Kernlochbohrer DKB-132/2H User manual

Operating instructions
DKB-132/2H DKB-165/3SH DKB-200/3SH
Kernlochbohrer GmbH
Geigersbühlweg 52
72663 Großbettlingen
Tel. [phone]
Email: [e-mail]
Version 0 5. Output 01/2022

Content
Introduction and description 3
About this guide 3
Thanks to the buyer 4
Explanation of symbols 4
Safety regulations 4
Product structure 7
Technical data 10
Operation on drill rig 10
Electrical connection 10
Water connection 11
Gearbox shift 12
Drill bits 12
Drill bit change 13
Operating the drilling unit 13
Preparation 14
Mounting the drill stand 15
Drilling with core drill rig 15
Overload protection 17
Safety coupling 17
Segment break 17
After drilling 17
Care and maintenance 18
Environmental protection 20
Noise / Vibration 20
Shutdown carbons 21
Behaviour in the event of disruptions 21
Troubleshooting 22
Warranty 22
EC Declaration of Conformity Attachment
2

Introduction and description
The core drilling equipment of the DKB series is intended for professional use and may
only be operated by instructed persons. Strictly adhere to the instructions in the operating
manual to avoid electric shock or fire.
Our company declines all responsibility in the event of violations of the operating
instructions that may result in injury or machine damage. In addition, all currently
applicable regulations of the Accident Prevention Regulations (UVV) and the Employer's
Liability Insurance Association (BG) must be observed.
In conjunction with the appropriate drill bits, the machine is intended for drilling concrete,
stone and masonry in wet and dry cutting. However, you must ensure that you select the
correct drill bit for the corresponding drilling technique in each case.
The machine may only be serviced by persons who have the appropriate qualification and
certification.
About this guide
These operating instructions are for the models
DKB-132/2H
DKB-165/3SH
DKB-200/3SH
Check the machine model against the type plate.
3

Thanks to the buyer
Thank you for purchasing a core drill of the DKB series from Kernlochbohrer GmbH.
Please read the operating instructions carefully and observe the safety instructions. By
operating it correctly, you will fully appreciate the outstanding performance of our products.
Keep this manual in a safe place for future reference.
If you have any questions about the operation of the core drill, please contact the company
Kernlochbohrer GmbH directly. We are always available to answer your questions.
Note:
Kernlochbohrer GmbH reserves the right to change the design and appearance of the
products and their operating instructions. Future changes to the operating instructions will
be made without prior notice.
Explanation of symbols
Warning of general danger. Failure to observe these safety precautions and instructions
may result in electric shock, fire and/or serious injury.
Safety regulations
❖Read all precautions before commissioning and keep the operating instructions. In
addition, all currently applicable regulations of the Accident Prevention Regulations
(UVV) and the Employer's Liability Insurance Association (BG) must be observed.
❖Please follow the operating instructions carefully, as failure to observe these safety
precautions and instructions may cause electric shock, fire and/or serious injury.
1. Keep your work area clean and well lit. Disorder or unlit work areas can lead to
accidents.
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2. Do not work with the power tool near flammable liquids, gases or dust. Power tools
produce sparks that can ignite dust or vapours, causing explosions.
3. Keep children and other people away while using the power tool. If you are distracted,
you may lose control of the tool.
4. Be attentive, work with concentration and pay attention to what you are doing. Do not
use a power tool when you are tired or under the influence of drugs, alcohol or
medicines. A moment of inattention can lead to serious injury.
5. Wear suitable protective equipment and always safety glasses. Wearing suitable
protective equipment such as a dust mask, non-slip safety shoes, hard hat or hearing
protection reduces the risk of injury.
6. Avoid unintentional starting of the machine. Make sure that the power tool is switched
off before connecting it to the power supply. If you have your finger on the switch when
carrying the power tool or connect the machine to the power supply when it is switched
on, this can lead to accidents.
7. Remove adjusting tools or spanners before switching on the power tool. A tool or
spanner that is on a rotary device can cause injury.
8. Avoid unusual postures. Make sure you stand securely and keep your balance at all
times. Do not work on a ladder. This will help you control the power tool in unexpected
situations.
