Hilti DCH 230 User manual

DCH230/
DCH180-SL
*47985*
47985
Hilti Corporation
LI-9494 Schaan
Tel.:[phone]
Fax: [phone]
www.hilti.com
Hilti = registered trademark of Hilti Corp., Schaan W 3492 0108 00-Pos.1 1 Printed in Liechtenstein © 2008
Right of technical and programme changes reserved S. E. & O. 47985/ A
Bedienungsanleitung de
Operating instructions en
Mode d’emploi fr
Istruzioni d’uso it
Manual de instrucciones es
Manual de instruções pt
Gebruiksaanwijzing nl
Brugsanvisning da
Bruksanvisning sv
Bruksanvisning no
Käyttöohje fi
ΟΟδδηηγγιιεεςςχχρρηησσεεωωςς
el
ja
ko
8 96
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DCH 230/ DCH 180‐SL diamond cutter
It is essential that the operating instructions
are read before the machine is operated for
the first time.
Always keep these operating instructions
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 24
2. Description 25
3. Accessories, consumables 27
4. Technical data 28
5. Safety instructions 29
6. Before use 34
7. Operation 37
8. Care and maintenance 39
9. Troubleshooting 40
10. Disposal 41
11. Manufacturer’s warranty 41
12. EC declaration of conformity 42
1These 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
“power tool” always refers to the DCH 230 and/or
DCH 180‐SL diamond cutters.
DCH 230 operating controls and indicators 1
@Spindle lockbutton
;Front grip
=On / off switch
%Switch‐on interlock release button
&Diamond cutting disc
(Spindle
)DCH‑EX 230 guard
)Guard (hood)
+Guide wheels
§Clamping nut wrench, 24 mm AF / 10 mm AF
/Hex. socket wrench, 6 mm AF
:Guard (hood) clamping screw
·Dust removal connector cap
$Service indicator
£Theft protection indicator (option)
DCH 230 mounting system 2
|Clamping flange, 41 mm dia., with O‑ring
¡M 14 clamping nut
QKwik‑Lock quick‐release clamping nut (op-
tional)
Depth gauge (option for the DCH 230) 3
WHood extension
EHook
RStop
TCutting depth sliding indicator
ZCutting depth scale
DCH 180‑SL operating controls and indicators 4
@Spindle lockbutton
;Front grip
=On / off switch
%Switch‐on interlock release button
&Diamond cutting disc
(Spindle
)DCH‑EX 180‐SL slitting hood
+Guide wheels
§Clamping nut wrench, 24 mm AF / 10 mm AF
/Hex. socket wrench, 6 mm AF
:Guard (hood) clamping screw
·Dust removal connector cap
$Service indicator
£Theft protection indicator (option)
Parts of the DCH 180‑SL 5
UDCH‑EX 180‐SL slitting hood
ISpindle extension
OM 6 x 65 screw
PSpacer ring
ÜHood extension release catch / cutting depth
adjustment
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1. General information
1.1 Safety notices and their meaning
DANGER
Draws attention to imminent danger that could lead
to serious bodily injury or fatality.
WARNING
Draws attention to a potentially dangerous situation
that could lead to serious personal injury or fatality.
CAUTION
Draws attention to a potentially dangerous situation
that could lead to slight personal injury or damage to
the equipment or other property.
NOTE
Draws attention to an instruction or other useful
information.
1.2 Explanation of the pictograms and other
information
Warning signs
General
warning Warning: electricity
Obligation signs
Wear a hard
hat. Wear eye protection. Wear ear protection. Wear protective
gloves.
Wear safety
shoes. Wear breathing
protection.
Symbols
Read the
operating
instructions
before use.
Return waste
material for
recycling.
Amps Volts
Alternating
current Revolutions per minute Diameter Double insulated
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.
Type:
Generation: 01
Serial no.:
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2. Description
2.1 Use of the product as directed
The DCH 230 is an electrically‐powered diamond cutter and the DCH 180‑SL is an electrically‐powered diamond
slitting tool, both designed for professional use in the construction industry.
The DCH 230 is designed for cutting mineral materials using diamond cutting discs without water and can also
be used for cutting metals when fitted with a synthetic resin‐bonded fiber‐reinforced cutting disc.
The DCH 180‑SL is designed for slitting mineral materials using diamond cutting discs without water.
When cutting mineral materials, a dust removal system equipped with the corresponding filter must be used,
e.g. the Hilti VCU 40, VCU 40‑M or VCD 50 vacuum cleaner.
In order to avoid electrostatic effects, a vacuum cleaner equipped with an antistatic hose should be used.
Use only diamond cutting discs approved for use at a peripheral speed of at least 80 m/sec or synthetic resin‐
bonded fiber‐reinforced cutting discs approved for use at a peripheral speed of at least 80 m/sec.
The power tool is to be used exclusively in pushing mode (counter rotation).
The use of liquids, e.g. to cool the disc or suppress dust, is not permissible.
Do not use the power tool for cutting with cutting tools of a type not specified in these operating instructions
(e.g. circular saw blades) or for grinding.
The working environment may be as follows: construction site, workshop, renovation, conversion or new
construction.
To avoid the risk of injury, use only genuine Hilti accessories and cutting tools.
Observe the safety rules and operating instructions for the accessories used.
Observe the information printed in the operating instructions concerning operation, care and maintenance.
The machine is designed for professional use and may be operated, serviced and maintained only by trained,
authorized personnel. This personnel must be informed of any special hazards that may be encountered. The
machine and its ancillary equipment may present hazards when used incorrectly by untrained personnel or
when used not as directed.
The machine may be used only in a dry environment.
The machine may be operated only when connected to a power supply providing a voltage and frequency in
compliance with the information given on its type identification plate.
Do not use the machine where there is a risk of fire or explosion.
Working on materials hazardous to the health (e.g. asbestos) is not permissible.
