RailMAB 925 Original- Operating Instructions
Contents
1. EC Declaration of Conformity Name address of the manufacturer BDS Maschinen GmbH Martinstra e 108 D 41063 Monchengladbach We hereby declare that the product 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 2010 DIN EN 61000 6 4 2007 A1 2011 DIN EN 55014 1 2006 A1 2009 A2 2011 DIN EN 55014 2 1997 Corr 1997 A1 2001 A2 2008 DIN EN 60745 1 2009 DIN EN 60745 2 1 2010 Responsible person for documentation according to EC Directive 2006 42 EC An nex II Pt A 2 was Surname forename position in company of the manufacturer Wolfgang Schr der Technical Director Monchengladbach ee E 4st February 2014 Legally binding signature of the issuer RailMAB 925 21 BA_RailMAB 925 0102 _A1 2014 BDS Maschinen GmbH BDS Maschinen GmbH Martinstra e 108 D 41063 Monchengladbach Fon 49 0 2161 3546 0 Fax 49 0 2161 3546 90 Internet www bds maschinen de E Mail info bds maschinen de2. ZN WARNING After mounting check for secure firm seating of the rail adapter 5 Only use tools adapter and accesso ries that match the machine Mounting the rail adapter 5 Loosen both fixing screws 15 of the rail adapter set on each respective side 0 Insert both rail adapters 5 and tighten the fixing screws 15 Dismantling the rail adapter Loosen both fixing screws 15 of the rail adapter set on each respective side Remove both rail adapters 5 11 Preparation Inserting the tool 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 Tool holder to be used Tools Use KEYLESS A with Weldon quick change drill chuck 19 mm shank system Tools Insert the tool directly into with MK the spindle taper 8 taper Tools with Use a drill chuck with MK3 straight B16 tapered mandrel shank available as an accessory Z WARNING Risk of injury gt Do not use damaged contaminated or worn tools gt Change tools only when the machine is switched off and at a standstill Disconnect the voltage supply After inserting check that the tool is engaged securely Only use tools adapter and accesso ries that match the machine 12 MK tool mounting Inserting the tool Before mounting clean the shank of
3. Original Operating Instructions RailMAB 925 Ce General instructions Table of Contents General instructions General instructions 3 A van san anna new en owe ae dare 5 Components delivery contents 9 Before using for the first time 9 Preparati0M oooooooooo 10 Using a apo De ra ia 14 Eliminating blockages 17 CICANING esra nnna a a 18 Maintenance 0 o ooocoooooo 18 SIOTAUE nennen ee ee ans 19 Troubleshooting 19 Technical data 20 EC Declaration of Conformity 21 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 instruc tions 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 RailMAB 925 Copyright This document is copyrighted Any duplica tion or reprinting in whole or in part and the reproduction of the illustrations even in modified form is only permitted with the written approval of the manufacturer Liability disclaimer All technical information data and instruc tions for commissioning operation and maintenance of the machine contained in these operating instructions represent the latest status at the ti
4. DON W F Reversible ratchet Before using for the first time Transport inspection As standard the machine is supplied with the components indicated in the Compo nents delivery contents section gt Check for visible signs of damage or missing items on delivery Report an incomplete or damaged delivery to your supplier retailer immediately Preparation This section contains important instructions on the required preparation before begin ning any work The machine is intended to be used in a horizontally aligned work position at close proximity to the ground Additional safety measures when not in a horizontal work position at close proximity to the ground Z WARNING Risk of injury from a falling machine When not working in a horizontal work position at close proximity to the ground the machine must be secured against falling down Use suitable slinging or hoisting equipment to secure the machine Only secure the machine to the han dle and free of backlash Attach the safeguards so that the ma chine slips away from the operator Take pendulum movement of a falling machine into account and secure a suitable danger zone Before beginning any work check secure positioning of the safety measures Use the protective equipment stipu lated in the section Personal protec tive equipment 10 Checking the rail type The holding force of the fast clamping system 4 de
