BDS AirMAB 5000 User manual

AirMAB 5000
Original-
Operating Instructions
GB

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3
General instructions
AirMAB 5000
GB
Table of Contents
General instructions . . . . . . . . . . . . . . . .3
Safety............................5
Components / delivery contents . . . . . .8
Before using for the rst time . . . . . . . .9
Preparation. . . . . . . . . . . . . . . . . . . . . . . .9
Use.............................13
Eliminating blockages. . . . . . . . . . . . . .14
Cleaning .........................15
Maintenance......................15
Storage .........................16
Troubleshooting . . . . . . . . . . . . . . . . . .16
Technical data . . . . . . . . . . . . . . . . . . . .17
EC Declaration of Conformity . . . . . . .18
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.
General instructions
Copyright
This document is copyrighted. Any duplica-
tion or reprinting, in whole or in part, and
the reproduction of the illustrations, even
in modied 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 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 modications
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 packaging materials
according to local environmental regula-
tions. This product may not be disposed of
in the domestic refuse within the
European Union. Dispose of the
device via communal collection points.

4
General instructions
AirMAB 5000
GB
Safety warning structure
The following warnings are used in these
operating instructions:
WARNING
A warning of this category indicates a
potentially dangerous situation.
If the dangerous situation is not avoided,
it may lead to injuries.
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.
Follow the instructions in this warning►to avoid material damage.
NOTE
A note indicates additional information►
that simplies the use of the machine.
Intended use
The machine is intended solely for drilling
operations in magnetic and non-magnetic
metals within the limits specied in the
technical data.
Any use other than previously stated is
considered as improper use.
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.
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 appliance
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 preven-
tion and occupational safety regula-
tions.

5
Safety
AirMAB 5000
GB
Safety
WARNING
When using tools driven by com-
pressed air, pay attention to the
following basic safety measures for
protection against injuries and damage
to property!
Fundamental safety precautions
Do not use the machine in ammable or ■potentially explosive environments.
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.
Children must not be allowed to use the■machine.
Check the machine and do not put a■damaged machine into operation.
Check the compressed air line for vis-■ible external damage before use and do
not put a damaged compressed air line
into operation.
Before beginning any work, check for■proper condition of the safety chain and
the function of the operating elements
of the machine.
Only allow repairs to the machine to be■carried out by an authorised workshop
or customer service. Unqualied repairs
can lead to considerable 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 leave the machine standing out-■doors and do not expose it to moisture.
Make sure that your work area is suf-■
ciently lit (>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.

6
Safety
AirMAB 5000
GB
Danger in conjunction
with polymers
WARNING
Risk to health from PTFE (synthetic
fully uorinated polymers)
Absorbing or inhaling PTFE is a health
risk!
Pay attention to the following safety notes
to avoid danger from PTFE because
PTFE particles can deposit on the inside
of the housing as a result of operating the
drive unit:
Do not smoke when carrying out►maintenance work.
PTFE particles may not come into►
contact with naked ames, embers
or heat
Motor parts must be cleaned with a►cleaning solution and not by blowing
compressed air.
After completing all work, wash your►hands.
Danger from compressed air
WARNING
Risk of injury when applying non-per-
missible pressures!
Pay attention to the following safety notes
to avoid danger from compressed air:
Only operate the machine with►prescribed air quantity and operating
pressure.
Danger of explosion if not observed.
Risk of injury
WARNING
Risk of injury from motor starting
unintentionally!
Pay attention to the following safety
notes to avoid danger from motor starting
unintentionally:
To completely stop the motor:►Move the motor switch to the OFF
position.
Disconnect the compressed air sup-
ply.
WARNING
Improper handling of the machine
increases the risk of injury!
Observe the following safety precautions
to avoid injuring yourself and/or others:
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 running. A glove can
be caught by the drilling machine and
torn off 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.
Always switch off the machine before►changing tools, performing main-
tenance or cleaning. Wait until the
machine has come to a complete
standstill.
Always disconnect the compressed►air supply before changing tools,
cleaning or performing maintenance
work in order to avoid unintentional
starting of the machine.

