Kernlochbohrer DKB-200/3SH User manual

Operating instructions
DKB-200/3SH
Kernlochbohrer GmbH
Geigersbühlweg 52
72663 Großbettlingen
Tel. [phone]
Email: [e-mail]
Version 0 6. Output 05/2023

Content
Introduction and description 3
About this guide 3
Thanks to the buyer 4
Explanation of symbols 4
Safety regulations 4
Product structure 8
Technical data 9
Use and care 9
Precautions 10
Preparation 10
Operation on drill rig 11
Mounting and assembly of core drill rig and standsr 11
Changing drill bits 11
Drill and machine cooling 12
Electrical connection 13
Water supply connection 14
Gear change 14
Drilling 15
Electronic overload protection 16
Mechanical overload protection 17
Shutdown carbons 17
Segment break 17
After drilling 18
Daily maintenance of the power tool 19
Behavior in the event of malfunctions 20
Troubleshooting 21
Environmental protection 22
Noise / Vibration 22
Warranty 23
Exploded view 24
EC Declaration of Conformity 27
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, care must be taken
to 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-200/3SH
Check the machine model against the nameplate.
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.
Through proper operation, 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 regarding the operation of the core drill, please contact
the company 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
General Danger Warning. Failure to follow these safety precautions and instructions
may result in electric shock, fire and/or serious injury.
Safety regulations
❖Read all precautions before start-up 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 follow 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 fumes, causing explosions.
3. Keep children and other persons 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 medication. A moment of inattention can result in serious injury.
5. Wear suitable protective equipment and always protective goggles. 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 setting tools or wrenches before switching on the power tool. A tool or
wrench that is on a rotating device can cause injury.
8. Avoid unusual postures. Ensure a secure footing and maintain your balance at
all times. Do not work on a ladder. This will give you better control of the power
tool in unexpected situations.
5

9. Wear appropriate clothing. Do not wear loose clothing or jewelry. Keep hair,
clothing and gloves away from moving parts. Loose clothing, jewelry or long hair
can be caught by moving parts.
10. Do not overload the device. 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 power tool from the wall outlet before making any adjustments,
replacing accessories, or setting aside the power tool. 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 device 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 grounding-type forces.
Unmodified plugs and matching outlets reduce the risk of electric shock.
16. Avoid body contact with grounded surfaces or grounded components such as
pipes, radiators, ranges, 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 the power tool
from the wall outlet. 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, use only 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 machine sand or other
materials can generate dust and fumes that may contain hazardous chemicals.
Check the type of material you are going to machine 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 damp environment is unavoidable, use a
residual current circuit breaker. The use of a ground fault circuit interrupter
reduces the risk of electric shock.
23. If a vacuum cleaner and suction device are required, make sure they are
connected and used properly. The use of a vacuum cleaner can reduce dust-
related hazards.
7

Product structure
1. Guide handle 5. 3 speed oil bath gearbox
2. Tool holder 6. Motor housing
1 ¼" UNC (male thread) 7. Shoulder support
½" (female thread) 8. Soft start / overload protection
3. Water connection 9. Main handle
4. Oil seal 10. Start switch
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1
3
4
2
9
8
7
6
5
10

Technical data
In order to constantly improve the product, our company reserves the right to
change the technical data without prior notice.
Use and care
Only use diamond core bits which are in a sharp and undamaged condition.
Properly maintained diamond core bits with sharp cutting segments do not become
entangled 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
performed. Using the power tool for operations other than its intended use could
result in a hazardous situation.
Have your power tool repaired only by qualified personnel and only with original
spare parts.
Model
DKB-200/3SH
Art no.
1897
Power
2100W
Voltage
230V
Weight
6kg
Frequency
50-60HZ
Max. Drilling diameter brick
200mm
Max. Drilling diameter concrete without
stand
150mm
Max. Drilling diameter concrete with stand
180mm
Speed
100-590/1310/2730 1/min
Spindle thread
1 ¼” UNC
Compatible stands
KBS-200/M, 60mm Clamp
holder
KBS-280/M, 60mm Clamp
holder
9

