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DD 160

Original operating instructions

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
DANGER !
  • Draws attention to imminent danger that will lead to serious personal injury or fatality.
WARNING
WARNING !
  • Draws attention to a potential threat of danger that can lead to serious injury or fatality.
CAUTION
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:
Image alternative Read the operating instructions before use.
Image alternative Instructions for use and other useful information
Image alternative Dealing with recyclable materials
Image alternative Do not dispose of electric equipment and batteries as household waste

Symbols in the illustrations

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

Symbols on the product

"Must do" symbols

The following "must do" symbols are used on the product:
Image alternative Wear eye protection
Image alternative Wear a hard hat
Image alternative Wear ear protection
Image alternative Wear protective gloves
Image alternative Wear protective footwear
Image alternative Wear light respiratory protection

Status indicator

The following symbols are used on the product:
Image alternative Theft protection indicator
Image alternative Drilling performance indicator
Image alternative Service indicator

Product-dependent symbols

The following symbols can be used on the product:
Image alternative Do not transport by crane
Image alternative Equipped with theft protection system
Image alternative Amps
Image alternative Volts
Image alternative Alternating current
Image alternative Watts
Image alternative Hertz
Image alternative Rated speed under no load
Image alternative Diameter
Image alternative Millimeters
Image alternative Revolutions per minute
Image alternative Wireless data transfer

Information notices

On the drill stand, base plate and diamond core drilling machine
Image alternative → On the drill stand and the vacuum base plate
Top : An additional means of securing the drill stand must be employed when the machine is used for horizontal drilling with the vacuum securing method.
Bottom : Use of the vacuum securing method for overhead drilling with the drill stand is not permissible.
Image alternative → On the diamond core drilling machine
Use of the water collection system in combination with a wet-type industrial vacuum extractor is mandatory for upward wet drilling.
Image alternative → On the diamond core drilling machine
Operate the system only with a fully functional PRCD.

Product information

Image alternative 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 about the 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
    Diamond core drilling machine
    DD 160
    Generation:
    02
    Serial no.:

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

Image alternative 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 energising 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.
  • 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.
  • 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 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.
  • Do not use this tool for overhead drilling with water supply. 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 or 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

Diamond core drilling machine DD 160-U

Image alternative
  1. On/Off switch
  2. Theft protection indicator
  3. Service indicator
  4. Drilling performance indicator
  5. Gear selector
  6. Gearing section
  7. Motor
  8. Carbon brush cover
  9. Water swivel
  10. Chuck
  11. Supply cord with PRCD
  12. Carriage lock
  13. Carriage play adjusting screw
  14. Carriage
  15. Hand wheel shaft
  16. Supply cord holder
  17. Drill stand
  18. End stop screw
  19. End stop screw

Drill stand

Image alternative
  1. End stop screw
  2. Rail
  3. Vacuum relief valve
  4. Pressure gage
  5. Leveling indicator
  6. Vacuum hose connector
  7. Combination base plate
  8. Grip
  9. Adjusting lever
  10. Hole center indicator
  11. Leveling screw
  12. Vacuum seal
  1. End stop screw
  2. Rail
  3. Base plate (anchors, small)
  4. Leveling screw

Accessories (optional)

Image alternative
  1. Star handle
  2. Lever
  3. Depth gage
  4. Threaded spindle
  5. Column swivel
  6. Wheel assembly
  7. Vacuum base plate
  1. Holder
  2. Water collector
  3. Seal

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 adjustment 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.

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 .

Drilling performance indicator

The diamond core drilling machine has an LED drilling performance indicator.
Symbol
Status
Meaning
Image alternative Orange light
Contact pressure too low
Green light
Contact pressure ideal
Red light
Contact pressure too high

Service indicator

The diamond core drilling machine has an LED service indicator.
Symbol
Status
Meaning
Image alternative Red light
Product running
The carbon brushes are badly worn.
End of service interval – servicing is due. You can continue working for a number of hours after the indicator first shows, before automatic cut-out is activated.
Bring the product to Hilti Service in good time.
Red light
Product not running
The carbon brushes must be replaced.
Flashing red light
The diamond core drilling machine has overheard or is damaged.
See Troubleshooting.