7
Safety
AirMAB 5000
GB
WARNING
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 scaffolding, the op-►erator must be secured with a safety
belt as the machine can oscillate
dangerously in the event of failure of
the compressed air supply.
Check for secure clamping of the►magnets on the substrate before
every use (see Preparation section).
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 when the magnet is
released.
Check that the tool is tightened►securely before using (see Inserting
the tool section).
Do not allow the compressed air line►to hang over edges (trip wire effect).
Preventing damage
CAUTION
Potential damage to property if the
machine is improperly used!
Observe the following instructions to
avoid property to damage:
Only use the prescribed air quality, air►quantity and operating pressures for
compressed air supply (see section
Preparing).
Always carry the machine by the►handle.
CAUTION
Do not crush the compressed air line.►
Do not expose the compressed air►line to heat or chemical liquids.
Do not pull the compressed air line►across sharp edges or hot surfaces.
Lay the compressed air line in such ►a way that it cannot be caught and
wound up in the rotating part of the
machine.
Safety appliances
Symbols on the machine
The symbols on the machine have the fol-
lowing meaning:
Symbol Meaning
Read the operating instructions
before beginning work!
Wear protective goggles and
ear protection!

8
Components / delivery contents
AirMAB 5000
GB
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 equip-
ment 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
Components / delivery
contents
Machine overview
1 Core drill
(not supplied as standard)
2 Tool mounting
3 MK2 spindle taper
4 Drive motor (pneumatic)
5 Handle
6 Hand lever (3-stage)
7 Magnetic foot
8 Machine slide and guide
9 Compressed air connection
10 Motor switch
11 Operating lever for the magnetic foot
12 Lock for the operating lever
of the magnetic foot
Scope of supply
20 Magnetic core drilling machine
21 Pump bottle
for cutting oil/drilling emulsion
22 ZAK075 and ZAK100 ejector pin
23 Transport case
AKEYLESS quick-change drill chuck
system 19 mm Weldon (3/4")
B Safety chain
C MK2 ejector pin

9
Preparation
AirMAB 5000
GB
Before using for the rst time
Transport inspection
As standard, the machine is supplied with
the components indicated in the Compo-
nents/delivery contents"section.
NOTE
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.
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 (B)
supplied.
Check the safety chain for proper►function before every use. A dam-
aged 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 stipu-►lated in the section Personal protec-
tive equipment.
Work on scaffolding
WARNING
Risk of falling from sudden oscillating
movements of the machine.
When working on scaffolding, the
machine can make a sudden oscillating
movement on starting or in the event of
failure of the compressed air supply.
Secure the machine with the safety►chain supplied.
Wear a safety harness to protect►yourself against falling.

10
Preparation
AirMAB 5000
GB
Check the condition
of the substrate
The magnetic clamping force is depend-
ent on the condition of the substrate. The
clamping force is signicantly reduced by
paint, zinc and scale coatings and rust.
The substrate must satisfy the following
conditions in order to achieve sufcient
magnetic clamping force:
The substrate must be magnetic.■
The clamping surface and the magnetic■foot (7) must be clean and grease-free.
The clamping surface must be com-■pletely smooth and level.
NOTE
Clean the substrate and the magnetic►foot (7) 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 effect 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 work-
pieces with an uneven surface.
NOTE
BDS offers a range of accessories►with special clamping devices for
tubes and non-magnetic materials.
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
with Weldon-
19 mm shank
Use KEYLESS (A)
quick-change drill chuck
system
Tools
with MK
taper
Insert the tool directly into
the spindle taper (3)
Tools with
straight
shank
Use drill chuck with MK2/
B16 tapered mandrel
(available as an accessory).
WARNING
Risk of injury!
Do not use damaged, soiled or worn►tools.
Change tools only when the machine►is switched off and at a standstill. Dis-
connect the compressed air supply