9. Wear appropriate clothing. Do not wear loose clothing or jewellery. Keep hair, clothing
and gloves away from moving parts. Loose clothing, jewellery or long hair can be
caught by moving parts.
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10. Do not overload the appliance. Use the appropriate power tool for your work. With the
appropriate power tool, you will work better and more gently in the specified power
range.
11. Do not use a power tool whose switch is damaged. A power tool that cannot be
switched on and off is dangerous and must be repaired.
12. Unplug the appliance from the mains before making any adjustments, replacing
accessories or putting the appliance aside. This safety measure prevents the power
tool from starting unintentionally.
13. Keep unused power tools out of reach of children. Do not allow persons to use the tool
who are not familiar with it or have not read these instructions. Power tools are
dangerous when used by inexperienced persons.
14. Note that the voltage must not exceed +/-5% of the nominal voltage. Higher voltages
can cause irreparable damage. Note that higher voltage peaks are not generated
when operating the machine via a generator.
15. The plug of the power tool must match the socket. Do not change the plug under any
circumstances. Do not use adapter plugs with earthed forces. Unmodified plugs and
matching sockets reduce the risk of electric shock.
16. Avoid body contact with earthed surfaces or earthed components such as pipes,
radiators, areas and refrigerators.
17. Do not expose power tools to rain or wet conditions. Water entering a power tool
increases the risk of electric shock.
18. Never use the cord to carry or pull the power tool or to unplug it from the wall socket.
Keep it away from heat, oil, sharp edges or moving parts. Damaged, crushed or
twisted cables increase the risk of electric shock.
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19. When using a power tool outdoors, only use an extension cord that is suitable for
outdoor use. Using a cord that is suitable for outdoor use reduces the risk of electric
shock. When using with an extension cord, also make sure that the extension cord has
the same cross-section as the cord on the machine.
20. The use of products such as cutters, grinders, drills that work sand or other materials
can generate dust and fumes that may contain hazardous chemicals. Check the type
of material you are going to work on and use a suitable respirator.
21. Non-approved spare parts and any modification are prohibited on our products.
22. If operating a power tool in a humid environment is unavoidable, use a ground fault
circuit interrupter. The use of a ground fault circuit interrupter reduces the risk of
electric shock.
23. If a hoover and extractor are required, ensure that they are connected and used
correctly. The use of a hoover can reduce dust-related hazards.
Product structure
7
5
4
2
1
7
3
8
1. Tool holder
2. Oil seal
3. Water connection
4. Motor housing
5. Cruise control
6. Mains switch
7. Main handle
8. Guide handle
9. 2-speed gearbox
DKB-132/2H
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8
7 8
9
6
5
4
3
2
1
1.Guide handle
2.Water connection
3.Tool holder
4.Oil seal
5.Mains switch
6.Main handle
7.Soft start/overload protection
8.Motor housing
9.Shoulder support
10.3-speed oil bath gearbox
DKB-200/3SH
4
3
2
1
5
6
7
DKB-165/3SH
1. Tool holder
2. Water connection
3. Motor housing
4. Cruise control
5. Mains switch
6. Main handle
7. Guide handle
8. 3-speed gearbox
8
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Note:
The model DKB-200/3SH has an oil bath gearbox. Please observe the change
intervals for this model according to the operating instructions. Diamond drilling
machines with an oil gear have a very long service life. The friction of the gear
wheels is significantly reduced in an oil gear, which reduces the wear of the gear
wheels and at the same time increases the service life of the machine. As the
machine is subjected to increasing stress and the gear oil heats up, optimum
lubrication is established due to the increasing viscosity of the oil.
CAUTION!
•Use the additional handle supplied with the appliance!
•Hold the handle while operating the machine!
•Wear hearing protection when operating the machine!
CAUTION!
As the core drilling machines of the DKB/H series are mobile devices without
protective equipment, we do not accept any liability for damage or injury caused by
operating the device. We would like to point out that suitable protective equipment
must be worn when operating the core drill and that all drilling should always be
carried out with the aid of a core drill stand.
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Technical data
In order to constantly improve the product, our company reserves the right to change
the technical data without prior notice.
