasefree.
■ The clamping surface must be com-
pletely smooth and level.
NOTE
► Clean the substrate and the magnetic
foot (12) of the machine before use.
► Remove any unevenness and loose
rust from the substrate.
► The BDS range of accessories in-
cludes special holding devices.
The best clamping eect is obtained on
low-carbon steel substrate with a thickness
of at least 20 mm.
Steel with low thickness
When drilling into low thickness steel, an
additional steel plate (minimum dimensions
100 x 200 x 20 mm) must be placed under
the workpiece. Secure the steel plate to
prevent it from falling.
NF metals or workpieces with an uneven
surface
A special holding device must be used
when drilling into NF metals or into workpieces with an uneven surface.
NOTE
► BDS oers a range of accessories
with special clamping devices for
tubes and non-magnetic materials.
Inserting the tool
WARNING
Risk of injury!
► Do not use damaged, contaminated
or worn tools.
► Change tools only when the machine
is switched o and at a standstill. Pull
the plug out of the mains socket.
► After inserting, check that the tool is
engaged securely.
► Only use tools, adapter and accesso-
ries that match the machine.
The machine is equipped with an MK tool
holder.
Depending on the type of tool to be used,
corresponding drill chucks, quick-clamping
systems or adapters must be used.
Tool
with:
Tool holder
to be used
Konus MK Insert directly into the spindle
taper (3).
19 mm
Weldon shaft
Use KEYLESS quick-change
drill chuck system (A)
Preparing
13MAB 455
GB
Straight
shank
Use drill chuck with MK2/B16
tapered mandrel
(available as accessory).
Thread
tap
Use KEYLESS quick-change
drill chuck system (A) with
the appropriate adapter (G)
for thread taps
(available as accessory).
MK tool mounting
WARNING
Risk of injury from incorrectly inserted
tool!
An insuciently secured tool can lead to
serious injuries.
► Check the proper seating of the tool,
adapter or drill chuck in the MK tool
mounting.
Inserting the tool
Before mounting, clean the shank of
the tool, adapter or drill chuck and the
spindle taper (3) of the machine.
Insert the tool into the spindle taper (3)
of the machine from below.
Removing the tool
Turn the tool until the ejector pin (E)
slips into the opening for the ejector
pin (4).
Lever out the tool with the ejector
pin (E) or loosen the tool by tapping
against the ejector pin.
Using the drill chuck
WARNING
Risk of injury!
An insuciently secured tool can lead to
serious injuries.
► Turn the drill chuck only with the
chuck key provided.
► Always remove the chuck key from
the drill chuck after tightening or
loosening.
Inserting the drill chuck
Insert the drill chuck onto the tapered
mandrel and insert the combination
into the spindle taper (3) of the machine.
Open the drill chuck and insert the tool
into the drill chuck.
Close the drill chuck by hand and then
turn the drill chuck with the chuck key.
Removing the drill chuck
Loosen the drill chuck with the chuck
key and remove the tool.
Turn the drill chuck until the ejector
pin (E) slips into the opening for the
ejector pin (4).
Lever out the drill chuck with the ejec-
tor pin (E) or loosen the drill chuck by
tapping against the ejector pin.
Preparing
14
MAB 455
GB
KEYLESS quick-change drill chuck
system (Fig. 2)
Inserting the tool
Push the KEYLESS quick-change
drill chuck system (A) into the spindle
taper (3) of the machine.
Connect the lubricant line.
Open the quick-change drill chuck sys-
tem (A) by pushing up the sleeve and
insert the tool into the chuck.
NOTE
► Insert the appropriate ejector pin
before inserting the core drill.
► Turn the tool briey to check whether
the collet is engaged.
Removing the tool
Open the quick-change drill chuck sys-
tem (A) by pushing up the sleeve and
pull the tool down out of the chuck.
Using
Activating/deactivating the mag-
netic clamp
Activating the magnetic clamp
ATTENTION
► To prevent the magnet from overheat-
ing, switch on the magnetic clamp
only when the machine is standing on
a magnetic substrate.
Switch the magnet (23) ON/OFF
switch on. The indicator lamp in the
magnet (23) ON/OFF switch on.
Check the magnet holding force with
the magnet indicator („MAGNET
POWER“ (22) indicator light)).
