KERN-DEUDIAM KDS-XXL-R User manual

Operating manual
Core drilling system (Drill stand/Drill motor)
KDS-XXL-R & DK 32 (S)

Manual
03/2015
0. Introduction
You bought a drilling system of KERN-
DEUDIAM firm.
We thank you for purchase and we wish you
successful and long-term work. We are always
open for your questions and offers.
Attention:
At the installation of system it is necessary to
observe the rules EG-RL 2006/42/EG.
1. Content
0. Introduction
1. Content
2. General instructions
3. System description
4. Technical data
5. Instructions of safety
6. First steps of operation
7. Management of system
8. Maintenance
9. Warranty
10. EU Declaration of Conformity
2. General instructions
2.1 Important terms
Danger: possible situation which can lead to
heavy traumas or even death of the service
personnel or the third parties.
Caution: possible situation which can lead to
light traumas or to property damage.
2.2 Explanation of symbols
Forbidding symbols
General ban
The entrance is prohibited for
strangers
It is forbidden to touch
Warning symbols
General danger
High voltage
Hot surface
Symbols of safety measures
Use protective glasses
Use protection of hearing
Use a protective helmet
Use safety shoes
Use protective gloves
1
1
1
2
5
7
8
8
9
11
12

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2.3 Your drill stand
On the plate of your drill stand are written the
serial number and type of machine.
Please write in these data in the following
frames.
Type:
Serial number
Please, report these data at your inquiries.
3. System description
3.1.1 Use of drill stand
The drill stand is designed for "dry" and "wet"
drilling in mineral materials by means of diamond
crowns.
The drill stand is suitable for work with electric,
hydraulic and pneumatic drilling motors with
power up to 3.5 kW.
The drill stand has to be reliably fixed on a
material surface by means of the expansion bolt
(anchor), the vacuum pump or a fast-sliding
support.
Strictly observe the regulation of the service and
the maintenance, described in this manual.
Observe also instructions on safety, installation
and operation of the used additional equipment
and the diamond tools.
In order to avoid traumas use only the original
equipment and the diamond tool of KERN-
DEUDIAM.
3.1.2 Use of motor
The motor is used according to data on the plate
on the motor case. When using the special
machines are to observe additional requirements
specified in order confirmation.
Drilling motors belong to the class of protection
of "I" that ensures safety through use of FI-
/PRCD switches.
When using the corresponding crowns possibly
drilling of openings in various materials:
- Concrete
(including with strong reinforcing)
- Sandstone and limestone
- Various construction materials for massive
walls
- Asphalt coverings.
The drill motors belong to category II that means
that they have to be used with drill stands (DIN
57100 or VDE 0100).
The drill stand should have:
- Protection of reverse motion
- Adjustability for water drainage.
The motor has to be connected:
- via the personal protective switch (FI or
PRCD) directly or
- through the coded (1h) plug with a
protective box (IP44) or with the FI switch
to a network of 230 V.
3.2 Consequences due to false use
When using a drill stand incorrectly, there is an
increased health hazard for the service
personnel and for the third parties.
Use of the drilling motor with power more than
3.5 kW belongs to it.
It can lead to breakage of a motor plate or other
parts.
Manipulations or changes of a drill stand are
forbidden.
For an adjustment of a drill stand don't use a
percussion instrument (hammer). That can lead
to the damage of drill stand.
3.3 Delivery set:
Drill stand KDS-XXL-R
Drill motor DK 32
Manual.

