DR. BENDER DX 6 DOLPHIN User manual

DR. BENDER GmbH
Innovative Elektrowerkzeuge
Manual for
drilling motor
DX 6 Dolphin
400 V 3~
Valid from 09.2004 Art.-Nr. 200674 Subject to alterations
Alle Rechte vorbehalten / All rights reserved
DR. BENDER GmbH • D-75382 Althengstett • Tel [phone] • Fax [phone]
Our website address is: http://www.dr-bender.de • eMail: [email protected]

2
Conformity Declaration
DR.BENDER GmbH
Innovative Elektrowerkzeuge
EC Conformity Declaration
for DR.BENDER stone processing machine
DX 6 Dolphin
DR.BENDER GmbH, as manufacturer, hereby declares that the electrical stone processing machine men-
tioned above comply with the requirements of the following guidelines:
- Machine guidelines (98/37/EC)
-Electromagnetic compatibility (EMV) (89/336/EEC)
-Low voltage guideline (73/23/EEC)
The following standards were applied for evaluating the machines:
a) with regard to the machine guidelines:
VDE 0740 21-22: 1994-1991
VDE 0701 Part 1: 1993
VDE 0702 Part 1: 1995
DIN EN 50144-1: 1999
DIN EN 50144-2-1: 2000
b) with regard to electromagnetic compatibility
Interfering emissions
DIN EN 55014-1: 2000 + A1: 2001 = VDE 0875 Part 14-1
DIN EN 61000-3-2: 2000
DIN EN 61000-3-3: 1995 + Cor.1: 1997 + A1: 2001
Interference immunity
DIN EN 55014-2: 1997 + A1: 2001 = VDE 0875 Part 14-2
c) with regard to the low voltage guideline
EN 61029-1: 2001
DR.BENDER GmbH Althengstett, 29.04.2003
Industriestraße 22
D-75382 Althengstett
Tel. [phone], Fax [phone]
B. Brehm, Geschäftsleitung
This declaration implies no assurance of properties.
Please observe the safety regulations of the attached product documentation.

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Contents
page
Conformity declaration 2
Contents 3
1.0 Symbol- and Pictograph description 4
1.1 Function description 4
2.0 General instructions 5
2.1 Application 5
2.2 Safety 5
3.0 Transport and storage 6
3.1 Transport 6
3.2 Storage 6
4.0 Main dimensions and technical data 7
4.1 Dimensions 7
4.2 Technical data 7
4.3 Noise emissions and vibrations [EN 50144] 8
5.0 Commissioning 8
5.1 Changing gear 9
5.2 Safety coupling 9
5.3 Core bits 9
5.4 To change a core bit 9
6.0 Safety instructions 10
7.0 Servicing and care 11
7.1 Daily care 11
7.2 After approx. 150 hours of use 11
7.3 Quarterly 11
8.0 Speed adjustment dependent on the cutting speed 12
9.0 Warranty 13
10.0 General safety instructions 14
11.0 Spare parts list 16
11.1 Motor complete 16
11.2 Gear complete 18
11.3 Connection cables and accessories 20

4
Warning
It is compulsory to observe the safety instructions included in this manual!
Special designs and versions may differ from the standard models in terms of their technical de-
tails. If any points are unclear, we urgently recommend that you contact DR.BENDER GmbH, indi-
cating the machine type and machine number.
1.0 Symbol- and Pictograph description
This sign tells you rules, if you not pay attention for this your health and the function of
the machine is in danger. You have no warranty if the machine breaks down because
you not looking about this.
1.1 Function description
Nameplate
Water connection
Gear control
Switch onn/of
f
Drill-spindle
Circuit breaker