Technical data

Product properties

Weight
Anchor base plate
16.3 kg
Combination base plate
19.3 kg
Dimensions (L×W×H)
Anchor base plate
400 mm x 945 mm x 165 mm
Combination base plate
610 mm x 952 mm x 250 mm
Rated speed under no load
1st gear
460 /min
2nd gear
760 /min
3rd gear
1,690 /min
Protection class
Protection class I (earthed)
Rated power (at 230 V)
2,200 W
Max. permissible water supply pressure
5 bar

Rated voltage

The product is available with various voltage ratings. Please refer to your product's type identification plate for details of its voltage and input power ratings.
Rated voltage
100 V
110 V
GB
110 V
TW
120 V
127 V
220 V
230 V
240 V
Rated current input
15 A
16 A
15 A
19.5 A
18.5 A
10 A
10.3 A
9.9 A
AC frequency
50/60 Hz
50/60 Hz
50/60 Hz
60 Hz
50/60 Hz
50/60 Hz
50/60 Hz
50/60 Hz

Using extension cords

Use only extension cords of a type approved for the application and with conductors of adequate gauge.
Recommended minimum conductor cross-sections and maximum power cord lengths:
Conductor cross-section →
↓ Mains (AC) voltage
1.5 mm²
2.5 mm²
3.5 mm²
4.0 mm²
100 V
Not recommended
Not recommended
25 m
Not recommended
110 V
Not recommended
15 m
Not recommended
30 m
127 V
Not recommended
20 m
Not recommended
35 m
220 V
35 m
65 m
Not recommended
105 m
230 V
40 m
70 m
Not recommended
Not recommended
240 V
40 m
70 m
Not recommended
110 m

Use of the machine with various items of equipment

Equipment
Core bit diameter
Drilling direction
Without water collection system
without dust removal system
25 mm … 202 mm
Not upwards
With water collection system
without dust removal system
25 mm … 162 mm
Not upwards
With water collection system
With dust removal system
25 mm … 162 mm
All directions

Gears and corresponding core bit diameters

Gear
Core bit diameter
Idling speed
1
152 mm … 202 mm
460 /min
2
72 mm … 142 mm
760 /min
3
25 mm … 67 mm
1,690 /min

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, organization of work patterns.
Noise information
Typical A-weighted sound power level
106 dB
Sound pressure level (LpA)
93 dB(A)
Uncertainty for the given sound pressure level
3 dB
Vibration values
Drilling in concrete (wet), ah,DD
4 m/s²
Uncertainty (K)
1.5 m/s²

Preparations at the workplace and starting work

Securing the diamond core drilling machine to the drill stand

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. Remove the end stop screw from the end of the rail.
  2. Using the opening provided for the purpose, set the diamond core drilling machine on the rail.
  3. Lock the diamond core drilling machine by fully tightening the carriage lock.
  4. Check that the diamond core drilling machine is locked by lightly turning the hand wheel.
  5. Install the end stop on the rail and check that it is secure.

Fitting the hand wheel on the drill stand

The hand wheel may be fitted on the left-hand or on the right-hand side of the carriage.
Image alternative
  1. Pull the black ring back to fit the hand wheel.
  2. Fit the hand wheel onto the axle.

Securing the drill stand with an anchor

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 and M16 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.
Image alternative
  1. Set an anchor that is suitable for the base material. Select the distance to suit the base plate used.
    Technical data
    Anchor base plate
    270 mm
    Combination base plate
    290 mm
  2. Screw the anchor spindle into the anchor.
  3. Slip the base plate of the diamond core drilling machine over the spindle and align it.
  4. Screw the clamping nut on to the spindle but do not tighten it.
  5. Use the leveling screws to level the base plate. Make sure that the leveling screws are firmly seated against the surface.
  6. Use a suitable open-end wrench to tighten the clamping nut on the clamping spindle.
  7. Make sure that the diamond core drilling machine is secure.

