BDS MAB 800 User manual

MAB 800 / MAB 840
Operating instructions

3 MAB 800 / MAB 840
Table of Contents
Foreword .........................4
Instructions for use ................4
Copyright .........................4
Structure of the safety warnings........5
Intended use.......................6
Liability disclaimer ..................6
Safety............................7
Fundamental safety precautions .......7
Electric shock hazard ................8
Risk of injury.......................9
Prevention of damage ..............10
Safety installations .................11
Personal protective equipment........12
Components/scope of supply .......13
Machine overview..................13
Delivery contents ..................14
Control panel .....................14
Before using for the rst time .......15
Transport inspection................15
Preparations .....................15
Additional safety measures for certain
operations........................15
Check the condition of the substrate ...16
Inserting the tool...................17
Operation .......................20
Activating/deactivating magnetic clamp .20
Switching machine ON/OFF..........21
Selecting the speed range ...........21
Setting the speed ..................22
Setting the torque cut-out ............22
Rotating mechanism................23
Drilling with the machine ............23
Thread cutting ....................25
Reaming/counter-sinking ............25
Eliminating blockages .............26
Cleaning ........................27
After every use ....................27
Maintenance .....................28
Adjusting the guide of the machine slide28
Replacing the carbon brushes ........28
After-Sales Service/Service ..........28
Troubleshooting ..................29
Faults - causes and remedies ........29
Storage/disposal .................30
Storage..........................30
Disposal .........................30
Annex ..........................31
Technical data ....................31
EC Declaration of Conformity .......32

4
Foreword
MAB 800 / MAB 840
Foreword
With the purchase of this machine you have decided in favour of a
quality product whose engineering and sturdiness have been de-
signed to meet the high demands of day-to-day professional use.
Read all the information contained here to familiarise yourself
quickly with the machine and to be able to make full use of its
functions.
This machine will serve you for many years to come if you handle
and treat it properly.
Instructions for use
These operating instructions form an integral part of the Magnetic
Core Drilling Machine MAB 800 / MAB 840 (hereinafter referred to
as "machine") and contains important information for the commis-
sioning, safety, intended use and care of the machine.
The operating instructions must be kept near the machine at all
times. They must be read and observed by all persons entrusted
with operation, troubleshooting and/or cleaning of the machine.
Keep these operating instructions in a safe place and pass them
on with the machine to any future owners.
Copyright
This document is protected by copyright.
Any duplication or reprinting, in whole or in part, and the reproduc-
tion of the illustrations even in modied form is only permitted with
the written approval of the manufacturer.

5
Instructions for use
MAB 800 / MAB 840
Structure of the safety warnings
The following warnings are used in the present operating instruc-
tions:
DANGER
A warning of this category draws attention to 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 the danger of
serious injury or even death.
WARNING
A warning of this category draws attention to a potentially
dangerous situation.
If the dangerous situation is not avoided, it may lead to injuries.
►Follow the instructions in this warning to avoid the risk of
injury.
CAUTION
A warning of this category draws attention to potential
material damage.
If the situation is not avoided, it may lead to material damage.
►Follow the instructions in this warning to avoid material dam-
age.
NOTE
►A note draws attention to additional information that simpli-
es the use of the machine.

6
Instructions for use
MAB 800 / MAB 840
Intended use
The machine is intended solely for drilling operations in magnetic
and non-magnetic metals, and for cutting threads, countersinking
and reaming within the limits specied in the technical data.
Use in any other or further way is not considered an intended use.
WARNING
Danger from use for other than the intended purpose!
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 or injury result-
ing from use of the machine for other than its intended purpose.
The risk has to be borne solely by the machine owner.
NOTE
►If used commercially, pay attention to compliance with the
accident prevention regulations and the Safety at Work
Ordinance.
Liability disclaimer
All technical information, data and instructions for commissioning,
operation and care 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 result-
ing from failure to observe the operating instructions, use for other
than the intended purpose, unprofessional repairs, unauthorised
modications or use of non-approved spare parts and accesso-
ries, tools and lubricants.