Manual
03/2015
4. Technical data
Type: KDS-XXL-R
Max. drill diameter: 400 mm
Max. drill bit length: 570 mm
Max. power of motor: 3.5 kW
Drilling with angle: up to 45º
Weight: 19 kg.
4.1 Noise and Vibration (EN 50144)
Noise level: 86 / 99 dB.
Vibration: 2.5 м/s².
Attention: above-mentioned data were
established in laboratory. Depending on
working conditions the specified data
can strongly differ.
1. head plate
2. stand
3. carriage
4. handle
5. support
6.foot
7.regulating screw
8.motor
1
2
3
4
5
6
7
8
Technical data
Type
DK 32
DK 32 S
Nominal Power
3200
3200
W
Output Power
2300
2300
W
Nominal Speed (Full Load)
230/480/720
300/590/930
1/min
Weight
11.9
11.9
kg
Tool fixture
1 1/4" UNC
1 1/4" UNC
Drilling Ø in concrete
55 - 350
35 - 250
mm

Manual
03/2015
5. Instructions of safety
5.1 Basic terms
Before mounting the motor on a
support and beginning the work,
please attentively read the safety
instructions and keep them for further
reference.
5.2 Organization of workplace
The drill work has to be approved by the
supervisor of the building site. Carrying out this
work can affect building statics considerably.
The workplace has to be constantly well-lit. Take
care of good ventilation of the workplace. Keep
thr workplace clean and tidy. The disorder on a
workplace can lead to accidents. In a work zone
there shouldn't be any foreign objects, which
could lead to injuries of the service personnel or
the third parties. In a work zone there shouldn't
be any foreign persons, especially children.
Make sure that neither the third parties nor any
surrounding objects won't suffer in case any
parts of the drill system come off.
Take measures that the core which is forming as
a result of drilling, doesn’t fall uncontrollably and
injures the third parties or objects. The openings
formed as a result of drilling have to be
accurately designated to prevent people falling.
Don't touch the drilling (diamond) tool.
Use means of personal safety:
At formation of dust (at "dry" drilling) use a
protective respiratory mask.
Don't wear wide clothes and jewellery, because
they can get into moving parts of the drilling
system. In case you have long hair, use a
special hair-net. Make sure that your working
footwear doesn't slide.
Lay electro cables and water hoses to avoid the
danger of people falling.
Hold all connections (hoses, cables) as far away
from rotating parts as possible.
ATTENTION: Make sure that in places of drilling
no hidden electro - water - and gas-connections
are present, for example by means of the special
metal detector. Don't work with a drill stand on a
step-ladder.
5.3 General measures of safety
Use the original additional KERN-
DEUDIAM equipment which is
described in this manual. The use
of equipment from other
manufacturers can be dangerous
for you.
A hand crank has to be free from oil and fat.
Avoid any overloads of your system. Work in the
set modes - it is economically and safe.
Store the parts of the system which are not used
in a safe place. This room shouldn't be
accessible to the third parties, especially
children.
Keep your tool clean and in good working order.
That will positively affect its efficiency. Before
each use of the system, check that it isn't
damaged and that all functions of the system are
in order. In case any damaged parts are
detected, safely replace them by a new one.
ATTENTION: Don't use the damaged tool!
Have the repair of the tool made only by KERN-
DEUDIAM enterprise or by its authorized
partners. In case of a non-professional repair of
the equipment, your life can be in danger. Avoid
slime hit your skin. Materials hazardous to health
(for example, asbestos) are forbidden to drill.
5.3.1 Mechanical part
Follow the instructions for
maintenance. Observe the rules of
lubrication and replacement of the
tool.
.
Make sure that the motor is safely and correctly
fixed on a drill stand.
Keep a distance to the rotating
drilling crown.
During operation with a drill bit or
during its changeover etc., make
sure, that the plug has been pulled
out from the socket.
5.3.2 Electrical part
When using electrical instruments
there is a danger of electrical
shock. Avoid contact with the
grounded objects, such as pipes,
radiators, furnaces, refrigerators, etc.
Make sure that the voltage of the socket
corresponds to the data given on the table on the
plate of the drilling motor.

