BDS RailMAB 960 User manual

RailMAB 960
Translation of the Original-
Operating Instructions
GB

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3RailMAB 960
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Table of Contents
General instructions ................3
Safety ............................5
Components/delivery contents .......9
Before using for the rst time ........9
Preparation. . . . . . . . . . . . . . . . . . . . . . .10
Use .............................14
Eliminating blockages. . . . . . . . . . . . . .17
Cleaning .........................18
Maintenance......................18
Storage ..........................19
Troubleshooting ..................19
Technical data ....................20
EC Declaration of Conformity .......21
Dear Customer,
Before using the machine, please read the
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 dupli-
cation 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 in
accordance with the local regulations in
force.
This product may not be disposed of
in the domestic refuse within the
European Union. Dispose of the
device via communal collection points.
General instructions

4RailMAB 960
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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 injuries.
►Follow the instructions in this warning
to avoid possible danger of serious
personal injuries.
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 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 rails 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.
General instructions

5RailMAB 960
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Safety
WARNING
When using engine-powered tools, the
following fundamental precautions
must be taken to protect against elec-
tric shock, re, injuries and damage to
property!
Fundamental safety precautions
■Do not use the machine in ammable or
potentially explosive environments.
■Never operate the machine in closed
rooms.
■Never refuel the machine when it is hot.
■When refuelling the machine, use suita-
ble auxiliary resources (e.g.: funnel,...)
■Only use the prescribed fuels and
lubrication.
■Persons who are unable to operate the
appliance due to their physical, mental
or motor response abilities may only
use the appliance under supervision or
instruction by a responsible person.
■Children must not be allowed to use the
machine.
■Before using, check the machine for
damage and do not put a damaged
machine into operation.
■Before beginning work, check the con-
dition of the machine and the function of
the operating elements.
■Repairs to the machine may only be
carried out by an authorised specialist
workshop or by the works customer
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
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-
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.
Safety

6RailMAB 960
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Dangers from exhaust gases
DANGER
Danger to life from exhaust gases!
Inhaling the exhaust of the engine (12)
can lead to suffocation!
Observe the following safety instructions
to avoid danger from exhaust gases.
►Never operate the machine in closed
rooms.
►Avoid inhaling exhaust gases.
►Pay attention the engine specica-
tions of the manufacturer (12).
Risk of injury!
WARNING
Danger of injury, re and explosion!
Pay attention to the following safety
notes to avoid danger:
►Only touch the engine (12) after it has
cooled down.
►Refuel the machine only when it has
been switched off.
►Only handle fuels in a well-ventilated
environment.
►Pay attention to the product data
sheet of the fuel.
►Pay attention the engine specica-
tions of the manufacturer (12).
WARNING
Risk of injury from engine starting
unintentionally!
Pay attention to the following safety notes
to avoid danger from the engine (12)
starting unintentionally:
For safe stopping of the engine (12):
►Move the accelerator (19) to the MIN
position.
►Move the ignition switch (20) of the
engine (12) to the OFF/AUS position.
►Close the fuel tap (21).
►Pay attention to the engine specica-
tions of the manufacturer (12).
Safety

7RailMAB 960
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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
section Personal protective equip-
ment).
►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.
►Ensure that the machine is in a safe
condition before changing any tools
and before maintenance and cleaning
in order to avoid unintentional starting
of the machine.
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.
►Before using each time, check for
rm stability of the quick clamping
system (5) on the rail (see section
Preparation).
►Check that the tool is tightened
securely before using (see section
Inserting the tool).
Preventing damage
CAUTION
Potential damage to property if the
machine is improperly used!
Observe the following instructions to
avoid damage:
►Use the prescribed operating materi-
als (fuel, oil...) only.
►Pay attention the engine specica-
tions of the manufacturer (12).
►Always carry the machine by the
handle (2).
►Always keep the machine upright.
Safety

8RailMAB 960
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Safety equipment
Oil level monitoring
The engine (12) is also equipped with oil
level monitoring. The machine cannot be
started if the oil level is not sufcient before
starting.
Check the oil level:
►See section "Preparing the engine and
checking/lling oil".
Symbols on the machine
NOTE
►Pay attention to the documentation of
the manufacturer.
The symbols on the machine have the
following meaning:
Symbol Meaning
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
Wear the following additional protective
equipment during special operations:
Symbol Meaning
Helmet for protecting your head
against falling objects
Wear a safety belt where there
is a danger of falling.
Gloves for protection against
injuries
Safety