Operation on drill rig
All DKB/H series drills are designed for use with a drill stand. Only place the machine in
a stable drill stand with precise guides. Make sure that the machine axis is parallel to
the drill stand column. Only use drill stands with sufficient stability.
Electrical connection
The core drilling machines of the DKB/H series are designed in protection class I. To
protect the operator, the machine may only be operated via a residual current device and
is therefore supplied as standard with a PRCD circuit breaker integrated in the cable for
use on an earthed socket!
WARNING!
•The PRCD circuit breaker must not be in the water.
•Do not use PRCD circuit breakers to switch the machine on and off.
•Before starting work, check for proper function by pressing the TEST button.
Model
Rated voltage
(V)
Power
consumptio
n (W)
Frequ
ency
(Hz)
Corresponding
speed (rpm)
Brick drilling
range (mm)
Concrete drilling
range without
upright (mm)
Concrete
drilling range
with upright
(mm)
DKB-132/2H
110/230～
1900
50-60
720-1230/1780
～132
～80
～100
DKB-165/3S
H
110/230～
2300
50-60
530-720/1220/1300
～165
～100
～130
DKB-200/3S
H
110/230～
2100
50-60
100-590/1310/2730
～200
～150
～180
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Before commissioning, check that the mains voltage and frequency correspond to the data
on the type plate. Use only 3-core extension cable with protective earth and sufficient
cross-section (min. 2.5mm²). A cross-section that is too weak can lead to excessive power
loss and overheating of the machine and cable. The machine has a start-up current limiter
that prevents the automatic safety device from being triggered unintentionally.
Water connection
If the core bit is not cooled sufficiently with water, the diamond segments can heat up,
which damages them and considerably reduces the service life of the core bit. Therefore,
you should always make sure that an even water supply is guaranteed.
To supply the drill rig with water, please proceed as follows:
1. Connect the machine to a water tap or a water pressure vessel.
2. Operate the machine only with clean water and sufficient water supply.
3. Make sure that the segments are cooled enough. If the drilling water is milky, the
cooling is sufficient.
4. Close the drilled hole if you want to enlarge it to be able to achieve a sufficient cooling
water supply.
5. Drain the water system if there is a risk of frost.
CAUTION!
The maximum water pressure must not exceed 3 bar!
11

Gearbox shift
The core drilling machines of the DKB/H series have a mechanical 2 or 3-speed gearbox.
Adjust the speed of the machine to the drill diameter (see type plate for details).
L: Drilling hard material with large drill bit
M: Drilling hard material with medium drill bit
H: Drilling soft material with small drill bit
Turn the transmission switch to the faster or slower gear until it engages. Only change the
speed when the machine is at a standstill. If necessary, support the shifting process by
slightly turning the work spindle. If the machine stalls due to the hardness of the material,
select a lower gear to protect the machine from overload. If the spindle does not turn after
starting or if there are noises, the gear may not be engaged properly. Stop the machine
immediately and adjust the gear accordingly until it engages. Turn the spindle back and
forth at the same time until it is engaged. Never change the machine to another gear
during operation.
WARNING!
•Only shift the gearbox when the vehicle is at a standstill!
•Never switch over by force!
•Do not use tools such as pliers or a hammer to switch!
Drill bits
Diamond core bits with an internal thread 1¼" UNC can be screwed directly onto the work
spindle of the core drilling rigs DKB-165/3SH and DKB-200/3SH. Adapters are available as
accessories for core bits with M16. The core drill rig DKB-132/2H has an M16 external
thread and an adapter for core bits with a 1¼" UNC internal thread included in the scope
of delivery. Only use core bits matched to the material to be drilled. You will protect the
core drill if you only use round-running and non-deformed core bits. Make sure that there
are no foreign bodies between the diamond segments to ensure a sufficient free cut.
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Drill bit change
Our drilling spindles of the core drilling rigs DKB-165/3SH and DKB-200/3SH have a right-
hand thread. Always use an open-end spanner SW 32 as a counterholder, which is
attached to the drill spindle. For the core drill DKB-132/2H, use an open-end spanner with
SW24 for loosening. Never loosen the core bit with (hammer) blows, as this will damage
the core drill. A little waterproof grease applied to the drill spindle thread and a copper ring
between the spindle and the drill bit make it easier to loosen the drill bit, but are not
absolutely necessary.
