HILTI DCH-EX 300 Electric Cutter Instruction Manual

HILTI DCH-EX 300 Electric Cutter Instruction Manual

DCH 300 diamond cutter

It is essential that the operating instructions are read before the machine is operated for the first time.

Always keep these operating instructions to-gether with the machine.

Ensure that the operating instructions are with the machine when it is given to other persons.

1. These numbers refer to the illustrations. You can find the illustrations at the beginning of the operating instructions.
   In these operating instructions, the designation “the power tool” always refers to the DCH 300 diamond cutter.

Operating controls and indicators 1

1. Spindle lockbutton
2. Front grip
3. On / off switch
4. Switch-on interlock release button
5. Diamond cutting disc
6. Spindle
7. Guard (hood)
8. Guide wheels
9. Clamping nut wrench, 24 mm AF / 10 mm AF
10. Hex. socket wrench, 6 mm AF
11. Guard (hood) clamping screw
12. Dust removal connector cap
13. Service indicator
14. Theft protection indicator (option)

DCH 300 mounting system for diamond cutting discs 2

15. Reversible flange 60 mm dia.
16. Clamping flange, 60 mm dia.
17. Clamping nut, M16 x 1.5

DCH 300 mounting system for synthetic resin-bonded fiber-reinforced abrasive cutting discs (optional) 3

18. Reversible flange 80 mm dia.
19. 300 mm dia. synthetic resin-bonded fiber-reinforced cutting disc
20. Clamping flange, 80 mm dia.
21. Clamping nut, M16 x 1.5

Hood extension with depth gauge (optional) 4

22. Hood extension
23. Hook
24. Stop
25. Cutting depth sliding indicator
26. Cutting depth scale

General information

1.1 Safety notices and their meaning

DANGER
Draws attention to imminent danger that will lead to serious bodily injury or fatality.
WARNING
Draws attention to a potentially dangerous situation that could lead to serious personal injury or fatality.

CAUTION
Draws attention to a potentially dangerous situation that could lead to slight personal injury or damage to the equipment or other property.
NOTE
Draws attention to an instruction or other useful information.

1.2 Explanation of the pictograms and other information

Symbols

Location of identification data on the machine
The type designation and serial number can be found on the type identification plate on the machine. Make a note of this data in your operating instructions and always refer to it when making an enquiry to your Hilti representative or service department.

Description

2.1 Use of the product as directed
The DCH 300 is an electrically powered diamond cutter for professional use in the construction industry.
It is designed for cutting mineral materials with diamond discs without use of water.
When cutting mineral materials, a dust removal system equipped with the corresponding filter must be used, e.g. the
Hilti VCU 40, VCU 40‑M or VCD 50 vacuum cleaner.
In order to avoid electrostatic effects, a vacuum cleaner equipped with an antistatic hose should be used.
Use only diamond cutting discs approved for use at a peripheral speed of at least 80 m/sec.
The power tool is to be used exclusively in pushing mode (counter rotation).
The use of liquids, e.g. to cool the disc or suppress dust, is not permissible.
Do not use the power tool for cutting with cutting tools of a type not specified in these operating instructions (e.g. circular saw blades) or for grinding.
When equipped with synthetic resin-bonded fiber-reinforced abrasive cutting discs, the power tool can also be
used for cutting metals. For this application, use only synthetic resin-bonded fiber-reinforced abrasive cutting discs approved for use at a peripheral speed of at least 80 m/sec.
The working environment may be as follows: construction site, workshop, renovation, conversion or new construction.
To avoid the risk of injury, use only genuine Hilti accessories and cutting tools.
Observe the safety rules and operating instructions for the accessories used.
Observe the information printed in the operating instructions concerning operation, care and maintenance.
The machine is designed for professional use and may be operated, serviced and maintained only by trained,
authorized personnel. This personnel must be informed of any special hazards that may be encountered. The machine and its ancillary equipment may present hazards when used incorrectly by untrained personnel or when used not as directed.
The machine may be used only in a dry environment.