7
Safety
MAB 800 / MAB 840
Safety
CAUTION
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 precautions
■Do not use the machine in ammable or potentially explosive
environments.
■Persons who due to their physical, mental or motor response
abilities are unable to operate the machine safely may only
use the machine under supervision or instruction by a respon-
sible person.
■Persons with heart pacemakers or other medical implants
must not use this machine.
■Children must not be allowed to use the machine.
■Inspect the machine for visible signs of damage before use.
Do not use a visibly damaged machine.
■Before beginning work, check the condition of the safety chain
and the function of the switches on the machine.
■Repairs to the mains cable may only be carried out by a quali-
ed electrician.
■Repairs to the machine may only be carried out by an author-
ised workshop or by the works after-sales service. Unqualied
repairs can lead to considerable danger for the user.
■Repairs to the machine during the warranty period may only
be carried out by a service centre authorised by the manufac-
turer, as otherwise the warranty will be voided.
■Defective parts may only be replaced with original spare parts.
Only these parts guarantee that the safety requirements are
satised.

8
Safety
MAB 800 / MAB 840
■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 outdoors and do not ex-
pose it to moisture.
■Make sure that your work area is su󰀩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.
Electric shock hazard
DANGER
Danger to life by electric shock!
Contact with live wires or components could lead to seri-
ous injury or even death!
Observe the following safety precautions to avoid electric
shocks:
►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.
►Use only extension leads or cable drums with a cable cross-
section of 1.5 mm².
►Only use extension leads that are approved for the place of
work.
►Check the condition of the extension lead regularly and
replace if damaged.
►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.
►When using the machine outside or in a humid environment,
an RCD (residual circuit device) must be used.

9
Safety
MAB 800 / MAB 840
Risk of injury
WARNING
Improper handling of the machine increases the risk of
injury!
Observe the following safety precautions to avoid injuring your-
self and/or others:
►Operate the machine only with the protective equipment
stipulated in these operating instructions (see section Per-
sonal 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 beginning work. Wear a hair
net if you have long hair.
►Always switch o󰀨 the machine before changing tools, per-
forming 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, in
order to avoid unintentional starting of the machine.
►Do not put your hand into the machine while it is in opera-
tion. Remove shavings only when the machine is at a stand-
still. Wear protective gloves when removing swarf.
►When working on sca󰀨olding, the operator 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 Preparing).
►Secure the machine with the safety chain supplied when
working from an inclined or vertical position or during over-
head 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 (dan-
ger of tripping).

10
Safety
MAB 800 / MAB 840
Prevention of damage
CAUTION
Potential property damage in case of inexpert handling of
the machine!
Observe the following instructions to avoid property damage:
►Before connecting the machine, compare 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 at the handle, not by the connect-
ing lead.
►Always pull the mains lead out of the plug socket at the plug,
not at the mains lead.
►Do not pinch the connecting lead.
►Do not expose the connecting lead to heat or chemical
liquids.
►Do not pull the connecting lead across sharp edges or hot
surfaces.
►Lay the connecting lead in such a way that it cannot be
caught and wound up in the rotating part of the machine.

11
Safety
MAB 800 / MAB 840
Safety installations
Restarting protection
NOTE
►The machine stops automatically if the magnetic clamp is
switched o󰀨 or in the event of a power failure.
In order to prevent unexpected starting of the machine when the
magnetic clamp is switched on again or when the power supply
returns after a power failure ("restarting protection"), the machine
must be switched on at the ON/OFF switch again.
Magnet indicator
The magnet indicator provides a visual control of the magnet's
clamping force.
■Magnet indicator is lit GREEN:
The magnet's clamping force satises the minimum require-
ments. Machining can be carried out.
■Magnet indicator is lit RED:
Insu󰀩cient magnet clamping force. Machining must not be
carried out with the machine. This can be the case in the event
of insu󰀩cient material thickness, uneven surface or due to
paint, scale or zinc coatings.
Thermal overload protection
The machine is additionally equipped with thermal overload pro-
tection. If the machine becomes too hot, it switches o󰀨 automati-
cally.
Carry out the following steps before continuing to work with the
machine:
Remove any blockages that may have occurred.
Allow the machine to run at no-load speed for
approx. 2 minutes.
The machine is then ready for operation again.
Slip clutch
In the event of the drill blocking, the gearbox is protected by a slip
clutch.