Modification of the machine or tampering with its parts is not permissible.
2.2 Switches
On/off switch with switch‐on interlock
2.3 Starting current limitation
The starting current drawn by the power tool is several times higher than its rated current. The electronic
starting current limiter reduces the starting current drawn by the power tool and thus prevents the mains fuse
blowing. It also allows the power tool to start smoothly, without a jolt.
2.4 Restart interlock
The power tool does not restart by itself after an interruption in the electric supply. The switch must first be
released and then pressed again after approx. 1 second.
2.5 TPS theft protection system (optional)
The power tool may be optionally equipped with the TPS theft protection system. If equipped with this feature,
the power tool can be unlocked and made ready for operation only through use of the corresponding TPS key.
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2.6 LED indicators
Service indicator LED (see section “Care and maintenance / service indicator”)
Theft protection system indicator (optional) (see section “Operation / TPS theft protection system (optional)”)
2.7 Guard (hood) with guide wheels
Cutting and slitting work on mineral materials may be carried out only when the power tool is equipped with a
dust removal hood with guide wheels.
2.8 Electronic overload protection
The electronic overload protection system monitors current input and thus protects the power tool from
overload.
If the motor is overloaded through application of excessive working pressure, the power tool’s performance
drops noticeably or it may come to a complete standstill. A standstill should be avoided.
Permissible overload cannot be given as a specific value as it depends on the temperature of the motor.
If the power tool has been overloaded, release the pressure applied and then allow it to run under no load for
approx. 30 seconds.
2.9 Using extension cords
Use only extension cords of a type approved for the application and with conductors of adequate gauge. The
power tool may otherwise lose performance and the extension cord may overheat. Check the extension cord
for damage at regular intervals. Replace damaged extension cords.
Recommended minimum conductor gauge (cross section) and max. cable lengths
Conductor cross section 1.5 mm²2mm²2.5 mm²3.5 mm²
Mains voltage 110127 V ‐‐40 m ‐
Mains voltage 220‐240 V 30 m ‐50 m ‐
Do not use extension cords with a conductor cross section of less than 1.5 mm².
2.10 Using extension cords outdoors
When working outdoors, use only extension cords that are approved and correspondingly marked for this
application.
2.11 Using a generator or transformer
This tool may be powered by a generator or transformer when the following conditions are fulfilled: The unit
must provide a power output in watts of at least twice the value printed on the type identification plate on
the power tool. The operating voltage must remain within +5% and ‐15% of the rated voltage at all times,
frequency must be in the 50 – 60 Hz range and never above 65 Hz, and the unit must be equipped with
automatic voltage regulation and starting boost.
Never operate other power tools or appliances from the generator or transformer at the same time. Where
applicable, use a generator or transformer designed for simultaneous power tool and vacuum cleaner operation.
Switching other power tools or appliances on and off may cause undervoltage and / or overvoltage peaks,
resulting in damage to the power tool.
2.12 Depth gauge (option for the DCH 230)
The DCH 230 can also be fitted with an optional depth gauge. This improves dust removal performance for
cutting mineral materials. The desired maximum cutting depth can be set with the aid of the cutting depth
scale on the hood extension.
The depth gauge is standard equipment with the DCH 180‑SL.
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2.13 Kwik‐Lock clamping nut for cutting discs (optional, only for the DCH 230)
The Kwik‐Lock nut can be used instead of the 41 mm dia. clamping nut. No tools are then required for changing
cutting discs.
2.14 Items supplied as standard with the DCH 230
1 Power tool with DCH‑EX 230 hood
1 Clamping flange, 41 mm dia., with O‑ring
1 M 14 clamping nut
1 Clamping nut wrench, 24 mm AF / 10 mm
AF
1 Hex. socket wrench, 6 mm AF
1 Cardboard box
1 Operating instructions
2.15 Items supplied as standard with the DCH 180‐SL
1 DCH‑EX 180‑SL with dust hood and depth
gauge
5 Spacer ring (3 mm, 6 mm, 2 x 13 mm,
21 mm)
1 M 14 clamping nut
1 Clamping nut wrench, 24 mm AF / 10 mm
AF
1 Hex. socket wrench, 6 mm AF
1 Cardboard box
1 Operating instructions
2.16 Cutting disc specifications
Diamond cutting discs in compliance with EN 13236 should be used with the DCH 230 and DCH 180‐SL.
Synthetic resin‐bonded fiber‐reinforced cutting discs in compliance with EN 12413 (straight, not offset, type
41) may also be used with the DCH 230 for working on metals.
The mounting instructions issued by the disc manufacturer must also be observed.
3. Accessories, consumables
DCH 230 / 180‑SL conversion set DCH‑EX 180‑SL slitting hood,
comprising; spindle extension;
M 6 x65 screw; 5 spacer rings
(3 mm, 6 mm, 2 x 13 mm, 21 mm)
Kwik‐Lock clamping nut (only for the DCH 230)
Key for quick‐release clamping nut
Depth gauge for the DCH 230
Vacuum cleaner VCU 40, VCU 40‑M, VCD 50
Antistatic hose, complete Length 5 m, Ø36 mm
Hilti toolbox
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DCH 230
Disc type Specification Material
Diamond cutting disc DCH‑D 230 C1 Concrete
Diamond cutting disc DCH‑D 230 C2 Hard concrete
Diamond cutting disc DCH‑D 230 M1 Masonry, sand‐lime block
Diamond cutting disc DCH‑D 230 M2 Masonry, tiles
Diamond cutting disc DCH‑D 230 FE1 Metal
Diamond cutting disc DCH‑D 230 C15 Economy Line for concrete
DCH 180‑SL
Disc type Specification Material
Diamond cutting disc DCH‑D 185 SE C1x2 Concrete
Diamond cutting disc DCH‑D 185 SE C2x2 Hard concrete
Diamond cutting disc DCH‑D 185 SE M1x2 Masonry, sand‐lime block
Diamond cutting disc DCH‑D 185 SE U10x2 Economy Line
4. Technical data
Right of technical changes reserved.
