BDB 802 - Drill Baier - Free user manual and instructions

USER MANUAL BDB 802 Baier

Two black-and-white warning symbols: a triangular warning triangle with an exclamation mark and a person reading a book (no text or numbers present)

Two BAIER electric drillers with attached hoses and connectors, shown from different angles (no visible text or symbols on the devices themselves)

Translation of the Original Instruction Manual –

Wet Diamond Drill

Technical diagram of a power drill with numbered parts for identification

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Technical diagram of a mechanical device with numbered parts labeled 1 through 7

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Technical diagram of three labeled mechanical components with numbered parts

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ON RESET OFF TEST 1 2 3

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Technical diagram of a mechanical assembly with labeled parts 1 and 2

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BDB 802

Technical line drawing of a BAER electric drill press with labeled components (no text or symbols beyond branding)

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BDB 802B

Line drawing of a mechanical power drill with labeled component (no text or symbols)

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BDB 802

Technical diagram of a mechanical assembly with labeled components, showing a drill bit and shaft assembly.

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BDB 802B

Technical diagram showing a drill bit being inserted into a motor, with labeled parts 1 and 2.

11 BDB 802 6 1 2 3 BAIER 5 4

12 BDB 802B 1 2 3

13 1 2

14 BDB 802 BAISR

BDB 802 BAJER 1

16 1 2 3 4

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Technical diagram of a mechanical clamp or lifting device with labeled parts 1 and 2

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Diagram of a mechanical tool interacting with a surface, showing motion direction (no text or symbols)

Inhalt

13 Gabelschlüssel SW22/24

14 Gabelschlüssel SW27

8 Gabelschlüssel SW22/24

9 Gabelschlüssel SW27

▶ Wenig Wasser: Position 1.
▶ Viel Wasser: Position 2.

1 About this instruction manual ..... 28

1.1 Important information 28

1.2 Symbols used in the instruction manual 28

2 General safety instructions for power tools 28

2.1 Workplace safety 28

2.2 Electrical safety 29

2.3 Safety of people 29

2.4 Using and handling the power tool ..... 29

2.5 Service 30

2.6 Safety instructions for wet diamond drills 30

2.6.1 Operating personnel requirements ..... 30

2.6.2 Safety instructions for all work 30

2.6.3 Workplace safety 30

2.6.4 Electrical safety 31

2.6.5 Safety of people 31

2.6.6 Hazards when using and handling the power tool 32

2.6.7 Safety instructions for using long drill bits 33

2.6.8 Service / Maintenance / Repair 33

2.6.9 Explanation of the pictograms on the machine 34

3 Technical Characteristics 35

3.1 Technical specifications 35

3.2 EU Declaration of Conformity 36

3.3 Machine characteristics 36

3.4 Machine parts and controls 36

3.5 Intended use 37

4 Before Starting Work 37

5 Operation and Control 38

5.1 Fitting or changing the wet diamond core drill bit 38

5.2 Connect water supply 39

5.2.1 BDB 802 39

5.2.2 BDB 802B 39

5.3 Using the BAIER centring guide BDB 802 with suction holder .... 39

5.4 Switching on the wet diamond drill and drilling 40

5.5 Ending the drilling process 41

5.5.1 Through-hole 41

5.5.2 Non through-hole (blind hole) 41

6 Cleaning 42

7 Maintenance 42

8 Handling wet diamond core drill bits 42

9 Disposal 43

10 Tools and Accessories 43

11 Scope of Supply 43

12 Warranty 44

Imprint

Version V05/2020-11

Copyright:

Maschinenfabrik

OTTO BAIER GmbH

Heckenwiesen 26

71679 Asperg

Germany

It is prohibited to forward or reproduce this document or to exploit and disclose its contents, unless expressly permitted. Any infringements will result in liability to pay compensation for damages. All rights reserved in case of patent, utility model or design registration.

This instruction manual has been prepared with the greatest possible care. Nonetheless, OTTO BAI-ER GmbH does not accept any liability whatsoever for possible errors in this instruction manual and their consequences. Equally, no liability whatsoever is accepted for direct or consequential damage or losses resulting from improper use of the machine.

The national health and safety regulations and the requirements of this instruction manual are to be observed when using the machine.

All product names and brand names used are the property of the holder and are not explicitly marked as such.

Subject to change without notice.

1 About this instruction manual

This instruction manual contains all important information necessary for safe handling of the wet diamond drill.

The wet diamond drill is also referred to as the "tool" or "machine" in this instruction manual.

Figure references

References to figures, which are located at the beginning of the instruction manual are displayed in the text with this symbol 1 (here, for example, the reference is to Figure number 1).

1.1 Important information

Read the instruction manual

Before starting any work with or on the tool, this instruction manual, the safety instructions and the warnings must be read through carefully and observed.

Always keep this instruction manual together with the equipment.

An approved half-mask with filter must be worn!

1.2 Symbols used in the instruction manual

DANGER

"DANGER" indicates an imminent hazard, which will result in immediate death or severe physical injuries.

→ This arrow indicates appropriate measures to avert the pending hazard.

WARNING

"WARNING" indicates an imminent hazard, which could result in death or severe physical injuries.

→ This arrow indicates appropriate measures to avert the pending hazard.

CAUTION

"CAUTION" indicates an imminent hazard, which can result in minor or moderate physical injuries.

→ This arrow indicates appropriate measures to avert the pending hazard.

NOTE

"NOTE" indicates possible property damage, gives use recommendations and helpful tips.

2 General safety instructions for power tools

WARNING

Read all safety instructions and precautions marked with the symbol.

Failure to observe the safety instructions and precautions can result in electric shock, fire and / or serious injuries.

Keep all safety instructions and precautions for future reference.

The term "power tool" used in the safety instructions refers to mains-operated power tools (with mains power lead) and battery-operated power tools (without mains power cable).