Securing the drill stand by vacuum

WARNING
Risk of injury if pressure is not checked !
  • Before and during drilling, check that the pressure gage pointer remains in the green zone.
In order to use the drill stand with anchor base plate, establish a secure, flat-on-flat connection between vacuum base plate and anchor base plate. Screw the anchor base plate securely to the vacuum base plate. Make sure that the core bit selected for use will not damage the vacuum base plate.
If you are going to drill horizontally, use additional means of securing the diamond core drilling machine (e. g. chain secured to anchor).
Before positioning the drill stand, check that you have sufficient space for assembly and operation.
Image alternative
  1. Turn all the leveling screws until they project approx. 5 mm underneath the base plate.
  2. Connect the vacuum connector on the vacuum base plate to the vacuum pump.
  3. Locate the center point of the hole to be drilled. Draw a line from the center of the hole to be drilled in the direction in which the machine is to be positioned.
  4. Make a mark on the line at the specified distance from the center of the hole to be drilled.
    Technical data
    Combination base plate
    290 mm
    Vacuum base plate
    290 mm
  5. Switch on the vacuum pump and press and hold down the vacuum release valve.
  6. Line up the mark on the base plate with the line.
  7. When the diamond core drilling machine is correctly positioned, release the vacuum release valve and press the base plate against the work surface.
  8. Use the leveling screws to level the base plate.
  9. Make sure that the diamond core drilling machine is secure.

Fastening the drill stand with the threaded spindle

  1. Secure the threaded spindle at the top end of the column.
  2. Position the drill stand on the work surface.
  3. Use the leveling screws to level the base plate.
  4. Secure the drill stand with the threaded spindle and tighten the threaded spindle.
  5. Check that the drill stand is secure.

Adjusting the drilling angle when using the drill stand with combination base plate

CAUTION
There is a risk of crushing fingers in the joint area !
  • Wear protective gloves.
Image alternative
  1. At the foot of the drill stand, release the adjusting lever until the sliding nuts are disengaged.
  2. Adjust the column to the desired angle.
  3. Tighten the adjusting lever until the sliding nuts are fully engaged and the column is again secured in position.

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)

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.
Image alternative
  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.

Fitting a diamond core bit in a BI+ chuck

CAUTION
Risk of injury when changing the tool! The tool becomes hot as a result of use. It may have sharp edges.
  • Always wear protective gloves when changing the tool.
Diamond core bits must be replaced when the cutting performance and/or rate of drilling progress drops significantly. Generally, this is the case when the segments have worn down to a certain height.
Image alternative
  1. Lock the carriage on the rail with the carriage lock. Check to ensure that it is securely fastened.
  2. Open the chuck by turning it in the direction of the "Open brackets" symbol.
  3. From below, push the diamond core bit into the chuck on the diamond core drilling machine, turning it until the teeth engage.
  4. Close the chuck by turning it in the direction of the "Closed brackets" symbol.
  5. Check that the diamond core bit is seated securely in the chuck.

Selecting the speed

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.
Image alternative
  • While using one hand to turn the core bit, set the switch to the recommended setting.

Removing a diamond core bit from a BI+ chuck

CAUTION
Risk of injury when changing the tool! The tool becomes hot as a result of use. It may have sharp edges.
  • Always wear protective gloves when changing the tool.
  1. Lock the carriage on the rail with the carriage lock. Check to ensure that it is securely fastened.
  2. Open the chuck 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.

Operation

Enabling a diamond core drilling machine with (optional) theft protection system (TPS)

The "Theft Protection System" function (TPS) is an option for the DD 160 diamond core drilling machine. If equipped with this feature, the diamond core drilling machine can be unlocked and readied for operation only through use of the corresponding TPS key.
Further detailed information on activation and use of the theft protection system can be found in the operating instructions for the TPS theft protection system.
  1. Plug the supply cord of the diamond core drilling machine into the power outlet.
  2. Press the "I " or "RESET " button on the portable residual current device (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 diamond core drilling machine 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.

Operating portable residual current device (PRCD)

An isolating transformer must be used for diamond core drilling machines without PRCD.
  1. Plug the diamond core drilling machine’s mains plug into an earthed/grounded power outlet.
  2. Press "I" or "RESET" on the portable residual current device (PRCD).
    • The drilling performance indicator shows orange.
  3. Press "0" or "TEST" on the portable residual current device (PRCD).
    • The drilling performance indicator goes out.
WARNING
Risk of injury due to electric shock! Do not continue operating the diamond core drilling machine if the indicator on the ground fault circuit interrupter does not go out when the 0 or the TEST button is pressed.
  • Have your diamond core drilling machine repaired by Hilti Service.
  1. Press "I" or "RESET" on the portable residual current device (PRCD).
    • The drilling performance indicator shows orange.