12
Safety
MAB 800 / MAB 840
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 working
with the machine:
Symbol Meaning
Close-tting work protection clothing with a low tear-
ing resistance
Goggles for protecting eyes against ying parts and
liquids and ear protection in areas with noise emission
>80 dB(A)
Safety shoes to protect the feet from falling objects
Wear the following additional protective equipment during special
operations:
Symbol Meaning
Helmet to protect your head from falling objects
Wear a safety belt where there is a danger of falling
Working gloves as protection against injury

13
Components/scope of supply
MAB 800 / MAB 840
Components/scope of supply
Machine overview
12
10
9
8
7
5
3
15 14
4
2
11
1
6
13
1 Core drill (not supplied as standard) 9 Cutting oil tank
2 Industrial holder MK3 19 mm Weldon 10 Handle
3 Morse taper MK3 11 Hand lever
4 Opening for ejector pin 12 Control panel
54-speed gearbox with selector 13 Rotating mechanism (MAB 840 only)
6 Speed and torque controller 14 Magnetic foot
7 Drive motor 15 Machine slide and guide
8 Filler neck for cutting oil

14
Components/scope of supply
MAB 800 / MAB 840
Delivery contents
A B,C D E
MAB 800 / MAB 840 machine
(not illustrated)
Hexagonal o󰀨set screwdriver, size SW2.5
(not illustrated)
A Industrial holder MK3 19 mm Weldon
ZIA 319-M MK3
Hexagonal o󰀨set screwdriver, size SW5
(not illustrated)
B Ejector pin ZAK 075
C Ejector pin ZAK 100 Open-end wrench, size SW8
(not illustrated)
D Safety chain
E Ejector pin MK3 Operating instructions/guarantee card
(not illustrated)
Transport case (not illustrated)
Control panel
21
22
24
23
31
32
21 Motor ON/OFF switch 31 Speed setting
22 Magnet ON/OFF switch
23 Direction of rotation switch 32 Torque setting
24 Magnet indicator

15
Before using for the rst time
MAB 800 / MAB 840
Before using for the rst time
Transport inspection
The machine is supplied as standard with the components indi-
cated in chapter Components/scope of supply.
NOTE
►Inspect the delivery for completeness and obvious signs of
damage. Report an incomplete or damaged delivery to your
supplier/dealer immediately.
Preparations
This chapter contains important instructions for the necessary
preparations before starting work.
Additional safety measures for certain operations
Additional safety precautions must be taken for the following
operations with the machine:
Non-horizontal working position
WARNING
Risk of injury from the falling machine.
When working in inclined or vertical position and during over-
head 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 dam-
aged safety chain immediately.
►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 stipulated in chapter Personal
protective equipment.

16
Preparations
MAB 800 / MAB 840
Work on sca󰀨olding
WARNING
Risk of falling from sudden oscillating movements of the
machine.
When working on sca󰀨olding, the machine can make a sud-
den oscillating movement on starting or in the event of a power
failure.
►Secure the machine with the safety chain (D) supplied.
►Wear a safety belt to protect yourself from falling.
Check the condition of the substrate
The magnet clamping force is dependent 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 preconditions in order
that a su󰀩cient magnet clamping force can be achieved:
■The substrate must be magnetic.
■The clamping surface and the magnetic foot (14) must be
clean and grease-free.
■The clamping surface must be completely smooth and level.
NOTE
►Clean the substrate and the magnetic foot (14) of the ma-
chine before use.
►Remove any unevenness and loose rust from the substrate.
►BDS o󰀨ers special holding devices in its range of accesso-
ries.
The best clamping e󰀨ect is obtained on low-carbon steel sub-
strate with a thickness of at least 20 mm.