2.1 Workplace safety

a) Keep your work area clean and well illuminated.
Untidiness and unlit work areas can result in accidents.
b) Never use the power tool in potentially explosive environments containing flammable liquids, gases or dusts.
Power tools generate sparks which can ignite dust or vapours.
c) Keep children and other persons away from the power tool during use.
A moment's distraction can cause you to lose control of the machine.

2.2 Electrical safety

a) The connecting plug of the power tool must fit in the plug socket. The plug must not be modified in any way. Do not use adapter plugs in conjunction with power tools with protective earth conductor.
Unmodified plugs and properly fitting plug sockets reduce the risk of electric shock.
b) Avoid physical contact with earthed surfaces such as pipes, heaters, cookers and refrigerators.
There is an increased risk of an electric shock if your body is earthed.
c) Keep power tools away from rain and moisture.
The ingress of water into a power tool increases the risk of an electric shock.
d) Do misuse the cable in any way by using it to carry or hang up the power tool or to pull the plug out of the socket. Keep the cable away from heat, oil, sharp edges and moving machine parts.
Damaged or kinked cables increase the risk of an electric shock.
e) When working with a power tool outdoors, use only extension leads that are suitable for outdoor use.
Use of an extension lead suitable for outdoor use reduces the risk of electric shock.
f) If the use of the power tool in a damp environment is unavoidable, use a residual-current circuit breaker.
Use of a residual-current circuit breaker (RCCB with 10 mA maximum tripping current) reduces the risk of an electric shock.

2.3 Safety of people

a) Always work carefully, attentively and sensibly when using a power tool. Do not use the power tools if you are tired or are under the influence of drugs, alcohol or medication.
A moment of inattention while using the power tool can result in serious injuries.
b) Wear personal protective equipment and always wear goggles.
The wearing of personal protective equipment, such as dust mask, non-slip safety shoes, helmet or ear protectors, depending on the type and application of the power tools, reduces the risk of injuries.
c) Avoid accidental switching on of the power tool. Ensure that the power tool is switched off before connecting it to the mains pow-

er supply and/or connecting the battery and before picking up or carrying the tool.

If you have your finger on the switch when carrying the power tool or you connect the tool to the power supply when it is switched on, this can lead to accidents.

d) Remove the adjusting tools or wrenches before switching on the power tool.

A tool or wrench in a rotating part of the tool can result in injuries.

e) Avoid abnormal postures when working. Ensure you are standing firmly and maintain your balance at all times.

This will enable you to control the power tool better in unexpected situations.

f) Wear suitable clothing. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts.

Loose clothing, jewellery and long hair can get caught in moving parts.

g) If dust extractor and collection equipment can be mounted, they must be connected and used correctly.

Use of a dust extraction system can reduce the hazards caused by dust.

h) Don't be lulled into a false sense of safety and do not break the safety rules for power tools even if, after much use, you are familiar with the power tool.

Careless action can cause severe injuries within fractions of a second.

2.4 Using and handling the power tool

a) Do not overload the power tool. Use the intended power tool for your work.
You work better and safer within the given power range if you use the suitable power tool.

b) Do not use a power tool whose switch is defective.

A power tool which can no longer be switched on or off is dangerous and must be repaired.

c) Remove the plug from the plug socket and/or remove the battery before carrying out tool adjustments, changing accessories or placing the tool aside.

This precautionary measure prevents unintentional starting of the power tool.

d) Store power tools out of the reach of children when not in use. Do not allow people to use the power tool if they are not familiar with it or if they have not read this instruction manual.

Power tools are dangerous if they are used by inexperienced people.

EN

e) Maintain power tools with care. Check whether moving parts are in proper working order and do not jam, whether parts are broken or damaged in such a way that they impair the function of the power tool. Have damaged parts repaired before using the tool. Many accidents are caused by poorly serviced and maintained power tools.
f) Keep cutting tools sharp and clean at all times. Carefully maintained cutting tools with sharp cutting edges jam less easily and are easier to control.
g) Use the power tool, insert tools, etc. in accordance with this instruction manual. Take into consideration the working conditions and the work to be carried out. Use of power tools for other than the intended applications can lead to dangerous situations.
h) Keep the handles and gripping surfaces dry, clean and free from oil and grease. Slippery handles and gripping surfaces prevent safe operation and control of the power tool in unforeseen situations.

2.5 Service

a) Have your power tool repaired by qualified personnel only and use original spare parts only. This will ensure that the safety of the power tool is maintained.

2.6 Safety instructions for wet diamond drills

2.6.1 Operating personnel requirements

• People below the age of 18 may not use the machine.
- The operating personnel must be familiar with the content of this instruction manual.

2.6.2 Safety instructions for all work

• Wear hearing protection when hammer drilling / diamond drilling. Exposure to noise can cause loss of hearing.
• Use the additional handle(s). Loss of control can result in injuries.

- Support the power tool properly before using. This power tool produces a large torque. If the power tool is not properly supported during use, the use can loose control of it and injuries can occur.

2.6.3 Workplace safety

• Secure the work area also behind openings and cutouts. Unsecured work areas can endanger you and other people.
• Watch out for open and concealed electricity cables, and water and gas pipes. Use suitable detectors to find concealed utility pipes and cables, or contact the local utility company for advice.
  Contact with electricity cables can cause fires and an electric shock. Damage to a gas pipe can cause an explosion. Penetrating a water pipe causes damage to property or could cause an electric shock.
• Do not use the power tool near flammable materials.
  Sparks could ignite these materials.
• Avoid causing situations where other people can stumble or trip.
  Tripping over cables can cause serious injuries.
• Secure the workpiece.
  A workpiece securely held in clamping devices or a vice is more safely held than in the hand.
• Avoid dust accumulation in the workplace.
  Dusts can easily ignite.
• Ensure adequate ventilation in closed rooms.
  Risk due to dust and impaired vision.

- When carrying out drilling work that requires the use of water, route the water away from the work area or use a liquid collection device.