5
2.0 General instructions
2.1 Application
The core drills can be used for the purposes outlined by the data on the model plate. If you are using spe-
cial machines, the details in the quotation and order confirmation also apply.
The core drills are supplied as standard in protection class I, only this can guarantee the full high quality
production of the residual current-operated circuit-breaker or PRCD switch.
If you use suitable core bits, you will be able to drill holes in the most diverse material types:
- Concrete (even if it contains thick reinforcement steel)
- Sandstone and limestone
- All building materials for solid walls
- Asphalt floors
The core drills comply with the regulations issued by the ”Stone and Earth” Professional Association issued
in July 1989. They are machines of category II, which means that they must be placed on stands and be
stable (pursuant to DIN 57100 or VDE 0100), the stand must be equipped with
- a reversing block, and
- a water suction device.
The machine must be
- CEE gronded at one duly electrical outlet (CEE 5pol., 3P +PE 16 amps – 400V) be attached. The
zero pus isn’t required.
- being operated to ensure the protection of the operation person with a preconnected FI protection.
2.2 Safety
Warning
Before using the machine for the first time, check that the conformity of the data
on the model plate with the mains voltage and frequency. Voltage deviations of ±
5 % and/or voltage deviations of ± 2 % are permissible. Repairs must only be
completed by quality persons who have suitable training and qualifications.
The following points are to be given special attention:
- the technical data and details of the permitted use of the machine (commissioning, ambient and
operating conditions) which are set out in the catalogue, the operating manual, the model plate
data and other product information,
- the relevant accident prevention regulations
- the correct use of tools
- the use of personal safety equipment

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3.0 Transport and storage
3.1 Transport
Warning
The core drills are to be checked for signs for transport damage on receipt. Any
damage must be documented in writing.
3.2 Storage
If possible, the storage site should be dry, clean and have a constant temperature. To ensure that the film
of lubricant in the bearings and sealing system is not lost, the motor shaft should be turned through several
revolutions by hand after a lengthy period of storage, for example at monthly intervals. The roller bearings
in the motors should be replaced (or regreased) if the period between delivery and commissioning is over
four years. If the machines are stored in adverse conditions, this period may differ considerably.

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4.0 Main dimensions and technical data
4.1 Dimensions
4.2 Technical data
Rated voltage 400 V
Current consumption 10,5 A
Power requirement 6000 W
Frequency 50 – 60 Hz
Idling speed 160 / 430 / 750 min-1
Full speed 160 / 430 / 750 min-1
Output rating 4200 W
Torque 280 / 120 / 65 Nm
Drilling diameter 100 – 450 mm
Safety class IP 56 -
Coolant water -
Weight 24,5 kg
Core bit connection UNC 1 ¼ “
Overload coupling torque 320 Nm

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4.3 Noise emissions and vibrations [EN 50144]
Noise level Noise level Vibration
dB(A) dB m/s2
73 85 < 2,5
5.0 Commissioning
Check that the mains voltage is identical to the voltage specified on the model plate.
Secure the core drill and the water collector to the drilling stand with its reverse block. The drilling stand
should be as rigid as possible and have precise, low-play guides. Ensure that the core drill axis is parallel
to the axis of the drilling stand.
Insert the core bit and set the speed. The setting instructions are on page 12.
Connect the water supply. Important: Do not exceed the maximum water pressure of 3 bar.
Connect the core drill to the mains using a residual current-operated circuit-breaker box and 6 h coded
CEE plug. Only use three-core extension cables with a protective conductor and an adequate cross-
section. If the cross-section is too low, you may lose excessive power and result in the motor and cable
overheating. An extension cable must have an overload cut-out switch. Recommended cable cross-
sections:
Rated current = 10,5 A
Cable length m 7,5 15 25 30 45 60
Cable cross section mm22,5 2,5 2,5 2,5 2,5 4
The drilling motor is water-cooled. Look after sufficient cooling water when drilling therefore. The drilling
motor must be operated during the full load with at least 1 liters of water per minute. Use only pure tapwa-
ter, no dirt or sewage, otherwise the drilling motor will damaged. Adjust the feed speed to the core bit di-
ameter and the drive rating of the core drill so that the rated current is not exceeded.