Precautions
1. ALWAYS wear hearing protection! When using drilling motors, the loud drilling
noise in the working area can cause hearing damage.
2. When drilling, keep a sufficient distance to 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. The 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 in accordance with 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 performed a visual inspection of the
device and core bit, the core drill can be restarted.
Preparation
Subject the core drill to a brief visual inspection before each start. Also check
whether the network voltage corresponds to the voltage specified on the nameplate
of the tool.
10

Operation on drill rig
All drilling machines of the DKB/H series are designed for use with a drill stand.
Only place the machine in a stable drill stand equipped with precise guides.
Make sure that the machine axis is parallel to the drill stand column. Only use
drill stands with sufficient stability.
Mounting and assembly of core drill rig and stand
Make sure that the core drill is not attached to the drill stand before mounting the
drill stand in the desired position.
The DKB-200/3SH core drill can be operated in manual mode or also with a core
drill stand. When mounting, a ᴓ60mm clamp holder must be used
Please observe the operating instructions of the core drill rig used.
Should you use our vacuum base plate VGP-420/PRO for mounting the core drill
stand, make sure that the vacuum is at least -0.9bar and also make sure that the
seal is not worn or damaged.
Changing drill bits
A diamond core bit is a cylinder which is equipped 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 threaded connection. Our DKB-
H series core drills can perform both wet and dry drilling. The drive spindle has a 1
¼" UNC male thread and a ½" female thread.
11

For easier removal of the core bit, you can apply waterproof grease to the spindle
thread of the machine.
To mount a drill bit on the core drill, simply screw it onto the drill spindle. With the
aid of a copper ring (not included in the accessories), you can loosen the drill bit
more easily.
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.
For the DKB-200/3SH core drill, use an open-end wrench with SW32 for loosening.
Never loosen the core bit with (hammer) blows, as this will damage the core drill.
After mounting the drill on the machine, run it briefly and check the radial runout of
the core bit.
Drill and machine cooling
The gearbox of the drill motor has splash lubrication for cooling.
The diamond segments of the wet core bit are cooled with water.
The electric motor is air-cooled.
12

Electrical connection
To reduce the risk of electric shock and to protect the operator, the DKB-200/3SH
core drill rig 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 energize
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 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.
Before commissioning, check that the mains voltage and frequency match the data
given on the type plate. Use only 3-core extension cable with protective conductor
and sufficient cross-section (min. 2.5mm²). Too weak a cross-section can lead to
excessive power loss and overheating of the machine and cable. The machine is
equipped with a start-up current limiter, which prevents the automatic safety device
from being triggered unintentionally.
13

Water supply connection
If the core bit is not cooled sufficiently with water, the diamond segments may heat
up, which will damage them and considerably reduce the service life of the core bit.
Therefore, you should always make sure that a steady water supply is ensured.
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 water seal
wear.
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 formed during drilling can clog the water supply system. If
necessary, this must be checked and cleaned.
Never allow water to enter the motor. It could lead to an electric shock.
Gear change
The DKB-200/3SH core drill has a mechanical 3-speed gearbox. Adjust the speed
of the machine to the drill diameter.
Turn the gear switch to the faster or slower gear until it engages. The speed change
is to be carried out only when the machine is at a standstill; if necessary, support
the switching 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.
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If the spindle does not rotate or noises occur after starting, the gear may not be
engaged properly. Stop the machine immediately and adjust the gear accordingly
until it engages. Simultaneously turn the spindle back and forth until it is engaged.
Never shift the machine to another gear during operation.
WARNING!
•Only shift the gear unit when it is at a standstill!
•Never use force to switch over!
•Do not use tools such as pliers or hammers to switch over!
Drilling
Always switch on the machine without load.
After switching on, next open the water line valve.
When water flows out of the center of the drill, you can carefully start drilling.
If you are operating the core drill without a drill stand, begin the gate cut 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 once the depth of cut reaches approximately 10mm.
Always keep an eye on the condition of the drill motor. If you notice that it starts to
smoke slightly or 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. In this
way, you prevent the carbon brushes from burning off due to a prolonged overload
of the electric motor.
15