Such precautions keep the work area dry and reduce the risk of an electric shock.

- Inform and consult the responsible structural engineer, architect or the responsible site engineer about planned drilling.

Cut through reinforcement only with the approval of a structural engineer.

- When drilling through walls and ceilings, ensure that people and work areas on the other side are protected.

The core drill bit can extend beyond the drill hole and the drilled core can fall out on the other side.

- Before drilling holes drilling objects, check the rooms concerned for obstructions and block off this area. Use formwork to secure the drill core against falling.

- Dust from materials such as coatings containing lead, several types of wood, minerals and metals can be harmful to health and cause allergic reactions, respiratory diseases and/or cancer.

Asbestos-containing material may only be machined by specialists.

▶ Where possible use dust extraction suitable for the material.

▶ Ensure the workplace is properly ventilated.

▶ We recommend wearing a face mask respirator with filter class P2 or P3 (to EN 149:2001).

Observe the relevant regulations in your country for the materials to be machined.

2.6.4 Electrical safety

- The power tool may only be used for wet drilling if operated with a perfectly functioning PRCD personal protection switch (see page 37).

- Before each use, check the power tool, connection cable and plug for damage.

Damaged equipment is dangerous, and no longer safe to use.

- Note the mains voltage! The power source voltage must match the details given on the rating plate of the power tool.

- If using the power tool with mobile generators, loss of power or atypical behaviour on switching on is possible.

- Do not use the power tool if the cable is damaged. Do not touch the damaged cable and disconnect the mains plug if the cable is damaged while you are working.

Damaged cables increase the risk of an electric shock.

- Only use extension cables suitable for the machine's power consumption and which have a minimum core cross-section of 1.5 mm². If you use a cable drum, always completely unwind the cable.

The rolled up cable can heat up and start to burn.

- Regularly clean the ventilation slots of your power tool by blowing it out. Never use liquids. Never insert screwdrivers or any other objects into the ventilation slits. Do not cover the ventilation slits.

The motor fan draws dust into the housing and a large accumulation of metal dust can cause electrical hazards.

- External electromagnetic interference (e.g. mains voltage fluctuations, electrostatic discharges) can cause the power tool to switch off automatically.

In this case, switch off the power tool and then switch it back on again.

- Before use, check all water-carrying parts – including those of the accessories – for perfect working order and leaks.

Leaking water increases the risk of an electric shock.

2.6.5 Safety of people

- Wear personal protective equipment and, depending on the work situation, use:

Full-face protection, eye protection or safety glasses/goggles, hard hat and special apron

Protect yourself against debris thrown up by wearing a hard hat, safety goggles or face protection and wear an apron, if necessary.

Hearing protection

The typical A-weighted sound pressure level of this power tool is over 85 dB (A) while working with the tool. If you are exposed to loud noise for lengthy periods, there is a risk of hearing damage or even hearing loss.

Anti-vibration safety glove

At a release value A (8) for arm-hand vibrations of over 2.5 m/s ^2 , the wearing of anti-vibration safety gloves is recommended.

Non-slip safety footwear

Dust mask, half-face filter mask or face mask respirator

Inhaling fine mineral dust can cause health damage. We recommend wearing a face mask respirator with filter class P2 or P3 (to EN 149:2001).

Wet drilling: Working with wet diamond core drill bits is a grinding process, during which extremely fine dust is produced, which is bound by the added water. If the used water with the bound dust is not collected, the bound dust is re-released after drying. When drilling materials containing quartz, the risk of silicosis is very high; therefore, the machine may therefore only be used in conjunction with the BAI-ER BDB 802 centring guide with suction holder.

- Ensure other people keep a safe distance from your work area. Any person entering the work area must be wearing personal protective equipment.

Broken pieces of the workpiece or broken insert tools can fly off and cause injuries, even outside the immediate work area.

- Operate the power tool by holding the insulated gripping surfaces when carrying out work during which the cutting tool can hit concealed electrical cables or the tool's own power lead.

Contact of a cutting tool with a live cable can also energise metallic parts of the power tool and result in an electric shock.

- Keep the mains power lead away from rotating insert tools.

If you lose control of the tool, the mains power lead can be cut or caught and your hand or arm can be pulled into the rotating insert tool.

- Never put down the power tool until the insert tool has come to a complete standstill.

The rotating insert tool can come into contact with the surface on which the power tool is placed, which could cause you to lose control of the power tool.

- Do not leave the power tool running while you are carrying it.

Your clothing can get caught by inadvertent contact with the rotating insert tool and the insert tool can drill into your body.

- If the machine is switched on, do not direct insert tools towards your own or other people's bodies. Do not touch or take hold of the tools.

• Always use the additional handle supplied with the tool.

Loss of control of the machine can result in injuries.

- Do not use this tool for overhead drilling with water supply.

The ingress of water into the power tool increases the risk of an electric shock.

2.6.6 Hazards when using and handling the power tool

- If the machine is used for hand-held drilling, always hold both handles firmly when switching on and while working with the machine. When switching on and while working with the machine, expect reaction torques (e.g. due to sudden jamming or breakage of the insert tool).

- If the insert tool becomes blocked, stop exerting feed and switch off the tool.

Check the reason for the jamming and remove the cause of jammed insert tools.

- If you want to restart a diamond drill, which is in the workpiece, before switching on, check whether the insert tool rotates freely. If the insert tool jams, it possibly does not rotate and this can cause overloading of the tool, or can cause the diamond drill to detach itself from the workpiece.

- Do not use any accessories, which have not been especially provided and recommended for this power tool by the manufacturer. Just because you can attach the accessories to your power tool is not a guarantee of safe use.

- The approved speed of the insert tool must be at least as high as the maximum speed given on the power tool.

Accessories which rotate faster than approved can break and fly off the tool.

- Change insert tools carefully and only use the mounting tools provided, if they are in perfect condition. Disconnect the mains plug before changing the insert tool.