Rated voltage 110 V 220 V 230 V 230 V / CH 240 V
Rated power
input 2,300 W 2,600 W 2,600 W 2,250 W 2,600 W
Rated current
input 22.5 A 12.5 A 12.1 A 10 A 11.7 A
Mains fre-
quency
50 Hz 50…60 Hz 50…60 Hz 50 Hz 50 Hz
Other information about the
power tool DCH 230 DCH 180‑SL
Dimensions (L x W x H) 670 mm x 240 mm x 210 mm 620 mm x 275 mm x 185 mm
Drive spindle thread M 14 M 14
Disc arbor size 22.2 mm 22.2 mm
Cutting disc ØMax. 230 mm ØMax. 185 mm
Cutting disc thickness Max. 3 mm Max. 3 mm
Weight in accordance with EPTA
procedure 01/2003 8.6 kg 9.2 kg
Protection class Protection class I (grounded)
or protection class II (double
insulated). See type identification
plate.
Protection class I (grounded)
or protection class II (double
insulated). See type identification
plate.
Rated speed under no load Max. 6,500/min Max. 6,500/min
Clamping nut tightening torque M14: 30 Nm M14: 30 Nm
Spindle extension tightening
torque
9Nm
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NOTE
The vibration emission level given in this information sheet has been measured in accordance with a
standardised test given in EN 60745 and may be used to compare one tool with another. It may be used for a
preliminary assessment of exposure. The declared vibration emission level represents the main applications of
the tool. However if the tool is used for different applications, with different accessories or poorly maintained,
the vibration emission may differ. This may significantly increase the exposure level over the total working
period. An estimation of the level of exposure to vibration should also take into account the times when the
tool is switched off or when it is running but not actually doing the job. This may significantly reduce the
exposure level over the total working period. Identify additional safety measures to protect the operator from
the effects of vibration such as: maintain the tool and the accessories, keep the hands warm, organisation of
work patterns.
Noise information (as perEN 60745):
Typical A‐weighted sound power level, DCH 230 113.5 dB (A)
Typical A‐weighted emission sound pressure level,
DCH 230 102.5 dB (A)
Typical A‐weighted sound power level, DCH 180‐SL 114.5 dB (A)
Typical A‐weighted emission sound pressure level,
DCH 180‐SL 103.5 dB (A)
Uncertainty for the given sound level 3 dB (A)
Vibration information in accordance with EN 60745
Triaxial vibration value for the DCH 230 (vibration
vector sum)
Measured in accordance with EN 60745‑2‑22
Cutting, ah,AG 4.7 m/s²
Uncertainty (K) 1.5 m/s²
Triaxial vibration value for the DCH 180‐SL (vibration
vector sum)
Measured in accordance with EN 60745‑2‑22
Cutting, ah,AG 5.6 m/s²
Uncertainty (K) 1.7 m/s²
5. Safety instructions
5.1 General power tool safety warnings
WARNING! Read all safety warnings and all instruc-
tions. Failure to follow the warnings and instructions
may result in electric shock, fire and/or serious in-
jury. 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.
c) Keep children and bystanders away while oper-
ating a power tool. Distractions can cause you to
lose control.
5.1.2 Electrical safety
a) Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power
tools. Unmodified plugs and matching outlets will
reduce risk of electric shock.
b) Avoid body contact with earthed or grounded
surfaces, such as pipes, radiators, ranges and
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refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
c) Do not expose power tools to rain or wet con-
ditions. Water entering a power tool will increase
the risk of electric shock.
d) Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled cords
increase the risk of electric shock.
e) When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of a
cord suitable for outdoor use reduces the risk of
electric shock.
f) If operating a power tool in a damp location
is unavoidable, use a residual current device
(RCD) protected supply. Use of an RCD reduces
the risk of electric shock.
5.1.3 Personal safety
a) Stay alert, watch what you are doing and use
common sense when operating a power tool. Do
not use a power tool while you are tired or under
the influence of drugs, alcohol or medication. A
moment of inattention while operating power tools
may result in serious personal injury.
b) Use personal protective equipment. Always wear
eye protection. Protective equipment such as dust
mask, non‐skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will
reduce personal injuries.
c) Prevent unintentional starting. Ensure the switch
is in the off‐position before connecting to power
source and/or battery pack, picking up or carrying
the tool. Carrying power tools with your finger on
the switch or energising power tools that have the
switch on invites accidents.
d) Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may
result in personal injury.
e) Do not overreach. Keep proper footing and bal-
ance at all times. This enables better control of
the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
away from moving parts. Loose clothes, jewellery
or long hair can be caught in moving parts.
g) If devices are provided for the connection of dust
extraction and collection facilities, ensure these
are connected and properly used. Use of dust
collection can reduce dust‐related hazards.
5.1.4 Power tool use and care
a) Do not force the power tool. Use the correct
power tool for your application. The correct power
tool will do the job better and safer at the rate for
which it was designed.
b) Do not use the power tool if the switch does not
turn it on and off. Any power tool that cannot be
controlled with the switch is dangerous and must
be repaired.
c) Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing ac-
cessories, or storing power tools. Such prevent-
ive safety measures reduce the risk of starting the
power tool accidentally.
d) Store idle power tools out of the reach of children
and do not allow persons unfamiliar with the
power tool or these instructions to operate the
power tool. Power tools are dangerous in the
hands of untrained users.
e) Maintain power tools. Check for misalignment or
binding of moving parts, breakage of parts and
any other condition that may affect the power
tool’s operation. If damaged, have the power
tool repaired before use. Many accidents are
caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits etc.
in accordance with these instructions, taking into
account the working conditions and the work to be
performed. Use of the power tool for operations
different from those intended could result in a
hazardous situation.