11
Preparation
AirMAB 5000
GB
WARNING
Risk of injury!
After inserting, check that the tool is►engaged securely.
Only use tools, adapter and accesso-►ries that match the machine.
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.
WARNING
Risk of injury from incorrectly inserted
tool!
Check the proper seating of the tool,►adapter or drill chuck in the MK tool
mounting.
Removing the tool
Insert the ejector pin (C) into theejector pin holder of the spindle taper
MK2 (3).
Lever out the tool with the ejector pin (C) or loosen the tool by tapping
against the ejector pin.
Using the drill chuck
Inserting the tool
Insert the drill chuck onto the taperedmandrel and insert the combina-
tion 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tighten the drill chuck with the chuck
key.
Removing the tool
Loosen the drill chuck with the chuck key and remove the tool.
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.

12
Preparation
AirMAB 5000
GB
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 (3) of the machine.
Push the KEYLESS quick-change drill chuck system (A) from below into the
spindle taper of the machine.
Connect the line of the pump bottle forcutting oil/drilling emulsion (21) to the
connection for the KEYLESS quick-
change drill chuck system.
Open the KEYLESS quick-change drill chuck system by pushing up the
outside sleeve and insert the tool into
the chuck.
NOTE
Insert the appropriate ejector pin►before inserting the core drill.
WARNING
Risk of injury from incorrectly inserted
tool or tool mounting!
Check by briey turning the tool ►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.
Compressed air supply
Perfect function and performance of the
drive unit depends on the air quality and
the quantity of air supplied.
The following requirements must be met
by the compressed air in order to achieve
perfect function and performance of the
drive unit:
The air quality is optimum at a dew■point of 10 °C and precipitation of solid
particles larger than 15 micrometres as
well as 90 % of liquid water.
The compressed air must contain oil■in order to guarantee the required air
lubrication.
Set the oil quantity according to the air■requirement.
L= air consumption (1/sec)
D= number of drops per minute
(1 drops = 15 mm²); L * 0.2 = D.
The compressed air connection must■have an operating pressure of 6 - 7 bar
= 600 - 700 kPa = 6 - 7 kp/cm².
Before connecting, blow through the■compressed air hose carefully to clean
it.
Hose diameter: min.10 mm (3/8").
NOTE
Only connect to the machine when it►is switched off.
Air consumption of the motor is►1000 l/min.
The motor performance is reduced
when the air supply is decreased!

13
Use
AirMAB 5000
GB
Use
Activating/deactivating the mag-
netic clamp
Activating the magnetic clamp
Turn the lever for the permanentmagnet (11) to the right (ON position)
to activate the magnets.
Deactivating the magnetic clamp
Hold the handle tightly (5) to stop themachine from slipping.
Push the locking button (12) and turnthe lever (11) for the magnetic clamps
to the left (OFF position) to release the
magnets.
Switching the machine ON/OFF
Switching on the machine
Turn the motor switch (10) to the ONposition to activate the motor.
Switching off the machine
Turn the motor switch (10) to the OFFposition to deactivate the motor.
WARNING
Risk of injury from motor starting
unintentionally!
Pay attention to the following safety
notes to avoid danger from motor starting
unintentionally:
To completely stop the motor:►Move the motor switch to the OFF
position.
Disconnect the compressed air sup-
ply.
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).
Install the appropriate ejector pinin the core drill and insert the core
drill into the quick-change drill chuck
system.
Place the machine at the working loca-tion, align it and switch on the mag-
netic clamps.
NOTE
Observe the following instructions when
drilling with core drills:
Drilling with core drills does not re-►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 pump bottle for cutting oil/►drilling emulsion (21) with BDS 5000
high-performance cutting oil supplied
for the machine.
When working overhead, use►ZHS 400 high-performance grease
spray. Spray the drill with grease
spray on the inside and outside
before drilling. Repeat this procedure
when drilling deeper holes.
Make sure that swarf is removed►regularly. With larger drilling depths,
break the chip.

