DENALI AAG2902B Angle Grinder Instruction Manual

: June 14, 2024
: DENALI

DENALI AAG2902B Angle Grinder

DENALI AAG2902B Angle Grinder

Read all safety warnings and all instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

Tool Description

(A) Handle thread
(B) Guard latch
(C) Main handle
(D) Battery slot
(E) openings
(F) Spindle lock button
(G) Switch button
(H) Auxiliary handle
(I) Wrench storage compartment
(J) Wrench
(K) Spindle
(L) Wheel guard
(M) Backing flange
(N) Grinding wheel
(O) Lock nut

Intended Use

This tool is intended for light grinding and deburring metal and stone materials without the use of water.
Do not use the grinding wheel (N) for cutting purposes.
This tool is intended to be used on dry surfaces and areas only.
This tool is intended for private use only.
Use in well ventilated areas.

Before First Use

Risk of suffocation!
Keep any packaging materials away from children and pets – these materials are a potential source of danger, e.g. suffocation.

Remove all the packing materials.
Remove and review all components before use.
Check the tool for transport damages.
Do not use the tool if it appears damaged.

Preparation

Wheel guard

Attaching the wheel guard

Risk of injury!

Take off the battery pack before attaching the wheel guard (L) to prevent accidentally starting the tool.
Do not operate the tool without the wheel guard (L) attached.

Push and hold the guard latch (B) (Fig. 1 ).
Place the wheel guard (L) around the spindle (K) (Fig. 1).
Release the guard latch (B).

Detaching the wheel guard

Risk of injury!

Take off the battery pack before attaching the wheel guard (L) to prevent accidentally starting the tool.
Do not operate the tool without the wheel guard (L) attached.

Push and hold the guard latch (B).
Take off the wheel guard (L) from around the spindle (K).
Release the guard latch (B).

Adjusting the wheel guard angle

Risk of injury!

Take off the battery pack before making adjustments to prevent accidentally starting the tool.
Do not operate the tool without the wheel guard (L) properly locked and adjusted.

The wheel guard (L) of the tool can be adjusted to point at different directions, blocking debris from flying towards the user.

Push and hold the guard latch (B) (Fig. 2).
Rotate the wheel guard (L) to the desired angle (Fig. 2).
Release the guard latch (B).
Check that the wheel guard (L) is securely engaged to one of the notches of the wheel guard (L). The wheel guard (L) should be between the user and the grinding wheel (N) locked and unable to rotate.

Grinding wheel

The grinding wheel (N) provided is intended for light grinding and deburring metal and stone materials without the use of water. Do not use the grinding wheel (N) for cutting purposes.
Only use 4-1 /2″ (115 mm) diameter, arbor hole 7 /8″ (22.23 mm), type 27 grinding wheels with a rated speed greater or equal to 8500 rpm with this tool.

Attaching the grinding wheel

Risk of injury!

Take off the battery pack before attaching the grinding wheel (N) to prevent accidentally starting the tool.
Wear protective work gloves while handling the grinding wheel (N). The grinding wheel (N) can injure unprotected hands.

Push and hold the spindle lock button (F) (Fig. 3).
Use the wrench (J) to loosen and take off the lock nut (O) from the spindle (K) (Fig. 3).
Release the spindle lock button (F).
Check that the backing flange (M) is facing the correct direction.
Place the grinding wheel (N) on the spindle (K) (Fig. 4).
Place the lock nut (O) on the spindle (K) (Fig. 4). Check that the lock nut (O) is facing the correct direction (Fig. 4).
Push and hold the spindle lock button (F) (Fig. 5).
Use the wrench (J) to tighten the lock nut (0) to the spindle (K) (Fig. 5).
Release the spindle lock button (F).

Detaching the grinding wheel

Risk of injury!

Take off the battery pack before detaching the grinding wheel (N) to prevent accidentally starting the tool.
Wear protective work gloves while handling the grinding wheel (N). The grinding wheel (N) can injure unprotected hands.

Push and hold the spindle lock button (F).
Use the wrench (J) to loosen and take off the lock nut (0) from the spindle (K).
Release the spindle lock button (F).
Take off the grinding wheel (N) from the spindle (K).
Place the lock nut (0) on the spindle (K).
Push and hold the spindle lock button (F).
Use the wrench (J) to tighten the lock nut (0) to the spindle (K).
Release the spindle lock button (F).

Attaching the auxiliary handle

Risk of injury!

Take off the battery pack before attaching the auxiliary handle (H) to prevent accidentally starting the tool.
Do not operate the tool without the auxiliary handle (H) attached.