The machine may be operated only when connected to a power supply providing a voltage and frequency in compliance with the information given on its type identification plate.
Do not use the machine where there is a risk of fire or explosion.
Working on materials hazardous to the health (e.g. asbestos) is not permissible.
Observe the national health and safety requirements.
Modification of the machine or tampering with its parts is not permissible.

2.2 Switches
On/off switch with switch-on interlock
2.3 Starting current limitation
The starting current drawn by the power tool is several times higher than its rated current. The electronic starting current limiter reduces the starting current drawn by the power tool and thus prevents the mains fuse blowing. It also allows the power tool to start smoothly, without a jolt.
2.4 Restart interlock
The power tool does not restart by itself after an interruption in the electric supply. The switch must first be released and then pressed again after approx. 1 second.
2.5 TPS theft protection system (optional)
The power tool may be optionally equipped with the TPS theft protection system. If equipped with this feature, the power tool can be unlocked and made ready for operation only through use of the corresponding TPS key.
2.6 LED indicators
Service indicator LED (see section “Care and maintenance”)
Theft protection system indicator (optional) (see section “Operation”)
2.7 Guard (hood) with guide wheels
Cutting and slitting work on stone may be carried out only when the power tool is equipped with a dust hood with wheels.
2.8 Electronic overload protection
This power tool is equipped with electronic overload protection.
The electronic overload protection system monitors the current input and thus prevents overloading of the tool during use.
The power tool switches itself off automatically when excessive pressure is applied resulting in excessively high electric current input.
After releasing the on / off switch, the power tool can be restarted.
The user can prevent activation of this automatic cut out by reducing the pressure applied to the tool.
The user should aim to work continuously with the tool without activation of the automatic cut-out.

2.9 Using extension cords
Use only extension cords of a type approved for the application and with conductors of adequate gauge. The power tool may otherwise lose performance and the extension cord may overheat. Check the extension cord for damage at regular intervals. Replace damaged extension cords.

Recommended minimum conductor gauge (cross section) and max. cable lengths

Do not use extension cords with a conductor cross section of less than 1.5 mm².

2.10 Using extension cords outdoors

When working outdoors, use only extension cords that are approved and correspondingly marked for this application.

2.11 Using a generator or transformer
This tool may be powered by a generator or transformer when the following conditions are fulfilled: The unit must provide a power output in watts of at least twice the value printed on the type identification plate on the power tool.
The operating voltage must remain within +5% and -15% of the rated voltage at all times, frequency must be in the 50
– 60 Hz range and never above 65 Hz, and the unit must be equipped with automatic voltage regulation and starting boost.
Never operate other power tools or appliances from the generator or transformer at the same time. Where applicable, use a generator or transformer designed for simultaneous power tool and vacuum cleaner operation. Switching other power tools or appliances on and off may cause undervoltage and / or overvoltage peaks, resulting in damage to the power tool.

2.12 Depth gauge (optional)
The power tool can be fitted with an optional depth gauge. This improves dust removal performance for cutting mineral materials. The maximum cutting depth can be set with the aid of the cutting depth scale on the hood extension.

2.13 The items supplied as standard include:

1 Power tool with DCH‑EX 300 hood
1 Reversible flange 60 mm dia.
1 Clamping flange, 60 mm dia.
1 Clamping nut, M16 x 1.5
1 Clamping nut wrench, 24 mm AF / 10 mm AF
1 Hex. socket wrench, 6 mm AF
1 Cardboard box
1 Operating instructions

2.14 Cutting disc specifications
Diamond cutting discs in compliance with the requirements of EN 13236 are to be used with the power tool.
Synthetic resin-bonded fiber-reinforced cutting discs in compliance with EN 12413 (straight, not offset, type 41) may also be used with this power tool for working on metals. In this case, the appropriate DCH 300 ABR disc mount (see accessories) must be used with the power tool.
The mounting instructions issued by the disc manufacturer must also be observed.

Accessories, consumables

Technical data

Right of technical changes reserved.