5. Make sure that swarf is removed regularly With larger drilling depths break up the swarf Make sure that swarf is removed regularly With larger drilling depths break up the swarf Drilling with twist drills When drilling with twist drills proceed as follows Push twist drills with MK taper into the spindle taper 8 of the machine from below Push twist drills with straight shank into the drill chuck after fitting the drill chuck Position the machine at the location of use align it and fix the machine with the fast clamping system 4 Select a suitable speed and switch on the machine Guide the machine carriage with the help of the reversible ratchet 2 and without exerting too much pressure until the desired drilling depth is estab lished 16 RailMAB 925 Eliminating blockages 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 off the motor with the red but ton of the motor switch 20 Switch off the machine with the main switch 19 Disconnect the voltage supply Move the machine carriages to the upper position with the help of the reversible ratchet 2 Replace defective tool Remove swarf Other blockages Switch off the motor with the red but ton of the motor switch 20 Switch off the machine with the main switch 19 Disconnect the volt
6. age supply Move the machine carriages to the upper position with the help of the reversible ratchet 2 Remove swarf and check tool RailMAB 925 Eliminating blockages ZN WARNING Risk of injury from motor 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 of the motor switch 20 Switch off the machine with the main switch 19 Disconnect the voltage supply 17 Cleaning maintenance Cleaning Maintenance ZN WARNING gt Switch off the machine and discon nect the voltage supply before per forming maintenance or cleaning When using compressed air for cleaning wear protective goggles and gloves and protect other persons in the working area CAUTION Never immerse the machine in water 18 or other liquids After every 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 13 Put the machine and accessories into the transport case ZN WARNING Danger caused by unqualified repairs Unqualified repairs can lead to consider able danger for the user and cause dam age to the machine gt Repairs to and maintenance on elec trical appliances may only be carried out by the works customer service or by specialists trained
7. by the manu facturer 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 0 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 au thorised specialist workshop Unauthorised repairs will invalidate the guarantee Customer service service Should you have any questions on cus tomer service service please contact BDS We will be happy to give you the address of your nearest service partner RailMAB 925 Storage troubleshooting 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 CT TT Remedy The motor does not start after pressing the ON OFF switch or stops during operation The automatic circuit breaker in the electrical distribution board trips Tools wear excessively are damaged The fast clamping system does fix the machine to the rail properly NOTE Plug not inserted into socket Automatic circuit breaker tripped The internal safety switch has switched off the machine due to overheating The torque cut off has tripped Main motor switch switche
8. d off Too many appliances con nected to the same power circuit The machine is defective No lubrication or not suffi ciently greased Wrong rail adapter E se lected Insert plug Switch on circuit breaker Allow the machine to cool down Switch the machine on and off Switch in the main motor switch Reduce the number of appli ances on the power circuit Disconnect the machine from the voltage and notify customer service Supply lubrication e g use high pressure container for cutting oil drilling emulsion Select and mount a suitable rail adapter E If you cannot resolve the problem with the steps described above please contact customer service RailMAB 925 19 Technical data Technical data Model RailMAB 925 Unit ree 170 x 295 x 625 775 mm Approx net weight 17 kg Operating voltage see type plate a alunk 100 125V 50 60Hz Power consumption 1600 W Noise emission 89 db A Vibration 0 85 m s Stroke 160 mm Core drill HKK R max Y 17 36 mm Cutting depth max 55 mm Twist drill max 20 mm Gear stage 1 speed n 70 280 rpm Gear stage 2 speed n 180 580 rpm Thermal protection Yes Variable torque Yes Full wave control electronics Yes Spindle taper MK3 Core drill assembly Weldon 19 mm 3 45 Connecting cable length 2 8 m Protection class 20 RailMAB 925 EC Declaration of Conformity
