Hilti 385638 Use and Care Manual
Contents
1. 00 Cover DSH700 900 P3 qxd 00 Cover 5 700 900 P3 15 11 2010 16 26 Uhr Seite 1 F DSH 700 DSH 900 Hilti Corporation LI 9494 Schaan Operating instructions Tel 423 2342111 Mode d emploi Fax 423 234 29 65 www hilti com Manual de instrucciones 288292 Hilti registered trademark of Hilti Corp Schaan W 3503 ina 00 Pos 3 1 Printed in Italy 92010 288292 amp 0 Right of technical and programme changes reserved 5 E 5 ys ORIGINAL OPERATING INSTRUCTIONS DSH 700 DSH 900 cut off saw It is essential that the operating instruc tions are read before the machine is oper ated 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 2 2 Description 3 3 Accessories 4 4 Technical data 5 5 Safety instructions 6 6 Before use g 7 Operation 13 8 Care and maintenance 14 9 Troubleshooting 18 10 Disposal 20 11 Federal emission control warranty statement 20 12 Manufacturer s warranty 21 E These numbers refer to the corresponding illustra tions The illustrations can be found on the fold out cover pages Keep these pages2. 7 Fit the rear drive belt cover and secure it with the four screws 8 Secure the forward drive belt cover with the two clamping nuts and two securing screws 9 Tighten the three clamping nuts securely 18 Nm 8 8 Adjusting the carburetor CAUTION Tampering with the carburetor settings may cause damage to the motor The carburetor of this machine jets H and L has been factory set for optimum performance and sealed to prevent tampering The idling speed of the machine jet T may be adjusted by the user All other adjust ments must be carried out at a Hilti service center NOTE Use a suitable flat screwdriver tip width 4 mm 5 32 and do not force the adjusting screw beyond its intended adjustment range 1 Clean the air filter 2 Allow the machine to run until it reaches its normal operating temperature 3 Adjust the idling speed jet T so that the motor runs smoothly when idling but the cutting disc does not begin to rotate 8 9 Cleaning Careful cleaning of the machine is one of the main prerequisites for trouble free reliable operation Heavy dirt and dust deposits on the motor and in the cooling openings may lead to overheating Don t permit foreign objects to enter the interior of the machine Don t use a high pressure jet system or running water for cleaning Don t use cleaning agents which contain silicone Clean the exterior of the machine at regular intervals with a slightly damp cloth or a
3. 2 Remove the cutting disc 17 3 Clean the machine thoroughly and grease the 6 metal parts 4 Remove the spark plug 5 Pour a little two stroke oil into the cylinder 1 to 2 teaspoons Fault Pull the starter handle a few times This will distribute the oil in the cylinder 7 Replace the spark plug Wrap the machine in plastic foil 9 Put the machine into storage 9 Troubleshooting Possible cause Remedy Cutting disc slows down or stops completely while cut ting Excessive cutting pressure applied cutting disc sticks and stalls in the kerf Drive belt tension too low or the drive belt is broken Cutting disc incorrectly fitted or not tightened properly Reduce cutting pressure and guide the machine in a straight line Re tension the drive belt or fit a new belt Check that the disc is fitted and tightened correctly Cutting disc direction of rotation is incorrect The forward section of the saw arm is loose Check the direction of rotation and correct if necessary Tighten the clamping nuts High vibration disc wanders off the cutting line Saw doesn t start or is diffi cult to start 18 Cutting disc incorrectly fitted or not tightened properly Cutting disc is damaged or unsuit able specification cracked seg ments missing bent overheated deformed etc The centering bushing is fitted in correctly The fuel tank is empty no fuel
4. Have it repaired if necessary Check the machine for dirt and dust and clean it if necessary Check that all operating controls function correctly Have them repaired if necessary Check that the cutting disc is in faultless condition Replace it if necessary 8 1 2 Every 6 months Check the tightness of all screws and nuts accessible from the outside Check that the fuel filter is clean no dirt or deposits and replace it if necessary Retension the drive belt if it slips when the cutting disc is under load 8 1 3 When necessary Check the tightness of all screws and nuts accessible from the outside Replace the air filter if the machine doesn t start or motor performance drops noticeably Check that the fuel filter is clean no dirt or deposits and replace it if necessary Clean or replace the spark plug if the machine doesn t start or is difficult to start Retension the drive belt if it slips when the cutting disc is under load Readjust the motor idling speed if the cutting disc doesn t stop rotating when the machine is idling 8 2 Replacing the air filter DANGER The operator and bystanders must wear breathing protection if the work causes dust CAUTION Dust entering the machine may cause irreparable damage Never operate the machine if the air filter is damaged or missing When changing the air filter the machine should stand upright and should not be laid on its side Take care to ensure that n
5. If any emission related part on your engine as listed above is defective the part will be repaired or replaced by Hilti Owner s warranty responsibilities As small non road engine owner you are respon sible for performance of the required maintenance as defined by Hilti the owner s manual Hilti recom mends that you retain all receipts covering mainte nance on your small non road engine but Hilti cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all sched uled maintenance Any replacement part or service that is equivalent in performance and durability may be used in non warranty maintenance or repairs and shall not reduce the warranty obligations of the en gine manufacturer As the small non road equipment engine owner you should be aware however that Hilti may deny you warranty coverage if your small non road engine or a part en of it has failed due to abuse neglect improper maintenance unapproved modifications or the use of parts not made or ap proved by the original equipment manufacturer You are responsible for presenting your small non road engine to Hilti as soon as the problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Coverage Hilti warrants to the ultimate purchaser and each sub sequent purchaser that your small non road equip ment engine will be designed built equipped at the time