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.
    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.
    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.

Operating diamond core drilling machine with a wet-type industrial vacuum extractor

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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 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.
    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.

Using the Rota-Rail (column swivel)

The Rota-Rail allows quick and easy access to the hole or core being drilled, with no need to partly or fully dismantle the system.
WARNING
Risk of injury caused by incorrect use! The drill stand can be damaged or it can break.
  • Never use the Rota-Rail as a column extension.
  1. Lock the carriage with the carriage lock. Check to ensure that it is securely fastened.
  2. Remove the end stop screw from the rear section of the column.
  3. Secure the Rota-Rail so that the toothed racks are facing the same direction.
  4. Tighten the screw on the Rota-Rail.
  5. Release the carriage lock and run the carriage on to the Rota-Rail.
  6. Slacken the securing screws of the Rota-Rail and pivot the machine with the Rota-Rail to the left or right. This will give you access to the drill hole.
  7. Remove the core or change the core bit.
  8. With the Rota-Rail, pivot the machine back to its original position and tighten the securing screws of the Rota-Rail.
  9. After removing the Rota-Rail, refit the end stop screw to the end of the rail.

Switching off the diamond core drilling machine

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.
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  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.

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.

Removal of the diamond core drilling machine

  1. Unplug the supply cord from the power outlet.
  2. Remove the diamond core bit from the BI+ chuck.
  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, transport and storage

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 .

Care of diamond core drilling machine

  • Do not use a spray, pressure jet washer or running water for cleaning.
  • Prevent unnecessary exposure of the battery to dust or debris and never subject the battery to soaking moisture (e.g., submerged in water or left out in the rain).
  • Clean the chuck and the clamping segments with a cloth at regular intervals and lubricate the parts with Hilti lubricant spray.
  • Remove all particles of foreign matter from the chuck.
  • Occasionally remove the filter from the water inlet in the side handle and flush the filter mesh with water in the direction opposite to the normal water flow.
  • Remove and clean the water flow rate indicator as soon as it is dirty.
  • Do not use abrasive cleaning agents or sharp objects to clean the sight glass.

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.

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.

Troubleshooting table

Trouble or fault
Possible cause
Action to be taken
Diamond core drilling machine does not start
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.
Interruption in the electric supply
  • Check the supply cord, extension cord, supply cord plug and PRCD and have them replaced as necessary by a trained electrical specialist.
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 shows
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.
Diamond core drilling machine does not start and service indicator lights up
The carbon brushes are worn out.
Diamond core drilling machine does not start and service indicator flashes
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.
Diamond core drilling machine does not start and theft protection indicator flashes
The diamond core drilling machine has not been unlocked (machines with optional theft protection system).
  • Use the TPS key to unlock the diamond core drilling machine.
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 decreasing.
The diamond core bit is polished.
  • Sharpen the diamond core bit by drilling into a sharpening plate.
Wrong core bit specification for the base material.
  • Select a more suitable diamond core bit specification.
The water flow rate is too high.
  • Reduce the water flow rate by adjusting the water flow regulator.
The core is stuck in the diamond core bit.
  • Remove the core.
Maximum drilling depth has been reached.
  • Remove the core and use a core bit extension.
The diamond core bit is defective.
  • Check the diamond core bit for damage and replace it if necessary.
Safety clutch disengages too soon or is slipping.
  • Have the machine repaired by Hilti Service.
The brake has been applied.
  • Release the brake.
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.
High steel content (indicated by clear water containing metal cuttings).
  • Select a more suitable diamond core bit specification.
The handwheel can be turned without resistance.
The split pin is broken.
  • Replace the split pin.
Water escapes at the water swivel or gear housing.
The water pressure is too high.
  • Reduce the water pressure.
The rotary shaft seal is worn out.
  • Replace the rotary shaft seal.
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 connection end and/or the chuck or replace these parts.

Disposal

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

RoHS (Restriction of Hazardous Substances)

Click on the link to go to the table of hazardous substances: qr.hilti.com/r5063.
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.
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