Kernlochbohrer DKS-162/DC-P User manual

Operating instructions
Diamond core drill
DKS-162/DC-P DKS-162/DC-H
Kernlochbohrer GmbH
Geigersbühlweg 52
72663 Großbettlingen
Tel. [phone]
E-Mail: [e-mail] Version 0 1. Output 05/2023

Content
Introduction and description 3
About this guide 3
Thanks to the buyer 4
Explanation of symbols 4
Safety regulations 4
Technical data 8
Product description 9
Use and care 10
Precautions 10
Preparation 11
Attachment and assembly of drill motor and stand 11
Changing drill bits 12
Cooling of drill and machine 13
Electrical connection 13
Water supply connection 14
Speed selection 14
Drilling 15
Soft strike function 16
Mechanical overload protection 17
Electronic overload protection 17
Surge protection 18
Overheating - Thermal protection 18
Carbon brush warning system 18
Daily maintenance of the power tool 19
Maintenance and inspection plan 20
Troubleshooting 21
Environmental protection 23
Noise/Vibration 24
Warranty 24
Wiring diagram 25
Exploded view 26
EC Declaration of Conformity 32
2

Introduction and description
The core drilling equipment of the DKS-DC 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. The machine has a soft-impact
function that makes drilling easier. However, care must be taken to select the
appropriate drill bit.
The machine may only be serviced by persons who have the appropriate
qualification and certification.
About this guide
These operating instructions are for the model
DKS-162/DC-H
DKS-162/DC-P
Check the machine model against the type plate.
3

Thanks to the buyer
Thank you for purchasing a core drill of the DKS-DC 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
Kernlochbohrer GmbH directly. We are available to answer your questions at any
time.
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.
4

1. Keep your work area clean and well lit. Disorder or unlit work areas can lead to
accidents.
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.
5

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.
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. Beachten Sie, dass die Spannung nicht mehr als +/-5% der Nennspannung
betragen darf. Höhere Spannungen können zu irreparablen Schäden führen.
Beachten Sie, dass beim Betrieb der Maschine über einen Generator keine
höheren Spannungsspitzen erzeugt werden.
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.
6

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.
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 the operation of 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.
7

Technical data
Model
DKS-162/DC-H
DKS-162-/DC-P
Art No.
6199
6198
Power
2200W
2200W
Voltage
230V
230V
Current
10A
10A
Weight
6,5kg
6,5kg
Frequency
50-60HZ
50-60HZ
Max. drilling diameter
without stand:
162mm (1st Gear)
76mm (1st Gear)
162mm (1st Gear)
76mm (2st Gear)
Max. drilling diameter
with stand:
202mm (1st Gear)
102mm (2st Gear)
202mm (1st Gear)
102mm (2st Gear)
Speed
640/1420 1/min
640/1420 1/min
Impact frequency
15360 BPM / 34080
BPM
15360 BPM / 34080
BPM
Spindle thread
1-1/4" UNC & G1/2"
1-1/4" UNC & G1/2"
Compatible stands
KBS-252/M-PRO
KBS-252/M-PRO
Packing dimension
635x460x215mm
635x460x215mm
8

Product description
DKS-162/DC-H and DKS-162/DC-P
1. Dragonfly
2. Switch for gears 1 / 2 with locking device
3. Adjustment ring Soft strike function
4. Quick-change system for (A) water connection / (B) hoover
5. LED red and yellow light
6. Carbon brushes
9
1
2
3
6
4
1
2
3
4
5
4 B
4 A

Use and care
Only use diamond core bits that are in a sharp and undamaged condition. Properly
maintained diamond core bits with sharp cutting segments do not get bent so
quickly and are easier to guide.
Use the power tool, accessories and drill bits etc. in accordance with these
operating instructions, taking into account the working conditions and the work to
be done. Using the power tool for operations other than its intended use could lead
to a dangerous situation.
Have your power tool repaired only by qualified personnel and only with original
spare parts.
Precautions
1. ALWAYS wear hearing protection! When using drill motors, the loud drilling
noise in the working area can cause hearing damage.
2. When drilling, keep a sufficient distance from the core drill and do not touch any
rotating parts. Protect the danger zone and keep children and other persons
away from it. Falling and splashing parts can cause injuries.
3. This diamond core drill is intended for professional use only and may only be
operated by trained personnel. Appropriate use of the core drill includes drilling
rock, reinforced concrete and masonry.
4. The drill motor must be checked regularly (approx. every 6 months) by a
certified electrician according to VDE.
5. When used for overhead drilling, a functional water collection ring must be
used. Make sure that no water can get into the motor.
6. Switch off the core drill immediately if it stops for any reason. After you have
determined and eliminated the cause and carried out a visual inspection of the
drill and core bit, the core drill can be restarted.
10