9RailMAB 960
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Components / scope of supply
Machine overview
1 Tank cover
2 Carrying handle
3 Spindle key
(fast clamping system)
4 Starter handle
5 Fast clamping system
6 Rail adapter
7 Core drill (not supplied as standard)
8 Feed lever
9Oil ller neck
10 Pressure connector for coolant/lubrica-
tion supply
11 Reduction gear
12 Drive engine
13 Exhaust
14 Air lter
15 Choke
16 Tank
17 Fixing screws
(rail adapter)
18 Clamping jaw (fast clamping system)
19 Accelerator
20 Ignition switch
21 Fuel tap
Delivery contents
Rail core driller
with petrol engine
A Rail adapter of your choice
(no special designs)
Offset screwdriver
(SW 4 + 5); (not illustrated)
High-pressure container 5l for cutting/
drilling emulsion (not illustrated)
Operating instructions
Before using for the rst time
Transport inspection
As standard, the machine is supplied with
the components indicated in the Delivery
contents section.
NOTE
►Inspect the delivery for completeness
and obvious signs of damage. Report
an incomplete or damaged delivery to
your supplier/retailer immediately.
Components / scope of supply

10 RailMAB 960
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Preparation
This section contains important instructions
on required preparation before starting
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
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.
►Before beginning any work, check
secure positioning of the safety
measures.
►Use the protective equipment stipulat-
ed in the section Personal protective
equipment.
Checking the rail type
The holding force of the fast clamping
system (5) depends on the tting accuracy
of the rail adapter (6) to the rail.
The following requirements must be fullled
in order to establish sufcient holding force:
■Only the rail adapters (6) associated
with the rail type may be used.
NOTE
►In addition to the rail adapters (A) list-
ed in the range of accessories, BDS
offers special adapters for special
rails on request.
Preparation

11RailMAB 960
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Mounting the rail adapter
The machine is equipped with a socket for
various rail adapters (A).
The corresponding adapter set must be
used according to the type of rail.
Rail type Order number
rail adapter
UIC 50 ZAS 250U
UIC 54 ZAS 254U
UIC 60 ZAS 260U
S 49 ZAS 249S
S 54 ZAS 254S
Other On request
WARNING
Risk of injury!
Incorrectly, damages or improperly
mounted rail adapters (6) decrease the
holding force of the fast clamping sys-
tem (5), this can lead to injuries
►Only use the matching rail adapter (6)
for the respective rail type.
►Do not use damaged, contaminated
or worn tools rail adapters (6).
►Change the rail adapter only when
the machine is switched off and at a
standstill. Put the machine into a safe
condition.
►Change the rail adapter only when
the fast clamping system (5) is not
tensioned.
WARNING
►After mounting, check for secure, rm
seating of the rail adapter (6).
►Only use tools, adapter and accesso-
ries that match the machine.
Mounting the rail adapter (6)
Loosen both xing screws (17) of the
rail adapter set on each respective
side.
Insert both rail adapters (6) and tight-
en the xing screws (17).
Dismantling the rail adapter
Loosen both xing screws (17) of the
rail adapter set on each respective
side.
Remove both rail adapters (6).
Preparation

12 RailMAB 960
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Inserting the tool
The machine is equipped with a 19 mm
Weldon (3/4") direct mounting.
Tools:
Only core drills with a 19 mm Weldon
shaft (3/4") can be used (HKK-R). The cut-
ting depth is limited by the maximum stroke
of 40 mm.
WARNING
Risk of injury!
►Do not use damaged, contaminated
or worn tools.
►Only perform tool changing when
the machine is switched off and not
moving.
►Ensure that the machine is in a safe
condition.
■Move the accelerator (19) to the
MIN position.
■Move the ignition switch (20) of
the engine (12) to the OFF/AUS
position.
■Close the fuel tap (21).
■Pay attention to the engine speci-
cations of the manufacturer (12).
►After inserting, check that the tool is
engaged securely.
►Only use tools, adapter and accesso-
ries that match the machine.
Inserting the tool
Before mounting, clean the shank of
the tool and the direct mounting of the
machine.
Insert the corresponding ejector pin
into the core drill.
Insert the tool into the direct mounting
of the machine from the front.
Secure the tool by tightening the safe-
ty screws (Allen head screws) in the
direct mounting.
WARNING
Risk of injury!
Risk of injury from incorrectly inserted,
not secured or improperly secured tool.
►Check the proper seating of the tool
in the tool mounting.
►Only tighten the Allen head screws
of the direct mounting with a suitable
tool (offset screwdriver supplied).
►After tightening/untightening the Allen
head screws, pull the offset screw-
driver out of the screw.
Removing the tool
Loosen the safety screws (Allen head
screws) on the direct mounting.
Remove the tool from the direct
mounting from the front.
Preparation