MAGNET POWER
indicator light
Magnetic holding
force condition
GREEN Sucient
magnetic holding
force
RED Insucient magnet-
ic holding force
ATTENTION
► The maximum magnetic clamping
force is only available after switching
on the motor.
Deactivating the magnetic clamp
Hold the handle tightly (9) to stop the
machine from slipping.
Switch the magnet (23) ON/OFF
switch o. The indicator lamp in the
magnet (23) ON/OFF switch extinguishes.
Preparing, Using
15MAB 455
GB
Switching the machine ON/OFF
Using the ON/OFF switch (21), turn
the machine ON with the green
button (I) and OFF with the red button (O).
NOTE
► The machine can only be switched on
when the magnetic clamp has been
switched on.
► Allow a severely overheated machine
to run on at idle speed for approx.
2 minutes.
► The machine switches o automati-
cally in the event of a power failure or
if the magnetic clamp is switched o.
Selecting the speed range
ATTENTION
► Switch the gear stages only with the
machine at standstill.
NOTE
► Select the speed range according to
the material and drilling diameter.
The machine has a gearbox with two mechanical gear stages. The gear stage is set
with the selector lever (5).
To select the desired gear stage,
switch the machine o and set the
selector lever (5) to the desired speed
as shown in the table below.
Gear stage Load speed
Level 1 250 min
-1
Level 2 450 min
-1
Drilling with the machine
Drilling with twist drills
When drilling with twist drills, proceed as
follows:
Push twist drills with MK taper into the
spindle taper (3) of the machine from
below.
Push twist drills with straight shank
into the drill chuck after tting the drill
chuck (see section “Using the drill
chuck”).
Position and x the machine at the
location of use.
Switch on the clamping magnet and
check the magnetic holding force (see
section “Activating/deactivating the
magnetic clamp”).
Select a suitable speed and switch on
the machine.
Direct the drill to the material with the
handle (10).
NOTE
Observe the following instructions when
drilling with twist drills:
► Under excessive pressure, the drill
can wear out and the machine can be
overloaded.
► Make sure that swarf is removed
regularly. With larger drilling depths,
break up the swarf.
Using
16
MAB 455
GB
Drilling with core drills
When drilling with core drills, proceed as
follows:
Install the quick-change drill chuck
system (A) and connect up the cooling
lubricant system.
Install the appropriate ejector pin
in the core drill and insert the core
drill into the quick-change drill chuck
system (A).
Position and x the machine at the
location of use.
Switch on the clamping magnet and
check the magnetic holding force (see
section “Activating/deactivating the
magnetic clamp”).
Select a suitable speed and switch on
the machine.
Direct the drill to the material with the
handle (10).
NOTE
Observe the following instructions when
drilling with core drills:
► Drilling with core drills does not require
great force. The drilling process is not
accelerated by higher pressure. The
drill wears faster and the machine can
be overloaded.
► Use the high-performance BDS 5000
cutting oil in the cooling lubricant sys
-
tem of the machine.
► The cooling lubricant system cannot
be used when working overhead. In
this case, use the high-performance
ZHS 400 grease spray. Spray the drill
on the inside and outside before drill
ing. In the case of larger drill depths,
repeat this procedure.
► Make sure that swarf is removed regu
larly. With larger drilling depths, break
up the swarf.
Eliminating blockages
WARNING
Danger of cut injuries from broken
tool parts or swarf.
► Put protective gloves on before start-
ing work.
Blockages caused by a broken tool:
Switch o the machine. Remove plug
from the mains socket.
Move the machine slide to the upper
position with the help of the hand
lever (10).
Replace defective tool. Remove swarf.
Other blockages:
Switch the machine o using the motor
switch. Leave the magnetic clamp
switched on.
Move the machine slide to the upper
position with the help of the hand
lever (10).
Remove swarf and check tool.
NOTE
► The BDS range of accessories
includes special devices (e.g.,
POW 200) for removing swarf.
Using, Eliminating blockages
17MAB 455
GB
Cleaning, maintenance
Cleaning/maintenance
WARNING
► Switch o the machine and discon-
nect the voltage supply before performing maintenance or cleaning (Pull
the plug out of the mains socket).
► When using compressed air for
cleaning, wear protective goggles and
gloves and protect other persons in
the working area.
ATTENTION
► Never immerse the machine in water
or other liquids.
Cleaning
After each use
Remove the inserted tool.
