Hilti 3503116 Use and Care Manual
Contents
1. With without the drill stand Core bit diameter Drilling direction Hand guided dry 37 162 mm All directions 11 2 61 4 8 132 mm 5 Not upwards Hand guided wet Hand guided wet With water collection 8 62 mm 1 2 21 2 All directions System On drill stand wet Without water collec 162 mm Not upwards tion system 76141 On drill stand wet All directions Core bit diameters Core bit diameters mm inches 102 162 28 87 11 2 31 2 2 75 2850 Speed under no load min Hand guided wet Core bit diameters mm 121 131 41 111 Gear Core bit diameters inches Speed under no load min 1 4 1 520 8 36 Core bit diameters mm 122 162 Vo MP Core bit diameters inches Speed under no load min Sy sla 37 62 Core bit diameters mm 2 4 Status indicator LED indicators State Core bit diameters inches Speed under no load min Description information Theft protection indicator 11 Blinking yellow light The machine s theft protection sys tem is active and must be unlocked with the TPS key Service indicator 12 starts Red light and the machine The carbon brushes are badly worn After the lamp lights for the first time the machine may continue to be used for several2. raneous comments and oral or written agreements concerning warranties eli Ti Hilti Corporation LI 9494 Schaan Tel 423 23421 11 Fax 423 234 29 65 www hilti com Hilti registered trademark of Hilti Corp Schaan W 3982 0711 00 Pos 3 1 Printedin Germany 2011 434950 E Right of technical and programme changes reserved S amp O
3. back onto the column of the drill stand in order to continue drilling 10 After removing the Rota Rail refit the end stop screw to the end of the rail 7 8 Procedure in the event of the core bit sticking In the event of the core bit sticking the clutch will slip until the user switches the power tool off The core bit can be released by taking the following action 1 8 1 Using an open end wrench to release the core hit 1 Disconnectthe supply cord plug from the power outlet 2 Grip the core bit with a suitable open end wrench close to the connection end and release the core bit by rotating it 3 Plug the machine s supply cord into the power outlet 4 Resume the drilling operation 7 8 2 Using the hand wheel to release a core bit when using the drill stand 1 Disconnectthe supply cord plug from the power outlet 2 Release the core bit from the hole by turning it with the hand wheel 3 Plug the machine s supply cord into the power outlet 4 Resume the drilling operation 7 9 Dismantling CAUTION Disconnect the supply cord plug from the power outlet 1 For instructions on removing the diamond core bit please refer to the section Removing the diamond core bit 2 Remove the core if necessary 1 10 Disposing of drilling slurry Please refer to the section Disposal 7 11 Transport and storage Open the water flow regulator before putting the machine into storage 19 CAUTION When temperature
4. bubble level on the base plate indicates when the base plate is level 5 Tighten the quick release brace securely 6 Checkto ensure that the drill stand is secure 6 1 9 Fastening the drill stand with the jack Screw 1 Fitthe jack screw at the top end of the rail 2 Position the drill stand on the work surface 3 Level the base plate by turning the four leveling screws 4 Secure the base plate by tightening the jack screw 5 Check to ensure that the machine is fastened securely 6 1 10 Adjusting the drilling angle when using the drill stand with combination base plate in 7 5 increments adjustable to max 45 CAUTION There is a risk of crushing the fingers in the pivot mechanism Wear protective gloves 1 Atthe foot of the drill stand release the adjusting lever until the sliding nuts are disengaged 2 Adjustthe column to the desired angle 3 Tighten the adjusting lever until the sliding nuts are fully engaged and the columnis again secured in position 6 1 11 Connecting the vacuum removal system 1 Unscrewthe cover from the water swivel suction head 2 Push the suction hose into the suction hose connector 3 Closethe water valve on the side handle 6 1 12 Fitting the water connection CAUTION Regularly check the hoses for damage and make sure that the maximum permissible water supply pressure of 6 bar is not exceeded CAUTION Make sure that the hose doesn t come into contact with rot
5. defective Guide the machine straight Relieve the load on the machine and press the switch several times to restart The machine should be repaired by Hilti Service The cooling fan is defective The retaining pin is broken The machine should be repaired by Hilti Service Fit a new retaining pin Water escapes at the water Swivel or gear housing The water pressure is too high Reduce the water pressure The shaft seal is defective The machine should be repaired by Hilti Service No water flows The filter or water flow indicator is blocked Remove the filter or water flow indicator and flush it through 22 Fault Possible cause Remedy The diamond core bit cannot The core bit connection end or Clean the connection end chuck or be fitted into the chuck chuck is dirty or damaged replace if necessary Water escapes from the The core bit is not screwed se Tighten it securely chuck during operation curely into the chuck The core bit connection end chuck Clean the connection end chuck is dirty The chuck or connection end seal Check the seal and replace it if nec is defective essary Excessive play in the drilling The core bit is not screwed se Tighten it securely system curely into the chuck The leveling screws or clamping Tighten the leveling screws or spindle are not tightened clamping spindle Excessive play at the carriage Adju
6. diamond coring machine CD Water swivel suction head 2 Water flow rate indicator 3 Side handle Water flow regulator 5 Water connection 8 Gear selector Gearing section Motor 9 On off switch Grip 7 Theft protection indicator option 12 Service indicator 3 Drilling performance indicator Carbon brush cover 5 Supply cord with Type identification plate 7 Interface plate Connector screws water swivel suction head Cover water swivel suction head Suction hose connector Chuck Drill stand 22 Grip 3 Column Carriage 05 Carriage lock Type identification plate 07 Vacuum release valve Vacuum hose connector Vacuum seal Base plate 8 Pressure gauge 82 Leveling indicator 83 Adjusting lever Leveling screws 85 Hole center indicator Depth gauge 67 Locking pin Carriage play adjusting screw End stop screw Supply cord holder Hand wheel accessories Star handle Lever Water collector for manual operation Eccentric pin Clamping screw Depth gauge Water collector Centering ring Centering ring adapter Seal Machine mount 1 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 dange