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5.1 Changing gear
Warning
Never change gear using force and only do so when the machine is slowing
down or at a standstill.
To change into the next higher or lower gear, move the gear-change lever through an angle of approx. 50°.
If necessary (if the gear is difficult to engage), turn the drive spindle briefly by hand until the gear engages
easily.
Do not use any tools (pliers, hammer, etc.) to change gear since otherwise gear damage is a natural con-
sequence.
5.2 Safety coupling
The values set out in the table are theoretical values and may be used to provide a rough guide for gear
changing. Since a whole range of other parameters also plays a major role in adjusting the speed, we can-
not offer any guarantee if the tool is damaged when using the values in the table. Drilling work for which the
speeds are outside the range of the core drill (values printed in italics), should only be completed with ex-
treme care and by trained personnel.
5.3 Core bits
All core bits with a connection thread of 1 ¼ ” UNC can be used.
Adapters can be supplied to allow core bits with other connection systems to be used.
Only use core bits that are suitable for the type of stone.
You will keep the core drill in good condition if you only use core bits that are concentric and not deformed
ones.
Ensure that the diamond segments have an adequate undercut against the core bit body.
Warning
To use wrong tools or accessories is danger for your life.
5.4 To change a core bit
The drill spindle has a right-handed thread.
Always use a 32 mm open-ended spanner to hold against the drill spindle.
Never release the core bit with (hammer) blows since this will damage the core drill.
The core bit can be removed more easily if you apply a little waterproof grease to the drill spindle thread.

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6.0 Safety instructions
Important
Only use the core drill under supervision. Disconnect the mains plug and check
that the switch has been turned off,
- if you intend to leave the core drill unsupervised,
- for attachment and disconnection work,
-if the voltage drops (below 340 V),
-at uneven mains voltage (phase asymetrical) or interruption of a phase (phase failure),
- for adjustments or for fitting an accessory,
Switch off the machine if it stops for any reason. This will prevent its starting suddenly when it is not under
supervision.
Do not use the tool if
-part of the casing is missing or defective,
- If water drips out of the overflow hole, stop work and have the core drill inspected by an authorised
service contractor.
- After a fault do not switch on the machine again until the core bit can be turned easily.
- Check the area you wish to drill with a line detector to prevent drilling through electric cables, water
or gas lines, etc.
- the switch, lead or plug connector has suffered damage (conduct a visual inspection every day).
-Cooling water must not be allowed to ingress into the motor or the electrical components when
operating the core drill in any position.
Do not expose the tool to rain and use not in humidity or wet environment. Use a good lightning. Do not use
the tool near flammable fluids or gase air mixes.

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7.0 Servicing and care
Warning
Disconnect the mains plug before commencing any servicing or repair work.
You must have the core drill checked by an electrician after every repair (statu-
tory regulation pursuant to VBG4 since 1.1.1990).
7.1 Daily care
Ensure that no water is emitted from the overflow hole. This will cause gear damage and may adversely
affect the electrical safety of the core drill. If water is emitted, see assistance from an authorised service
outlet.
Visual inspection for damage to the switch, connection lead or plug connector
After completing the drilling work clean the core drill. Grease the core bit mounting thread. The ventilation
slits must always be clean and open. Ensure that during the cleaning process, no water gets into the core
drill.
Empty the cooling water in the drilling motor after the use. Open to this the ball cock completely and let the
cooling water go off. This is particulary very important because of freezing education in the winter months.
To maintain the seal, oil the drilling spindle as follows
- Disconnect the core drill from the water supply. Open the water connector shut-off cock, add
several drops of oil, close the shut-off cock, add several drops of oil to the overflow hole and
turn the machine briefly by hand.
7.2 After approx. 150 hours of use
After the first 150 hours of use, the gearbox oil must be changed.
7.3 Quarterly
Have the cable, switch and plug connectors inspected by a specialist (regulation pursuant to VBG4) and
document this inspection. Changing the gearbox oil will produce a considerably increase in the service life
of the gear.