NOTE
The sound pressure and vibration values given in these instructions have been measured in accordance with a
standardized test and may be used to compare one electric tool with another. They may be used for a preliminary assessment of exposure. The data given represents the main applications of the electric tool. However, if the electric tool is used for different applications, with different accessories or is poorly maintained, the data may vary. This may significantly increase exposure over the total working period. An accurate estimation of exposure should also take into account the times when the tool is switched off, or when it is running but not actually being used for a job. This may
significantly reduce exposure over the total working period. Identify additional safety measures to protect the operator from the effects of noise and/or vibration, for example: maintaining the tool and the accessories, keeping the hands warm, organization of work patterns.

Noise information (as perEN 60745‑1):

Vibration information in accordance with EN 60745

Safety instructions

5.1 General Power Tool Safety Warnings

a) WARNING
Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result
in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery- operated (cordless) power tool.

5.1.1 Work area safety
a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

5.1.2 Electrical safety
a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any ad- apter plugs with earthed (grounded) power tools.
Unmodified plugs and matching outlets will reduce risk of electric shock.
b) Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the
risk of electric shock.
d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
f) If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

5.1.3 Personal safety
a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
b) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
c) Prevent unintentional starting. Ensure the switch is in the off‐position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents.
d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left at- tached to a rotating part of the power tool may result in personal injury.
e) Do not overreach. Keep proper footing and bal-ance at all times. This enables better control of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.

5.1.4 Power tool use and care
a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
c) Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits etc.in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

5.1.5 Service
a) Have your power tool serviced by a qualified repair person using only identical replacement parts.
This will ensure that the safety of the power tool is maintained.

5.2 Cut‑off machine safety warnings
a) The guard provided with the tool must be securely attached to the power tool and positioned for maximum safety, so the least amount of wheel is exposed towards the operator. Position your- self and bystanders away from the plane of the rotating wheel. The guard helps to protect operator from broken wheel fragments and accidental contact with wheel.
b) Use only bonded reinforced or diamond cut-off wheels for your power tool. Just because an accessory can be attached to your power tool, it does not assure safe operation.
c) The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.
d) Wheels must be used only for recommended applications. For example: do not grind with the side of cut-off wheel. Abrasive cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.
e) Always use undamaged wheel flanges that are of correct diameter for your selected wheel. Proper
wheel flanges support the wheel thus reducing the possibility of wheel breakage.
f) Do not use worn down reinforced wheels from larger power tools. Wheels intended for a larger power tool are not suitable for the higher speed of a smaller tool and may burst.
g) The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories can- not be adequately guarded or controlled.

h) The arbour size of wheels and flanges must properly fit the spindle of the power tool. Wheels and flanges with arbour holes that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.
i) Do not use damaged wheels. Before each use, inspect the wheels for chips and cracks. If power tool or wheel is dropped, inspect for damage or install an undamaged wheel. After inspecting and installing the wheel, position yourself and bystanders away from the plane of the rotating wheel and run the power tool at maximum no load speed for one minute. Damaged wheels will normally break apart during this test time.
j) Wear personal protective equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and shop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stop-ping flying debris generated by various operations.
The dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged
exposure to high intensity noise may cause hearing loss.
k) Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpiece or of a broken wheel may fly away and cause injury beyond immediate area of operation.
l) Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.
m) Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged
and your hand or arm may be pulled into the spinning wheel.
n) Never lay the power tool down until the accessory has come to a complete stop. The spinning wheel may grab the surface and pull the power tool out of your control.
o) Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.
p) Regularly clean the power tool’s air vents. The motor’s fan will draw the dust inside the housing
and excessive accumulation of powdered metal may cause electrical hazards.
q) Do not operate the power tool near flammable materials. Sparks could ignite these materials.
r) Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.

