HILTI DD 120 Diamond Drilling Machine Instruction Manual

HILTI DD 120 Diamond Drilling Machine

Information about the documentation

About this documentation

• Read this documentation before initial operation or use. This is a prerequisite for safe, trouble-free handling and use of the product.
• Observe the safety instructions and warnings in this documentation and on the product.
• Always keep the operating instructions with the product and make sure that the operating instructions are with the product when it is given to other persons.

Explanation of symbols used
Warnings
Warnings alert persons to hazards that occur when handling or using the product. The following signal words are used:

DANGER!

• Draws attention to imminent danger that will lead to serious personal injury or fatality.

WARNING!

• Draws attention to a potential threat of danger that can lead to serious 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

Symbols in the documentation
The following symbols are used in this document:

• Read the operating instructions before use.
• Instructions for use and other useful information
• Dealing with recyclable materials
• Do not dispose of electric equipment and batteries as household waste

Symbols in the illustrations
The following symbols are used in illustrations:

• These numbers refer to the corresponding illustrations found at the beginning of these operating instructions
• The numbering reflects the sequence of operations shown in the illustrations and may deviate from the steps described in the text
• Item reference numbers are used in the overview illustrations and refer to the numbers used in the product overview section
• This symbol is intended to draw special attention to certain points when handling the product.

Product-dependent symbols

“Must do” symbols
The following “must do” symbols are used:

• Wear eye protection
• Wear a hard hat
• Wear ear protection
• Wear protective gloves
• Wear protective footwear
• Wear light respiratory protection

Symbols on the product
The following symbols can be used on the product:

• Theft protection indicator
• Service indicator
• Drilling performance indicator
• Protective ground
• Rated speed under no load
• Wireless data transfer

Information notices

On the drill stand, base plate or diamond core drilling machine

| On the vacuum base plate

Upper half of the image: An additional means of securing the drill stand must be employed when the machine is used for horizontal drilling with the vacuum securing method.

Lower half of the image: Use of the vacuum securing method without an additional means of securing is prohibited for drilling in an upward direction.

---|---
|

On the diamond core drilling machine

Use of the water collection system in conjunction with a wet-type industrial vacuum extractor is a mandatory requirement for working overhead.

|

On the diamond core drilling machine

Operate the system only with a fully functional PRCD.

Product information
products are designed for professional users and only trained, authorized personnel are permitted to operate, service and maintain the products. This personnel must be specifically informed aboutthe possible hazards. The product and its ancillary equipment can present hazards if used incorrectly by untrained personnel or if used not in accordance with the intended use. The type designation and serial number are printed on the rating plate.

• Write down the serial number in the table below. You will be required to state the product details when contacting Hilti Service or your local Hilti organization to inquire about the product.

Product information

Declaration of conformity
We declare, on our sole responsibility, that the product described here complies with the applicable directives and standards. A copy of the declaration of conformity can be found at the end of this documentation. The technical documentation is filed here:
Hilti Entwicklungsgesellschaft mbH | Tool Certification | Hiltistrasse 6 | 86916 Kaufering, Germany

Safety

General power tool safety warnings
WARNING Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below 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.
Work area safety

• Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• 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.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical safety

• Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
• 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.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• 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.
• 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.
• 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.

Personal safety

• 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.
• Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.
• 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 energizing power tools that have the switch on invites accidents.
• Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• 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.
• f 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.
• Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

Power tool use and care

• 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.
• 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.
• Disconnect the plug from the power source and/or remove the battery pack, if detachable, 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.
• 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.
• Maintain power tools and accessories. 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.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• 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.
• Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

Service

• 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.

Diamond drill safety warnings

• When performing drilling that requires the use of water, route the water away from the operator’s work area or use a liquid collection device. Such precautionary measures keep the operator’s work area dry and reduce the risk of electrical shock.
• Operate power tool by insulated grasping surfaces, 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.
• Wear hearing protection when diamond drilling. Exposure to noise can cause hearing loss.
• When the bit is jammed, stop applying downward pressure and turn off the tool. Investigate and take corrective actions to eliminate the cause of the bit jamming.
• When restarting a diamond drill in the workpiece check that the bit rotates freely before starting. If the bit is jammed, it may not start, may overload the tool, or may cause the diamond drill to release from the workpiece.
• When securing the drill stand with anchors and fasteners to the workpiece, ensure that the anchoring used is capable of holding and restraining the machine during use. If the workpiece is weak or porous, the anchor may pull out causing the drill stand to release from the workpiece.
• When securing the drill stand with a vacuum pad to the workpiece, install the pad on a smooth, clean, non-porous surface. Do not secure to laminated surfaces such as tiles and composite coating. If the workpiece is not smooth, flat or well affixed, the pad may pull away from the workpiece
• Ensure there is sufficient vacuum before and during drilling. If the vacuum is insufficient, the pad may release from the workpiece.
• Never perform drilling with the machine secured by the vacuum pad only, except when drilling downwards. If the vacuum is lost, the pad will release from the workpiece.
• When drilling through walls or ceilings, ensure to protect persons and the work area on the other side. The bit may extend through the hole or the core may fall out on the other side.
• When drilling overhead, always use the liquid collection device specified in the instructions. Do not allow water to flow into the tool. Water entering the power tool will increase the risk of electric shock.