9. e controller 17 The machine shuts down when it reaches the maximum set torque After shutdown the machine must be switched off and on again via the motor switch 20 and the main switch 19 Drilling with the machine Drilling with core drills When drilling with core drills proceed as follows Mount the KEYLESS quick change drill chuck system A 0 Install the appropriate ejector pin in the core drill and insert the core drill into the quick change drill chuck system Position the machine at the location of use align it and fix the machine with the fast clamping system 4 Select a suitable speed and switch on the machine Guide the machine carriage with the help of the reversible ratchet 2 and without exerting too much pressure until the desired core drill is estab lished 15 Using Observe the following instructions when drilling with core drills Drilling with core drills does not re Under excessive pressure the drill can wear out and the machine can be overloaded Use ZHS 400 high performance grease spray Before drilling spray the drill with grease spray In the case of larger drill depths repeat this procedure quire great force The drilling process is not accelerated by higher pres sure The drill wears faster and the machine can be overloaded Use the high pressure container for cutting oil drilling emulsion with BDS 6000 cooling lubricant at the machine
10. e plug from the mains socket Do not crush the connecting cable Do not expose the connecting cables to heat or chemical liquids Do not pull the connecting cable across sharp edges or hot surfaces Lay the connecting cable so that it cannot be caught and wound up in the rotating parts of the machine Safety Safety equipment Overheat protection The machine is additionally equipped with thermal overload protection If the machine becomes too hot it switches off automati cally Perform the following steps before continu ing to work with the machine Switch off the motor with the red but ton of the motor switch 20 Switch off the machine at the main switch 19 and disconnect the ma chine from the voltage supply Remove any blockages that may have occurred Allow the machine to cool down The machine is then ready for operation again Symbols on the machine The symbols on the machine have the fol lowing meaning Symbol Meaning O O O Electric shock hazard Read the operating instructions before beginning work Symbol A Wear protective goggles and ear protection Personal protective equipment Wear the following protective equipment at all times when operating the machine Symbol Meaning ETEN Gig Also wear the following protective equip ment during special work Symbol Meaning Helmet for protecting your head against falling objects Cl
11. in switch 19 14 ZN WARNING Risk of injury from motor 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 of the motor switch 20 gt Switch off the machine with the main switch 19 gt Disconnect the voltage supply RailMAB 925 Selecting the speed range gt Switch the gear stages only with the machine at standstill The machine has a gearbox with two me chanical gear stages Gear stage 1 70 280 rpm Gear stage 2 180 580 rpm To select the desired gear stage set selector lever to stage 1 or 2 with the machine switched off NOTE gt Select the speed range according to the material and drilling diameter Setting the speed In addition to the mechanical gearbox the machine is also equipped with full wave control electronics for stepless variable speed adjustment 0 First set the appropriate gear stage then adapt the speed using the elec tronic speed control 18 70 280 rpm 180 580 rom Gear stage 1 Gear stage 2 gt If possible always select a setting with low gear stage and high motor speed The motor is then set with a higher torque and therefore protected against overheating under heavy load RailMAB 925 Using Setting the torque In order to protect the tool the maximum torque of the machine can be set using th
12. ing A glove can be caught by the drilling machine and torn off the hand Risk of losing one or more fingers Remove loose jewellery before begin ning work Wear a hair net if you have long hair Always switch off the machine before changing tools performing main tenance or cleaning Wait until the machine has come to a complete standstill RailMAB 925 Safety gt Always disconnect the voltage supply 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 Before using each time check for firm stability of the quick clamping system on the rail see section Preparation Check that the tool is tightened securely before using see Inserting the tool section Do not allow the connecting cable to hang over edges trip wire effect RailMAB 925 CAUTION Potential damage to property if the machine is improperly used Observe the following instructions to avoid property to damage 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 carry the machine by the handle Do not pull the mains cable to remove th