CAUTION!
The tool is heavy and can get hot from use. You can burn your hands, crush them or
cut or tear them on the segments. Therefore, always use protective gloves when
changing tools.
Always disconnect the mains plug before working on the unit!
Operating the drilling unit
To operate the machine safely, please observe the following instructions:
Details of the place of use
•Clear the work site of anything that could obstruct the work process.
•Ensure that there is sufficient lighting at the place of use.
•Observe the specified conditions for connection to the power supply.
•Lay the supply line in such a way that damage by the tool is excluded.
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•Make sure that you have sufficient visibility of the work area at all times and that you
can reach all necessary controls and safety equipment at all times.
•Keep other people away from your work area to avoid accidents.
Space requirements for operation and maintenance
If possible, keep approx. 2m free around the machine for operation and maintenance so
that you can work safely and immediate action can be taken in the event of malfunctions.
Preparation
•When drilling into blocks, make sure the blocks are well anchored and secured.
•Before drilling into load-bearing parts, make sure that you do not endanger the statics.
Follow the instructions of the professionals responsible for planning.
•Make sure that you cannot damage any gas or water pipes or power cables when
drilling.
•Make sure that the power supply of the drill is never in the water.
•Make sure that the drill core cannot injure anyone or damage anything if it falls out.
Clear and secure the work area.
•If the drill core could cause damage if it falls out, set up an appropriate device to prevent
the core from falling out uncontrollably.
•Make sure that the core bit is properly attached.
•Use the correct tool depending on the material to be machined.
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Mounting the drill stand
The diamond core drilling rigs of the DKB/H series can be operated mounted on a drill
stand. Since the drill stand is not part of the scope of delivery for all models, we would like
to point out some important mounting variants. Please refer to the operating instructions
for the drill stand.
1. Use metal dowels M14.
2. To fix the drilling unit correctly, you need a fixing set consisting of metal dowels M14, a
threaded rod M14, a washer and a fixing nut.
3. Drill an appropriately deep hole with the necessary diameter and clear it of dust.
4. Insert a metal dowel and spread it with the help of the setting iron.
5. Screw the threaded rod into the dowel.
6. Place the drilling unit with the oblong hole in the foot on the threaded rod.
7. Place the washer and lightly screw on the fastening nut.
8. Adjust the drilling unit using the four screws in the foot plate.
9. Now tighten the fastening nut.
Drilling with core drill rig
1. Fixing the core drill stand: Drill a hole with a percussion drill in the set position,
screw the threaded rod in place, make sure it is tight, fix your core drill stand to it
and adjust the four adjusting screws to ensure a secure stand.
2. Insert the core drill into the clamping holder provided and fix the machine with the
quick-release screw.
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3. Now attach the drill bit to the core drill and fix it with the tool provided.
4. Now connect the power and water supply and open the water inlet.
5. Switch on the motor without the core bit touching the surface.
6. Turn the handle to lower the drill bit until it touches the surface.
7. To get an exact centring of the drill bit, keep the feed low for the first centimetre of
cutting depth. After that you can drill faster. A drilling speed that is too low limits the
performance. If the drilling speed is too high, the diamond segments will quickly
become blunt.
If during the drilling process you notice that the feed rate slows down, you have to use
more force and the water coming out of the borehole is clear and has some metal
splinters, you have encountered rebar. Reduce the pressure on the drill bit to cut through
this easily. You can increase the pressure again when you have cut through the rebar.
Drill bit extension
If you need to drill deeper than the useful length of your core bit:
1. First, drill only as far as the usable length of the crown allows.
2. Remove the crown and release the drill core from the hole without moving the core
drilling unit.
3. Now screw the required extension between the core bit and the core drill to the drill
spindle.
4. Now attach the drill bit to the extension.
5. Push the crown back into the drill hole.
Note:
A copper ring can facilitate loosening the diamond core bit and extension. (Not
included in the scope of delivery.)
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Overload protection
The core drilling rigs of the DKB/H series are equipped with overload protection to protect
the operator, motor and core bit.