Use of the mounting tool provided prevents damage to the power tool and insert tool.

- Never use damaged insert tools. Before each use, check insert tools for splinters and cracks. If the power tool or insert tool is dropped or falls, check whether it is damaged, or use an undamaged insert tool. If you have checked and inserted the insert tool, keep yourself and other people nearby outside the plane of the rotating insert tool and let the power tool run at maximum speed for one minute.

Most damaged insert tools break during this test period.

- Do not expose power tools to extreme heat or cold.

Mechanical and electrical damage can occur during extreme heat and/or cold.

- Allow the insert tools, tool holders and other parts cool in the immediate vicinity of the work area after use.

The equipment can be very hot after use. Do not touch or grip the parts. Risk of injury.

- Additional signs or other, non BAIER-specific parts may not be screwed or riveted onto the motor, handle, gearbox or protective housing.

This could damage the power tool and cause malfunctions to occur.

- When fixing the drill stand on the workpiece using anchors and screws, ensure that the anchoring used is able to hold the machine safely during use.

If the workpiece is not resistant or is porous, the anchor can be pulled out, which causes the drill stand to detach from the workpiece.

- If fixing the drill stand on the workpiece by means of a vacuum plate, ensure that the surface is smooth, clean and not porous. Do not fix the drill stand onto laminated surfaces, such as tiles and facings of composite materials.

If the surface of the workpiece is not smooth, flat or adequately fixed, the vacuum plate can detach from the workpiece.

- Before and while drilling, ensure that the vacuum is sufficient.

If the vacuum is insufficient, the vacuum plate can detach from the workpiece.

- Never carry out overhead drilling and drilling in the wall, if the machine is only fixed by means of a vacuum plate.

In the event of loss of vacuum, the vacuum plate detaches from the workpiece.

- Avoid unnecessary noise emissions.

• Note and follow the safety and work instructions for the accessories used.

2.6.7 Safety instructions for using long drill bits

- Never work with a higher speed than the maximum allowable speed of the drill bit. At higher speeds the drill bit can bend easily, if it can twist itself free without contact with the workpiece and result in injuries.

• Always start drilling at a low speed and while the drill has contact with the workpiece.

At higher speeds the drill bit can bend easily, if it can twist itself free without contact with the workpiece and result in injuries.

- Do not exert excessive pressure and only press in the longitudinal direction of the drill bit.

Drill bits can bend and therefore break or result in a loss of control and injuries.

2.6.8 Service / Maintenance / Repair

- If the power tool is dropped or becomes wet, have it checked. A possibly damaged power tool is dangerous and no longer safe to operate. Before using the power tool again, have it checked by our customer service or an authorised service centre of Maschinenfabrik OTTO BAIER GmbH.

• Repair and maintenance work may only be carried out by an authorised workshop of Maschinenfabrik OTTO BAIER GmbH.

Otherwise, all liability and warranty claims against Maschinenfabrik OTTO BAIER GmbH expire.

NOTE

If using new carbon brushes, do not overload the machine during the first 10 minutes of operation.

- Ensure that original BAIER spare parts and original BAIER accessories only are used when needed. Original parts are available from authorised dealers. Use of non original parts can cause damage to the machine and an increased risk of accidents.

- Regular servicing by Maschinenfabrik OTTO BAIER GmbH or a servicing and repair company authorised by us is specified.

Many accidents are caused by poorly serviced and maintained power tools.

2.6.9 Explanation of the pictograms on the machine

The CE mark on a product means that the product conforms with all the applicable European regulations and has been subjected to the prescribed conformity assessment procedures.

Protection class I equipment

The machine is insulated in such a way that it has no exposed metal parts that could be live in the event of a fault. An additional safeguard becomes active if the basic insulation fails.

Environmentally friendly disposal of waste equipment

Waste equipment contains valuable recyclable materials which should be reused or recycled. Batteries, lubricants and similar materials must not be allowed to get into the environment. Therefore, please dispose of waste equipment through suitable collection systems.

Wear hearing protection!

The typical A-weighted sound pressure level of this power tool is over 85 dB (A) – wear ear protectors when working with the tool!

Read the instruction manual!

Before starting any work with or on the machine, this instruction manual, the safety instructions and the warnings must be read through carefully and observed.

3 Technical Characteristics

3.1 Technical specifications

Wet diamond drill type BDB 802 BDB 802B
Manufacturer Maschinenfabrik OTTO BAIER GmbH
Operating voltage (V/Hz) ~230 / 50/60
Power consumption (watt) 800
Protection class	1/1
	1. Gear 2. Gear 1st gear		2nd gear
No-load speed (min-1)1)	4200	7500	4200	7500
Wet core drill bit diameter, hand-guided (mm)	20 - 40	6 - 20	20 - 40	6 - 20
Bit holder	G1/2 inch
Water tank	included		no
Weight (kg)2)	4.0		3.5
Speed electronics	Yes		Yes
Sound measurement3) K = 3 dB
LpA (sound pressure) dB (A)	91		91
LWA (sound power) dB (A)	100		100
Vibration measurement:4) K = 1.5 m/s2
Rear handle (7) 1/(3) 2 m/s2	2.6		2.6

1) The given speeds are to be viewed as maximum speeds for the given wet diamond bit diameters. Depending on the property of the material to be drilled, such as concrete with steel reinforcement of different thicknesses, the speed is set "by feel". When drilling through concreted in steel with large wet diamond core drill bit diameters the 1st gear is always set.
2) Weight according to EPTA procedure 01/2003.
3) Measured values for noise determined according to EN 60745. Wear hearing protection!
4) Total vibration values (vector sum in three directions) determined according to EN 60745 The vibration emission values given in this instruction manual have been measured according to a method of measurement standardised in EN 60745 and can be used for comparison between power tools. They are also suitable for a preliminary estimate of the vibratory stresses.