Additional safety instructions
Personal safety

• Do not tamper with or attempt to make alterations to the machine.
• The machine is not intended for use by debilitated persons who have received no special training.
• Keep the machine out of reach of children.
• Do not touch rotating parts. Switch the machine on only after it is in position at the workpiece. Touching rotating parts, especially rotating accessory tools, can result in injury.
• Avoid skin contact with drilling slurry.
• Dust from materials such as lead-based paint, certain types of wood and concrete/masonry/stone containing quartz, minerals or metal can be harmful to health. Contact with or inhalation of the dust can cause allergic reactions and/or respiratory or other diseases among operators or bystanders. Certain kinds of dust such as oakwood and beechwood dust are classified as carcinogenic, especially in conjunction with additives for wood conditioning (chromate, wood preservative). Only specialists are permitted to handle material containing asbestos. Use as effective a dust removal system as possible. To achieve a high level of dust collection, use a suitable vacuum extractor of the type recommended by Hilti for wood dust and/or mineral dust and which is designed for use with this power tool. Make sure that the workplace is well ventilated. It is advisable to wear a respirator appropriate for the type of dust generated. Comply with national regulations applicable to the materials you will be working with.
• The diamond core drilling machine and the diamond core bit are heavy. There is a risk of crushing parts of the body. The user and persons in the vicinity must wear suitable protective goggles, a hard hat, ear defenders, protective gloves and protective footwear while the machine is in use.

Power tool use and care

• Make sure that the machine is correctly secured to the drill stand.
• Always make sure that an end stop is installed on the drill stand as otherwise the safety-relevant end-stop function is not implemented.
• Check that accessory tools are compatible with the machine’s chuck/drive system and that they are installed and secured correctly.

Electrical safety

• Do not use extension cords with multiple power outlets powering two or more devices in operation
  at the same time.

• Operate the machine only when it is connected to an adequately rated power supply with a ground conductor.

• 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 can become live, for example if you inadvertently damage electric wiring. This constitutes a serious risk of electric shock.

• Make sure that the supply cord cannot be damaged as the carriage advances.

• Never operate the machine without the accompanying PRCD (machines without PRCD: Never operate the machine without an isolating transformer). Test the PRCD each time before use.

• 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 specially prepared and approved 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 orV extension cord if it is damaged while working. Disconnect the supply cord plug from the power outlet. Damaged supply cords or extension cords present a risk of electric shock.

• Never operate the machine when it is dirty or wet. Dust (especially dust from conductive materials) or dampness adhering to the surface of the machine may, under unfavorable conditions, lead to electric shock. Dirty or dusty machines should thus be checked by Hilti Service at regular intervals, especially if used frequently for working on conductive materials.

Workplace

• Approval must be obtained from the site engineer or architect prior to beginning drilling work. Drilling work on buildings and other structures may influence the static equilibrium of the structure, especially when steel reinforcing bars or load-bearing components are cut through.
• If the drill stand has not been fastened correctly, always move the machine mounted on the drill stand all the way down in order to prevent the stand from falling over.
• Keep the supply cord, extension cord, water hose and vacuum hose away from rotating parts of the machine.
• Use of the water collection system in conjunction with a wet-type industrial vacuum extractor is a mandatory requirement for wet drilling overhead.
• Use of the vacuum securing method without an additional means of fastening is prohibited for drilling in an upward direction.
• An additional means of securing the drill stand must be employed when the machine is secured with the vacuum securing method (accessory) for horizontal drilling.

Description

Intended use
The product described is an electrically powered diamond core drilling machine. It is designed for drilling through holes and blind holes in (reinforced) mineral base materials using a drill stand and the wet drilling technique. Hand-held use of the diamond core drilling machine is not permitted. The product described is designed for professional use and only trained, authorized personnel are permitted to operate, service and maintain the product. This personnel must be specifically informed about the possible hazards. The product described and its ancillary equipment can present hazards if used incorrectly by untrained personnel or if used not in accordance with the intended use.