7. gear while the machine is running Wait until the drive spindle has stopped rotating WARNING When using a two part hole starting aid do not allow the machine to run without contact with the work surface 7 1 TPS theft protection system optional NOTE The machine may be equipped with the optional theft protection system If the machine is equipped with this feature it can be unlocked and made ready for operation only with the corresponding TPS key 7 1 1 Unlocking the machine 1 Connect the supply cord to the electric supply and press the I or Reset button on the ground fault circuit interrupter The yellow theft protec tion indicator LED blinks The machine is now ready to receive the signal from the TPS key 2 Hold the TPS key or the TPS watch strap buckle againstthe lock symbol The machine 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 work place the machine 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 machine 1 1 2 Activation of the theft protection system for the machine 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 2 Switching
8. hours before the auto matic cut out is activated Have the carbon brushes changed in good time so that the machine is always ready NOTE for use Red light and the machine The carbon brushes must be doesn t start changed Blinking red light Temporary fault see Troubleshooting section Drilling performance indicator 13 Orange light Contact pressure too low only in conjunction with the drill Green light Optimum contact pressure stand Red light Contact pressure too high When using the machine for hand guided coring the drilling performance indicator gives no indication of the optimum pressure 2 5 TPS theft protection system optional The machine may be optionally equipped with the TPS theft protection system If equipped with this feature the machine can be unlocked and made ready for operation only through use of the corresponding TPS key 2 6 Items supplied as standard 1 Machine 1 Operating instructions 1 Hilti toolbox or cardboard box EN 2 1 Using extension cords Use only extension cords of a type approved for the application and with conductors of adequate gauge Recommended minimum conductor gauge cross section and max cable lengths Conductor cross section Mains voltage 120 V Mains voltage 127 V 2 8 Using a generator or transformer 3 Accessories Designation Short designation Description TPS theft protection system with Option company card company remote and TPS K
9. position and secure it see Section 6 1 1 2 Fitthe hole starting aid optional operation 12 WARNING A water collection system with wet type vacuum cleaner must be used when drilling in an upwards direction NOTE The optional operations are to be carried out when the two part hole starting aid is used NOTE Start the wet type vacuum cleaner manually before opening the water supply valve and switch it off again manually when the drilling operation is completed and after closing the water supply valve NOTE Do not use the power outlet on the vacuum cleaner 1 If a water extraction system vacuum cleaner is used switch it on 2 Securethe side handle in the desired position 3 Fitthe hole starting aid optional operation 4 Plug the supply cord into the power outlet and press the Reset button or the I button on the PRCD 5 Position the machine at the point where the hole is to be drilled hole center 6 Slowly open the water flow regulator until the desired volume of water is flowing The indicator on the side handle can be used to check the water flow 7 Pressthe on off switch on the machine 8 When beginning drilling apply only light pres sure until the core bit has centered itself and then increase the pressure Drill to a depth of 3 5 mm to form a guide kerf optional operation 9 Switch the machine off by releasing the on off switch and then wait until the core bit has stopped rotating op
10. LE 009 Operating instructions en Mode d emploi fr instrucciones 5 Manual de instruc es pt This Product is Certified Ce produit est certifi Este producto esta certificado Este produto est certificado c Bus der E Hoo 267mm 101 2 LU U UU HE mm E gull J ORIGINAL OPERATING INSTRUCTIONS DD 150 U diamond coring system It is essential that the operating instruc tions are read before the machine is oper ated for the first time Always keep these operating instructions together with the machine Ensure that the operating instructions are with the machine when it is given to other persons Contents Page 1 General information 2 2 Description 3 3 Accessories 6 4 Technical data T 5 Safety instructions if 6 Before use 10 7 Operation 14 8 Care and maintenance 20 9 Troubleshooting 21 10 Disposal 23 11 Manufacturer s warranty 24 These numbers refer to the corresponding illustra tions The illustrations can be found on the fold out cover pages Keep these pages open while studying the operating instructions In these operating instructions the designation the machine always refers to the DD 150 U diamond core drilling machine Operating controls parts and indicators motor unit and drill stand DD 150 U
11. ar 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 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 8 b 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 the battery pack from the power tool before making any adjustments changing ac cessories or storing power tools Such preven tive safety measures reduce the risk of starting the power tool accidentally Store idle power tools out of the reach of chil dren 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 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 maintai
12. ating parts CAUTION Make sure that the hose is not pinched and damaged as the carriage advances CAUTION Max water temperature 40 C CAUTION Check the water supply system to ensure there are no leaks NOTE To avoid damage to the components use only fresh water containing no dirt particles 1 Close the cover on the water swivel suction head 2 Connect the water regulator to the machine 3 Connectthe water supply hose coupling 6 1 13 Fitting the water collection system accessory EJ WARNING Use of the water collection system in conjunction with a wet type industrial vacuum cleaner is a mandatory requirement for work on ceilings The machine must be positioned at an angle of 90 to the ceiling The seal used must be of the correct size for the diamond core bit diameter NOTE Use of the water collection system allows water to be led away in controlled fashion thus avoiding a mess or damage to the surrounding area Best results are achieved with a wet type industrial vacuum cleaner Release the screw at the front of the rail Push the water collector holder into position Fit the screw and tighten it Fit the water collector between the two movable arms of the water collector holder 5 Pressthe water collector against the work surface by turning the two screws on the water collector holder 6 Connecta wet type industrial vacuum cleaner to the water collector or fit a length of hose through w