5.3 Kickback and related warnings
Kickback is a sudden reaction to a pinched or snagged rotating wheel. Pinching or snagging causes rapid stalling of the rating wheel which in turn causes the uncontrolled power tool to be forced in the direction opposite of the wheel’s rotation at the point of the binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may either jump toward or away from the operator, depending on direction of the wheel´s movement at the point of pinching. Abrasive wheels may also break under these conditions.
Kickback is the result of power tool misuse and/or in- correct operating procedures or conditions and can be avoided by taking proper precautions as given below.

a) Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start-up. The operator can control torque reactions or kickback forces, if proper precautions are taken.
b) Never place your hand near the rotating accessory. Accessory may kickback over your hand.
c) Do not position your body in line with the rotating wheel. Kickback will propel the tool in direction opposite to the wheel’s movement at the point of snagging.
d) Use special care when working corners, sharp edges etc. Avoid bouncing and snagging the accessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.
e) Do not attach a saw chain woodcarving blade, segmented diamond wheel with a peripheral gap
greater than 10 mm or toothed saw blade. Such blades create frequent kickback and loss of control.
f) Do not “jam” the wheel or apply excessive pressure. Do not attempt to make an excessive depth of cut. Overstressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of kickback or wheel breakage.
g) When wheel is binding or when interrupting a cut for any reason, switch off the power tool and hold the power tool motionless until the wheel comes to a complete stop. Never attempt to remove the wheel from the cut while the wheel is in motion otherwise kickback may occur. Investigate and take corrective action to eliminate the cause of wheel binding.
h) Do not restart the cutting operation in the work- piece. Let the wheel reach full speed and carefully re-enter the cut. The wheel may bind, walk up or kickback if the power tool is restarted in the work- piece.
i) Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback.
Large workpieces tend to sag under their own weight.
Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.
j) Use extra caution when making a “pocket cut” into existing walls or other blind areas. The protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.

5.4 Additional safety instructions
5.4.1 Personal safety

a) Use only wheel types that are recommended for your power tool and the specific guard designed for the selected wheel. Wheels for which the power tool was not designed cannot be adequately guarded and are unsafe.
b) During hand-held use, always hold the machine securely with both hands on the grips provided.
Keep the grips dry, clean and free from oil and grease.
c) Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord.

Contact with a live wire will make exposed metal parts of the power tool live and the operator will be at risk of receiving an electric shock.
d) Breathing protection must be worn if the power tool is used without a dust extraction system for work that creates dust. Close the cap over the dust removal connector.
e) Improve the blood circulation in your fingers by relaxing your hands and exercising your fingers during breaks between working.
f) Avoid touching rotating parts. Switch the power tool on only after bringing it into position at the workpiece. Touching rotating parts, especially rotating drill bits, discs or blades, etc. may lead to injury.
g) Always lead the supply cord and extension cord away from the power tool to the rear while working. This helps to avoid tripping over the cord while working.
h) The guard must always be fitted when the power tool is used for cutting metals. Close the cap over the dust removal connector.
i) If the work involves breaking right through, take the appropriate safety measures at the opposite side. Parts breaking away could fall out and / or fall down and injure other persons.
j) Do not use the power tool if it starts with a jolt. This may be an indication that the electronic control unit
is defective. Have the power tool repaired by Hilti Service immediately.
k) Children must be instructed not to play with the machine.
l) The machine is not intended for use by children, by debilitated persons or those who have received no instruction or training.
m) Dust from material such as paint containing lead, some wood species, minerals and metal may be harmful. Contact with or inhalation of the dust may cause allergic reactions and/or respiratory diseases to the operator or bystanders. Certain kinds of dust are classified as carcinogenic such as oak and beech dust especially in conjunction with additives for wood conditioning (chromate, wood preservative). Material containing asbestos must only be treated by specialists. Where the use of a dust extraction device is possible it shall be used. To achieve a high level of dust collection, use a suitable vacuum cleaner of the type recommended by Hilti for wood dust and/or mineral dust together with this tool. Ensure that the workplace is well ventilated. The use of a dust mask of filter class P2 is recommended. Fol- low national requirements for the materials you want to work with.