• Always use a drill stand when using the diamond core drilling machine. The drill stand must be sufficiently anchored in the base material by an anchor base plate or vacuum base plate.
• Do not use a hammer or other heavy object to adjust the base plate.
• Operate the machine only when it is connected to a power supply providing a voltage and frequency in compliance with the information given on its type identification plate.
• Comply with national health and safety requirements.
• Comply with the safety rules and operating instructions for the accessories used.
• To reduce the risk of injury, use only genuine Hilti core bits and accessories.

Parts and operating controls 1

DD 120 diamond core drilling system

1. Theft protection indicator (optional)

2. Service indicator

3. Drilling performance indicator

4. On/off switch

5. End stop

6. Rail

7. Hand wheel

8. Adjusting screws for carriage play (4x)

9. Carriage lock

10. Carriage

11. Anchor base plate

12. Leveling screws (4x)

13. Chuck

14. Water swivel

15. Gear switch

16. Gearing section

17. Motor

18. Carbon-brush cover

19. Supply cord with PRCD
    Vacuum base plate (accessory) 2

20. Clamping spindle

21. Vacuum hose connector

22. Pressure gauge

23. Vacuum relief valve

24. Vacuum seal
    Fastening accessories 3

25. Clamping spindle

26. Anchor

27. Clamping spindle nut
    Water collection system 4

28. Water collector holder

29. Water collector

Service indicator
The product is equipped with a service indicator LED.
Items supplied
Diamond core drilling machine, hand wheel, operating instructions. The drill stand is supplied as a separate unit. Other system products approved for use with this product can be found at your local Hilti Store or at: www.hilti.group.
Using a generator or transformer
This machine can be powered by a generator or transformer when the following conditions are fulfilled: The generator or transformer’s power output must be at least twice the rated input power shown on the machine’s type identification plate, the operating voltage of the transformer or generator must always be within +5 % and -15 % of the machine’s rated voltage and the frequency must be 50 to 60 Hz and never above 65 Hz and the transformer or generator must have automatic voltage regulation with starting boost.

Technical data

720 mm
Dimensions of drill stand, long rail (L x W x H)| 330 mm x 147 mm x 830 mm
Protection class| Protection class I (earthed)

Gears and corresponding core bit diameters

Your machine’s core bit diameter is stated on the type identification plate. Second gear can be used to achieve faster progress when drilling holes up to 82 mm (3 1⁄2 in) in Vlightly reinforced concrete.

Noise information and vibration values in accordance with EN 62841
The sound pressure and vibration values given in these instructions were measured in accordance with a standardized test and can be used to compare one power tool with another. They can also be used for a preliminary assessment of exposure. The data given represent the main applications of the power tool. However, if the power tool is used for different applications, with different accessory tools, or is poorly maintained, the data can vary. This can 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 can 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 power tool and accessory tools, keeping the hands warm, and organization of work patterns.

Noise information

Vibration values

Preparations at the workplace

WARNING
Risk of injury! The drill stand can rotate or topple if not securely fastened.

• Before using the diamond core drilling machine, secure the drill stand to the work surface with anchors or with a vacuum base plate.
• Use only anchors suitable for the base material and comply with the anchor manufacturer’s instructions.
• Use a vacuum base plate only when the work surface is suitable for securing the drill stand by the vacuum method.

Install the hand wheel on the diamond core drilling machine 4

1.  Remove the retaining pin and fit the hand wheel on to the shaft.
2. Secure the hand wheel by inserting the retaining pin.

The hand wheel can be installed on either side of the carriage.
Securing the diamond core drilling machine to the drill stand 5
CAUTION
Risk of injury Hazard presented by inadvertent starting of the diamond core drilling machine.

• The diamond core drilling machine should not be connected to the power supply during set-up.

1. Use the hex key to slacken the screw on the inside.
2. Remove the end stop from the rail.
3. Open the carriage lock by turning the knob all the way in the opening direction.
4. Using the opening provided for the purpose, set the diamond core drilling machine on the rail.
5. Use the hand wheel to advance the diamond core drilling machine fully on to the rail.
6. Lock the diamond core drilling machine by fully tightening the carriage lock.
7. Check that the diamond core drilling machine is locked by lightly turning the hand wheel.
8. Install the end stop on the rail and check that it is secure.