13. bon brushes just as the old ones were fitted spare part numbers 100 127 V car bon brush set 2006844 220 240 V carbon brush set 2006843 NOTE Take care to avoid damaging the insulation on the indicator lead as you insert the brushes 5 Close the carbon brush covers on the left hand and right hand side of the motor and tighten the retaining screws 6 Allow the tool to run in for approx 1 min under no load NOTE After replacing the carbon brushes the indicator lamp will go out after the machine has run for approx 1 minute 8 5 Checking the power tool after care and maintenance NOTE 8 6 Adjusting the play between rail and carriage Play between the rail and the carriage can be adjusted by turning the carriage play adjustment screws Use an Allen key to tighten the carriage adjustment screws to torque of 5 Nm finger tight then turn the screws back 1 4 of a turn The carriage is correctly adjusted if it remains in position when no core bit is fitted but moves down under its own weight when a core bit is fitted After carrying out care and maintenance check that all protective and safety devices are fitted and that they function faultlessly 9 Troubleshooting Fault Possible cause Remedy The machine doesn t start The service indicator lights Interruption in the electric supply On off switch defective Interruption in the electric supply The electro
14. e hole starting aid into the open end of the diamond core bit 7 3 1 2 Vacuum cleaner with power outlet for power tools CAUTION Do not use slotted core bits when working with a dust removal system NOTE The optional operations are to be carried out when the two part hole starting aid is used 15 1 Bring the side handle into the desired position and secure it see Section 6 1 1 2 Fitthe hole starting aid optional operation 3 Plug the machine s supply cord into the power outlet on the vacuum cleaner 4 Plug the vacuum cleaner supply cord into the power outlet and press the Reset button or the button on the PRCD see Section 7 2 5 Position the machine at the point where the hole is to be drilled hole center 6 Pressthe on off switch on the machine NOTE The vacuum cleaner starts with a delay after the machine is switched on After switching the machine off the vacuum cleaner continues to run for a short time before switching itself off 7 When beginning drilling apply only light pres sure until the core bit has centered itself and then increase the pressure Drill to a depth of 3 5 mm to form a guide kerf optional operation 8 Switch the machine off by releasing the on off switch and then wait until the core bit has stopped rotating optional operation 9 Remove the hole starting aid from the core bit optional operation 10 Position the core bit in the guide kerf and then press the
15. erating instructions concerning operation care and maintenance Nationally applicable industrial safety regulations must be observed The machine accessories and cutting tools may present hazards when handled incorrectly by untrained personnel or when used not as directed Use of the water collection system in conjunction with a wet type industrial vacuum cleaner is a mandatory requirement for wet drilling overhead Use of the vacuum fastening method for overhead drilling is prohibited An additional means of securing the drill stand must be employed when the machine is secured with the vacuum base plate accessory for horizontal drilling Do not strike the base plate with a hammer or other heavy object when making adjustments to it Tampering with or modification of the machine drill stand and accessories is strictly prohibited WARNING The machine may be operated only when connected to an adequately rated electric supply equipped with an earth ground conductor WARNING Drilling into materials hazardous to the health e g asbestos is not permissible DANGER Use only the genuine Hilti accessories or ancillary equipment listed in the operating instructions Use of accessories or ancillary equipment not listed in the operating instructions may present a risk of personal injury 2 2 Use of the machine with various items of equipment With without the system With dust removal system Without water collec tion system
16. hich the water can drain away pe onm 6 1 14 Fitting the diamond core bit DANGER To avoid injury use only genuine Hilti core bits and DD 150 U accessories If using a machine with a Bl chuck only genuine Hilti core bits may be used with it CAUTION The core bit may become hot during use or during sharpening There is a risk of burning your hands Wear protective gloves when changing the core bit CAUTION Disconnect the supply cord plug from the power outlet NOTE If using an alternative type of chuck lock the drive spindle with a suitable open end wrench and use 13 another suitable open end wrench to tighten the core bit 1 Engage the carriage locking system with the channel and check that the channel is securely fastened 2 Open the chuck Bl by turning it in the direction of the open brackets symbol 3 Push the diamond core bit into the chuck Bl from below turning the core bit until the teeth in the chuck engage with the core bit 4 Closethechuck Bl by turning it in the direction of the closed brackets symbol 5 Check that the diamond core bit is securely mounted in the chuck by pulling on the core bit and attempting to move it from side to side 6 1 15 Selecting the speed CAUTION Do not change gear while the machine is running Wait for the spindle to come to a halt 1 Set the switch to the correct position according to the core bit diameter used see Section 2 3 When turning the