Manual
03/2015
Check the electrical connections after each use
of the system for damages and address a
professional electrician in case of damages.
Electrical instruments shall be checked by the
professional electrician every year.
If the cable or its extender has been damaged
during operation, don't touch it. In this case
directly pull the plug from the socket.
The damaged electrical switches shall be
replaced by the professional electrician. The
operation of motors with the damaged switches
is forbidden! The power cable of the motor
shouldn't be used for carrying the motor.
Protect a cable from high temperatures and
sharp edges.
Use only the allowed and especially designated
extenders of cables.
Pay attention that your extender corresponds to
the power of the drilling motor.
Before putting the system into operation,
check the compliance of the voltage with the
socket and the frequency with the data
specified on the table. Tolerances: ± 5% for
voltage and ± 2% for frequency. Qualified
personnel only is authorized to carry out
repair work.
It is especially important to observe
-the technical operation instructions
-the rules of prevention of injury
-the appropriate use of the tool
-the use of personal safety gear.
5.3.3 Thermal part
Used diamond crowns can heat up
very strongly. Therefore use
protective gloves in case a
diamond crown needs to be
changed.
5.4 Requirements to the operator
The drill stand is designed for the
use by a professional operator.
This operator shall get special
permission from the owner of a
drill stand to carry out the operation. Operators
of the machine have to be informed about
possible dangers.
Repair shall be carried out only by specialists of
the KERN-DEUDIAM enterprise or its official
representatives.
Operation while drilling requires big
concentration. If you are overstrained or you are
under the influence of medication or narcotic
substances, operation on drilling is strictly
forbidden. In this case there is a big danger not
only for the operator, but also for the third
parties.
5.5 Means of safety
The operator and the people being in his direct
vicinity are obliged to wear protective glasses,
hearing protection, a helmet, safety shoes and
safety gloves.
6. First steps of operation
6.1 Motor mounting
The motor has to be fixed on a drill stand by
means of a motor plate. It allows to fix the
majority of motors by means of four screws. The
motor plate allows fast fastening of the motor on
a drill stand. For this purpose the motor plate is
set on a carriage.
The drill stand is designed only for electric,
hydraulic and pneumatic motors with a power up
to 3.5 kW.
The scheme of openings for motor
installation
Make sure that the voltage from the socket
corresponds to the voltage specified on the table
of your machine.
Fix the motor and the water collector on a drill
stand, using the lock on the carriage against
return motion. The carriage shall move on a drill
stand freely, but without play.
Set the crown and select the appropriate rotating
speed.
Connect the water supply.
Attention: maximum pressure: 3 bars.

Manual
03/2015
During the drilling work pay attention to have
enough water for cooling. Use only clear water
from a water supply system, by no means –dirty
water or sewage.
Speed switching
Attention:
Never use force during
switching speed. Switching is
authorized only in case of a full
stop of the machine.
If speed switches hard, it is recommended to
turn motor shaft a little by hand until the speed
switch can be switched. Use of additional tools
(hammer) for switching of speeds is strictly
forbidden!
Sliding sleeve (coupling)
If the protective sleeve works, it means that the
motor is overloaded twice! The sleeve doesn't
guarantee absolute protection, it is necessary
therefore to drill with extra care. To spare a
sleeve to make it last longer, sliding should not
exceed 2 seconds. Only the professional
mechanic can set up a sleeve.
Diamond drill bits
You can use any drill bits with a UNC 1 ¼ ".
connection. When using other connections an
adapter should be used.
For a longer life of the motor it is recommended
to use crowns without deformations.
Attention:
Use of inappropriate tools is
life-threatening!
Change of a diamond drill bit
The shaft of the motor has a right hand thread.
Against turning of a shaft use SW32 key. Don't
use hammer shocks to remove the drill bit from a
shaft as it can damage the motor.
6.2 Fastening of drill stand
6.2.1 Expansion bolt (anchor)
For our range of drill stands: KDS-150, KDS-
200, KF-250, KDS-XXL, BS-620, XXXL-600 we
recommend our checked anchor. For this
purpose contact us or our official representative.
In addition to the reliable anchor you should
understand the correct drilling and mounting
technique. The errors made in case of mounting
the system, lead to a reduction of the abilities of
the system. In extreme cases it can happen that
your anchor cannot cope with its task!
Attention:
The opening for an anchor shall be drilled at
a 90° angle to a steel foot of drill stand.
Good cleaning of an opening is very
important for the bearing capacity of the
anchor.
The opening should not be done through
reinforcement.
Length of an opening shall correspond to
anchor’s length.
Pay attention to sufficient material thickness
in which the anchor is fastened.
Use the anchor with an inside diameter of a
thread at least 12 mm
Check the if the drill stand is securely
fastening by hand.
Observe the rules of operation provided on a
building site.
Fastening of drill stand by means of the
anchor
Calculation of load for the anchor
Example:
a
b
l
F2
F1