13. ldren must not be allowed to use the machine m Before using check the machine and the connecting cable for damage and do not put a damaged machine into operation m Before beginning work check the condi tion of the machine and the function of the operating elements m Only allow repairs to the connecting cable to be carried out by a qualified electrician RailMAB 925 Safety Only allow repairs to the machine to be carried out by an authorised specialist workshop or works customer service Unqualified repairs can lead to consid erable danger for the user Repairs to the machine during the war ranty period may only be carried out by a service centre authorised by the manufacturer otherwise the guarantee will be invalidated Defective parts may only be replaced with original spare parts Only original spare parts guarantee 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 suf ficiently lit gt 300 Lux Do not use low power machines for heavy working Make sure that your workplace is clean Keep the machine clean dry and free of oil and grease Follow the instructions on lubricating and cooling the tool Safety Danger from electric current Danger to life from elec
14. me 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 modifications or use of non approved spare parts and accessories tools and lubricants Instructions on disposal Az The packaging materials used can be ore recycled When no longer required dispose of the packaging materials according to local environmental regula tions This product may not be disposed of E in the domestic refuse within the European Union Dispose of the device via communal collection points General instructions Safety warning structure The following warnings are used in these operating instructions 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 gt Follow the instructions in this warning to avoid possible danger of serious injury or even death Z WARNING A warning of this category indicates a potentially dangerous situation If the dangerous situation is not avoided it may lead to injuries gt Follow the instructions in this warning to avoid possible danger of serious personal injuries CAUTION A warning statement for this safety risk class indicates a damage risk If the situation is not avoided it may lead to material damage gt F
15. nnect the line of the high pressure container for cutting oil drilling emul sion to the connection for the KEY LESS quick change drill chuck system A Open the KEYLESS quick change drill chuck system A by pushing up the outside sleeve and insert the tool into the chuck NOTE Insert the appropriate ejector pin C D before inserting the core drill ZN WARNING Risk of injury from incorrectly inserted tool or tool mounting gt Turn the tool briefly to check whether the collet is engaged Removing the tool Open the KEYLESS quick change drill chuck system A by pushing up the outside sleeve and pull the tool down out of the chuck 13 Using Fixing the machine Tensioning the fast clamping system 0 Insert the machine with the rail adapter 5 into the rail profile at right angles to the rail Press the clamping jaw 16 onto the rail by turning the spindle key 3 Slackening the fast clamping system 9 Hold the handle tightly 14 to stop the machine from slipping Release the clamping jaw 16 from the rail by turning the spindle key 3 Remove the machine from the rail Switching the machine ON OFF Switching on the machine Switch on the machine with the main switch 19 Switch on the motor at the motor switch 20 with the green button Switching off the machine Switch off the motor at the motor switch 20 with the red button Switch off the machine with the ma
16. ollow the instructions in this warning to avoid material damage gt Anote indicates additional information that simplifies the use of the machine Intended use The machine is intended solely for drilling operations in rails within the limits specified in the technical data Any use other than previously stated is considered as improper use ZN WARNING Danger resulting from 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 gt Use the machine only for its intended purpose gt Observe the procedures described in these operating instructions No claims of any kind will be accepted for damage resulting from use of the appliance for other than its intended purpose The risk must be borne solely by the user gt If used commercially pay attention to compliance with the accident preven tion and occupational safety regula tions RailMAB 925 ZN WARNING When using electrical tools the follow ing fundamental precautions must be taken to protect against electric shock fire injuries and damage to property Fundamental safety precautions m Do not use the machine in flammable or potentially explosive environments m Persons who are unable to operate the machine due to their physical mental or motor response abilities may only use the machine under supervision of or instruction by a responsible person m Chi