5.4.2 Power tool use and care

a) Cutting discs must be stored, handled and fitted carefully in accordance with the manufacturer’s instructions.
b) If use of a spacer ring or other intermediate part is specified and the part is supplied with the cutting disc, check to ensure that the part is fitted.

c) Secure the workpiece. Use clamps or a vice to secure the workpiece. The workpiece is thus held more securely than by hand and both hands remain free to operate the machine.
d) Before use, check that the cutting disc has been fitted correctly and the clamping nut tightened. Then allow the power tool to run for 30 seconds under no load while holding it in a secure position. Switch off the power tool immediately if significant vibration or any other faults are noticed. Should this occur, check the entire system in order to determine the cause.
e) Take steps to ensure that flying sparks from the power tool do not present a hazard, i.e. by striking yourself or other persons. Adjust the position of the disc guard accordingly.
f) Slits cut in loadbearing walls of buildings or other structures may influence the statics of the structure, especially when steel reinforcing bars or load-bearing components are cut through. Consult the structural engineer, architect, or person in charge of the building project before beginning the work.
g) Guide the power tool carefully and make straight cuts in order to avoid jamming the cutting disc. Cutting curves is not permissible.
h) Guide the power tool evenly and do not apply lateral pressure to the cutting disc. Always bring the power tool into contact with the workpiece at right angles. Do not attempt to alter the line of cut by applying lateral pressure or by bending the cutting disc while cutting is in progress. This presents a risk of damaging or breaking the cutting disc.

5.5 Additional safety instructions
5.5.1 Electrical safety

a) Before beginning work, check the working area (e.g. using a metal detector) to ensure that no concealed electric cables or gas and water pipes are present. External metal parts of the machine may become live, for example, when an electric cable is damaged accidentally. This presents a serious risk of electric shock.
b) Check the machine’s supply cord at regular intervals and have it replaced by a qualified specialist if found to be damaged. If the machine’s supply cord is damaged it must be replaced with a special approved, ready-made supply cord available from Hilti Customer Service. Check extension cords at regular intervals and replace them if found to be damaged. Do not touch the supply cord or extension cord if damaged while working. Unplug the supply cord from the power outlet. Damaged sup- ply cords or extension cords present a risk of electric shock.
c) Dirty or dusty machines which have been used frequently for work on conductive materials should be checked at regular intervals at a Hilti Service Center. Under unfavorable circumstances, damp- ness or dust adhering to the surface of the machine, especially dust from conductive materials, may present a risk of electric shock.
d) When working outdoors with an electric tool or machine, check to ensure that the tool or machine is connected to the electric supply by way of a ground fault circuit interrupter (RCD) with a rating of max. 30 mA (tripping current). Use of a ground fault circuit interrupter reduces the risk of electric shock.
e) Use of a ground fault circuit interrupter (RCD residual current device) with a maximum tripping current of 30 mA is recommended.

5.5.2 Work area safety
Ensure that the workplace is well ventilated. Exposure to dust at a poorly ventilated workplace may result in damage to the health.

5.5.3 Personal protective equipment

The user and any other persons in the vicinity must wear suitable eye protection, a hard hat, ear protection, protective gloves and safety footwear while the machine is in use.

Before use

WARNING
The supply cord must be disconnected from the electric supply and the cutting disc or drive spindle must have come to a complete stop before attempting to change or adjust discs, parts of the tool or its ac-
cessories.

CAUTION
The mains voltage must comply with the specification given on the type identification plate. Ensure that the power tool is disconnected from the electric supply.

CAUTION
Wear protective gloves, especially when changing discs, adjusting the guard (hood) and when fitting the hood extension with depth gauge.

6.1 Guard (hood)
WARNING
Never use the power tool without the guard (hood).
NOTE
If the guard (hood) clamping force is found to be inad- equate, this can be increased by tightening the clamping screw slightly.