Manual
03/2015
Pressure upon a drill bit : up to 250 N/cm²
(approx. 25 Kp/cm²)
The active surface of drilling by segments
Ø 107 mm : 7,5 cm²
Ø 162 mm : 11,5 cm²
The maximum pressure (F1)
Ø 107 mm : 1.850 N (approx. 190 Kp)
Ø 162 mm : 2.800 N (approx. 290 Kp)
Opposing force F F2
Calculation F2 : F2 x b = F1 x l
F2 = F1 x (1 + a /b )
Conclusion: F > F2иF2 > F1
6.2.2 Fastening by means of the vacuum
pump
For our range of drill stands: KDS-150 and KDS-
200
we recommend our checked vacuum pumps.
For this purpose contact us or our official
representative.
In addition to the reliable pump you shall
understand drilling and mounting technique. In
case the system is not correctly mounted, this
may lead to a reduction of the abilities of the
system.
In extreme cases it can lead to a lift-off of a steel
foot of a drill stand from a surface of a material
in which it is fixed!
Fastening by means of vacuum:
Pay attention that when the vacuum pump is
being switched off, the drill stand can fall
from the surface on which it is fixed. In this
case there is an increased danger of injury!
Drilling "over the head" with use of the
vacuum pump is forbidden.
Begin drilling only if the low pressure
reaches 0.7 bars.
Check reliability of fastening of system with
the help of a hand.
6.2.3 Other options of fastening
Fast-extensible support
Special belt

Manual
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7. Management of system
7.1 Drilling with angle
For drilling with angle loosen the bolts (on the
picture). After having set up the angle tighten
bolts securely.
7.2 Drilling while using the water-collecting
ring
In some cases (for example for safety) the use of
a water-collecting ring with the appropriate fixing
is recommended. This additional equipment can
be acquired separately.
8. Maintenance
In addition to this instruction use operating
instructions for motors, vacuum pumps, etc.
8.1 Installation of a carriage
If a carriage moves on a stand with big effort
or if it has a big play, it is necessary to make
an adjustment of the carriage by means of
special screws.
Carriage shall move parallelly in
relation to a stand.
For this purpose it is necessary:
Loosen the screws (pos. 414).
Regulate screws (pos. 416) so, that a hand
crank can be easily turned and a carriage moved
parallelly along a stand.
Fix screws (pos. 414).
In case of wear of sliders (pos. 415) they need to
be replaced.
8.2 Maintenance
Clean the drill stand (but do not lubricate)
Check adjustment of the carriage
8.3 Technical care
Attention:
Before execution of
maintenance draw out the plug
from the power net.
8.3.1 A daily check
Check the motor for possible damages of the
switch, the cable and the plug.
After operation you shall clean the motor.
Lubricate with the motor shaft. Holes for air-input
shall be always open. Pay attention that during
cleaning no water will get to the motor.
8.3.2 After 150 working hours
After 150 working hours motor oil needs to be
replaced.
8.3.3 After 250 working hours
Carbon brushes shall be checked by the
electrician and if necessary be replaced.
Use only original spare parts.
8.3.4 Once in three months