6. Use regular or super gasoline with an octane rating of at least 90 ROZ The alcohol content e g ethanol methanol of the fuel used must not exceed 10 otherwise the life expectancy of the motor will be greatly reduced 6 1 3 Mixing fuel CAUTION The motor will suffer damage if run with fuel mixed in the wrong ratio or with unsuitable oil Use the following mix ratio with Hilti two stroke oil 1 part oil 50 parts gasoline Use the following mix ratio with quality two stroke oil with the TC classification 1 part oil 25 parts gasoline 1 Pour the required quantity of two stroke oil into the fuel container 2 Add the gasoline to the fuel container 3 Close the cap on the fuel container 4 the fuel by shaking the fuel container 6 1 4 Storing the fuel mixture CAUTION Pressure may build up in the fuel tank Accordingly take care when opening the fuel tank cap CAUTION Store the fuel in a dry well ventilated room Mix only enough fuel for a few days use Clean the fuel container occasionally 6 1 5 Filling the machine with fuel CAUTION Don t refuel the machine right at the place where you are working move at least 3 meters 10 feet away from the object you have been cutting DANGER Don t smoke when filling the tank with fuel CAUTION Don t refuel the machine in a room where a naked flame or sparks could ignite the gasoline vapors CAUTION Don t refuel the machine while the mo
7. to its original position 12 Repeat this procedure with the choke disen gaged until the motor starts NOTE The motor will flood if the starting proce dure is repeated too many times with the choke engaged 13 13 Press the throttle as soon as the motor starts This disengages the half throttle position and the choke if previously engaged and the motor then runs at idling speed when the throttle is released 7 2 Cutting techniques DANGER Always hold the saw and the saw carriage securely with both hands on the grips provided Keep the grips dry clean and free from oil and grease DANGER Check that no persons are present within the work ing area and in particular in the area ahead of the saw in the cutting direction DANGER Guide the machine evenly and do not apply lat eral pressure to the cutting disc Always bring the machine into contact with the workpiece at right angles Don t 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 CAUTION Secure the workpiece and the part to be cut off in order to prevent uncontrolled movement NOTE Always apply full throttle when cutting NOTE Avoid making excessively deep cuts Cutting through thick workpieces should be accomplished as far as possible by making a several cuts 7 2 1 Avoiding stalling El CAUTION Avoid apply
8. belt if it slips when a load is applied to the cutting disc NOTE The drive belt must be replaced as soon as the wear mark on the saw arm becomes visible after retensioning This machine is equipped with a semi automatic spring assisted drive belt tensioning system 1 Slacken the three clamping nuts on the forward section of the saw arm approx one complete turn 2 After releasing the nuts the drive belt is ten sioned automatically by spring pressure 3 Retighten the three clamping nuts securely 18 Nm 8 7 Changing the drive belt NOTE After doing this check that the cutting disc can be turned easily by hand and that all screws have been tightened securely 1 Slacken the three clamping nuts on the forward section of the saw arm approx one complete turn 2 Release the tension on the drive belt by turning the belt tensioning cam counterclockwise care fully as far as it will go until resistance is felt i e approx 4 of a turn 3 Remove the upper and lower clamping nuts and thetwo securing screws from the forward section of the saw arm and remove the drive belt cover 4 Release the four securing screws on the rear drive belt cover and remove the cover 5 Remove the defective drive belt Place the new drive belt carefully over the two drive pulleys 6 Tension the drive belt by turning the belt tension ing cam clockwise carefully as far as it will go until resistance is felt i e approx 4 of a turn
9. disc clamping screw by turning it clockwise 8 Insertthe locking pin in the hole in the drive belt cover and turn the cutting disc until the locking pin engages 9 Tighten the cutting disc clamping screw to a torque of 25 Nm e 6 3 Adjusting the guard DANGER Don t operate the machine without the protective devices that belong to it DANGER Adjust the guard to the correct position Direct the particles of material removed away from the operator and the machine WARNING The motor and the cutting disc must have come to a complete stop before making adjustments or changing parts etc Hold the guard by the grip provided and rotate it to the desired position 6 4 Converting the saw from normal cutting mode to flush cutting mode Ei A DANGER Adjust the guard to the correct position Direct the particles of material removed away from the operator and the machine NOTE After completion of flush cutting it is recommended that the saw is converted back to normal cutting mode due to the more favorable balance in this position NOTE After doing this check that the cutting disc can be turned easily by hand and that all screws have been tightened securely 11 DANGER Don t operate the machine without the protective devices that belong to it In order to facilitate cutting as closely as possible to edges and walls etc the forward section of the saw arm can be turned and fitted in the reversed position so
10. fatality respiratory protection and a hard hat Eye CAUTION protective Draws attention to a potentially dangerous situation nM that could lead to slight personal injury or damage to ANSI Z87 1 the equipment or other property NOTE ON Draws attention to an instruction or other useful information Don t use Smoking and damaged naked flames 1 2 Explanation of the pictograms and other cutting discs prohibited information Symbols Prohibition signs ro3 P WARNING Motor stop Fuel pump Transport by Read and system crane is not follow all permissible safety precautions in Warning signs the operator s manual Failure to follow these instructions could result in serious or fatal General Warning hot Warning Warning Risk injury warning surface Flying sparks of kickback present a fire Location of identification data on the machine risk 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 Warning Don t Minimum inhale toxic permissible 5 speed rating of Type exhaust the cutting fumes discs used Generation 01 Serial no 2 Description 2 1 Use of the product as directed The machine is intended for hand held or walk behind use for dry or wet
11. fingers during breaks between working Stay alert watch what you are doing and use common sense when operating the machine Don t use the machine when you are tired or under the influence of drugs alcohol or medi cation A moment of inattention while operating machines may result in serious personal injury 5 9 Safety warnings for abrasive cutting off operations O O Check that cutting disc is fitted in accordance with the manufacturer s instructions Cutting discs must be stored and handled care fully in accordance with the manufacturer s in structions Use only cutting discs with a rated maximum permissible speed which is at least as high as the machine s highest running speed Cutting discs which are damaged or out of round causing vibration must not be used The outside diameter and the thickness of the cutting disc must be within the capacity rating of the machine Incorrectly sized accessories cannot be adequately guarded or controlled Don t use toothed cutting discs saw blades or similar Blades or discs of this kind frequently cause kickback or loss of control of the machine Guide the machine evenly and do not apply lateral pressure to the cutting disc Always bring the machine into contact with the workpiece at right angles Don t 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 breaki