17. hing the machine In order to avoid the risk of collapse it is important that the parts are assembled correctly Attach the machine to the mounting device se curely before beginning use Movement of the machine on the mounting device could lead to loss of control Place the mounting device on a solid flat and level surface If the mounting device can slip or wobble the machine cannot be guided smoothly and safely Check the nature of the surface Rough surfaces may reduce holding power Coatings or composite materials may pull away from the surface while you are working Do not overload the mounting device and do not use it as a substitute for a ladder or platform Overloading the mounting device or standing on it may shift its center of gravity to a higher position causing it to tip over Respiratory protection must be worn if the ma chine is used without a dust extraction system for work that creates dust Improve the blood circulation in your fingers by relaxing your hands and exercising your fingers during breaks between working 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 When using the equipment always lead the supply cord the extension cord and the water hose if applicable away from the machine to the rear This will reduce the risk of tripping and falli
18. ings 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 atmo spheres 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 oper ating a power tool Distractions can cause you to lose control 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 con ditions 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 o
19. isposal of drilling dust can be problematic Ask the local public authorities for information about current regulations 23 11 Manufacturer s warranty Hilti warrants that the tool supplied is free of defects in material and workmanship This warranty is valid so long as the tool is operated and handled correctly cleaned and serviced properly and in accordance with the Hilti Operating Instructions and the technical system is maintained This means that only original Hilti consumables components and spare parts may be used in the tool This warranty provides the free of charge repair or replacement of defective parts only over the entire lifespan of the tool Parts requiring repair or replace ment as a result of normal wear and tear are not covered by this warranty Additional claims are excluded unless stringent na tional rules prohibit such exclusion In particular Hilti is not obligated for direct indirect inciden tal or consequential damages losses or expenses in connection with or by reason of the use of or inability to use the tool for any purpose Im plied warranties of merchantability or fitness for a particular purpose are specifically excluded For repair or replacement send the tool or related parts immediately upon discovery of the defect to the address of the local Hilti marketing organization provided This constitutes Hilti s entire obligation with regard to warranty and supersedes all prior or contempo
20. itch and then wait until the core bit has 5 Slowly open the water flow regulator until the stopped rotating optional operation desired volume of water is flowing 8 Remove the hole starting aid from the core bit 6 Press the on off switch on the machine optional operation 7 When beginning drilling apply only light pres sure until the core bit has centered itself and then increase the pressure Drill to a depth of 3 5 mm to form a guide kerf optional operation 8 Switch the machine off by releasing the on off switch and then wait until the core bit has stopped rotating optional operation 9 Remove the hole starting aid from the core bit optional operation 10 Position the core bit in the guide kerf and then press the on off switch to continue drilling optional operation 9 Position the core bit in the guide kerf and then press the on off switch to continue drilling optional operation 7 4 Hand guided wet drilling without use of a water collection system 7 5 Hand guided wet drilling with use of a water collection system WARNING Water must not be allowed to run over the motor and cover WARNING A water collection system with wet type vacuum cleaner must be used when drilling in an upwards direction NOTE WARNING The optional operations are to be carried out when niot allowed 1G run Over the motor the two part hole starting aid is used 1 Bring the side handle into the desired
21. key Water collection system for use with the drill stand Water collection system for hand guided drilling Drill stand with combination base plate and tilt mechanism Drill stand with anchor base plate Vacuum base plate DD ST 120 160 VBP Depth gauge Hand wheel lever Hand wheel star handle Core bit extension Bl Jack screw Rota Rail column swivel 4 Technical data Right of technical changes reserved NOTE The machine is available in various voltage ratings Please refer to the machine s type identification plate for details of its rated voltage and rated input power Rated voltage V Rated current A Mains frequency Hz tner information mi Max permissible water supply pressure 6 bar 87 02 psi Drilling depth 450 mm Machine dimensions L x W x H 516 mm 20 31 x 129 mm 5 08 x 159 mm 6 26 Drill stand dimensions L x W x H 610 mm 24 02 x 250 mm 9 84 x 952 mm 37 48 Weight of machine Weight of the DD ST 150 drill stand with combina tion base plate and carriage 8 2 kg 18 08 Ib 13 3 kg 29 32 Ib Rated speed under no load 780 min 1st gear 1520 min 2nd gear 2850 min 3rd gear Protection class Protection class earthed 5 Safety instructions 5 1 2 Electrical safety 5 1 General Power Tool Safety Warnings a ZN WARNING Read all safety warnings and instructions Fail ure to follow the warn
22. lling without a dust removal system NOTE The optional operations are to be carried out when the two part hole starting aid is used CAUTION Disconnect the machine from the power outlet be fore removing the core from the slotted core bit DANGER Wear respiratory protection NOTE Dust is released in all directions Drilling without a dust removal system especially overhead drilling is very unpleasant and optimum performance is not achieved Overhead drilling without use of dust re moval system is therefore not recommended For dry coring it is recommended that the dust removal at tachment and a suitable vacuum cleaner are always used 1 Secure the side handle in the desired position 2 Fitthe hole starting aid optional operation 3 Insert the supply cord plug in the power outlet and then press the Reset button or I button on the PRCD if applicable 4 Position the machine at the point where the hole is to be drilled hole center 5 Pressthe on off switch on the machine 6 When beginning drilling apply only light pres 3 Plug the supply cord into the power outlet and sure until the core bit has centered itself and then press the Reset button or the I button on the increase the pressure Drill to a depth of 3 5 mm PRCD to form a guide kerf optional operation 4 Position the machine at the point where the hole 7 Switch the machine off by releasing the on is to be drilled hole center off sw