Manual
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The cable, the switch and the plug shall be
checked by the electrician (VBG4) and be
documented.
9. Warranty
The available technical information of this
manual can be changed without warning the
user.
KERN-DEUDIAM doesn't have any
responsibility concerning this manual.
In addition to this the KERN-DEUDIAM
firm doesn't have responsibility for
errors in the operation manual and in
the specification of spare parts or for
the damage connected to delivery,
execution of services or application of
materials.
The right to warranty service disappears in case
the machine has been changed, non-original
parts have been used or the machine has been
incorrectly operated.
KERN-DEUDIAM doesn't have any responsibility
for machines used by a third party or when the
machine has not been regularly maintained.
Address:
KERN DEUDIAM Diamantwerkzeuge und
Maschinen GmbH
Industriestrasse 24
D-33161 Hövelhof
Germany
Tel.: [phone]
Fax: [phone]
[e-mail]
www.kern-deudiam.de

Manual
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Manual
03/2015
10. EU Declaration of Conformity
in accordance with EU machine directive 2006/42/EG
We herewith declare that the following machine complies with the pertinent basic safety and health
requirements of the EU machine directive as regards concept, design and the commercially
available version. This declaration becomes null and avoid when any changes are made to the
machine without our consultation and approval.
Producer: KERN DEUDIAM Diamantwerkzeuge und Maschinen
GmbH
Industriestrasse 24, D-33161 Hövelhof, Germany
Designation of the machine: Core drilling system
Machine type: KDS-X XL-R & DK 32 (S)
Pertinent EU directives: EU Machine Directive 2006/42/EG
EU Low Voltage Directive 2006/95/EG
EU Directive Electromagnetic Compatibility 2004/108/EG
Applied standardised
standards, particularly: EN 55014, EN 50082-2, EN 61000-3-2, EN 61000-3-3,
EN12348, DK22 zusätzlich IEC 1029-1 und IEC 1029-2-6
EG-Konformitätserklärung
im Sinne der EG-Maschinenrichtlinie 2006/42/EG
Hiermit erklären wir, dass die nachfolgend bezeichnete Maschine aufgrund ihrer Konzipierung und
Bauart sowie in der von uns in Verkehr gebrachten Ausführung den einschlägigen grundlegenden
Sicherheits- und Gesundheitsanforderungen der EG-Maschinenrichtlinie entspricht. Bei einer nicht
mit uns abgestimmten Änderung der Maschine verliert diese Erklärung ihre Gültigkeit.
Hersteller: KERN DEUDIAM Diamantwerkzeuge und Maschinen
GmbH
Industriestrasse 24, D-33161 Hövelhof, Germany
Bezeichnung der Maschine: Bohrsystem
Maschinentyp: KDS-XXL-R & DK 32 (S)
Einschlägige EG-Richtlinien: EG-Maschinenrichtlinie 2006/42/EG
EG-Niederspannungsrichtlinie 2006/95/EG
EG-Richtlinie Elektromagnetische Verträglichkeit 2004/108/EG
Angewandte harmonisierte
Normen, insbesondere: EN 55014, EN 50082-2, EN 61000-3-2, EN 61000-3-3,
EN 12348, DK22 in addition IEC 1029-1 and IEC 1029-2-6
Datum / Hersteller-Unterschrift: 21.04.14
Date / Manufacturer signature:
Angaben zum Unterzeichner: Geschäftsführer
Information about the signatory: General Manager