12. open while studying the operating instructions In these operating instructions the designation the machine always refers to the DSH 700 or DSH 900 gasoline powered cut off saw Parts operating controls and indicators DSH 700 DSH 900 Forward grip 2 Rear grip 3 Guide wheels 4 Start stop switch 5 Choke lever half throttle lock 8 Throttle safety grip 7 Throttle trigger Decompression valve 3 Fuel pump Starter handle Q Cutting disc 2 Clamping screw 43 Hole for locking pin for changing cutting discs Clamping flange 8 Guard hood Disc guard adjustment grip 47 Water valve Water connection Fuel tank cap Air filter cover 21 Belt tensioner 2 Exhaust muffler 03 Spark filter Spark plug connector 25 Type identification plate DSH FSC saw carriage Fl CD Grip 2 Throttle trigger 3 Cutting depth adjustment 4 Hold down device 5 Water tank 6 Water connection 7 Axial adjustment Throttle cable 8 Machine cradle 1 General information 1 1 Safety notices and their meaning Obligation signs DANGER 4 N Draws attention to imminent danger that could lead to serious bodily injury fatality 4 WARNING Wear Wear safety Wear ear Don t use protective shoes protection eye toothed Draws attention to a potentially dangerous situation gloves protection cutting discs that could lead to serious personal injury or
13. t leave the machine unattended while the motor is running Always apply full throttle when cutting Hold the machine by insulated gripping surfaces when performing an operation where the cutting disc may contact hidden wiring Contact with a live wire will make exposed metal parts of the machine live and shock the operator 9 Children must be instructed not to play with the machine u The appliance is not intended for use by children or debilitated persons v Lifting the saw and saw carriage by crane is not permissible w Do not stand the saw and saw carriage on an inclined surface Always check to ensure that the saw and saw carriage are standing securely 5 2 Proper organization of the work area A a Ensure that the workplace is well lit b Ensure that the workplace is well ventilated Exposure to dust at a poorly ventilated workplace may result in damage to the health c Don t work in closed rooms Carbon monox ide unburned hydrocarbons and benzene in the exhaust gas may cause asphyxiation d Keep the workplace tidy Objects which could cause injury should be removed from the work ing area Untidiness at the workplace can lead to accidents e Secure the workpiece When necessary use clamps or a vice to secure the workpiece Don t hold the workpiece by hand f Dress properly Do not wear loose clothing or jewellery Keep your hair clothing and gloves away from moving parts Loose clothes jew
14. water alkaline pH value gt 7 must be neutralized by the addition of an acidic neutralizing agent or diluted with a large volume of water before it is allowed to flow into the sewerage system 11 Federal emission control warranty statement Your warranty rights and obligations The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Hilti are pleased to explain the Emission Control System War ranty applicable to your small non road engine In U S and Canada small non road engines must be designed built and equipped to meet the stringent federal antismog standards The equipment engine must be free from defects in materials and work manship which cause it to fail to conform with U S EPA standards for the first two years of engine use from the date of sale to the ultimate purchaser Hilti must warrant the emission control system on your small non road engine for the periods of time listed above provided there has been no abuse neglect or improper maintenance of your unit Your emission 20 control system includes parts such as the carburetor and the ignition system Where a warrantable condi tion exists Hilti will repair your small non road engine at no cost to you Expenses covered under warranty include diagnosis parts and labor Manufacturer s warranty coverage All 2001 and later small non road engines are war ranted to meet the applicable EPA and CARB require ments for two years
15. 4 125 mm 4 92 125 mm 4 92 150 mm 5 91 depth 5 Safety instructions In addition to the information relevant to safety given in each of the sections of these operating instructions the following points must be strictly observed at all times 5 1 General safety rules a Use the right tool or machine for the job Do not use the tool or machine for purposes for which it was not intended Use it only as directed and when in faultless condition b 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 c Use only the genuine Hilti accessories or an cillary equipment listed in the operating in structions Use of accessories or ancillary equip ment not listed in the operating instructions may present a risk of personal injury d Always hold the saw and the saw carriage se curely with both hands on the grips provided Keep the grips dry clean and free from oil and grease 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 begin ning the work Do not overload the machine It will work more efficiently and more saf
16. 7 Drive belt DSH 12 14 359476 Drive belt DSH 16 359477 Filter element DSH 412228 Spark plug DSH 412237 Tool set DSH 359648 Cylinder set DSH 900 412384 Fastening screw assy DSH 412261 Flange 2 DSH 412257 Centering ring 20 mm 1 DSH 412264 4 Technical data Right of technical changes reserved Machine Motor type Cubic capacity Weight without cutting disc tank empty Weight with saw carriage without cutting disc tank empty DSH 700 30 cm 12 Two stroke single cylinder air cooled 68 7 cm 4 19 in 42 3 kg 93 25 Ib DSH 700 35 cm 114 Two stroke single cylinder air cooled 68 7 cm 4 19 in 11 5 kg 25 35 Ib 42 5 kg 93 7 Ib DSH 900 35 cm 114 Two stroke single cylinder air cooled 87 cm 5 31 in 11 7 kg 25 79 Ib 42 7 kg 94 14 Ib DSH 900 40 cm 116 Two stroke single cylinder air cooled 87 cm 5 31 in 11 9 kg 26 23 Ib 42 9 kg 94 58 Ib Power rating 3 5 kW 3 5 kW 4 3 kW 4 3 kW Maximum arbor 5 100 min 5 100 min 5 100 min 4 700 min speed Motor speed 10 000 200 min 10 000 200 min 10 000 200 min 10 000 200 min Idling speed 2 500 3 000 min 2 500 3 000 min 2 500 3 000 min 2 500 3 000 min Dimensions with cutting disc L x W x mm Ignition type 783 x 261 x 434 Electronically controlled ignition timing 808 x 261 x 434 Electronically controlled ignition timing 808 x 261 x 434 Elec