23. lter mesh through with water in the direction opposite to the normal water flow If the water flow indicator is dirty remove it from the machine and clean it as necessary Do not use abrasive cleaning agents or sharp objects to clean the sight glass This may adversely affect the functionality of the water flow 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 Replacing the carbon brushes A NOTE The indicator lamp with wrench symbol lights up when the carbon brushes need to be replaced DANGER The machine may be operated serviced and re paired only by trained authorized personnel This personnel must be particularly informed of any possible hazards Failure to observe the following instructions may result in contact with dangerous electric voltage 1 Disconnectthe machine from the electric supply 2 Open the carbon brush covers on the left hand and right hand side of the motor 3 Take note of how the carbon brushes are fitted and how the conductors are positioned Remove the worn carbon brushes from the machine 4 Fitthe new car
24. ned 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 5 1 5 Service 8 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 Drill safety warnings Wear ear protectors when impact drilling Ex posure to noise can cause hearing loss Use auxiliary handle s if supplied with the tool Loss of control can cause personal injury Hold power tool by insulated gripping 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 operatoran electric shock 5 3 Additional safety rules 5 3 1 Personal safety A d 9 h 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 Check that the side handle is tightened securely Assemble the parts of the mounting device cor rectly before attac
25. ng down process Switch the machine off and on again Use the TPS key to unlock the power tool blinks yellow protection system The motor runs The diamond Gear selector doesn t engage Move the gear selector until felt to core bit doesn t rotate engage The gearing is defective If necessary the machine should be repaired by Hilti Service Drilling speed drops The diamond core bit is polished Sharpen the diamond core bit on a sharpening plate with water flow ing The diamond core bit is polished The wrong type of core bit has been used Seek advice from Hilti Water pressure flow rate too high Reduce the water flow rate by ad justing the flow regulator The core is stuck in the core bit Remove the core Maximum drilling depth is reached The diamond core bit is defective Remove the core and use a core bit extension Check the diamond core bit for damage and replace it if necessary The slip clutch is disengaging pre maturely or slipping If necessary the machine should be repaired by Hilti Service The carriage is locked Unlock the carriage The water flow rate is too low Adjust open the water flow regu lator Check the water supply The motor cuts out The handwheel turns but doesn t engage The machine has stalled The machine is too hot The motor overheating protection system has been activated The electronics are
26. ng over the cord or hose while working Avoid skin contact with drilling slurry m Wear protective gloves when changing core bits The core bit may become hot during use n Children must be instructed not to play with the machine 0 The machine is not intended for use by chil dren by debilitated persons or those who have received no instruction or training p WARNING Some dust created by grinding sanding cutting and drilling contains chem icals known to cause cancer birth defects infertility or other reproductive harm or seri ous and permanent respiratory or other injury Some examples of these chemicals are lead from lead based paints crystalline silica from bricks concrete and other masonry products and natural stone arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce exposure to these chemi cals the operator and bystanders should work in a well ventilated area work with approved safety equipment such as respiratory protec tion appropriate for the type of dust generated and designed to filter out microscopic particles and direct dust away from the face and body Avoid prolonged contact with dust Wear pro tective clothing and wash exposed areas with soap and water Allowing dust to get into your mouth nose eyes or to remain on your skin may promote absorption of harmful chemicals 5 3 2 Power tool u
27. nics are defective Water in the machine The carbon brushes are worn the machine will continue to run for a few hours Plug in another electric appliance and check whether it works Check the plug connections supply cords and extension cords PRCD and electric supply If necessary the power tool should be repaired by Hilti Service Check the supply cord extension cord supply cord plug PRCD and have them replaced by a qualified electrician if necessary The machine should be repaired by Hilti Service Dry the machine The machine should be repaired by Hilti Service The carbon brushes should be changed See section 8 4 Replacing the car bon brushes T The machine doesn t start and the service indicator lights The machine doesn t start carbon brushes have been changed service indicator lights The carbon brushes are worn A fault has occurred in the power tool Replace the carbon brushes See section 8 4 Replacing the car bon brushes ET If necessary the power tool should be repaired by Hilti Service Fault Possible cause Remedy The machine doesn t run and the service indicator blinks The machine doesn t start theft protection indicator The machine has overheated Overload error The power tool has not been un locked tools with optional theft Wait a few moments until the mo tor has cooled down or allow it to run under no load in order to speed up the cooli