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 are vertical and horizontal bores as well as angle bores. For angle drilling,
use the angle adjustment function of the drill stand.
If you have selected too high a speed during drilling or 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 rate decreases while the force
remains the same and the water coming out of the drill hole 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 reinforcing iron.
If wooden beams, thick asphalt or bitumen are cut, this will increase the current. In
this case, reduce the feed rate to continue drilling.
If you need to drill deeper than the usable length of your drill allows, an optional
extension can be used. Initially, drill only as far as the usable length of the crown
allows. Remove the crown and loosen the drill core from the hole without moving
the core drill unit. Now screw the required extension between the core bit and the
core drill unit to the drill spindle. Now attach the core bit to the extension. Push the
crown back into the drill hole.
Note:
A copper ring can facilitate the loosening of the diamond core bit and
extension. (Not included in the scope of delivery.)
Electronic overload protection
The DKB-200/3SH is equipped with an electronic overload protection. If the core
drill is in an overload state for a long time, the machine switches off for its own
protection. Disconnect the device from the power supply. Carry out a visual
inspection of the device.
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 does not exceed max. 3-4 seconds. Unload
the machine immediately. Otherwise, the high wear may destroy the safety
coupling. Do not continue drilling if the slipping clutch has been triggered, reduce
the feed rate 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 authorized
workshop. Working with a worn slipping clutch can lead to serious injuries.
Shutdown carbons
The power tool is equipped with a self-shutting carbon brush to protect the motor. If
the carbon brushes are worn out, the machine switches off automatically. In this
case, both carbon brushes must be replaced at the same time by original carbon
brushes from our store by a trained electrician according to VDE.
Segment break
If a diamond segment, part of the reinforcement or similar comes loose during
drilling, causing the drill bit to jam, stop work on that hole and drill a hole with the
same center and a 15-20mm larger diameter.
Note:
Do not try to finish drilling with another core bit of the same diameter!
17

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
circuit breaker.
3. Close the water supply.
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 barrel with a wooden hammer handle or a rubber
mallet until the 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-end wrenches, as otherwise
the core barrel may become distorted and neither the drill core can be removed
nor the core bit can be reused.
Remove drill core for 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 an eyebolt into it with the aid of a suitable dowel and pull
the drill core out on it.
18

Daily maintenance of the power tool
Before starting maintenance or repair work, be sure to disconnect the power plug!
Repairs may only be carried out by qualified personnel who are suitable on the
basis of their training and experience. The unit 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:
1. Check that all screws and nuts are well tightened.
2. Check that the water seals are intact.
4. Check if the PRCD circuit breaker is working properly.
5. Always keep all accessories and the machine clean and dry.
6. The DKB-200/3SH has an oil bath gearbox. The gear oil must be changed
after approx. 6 years. Proceed as follows: Place the machine vertically. Loosen
the gearbox housing cover. Remove the generator and the intermediate cover.
Change the gear oil. The filling quantity is approx. 230ml.Use only gear oil
SAE 85W-140!
A renewal of the gear oil causes a significant increase in the service life of the
gear unit.
Caution!
If gear oil leaks, switch off the core drill immediately, otherwise the gearbox
may be damaged.
7. After approx. 300 operating hours, the carbon brushes must be checked by a
trained electrician according to VDE and replaced if necessary (only use
original carbon brushes from our store).
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8. If cooling water leaks uncontrollably from the oil seal, have it replaced by a
specialist workshop and use only original spare parts from our store for this
purpose..
9. 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.
Behavior in the event of malfunctions
Switch off the machine in case of malfunctions, disconnect it from the power supply.
Work on the electrical system of the machine may only be carried out by a qualified
electrician in accordance with VDE.
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