NOTE

Check carriage play; adjust if necessary. → page 15

Securing the drill stand with an anchor 3
WARNING
Risk of injury due to use of wrong anchors! The machine can break loose and cause damage.

• Use anchors suitable for the material on which you are working and observe the anchor manufacturer’s instructions.

Hilti metal expansion anchors M12 are usually suitable for use as anchors for diamond core drilling equipment in uncracked concrete. Under certain conditions, however, it may be necessary to use an alternative fastening method. Contact Hilti Technical Service if you have questions about secure fastening.

1. Set an anchor suitable for the base material at a distance of 203 mm (8 in) from where the center point of the drillhole will be.

2. Screw the clamping spindle into the anchor.

3. Back off all leveling screws until the base plate is flush with the surface.

4. Slip the drill stand over the clamping spindle and align the drill stand.

5. Screw the clamping spindle nut on to the clamping spindle but do not tighten it.

6. Level the base plate by turning the 4 leveling screws.
   NOTE
   All leveling screws make be seated firmly on the surface.

7. Secure the drill stand by tightening the clamping spindle nut with a 19 mm open-ended wrench.(SW 19)

8. Check that the drill stand is secure.

Fastening the drill stand with the vacuum base plate (accessory)
DANGER
Risk of injury if the diamond core drilling machine falls!

• Fastening the drill stand to the ceiling only by means of the vacuum securing method is not permissible. A heavy structural support or a threaded spindle, for example, can serve as an additional means of fastening.

WARNING
Risk of injury if pressure is not checked!

• Before and during drilling, check that the pressure gage pointer remains in the green zone.

Make sure that the core bit selected for use will not damage the vacuum base plate. Before positioning the drill stand, check that you have sufficient space for assembly and operation. Use the vacuum fastening method only together with core bits ≤ 300 mm (≤ 12 in) in diameter and when no spacer is fitted.

1. From the center point of the hole to be drilled, draw an orientation line approx. 800 mm (31.5 in) toward
   and past where the diamond core drilling machine will be positioned.

2. Draw a positioning line intersecting the orientation line at right angles 203 mm (8 in) from the center point of the hole to be drilled.

3. Back off all leveling screws until the anchor base plate is flush with the surface.

4. Slip the drill stand over the spindle and on to the vacuum base plate. ➥ The anchor base plate is seated flush with the end stops of the vacuum base plate.

5. Secure the drill stand by tightening the clamping spindle nut with a 19 mm open-ended wrench.SW 19

6. Connect the vacuum connector on the vacuum base plate to the vacuum pump.

7. Switch on the vacuum pump and press the vacuum base plate against the surface.

8. To align the diamond core drilling machine, press and hold down the vacuum relief valve.

9. Release the vacuum relief valve and press the vacuum base plate against the surface.

10. Check that the drill stand is secure.

11. Level the diamond core drilling machine, if necessary, by turning the 4 leveling screws.

Fitting the water connection (accessory)
ATTENTION
Hazard due to incorrect use! Incorrect use can result in irreparable damage to the hose.

• Regularly check the hoses for damage and make sure that the maximum permissible water supply pressure of 6 bar is not exceeded.
• Make sure that the hose does not come into contact with rotating parts.
• Make sure that the hose is not damaged as the carriage advances.
• Maximum water temperature: 40 °C.
• Check the water supply system to ensure there are no leaks.

To avoid damage to the components, use only fresh water containing no dirt particles. A flow meter can be inserted as an accessory between the machine and the water supply.

1. Connect the water flow regulator to the diamond core drilling machine.
2. Connect the water supply (hose connection).

installing the water collection system (accessory) 6

WARNING
Danger of electric shock! There is a possibility of water flowing over the motor and cover if the vacuum removal system is faulty.

• Cease operations immediately if the vacuum removal system is not working.

CAUTION
Risk of injury! Inadvertent starting of the product.

• Unplug the supply cord before making adjustments to the power tool or before changing accessories.

For drilling upward, the diamond core drilling machine must be at a 90° angle to the underside of the slab. The water collection system sealing disc must match the diamond core bit diameter. Use of the water collection system allows water to be led away under control, thus preventing the surrounding area from being heavily soiled.

1. Remove the screw from the drill stand.
2. Install the water collector holder on the drill stand with the screw.
3. Position the water collector, with seal and water collector sealing disc installed, between the two movable arms of the water collector holder.
4. Press the water collector against the work surface by turning the two screws on the water collector holder.
5. Connect a wet-type industrial vacuum extractor to the water collector or establish a hose connection through which the water can drain away.