28. nning drilling apply only light pres sure until the core bit has centered itself and then increase the pressure 6 Regulate the contact pressure while observing the drilling performance indicator NOTE The drilling performance indicator lights orange after switching on Optimum drilling per formance is achieved when the drilling perfor mance indicator shows a green light If the drilling performance indicator shows a red light reduce the pressure applied to the core bit 7 7 Using the Rota Rail column swivel CAUTION Do not use the Rota Rail as a column extension The Rota Rail allows quick and easy access to the hole being drilled or to the core with no need to partly or fully dismantle the system 1 Switch the machine off 2 Lock the carriage on the channel by engaging the carriage locking mechanism and check that it is securely attached 3 Remove the end stop screw from the end of the rail 4 Attach the Rota Rail so that the toothed racks are facing the same direction 5 Tighten the screw on the Rota Rail securely 6 Release the carriage lock and run the carriage along the rail onto the Rota Rail 7 Release the Rota Rail fastening screw and pivot the machine with the Rota Rail to the left or right to provide access to the hole being drilled 8 Remove the core or change the core bit 9 Pivot the machine back to its original position tighten the Rota Rail fastening screw securely and then run the carriage
29. on off switch to continue drilling optional operation 7 3 1 3 Vacuum cleaner without power outlet for power tools CAUTION Do not use slotted core bits when working with a dust removal system NOTE The optional operations are to be carried out when the two part hole starting aid is used 1 Bring the side handle into the desired position and secure it see Section 6 1 1 2 Fitthe hole starting aid optional operation 3 Plug the vacuum cleaner s supply cord into the power outlet and switch the vacuum cleaner on 4 Plug the machine s supply cord into the power outlet and press the Reset button or the I button on the PRCD see Section 7 2 5 Pressthe on off switch on the machine 6 When beginning drilling apply only light pres sure until the core bit has centered itself and then increase the pressure Drill to a depth of 3 5 mm to form a guide kerf optional operation 7 Switch the machine off by releasing the on off switch and then wait until the core bit has stopped rotating optional operation 8 Remove the hole starting aid from the core bit optional operation 9 Position the core bit in the guide kerf and then press the on off switch to continue drilling optional operation 10 Allow the vacuum cleaner to run for a few sec onds after switching off the machine in order to ensure that the remaining dust is removed 7 3 2 Working without dust removal NOTE Use slotted core bits when dri
30. on and checking the ground fault circuit interrupter PRCD An isolating transformer must be used with machines not equipped with a PRCD 1 Plug the machine s supply cord earthed grounded power outlet 2 Press the I or Reset button on the ground fault circuit interrupter PRCD The drilling performance indicator lights orange 3 Press the 0 or Test button on the ground fault circuit interrupter PRCD The indicator must go out into an 4 WARNING If the indicator continues to light further operation of the machine is not per missible Have the machine repaired by trained personnel using genuine Hilti spare parts Press the I or Reset button on the ground fault circuit interrupter PRCD The indicator must light 7 3 Hand guided dry drilling NOTE If a considerable quantity of dust collects in the core bit this can cause the core bit to run out of balance Remove the dust from the core bit 7 3 1 Dry drilling with dust removal CAUTION When working always lead the vacuum cleaner hose away to the rear of the machine so that it cannot come into contact with the core bit CAUTION Please read the operating instructions for the vac uum cleaner for information about disposal of the material collected NOTE To avoid electrostatic effects use an anti static vac uum cleaner 7 3 1 1 Fitting the hole starting aid A different hole starting aid is required for each core bit diameter Fit th
31. on the side handle 6 Connectthe water supply 6 1 6 Removing the machine from the drill stand DANGER The machine must be disconnected from the electric supply The carriage must be locked in position 1 Closethe water valve on the side handle 2 Disconnect the water supply 3 Remove the switch locking device from the grip 4 Use the hand wheel to release the locking pin turn counterclockwise 5 Pullthe locking pin out of the slot 11 6 Pivot the machine away from the drill stand 6 1 7 Fastening the drill stand by vacuum DANGER Overhead drilling with the machine secured only by the vacuum base plate is not permissible CAUTION Make yourself familiar with information contained in the operating instructions for the vacuum pump and follow these instructions before using it WARNING Before beginning drilling and during operation it must be ensured that the pressure gauge indicator remains within the green area NOTE Optional when using the drill stand with the anchor base plate Screw the anchor base plate onto the vacuum base plate NOTE Make sure that the anchor base plate lies flat against the vacuum base plate and that the two plates are se curely connected Make sure that the core bit selected for use will not damage the vacuum base plate 1 Turn retract the 4 leveling screws until they project approx 5 mm beneath the combination base plate or respectively the vacuum base plate 2 C
32. onnect the vacuum pump to the vacuum con nector on the combination base plate or vacuum base plate 3 Locate the center point of the hole to be drilled 4 Draw a line approximately 800 mm in length from the center of the hole to be drilled towards where the drill stand is to be positioned 5 Make a mark on the line at a distance of 292 mm 11 from the center of the hole to be drilled 6 Switch on the vacuum pump and press the vacuum release valve 7 Bringthe mark on the combination base plate or vacuum base plate into alignment with the line 8 Once the drill stand has been positioned cor rectly release the vacuum release valve and press the base plate against the work surface 9 Level and steady the combination base plate or vacuum base plate by turning the 4 leveling SCrews 10 An additional means of securing the drilling sys tem must be provided when drilling horizontally e g a chain attached to an anchor etc 11 Make sure that the drilling system is secured reliably 6 1 8 Securing the system with the quick release brace e g between floor and ceiling 1 Extend the hole center indicator and use it to help bring the drill stand into position at the hole center 2 Position the quick release brace on the base plate not on the level indicator or pressure gauge 3 Apply slight pressure to the base plate by adjust ing the quick release brace 4 Use the four leveling screws to level the base plate The