17. ose fitting work protection clothing with a low tear strength Goggles for protecting eyes against flying parts and liquids and ear protection in areas with noise emission gt 80 dB A Safety shoes for protecting feet against falling objects Wear a harness where there is a danger of falling Gloves for protection against injuries RailMAB 925 Components delivery con tents Machine overview 1 Operating panel 2 Reversible ratchet Spindle key fast clamping system 4 Fast clamping system 5 Rail adapter 6 Core drill not supplied as standard 7 Tool mounting KEYLESS quick change drill chuck system 8 MK3 spindle taper 9 Opening for ejector pin 10 2 speed gearbox with selector 11 Drive motor 12 Speed and torque controller 13 Machine slide with guide 14 Handle 15 Fixing screws rail adapter 16 Clamping jaw fast clamping system 17 Torque regulator 18 Speed regulator 19 Master switch 20 Motor switch RailMAB 925 Components delivery contents Delivery contents Rail core drill with high pressure container 5I for cut ting drilling emulsion in the transport case not illustrated KEYLESS quick change drill chuck system 19 mm Weldon 3 4 MK3 ejector pin ZAK075 ejector pin ZAK100 ejector pin Rail adapter of your choice no special designs gt m
18. pends on the fitting accuracy of the rail adapter 5 to the rail The following requirements must be fulfilled in order to establish sufficient holding force m Only the rail adapters 5 associated with the rail type may be used m The surfaces of the fast clamping system 4 must be clean and free of grease In addition to the rail adapters E listed in the range of accessories BDS offers special adapters for spe cial rails on request Eliminate unevenness rust as well as dirt and grease residue from the rail RailMAB 925 Mounting the rail adapter The machine is equipped with a socket for various rail adapters E The corresponding adapter set must be used according to the type of rail Rail type Order number rail adapter UIC 50 ZAS 050U UIC 54 ZAS 054U UIC 60 ZAS 060U S 49 ZAS 049S S 54 ZAS 054S Other On request Z WARNING Risk of injury Incorrectly damages or improperly mounted rail adapters 5 decrease the holding force of the fast clamping sys tem 4 this can lead to injuries gt Only use the matching rail adapter 5 for the respective rail type gt Do not use damaged contaminated or worn tools rail adapters 5 Change the rail adapter only when the machine is switched off and at a standstill Disconnect the voltage supply Change the rail adapter only when the the fast clamping system is not tensioned RailMAB 925 Preparation
19. the tool adapter or drill chuck and the spindle taper 8 of the machine 0 Insert the tool into the spindle taper 8 of the machine from below A WARNING Risk of injury from incorrectly inserted tool gt Check the proper seating of the tool adapter or drill chuck in the MK tool mounting Removing the tool 0 Insert the ejector pin B into the ejec tor pin holder 9 of the MK3 spindle taper 8 Lever out the tool with the ejector pin B or loosen the tool by tapping against the ejector pin B RailMAB 925 Using the drill chuck Inserting the tool 0 Insert the drill chuck onto the tapered mandrel and insert the combina tion into the spindle taper 8 of the machine Open the drill chuck and insert the tool into the drill chuck Close the drill chuck by hand and then tighten the drill chuck with the chuck key Removing the tool Loosen the drill chuck with the chuck key and remove the tool Z WARNING Risk of injury Only tighten the drill chuck with the chuck key provided Always remove the chuck key from the drill chuck after tightening or loosening RailMAB 925 Preparation Keyless quick change drill chuck system Inserting the tool Before mounting clean the shank of the tool adapter or drill chuck and the spindle taper 8 of the machine Push the KEYLESS quick change drill chuck system A from below into the spindle taper of the machine Co
20. tric 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 gt Do not open the housing of the machine Risk of electric shock if live terminals are touched Never immerse the machine or the plug into water or other liquids Only use extension or cable drums with a cable cross section of at least 1 5 mn Only use extension that are approved for the place of work Check the condition of the extension cable regularly and replace if dam aged Avoid direct body contact with grounded parts e g tubes radiators steel girders to reduce the risk of electric shock in the event of a defect Risk of injury A WARNING Risk of injury from motor 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 of the motor switch 20 Switch off the machine with the main switch 19 Disconnect the voltage supply ZN WARNING Improper handling of the machine increases the risk of injury Observe the following safety precautions to avoid injuring yourself and or others gt Operate the machine only with the protective equipment stipulated in these operating instructions see Personal protective equipment section Do not wear protective gloves when the machine is runn
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