6.1.1 Fitting and adjusting the guard (hood) 5

1. Disconnect the supply cord plug from the power outlet.
2. Use the hex. socket wrench to release the clamping screw.
3. Fit the guard (hood) onto the collar on the gearing section.
4. Rotate the guard (hood) into the desired position.
5. Use the hex. socket wrench to tighten the clamping screw.

6.1.2 Removing the guard (hood)

1. Disconnect the supply cord plug from the power outlet.
2. Use the hex. socket wrench to release the clamping screw.
3. Rotate the guard (hood) and pull it away from the tool.

6.2 Depth gauge (optional)
DANGER
The hood extension with depth gauge is to be used exclusively for cutting mineral materials with diamond discs.

6.2.1 Fitting / removing the hood extension with depth gauge 4

1. Disconnect the supply cord plug from the power outlet.
2. Fit the hook over the guide wheel axle.
3. Pivot the hood extension into the hood until the catch is heard to engage.
4. To remove the hood extension, press the catch and pivot the hood extension down and away from the hood.

6.2.2 Using the depth gauge to adjust cutting depth

1. Press the cutting depth sliding indicator.
2. Move the cutting depth sliding indicator to the desired cutting depth.

6.3 Fitting a cutting disc
CAUTION
Use only cutting tools with a rated maximum permissible speed which is at least as high as the machine’s highest no-load running speed.

CAUTION
Cutting discs which are damaged or out of round (causing vibration) must not be used.
CAUTION
Do not use synthetic resin-bonded fiber-reinforced cutting discs that have exceeded their use-by date.

NOTE
Diamond cutting discs in compliance with the requirements of EN 13236 are to be used with the power tool.
Synthetic resin-bonded fiber-reinforced cutting discs in compliance with EN 12413 (straight, not offset, type 41) may also be used with this power tool for working on metals. In this case, the appropriate DCH 300 ABR disc mount (see accessories) must be used with the power tool. The mounting instructions issued by the disc manufacturer must also be observed.

NOTE
Diamond discs must be replaced when the cutting or grinding performance drops significantly. This generally
is the case when the segments reach a height of less than 2 mm.

6.3.1 Fitting diamond cutting discs

The segments must have a negative rake angle and the size of the gap G between the segments must not exceed 10 mm. The maximum disc thickness is 3.5 mm.
The 60 mm diameter reversible flange is used for mounting cutting discs with arbor size 22.2 mm or 25.4 mm.
Check which side of the flange fits the arbor hole in the cutting disc. The flange must center the disc.

1. Disconnect the supply cord plug from the power outlet.

2. Clean the clamping flange and the clamping nut.

3. Fit the 60 mm diameter reversible flange onto the spindle the right way round, so that it is no longer free to rotate.

4. Place the diamond cutting disc on the reversible flange.

5. Fit the 60 mm diameter clamping flange and the clamping nut.

6. CAUTION Do not press the spindle lock button before the drive spindle has stopped rotating.
   Press the spindle lock button and hold it in this position.

7. Use the wrench to tighten the clamping nut securely and then release the spindle lockbutton.

8. Check to ensure that the spindle lockbutton has disengaged.

6.3.2 Fitting synthetic resin-bonded fiber-reinforced abrasive cutting discs (optional)

CAUTION
Never use flanges with a diameter of less than 80 mm with synthetic resin-bonded fiber-reinforced cutting discs.

The 80 mm diameter reversible flange is used for mounting cutting discs with arbor size 22.2 mm or 25.4 mm.
Check which side of the flange fits the arbor hole in the cutting disc. The flange must center the disc.

1. Disconnect the supply cord plug from the power outlet.
2. Clean the clamping flange and the clamping nut.
3. Fit the 80 mm diameter reversible flange onto the spindle the right way round, so that it is no longer free to rotate.
4. Place the diamond cutting disc on the reversible flange.
5. Fit the 80 mm diameter clamping flange and the clamping nut.
6. CAUTION Do not press the spindle lockbutton before the drive spindle has stopped rotating. Press the spindle lockbutton and hold it in this position.
7. Use the wrench to tighten the clamping nut securely and then release the spindle lockbutton.
8. Check to ensure that the spindle lockbutton has disengaged.