17. atch the mounting hardware of the machine will run out of balance vibrate excessively and may cause loss of control CAUTION Don t use synthetic resin bonded fiber reinforced cutting discs that have exceeded their use by date CAUTION Don t use damaged diamond cutting discs cracks in the steel disc broken or polished segments dam aged arbor hole bent or distorted steel disc heavy discoloration due to overheating steel disc worn away beneath the segments diamond segments with no lateral overhang etc 1 Insert the locking pin in the hole in the drive belt cover and turn the cutting disc until the locking pin engages 2 Use the wrench to release the clamping screw by turning it counterclockwise Remove the clamping flange and the cutting disc 4 Check that the mounting bore of the cutting disc to be fitted corresponds with the centering collar of the cutting disc mounting flange The mount ing flange is provided with a 20 mm diameter centering collar on one side and a 25 4 mm 1 diameter centering collar on the opposite side 5 Clean the clamping and centering surfaces on the machine and on the cutting disc 6 CAUTION Take care to ensure that the direction of rotation of the cutting disc indicated by an arrow matches the direction of rotation shown on the machine Place the cutting disc on the centering collar of the clamping flange 7 Place the clamping flange on the drive arbor and tighten the cutting
18. be reduced accordingly If this is not possible or does not achieve the desired result the machine must be returned for repair WARNING If you notice that the throttle trigger has jammed stop the motor immediately by operating the on off switch WARNING After fitting a new cutting disc the machine must be allowed to run at full speed under no load for approx 1 minute WARNING Before using the machine check to ensure that the start stop switch functions correctly The motor must stop running when the switch is moved to the stop position 1 Stand the machine on a solid surface on the floor 2 Move the start stop switch to the start posi tion 3 Pressthe fuel pump button P 2 to 3 times until the pump button is seen to be completely filled with fuel 4 Press the decompression valve 5 If the motor is cold pull the choke lever up wards This activates the choke and engages half throttle 6 If the motor is hot pull the choke lever up and then push it back down This engages half throttle with no choke 7 Check that the cutting disc is free to rotate 8 Hold the forward grip securely with the left hand and place your right foot in the lower section of the rear grip 9 Pull the starter handle slowly with your right hand until resistance is felt 10 Pull the starter handle vigorously 11 When the motor fires for the first time after 2 to 5 pulls of the starter move the choke lever back
19. ble peripheral speed of at least 100m sec The cutting disc manufacturer s instructions on fitting and using the discs must also be observed 2 6 Recommendations for use We recommend that the workpiece is not cut through in a single operation Advance to the required depth of cut by making several to and fro movements To avoid damaging the diamond cutting disc when dry cutting lift the blade out of the cut for approx 10 seconds every 30 to 60 seconds while the machine is To reduce the amount of dust produced when cutting still running we recommend use of the wet cutting method ERE 3 Accessories Accessories for the DSH 700 and DSH 900 Diamond cutting disc 000000 See main catalog Abrasive cutting disc 000000 See main catalog Two stroke oil DSH 11 365826 Water supply unit DWP 10 365595 Saw carriage DSH FSC 431364 Hard hat 267736 Protective glasses B05 PS clear 285780 Container DSH 365828 Consumables kit DSH 365602 Consumables and wearing parts for the DSH 700 Air filter DSH 261990 Cord 5 pcs DSH 412230 Starter DSH 700 359425 Drive belt DSH 12 14 359476 Filter element DSH 412228 Spark plug DSH 412237 Tool set DSH 359648 Cylinder set DSH 700 412245 Fastening screw assy DSH 412261 Flange 2 DSH 412257 Centering ring 20 mm 1 DSH 412264 Consumables and wearing parts for the DSH 900 Air filter DSH 261990 Cord 5 pcs DSH 412230 Starter DSH 900 35942
20. cutting of asphalt and mineral or metallic construction materials using abrasive or diamond cutting discs To reduce the amount of dust produced when cutting we recommend use of the wet cutting method The working environment may be as follows con struction 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 Working on materials hazardous to the health e g asbestos is not permissible Observe the information printed in the operating in structions concerning operation care and mainte nance Nationally applicable industrial safety regulations must be observed 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 encoun tered The machine and its ancillary equipment may present hazards when used incorrectly by untrained personnel or when used not as directed Take the influences of the surrounding area into account Do not use the power tool or appliance where there is a risk of fire or explosion Modification of the machine or tampering with its parts is not permissible Don t work in closed poorly ventilated rooms 2 2 Items supplied as standard 1 Machine 1 DSH tool set 1 Operating instructions 1 DSH consumable
21. dry brush Check that all grips are clean dry and free from oil and grease 8 10 Maintenance Check all external parts of the machine and the accessories for damage at regular intervals and check that all controls operate faultlessly Don t operate the machine if parts are damaged or when the controls do not function faultlessly If necessary the machine should be repaired by Hilti Service 8 11 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 8 12 Transporting the machine in a vehicle CAUTION To avoid a fire hazard allow the machine to cool down completely before transporting it CAUTION The fuel tank must be completely empty before the machine is shipped by a parcels service We recommend that the original packaging is kept for use in the event of a need to transport the machine in this way Remove the cutting disc 2 Secure the machine to prevent it falling over causing damage or fuel spillage 3 Transport the saw carriage only when the water tank is empty 8 13 Storing the machine for a long period of time DANGER Store machines in a secure place when not in use When not in use machines must be stored in a dry high place or locked away out of reach of children 1 Empty the fuel tank and then start the motor and allow it to idle until all remaining fuel is used up
22. e machine and any bystanders must wear respiratory protection that is approved for use in conjunction with the applicable substance To reduce the amount of dust generated when cutting mineral materials and asphalt we rec ommend use of the wet cutting technique WARNING Some dust created by grinding sanding cutting and drilling contains chem icals known to cause cancer birth defects infertility or other reproductive harm or seri ous and permanent respiratory or other injury Some examples of these chemicals are lead from lead based paints crystalline silica from bricks concrete and other masonry products and natural stone arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce exposure to these chemi cals the operator and bystanders should work in a well ventilated area work with approved safety equipment such as respiratory protec tion appropriate for the type of dust generated and designed to filter out microscopic particles and direct dust away from the face and body Avoid prolonged contact with dust Wear pro tective clothing and wash exposed areas with soap and water Allowing dust to get into your mouth nose eyes or to remain on your skin may promote absorption of harmful chemicals 5 8 Requirements to be met by users a b Improve the blood circulation in your fingers by relaxing your hands and exercising your