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8.0 Speed adjustment dependent on the cutting speed
The values set out in the table are theoretical values and may be used to provide a rough guide for gear
changing. Since a whole range of other parameters also plays a major role in adjusting the speed, we
cannot offer any guarantee if the tool is damaged when using the values in the table. Drilling work for
which the speeds are outside the range of the core drill (values printed in italics), should only be com-
pleted with extreme care and by trained personnel.
34567[m/s]
70 750 1091 1364 1637 1910 3rd gear
80 716 955 1194 1432 1671 3rd gear
90 637 849 1061 1273 1485 3rd gear
100 573 750 955 1146 1337 3rd gear
110 521 694 868 1042 1215 3rd gear
120 477 637 796 955 1114 3rd gear
130 441 588 750 881 1028 3rd gear
140 430 546 682 819 955 3rd gear
150 382 509 637 750 891 3rd gear
160 358 477 597 716 836 3rd gear
170 337 449 562 674 786 3rd gear
180 318 430 531 637 750 3rd gear
190 302 402 503 603 704 2 or 3
200 286 382 477 573 668 2 or 3
210 273 364 455 546 637 2 or 3
220 260 347 430 521 608 2 or 3
230 249 332 415 498 581 2 or 3
240 239 318 398 477 557 2 or 3
250 229 306 382 458 535 2 or 3
260 220 294 367 430 514 2 or 3
270 212 283 354 424 495 2 or 3
280 205 273 341 409 477 2 or 3
290 198 263 329 395 461 2 or 3
300 191 255 318 382 430 2nd gear
320 179 239 298 358 418 1 or 2
340 169 225 281 337 393 1 or 2
360 160 212 265 318 371 1 or 2
380 151 201 251 302 352 1 or 2
400 143 191 239 286 334 1 or 2
420 136 182 227 273 318 1 or 2
440 130 174 217 260 304 1 or 2
460 125 166 208 249 291 1st gear
480 119 160 199 239 279 1st gear
500 115 153 191 229 267 1st gear
520 110 147 184 220 257 1st gear
550 104 139 174 208 243 1st gear
600 95 127 160 191 223 1st gear
700 82 109 136 160 191 1st gear
800 72 95 119 143 160 1st gear
Bit ca
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9.0 Warranty
In keeping with our terms of sale, we offer a warranty for six months from the date of sale. This refers to the
free repair of material and workmanship defects, which were verifiably caused before the sale.
An original purchase document must always be submitted in case of a warranty claim. It has to contain the
full address of the dealer, the date of purchase and the type designation of the product. The operating in-
structions of the particular product and the safety instructions must have been followed.
Damages resulting from operational faults cannot be acknowledged as warranty cases.
The products of the manufacturer have been developed and produced for specific applications. No war-
ranty claim is accepted in case of non-compliance with the due employment according to the operating in-
structions, in case of the employment for other purposes than originally intended or the employment of in-
adequate accessories.
The periodical maintenance and cleaning of the products according to the directions of the operating in-
structions is absolutely necessary. The intervention of third persons (opening the machine) renders any
warranty claim void.
Maintenance and cleaning operations cannot be claimed on the basis of warranty.
Make sure only original spare parts and original accessories are used. They are available at the authorized
specialized product dealer. If non-original parts are used, consequential damages and increased hazard
cannot be ruled out. The producer is not liable for such damages. Disassembled or partially disassembled
hand saws and those repaired with non-original parts are excluded from the warranty.
Certain components, such as carbon brushes, ball bearings, switches, power-supply lines, gaskets, etc.,
are exposed to usage dependent or to normal wear. These wearing parts are not object of this warranty.
Wearing parts are marked on the spare parts lists.