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List of spare parts

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Stand (Säule)
pos.
article
article-nr.
quant.
remark
100a
Stahlgrundplatte
47874
1
113
6kt-Schraube M12 x 120
47945
1
114
Spannbuchse
47847
10
115
Mutter M12
47946
4
116
U-Scheibe
47947
6
118
Schild
47969
1
119
6kt- Schraube
14157
4
120
Hutmutter
14922
4
121
Gelenkstück
49454
4
optional
201
Spannklotz
47873
4
202
6kt-Schraube M12 x 100
47948
2
203
6kt-Schraube M12 x 40
47949
2
204
Abstützung
47841
2
205
6kt-Schraube M12 x 110
47951
1
206
Tragegriff
47876
1
207
Inbusschr. mit niedrigem Kopf M6x16
47952
2
301
Bohrsäule für Gleiter
47844
1
XXL
301.1
Bohrsäule für Rollen
49064
1
303
Inbusschraube M8 x 12
47954
2
304
Klotz
47860
1
305
Kopfplatte
47861
1
306
Inbusschraube M6 x 10
47955
2
307
Inbusschraube M8 x 20
47956
2
308
Führungsschiene
48808
2
309
Senk- Niet
48939
16
310
Inbusschraube
13951
2

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Carriage (Vorschub)
Pos.
Bezeichnung
Artikelnr.
Anz.
Bemerkung
400.1
Vorschubeinheit Rollen kompl.
49065
1
401
Vorschubschlitten
47877
1
402.1
Vorschubwelle vierkant
48835
1
403
Zylinderstift 5 x 28 m6
47879
1
405
Nadellager RNA 4902
47866
2
406
Ring
47870
1
407
Schmiernippel D1 M6
47872
2
408
Abdeckscheibe
47840
1
409
Sicherungsring 15mm
47958
1
410
Buchse 1
47845
1
411
Excenterwelle
47851
1
412
Druckstück M8
47849
1
413
Buchse 2
47846
1
414
Gewindestift M 8 x 12
47884
4
415
Gleitstück
47854
4
XXL
416
Justierschraube für Gleiter
47858
4
XXL
418
Rastbolzen
47869
1
419
PE-Kugel
47868
4
420
Arretierschraube
47843
2
421
Justierschraube für Rollen
48811
4
422
Druckstück
48813
4
423
Führungsrolle
48815
4
424
Druckstück M5
14248
2
450
Ringmaulschlüssel SW 19
47959
1
500.1
Drehkreuz kompl.
19513
1
506
Nabe
16394
1
507
Griffstange
16147
2
500.2
Drehstange kompl.
49455
1
508
Schwenknabe
49456
1
509
Stange
49457
1
510
Schaltknopf
49458
2
511
Druckfeder
49459
1
512
Scheibe
49460
600
Motorplatte, kompl.
48555
1
601
Motorplatte
47865
1
602
Achse
47842
1
603
Buchse
47848
1

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Accessories
Vakuum-Pumpe (80l/min)
45451
Vakuumschlauch 3,0m mit Kupplungen
20574
Vakuumsatz Typ LD-Deltadrill XXL
48038
Wassersammelringhalter
48136
Wassersammelring kpl. ø 130 mm
48134
Wassersammelring kpl. ø 250 mm
48135
Dichtkappe ø 130 mm
48103
Dichtkappe ø 250 mm
48104
Rädersatz
48127
Distanzstück (erweitert um 75 mm)
48117
Befestigungssatz XXL
48278
700
Vorschubgetriebe, kompl.
48485
1
701
Antriebswelle vierkant
49003
1
702
Antriebsritzel
48488
1
703
Zahnrad
48895
1
704
Deckel
48487
1
705
Gehäuse
48486
1
706
Spannstift
11578
1
707
Druckstück
14248
1
708
Nadellager
48491
1
709
Rillenkugellager
49074
1
710
Rillenkugellager
15142
1
711
Stellring
42321
1
712
Zylinderschraube
13952
2
713
Zylinderschraube
13976
1
714
Stützscheibe
14281
1
715
Zylinderstift
11535
2
716
Senkkopfschraube
14110
1
717
Spannstift
11564
1
718
Kegelschmiernippel
14262
1

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