23. ect from the segment matrix by cutting with the disc in a very abrasive material such as sandstone r Don t use damaged diamond cutting discs cracks in the steel disc broken or polished segments damaged arbor hole bent or distorted steel disc heavy discoloration due to overheating steel disc worn away beneath the segments diamond segments with no lateral overhang etc 5 10 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 9 9 6 1 The two stroke motor runs a mixture of gasoline and oil The quality of the fuel mixture decisively influences the running and life expectancy of the motor CAUTION Avoid direct skin contact with gasoline CAUTION Ensure that the workplace is well ventilated in order to avoid breathing in gasoline fumes CAUTION Use a fuel container that complies with the appli cable regulations CAUTION Alkylate gasoline does not have the same density specific weight as conventional gasoline To avoid damage when alkylate gasoline is used the machine must be readjusted by Hilti Service Alternatively the oil content can be increased to 4 1 25 6 1 1 Two stroke oil Use Hilti two stroke oil for air cooled motors or a good quality two stroke oil with the TC classification 6 1 2 Gasoline
24. el filter The filter must be replaced if badly soiled 4 Push the fuel filter back into the fuel tank 5 Close the cap on the fuel tank 8 5 Cleaning the spark plug setting the spark plug gap replacing the spark plug IZ CAUTION The spark plug and parts of the motor may be hot immediately after the machine has been running To avoid burning your hands wear suitable protective gloves or allow the machine to cool down before touching its parts only spark plugs of the type NGK CMR7A 5 Use a gentle twisting motion to pull the cable connector off the spark plug 2 Use the spark plug wrench to unscrew and re move the spark plug from the cylinder 3 If necessary clean the spark plug electrode with a soft wire brush 4 Check the spark plug gap 0 5 mm with the aid of a feeler gauge and reset it to the correct gap if necessary 5 Fit the ignition cable connector to the spark plug and hold the threaded section of the spark plug against the cylinder 16 6 Move the start stop switch to the start posi tion 7 CAUTION Avoid touching the spark plug elec trode Pull the starter cord press the decompression valve first An ignition spark must now be clearly visible 8 Use the spark plug wrench to screw the spark plug into the cylinder 12 Nm 9 Fit the ignition cable connector to the spark plug 8 6 Retensioning the drive belt CAUTION A slack drive belt can damage the machine Reten sion the drive
25. ellery or long hair can be caught in moving parts g Itis recommended that non slip shoes or boots are worn when working outdoors h Keep children away Keep other persons away from the working area i Do not overreach Keep proper footing and bal ance at all times This enables better control of the power tool in unexpected situations j Fit the filled water tank to the saw carriage only after fitting the saw to the saw carriage This will prevent the saw carriage falling over k Concealed electric cables or gas and water pipes presenta serious hazard if damaged while you are working Accordingly check the area in which you are working beforehand e g using a metal detector External metal parts of the machine may become live for example when an electric cable is damaged accidentally 1 Don t work from a ladder m Don t work above shoulder height n Ifthe 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 0 When using the wet cutting technique take care to ensure that the water drains away in controlled fashion and check that the water or water spray presents no hazard and causes no damage to the surrounding area p Secure the area below the working area 5 3 Thermal a Wear protective gloves when changing cutting tools as they get hot during use b The exhaust system and mo
26. ely within its intended performance range g Never use the power tool without the guard hood h 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 Adjust the position of the disc guard on the machine correctly The guard must be securely attached to the machine and positioned for max imum safety so the least amount of cutting disc is exposed towards the operator The guard helps to protect the operator from broken disc fragments and accidental contact with the disc Store machines in a secure place when not in use When notin use machines must be stored in a dry high place or locked away out of reach of children Switch the machine off before transporting it When laying the machine down make sure that it stands securely m Switch the machine off after use n 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 Maintain the machine carefully Check for mis alignment or binding of moving parts breakage of parts and any other condition that may affect the machine s operation If damaged have the machine repaired before use Poor maintenance is the cause of many accidents Set the switch to the stop position before changing the cutting disc or adjusting the guard Don
27. he front 15 Fit the spray jets in the openings at the front of the blade guard 12 6 5 Locking rotary movement of the guide wheels WARNING When working on roofs scaffolds and or slight slopes always lock the guide wheels to prevent the saw rolling away inadvertently and possibly falling Use the built in safety feature which allows you to lock the wheels by fitting them in the reversed position turned through 180 1 Release the guide wheel mounting screws and remove the guide wheels 2 Reverse the guide wheels turn through 180 and refit the mounting screws 3 Check that the guide wheels are mounted se curely 6 6 Saw carriage NOTE We recommend use of the saw carriage when the machine is used extensively for floor sawing NOTE Especially when using the machine in this config uration for the first time check to ensure that the throttle cable is correctly adjusted When the throttle control is pressed fully the machine must run up to maximum speed If this is not the case the throttle cable can be readjusted by way of the cable tensioner CAUTION Switch off the saw at the stop switch immediately if the throttle cable on the saw carriage gets stuck DANGER Before starting the engine check that the saw is correctly secured to the saw carriage 1 Move the cutting depth adjustment lever into the upper position 2 Open the hold down device by releasing the screw knob 3 Fit the saw int