14
Eliminating blockages
AirMAB 5000
GB
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.
Place the machine at the working loca-tion, align it and switch on the mag-
netic clamps.
NOTE
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 the chip.
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 the machine off using the mo-
tor switch. Leave the magnetic clamp
switched on.
Disconnect the compressed air supply
Use the handle to move the machineslide to the upper position.
Replace defective tool. Remove swarf.
Other blockages:
Switch the machine off using the mo-
tor switch. Leave the magnetic clamp
switched on.
Disconnect the compressed air supply
Use the handle to move the machineslide to the upper position.
Remove swarf and check tool.
WARNING
Risk of injury from motor starting
unintentionally!
Pay attention to the following safety
notes to avoid danger from motor starting
unintentionally:
To completely stop the motor:►Move the motor switch to the OFF
position.
Disconnect the compressed air sup-
ply.

15
Maintenance
AirMAB 5000
GB
Cleaning
WARNING
Switch off the machine and discon-►nect from the compressed air supply
before performing maintenance or
cleaning.
When using compressed air for►cleaning, wear protective goggles and
gloves and protect other persons in
the working area.
Motor parts must be cleaned with►cleaning solution and not by blowing
compressed air.
Do not smoke when servicing.►
After completing all work, wash your►hands.
CAUTION
Never immerse the machine in water►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.
Put the machine and accessories intothe transport case.
Maintenance
WARNING
Danger caused by unqualied repairs!
Unqualied repairs can lead to consider-
able danger for the user and cause dam-
age to the machine.
Repairs to and maintenance on the►drive motor may only be carried out
by the works customer service or by
specialists trained by the manufac-
turer.
Adjusting the machine slide guide
If the machine slide guide (8) 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.
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.

16
Troubleshooting
AirMAB 5000
GB
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
Fault Possible cause Remedy
The motor does not start after
pressing the ON/OFF switch
or stops during operation.
Compressed air supply not
connected. Connect the compressed air supply .
Compressed air supply not
switched on. Switch on the compressed air supply.
Compressed air supply not
sufcient.
Check the compressed air
supply and set up according
to specications.
The magnetic clamp does not
function.
Magnet not switched on. Switch on magnet.
The surface is not magnetic. Use a suitable base.
Tools wear excessively/are
damaged. No lubrication or not suf- ciently greased.
Supply lubrication
(e.g.,:use pump bottle for cut-
ting oil/drilling emulsion (21)).
NOTE
If you cannot resolve the problem with the steps described above, please contact►customer service.

17
Technical data
AirMAB 5000
GB
Technical data
Model AirMAB 5000 Unit
Dimensions
(L x W x H) 165 x 322 x 345-535 mm
Magnetic foot (L x W x H) 90 x 190 x 60 mm
Approx. net weight. 17.5 kg
Motor power 830 W
Nominal torque 27 Nm
Air consumption 1000 l/min
Noise emission 96 db(A)
Vibration 1.55 m/s²
Stroke 160 mm
Core drill (short) max. Ø 12 - 35 mm
Cutting depth max. 55 mm
Twist drill max. Ø 23 mm
Gear stage 1 speed 290 - 575 rpm
Core drill assembly Weldon 19 mm (3/4“)

18
EC Declaration of Conformity
AirMAB 5000
GB
EC Declaration of Conformity
Name/address of the manufacturer: BDS Maschinen GmbH
Martinstraße 108
D-41063 Mönchengladbach
We hereby declare that the product
Model: Magnetic core drilling machine
Type AirMAB 5000
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 ISO 11148-3:2013●
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)
Mönchengladbach,
22nd January, 2014
Wolfgang Schröder, Technical Director
________________________________________
(Legally binding signature of the issuer)