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10.0 General safety instructions
1. Read and follow these instructions before you use the tool. Keep these safety instructions in a safe
place.
2. Keep your workplace tidy. Untidiness in the workplace can cause accidents.
3. Protect yourself from electric shocks. Refer to the applicable regulations. Avoid physical contact with
earthed parts, such as pipes, heaters, furnaces and refrigerators.
4. Keep children away. Do not allow other people to touch the tool or cable, keep them away from
where you are working.
5. Keep your tools in a safe place. Unused tools should be kept in a dry, locked room out of the reach of
children.
6. Do not overload your tool. It will work better and more safely in the specified capacity range.
7. Use the correct tool. Do not use tools that are too weak or mounted tools for heavy work. Do not use
tools for purposes and work for which they have not been designed.
8. Wear suitable clothing. Do not wear excessively baggy clothing or jewellery, which may be caught by
moving parts. For working outdoors, we recommend the use of rubber gloves and sturdy shoes.
Wear a hairnet if you have long hair.
9. Use goggles. Use a breathing mask for work that generates dust.
10. Do not use the cable for any purpose other that that for which it is designed. Do not carry the tool by
the cable and do not use it to pull the plug out of the socket. Protect the cable from heat, oil and
sharp edges.
11. Check the connection lead and plug every time before you use the tool for signs of damage. If they
are damaged, have them replaced by a specialist. Always keep the connection lead away from the
working area of the machine.
12. Secure the workpiece. Use clamps or a vice to hold the workpiece. This will make it more secure that
if you hold it in your hand and will allow you to use both hands to control the machine.
13. Do not overstretch yourself. Avoid abnormal body positions. Ensure that you have a stable area on
which to stand and keep your balance at all times.
14. Look after your materials with care. Keep your tools sharp and clean so that they produce good safe
results. Check the plug and cable at regular intervals and have them replaced by a specialist if they
suffer any damage. Check the extension cable at regular intervals and replace damaged cables.
Keep the handles free of oil and grease.
15. Disconnect the mains plug from the supply when the tool is not in use and when changing the tool.
15. Do not leave a tool spanner on the tool. Before switching on the tool check that the wrench and set-
ting tools have been removed.
16. Avoid the machine starting when you do not intend it to. Do not carry a tool that is connected to the
mains supply with your finger on the switch. Ensure that the switch is turned off when you connect
the tool to the mains supply.
18. Electric tools outdoors and in wet areas: Mobile tools which are used outdoors should be connected
to the mains supply using a residual-current circuit breaker or the like for added safety. This is par-
ticularly important when working with freehand tools. If there is a water supply, you should use an
isolation transformer and a voltage supply of 115 V; please specify in your order.
19. For outdoors work, only use extension cables, which are approved for this purpose and marked ac-
cordingly.
20. Be vigilant at all times. Watch your work. Proceed sensibly. Do not use the tool if you are not con-
centrating fully on what you are doing.
21. Important:
Safety equipment (such as overcurrent protection devices, undervoltage trips, safety couplings etc.)
are tools but do not offer guaranteed safety. As a responsible manufacturer we tailor these tools to
each other so that they offer the best possible protection. But without the care and caution of the use,
these tools may even cause damage it they are not used properly. Have the slip couplings, in par-
ticular, checked during the quarterly inspection to ensure that it is correctly adjusted and functions
properly. This inspection should be conducted by the manufacturer or an authorised service outlet
and documented.

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22. Check the machine every day for signs of damage, conduct a visual inspection:
Before reusing the tool, carefully check the safety equipment or slightly damaged parts to ensure that
they offer perfect and proper function. Check that all moving parts function correctly, that they do not
jam and that none of the parts are damaged. All parts must be correctly fitted and satisfy all the con-
ditions to ensure the perfect operation of the tool. Damaged safety equipment and parts must be re-
paired or replaced properly by a specialist service contractor. Do not use any tools, which cannot be
switched on and off using the switch. Pay particular attention to ensuring electrical safety: Cables?
Plugs? Switches? Do all the components satisfy safety regulations?
23. Repairs may only be completed by trained personnel. Before being used for the first time and after all
repair work, the safety of electric tools must be checked by an electrician pursuant to VBG 4, § 5.
This inspection must also be conducted and documented at regular intervals – at least once per year.
24. Please note that as the operator you are responsible for complying with any additional regulations.
For example if electric tools are used in a wet and/or damp environment, the regulations of the
”Stone and Earth” Professional Association must be satisfied.
25. Electrical safety and fire safety: We now also recommend the additional safety and fire safety for all
out tools, as set out in the new version of VDE 0100 which can be achieved by using low cost resid-
ual current-operated circuit-breakers or DI/PRCD switches.