The vibration emission values given represent the main applications of the power tool. If the power tool is used for other applications, with different insert tools or are insufficiently serviced, this can significantly increase the vibratory stresses over the whole work period. For a precise estimate of the vibration emission values, the times during which the tool is switched off or is running but not actually in use should also be taken into account. This can reduce the vibration stresses over the whole work period significantly.

WARNING

Health risk due to vibrations.

Additional safety measures should be taken to protect the user, e.g. wearing anti-vibration protective gloves, correct maintenance of power tools and insert tools, keeping hands warm and good organisation of work sequences.

3.2 EU Declaration of Conformity

CE

We herewith declare, with sole responsibility, that this product conforms to the following standards or normative documents:

EN62841-1:2015+AC:2015

EN62841-2-1:2018

EN62841-3-6:2014 + AC:2015 + A11:2017

EN55014-1:2017

EN55014-2:2015

EN IEC 61000-3-2:2019

EN61000-3-3:2013

In accordance with the provisions of the Directives

2006/42/EC

2011/65/EU

in conjunction with the safety instructions documented in the instruction manual and the specified intended use.

The factory manager is authorised to write the technical documents.

These are available from:

Maschinenfabrik OTTO BAIER GmbH, Heckenwiesen 26, 71679 Asperg Germany

Thomas Schwab

Managing Director

Robert Pichl

Factory Manager

Asperg, 02.04.2020

3.3 Machine characteristics

The wet diamond drills are only approved for wet drilling. They have electronic speed control, i.e. the speed increases with the pressure on the ON / OFF switch.

The wet diamond core drill is equipped with a personal protection switch (PRCD).

3.4 Machine parts and controls

1 Wet diamond drill BDB 802

1 Piston pump

2 Lock nut

3 Water tank

4 Marking: maximum water fill level

5 Lock for ON / OFF switch

6 ON / OFF switch

7 Handle

8 Gear change knob

9 Connection cable

10 Personal protection switch PRCD

11 BAIER drill core ejector 1.5 RD

12 BAIER drill core ejector SW3

13 Open-ended spanner SW22/24

14 Open-ended spanner SW27

15 Water feed valve

16 Flow control valve for flushing water

17 Plugs for external water connection (see "Tools and Accessories" on page 43 or BAIER catalogue)

18 Additional handle (accessories, see "Tools and Accessories" on page 43 or BAIER catalogue)

19 Output shaft

20 Sliding sleeve for locking and unlocking the quick-change adapter

21 Valve block

2 Wet diamond drill BDB 802B

1 Lock for ON / OFF switch

2 ON / OFF switch

3 Handle

4 Gear change knob

5 Connection cable

6 Personal protection switch PRCD

7 BAIER drill core ejector 1.5 RD

8 Open-ended spanner SW22/24

9 Open-ended spanner SW27

10 Water connection with stopcock and Gardena coupling

11 Additional handle (accessories, see "Tools and Accessories" on page 43 or BAIER catalogue)

12 Output shaft

13 Sliding sleeve for locking and unlocking the quick-change adapter

14 Rotary swivel

3 BAIER centring guide BDB 802 with suction holder

The BAIER BDB 802 centring guide with suction holder is only included with the BDB 802 professional kit; otherwise it is available as an optional accessory.

The BAIER BDB 802 centring guide and the BAI-ER suction holder must be ordered separately (see "Tools and Accessories" on page 43 or BAIER catalogue).

1 Clamping lever
2 Suction holder
3 Knurled screw
4 Centring guide
5 Splash guard
6 Centring rolls
7 Hose connection

4 Accessories

1 Wet diamond core drill bit
2 Wet diamond core drill bit
3 Quick-change adapter

3.5 Intended use

The BDB 802 and BDB 802B wet diamond drills are designed not only for hand-held operation (with the BAIER BDB 802 centring guide with suction holder), but also for use with a drill stand.

Wet diamond core drill bits up to diameter 40 mm can be used with the BAIER BDB 802 centring guide with suction holder.

The drillholes made have smooth walls. Comply with the relevant regulations regarding plug and anchor fixings.

NOTE

The wet diamond drill is not suitable for overhead drilling.

Use the BAIER BDB 802 centring guide with suction holder for hand-held drilling.

The wet diamond drill, in conjunction with wet diamond core drill bits and a water supply, is only intended for wet drilling into mineral materials such as concrete, reinforced concrete or masonry, natural stone, ceramics or tiles.

Never work without draining the water into a collection vessel.

The following materials may not be drilled: wood, metal and glass, etc.

Observe the relevant regulations in your country for the materials to be machined and extraction.

4 Before Starting Work

To ensure safe working with the wet diamond drill, the following points must be observed before each use:

• Read through all safety instructions and warnings in this instruction manual.
• Wear protective clothing such as hard hat, face protection or safety goggles, safety gloves, suitable half-face filter mask, slip-resistant safety footwear and if necessary an apron.
• The voltage on the rating plate must be identical with the mains voltage.
• Before each use, check the machine, connection cable, plug, secure fit of the wet diamond core drill bit and, if applicable, the fixing of the drill stand.
• Connect a suitable water supply (e.g. BAIER water pressure vessel, see "Tools and Accessories" on page 43 or BAIER catalogue) to the BDB 802B (see page 39).
• Inform and consult the responsible structural engineer, architect or the responsible site engineer about planned drilling. Cut through reinforcement only with the approval of a structural engineer.

5 Checking the personal protection switch

DANGER

Risk of injury due to electric shock.

The personal protection switch PRCD must be checked each time before the wet diamond drill is started up (see below). If the PRCD does not trip during the test or if it repeatedly switches off when the wet diamond drill is switched on, the wet diamond drill together with the PRCD personal protection switch must be examined by a qualified electrician.

- 5 With the mains plug pugged in and the wet diamond drill switched off, press the -ON- (RESET) button (2). The red indicator light (1) must light up.