5.1.5 Service
a) Have your power tool serviced by a qualified
repair person using only identical replacement
parts. This will ensure that the safety of the power
tool is maintained.
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5.2 Additional safety instructions
5.2.1 Safety instructions for abrasive cutting off
operations
a) Read all safety warnings, instructions, illustra-
tions and specifications provided with this power
tool. Failure to follow all instructions listed below
may result in electric shock, fire and/or serious
injury.
b) Always use guard provided with the tool. The
guard must be securely attached to the power
tool and positioned for maximum safety, so
the least amount of wheel is exposed towards
the operator. Position yourself and bystanders
away from the plane of the rotating wheel. The
guard helps to protect operator from broken wheel
fragments and accidental contact with wheel.
c) Use only flat reinforced or diamond cut‐off
wheels for your power tool. Just because an
accessory can be attached to your power tool, it
does not assure safe operation.
d) The rated speed of the wheel must be at least
equal to the maximum speed marked on the
power tool. Wheels running faster than their rated
speed can break and fly apart.
e) Wheels must be used only for recommended
applications. For example: Do not grind with
the side of cut‐off wheel. Abrasive cut‐off wheels
are intended for peripheral grinding, side forces
applied to these wheels may cause them to shatter.
f) Always use undamaged wheel flanges that are of
correct diameter for your selected wheel. Proper
wheel flanges support the wheel thus reducing the
possibility of wheel breakage.
g) Do not use worn down flat reinforced wheels
from larger power tools. Wheels intended for a
larger power tool are not suitable for the higher
speed of a smaller tool and may burst.
h) The outside diameter and the thickness of your
wheel must be within the capacity rating of your
power tool. Incorrectly sized wheels cannot be
adequately guarded or controlled.
i) The arbor size of wheels and flanges must prop-
erly fit the spindle of the power tool. Wheels and
flanges with arbour holes that do not match the
mounting hardware of the power tool will run out
of balance, vibrate excessively and may cause loss
of control.
j) Do not use damaged wheels. Before each use,
inspect the wheels for chips and cracks. If power
tool or wheel is dropped, inspect for damage
or install an undamaged wheel. After inspecting
and installing the wheel, position yourself and
bystanders away from the plane of the rotating
wheel and run the power tool at maximum no
load speed for one minute. Damaged wheels will
normally break apart during this test time.
k) Wear personal protective equipment. Depending
on application, use face shield, safety goggles
or safety glasses. As appropriate, wear dust
mask, hearing protectors, gloves and shop apron
capable of stopping small abrasive or workpiece
fragments. The eye protection must be capable
of stopping flying debris generated by various
operations. The dust mask or respirator must be
capable of filtrating particles generated by your
operation. Prolonged exposure to high intensity
noise may cause hearing loss.
l) Keep bystanders a safe distance away from
work area. Anyone entering the work area must
wear personal protective equipment. Fragments
of workpiece or of a broken wheel may fly away and
cause injury beyond immediate area of operation.
m)Hold the power tool by insulated gripping sur-
faces only, when performing an operation where
the wheel may contact hidden wiring or its own
cord. Wheel contacting a “live” wire may make
exposed metal parts of the power tool “live” and
shock the operator.
n) Position the cord clear of the spinning wheel.If
you lose control, the cord may be cut or snagged
and your hand or arm may be pulled into the
spinning wheel.
o) Never lay the power tool down until the wheel
has come to a complete stop. The spinning wheel
may grab the surface and pull the power tool out
of your control.
p) Do not run the power tool while carrying it at
your side. Accidental contact with the spinning
wheel could snag your clothing, pulling the wheel
into your body.
q) Regularly clean the power tool’s air vents. The
motor’s fan will draw the dust inside the housing
and excessive accumulation of powdered metal
may cause electrical hazards.
r) Do not operate the power tool near flammable
materials. Sparks could ignite these materials.
s) Do not use wheels that require liquid coolants.
Using water or other liquid coolants may result
in electrocution or shock.
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5.2.2 Further safety instructions for abrasive
cutting off operations
Kickback and related warnings
Kickback is a sudden reaction to a pinched or snagged
rotating wheel. Pinching or snagging causes rapid
stalling of the rotating wheel which in turn causes the
uncontrolled power tool to be forced in the direction
opposite of the wheel’s rotation at the point of the
binding.
a) Maintain a firm grip on the power tool and
position your body and arm to allow you to resist
kickback forces. Always use auxiliary handle,
if provided, for maximum control over kickback
or torque reaction during start‐up. The operator
can control torque reactions or kickback forces if
proper precautions are taken.
b) Never place your hand near the rotating wheel.
Wheel may kick back over your hand.
c) Do not position your body in line with and behind
the rotating wheel. Kickback will propel the tool
in direction opposite to the wheel’s movement at
the point of snagging.
d) Use special care when working corners, sharp
edges etc. Avoid bouncing and snagging the
wheel. Corners, sharp edges or bouncing have
a tendency to snag the rotating wheel and cause
loss of control or kickback.
e) Do not attach a saw chain, woodcarving blade or
toothed saw blade. Such blades create frequent
kickback and loss of control.
f) Do not “jam” the wheel or apply excessive pres-
sure. Do not attempt to make an excessive depth
of cut. Overstressing the wheel increases the load-
ing and susceptibility to twisting or binding of the
wheel in the cut and the possibility of kickback or
wheel breakage.
g) When wheel is binding or when interrupting a cut
for any reason, switch off the power tool and hold
the power tool motionless until the wheel comes
to a complete stop. Never attempt to remove the
wheel from the cut while the wheel is in motion
otherwise kickback may occur. Investigate and
take corrective action to eliminate the cause of
wheel binding.
h) Do not restart the cutting operation in the work-
piece. Let the wheel reach full speed and care-
fully reenter the cut. The wheel may bind, walk
up or kickback if the power tool is restarted in the
workpiece.
i) Support panels or any oversized workpiece to
minimize the risk of wheel pinching and kick-
back. Large workpieces tend to sag under their
own weight. Supports must be placed under the
workpiece near the line of cut and near the edge of
the workpiece on both sides of the wheel.
j) Use extra caution when making a “pocket cut”
into existing walls or other blind areas. The
protruding wheel may cut gas or water pipes,
electrical wiring or objects that can cause kickback.