13RailMAB 960
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Coolant/lubrication
The back of the machine is equipped with a
coolant/lubrication connector (10) in order
to connect the high-pressure container
supplied. This allows the core drill and the
cutting surface to be supplied with coolant/
lubrication.
Connect the high-pressure container:
Push the hose of the high-pressure
container into the coolant/lubrication
connector (10) until it audibly snaps in.
Release the high-pressure container:
Depressurise the high-pressure con-
tainer.
Remove the hose by pulling back the
safeguard on the connection coupling.
NOTE
►Remove excess coolant/lubrica-
tion with appropriate means (e.g.:
cloth,...).
Preparing the engine
WARNING
Risk of injury!
►Carry out all work on the engine (12)
only when the machine is switched off
and at a complete stop.
►Ensure that the machine is in a safe
condition.
■Move the accelerator (19) to the
MIN position.
■Move the ignition switch (20) of
the engine (12) to the OFF/AUS
position.
■Close the fuel tap (21).
■Pay attention to the engine speci-
cations of the manufacturer (12).
►Allow the machine to cool down
before starting any work on the en-
gine (12).
CAUTION
Potential damage to property if the
machine is improperly refuelled!
Observe the following instructions to
avoid damage:
►Only use the prescribed fuels and
lubrication as well as specied
amounts.
Recommended fuel:
Lead-free petrol, 95 octane
Recommended engine oil:
SEA 10W-30
(Pay attention to the manufacturer
documentation on the engine (12).)
►Absorb excess fuels and lubricants
immediately with suitable means.
►Carry out all work on the engine (12)
on a rm, at and level surface.
Preparation

14 RailMAB 960
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Refuelling the machine
Screw off the tank lid (1).
Fill with fuel
Screw in the tank lid (1).
Checking/lling oil
Open the oil ller neck (9).
Check the oil level with the help of
the dipstick on the cap of the oil ller
neck (9) (pay attention to the manufac-
turer documentation).
Rell with oil if necessary.
Close the oil ller neck (9) with the
cap.
Use
Fixing the machine
Tensioning the fast clamping system
Insert the machine with the rail adapt-
er (6) into the rail prole at right angles
to the rail.
Press the clamping jaw (18) onto the
rail by turning the spindle key (3).
Slackening the fast clamping system
Secure the machine at the handle (2)
to stop it from slipping.
Release the clamping jaw (18) from
the rail by turning the spindle key (3)
Remove the machine from the rail.
Switching the machine ON/OFF
Switching on the machine
Move the fuel tap (21) to the ON
position.
Move the choke (15) to the CLOSED
position.
(to restart a warm engine (12), leave
the choke (15) in the opened position.)
Move the accelerator (19) to the MAX
position.
Switch on the ignition (20)
(ON position).
Start the engine (12) with the help of
the starter handle (4). For this pur-
pose, pull the starter handle (4) lightly
until resistance is felt, then start the
engine (12) by pulling rapidly.
Allow the engine (12) to warm up
and move the choke (15) back to the
OPEN position.
Switching off the machine
Move the accelerator (19) to the MIN
position.
Switch off the ignition (20)
(OFF position).
Move the fuel tap (21) to the OFF
position.
NOTE
►Pay attention to the manufacturer
documentation when starting and
switching off the engine (12).
Use

15RailMAB 960
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WARNING
Risk of injury from engine starting
unintentionally!
Pay attention to the following safety notes
to avoid danger from the engine (12)
starting unintentionally.
For safe stopping of the engine (12):
►Move the accelerator (19) to the MIN
position.
►Move the ignition switch (20) of the
engine (12) to the OFF/AUS position.
►Close the fuel tap (21).
►Pay attention to the engine specica-
tions of the manufacturer (12).
Setting the speed
The rotation speed is determined by the
engine speed.
The position of the accelerator (19) deter-
mines the speed of the drill.
■MAX position
= max. speed (225 rpm)
■MIN position
= min. speed (150 rpm)
Drilling with the machine
Drilling with core drills
When drilling with core drills, proceed as
follows:
Insert the core drill into the 19 mm
Weldon (3/4") direct mounting of the
machine as described in the section
Inserting the tool.
Position the machine at the location of
use, align it and x the machine with
the fast clamping system (5).
Connect the high-pressure container
as described in the section Coolant/
lubrication.
Pressurise the cooling/lubrication sys-
tem (approx. 2-3 strokes with the hand
pumping device of the high-pressure
container).
Switch the machine on.
Guide the machine carriage with the
help of the feed lever (8) and without
exerting too much pressure until the
desired core drill is established.
Use