Inserting a diamond core bit (BI+ chuck) 7
DANGER
Risk of injury Fragments of the workpiece or of broken insert tools may be ejected and cause injury beyond the immediate area of operation.

• Do not use damaged insert tools. Check the insert tools for chipping, cracks, or heavy wear each time before use.

CAUTION
Risk of injury! Inadvertent starting of the product.

• Unplug the supply cord before making adjustments to the power tool or before changing accessories.

NOTE

Replace diamond core bits as soon as their cutting performance and/or rate of drilling progress drops significantly. This generally is the case when the diamond segments wear to a height of less than 2 mm (1/16 in). A 27 mm open- ended wrench is required for C-Rod, A-Rod, M27 and BR chucks.SW 27.

1. Lock the diamond core drilling machine by fully tightening the carriage lock.
2. Open the chuck (BI+) by turning it in the direction indicated by the “open brackets” symbol.
3. From below, push the connection end of the diamond core bit into the splines of the chuck on the diamond core drilling machine.
4. Close the chuck by turning it in the direction indicated by the “closed brackets” symbol.
5.  Check that the diamond core bit is seated securely in the chuck.

Selecting the speed 8
CAUTION
Risk of wear and tear Risk of damage to the gearing

• Do not attempt to change gear while the machine is running. Wait until the arbor comes to a complete stop.

1. Set the selector switch to suit the diameter of the core bit used.
2. Turn the switch to the recommended setting while turning the core bit by hand at the same time.

Removing the diamond core bit (BI+ chuck)
DANGER
Risk of injury Fragments of the workpiece or of broken insert tools may be ejected and cause injury beyond the immediate area of operation.

• Do not use damaged insert tools. Check the insert tools for chipping, cracks, or heavy wear each time before use.

CAUTION
Risk of injury! Inadvertent starting of the product.

• Unplug the supply cord before making adjustments to the power tool or before changing accessories.

C-Rod, A-Rod, M27 SW 27or BR chucks require the use of a 27 mm open-ended wrench to lock the arbor and a suitable open-ended wrench for removing the core bit.

1. Lock the diamond core drilling machine by fully tightening the carriage lock.
2. Open the chuck (BI+) by turning it in the direction of the open brackets symbol.
3. Pull the sleeve toward the machine, as indicated by the arrow, to unlock the core bit.
4. Remove the core bit from the chuck (BI+).

Operation

TPS theft protection system (optional)
The product can be equipped with an optional TPS theft protection system. It can then be unlocked and made ready for operation only through use of the corresponding TPS key.
Enabling a machine equipped with theft protection system (TPS)

1. Plug the supply cord of the diamond core drilling machine into the power outlet.

2. Press the “Reset” or “I” button on the PRCD.
   ➥ The yellow theft protection indicator LED flashes.

3. Hold the TPS key directly against the lock symbol.
   ➥ The yellow theft protection indicator LED goes out and the machine is enabled.

If the power supply is interrupted, the product remains ready for operation for approximately 20 minutes. If the interruption is longer, the theft protection system has to be deactivated again with the TPS key.
Portable residual current device (PRCD)

1. Plug the diamond core drilling machine’s mains plug into an earthed/grounded power outlet.

2. Press the “I” or “RESET” button on the PRCD.
   ➥ The indicator lights up.

3. Press the “0” or “TEST” button on the PRCD.
   ➥ The indicator goes out.

4. Press the “I” or “RESET” button on the PRCD.
   ➥ The indicator lights up.

Operating diamond core drilling machine without a wet-type industrial vacuum extractor

1. Slowly open the water flow regulator until the water flows at the desired rate.
   The diamond core drilling machine can be operated with or without water collection system. With the water collection system, the cooling water is drained away through a hose, without the water collection system the water runs off in an uncontrolled manner. For operation with water collection system, first install the water collection system → page 11. In both applications, upward drilling is not allowed.

2. Push the ON/OFF switch to the “I” position.

3. Release the carriage lock.

4. Turn the hand wheel until the diamond core bit is in contact with the work surface.

5. When you start drilling apply only light pressure until the core bit has centered itself and only then, increase the pressure against the working surface.

6. Observe the drilling performance indicator.

NOTE

Operating diamond core drilling machine with a wet-type industrial vacuum extractor 9
WARNING
Danger of electric shock! There is a possibility of water flowing over the motor and cover if the vacuum removal system is faulty.

• Cease operations immediately if the vacuum removal system is not working.