5.3 Additional safety instructions
5.3.1 Safety instructions for all operations
a) Do not use wheels that require liquid coolants.
Using water or other liquid coolants may result in
electrocution or shock.
b) Use only wheel types that are recommended for
your power tool and the specific guard designed
for the selected wheel. Wheels for which the
power tool was not designed cannot be adequately
guarded and are unsafe.
5.3.2 Personal safety
a) Always hold the machine securely with both
hands on the grips provided. Keep the grips dry,
clean and free from oil and grease.
b) Breathing protection must be worn if the power
tool is used without a dust extraction system for
work that creates dust. Close the cap over the
dust removal connector.
c) Improve the blood circulation in your fingers by
relaxing your hands and exercising your fingers
during breaks between working.
d) 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.
e) Always lead the supply cord and extension cord
away from the power tool to the rear while
working. This helps to avoid tripping over the cord
while working.
f) The guard must always be fitted when the power
tool is used for cutting metals. Close the cap
over the dust removal connector.
g) If the work involves breaking right through, take
the appropriate safety measures at the opposite
side. Parts breaking away could fall out and / or
fall down and injure other persons.
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h) Dust from material such as paint containing lead,
some wood species, minerals and metal may be
harmful. Contact with or inhalation of the dust
may cause allergic reactions and/or respiratory
diseases to the operator or bystanders. Certain
kinds of dust are classified as carcinogenic such
as oak and beech dust especially in conjunction
with additives for wood conditioning (chromate,
wood preservative). Material containing asbestos
must only be treated by specialists. Where the
use of a dust extraction device is possible it
shall be used. To achieve a high level of dust
collection, use a suitable vacuum cleaner of the
type recommended by Hilti for wood dust and/or
mineral dust together with this tool. Ensure that
the workplace is well ventilated. The use of a
dust mask of filter class P2 is recommended.
Follow national requirements for the materials
you want to work with.
5.3.3 Power tool use and care
a) Cutting discs must be stored, handled and fitted
carefully in accordance with the manufacturer’s
instructions.
b) If use of a spacer ring or other intermediate
part is specified and the part is supplied with
the cutting disc, check to ensure that the part is
fitted.
c) Secure the workpiece. Use clamps or a vice
to secure the workpiece. The workpiece is thus
held more securely than by hand and both hands
remain free to operate the machine.
d) Before use, check that the cutting disc has been
fitted correctly and the clamping nut tightened.
Then allow the power tool to run for 30 seconds
under no load while holding it in a secure po-
sition. Switch off the power tool immediately if
significant vibration or any other faults are no-
ticed. Should this occur, check the entire system
in order to determine the cause.
e) Take steps to ensure that flying sparks from
the power tool do not present a hazard, i.e.
by striking yourself or other persons. Adjust the
position of the disc guard accordingly.
f) Slits cut in loadbearing walls of buildings or other
structures may influence the statics of the struc-
ture, especially when steel reinforcing bars or
load‐bearing components are cut through. Con-
sult the structural engineer, architect, or person
in charge of the building project before beginning
the work.
g) Guide the power tool carefully and make straight
cuts in order to avoid jamming the cutting disc.
Cutting curves is not permissible.
h) Guide the power tool evenly and do not apply
lateral pressure to the cutting disc. Always bring
the power tool into contact with the workpiece
at right angles. Do not attempt to alter the line
of cut by applying lateral pressure or by bending
the cutting disc while cutting is in progress. This
presents a risk of damaging or breaking the cutting
disc.
5.4 Additional safety instructions
5.4.1 Electrical safety
a) Before beginning work, check the working area
(e.g. using a metal detector) to ensure that no
concealed electric cables or gas and water pipes
are present. External metal parts of the machine
may become live, for example, when an electric
cable is damaged accidentally. This presents a
serious risk of electric shock.
b) Check the machine’s supply cord at regular inter-
vals and have it replaced by a qualified specialist
if found to be damaged. 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.
c) Dirty or dusty machines which have been used
frequently for work on conductive materials
should be checked at regular intervals at
a Hilti Service Center. Under unfavorable
circumstances, dampness or dust adhering to
the surface of the machine, especially dust from
conductive materials, may present a risk of
electric shock.
d) When working outdoors with an electric tool
or machine, check to ensure that the tool or
machine is connected to the electric supply by
way of a ground fault circuit interrupter (RCD)
with a rating of max. 30 mA (tripping current).
Use of a ground fault circuit interrupter reduces
the risk of electric shock.
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e) Use of a ground fault circuit interrupter (RCD
residual current device) with a maximum tripping
current of 30 mA is recommended.
5.4.2 Work area safety
Ensure that the workplace is well ventilated. Ex-
posure to dust at a poorly ventilated workplace may
result in damage to the health.
5.4.3 Personal protective equipment
The user and any other persons in the vicinity
must wear suitable eye protection, a hard hat, ear
protection, protective gloves and safety footwear
while the machine is in use.
6. Before use
WARNING
The supply cord must be disconnected from the
electric supply and the cutting disc or drive spindle
must have come to a complete stop before attempt-
ing to change or adjust discs, parts of the tool or its
accessories.
CAUTION
The mains voltage must comply with the specific-
ation given on the type identification plate. Ensure
that the power tool is disconnected from the electric
supply.
CAUTION
Wear protective gloves, especially when changing
discs, adjusting the guard (hood) and when fitting
the depth gauge.