28. in the carburetor Check that the disc is fitted and tightened correctly Fit a new cutting disc Check that the mounting bore of the cutting disc to be fitted corre sponds with the centering collar of the cutting disc mounting flange Fill the fuel tank Air filter clogged with dirt or dust Replace the air filter The motor is flooded spark plug wet Wrong fuel mixture Dry the spark plug and cylinder remove the spark plug Disengage the choke lever and re peat the starting procedure several times Empty the fuel tank and flush out the tank and fuel lines Fill the tank with the correct fuel Air in the fuel line no fuel reaching the carburetor Remove the air from the fuel line by operating the fuel pump several times The fuel filter is dirty or blocked no fuel or too little fuel reaching the carburetor Clean the tank and fit a new fuel filter Fault Possible cause Remedy Saw doesn t start or is diffi cult to start No ignition spark visible or spark is too weak when spark plug is removed Clean the spark plug to remove carbon deposits Check the spark plug gap and ad just it if necessary Fit a new spark plug Check the ignition coil cable con nectors and switch and replace the parts if necessary Motor compression is too low Check the motor compression and if necessary replace worn parts piston rings cylinder etc Very low tempe
29. ing excessive pressure when cutting and don t allow the cutting disc to stick and stall Don t attempt to cut to great depth immediately Application of excessive pressure increases the risk of cutting disc distortion Allowing the cutting disc to stick or stall increases the probability of kickback or disc breakage CAUTION Support slabs or large workpieces so that the kerf remains open during the cutting operation 7 2 2 Avoiding kickback EJ CAUTION Always bring the machine into contact with the workpiece from above Allow the cutting disc to contact the workpiece only at a point below its rotational axis CAUTION Take special care when inserting the cutting disc in an existing kerf 7 3 Stopping the motor WARNING If the motor cannot be stopped by operating the on off switch the motor must be stopped if need be by pulling the choke lever WARNING Do not lay the machine down until the cutting disc has stopped rotating The machine must always be stored and transported in an upright position 1 Release the throttle trigger 2 Move the start stop switch to the stop posi tion 8 Care and maintenance WARNING Set the switch to stop before carrying out any maintenance or repairs and before cleaning the machine 14 8 1 Maintenance 8 1 1 Each day before use Check that the machine is complete and in faultless condition Have it repaired if necessary Check the machine for leakage
30. ing instructions Have the carburetor adjusted by Hilti Service Incorrect carburetor setting fuel air mixture Have the carburetor adjusted by Hilti Service 19 Fault Possible cause Remedy Cutting disc rotates while the Idling speed is too high Check the idling speed and adjust if motor is idling necessary The half throttle position is en gaged Disengage the half throttle setting Faulty centrifugal clutch Replace the centrifugal clutch Starter unit doesn t work The clutch claws are not engaging Clean the parts so that they can move freely 10 Disposal Most of the materials from which Hilti machines or appliances are manufactured can be recycled The materials must be correctly separated before they can be recycled In many countries Hilti has already made arrangements for taking back old machines and appliances for recycling Ask Hilti customer service or your Hilti representative for further information NOTE Disposing of slurry directly into rivers lakes or the sewerage system without suitable pretreatment presents environmental problems Ask the local public authorities for information about current regulations 1 Collect the slurry e g using a wet type industrial vacuum cleaner 2 Allow the slurry to settle and dispose of the solid material at a construction waste disposal site the addition of a flocculent may accelerate the separation process 3 remaining
31. le for performing the required maintenance as defined by Hilti the owner s manual Limitations The Emission Control Systems Warranty shall not cover any of the following a repair or replacement required because of misuse neglect or lack of re quired maintenance b repairs improperly performed or replacements not conforming to Hilti specifications that adversely affect performance and or durability and alterations or modifications not recommended or approved in writing by Hilti and c replacement of parts and other services and adjustments necessary for required maintenance at and after this first sched uled replacement point Except as set forth above the warranty terms set forth in section 12 below apply 12 Manufacturer s warranty Hilti warrants that the tool supplied is free of defects in material and workmanship This warranty is valid so long as the tool is operated and handled correctly cleaned and serviced properly and in accordance with the Hilti Operating Instructions and the technical system is maintained This means that only original Hilti consumables components and spare parts may be used in the tool This warranty provides the free of charge repair or replacement of defective parts only over the entire lifespan of the tool Parts requiring repair or replace ment as a result of normal wear and tear are not covered by this warranty Additional claims are excluded unless stringent na tional rules pr
32. ng the cutting disc Don t attempt to brake the cutting disc with the hand The cutting disc and flange or any other acces sory must fit the arbor of the machine exactly Cutting discs or accessories with arbor holes that do not match the mounting hardware of the ma chine will run out of balance vibrate excessively and may cause loss of control j Always use undamaged disc mounting flanges of the correct diameter for the cutting discs used Correctly sized flanges support the cut ting disc and thus reduce the possibility of disc breakage k When fitting the cutting disc always take care to ensure that the disc s specified direction of rotation corresponds to the direction of rotation of the machine 1 Store the cutting disc in accordance with the manufacturer s recommendations Incorrect or careless storage may damage the cutting disc m Don t use cutting discs with a thickness greater than 5 5 mm 0 22 n Remove the cutting disc from the machine after use The cutting disc may suffer damage if the machine is transported with the disc fitted 0 Abrasive cutting discs for gasoline powered cut off saws which are used for wet cutting must be used up the same day as long periods of exposure to moisture have a negative effect on the strength of the disc p Observe the expiry date for resin bonded cutting discs and don t use the discs after this date q Resharpen polished diamond segments no di amonds proj