1. Install the water collection system → page 11 and connect the wet-type industrial vacuum extractor.
2. Switch on the wet-type industrial vacuum extractor; do not use automatic mode.
3. Slowly open the water flow regulator until the water flows at the desired rate.
4. Push the ON/OFF switch to the “I” position.
5. Release the carriage lock.
6. Turn the hand wheel until the diamond core bit is in contact with the work surface.
7. When you start drilling apply only light pressure until the core bit has centered itself and only then, increase the pressure against the working surface.
8. Observe the drilling performance indicator.

NOTE

Initially, the drilling performance indicator shows orange. Optimum drilling performance is achieved when the drilling performance indicator shows green. Reduce the pressure against the work surface if the drilling performance indicator shows red.

Procedure in the event of the core bit jamming
If the bit jams the safety clutch disengages. The electronic control system then switches the motor off and subsequently on again; this is done twice without manual intervention by the user. If this does not free the core bit, the electronic control system switches the motor off for 90 seconds. You can free a jammed bit manually, as follows:
Using an open-end wrench to free the core bit

1. Unplug the supply cord from the power outlet.
2. Grip the diamond core bit with a suitable open-end wrench close to the connection end and turn the diamond core bit to free it.
3. Plug the supply cord into the power outlet.
4. Resume the drilling operation.

Using the hand wheel to free the core bit

1. Unplug the supply cord from the power outlet.
2. Free the core bit from the base material by turning the hand wheel.
3. Plug the supply cord into the power outlet.
4. Resume the drilling operation.

Switching off the diamond core drilling machine 10
WARNING Risk of personal injury and material damage The diamond core bit fills with water during overhead drilling. The diamond core drilling machine may become damaged and the risk of electric shock is increased.

• As a first step, carefully allow the water to drain away after completing overhead drilling. This is done by disconnecting the water supply from the water flow regulator and draining the water by opening the water flow regulator. Do not allow the water to run over the motor and cover.

1. Connect the water flow regulator to the diamond core drilling machine.
2. Remove the diamond core bit from the hole.
3. Lock the diamond core drilling machine with the carriage lock.
4. Switch off the diamond core drilling machine.
5. Switch off the wet-type industrial vacuum extractor, if used.

Removal of the diamond core drilling machine

1. Unplug the supply cord from the power outlet.
2. See the section headed “Removing the diamond core bit” → page 12 for instructions on removing the diamond core bit.
3. Remove the core, if necessary.
4.  Remove the diamond core drilling machine from the working surface.

If you remove the system as a complete unit, after setting it down it is advisable to run the machine all the way down the rail until the core bit is in contact with the floor. This will help prevent the diamond core drilling machine from toppling over.

Care and maintenance

WARNING
Electric shock hazard! Attempting care and maintenance with the supply cord connected to a power outlet can lead to severe injury and burns.

• Always unplug the supply cord before carrying out care and maintenance tasks.

Care

• Carefully remove any dirt that may be adhering to parts.
• Clean the air vents carefully with a dry brush.
• Use only a slightly damp cloth to clean the casing. Do not use cleaning agents containing silicone as these may attack the plastic parts.

Maintenance
WARNING
Danger of electric shock! Improper repairs to electrical components may lead to serious injuries including burns.

• Repairs to the electrical section of the tool or appliance may be carried out only by trained electrical specialists.
• Check all visible parts and controls for signs of damage at regular intervals and make sure that they all function correctly.
• Do not operate the product if signs of damage are found or if parts malfunction. Have it repaired immediately by Hilti Service.
• After cleaning and maintenance, fit all guards or protective devices and check that they function correctly.

To help ensure safe and reliable operation, use only genuine Hilti spare parts and consumables. Spare parts, consumables and accessories approved by Hilti for use with the product can be found at your local Hilti Store or online at: www.hilti.group.

Adjusting the play between the rail and carriage

1. Tighten the carriage play adjusting screws with a hex key.
2. Slacken the adjusting screws slightly by turning back a 1/4 turn.
3. The carriage is correctly adjusted when it remains in position without a diamond core bit but moves down when a diamond core bit is fitted.

Replacing the carbon brushes 11
WARNING
Risk of injury due to electric shock!

• The machine may be operated, serviced and repaired only by trained, authorized personnel. This personnel must be specially informed of any possible hazards.

WARNING
Electric shock hazard! Attempting care and maintenance with the supply cord connected to a power outlet can lead to severe injury and burns.

• Always unplug the supply cord before carrying out care and maintenance tasks.