Remove swarf and coolant residues.
Clean the tool and the tool holder on
the machine.
Clean the guide of the machine slide.
Put the machine and accessories into
the transport case.
Maintenance
WARNING
Danger caused by unqualied repairs!
Unqualied repairs can lead to considerable danger for the user and cause
damage to the machine.
► Repairs to electrical appliances may
only be carried out by the works customer service or by specialists trained
by the manufacturer.
Adjusting the machine slide guide
If the machine slide guide (13) exhibits too
much clearance, it must be adjusted. To do
this, proceed as follows:
Loosen the clamping bolts.
Tighten the adjusting screws evenly.
Tighten the clamping bolts again.
Replacing the carbon brushes
Replacement of the carbon brushes may
only be carried out by BDS or by an authorised specialist workshop. Unauthorised
repairs will invalidate the guarantee.
Customer service/service
Should you have any questions on customer service/service, please contact BDS.We
will be happy to give you the address of
your nearest service partner.
18
MAB 455
GB
Storage, Troubleshooting
Storage
If you do not intend to use the machine for a longer period of time, clean it as described in
the section “Cleaning”. Store the machine and all its accessories in the transport case at
a dry, clean and frost-free location.
Troubleshooting
Error Possible cause Remedy
The motor does not start after
pressing the ON/OFF switch
or stops during operation.
Plug not inserted into socket. Insert plug.
Circuit breaker switched o. Switch on circuit breaker.
The magnetic clamp is not
switched on.
Switch on the magnetic clamp.
The circuit breaker in the
power distributor trips.
Too many appliances connected to the same power circuit.
Reduce the number of appliances on the power circuit.
The machine is defective. Contact customer service.
The magnetic clamp does not
function.
Magnet not switched on. Switch on magnet.
The surface is not magnetic. Use a suitable base.
The lubrication system does
not function.
No lubricant available. Top up the lubricant.
Lubricant tap closed. Open the lubricant tap.
Connecting nipple clogged. Clean the tank and nipple.
NOTE
► If you cannot resolve the problem with the steps described above, please contact
customer service.
19MAB 455
GB
Technical data
Model MAB 455
Dimensions (L x W x H) 295 x 178 x 598 mm
Magnetic foot (L x W) 168 x 84 mm
Approx. net weight. 13 kg
Operating voltage (see type plate)
230 V / 50-60 Hz
or 110-125 / 50-60 Hz
Power consumption 1150 W
Noise emission 87 db(A)
Vibration 0.81 m/s²
Stroke 160 mm
Core drill:
■ short Ø
12 - 40 mm
■ long Ø
12 - 40 mm
Twist drill:
■ max. Ø
18 mm
Speed stage 1 n
0
= 250 rpm
Speed stage 2 n
0
= 450 rpm
Spindle taper MK2
Core drill assembly KEYLESS MK 2/19 (3/4“) Weldon
Connecting cable length 4 m
Protection class I
Protection type IP20
Technical data
20
MAB 455
GB
EC Declaration of Conformity
in accordance with Machine Directive 2006/42/EC, appendix II 1A
Name/address of the manufacturer: BDS Maschinen GmbH
Martinstraße 108
D-41063 Mönchengladbach
We hereby declare that the product:
Model: Magnetic core drilling machine
Model MAB 455
conforms to the following relevant regulations:
■ EC Directive 2006/42/EC on machinery
The following harmonised standards were applied in whole or in part:
● DIN EN ISO 12100:2011-03
● DIN EN 62841-1:2016-07
Authorised person for compiling the
technical documentation:
BDS Maschinen GmbH
Full technical documentation is available.
The operating instructions associated with the product is available.
It is required that the product is only operated as intended. Information on operating
as intended can be obtained from the technical documentation.
Mönchengladbach, 01st Septemer, 2016
Wolfgang Schroeder, Technical Director
________________________________________
(Legally binding signature of the issuer)
EC Declaration of Conformity
B, C D EA
Fig. 2
Fig. 3
BDS Maschinen GmbH
Martinstraße 108
D-41063 Mönchengladbach
Fon: +49 (0) 2161 / 3546-0
Fax: +49 (0) 2161 / 3546-90
Internet: www.bds-maschinen.de
E-mail: info@bds-maschinen.de
BA_MAB 455_A4 © 2016 BDS Maschinen GmbH
Loading...