EN

• 5 Press the -OFF- (TEST) button (3). The PRCD must switch off, i.e. the red indicator light (1) goes out.
• 5 Press the -ON- (RESET) button (2) again. The wet diamond drill must now be able to be switched on.
• If the PRCD does not trip during the test or if it repeatedly switches off when the wet diamond drill is switched on, the wet diamond drill together with the PRCD personal protection switch must be examined by a qualified electrician.
• Operation of the wet diamond drill with a defective PRCD personal protection switch is not permitted – risk of fatal injuries.

6 Screwing wet diamond core drill bits into the quick-change adapter

• Only use diamond core drill bits recommended by OTTO BAIER GmbH for the respective area of use.
• Always note and follow the thread dimension of the wet diamond drill bit holder. The thread of the wet diamond core drill bit must fit in the thread of the quick-change adapter (G ^1/2 " internal thread) without clearance. Do not use reducers or adaptors to fit the wet diamond core drill bits.
• Check the condition of the wet diamond drill bit with a visual inspection.

NOTE

Damaged wet diamond core drill bits may not be used and must be replaced immediately.

- 6 Before using for the first time, screw the wet diamond core drill bit (1) (open-ended spanner SW22 or SW24) into the quick-change adapter (2) (open-ended spanner SW27).

NOTE

Always keep the quick-change adapter clean.

7/8 Setting the speed

- 7/8 Set the appropriate speed for the core drill diameter (see "Technical specifications" on page 35) at the gear change knob (1).

NOTE

Changing gear while the machine is running can cause damage to the drill.

Wait for the machine to completely stop.

5 Operation and Control

DANGER

Risk of injury due to electric shock.

→ Disconnect the mains plug before carrying out any work on the wet diamond drill.

5.1 Fitting or changing the wet diamond core drill bit

The quick-change adapter is inserted into the output shaft together with the screwed-in BAIER wet diamond core drill bit.

CAUTION

Risk of injury due to hot drill bits.

→ The drill bits fitted can get hot if used for a lengthy time. Wear safety gloves when changing the drill bits or allow the drill bits to cool first.

• 9/10 To change the wet diamond core drill bit, push back the sliding sleeve (2) on the output shaft.
• 9/10 Remove the quick-change adapter (1) with the screwed-in wet diamond core drill from the front and replace with another quick-change adapter with mounted wet diamond core drill bit.
• 9/10 To insert a quick-change adapter (1), push back the sliding sleeve (2) and insert the quick-change adapter (1) with screwed-in wet diamond core drill bit into the correct position in the output shaft.
• 9/10 Let go of the sliding sleeve (2) and check the locked fit of the quick-change adapter (1) with the screwed-in wet diamond core drill bit, i.e. the quick-change adapter with the screwed in wet diamond core drill bit cannot be pulled out of the drive shaft.

NOTE

The quick-change adapter may only be inserted in the output shaft if it has been cleaned.

Check the fit and condition of the wet diamond core drill bit. A damaged wet diamond core drill bit may not be used and must be replaced immediately.

5.2 Connect water supply

DANGER

Risk of injury due to electric shock.

→ Disconnect the mains plug before carrying out any work on the wet diamond drill.

5.2.1 BDB 802

DANGER

Risk of injury due to electric shock.

→ Protect the machine against splashing water. When filling the water tank, ensure that no water penetrates the air slots of the machine; if necessary, use a funnel.

11 During drilling, water is supplied from the water tank (6) of the BDB 802.

- 11 To fill the water tank, open the lock nut (2), remove the piston pump (1) and add water up to the "max" mark (3).

NOTE

Fill the water tank with clean water (tap water) only.

• 11 Re-insert the piston pump (1) and screw tight the lock nut (2).
• 11 The piston pump (1) produces the necessary pressure in the water tank (6) for the water supply (approx. 10 pump strokes).
• 11 The flow control valve (5) is used to set the flushing water flow rate; Position 1 means low flow rate, Position 2 means high flow rate.
• 11 The intermittent water flow to the wet diamond core drill bit and the drilling point is controlled manually via the water feed valve (4).

NOTE

The BDB 802 wet diamond drill can be retrofitted with a connection for an external water supply (see "Tools and Accessories" on page 43 or BAIER catalogue).

The water connection is then made in the same way as described in the connect water supply chapter, see "5.2.2 BDB 802B" on page 39.

5.2.2 BDB 802B

DANGER

Risk of injury due to electric shock.

→ Protect the machine against splashing water. When inserting and removing the water hose, ensure that no water penetrates the air slits of the machine. Use intact Gardena couplings and Gardena hose lengths only. Check the sealing rings for wear or damage. The drill may not be run with leaking hose couplings.

• 12 Connect the water supply (1) with the coupling (3) to a hose with a Gardena hose connector ( 12 inch).
• 12 The water supply can be switched on and off and finely controlled using the tap (2).
- Set the water flow rate as low as possible to avoid the risk of splashing/spraying.

5.3 Using the BAIER centring guide BDB 802 with suction holder

NOTE

The BAIER BDB 802 centring guide with suction holder is only included with the BDB 802 professional kit; otherwise it is available as an optional accessory.

The BAIER BDB 802 centring guide and the BAI-ER suction holder must be ordered separately (see "Tools and Accessories" on page 43 or BAIER catalogue).

• 3 Use the knurled screw (3) to screw the BAIER BDB 802 centring guide (4) onto the BAIER suction holder (2).

EN

Wet diamond core drill bits up to diameter 40 mm can be used with the BAIER BDB 802 centring guide with suction holder.

The BAIER BDB 802 centring guide with suction holder enables drilling with millimetre precision.

The surface for the suction holder of the BDB 802 centring guide must be smooth and impermeable to air.

WARNING

Health hazard due to materials containing quartz. The risk of silicosis is very high when drilling in materials containing quartz.

→ Wear dust mask, half-face filter mask or face mask respirator.
→ Collect flushing water in a suitable container and dispose of according to the relevant national regulations.

- 13 Push the water drainage hose (2) onto the socket (1).