16 RailMAB 960
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NOTE
Observe the following instructions when
drilling with core drills:
►Drilling with core drills does not re-
quire great effort. The drilling process
is not accelerated by higher pressure.
The drill wears faster and the ma-
chine can be overloaded.
►Use the high-pressure container sup-
plied for cutting oil/drilling emulsion
with BDS 6000 cooling lubricant at
the machine.
►Pay attention to the production of
swarf. With larger drilling depths,
break the chip.
Eliminating blockages
WARNING
Danger of cutting by broken tool parts
or shavings.
►Put protective gloves on before start-
ing work.
Before eliminating a blockage, stop the
machine completely.
For safe stopping of the engine (12):
►Move the accelerator (19) to the MIN
position.
►Move the ignition switch (20) of the
engine (12) to the OFF/AUS position.
►Close the fuel tap (21).
►Pay attention to the engine specica-
tions of the manufacturer (12).
Blockages caused by a broken tool:
Move the machine carriage to the
base position with the help of the feed
lever (8).
Replace defective tool. Remove
shavings.
Other blockages:
Move the machine carriage to the
base position with the help of the feed
lever (8).
Remove shavings and check tool.
Eliminating blockages

17RailMAB 960
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Cleaning
WARNING
Risk of injury!
Risk of injury in the case of improper
cleaning work. To avoid injury, pay atten-
tion to the following instructions:
►Before any maintenance and clean-
ing, switch off the machine and stop
the engine (12) completely
■Move the accelerator (19) to the
MIN position.
■Move the ignition switch (20) of
the engine (12) to the OFF/AUS
position.
■Close the fuel tap (21).
■Pay attention the engine specica-
tions of the manufacturer (12).
►When using compressed air, wear
protective goggles and gloves.
►Protect other persons in the work
area.
CAUTION
►Never immerse the machine in water
or other liquids.
After every use
Remove the inserted tool.
Remove shavings and coolant resi-
dues.
Clean the tool and the tool holder on
the machine.
Clean the guide of the machine slide
(13).
Store the machine and accessories
at a suitable location (see section
Storage).
NOTE
►Pay attention to the manufacturer
documentation when cleaning the
engine and gear unit.
Cleaning/maintenance

18 RailMAB 960
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Maintenance
WARNING
Danger caused by unqualied repairs!
Unqualied repairs can lead to consid-
erable danger for the user and cause
damage to the machine.
►Maintenance work may only be car-
ried out by authorised qualied staff.
►Only original spare parts may be
used.
Adjusting the guide of the machine
slide
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 uniformly.
Tighten the clamping bolts again.
NOTE
►Pay attention to the manufacturer
documentation when carrying out
maintenance on the engine and gear
unit.
Customer service/service
Should you have any questions about af-
ter-sales service or service, please contact
BDS. We will be happy to give you the
address of your nearest service partner.
Cleaning/maintenance

19RailMAB 960
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 accessories at a dry, clean and frost-free
location.
Troubleshooting
Fault Possible cause
The engine (12) does not
start.
Fuel supply faulty.
Check the fuel level
and refuel if necessary.
Open the fuel tap.
Motor oil level too low. Check the oil level
and rell if necessary.
Ignition (20) not switched on. Switch on the ignition.
Choke (15) not at a suitable start
position.
Check the position of the
choke.
(CLOSED position for cold
starting)
Pay attention to the manufacturer documentation for further
troubleshooting.
Tools wear excessively/
are damaged.
No lubrication or not sufciently
greased.
Supply lubrication (e.g.:use
high-pressure container for
cutting oil/drilling emulsion).
The fast clamping
system (5) does not x
the machine to the rail
properly.
Wrong rail adapter (A) selected. Select and mount a suitable
rail adapter (A).
NOTE
►If you cannot resolve the problem with the steps described above, please contact the
After-Sales Service.
Storage/troubleshooting

20 RailMAB 960
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Technical Specications
Model RailMAB 960 Unit
Dimensions
(L x W x H) 535 x 345 x 470 mm
Net weight approx. 21.5 kg
Cylinder capacity 49.4 cm3
Tank capacity 0.5 l
Motor power 1.5 kW
Max. torque 3.04 Nm at 4500 rpm W
Stroke 40 mm
Core drill (HKK-R) max. Ø 17 - 36 mm
Cutting depth max. 30 mm
Speed (adjustable) 150 - 225 rpm
Core drill assembly Weldon 19 mm (3/4")
Technical Specications