17
Preparations
MAB 800 / MAB 840
Steel of low thickness
When drilling in steel of low thickness, 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 in NF metals
or in workpieces with an uneven surface.
NOTE
►BDS o󰀨ers special clamping devices for tubes and non-
magnetic materials in its range of accessories.
Inserting the tool
The machine is equipped with an MK tool mounting. Depending
on the type of tool to be used, corresponding drill chucks, quick-
clamping systems or adapters must be employed.
Tool Tool mounting to be used
Tool with
MK3 taper
Insert the tool directly into the morse
taper (3).
Tool with
MK2 taper
Use MK3:2 adapter sleeve (available as an
accessory).
Tools with
19 mm Weldon shank Industrial holder MK3 19 mm Weldon (A).
Tools with
straight shank
Use drill chuck with MK3/B16 tapered man-
drel (available as an accessory).
Thread taps Use the appropriate adapter for thread
taps (available as an accessory).

18
Preparations
MAB 800 / MAB 840
Safety precautions
WARNING
Risk of injury!
►Do not use damaged, soiled or worn tools.
►Carry out tool changes only when the machine is switched
o󰀨 and at a standstill. Remove plug from the mains socket.
►After inserting, check that the tool is engaged securely.
►Only use tools, adapter and accessories that match the
machine.
MK tool mounting
Insert the tool
Before mounting, clean the shank of the tool, adapter or
industrial holder and the morse taper (3) of the machine.
Push the tool from below into the morse taper (3) of the
machine.
WARNING
Risk of injury from incorrectly inserted tool!
►Check the proper seating of the tool, adapter or drill chuck in
the MK tool mounting
NOTE
►When using tools/adapters with MK2 taper, use MK3:2
adapter sleeve.
Removing the tool
Turn the tool until the ejector pin (E) slips into the opening for
the ejector pin (4).
Prise out the tool with the ejector pin (E) or loosen the tool by
tapping against the ejector pin.

19
Preparations
MAB 800 / MAB 840
Weldon industrial tool holder
Inserting the tool
Insert the MK3/19 mm Weldon industrial holder (A) into the
morse taper (3) of the machine.
Before inserting, clean the Weldon shank of the tool and the
tool holder.
Loosen both hexagonal socket screws in the tool mount (A)
with the corresponding hexagonal o󰀨set screwdriver supplied.
Insert the tool into the tool mounting
NOTE
►Insert the appropriate ejector pin (B,C) before inserting a
core drill.
Tighten both hexagonal socket screws in the tool mount (A)
with the corresponding hexagonal o󰀨set screwdriver supplied.
Removing the tool
Loosen both hexagonal socket screws in the tool mount (A)
with the corresponding hexagonal o󰀨set screwdriver supplied
and remove the tool from below.

20
Operation
MAB 800 / MAB 840
Operation
Activating/deactivating magnetic clamp
Activating magnetic clamp
CAUTION
►Switch on the magnetic clamp only when the machine is
standing on a magnetic substrate to avoid overheating of the
magnet.
Turn on switch (22). The indicator light in switch (22) comes
on.
Check the magnet clamping force at the magnet indica-
tor (24). When the magnet clamping force is su󰀩cient, the
MAGNET POWER indicator light (24) is green. If the MAG-
NET POWER indicator light (24) is red, there is not su󰀩cient
magnet clamping force available.
CAUTION
►The maximum magnet clamping force is only available after
switching on the motor.
Deactivating magnetic clamp
Secure the machine at the handle (10) to prevent the ma-
chine from slipping o󰀨 the surface.
Turn o󰀨 switch (22). The indicator light in switch (22) goes
out.