6.4 Removing the cutting disc from the tool
To remove the cutting disc from the tool, follow the instructions for fitting the disc but carry out the steps in the reverse order.
6.5 Storing and transporting cutting discs
CAUTION
Remove the cutting disc from the power tool after use. The cutting disc may suffer damage if the power tool is transported with the disc fitted.

CAUTION
Store the cutting disc in accordance with the manufacturer’s recommendations. Incorrect or careless storage may damage the cutting disc.

Operation

DANGER
Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring or its own cord.
Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.
WARNING
Do not use the power tool if it starts with a jolt. This may be an indication that the electronic control unit is defective. Have the power tool repaired by Hilti Service immediately.

CAUTION
The power tool and the cutting operation generate noise.
Wear ear protectors. Exposure to noise can cause hearing loss.
CAUTION
The cutting operation may cause dangerous splinters.
Splintering material presents a risk of injury to the eyes and body. Wear eye protection and a hard hat.
CAUTION
The direction of advance is important. The power tool must always be advanced with the guide wheels ahead and in contact with the material being cut.
There is otherwise a risk of kick-back.
CAUTION
The electric supply voltage must comply with the in- formation given on the type identification plate on the power tool. 230 V power tools may also be connected to a 220 V supply.

CAUTION
The cutting disc and parts of the power tool may get hot through use. There is a risk of burning your hands. Wear protective gloves. Touch the power tool only at the grips provided.
CAUTION
Use clamps or a vice to hold the workpiece securely.
WARNING
Slits cut in loadbearing walls of buildings or other structures may influence the statics of the structure, especially when steel reinforcing bars or load- bearing components are cut through. Consult the structural engineer, architect, or person in charge of the building project before beginning the work.

7.1 Working with the power tool
Take care to ensure that the closed side of the guard is always positioned toward the operator’s body.
Adjust the position of the guard (hood) to suit each cutting application.

7.2 TPS theft protection system (optional)
NOTE
The power tool may be equipped with the optional theft protection system. If the power tool is equipped with this feature, it can be unlocked and made ready for operation only with the corresponding TPS key.

7.2.1 Unlocking the power tool

1. Plug the supply cord into the power outlet. The yellow theft protection indicator LED blinks. The power tool is then ready to receive the signal from the TPS key.
2. Hold the TPS key against the lock symbol. The power tool is unlocked as soon as the yellow theft protection indicator LED no longer lights.
   NOTE If, for example, the electric supply is briefly interrupted due to a power failure or disconnected
   when moving to a different workplace, the power tool remains ready for operation for approx. 20 minutes. In the event of a longer interruption, the TPS key must be used again to unlock the power tool

7.2.2 Activation of the tool’s theft protection system

NOTE
Further detailed information on activation and use of the theft protection system can be found in the operating instructions for the theft protection system.

7.3 Switching on

1. Plug the supply cord into the power outlet.
2. Always hold the tool securely with both hands on the grips provided.
3. Unlock the on / off switch by pressing the switch-on interlock release button.
4. Press the on / off switch.
5. Reposition your thumb around the rear grip.

7.4 Switching off
Release the on / off switch.
The tool stops after the on / off switch is released.
The switch-on interlock is re-activated.

7.5 Working with cutting discs

DANGER
To reduce the risk of kick-back, avoid bringing the cutting tool into contact with the material in the area indicated.
DANGER
Wherever possible, bring the wheels into contact with the workpiece before starting the cut. Take extra care in situations where this is not possible or where the cutting disc is inserted in an existing cut.