5.4 Switching on the wet diamond drill and drilling

• Before starting up the wet diamond drill, check all the points described in the "Before starting work" chapter (see page 37).
• 5 Test the PRCD switch and switch on (see page 37).

NOTE

Changing gear while the machine is running can cause damage to the drill. Wait for the machine to completely stop.

- 7/8 Set the appropriate speed for the core drill bit diameter at the gear change knob (1) (see "Technical specifications" on page 35).

BDB 802

• 14 Build up the pressure in the water tank with approx. 10 pump strokes.
• 15 Set the required water flow rate at the flow control valve (1):
▶ Low water flow rate: position 1.
▶ High water flow rate: position 2.

BDB 802 and BDB 802B

• 16 Align the centring guide (4) with the drill hole and hold tight.
- 16 Attach the suction holder (2) with the clamping lever (1) onto the smooth and air-impermeable surface by suction.
- 16 Loosen the knurled screw (3) and align the centring guide (4) exactly with the hole to be drilled.
• 16 Re-tighten the knurled screw (3).
• 16 Check whether the suction holder (2) is securely attached to the wall or floor.
- Collect flushing water in a suitable container and dispose of according to the relevant national regulations.

BDB 802B

- Open water supply slightly (see page 39).

BDB 802 and BDB 802B

WARNING

Risk of injury due to falling.

→ Always adopt a firm posture for drilling. Do not stand on ladders or other moveable parts.

BDB 802

- 1 Hold machine firmly by the handle (7). Use your other hand to guide the machine at the front, on the neck under the valve block (1), or mount the additional handle (18).

BDB 802B

• 2 Hold machine firmly by the handle (3). Use your other hand to guide the machine at the front, on the rotary swivel (14), or mount the additional handle (11).

BDB 802 and BDB 802B

• 17 With the wet diamond core drill bit (1) at a standstill, feed it into the centring guide with the centring rolls (2); the wet diamond core drill bit must not touch the wall or floor.
- Check again whether the suction holder is firmly attached to the wall or floor.

NOTE

The ON / OFF switch must not be locked for handheld drilling.

• Switch on the wet diamond drill by pressing the ON / OFF switch, press the switch fully and wait until the maximum speed is reached.
• Position the wet diamond core drill bit and spot-drill with a uniform, light feed pressure.

BDB 802

• 11 Actuate the water feed valve (4) briefly.

- Continue drilling with light feed pressure.

• 11 Press the water feed valve (4) with pulsed action repeatedly.

NOTE

Do not actuate the water feed valve for the water supply to the wet diamond core drill bit continuously, but instead with a pulsed action at intervals, to prevent drill cores and drill core residues from becoming stuck in the wet diamond core drill bit.

If the wet diamond core drill bit nonetheless becomes blocked with drill core residues or the water throughput is impaired by drilling sludge, the drill hole must be pushed through with the help of a suitable tool (drill core ejector or suitable wire).

BDB 802 and BDB 802B

- Relieve the wet diamond core drill bit at intervals and move back slightly (oscillating movement), to flush out the drilling sludge out.

NOTE

On changing over from the tiles or natural stone to be drilled into the parent rock, continuous flushing must be used while working, to keep the wet diamond core drill bit as free as possible of drilling sludge.

The diamond core drill bit can become blunt or damaged due to overheating.

The feed may only be as high as the diamond core drill bit can wear away the material. Therefore, do not exert too much pressure on the diamond core drill bit (see "Handling wet diamond core drill bits" on page 42).

The wet diamond drill also switches off if the wet diamond core drill bit has insufficient cutting power. In this case, check whether the wet diamond core drill bit has become blunt (see "Handling wet diamond core drill bits" on page 42).

5.5 Ending the drilling process

• After reaching the required drilling depth, slowly withdraw the wet diamond drill with the wet diamond core drill bit rotating slowly – the wet diamond core drill bit still remains in the centring guide.
• After drilling, allow the water to continue running for a short time to flush out the drilling sludge between the wet diamond core drill bit and the drill core.
• Release the ON / OFF switch to switch off the wet diamond drill.
• Switch off the water supply.
• Now pull the stopped wet diamond core bit out of the drill hole and pull out the centring guide.
• After each drilling operation, remove any drill cores and drill core residues from the wet diamond core drill bit immediately, before they become hardened and caked.
• Remove the drill core from the drill hole (see Chapter 5.5.2, page 41).

5.5.1 Through-hole

NOTE

Risk of deformation or fracture! Do not hit the diamond drill bit with hard objects! If the drill core is stuck in the diamond core drill bit, knock the diamond core drill bit with a soft piece of wood or plastic to loosen the drill core.

5.5.2 Non through-hole (blind hole)

NOTE

The diamond core drill bit can be damaged irreparably if it is jammed in the core drill hole. Never use the diamond core drill bit to break out the drill core!

• 18 If the drill core is still stuck in the drill hole after the diamond core drill bit has been removed, it can be broken out using a suitable tool (e.g. chisel).

6 Cleaning

DANGER

Risk of injury due to electric shock.

→ Disconnect the mains plug before carrying out any work on the wet diamond drill.

The machine must be cleaned after each drilling work session.

• Carefully clean the machine and blow out with compressed air.
• Lightly grease the thread of the wet core drill bit holder.
• Clean the BAIER BDB 802 centring guide with suction holder under running water.
• Empty the rotary swivel, blow out and lightly oil the thread.
• After use, the water tank must be completely emptied.
• Ensure handles are dry and free from grease.

7 Maintenance

DANGER

Risk of injury due to electric shock.

→ Disconnect the mains plug before carrying out any work on the wet diamond drill.

The wet diamond drill must be serviced at least once a year. Further, servicing will be necessary depending on the wear of the carbon brushes.

NOTE

If using new carbon brushes, do not overload the machine during the first 10 minutes of operation.