1. Open the carbon brush covers on the left-hand and right-hand sides of the motor.
2. Take note of how the carbon brushes are fitted and how the conductors are positioned. Remove the worn carbon brushes from the diamond core drilling machine.
3. Fit the new carbon brushes, positioning them exactly the same as the old ones fitted previously. Take care to avoid damaging the insulation on the indicator lead as you insert the brushes.
4. Screw on the carbon brush covers on the left- and right-hand side of the motor.
5. Run in the carbon brushes by letting the machine run under no load for at least one minute without interruption.
   ➥ The indicator lamp goes out after approx. 1 minute’s operation.

Transport and storage

Transport

• Do not transport this product with an accessory tool installed.
• Make sure that the equipment is held securely throughout all transport operations.
• After transporting, always check all visible parts and controls for signs of damage and make sure that they all function correctly.

Storage

• Always store this product with the electric supply cable unplugged from the electricity supply.
• Store this product in a dry place, where it cannot be accessed by children or unauthorized persons.
• After a long period of storage, always check all visible parts and controls for signs of damage and make sure that they all function correctly.

Transport of the diamond core drilling machine
WARNING
Risk of injury! Parts can work loose and drop off.

• Do not lift the diamond core drilling machine and/or the drill stand by crane.

• Transport the diamond core drilling machine, drill stand and core bit as separate units.
  ➥ Use the wheel assembly (accessory) as an aid when transporting the equipment.

• Open the water flow regulator before stowing away the diamond core drilling machine.

Troubleshooting

• If the trouble you are experiencing is not listed in this table or you are unable to remedy the problem by yourself, please contact Hilti Service.

The diamond core drilling machine is not in working order

The service indicator shows nothing.

| The PRCD isn’t switched on.| ▶  Check that the PRCD is

functioning and switch it on.

Interruption in the electric supply.| ▶ Plug in another electric tool or appliance and check whether it works.

▶ Check the plug connections, supply cord, power supply line

and main supply fuse.

The on / off switch is defective.| ▶ Have the machine repaired by

Hilti Service.

Fault in the electronics.| ▶ Have the machine repaired by

Hilti Service.

Water in the motor.| ▶ Allow the diamond core drilling machine to dry out completely

in a warm, dry place.

Service indicator lights.

| The carbon brushes are worn out.| ▶ Replace the carbon brushes.

Service indicator flashes.

| Motor speed error.| ▶ Have the machine repaired by Hilti Service.

The drilling performance indi- cator flashes red.

| The motor has overheated.| ▶ Wait a few minutes until the motor has cooled down or allow the diamond core drilling machine to run under no load in order to speed up the cooling process. Switch the diamond core drilling machine off and

then on again.

Overload error.| ▶  Switch the diamond core drilling

machine off and then on again.

Theft protection indicator

blinks.

| The diamond core drilling machine has not been unlocked (machines with optional theft protection sys- tem).| ▶ Use the TPS key to unlock the diamond core drilling machine.
Malfunction| Possible cause| Action to be taken
---|---|---

Service indicator lights.

| The carbon brush wear limit has almost been reached. The diamond core drilling machine will continue to run for a few hours until it shuts

down automatically.

| ▶ Have the carbon brushes replaced at the next opportunity.
Malfunction| Possible cause| Action to be taken
---|---|---
The diamond core drilling machine doesn’t achieve full performance.| Supply network fault – undervolt- age occurred.| ▶ Check whether other power consumers are disrupting the power supply from the network or generator.

▶  Check the length of the exten-

sion cord used.

The diamond core bit doesn’t rotate.| The gear selector isn’t engaged.| ▶ Operate the gear selector until

it engages.

The diamond core bit has become jammed in the base material.| ▶ Use an open- end wrench to release the diamond core bit: Disconnect the supply cord plug from the power outlet. Grip the diamond core bit with a suitable open-end wrench close to the connection end and release the

diamond core bit by rotating it.

Stand-guided drilling

▶ Turn the handwheel and try to release the diamond core bit by moving the carriage up and

down.

The gearing is defective.| ▶ Have the machine repaired by

Hilti Service.

The drilling speed is decreas- ing.| Maximum drilling depth has been

reached.

| ▶ Remove the core and use a core

bit extension.

The core is stuck in the diamond

core bit.

| ▶ Remove the core.
Wrong core bit specification for the

base material.

| ▶ Select a more suitable diamond

core bit specification.

High steel content (indicated by clear water containing metal cut-

tings).

| ▶ Select a more suitable diamond core bit specification.
The diamond core bit is defective.| ▶ Check the diamond core bit for damage and replace it if

necessary.