Safety coupling
The safety coupling is designed to absorb shocks and excessive loads. However, it is not
an absolute protection, so you should always drill carefully and with the help of a core drill
rig.
Note:
To ensure the functionality of the safety coupling, it may only slip for max. 2s.
Slipping for longer than this will destroy the safety clutch. In case of excessive
wear, it must be replaced by an authorised specialist workshop.
Segment break
If a diamond segment, parts of the reinforcement or similar come loose during drilling and
jam the drill bit as a result, stop working on this hole and drill a hole with the same centre
and a 15-20mm larger diameter.
Note:
Do not try to finish the drilling with another core bit of the same diameter!
After drilling
When the drilling process is completed:
1. Pull the drill bit out of the hole.
2. Switch off the motor. Use the motor switch for this purpose and not the PRCD.
3. Close the water supply.
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Remove the drill core if it remains in the drill bit:
1.Disconnect the core bit from the core drill (if possible).
2.Set the drill bit vertically.
3.Tap lightly against the core drill cylinder with a wooden hammer handle or a rubber
mallet until the drill core slips out. Never hit the core bit with force against a wall or
similar or hit it with tools such as a hammer or open-ended spanner, as otherwise the
core barrel can become distorted and neither the core can be removed nor the core bit
can be reused.
Remove drill core from a blind hole
Break off the core with a wedge or lever. Lift out the core with suitable pliers or drill a hole
in the core. Screw in an eyebolt with the aid of a suitable dowel and pull out the core from
it.
Care and maintenance
Before starting maintenance or repair work, be sure to pull out the mains plug!
Repairs may only be carried out by qualified personnel who are suitable on the basis of
their training and experience. The tool must be checked by a trained electrician according
to VDE after each repair. The power tool is designed to require a minimum of care and
maintenance. However, the following points must always be observed:
•After finishing the drilling work, clean the core drilling unit. Then grease the drill spindle
thread. The ventilation slots must always be clean and open. Make sure that no water
gets into the core drilling machine during the cleaning process.
18

•The gear oil in the DKB-200/3SH must be changed after approx. 6 years. Proceed as
follows:
1. Place the machine vertically.
2. Loosen the gearbox housing cover.
3. Remove the generator and the intermediate cover.
4. Change the gear oil. The filling quantity is approx. 230ml.
•The DKB-132/2H and the DKB-165/3SH have a grease gear. These are filled with
high-performance grease MoS2 and are maintenance-free.
•After approx. 300 hours of operation, the carbon brushes must be checked by a
trained electrician according to VDE and replaced if necessary (only use original
carbon brushes from our shop).
•If cooling water leaks uncontrollably from the oil seal, have it replaced by a specialist
workshop and only use original spare parts from our shop.
•Have switches, cables and plugs checked quarterly by a trained electrician in
accordance with VDE.
Note for the DKB-200/3SH:
Use only gear oil SAE 85W-140!
Renewing the gearbox oil significantly increases the service life of the gearbox.
CAUTION!
If gear oil leaks, switch off the drill immediately, otherwise the gearbox may be
damaged.
19

Environmental protection
Raw material recovery instead of waste disposal!
To avoid transport damage, the unit must be delivered in sturdy packaging. Packaging as
well as the unit and accessories are made of recyclable materials.
The plastic parts of the unit are labelled according to the material. This enables
environmentally friendly, sorted disposal via the collection facilities offered.
Only for EU countries
Do not throw power tools in the household waste! According to the European Directive
2012/19/EU on waste electrical and electronic equipment and its implementation in
national law, used power tools must be collected separately and recycled in an
environmentally sound manner.
Noise / Vibration
The noise of this power tool is measured according to DIN 45 635, part 21. The sound
pressure level at the workplace may exceed 85dB (A); in this case, sound protection
measures for the operator are required.
Wear ear protection!
H a n d / a r m v i b r a t i o n i s typically lower than 2.5m/s². Measured values
determined according to EN 61 029.
The indicated vibration level represents the actual applications of the power tool. However,
if the power tool is used for other applications, with deviating application tools or
insufficient maintenance, the vibration level may deviate. This can significantly increase the
vibration load over the entire working period.
20