Preparation
Before each start, subject the core drill to a brief visual inspection. Also check that
the network voltage corresponds to the voltage indicated on the tool's type plate.
The adapters supplied can be exchanged and, in the case of dry drilling, enable
suction with a hoover or serve as a water supply. For wet drilling, a water collection
ring is strongly recommended.
Attachment and assembly of drill motor and stand
Make sure that the core drill is not attached to the drill stand before mounting the
drill stand and that the core drill is not connected to the power supply.
The core drills DKS-162/DC-H and DKS-162/DC-
P can be operated in manual mode or also with a
core drill stand. When mounting, a ᴓ60mm clamp
holder must be used
If you use our vacuum base plate VGP-420/PRO to fix the core drill rig, make sure
that the vacuum is at least -0.8bar and also make sure that the seal is not worn or
damaged.
11

Use an impact anchor together with a plate wing nut and
a cord threaded rod (optional fastening set) to fasten the
drill stand to the substrate. The plate wing nut should be
placed in the centre of the drill stand. After fixing, adjust
the 4 levelling screws on the drill stand to achieve a
good levelling position. You can do this with the help of
the spirit level on the drill stand.
Use and change of drill bits
A diamond core bit is a cylinder that is fitted with brazed or laser-welded segments.
There are 2 types of diamond core bits, wet drill bits and dry drill bits. These usually
have a 1 1/4UNC or an M16 female thread connection. Our DKS-DC series core
drills can perform both wet and dry drilling. The drive spindle has a 1 1/4UNC
external and a G1/2 internal thread connection.
For easier removal of the drill bit, you can apply waterproof grease to the spindle
thread of the machine.
Make sure that you have disconnected the mains plug from the mains before
changing drill bits or removing them.
The core drill and the drill bit are relatively heavy. For this reason, always wear
protective gloves to prevent injuries to your hand from the sharp tool.
12

To change the drill bit, use a 32mm spanner on the drill
spindle and a 41mm spanner on the drill bit at the same
time.
Adapters are available as accessories for drills with
different internal threads.
After mounting the drill on the machine, let it run briefly and check the radial run-out
of the drill bit.
Cooling of drill and machine
The gearbox of the drill motor has splash lubrication for cooling.
The diamond segments of the wet drill bit are cooled with water.
The electric motor is air-cooled.
Electrical connection
To reduce the risk of electric shock and to protect the operator, the DKS-162/DC-H
and DKS-162/DC-P core drill must only be operated via a Portable Residual
Current Device, or PRCD personal circuit breaker.
After connecting to the power supply, first press the
"RESET" button on the PRCD circuit breaker to
energise the circuit to the core drill. In the event of a
voltage drop, the PRCD circuit breaker switches off and
must be switched on again as soon as the power supply
is restored. The fault current at which the PRCD circuit
breaker switches off is 10mA.
Never place or put the PRCD circuit breaker in water. Before starting work, check
for proper operation by pressing the TEST button on the PRCD circuit breaker.
Never operate the core drill directly from the mains power source without a PRCD
circuit breaker.
13

Water supply connection
To connect the water supply, attach the quick coupling to a water hose. Use clean
water. Using water that is contaminated will accelerate the process of wearing out
the water seal.
The maximum water pressure must not exceed 3 bar.
The water serves as a coolant to prevent the drill from heating up excessively
during drilling.
Dust and particles that form during drilling can clog the water supply system. If
necessary, this must be checked and cleaned.
Never let water get into the motor. It could cause an electric shock.
There is a small inspection hole on the core drill at the water supply collar. If water
leaks through this hole, it indicates that the water seals are worn. Replace them
immediately.
Speed selection
The DKS-162/DC-H and the DKS-162/DC-P is equipped with a mechanical 2-speed
oil bath gearbox.
Select the speed according to the drill diameter (type plate).
Speed selection or gear change may only be carried out
when the core drill is switched off. Turn the gear selector
either clockwise or counterclockwise to the desired
position until it is engaged. If necessary, turn the drill
spindle slightly with a spanner to facilitate the speed
change. In this case, disconnect the machine from the
mains beforehand.
The maximum diameter and speeds indicated on the nameplate are based on an
average concrete hardness. The speed varies depending on the hardness of the
material. For reinforced concrete, please select a low gear to reduce the speed.
14

Drilling
Always switch on the machine without a load.
After switching on, next open the water line valve.
When water flows out of the centre of the drill, you can carefully start drilling.
Should you operate the core drill without a drill stand, start the notch by not
approaching the drill diameter with the full cutting face of the drill. Once a V-notch
cut is drilled on the drill face, line up the drill at a right angle while increasing the
feed pressure.
Increase the feed pressure as soon as the depth of cut reaches approx. 10mm.
Always keep an eye on the condition of the drill motor. If you notice that it starts to
smoke slightly or if you notice the smell of an electric motor, relieve the core drill by
withdrawing it from the core hole. Then continue drilling slowly and carefully. This
will prevent the carbon brushes from burning out due to a prolonged overload of the
electric motor.
When you have almost reached the end of the through hole, please reduce the feed
pressure at this point until the drill bit exits at the other side.
There is vertical drilling and angle drilling. When drilling at an angle, use the angle
adjustment function of the drill stand.
If you have selected too high a speed when drilling or if you are working with too
high a feed pressure, this can cause the drill bit to jam.
If, during the drilling process, you notice that the feed speed decreases at the same
force and the water coming out of the drill hole is clear and has some metal
splinters, you have hit 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
reinforcing iron.
If wooden beams, thick asphalt or bitumen are cut, this will increase the current. In
this case, reduce the feed to continue drilling.
If you need to drill deeper than the effective length of your drill allows, an optional
extension can be used.
15