Wrong gear selected.| ▶  Select the right gear.
Contact pressure is too low.| ▶  Increase the contact pressure.
The machine has too little power.| ▶  Select the next lower gear.
The diamond core bit is polished.| ▶ Sharpen the diamond core bit by drilling into a sharpening

plate.

The water flow rate is too high.| ▶ Reduce the water flow rate by adjusting the water flow

regulator.

The water flow rate is too low.| ▶ Check the water supply to the diamond core bit or, respectively, increase the water flow by adjusting the water flow

regulator.

The brake has been applied.| ▶ Release the brake.
Safety clutch disengages too soon

or is slipping.

| ▶ Have the machine repaired by

Hilti Service.

The handwheel can be turned

without resistance.

| The split pin is broken.| ▶ Replace the split pin.
Malfunction| Possible cause| Action to be taken
---|---|---
The diamond core bit can’t be fitted into the chuck.| The core bit connection end or chuck is dirty or damaged.| ▶ Clean and grease the connec- tion end and/or the chuck or

replace these parts.

Water escapes at the water

swivel or gear housing.

| The water pressure is too high.| ▶ Reduce the water pressure.
Water escapes from the chuck during operation.| The diamond core bit isn’t securely tightened in the chuck.| ▶ Tighten the diamond core bit securely.

▶ Remove the core bit. Rotate the diamond core bit approx. 90° about its own axis. Refit the

diamond core bit.

The core bit connection end /

chuck is dirty.

| ▶ Clean and grease the connec-

tion end and/or the chuck.

The seal at the chuck or at the

connection end is defective.

| ▶ Check the seal and replace it if

necessary.

The drilling system has too much play.| The diamond core bit isn’t securely tightened in the chuck.| ▶ Tighten the diamond core bit securely.

▶ Remove the core bit. Rotate the diamond core bit approx. 90° about its own axis. Refit the

diamond core bit.

The core bit connection end / chuck is defective.| ▶ Check the connection end and chuck and replace them if

necessary.

The carriage has too much play.| ▶  Adjust the play between the rail

and carriage. → page 15

Screws / bolts on the drill stand are loose.| ▶  Check the security of screws

/ bolts on the drill stand and

tighten them if necessary.

The drill stand is inadequately fas-

tened.

| ▶  Fasten the drill stand more

securely.

Disposal

Most of the materials from which Hilti tools and appliances are manufactured can be recycled. The materials must be correctly separated before they can be recycled. In many countries, your old tools, machines or appliances can be returned to Hilti for recycling. Ask Hilti Service or your Hilti representative for further information.

• Do not dispose of power tools, electronic equipment or batteries as household waste!

Pretreatment of drilling slurry for disposal
The disposal of drilling slurry directly into rivers, lakes or the sewerage system without suitable pretreatment presents problems of an environmental nature. Ask the local public authorities for information about current regulations.

1. Collect the drilling slurry (e.g. using a wet-type industrial vacuum extractor).
2. Allow the drilling slurry to settle and dispose of the solid material at a construction waste disposal site (adding a flocculant can accelerate the settling process).
3. Neutralize the left-over water (alkaline, pH > 7) by adding acidic neutralizing agent or diluting it with a large quantity of water before it is allowed to flow into the sewerage system.

RoHS (Restriction of Hazardous Substances)
Click on the link to go to the table of hazardous substances: qr.hilti.com/r3677 (DD 120). There is a link to the RoHS table, in the form of a QR code, at the end of this document.

Manufacturer’s warranty

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

EC Declaration of Conformity | UK Declaration of Conformity

Manufacturer:
Hilti Corporation
Feldkircherstraße 100
9494 Schaan | Liechtenstein

Importer
Hilti (Gt. Britain) Limited
1 Trafford Wharf Road, Old Trafford
Manchester, M17 1BY

Serial Numbers: 1-99999999999
EN 62841-3-6:2014 +A11:2017
2006/42/EC I Supply of Machinery (Safety)
Regulations 2008
EN 62841-1:2015+
AC: 2015
EN 55014-1:2021
2014/30/EU | Electromagnetic Compatibility Regulations 2016
EN 55014-2:2021
2011/65/EU I The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012
EN 61000-3-2:2019,
A1: 2021
EN 61000-3-3:2013+ A1:2019

Hilti Corporation
LI-9494 Schaan
Tel.: +423 234 21 11
Fax: +423 234 29 65
www.hilti.group

References

• HILTI Country selector
• HILTI Country selector
• Главная страница - Hilti Россия

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