33. o dust finds its way onto the underlying filter screen NOTE Change the air filter if motor performance drops noticeably or if the machine becomes difficult to start NOTE In this machine most of the dust is removed from the air flow by a maintenance free cyclone type pre screening system This preliminary air cleaning pro cess greatly reduces the amount of maintenance required compared to conventional systems 1 Release the securing screw on the air filter cover and remove the cover 2 Carefully remove the dust adhering to the air filter and the filter chamber use a vacuum cleaner 3 Release the screws retaining the filter holder and remove the air filter 4 Fit the new filter and secure it with the filter holder 5 Fit the air filter cover and tighten the retaining SCrews 8 3 Replacing a broken starter cord CAUTION The housing may suffer damage if the starter cord is too short Never shorten the starter cord 1 Unscrew the three securing screws and remove the starter assembly 2 Remove the remaining pieces of the starter cord from the spool and the starter handle 3 Makea secure knot in the end of the replacement starter cord and then pass the free end of the cord through the hole in the spool from above 4 Pass the end of the cord through the opening in the starter housing from below also through the starter handle from below and then make a secure knot in the end of the cord 5 Pullalength ofthe s
34. o the forward mount with the wheels as shown and swing the grip of the saw under the hold down device Secure the saw by tightening the screw knob Fit the water tank after filling it Adjust the grip to a convenient working height Adjust the guard to the correct position 7 Operation e G08 7 1 Starting the motor CAUTION Working on the material may cause it to splinter Wear eye protection and protective gloves Wear breathing protection if no dust removal system is used Splintering material presents a risk of injury to the eyes and body CAUTION The power tool and the cutting operation generate noise Wear ear protectors Exposure to noise can cause hearing loss CAUTION The cutting disc and parts of the machine get hot dur ing use Wear protective gloves when changing the cutting disc Touch the power tool only at the grips provided You may otherwise burn your hands Take care to ensure that the machine when hot does not come into contact with flammable materials during transport or storage WARNING Keep other persons approx 15 m away from your workplace Pay special attention to the working area behind you DANGER Don t work in closed rooms Carbon monoxide un burned hydrocarbons and benzene in the exhaust gas may cause asphyxiation WARNING When the motor is idling the cutting disc must come to a complete stop If this is not the case the idling speed must
35. of sale to meet all applicable regulations Hilti also warrants to the initial purchaser and each subse quent purchaser that the emission related warranted parts are free from defects in material and work manship which cause the engine to fail to conform with applicable regulations for a period of two years These warranty periods will begin on the date small non road equipment engine is purchased by the ini tial purchaser If any emission related part on your engine is defective the part will be replaced by Hilti at no cost to the owner Hilti shall remedy warranty defects at authorized Hilti service and repair centers Any authorized work done at an authorized Hilti ser vice and repair center shall be free of charge to the owner if it is determined that a warranted part is defective Any manufacturer approved or equivalent replacement part may be used for any warranty main tenance or repairs on emission related parts and must be provided free of charge to the owner if the part is still under warranty Hilti is liable for damages to other engine components caused by the failure of a warranted part still under warranty The California Air Resources Board s Emission Warranty Part List specifically defines the emission related warranted parts These warranted parts are the carburetor as sembly coil assembly rotor spark plug air filter fuel filter breather manifold and the gaskets Maintenance requirements The owner is responsib
36. ohibit such exclusion In particular Hilti is not obligated for direct indirect inciden tal or consequential damages losses or expenses in connection with or by reason of the use of or inability to use the tool for any purpose Im plied warranties of merchantability or fitness for a particular purpose are specifically excluded For repair or replacement send the tool or related This constitutes Hilti s entire obligation with regard parts immediately upon discovery of the defect to to warranty and supersedes all prior or contempo the address of the local Hilti marketing organization raneous comments and oral or written agreements provided concerning warranties 22
37. ratures Allow the machine to warm up slowly to room temperature and repeat the starting procedure Dirt or dust in the spark guard exhaust exit The decompression valve is stiff to operate Clean the parts Release the valve Low motor power poor cut ting performance Air filter clogged with dirt or dust Replace the air filter No ignition spark visible or spark is too weak when spark plug is removed The wrong fuel or dirt and water in the fuel tank Clean the spark plug to remove carbon deposits Check the spark plug gap and ad just it if necessary Fit a new spark plug Check the ignition coil cable con nectors and switch and replace the parts if necessary Flush out the fuel system replace the fuel filter and refill with fuel The disc specification is unsuitable for the material to be cut Drive belt or cutting disc slips Change the specification or request advice from Hilti Check the drive belt tension and disc clamping parts and eliminate the fault Motor compression is too low Check the motor compression and if necessary replace worn parts piston rings cylinder etc The machine is operated or han dled incorrectly excessive cut ting pressure applied cutting disc overheats disc sticks in the kerf unsuitable disc type etc Working at an altitude of more than 1500 m 4900 ft above sea level Observe the information provided in the operat
38. s kit 2 3 Abrasive cutting discs for hand guided gasoline powered cut off saws Abrasive cutting discs for gasoline powered cut off saws are composed of synthetic resin bonded abra sive granulate These cutting discs feature fabric or fiber reinforcement which improves their strength toughness and breakage resistance NOTE Abrasive cutting discs for gasoline powered cut off saws are used mainly for cutting ferrous and non ferrous metals NOTE Various grit types such as aluminum oxide silicon carbide zirconium etc with a different bonding material matrix or matrix hardness are available depending on the construction material to be cut 2 4 Diamond cutting discs for hand guided gasoline powered cut off saws Diamond cutting discs for gasoline powered cut off saws consist of a steel core disc with diamond segments metallically bonded industrial diamonds NOTE Segmented diamond cutting discs or those with a continuous cutting face are mainly used for cutting asphalt and mineral construction materials 2 5 Cutting disc specifications With the DSH 700 12 use only diamond discs or synthetic resin bonded fiber reinforced cutting discs with a diameter of 12 and a permissible peripheral speed of at least 80m sec With the DSH 700 14 DSH 900 14 and DSH 900 16 use only diamond discs or synthetic resin bonded fiber reinforced cut ting discs with a diameter of 14 or respectively 16 DSH 900 16 and a permissi