6.1 Guard (hood)
WARNING
Never use the power tool without the guard (hood).
NOTE
If the guard (hood) clamping force is found to be
inadequate, this can be increased by tightening the
clamping screw slightly.
6.1.1 Fitting and adjusting the guard
(hood) 67
1. Disconnect the supply cord plug from the power
outlet.
2. Use the hex. socket wrench to release the clamp-
ing screw.
3. Fit the guard (hood) onto the collar on the gearing
section.
4. Rotate the guard (hood) into the desired position.
5. Use the hex. socket wrench to tighten the clamp-
ing screw.
6.1.2 Removing the guard (hood)
1. Disconnect the supply cord plug from the power
outlet.
2. Use the hex. socket wrench to release the clamp-
ing screw.
3. Rotate the guard (hood) and pull it away from the
tool.
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6.2 Depth gauge (optional)
6.2.1 Fitting / removing the depth gauge for the
DCH 230 3
1. Disconnect the supply cord plug from the power
outlet.
2. Fit the hook over the guide wheel axle.
3. Pivot the hood extension into the hood until the
catch is heard to engage.
4. To remove the hood extension, press the catch
and pivot the hood extension down and away
from the hood.
6.2.2 Using the depth gauge to set the cutting
depth for the DCH 230
1. Press the cutting depth sliding indicator.
2. Move the cutting depth sliding indicator to the
desired cutting depth.
6.2.3 Using the depth gauge to set the cutting
depth for the DCH 180‑SL
The depth gauge forms and integral part of the
DCH 180‑SL and cannot be removed.
1. Press the catch.
2. Set the desired cutting depth by adjusting the
depth gauge.
6.3 Fitting a cutting disc
CAUTION
Use only cutting tools with a rated maximum per-
missible speed which is at least as high as the
machine’s highest no‐load running speed.
CAUTION
Cutting discs which are damaged or out of round
(causing vibration) must not be used.
CAUTION
Do not use synthetic resin‐bonded fiber‐reinforced
cutting discs that have exceeded their use‐by date.
CAUTION
The spindle extension may used only in conjunction
with the DCH‑EX 180‑SL slitting hood.
NOTE
Diamond cutting discs in compliance with EN 13236
should be used with the DCH 230 and DCH 180‐SL.
Synthetic resin‐bonded fiber‐reinforced cutting discs
in compliance with EN 12413 (straight, not offset,
type 41) may also be used with the DCH 230 for
working on metals. The mounting instructions issued
by the disc manufacturer must also be observed.
6.3.1 Fitting diamond cutting discs and synthetic
resin‐bonded fiber‐reinforced cutting discs
to the DCH 230
1. Disconnect the supply cord plug from the power
outlet.
2. Clean the clamping flange and the clamping nut.
3. CAUTION The clamping flange is equipped with
an O‐ring. If this O‐ring is missing, the clamping
flange must be replaced.
Place the 41 mm dia. clamping flange on the
spindle so that it cannot rotate.
4. Place the cutting disc on the centering collar of
the clamping flange.
5. Fit the clamping nut.
6. CAUTION Do not press the spindle lockbutton
before the drive spindle has stopped rotating.
Press the spindle lockbutton and hold it in this
position.
7. Use the wrench to tighten the clamping nut se-
curely and then release the spindle lockbutton.
8. Check to ensure that the spindle lockbutton has
disengaged.
6.3.2 Using the Kwik‐Lock nut to fit cutting discs
(only for the DCH 230)
NOTE
The Kwik‐Lock nut may be used instead of the stand-
ard clamping nut. No tools are then required for
fitting/changing the cutting discs.
NOTE
The arrow on the upper surface of the nut must be
within the index marks. If the arrow is not within
the index marks when the nut is tightened it will be
impossible to release the nut by hand. Should it be
necessary, use the key to release the Kwik‐Lock nut
(do not use a pipe wrench!).
1. Disconnect the supply cord plug from the power
outlet.
2. Clean the clamping flange and the quick release
clamping nut.
3. CAUTION The clamping flange is equipped with
an O‐ring. If this O‐ring is missing, the clamping
flange must be replaced.
Place the 41 mm dia. clamping flange on the
spindle so that it cannot rotate.
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35

4. Place the cutting disc on the centering collar of
the clamping flange.
5. Screw the quick‐release clamping nut onto the
spindle until it contacts the cutting disc (the side
with the lettering should be visible after the nut is
screwed on).
6. CAUTION Do not press the spindle lockbutton
before the drive spindle has stopped rotating.
Press the spindle lockbutton and hold it in this
position.
7. Turn the cutting disc firmly by hand in a clockwise
direction until the quick‐release clamping nut is
tightened securely.
8. Release the spindle lockbutton.
9. Check to ensure that the spindle lockbutton has
disengaged.
6.3.3 Fitting cutting discs to the DCH 180‑SL
slitting tool 8
NOTE
Use of the Kwik‐Lock nut with the DCH 180‑SL slitting
tool is not permissible.
1. Disconnect the supply cord plug from the power
outlet.
2. Press the catch and pivot the hood extension
down and away from the hood.
3. Place the first diamond disc on the spindle exten-
sion.
4. Fit the spacer ring corresponding to the desired
slitting width.
5. Fit the second diamond cutting disc.
NOTE To achieve the maximum slitting width, all
spacer rings have to be positioned between the
diamond discs.
NOTE All the spacer rings thus have to be fitted.
6. CAUTION Do not press the spindle lockbutton
before the drive spindle has stopped rotating.
Press the spindle lockbutton and hold it in this
position.
7. Screw the clamping nut onto the drive spindle
and tighten it securely with the wrench.
8. Release the spindle lockbutton.
9. Check to ensure that the spindle lockbutton has
disengaged.
10. Press the catch to release the hood extension and
allow it to be pushed in and, at the same time, set
to the desired cutting depth.