Only servicing and repair firms authorised by Maschinenfabrik OTTO BAIER GmbH may carry out maintenance of the machine. Ensure that original BAIER spare parts and original BAIER accessories only are used (see "Tools and Accessories" on page 43 or BAIER catalogue).

8 Handling wet diamond core drill bits

• Always use and store wet diamond core drill bits in accordance with the manufacturer's instructions.
  • Too soft diamond segments:
  ▶ Wet diamond core drill bits wear too quickly at very high removal rate.
  Remedy: The material to be machined requires wet diamond core drill bits with a harder bond.
  • Too hard diamond segments:
  The diamond grains become blunt and do not break out of the bond. The wet diamond core drill bits no longer have any cutting power.
  Remedy: The material to be machined requires wet diamond core drill bits with a softer bond.
• If water flushing is not used during machining, the wet diamond core drill bit increasingly rubs against "soft" drill dust. The core drill bit segments heat as a result, they become soft and the diamond splinters sink into the substrate. The wet diamond core drill bit becomes less sharp. The cutting performance weakens and the user increases the pressure on the wet diamond core drill bit, which in turn increases the effect. After drilling a few holes, the wet core drill bit segments are "glazed" or they tear off at the least resistance in the stone and the wet diamond core drill bit must be replaced.
• Sharpening the wet diamond core drill bit using the BAIER professional whetstone (ID No. 15453) or a soft stone between drilling enables sunken in diamonds to be re-released and the wet diamond core drill bit is sharp again.
• Water cooling of the core drill bit segments is necessary to extend the life of the wet diamond core drill bit and to keep the cutting speed high.
• Excessive drilling pressure can cause material fatigue in the base metal and therefore the formation of cracks. Before use, ensure that there are no cracks in the wet diamond core drill bit.
• The wet diamond core drill bit should not plunge into the wall until after the maximum speed has been reached.

9 Disposal

Recycle the machine and its packaging in an environmentally friendly way in accordance with the provisions applicable in your country.

10 Tools and Accessories

BAIER centring guide BDB 802 (for diamond core drill bits up to ∅ 40 mm) ID No. 6319
• BAIER for centring guide BDB 802 ID No. 60673
- BAIER drill bit holder G ^1/2 inch coupling ID No. 59329
- BAIER drill core ejectorSW2 (for ∅ 6 mm up to ∅ 10 mm) ID No. 60871
• BAIER drill core ejector SW3 (for ∅ 12 mm up to ∅ 16 mm) ID No. 59600

• BAIER open-ended spanner SW27 ID No. 32862
• BAIER open-ended spanner SW22/24 ID No. 61127
• BAIER transport box for BDB 802 ID No. 59592
• BAIER additional handle ID No. 64022
• BAIER water pressure vessel (10 l capacity) ID No. 60723
• BAIER connection for external water supply ID No. 55277
• BAIER professional whetstone ID No. 15453
• BAIER drill stand with suction feet ID No. 67033
- BAIER special dust extractor, see BAIER catalogue

11 Scope of Supply

Please refer to the enclosed delivery note for the individual scope of supply of a customer-specific order.

Please refer to the table below for the scope of supply of basic models. Please contact your dealer if parts are missing or damaged.

Wet Diamond Drill ID No.		Machine	Plastic case	Metal case	Drill core ejector, small	Drill core ejector, large	Drill bit holder	Drill bit ∅ [mm] ∅ 6, ∅ 8, ∅ 10	Centring guide with suction holder	Open-ended span-ner SW27	Open-ended span-ner SW22/24
BDB 802 professional machine 58719	x x x x 1x x
BDB 802 professional kit	59642	x	x		x	x	3x	1x each	x	x
BDB 802B without tank	67322	x		x	x		1x			x

x included in scope of supply

12 Warranty

The power tools placed on the market and distributed by Maschinenfabrik OTTO BAIER GmbH take into account the regulations of the laws concerning engineering tools and equipment to protect against risks to health and safety.

We guarantee the perfect quality of our products and accept the costs of subsequent repairs by replacing the damaged parts or replacement with a new tool in case of design, material and/or manufacturing errors within the warranty period. The warranty period for commercial use is 12 months.

The following are prerequisite for a warranty claim due to design, material and/or manufacturing errors:

1. Proof of purchase and compliance with the instruction manual

A mechanically produced original copy of a purchase voucher must always be submitted in order to make a warranty claim. It must contain the complete address, date of purchase and type designation of the product.

The instruction manual for the respective machine and the safety instructions must have been complied with.

Damage due to faulty operation cannot be recognised as a warranty claim.

2. Correct deployment of the machine

Maschinenfabrik OTTO BAIER GmbH's products are developed and produced for specific purposes.

A warranty claim cannot be acknowledged in the event of failure to comply with the intended use in accordance with the instruction manual, misuse or use for another purpose or use of unsuitable accessories. The warranty does not apply if the machine is deployed in continuous and piece-work operation or for rental and hire purposes.

3. Compliance with servicing intervals

Regular servicing by us or a servicing and repair firm authorised by us is prerequisite for warranty claims. Servicing is specified for when the carbon brushes are worn, however at least once a year.

The machine must be cleaned in accordance with the provisions of the instruction manual. All warranty entitlements expire in case of intervention/tampering with the machine by third parties (opening the machine).

Servicing and cleaning work are not generally covered by the warranty.

4. Use of original BAIER spare parts

Ensure that original BAIER spare parts and BAI-

ER accessories only are used. They are available from authorised dealers. The type and quantity of grease are to be used according to the valid grease list. Use of non-original parts can cause consequential damage to the machine and an increased risk of accidents. Dismantled, partly dismantled machines and machines repaired with third party spare parts are excluded from the warranty.

5. Wearing parts

Certain components are subject to use-induced wear or normal wear and tear caused by use of the respective power tool. These components include, among other things, carbon brushes, ball bearings, switches, power cords, seals, shaft sealing rings. Wearing parts are not covered by the warranty.

Indice