33. requirement for working on ceilings 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 Upper An additional means of securing the drill stand must be employed when the machine is used for Type horizontal drilling with the vacuum securing method ut Generation 01 Serial no 2 Description 2 1 Use of the product as directed The DD 150 U is an electrically powered diamond core drilling machine for hand guided wet and dry drilling of through holes or blind holes e g anchor holes and for wet drilling of through holes or blind holes in reinforced mineral materials with the machine mounted on a drill stand When mounted on the drill stand the system must be adequately secured to the working surface with an anchor or vacuum base plate before use Drilling into materials that produce electrically conductive dust e g magnesium is not permissible Where possible use a suitable industrial vacuum cleaner when working with the system e g the Hilti VC 20 U UM VC 40 U UM or VC 60 U To avoid injury use only genuine Hilti core bits and DD 150 U accessories Observe the safety rules and operating instructions for the accessories used Observe the information printed in the op
34. rous 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 Prohibition signs Transport by crane is not permissible Warning signs A A General Warning Warning hot warning electricity surface Water collector for drill stand operation 57 Holder 2 Water collector 63 Seal Various accessories E Jack screw 65 Wheel assembly Rota Rail 67 Switch lock for drill stand operation Vacuum base plate Obligation signs Wear eye Wear a hard Wear ear Wear protection hat protection protective gloves Wear safety Wear shoes breathing protection Symbols ES D Read the Lock symbol Equipped with Return waste operating theft material for instructions protection recycling before use system Service indicator Drilling Amps performance indicator V Volts Lower Use of the vacuum securing method for over U W Hz no head drilling with the drill stand is not permissible On the machine Alternating Watts Hertz Nominal speed current under no load RPM Diameter Millimeters Revolutions per minute Revolutions per minute On the drill stand and the vacuum base plate Use of the water collection system in conjunction with a wet type industrial vacuum cleaner is a mandatory
35. s drop below zero check to en sure that no water remains in the power tool WARNING Do not lift the machine and or the drill stand by crane 8 Care and maintenance CAUTION Disconnect the supply cord plug from the power outlet 8 1 Care of cutting tools and metal parts Remove any dirt adhering to the surface of cutting tools the chuck and drive spindle and protect their surfaces from corrosion by rubbing them with an oily cloth from time to time Always keep the connection end clean and lightly greased 8 2 Care of the machine CAUTION Keep the machine especially its grip surfaces clean and free from oil and grease Do not use cleaning agents which contain silicone The outer casing of the machine is made from impact resistant plastic Never operate the machine 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 machine Clean the outside of the machine 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 machine Clean the chuck and the clamping segments with a cloth at regular intervals and lubricate the parts with Hilti lubricant spray Remove any particles of foreign matter from the chuck Remove the filter from the water inlet on the side handle occasionally and flush the fi
36. se and care a 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 b Check that the core bits used are compatible with the chuck system and that they are secured in the chuck correctly c Switch the machine off and unplug the supply cord in the event of a power failure or inter ruption in the electric supply This will prevent accidental restarting when the electric power re turns 5 3 3 Electrical safety A A EN 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 Never operate the machine without the supplied GFCI ground fault circuit interrupter machines without GFCI Never operate the machine with out an isolating transformer Test the GFCI each time before use C Check the machine s supply cord at regular in tervals and have it replaced by a qualified spe cialist if found to be damaged If the machine s supply cord is damaged it must be replaced with a specially prepared 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 s
37. st the play between rail and carriage See section 8 6 Adjusting the play between rail and carriage The core bit connection end is de Check the connection end and re fective place it if necessary 10 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 Recommended pretreatment for disposal of drilling slurry NOTE The disposal of drilling slurry directly into rivers lakes or the sewerage system without suitable pretreatment presents environmental problems Ask the local public authorities for information about current regulations 1 Collect the drilling slurry e g using a wet type industrial vacuum cleaner 2 Allow the drilling slurry to settle and dispose of the solid material at a construction waste disposal site the addition of a flocculent may accelerate the separation process 3 The remaining water alkaline pH value gt 7 must be neutralized by the addition of an acidic neutralizing agent or diluted with a large volume of water before it is allowed to flow into the sewerage system Recommended pretreatment for disposal of drilling slurry NOTE From the environmental and health point of view the d
38. switch rotate the core bit by hand at the same time until the switch can be engaged in the recommended position 6 1 16 Removing the diamond core bit CAUTION The core bit may become hot during use or during sharpening There is a risk of burning your hands Wear protective gloves when changing the core bit CAUTION Disconnect the supply cord plug from the power outlet NOTE If using an alternative type of chuck lock the drive spindle with a suitable open end wrench and use another suitable open end wrench to release the core bit 1 Engage the carriage locking system with the channel and check that the channel is securely fastened 2 Open the chuck Bl by turning it in the direction of the open brackets symbol 3 Pull the sleeve on the chuck in the direction of the arrow towards the machine This releases the core bit 4 Remove the core bit 7 Operation 0000 WARNING Take care to ensure that the supply cord and water or vacuum cleaner hoses do not come into contact with rotating parts WARNING Make sure that the supply cord is not pinched and damaged as the carriage advances CAUTION The machine and the drilling operation generate noise Wear ear protectors Excessive noise may damage the hearing CAUTION The drilling operation may create dangerous splinters Splintering material presents a risk of injury to the eyes and body Wear eye protection and a hard hat CAUTION Do not change