6.4 Removing the cutting disc from the tool
To remove the cutting disc from the tool, follow the
instructions for fitting the disc but carry out the steps
in the reverse order.
6.5 Instructions for converting the DCH 230 to a
DCH 180‑SL 9
1. Disconnect the supply cord plug from the power
outlet.
2. To remove the depth gauge (optional), press the
catch and pivot the combined hood extension /
depth gauge out of the hood.
3. Press the spindle lockbutton.
4. Use a wrench to release and remove the M 14
clamping nut or remove the Kwik‐Lock nut by
hand.
5. Remove the diamond cutting disc.
6. Remove the 41 mm diameter clamping flange
from the spindle.
7. Use the 6 mm hex. socket wrench to release the
hex. socket screw securing the hood.
8. Rotate the DCH‐EX 230 guard (hood) and pull it
away from the tool.
9. Check thatthe set of parts required for the conver-
sion is complete (DCH‑EX 180‑SL slitting hood,
spindle extension, M 6 x 65 screw, 5 spacer rings
(3 mm, 6 mm 2 x 13 mm, 21 mm)).
10. Fit the DCH‑EX 180‑SL slitting hood onto the
spindle collar.
11. Rotate the guard (hood) into the desired position.
12. Use the hex. socket wrench to tighten the hex.
socket screw.
13. Press the catch and pivot the hood extension
down and away from the hood.
14. Place the spindle extension on the spindle so that
it cannot rotate.
15. Fit the M 6 x 65 screw through the spindle
extension.
16. Press the spindle lockbutton.
17. Secure the spindle extension on the spindle with
the M 6 x 65 screw and tighten the screw with the
10 mm AF wrench.
18. From here on, follow the instructions for fitting
the cutting discs to the slitting tool.
NOTE The procedure for fitting the cutting discs
is described in the section “Fitting cutting discs
to the DCH 180‑SL slitting tool”.
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6.6 Instructions for converting the DCH 180‑SL
to a DCH 230
Items required for the conversion: DCH‑EX 230 hood,
41 mm dia. clamping flange with O‐ring, M 14 clamp-
ing nut; 24 mm AF / 10 mm AF wrench, 6 mm hex.
socket wrench, diamond cutting discs max. 230 mm
diameter.
1. Disconnect the supply cord plug from the power
outlet.
2. Press the catch on the DCH‑EX 180‑SL hood and
pull out the depth gauge.
3. Press the spindle lockbutton.
4. Use a 24 mm AF wrench to release the 41 mm
diameter clamping nut and remove the nut from
the spindle extension.
5. Release the spindle lockbutton.
6. Remove all spacer rings and both diamond cutting
discs from the spindle extension.
7. Use the 10 mm AF wrench to release the M 6 x 65
screw and remove the screw.
8. Remove the spindle extension from the spindle.
9. Use the hex. socket wrench to release the slitting
hood.
10. Rotate the slitting hood on the spindle collar and
remove it.
11. The procedure for fitting the DCH‑EX 230 guard
and the corresponding cutting disc is described
in the sections “Fitting and adjusting the guard”
and “Fitting cutting discs”.
6.7 Storing and transporting cutting discs
CAUTION
Remove the cutting disc from the power tool after
use. The cutting disc may suffer damage if the power
tool is transported with the disc fitted.
CAUTION
Store the cutting disc in accordance with the man-
ufacturer’s recommendations. Incorrect or careless
storage may damage the cutting disc.
7. Operation
Hold tool by insulated gripping surfaces when per-
forming an operation where the cutting tool may
contact hidden wiring or its own cord. Contact with
a “live” wire will make exposed metal parts of the tool
“live” and shock the operator.
CAUTION
The power tool and the cutting operation generate
noise. Wear ear protectors. Exposure to noise can
cause hearing loss.
CAUTION
The cutting operation may cause dangerous splinters.
Splintering material presents a risk of injury to the
eyes and body. Wear eye protection and a hard hat.
CAUTION
The direction of advance is important. The power
tool must always be advanced with the guide wheels
ahead and in contact with the material being cut.
There is otherwise a risk of kick‐back.
CAUTION
The electric supply voltage must comply with the
information given on the type identification plate
on the power tool. 230 V power tools may also be
connected to a 220 V supply.
CAUTION
The cutting disc and parts of the power tool may
get hot through use. There is a risk of burning your
hands. Wear protective gloves. Touch the power
tool only at the grips provided.
CAUTION
Use clamps or a vice to hold the workpiece securely.
WARNING
Slits cut in loadbearing walls of buildings or other
structures may influence the statics of the structure,
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37

especially when steel reinforcing bars or load‐bearing
components are cut through. Consult the structural
engineer, architect, or person in charge of the
building project before beginning the work.
7.1 Working with the power tool
Take care to ensure that the closed side of the guard
is always positioned toward the operator’s body.
Adjust the position of the guard (hood) to suit each
cutting application.
7.2 TPS theft protection system (optional)
NOTE
The power tool may be equipped with the optional
theft protection system. If the power tool is equipped
with this feature, it can be unlocked and made ready
for operation only with the corresponding TPS key.
7.2.1 Unlocking the power tool
1. Plug the supply cord into the power outlet. The
yellow theft protection indicator LED blinks. The
power tool is then ready to receive the signal from
the TPS key.
2. Hold the TPS key against the lock symbol. The
power tool is unlocked as soon as the yellow theft
protection indicator LED no longer lights.
NOTE If, for example, the electric supply is briefly
interrupted due to a power failure or disconnected
when moving to a different workplace, the power
tool remains ready for operation for approx. 20
minutes. In the event of a longer interruption, the
TPS key must be used again to unlock the power
tool.
7.2.2 Activation of the tool’s theft protection
system
NOTE
Further detailed information on activation and use
of the theft protection system can be found in the
operating instructions for the theft protection system.