Soft strike function
You can use the DKS-162/DC-H and DKS-162/
DC-P with soft impact function or in normal
drilling mode. To make this selection, you must
adjust the ring on the spindle. To select soft
impact mode, first press the mode selection ring
in the direction of the arrow on the spindle until
the spring is compressed.
Then turn the ring to the " " symbol for soft
impact mode, the " " symbol stands for normal
drilling mode. The soft impact function is
preferred when the machine is used for dry
drilling.
16

Mechanical overload protection
This machine is equipped with a mechanical slip clutch to protect the operator and
the machine from excessive torque forces. If the drill suddenly jams in the hole, the
safety clutch disengages and the drill spindle stops.
Make sure that the load on the clutch is not more than max. 3-4 seconds. Unload
the machine immediately. Otherwise the safety clutch may be destroyed by the high
wear. Do not continue drilling if the slipping clutch has been triggered, reduce the
feed immediately and wait until the drill bit has reached the desired speed again.
Caution!
A worn clutch must be replaced immediately by a specialist at an authorised
workshop. Working with a worn slipping clutch can lead to serious injuries.
Electronic overload protection
There are 2 LED indicators on both our hand-held drill
motors and our pedestal-mounted drill motor. Should the
core drill be in an overload condition, the red LED will
illuminate to indicate to the operator that maximum
power has been reached. Immediately reduce the feed
rate until the red LED goes out.
If the core drill is in overload condition for a long time, the machine switches off for
self-protection and the red LED remains lit. Disconnect the machine from the power
supply. Carry out a visual inspection of the machine.
17

Surge protection
The drill motor can absorb short-term voltage peaks of up to max. 260V. Higher
voltages can cause irreparable damage. Please note that if the machine is operated
via a generator, they do not exceed the maximum specified value.
If the overvoltage protection trips during operation of the core drill DKS-162/DC-H
and DKS-162/DC-P, please check the power supply unit and replace it if necessary.
Overheating - Thermal protection
If the temperature of the drill motor becomes too high, the built-in thermal protection
switch in the machine responds. At the same time, the yellow LED lights up and the
motor switches off. If this happens, do not restart the motor immediately. Always let
the motor cool down first for approx. 2-3 min.
Carbon brush warning system
As soon as the carbon brushes have reached the end of their service life, the core
drill stops automatically to protect the motor from further damage.
The carbon brush warning system consists of 2 LED lights with one red and one
yellow LED. If both the red and yellow lights are on at the same time, you should
check the carbon brushes and replace them if necessary. Remember, always
replace them in pairs.
18

Daily maintenance of the power tool
Caution!
All repair and maintenance work must always be carried out with the mains plug
disconnected.
1. Check that all bolts and nuts are well tightened.
2. Check that the water seals are intact.
3. Check if the gearbox is tight or if oil is leaking out.
4. Check that the PRCD circuit breaker is working properly.
5. Always keep all accessories and the machine clean and dry.
6. Pay attention to the carbon brushes. If they have reached the end of their
service life and/or both LED lights are on, replace them immediately. To
replace them, first remove the cover of the carbon brush holder and pull the
carbon brush out of the holder. Then insert a new one and close the cover
again. Repeat the process with the other carbon brush on the opposite side of
the core drill.
7. Check the condition of the gearbox oil after the gearbox has reached approx.
300 working hours. Should the gearbox oil be heavily contaminated, have the
Getriebeöl sofort durch einen autorisierten Kundendienst auswechseln.
8. After finishing the work, remove the drill bit and then clean the entire machine.
Do not forget to lubricate the spindle thread. Keep the power tool out of reach
of children and in a dry environment.
9. Measure the insulation resistance. Use a 500V ohmmeter to measure the
insulation resistance between L1 (phase), N (neutral) and the housing. The
value must not be less than 7 MΩ.
19

Maintenance and inspection plan
Regular inspection according to the maintenance and inspection schedule is
urgently required. Shorten the intervals between maintenance if you use the
product very frequently.
Maintenance points
(regular inspection
required)
Each time
before use
In the first
month or
after 25
working
hours
In the
third
month or
after 50
working
hours
Every
year or
after 300
working
hours
Leakage of the gearbox
seals
√
√
√
√
Leakage of the water
seals
√
√
√
√
Mains cable Visual
inspection
√
√
√
√
PRCD circuit breaker
√
√
√
√
Concentricity of the
drilling spindle
√
√
√
√
Abrasion on the drill
spindle
-
-
√
√
Mains switch Function
test
√
√
√
√
Drilling spindle
lubrication
√
√
√
√
Check the water valve
for free movement
√
√
√
√
Nuts and bolts
√
√
√
√
Carbon brushes
－
－
－
√
Gear oil
－
－
－
√
General cleaning
-
√
√
√
20