1. When cutting mineral materials, first bring the tool’s guide wheels into contact with the object to be cut.
2. Allow the power tool to reach full speed.
3. Apply pressure to the power tool so that the cutting disc is pressed into the material slowly. This ensures that particles and sparks generated by the cutting operation are caught by the hood and extracted by
   the dust removal system.
   NOTE Apply moderate pressure, adjusting the rate of advance to suit the material being cut.
   NOTE The diamond disc may overheat and suffer damage when cutting very hard mineral materials, e.g. concrete with a high hard pebble content. A trail of sparks right round the circumference of the diamond cutting disc is a sure indication of this. Should this occur, stop cutting and cool the disc by allowing the tool to run under no load.
   A drop in the rate of cutting progress can be an indication of “blunt” (polished) diamond segments.
   The segments can be resharpened by making a few cuts in an abrasive material (Hilti sharpening plate or sand-lime block).

7.6 Using a suitable vacuum cleaner for working on mineral materials

NOTE
Please read the operating instructions for the vacuum cleaner for information about disposal of the material collected.

Use of a suitable vacuum cleaner (such as the Hilti VCU 40, VCU 40‑M or VCD 50) makes it possible to keep dust to a minimum while working with the tool. Use of a vacuum cleaner also helps to cool the segments on the disc and thus reduces segment wear. In order to avoid electrostatic effects, a vacuum cleaner equipped with an antistatic hose should be used.

Care and maintenance

CAUTION
Disconnect the supply cord plug from the power outlet.

8.1 Care of the power tool
DANGER
Under extreme conditions, when used for working on metal, conductive dust may accumulate inside the tool.
This may have an adverse effect on the tool’s protective insulation. Under such conditions, the tool should be
plugged into a ground fault circuit interrupter (RCD) and use of a stationary dust removal system and frequent cleaning of the tool’s cooling air slots is recommended.

The outer casing of the motor and the grips are made from impact-resistant plastic. Parts of the grips have a synthetic rubber covering.
Never operate the power tool when the ventilation slots are blocked. Clean the ventilation slots carefully using
a dry brush. Do not permit foreign objects to enter the interior of the power tool. Clean the outside of the power tool at regular intervals with a slightly damp cloth. Do not use a spray, steam pressure cleaning equipment or running water for cleaning. This may negatively affect the electrical safety of the power tool. Always keep the grip surfaces of the power tool free from oil and grease. Do not use cleaning agents which contain silicone.

8.2 Service indicator
NOTE
The power tool is equipped with a service indicator.

8.3 Maintenance

WARNING
Repairs to the electrical section of the machine may be carried out only by trained electrical specialists.

Check all external parts of the power tool for damage at regular intervals and check that all controls operate faultlessly. Do not operate the power tool if parts are damaged or when the controls do not function faultlessly.
If necessary, the power tool should be repaired by Hilti Service.

8.4 Checking the power tool after care and maintenance
After carrying out care and maintenance, check that all protective and safety devices are fitted and that they
function faultlessly.

Troubleshooting

Disposal

Most of the materials from which Hilti machines or appliances are manufactured can be recycled. The materials must be correctly separated before they can be recycled. In many countries, Hilti has already made arrangements for taking back old machines and appliances for recycling. Ask Hilti customer service or your Hilti representative for further information.

For EC countries only
Disposal of electric appliances together with household waste is not permissible.
In observance of the European Directive on waste electrical and electronic equipment and its implementation in accordance with national law, electrical appliances that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility.

Manufacturer’s warranty

Please contact your local Hilti representative if you have questions about the warranty conditions.

EC declaration of conformity (original)

We declare, on our sole responsibility, that this product complies with the following directives and standards:
2006/42/EC, until 19th April 2016: 2004/108/EC, from 20th April 2016: 2014/30/EU, 2011/65/EU, EN 60745‑1, EN 60745‑2‑22, EN ISO 12100.

Hilti Corporation, Feldkircherstrasse 100, FL‑9494 Schaan

Technical documentation filed at:
Hilti Entwicklungsgesellschaft mbH
Zulassung Elektrowerkzeuge
Hiltistrasse 6
86916 Kaufering
Deutschland

www.hilti.group

Hilti = registered trademark of Hilti Corp., Schaan

20230130

References

• DB Fahrplan, Auskunft, Tickets, informieren und buchen - Deutsche Bahn

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