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11.0 Spare parts list
11.1 Motor complete

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Item Art. No. Description No.
1 300993 Motor compl. 1
2 200675 Motor casing 1
3 401201 Stoppers 1
4 801375 Stator 1
5 401200 Thick hull 2
6 801384 O Ring 4 **
7 300996 Rotor compl. 1
8 800757 Grooved ball bearings 1 **
9 900202 Spring washer 1 **
10 900679 Grooved ball bearings 1 **
11 200676 Intermediate cover 1
12 900678 Spring washer 1 **
11 900199 Spring washer 1 **
13 300958 Flat sealing 2 **
15 900682 Shaft sealing ring 1 **
16 800760 Spring washer 1 **
14 900715 Shaft sealing ring 2 **
15 900716 Spring ring 1 **
16 900156 Needle sleeve 1 **
17 900680 Needle sleeve 2 **
18 800083 O ring 1 **
19 800027 Sealing ring 2 **
20 800026 Sealing screw 2
24 200677 Bearing cap 1
26 800764 Ball bearing compensating disc 1
27 401199 Threaded rod 6
28 800077 Spring washer 6
29 900779 Hexagon domed cap nut 6
30 300074 Water connection compl.. 1 **
31 800733 Hose compl. 1
32 800028 Sealing ring 2
33 800023 Ball cock compl. 1
34 800299 Sealing ring 1
35 800020 Nipple 1
36 800040 O ring 1
37 801385 Flat sealing 1 **
38 801382 Toggle switch 1
39 801386 Button head socket screw 2
42 900251 Hexagon nut 2
43 801383 Cable grommet 1
41 801466 Connection cable, compl. 1 **
42 900164 Plug, 6h, phase reversal, 16 A 1
43 800037 Strain relief 1
44 801748 RC – Modul 1
45 801476 Start-up current limiter 1
46 800076 Locking washer 2
47 900412 Slotted pan head screw 2
44 900229 Washer 1
49 401508 Seal 1 **
47 300997 Plate 1
51 802107 Handle 1
52 902090 Hexagon socket countersunk head screw 2
53 801232 Button head socket screw 5
54 801699 Button head socket screw 1
Wearing parts **

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11.2 Gear complete

19
Item Art. No. Description No.
1 200678 Gear, complete 1
2 100067 Gear casing 1
3 900051 Grooved ball bearings 1 **
4 900495 Grooved ball bearings 1 **
5 401342 Interim washer 1
6 401343 Sleeve 1
7 900669 Axial needle rim 2 **
8 401345 Interim washer 1
9 900671 Needle bearing 1 **
10 900672 Rotor disc 1
11 300670 Support disc 1
12 400011 Brake disc 1 **
13 401538 Floor wheel, complete 1
14 301227 Floor wheel 1
15 401416 Bearing sleeve 1 **
16 400048 Gear change shaft, complete 1
17 800097 O ring 1 **
18 400096 Gear change lever, complete 1
19 800075 Locking disc 1
20 900354 Allen bolt 1
21 301239 Drill spindle, complete 1
22 401415 Brake disc 3 **
23 401414 Support disc I 1
24 401413 Support disc O 1
25 900078 Cylindrical pin 2
26 401412 Bridge sleeve 1
27 900663 Disc spring 9
28 900662 Hexagonal nut 1
29 900500 Sealing ring 1 **
30 900498 Sealing screw 1
31 801059 O ring 1 **
32 401202 Connection ring 1
33 900673 Shaft seal 1 **
34 800760 Locking ring 1 **
35 900332 Allen bolt 3
36 900674 Bush 1
37 300671 Pump wheel 1
37 300666 Pinion shaft 1
39 400851 Loose wheel 1, complete 1
40 300667 Loose wheel 1 1
41 400082 Bearing sleeve 1 1 **
42 400129 Adjusting washer 1
43 800080 Spring ring 1 **
44 900504 Adjusting spring 1
45 800165 Bridge spring 1
46 900014 Ball 2
47 300679 Gear change wheel 1
48 400852 Loose wheel 2, complete 1
49 300669 Loose wheel 2 1
50 400083 Bearing sleeve 2 1 **
51 900163 Adjusting washer 1
52 900209 Locking ring 1 **
53 900503 Adjusting washer 1
54 900681 Bush 2
55 300217 Reduction gear shaft 1
56 900127 Adjusting spring 1
57 300995 Reduction gear wheel 1
58 800077 Locking washer 3
59 900320 Allen bolt 3
60 801019 Gear lubricant oil 0,3 l 1 **
Wearing parts **

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11.3 Connection cable and accessories