39. tarter cord out of the housing as shown in the illustration and pass it through the slot in the spool 6 Hold the cord securely close to the slot in the spool and then rotate the spool in a clockwise direction as far as it will go 7 Rotate the spool back from its end point at least revolution max 1 revolutions until the slot in the spool is in alignment with the opening in the starter housing 8 Hold the spool securely and pull the free end of the cord at the starter handle out of the housing 9 Hold the cord under tension release the spool and allow the starter cord to be pulled in 15 10 Pull the starter cord out as far as it will go and check to ensure that the spool can be turned by hand at least a further turn in a clock wise direction If this is not possible spring tension must be reduced by one revolution in a counterclockwise direction 11 Fitthe starter assembly to the machine and press it down gently Pull the starter cord slightly until the coupling engages and the starter assembly is fully seated 12 Secure the starter assembly with the three re taining screws 8 4 Checking and replacing the fuel filter NOTE Check the condition of the fuel filter regularly NOTE When refueling the machine take care to ensure that no dirt or foreign matter finds its way into the fuel tank 1 Remove the cap from the fuel tank 2 Pull the fuel filter out of the fuel tank 3 Check the condition of the fu
40. that the cutting disc when seen from behind is positioned to the right of the saw arm 1 Remove the spray jets from the guard 2 Slacken the three clamping nuts on the forward section of the saw arm approx one complete turn 3 Release the tension on the drive belt by turning the belt tensioning cam counterclockwise care fully as far as it will go until resistance is felt i e approx 1 4 of a turn 4 Remove the three clamping nuts and the two securing screws from the forward section of the saw arm then remove the drive belt cover and the forward section of the saw arm 5 Release the four securing screws on the rear drive belt cover and remove the cover 6 Removethe stop screw that limits rotation of the forward section of the saw arm 7 Place the drive belt carefully over drive pulley 8 Fit the forward section of the saw arm onto the rear section of the saw arm Fit only the middle clamping nut Tighten the nut only finger tight 9 Rotate the disc guard until the opening is at the rear 10 Tension the drive belt by turning the belt tension ing cam clockwise carefully as far as it will go until resistance is felt i e approx 4 of a turn 11 Secure the forward drive belt cover with the two clamping nuts and two securing screws 12 Tighten the three clamping nuts securely 18 Nm 13 Fit the rear drive belt cover and secure it with the four screws 14 Rotate the disc guard until the opening is at t
41. tor get very hot Always hold the machine securely with both hands on the grips provided 5 4 Liquids gasoline and oil a Store gasoline and oil in a well ventilated room in fuel containers in compliance with regula tions b Allow the machine to cool before refueling Use a suitable funnel when refueling d Don t use the gasoline or other flammable liq uids for cleaning e Don t refuel the machine at the workplace f When refueling take care to avoid spillage of gasoline 5 5 Sawing slurry Avoid skin contact with sawing slurry 5 6 Vapors 2 b a Don t smoke when filling the tank with fuel b Avoid inhaling gasoline vapors and exhaust fumes Hot exhaust gases containing sparks or sparks generated by the cutting operation may cause fire 5 7 Dusts or explosion Take to ensure that sparks generated do not ignite flammable gasoline dry grass etc or explosive gas etc sub stances a Large quantities of dust hazardous to the health are generated when cutting especially when dry cutting The operator and bystanders must wear suitable dust masks while the machine is in use Dust or vapors containing chemical substances may be generated when working on unknown materials These substances could cause serious damage to the health Obtain information about hazards presented by the materials from the client or the authorities responsible The opera tor of th
42. tor is running CAUTION Don t refuel the machine while the motor is hot CAUTION Wear suitable protective gloves when refueling 10 CAUTION Take care to avoid spilling fuel CAUTION If your clothing becomes soiled with gasoline while refueling you must change your clothing CAUTION After refueling clean the machine and accessories to remove any spilt fuel DANGER Check to ensure there is no leakage from the ma chine Don t start the machine if fuel is found to be leaking from it 1 Mix the fuel two stroke oil gasoline mixture by shaking the fuel container 2 Place the machine in a steady upright position 3 Open the fuel tank cap by turning it counterclock Wise 4 Fill the tank slowly using a funnel 5 Close the fuel tank cap by turning it clockwise 6 Close the cap on the fuel container 6 2 Fitting and changing the cutting disc 904 CAUTION Cutting discs which are damaged or out of round causing vibration must not be used CAUTION The maximum permissible speed of the disc or blade must be at least as high as the maximum speed printed on the machine Accessories driven at a speed above their maximum permissible speed may break and fly apart CAUTION Use only cutting discs with a 20 mm or 25 4 mm 1 arbor hole CAUTION The cutting discs flanges or other accessories must properly match the arbor size of the machine Cutting discs or accessories with arbor holes that do not m
43. tronically controlled ignition timing 856 x 261 x 466 Electronically controlled ignition timing Electrode gap 0 5 mm 0 02 0 5 mm 0 02 0 5 mm 0 02 0 5 mm 0 02 Spark plug Manufacturer NGK Manufacturer NGK Manufacturer NGK Manufacturer NGK Type CMR7A 5 Type CMR7A 5 Type CMR7A 5 Type CMR7A 5 Carburetor Manufacturer Manufacturer Manufacturer Manufacturer Walbro Walbro Walbro Walbro Model WT Model WT Model WT Model WT Type 895 Type 895 Type 895 Type 895 Fuel mixture Hilti oil 2 50 1 Hilti oil 2 50 1 Hilti oil 2 50 1 Hilti oil 2 50 1 oil 4 oil 4 oil 4 oil 4 25 1 25 1 25 1 25 1 Tank capacity 900 cm 54 9 ins 900 cm 54 9 900 cm 54 9 900 54 9 in Cutting disc mount Reversible Reversible Reversible Reversible Disc arbour size 20 mm 0 79 20 mm 0 79 20mm 0 79 or 20 mm 0 79 or 25 4 mm 1 25 4 mm 1 25 4 mm 1 25 4 mm 1 Max disc outside diameter Min flange outside diameter 308 mm 12 137 102 mm 4 027 359 mm 14 13 102 mm 4 02 359 mm 14 13 102 mm 4 02 410 mm 16 147 102 mm 4 02 Machine DSH 700 30 cm DSH 700 35 cm DSH 900 35 cm DSH 900 40 cm 12 14 14 116 Max disc thick 5 5 mm 0 22 5 5 mm 0 22 5 5 mm 0 22 5 5 mm 0 22 ness steel disc thickness Maximum cutting 100 mm 3 9
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