7.3 Switching on
1. Plug the supply cord into the power outlet.
2. Always hold the tool securely with both hands on
the grips provided.
3. Unlock the on / off switch by pressing the
switch‐on interlock release button.
4. Press the on / off switch.
5. Reposition your thumb around the rear grip.
7.4 Switching off
Release the on / off switch.
The tool stops after the on / off switch is released.
The switch‐on interlock is re‐activated.
7.5 Working with diamond cutting discs
(DCH 230 and DCH 180‑SL) and synthetic
resin‐bonded fiber‐reinforced cutting discs
(only DCH 230)
DANGER
To reduce the risk of kick‐back, avoid bringing the
cutting tool into contact with the material in the
area indicated.
DANGER
Wherever possible, bring the guide wheels into
contact with the workpiece before starting the cut.
Take extra care in situations where this is not
possible or where the cutting disc is inserted in an
existing cut.
1. When cutting mineral materials, first bring the
tool’s guide wheels into contact with the object to
be cut.
2. Allow the power tool to reach full speed.
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3. Apply pressure to the power tool so that the
cutting disc is pressed into the material slowly.
This ensures that particles and sparks generated
by the cutting operation are caught by the hood
and extracted by the dust removal system.
NOTE Apply moderate pressure, adjusting the
rate of advance to suit the material being cut.
NOTE The diamond disc may overheat and suffer
damage when cutting very hard mineral materials,
e.g. concrete with a high hard pebble content. A
trail of sparks right round the circumference of
the diamond cutting disc is a sure indication of
this. Should this occur, stop cutting and cool the
disc by allowing the tool to run under no load.
A drop in the rate of cutting progress can be an in-
dication of “blunt” (polished) diamond segments.
The segments can be resharpened by making a
few cuts in an abrasive material (Hilti sharpening
plate or sand‐lime block).
7.6 Using a suitable vacuum cleaner for working
on mineral materials
NOTE
Please read the operating instructions for the vacuum
cleaner for information about disposal of the material
collected.
Use of a suitable vacuum cleaner (such as the Hilti
VCU 40, VCU 40‑M or VCD 50) makes it possible
to keep dust to a minimum while working with the
tool. Use of a vacuum cleaner also helps to cool
the segments on the disc and thus reduces segment
wear. In order to avoid electrostatic effects, a vacuum
cleaner equipped with an antistatic hose should be
used.
8. Care and maintenance
CAUTION
Disconnect the supply cord plug from the power
outlet.
8.1 Care of the power tool
DANGER
Under extreme conditions, when used for working
on metal, conductive dust may accumulate inside
the tool. This may have an adverse effect on the
tool’s protective insulation. Under such conditions,
the tool should be plugged into a ground fault
circuit interrupter (RCD) and use of a stationary
dust removal system and frequent cleaning of the
tool’s cooling air slots is recommended.
The outer casing of the motor and the grips are made
from impact‐resistant plastic. Parts of the grips have
a synthetic rubber covering.
Never operate the power tool when the ventilation
slots are blocked. Clean the ventilation slots carefully
using a dry brush. Do not permit foreign objects to
enter the interior of the power tool. Clean the outside
of the power tool at regular intervals with a slightly
damp cloth. Do not use a spray, steam pressure
cleaning equipment or running water for cleaning.
This may negatively affect the electrical safety of the
power tool. Always keep the grip surfaces of the
power tool free from oil and grease. Do not use
cleaning agents which contain silicone.
8.2 Service indicator
NOTE
The power tool is equipped with a service indicator.
LED indicators Constant red light End of service interval ‐servicing is due. After the
lamp lights for the first time, the power tool may
continue to be used for several hours (switched‐on
running time) before the automatic cut‐out is
activated. To ensure that the power tool is always
ready for use, it should be returned to Hilti for
servicing in good time.
Blinking red light See section “Troubleshooting”.
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8.3 Maintenance
WARNING
Repairs to the electrical section of the machine may
be carried out only by trained electrical specialists.
Check all external parts of the power tool for damage
at regular intervals and check that all controls operate
faultlessly. Do not operate the power tool if parts
are damaged or when the controls do not function
faultlessly. If necessary, the power tool should be
repaired by Hilti Service.
8.4 Checking the power tool after care and
maintenance
After carrying out care and maintenance, check that
all protective and safety devices are fitted and that
they function faultlessly.
9. Troubleshooting
Fault Possible cause Remedy
The power tool doesn’t start. Interruption in the electric supply. Plug in another electric appliance
and check whether it works.
The supply cord or plug is defective. Have checked by a trained electrical
specialist and replaced if necessary.
The power tool has not been
unlocked (tools with optional theft
protection system).
Use the TPS key to unlock the power
tool.
The on / off switch is defective. If necessary, the power tool should
be repaired by Hilti Service.
The power tool has been overloaded
(application limits exceeded). Use the right power tool for the job
(don’t use a low‐powered tool for
heavy work).
The overheating protection system
is active. Allow the power tool to cool down.
Clean the ventilation slots.
Other electrical fault. Have it checked by a trained
electrical specialist.
The electronic restart interlock is
activated after an interruption in the
electric supply.
Switch the power tool off and on
again.
The power tool doesn’t achieve
full power. The extension cord’s conductor cross section is inadequate. Use an extension cord with an
adequate conductor cross section.
(Please refer to “Before use”.)
The power tool doesn’t start
and the service indicator blinks
red.
A fault has occurred in the power
tool. If necessary, the power tool should be repaired by Hilti Service.
The power tool doesn’t start
and the service indicator lights
red.
The carbon brushes are worn. Have checked by a trained electrical
specialist and replaced if necessary.
The power tool doesn’t start
and the theft protection system
indicator blinks yellow.
The power tool has not been
unlocked (tools with optional theft
protection system).
Use the TPS key to unlock the power
tool.
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