39. te The anchor must be capable of taking up a tensile force of at least 12 6 kN please refer to the anchor s specification 2 Screwthe clamping spindle into the anchor 3 Place the drill stand base plate over the spindle and align it 4 Screw the clamping nut onto the spindle but do not tighten it 5 Level the base plate by turning the four leveling screws Take care to ensure that the leveling screws make firm contact with the underlying surface 6 Use a suitable open end wrench to tighten the clamping nut on the clamping spindle 7 Make sure that the drilling system is secured reliably 6 1 4 Fitting the hand wheel The hand wheel can be fitted on either side of the drill stand 1 Fitthe hand wheel onto the axle 2 Securethe hand wheel 6 1 5 Mounting the machine on the drill stand El El CAUTION The locking pins on the drill stand must be in the open position and the carriage should be atthe top of the column The carriage must be locked in position 1 Use the hand wheel to release the locking pin turn counterclockwise and then pull the locking pin out 2 Engage the interface plate on the machine with the hooks on the drill stand 3 Push the locking pin in and use the hand wheel to tighten it securely turn clockwise 4 Insert the switch locking device in the grip The switch locking device can be used to lock the on off switch in the on position for sustained operation 5 Close the water valve
40. tional operation 10 Remove the hole starting aid from the core bit optional operation 11 Position the core bit in the guide kerf and then press the on off switch to continue drilling optional operation 7 6 Wet drilling using the drill stand FZ ES WARNING Water must not be allowed to run over the motor and cover WARNING A water collection system with wet type vacuum cleaner must be used when drilling in an upwards direction WARNING Stop working if the vacuum removal system no longer functions WARNING The end stop screw must be fitted at the end of the guide rail when drilling in an upwards direction CAUTION Releasing the tilt mechanism on the drill stand may cause the column to tilt suddenly NOTE Start the wet type vacuum cleaner manually before opening the water supply valve and switch it off again manually when the drilling operation is completed and after closing the water supply valve NOTE Do not use the power outlet on the vacuum cleaner 1 Open the water flow regulator on the side han dle slowly until the desired volume of water is flowing The indicator on the side handle can be used to check the water flow 2 Use the switch locking device to switch the machine on for sustained operation The drilling performance indicator lights orange 3 Release the carriage locking mechanism 4 Turn the hand wheel until the diamond core bit is in contact with the work surface 5 When begi
41. upply cord or extension cord if damaged while working Disconnect the supply cord plug from the power outlet Damaged supply cords or extension cords present a risk of electric shock 5 3 4 Work area AN 3 Ensure that the workplace is well ventilated Exposure to dust at a poorly ventilated workplace may result in damage to the health b Wear a protective mask during work that gener ates dust e g dry drilling Connect a dust re moval system Drilling in materials hazardous to the health e g asbestos is not permissible C Approval must be obtained from the site en gineer or architect prior to beginning drilling work Drilling work on buildings and other struc tures may influence the statics of the structure especially when steel reinforcing bars or load bearing components are cut through d It is recommended that rubber gloves and non skid shoes are worn when working outdoors 5 3 5 Personal protective equipment o O user and other persons the vicinity must wear ANSI Z87 1 approved eye protection a hard hat ear protection protective gloves and breathing protection while the machine is in use 6 Before use CAUTION The mains voltage must comply with the specifica tion given on the type identification plate Ensure that the power tool is disconnected from the electric supply DANGER When drilling through walls cover the area behind the wall as material or the core ma
42. utdoors 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 5 1 3 Personal safety a b d 9 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 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 energising power tools that have the switch on invites accidents Remove any adjusting key or wrench hefore 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 bal ance at all times This enables better control of the power tool in unexpected situations Dress properly Do not we
43. y fall out on the other side of the wall When drilling through ceilings secure cover the area below as drilled material or the core may drop out and fall down DANGER Check that the drill stand is securely fastened to the work surface CAUTION Do not break the connection to earth by using an adaptor plug 6 1 Preparing for use CAUTION The machine and the diamond core bit are heavy There is a risk of pinching parts of the body Wear a hard hat protective gloves and safety boots 6 1 1 Adjusting the side handle EJ 1 Release the side handle 2 Pivotthe side handle into the desired position 3 Tighten the side handle securely by turning its grip 4 Checkto ensure that the side handle is tightened securely 6 1 2 Adjusting the depth gauge when using the drill stand 1 Setthe depth gauge to the desired depth 2 Securethe depth gauge by tightening the clamp ing screw 6 1 3 Fastening the drill stand with an anchor 3 El WARNING Use an anchor suitable for the material on which you are working and observe the anchor manufacturer s instructions NOTE Use a metal expansion anchor for example a Hilti HKV M16 for fastening on uncracked concrete 1 Settheanchor of a type suitable for the material on which you are working at the ideal distance from the center of the point where the hole is to be drilled 267 mm 10 7 when using the anchor base plate or 292 mm 11 1 2 when using the combination base pla
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