The auxiliary handle (H) is used to balance the tool and can be installed to any of the handle threads (A) depending on the work at hand.

Rotate and tighten the auxiliary handle (H) clockwise into the desired handle thread (A) (Fig. 6).
Preparation

Detaching the auxiliary handle

Risk of injury!

Take off the battery pack before detaching the auxiliary handle (H) to prevent accidentally starting the tool.
Do not operate the tool without the auxiliary handle (H) attached.

Rotate the auxiliary handle (H) counter-clockwise to detach from the handle thread (A).

Attaching the battery pack

Risk of injury!
Battery tools are always in operating condition. Therefore, take off the battery when the tool is not in use or when it is being carried.

Use the tool with a fully charged battery pack that is suitable for this tool. Use this tool only with the provided battery pack (model ABYS 197B-00, ABYS 197B-00E, ABYS 196B-00 or ABYS 196B-00E) and charger. Use of non-compliant battery packs and chargers may cause risk of fire and/or explosion.
When placing the battery pack on the tool, be sure that the raised rib on the battery pack aligns with the groove inside the tool and that the latches snap into place properly. Improper attachment of the battery pack can cause damage to internal components.

Align the raised ribs on the battery pack with the battery slot (D) on the tool.
Slide the battery pack onto the tool (Fig. 7). The battery pack snaps and locks into place.

Detaching the battery pack

Press and hold the battery-release button located on the front of the battery pack to release it from the battery slot (D) (Fig. 8).
Slide the battery pack off the tool (Fig. 8).

Use

Before each use

Wear personal protective equipment (PPE). Depending on the application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and full body suit capable of stopping small abrasive or workpiece fragments (Fig. 9).
Check the tool and its accessories for damage. Do not use the tool if it is damaged or worn out.
Check for loose screws, misalignment or banding of moving parts, or any other condition that may affect the operation. If abnormal vibration or noise occurs, switch the tool off immediately and have the problem corrected before further use.
Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious injury.
Check the condition of the battery pack. Charge the battery pack if needed. Do not use the battery if it is bulging or hot.
Always firmly hold the tool by its handles. Keep the tool clean and wear clean gloves to maintain a firm grip while in use.
Check that the ventilation openings are not obstructed. Obstructed ventilation openings can cause overheating. Clean the tool with compressed dry air if needed.
Stop operating the tool immediately if bystanders are interrupting the work. Never lay the tool down until it has stopped completely. The grinding wheel may grab the surface and pull the tool out of control.
Do not work continuously for extensive amounts of time with the tool. Take breaks in between work to ensure full concentration while using the tool.

Switching on/off the tool without locking the button

Manually hold the switch button for short time use of the tool.

Slide and hold the switch button (G) forward to the I position by applying pressure only at the rear portion of the button (Fig. 10). The grinding wheel (N) starts spinning.
When the pressure is released the switch button (G) returns to the O position and the grinding wheel (N) gradually slows down the speed until it comes to a complete stop.

Switching on the tool and locking the button

Lock the switch button (G) for prolonged use of the tool.
Slide the switch button (G) forward to the I position by applying pressure only at the rear portion of the button and then press on the front portion of the button to lock it in place. (Fig. 11 ). The switch button (G) locks and the grinding wheel (N) starts spinning.

Unlocking and switching off the tool

Press the rear portion of the switch button (G) (Fig. 12). The switch button (G) snaps back immediately to the O position and the grinding (N) wheel gradually slows down the speed until it comes to a complete stop..

Grinding

Risk of injury!

Do not use excessive or sudden pressure on the grinding wheel (N). It slows the grinding action and put dangerous stress on the grinding wheel (N).
Do not use a faulty grinding wheel (N). If there are chips or cracks on the grinding wheel (N), it is time to change to a new one.

Risk of fire!

This tool sends off sparks while grinding metal. Keep flammable items away from the work area.

Do not switch the tool on and off while the tool is under load. This can greatly decrease the life of the switch button (G).
If the tool feels difficult to control, the angle of the grinding wheel (N) is too steep. The pressure is concentrated on a small area and may cause burning of the workpiece.

Secure the workpiece with clamps. Check for clearance surrounding the workpiece to ensure that the grinding wheel (N) does not come into contact with other objects.
Attach the grinding wheel (N) to the tool following 4.3 Attaching the grinding wheel chapter.
Adjust the angle of the wheel guard (L) following 4. 1 .3 Adjusting the wheel guard angle chapter. Make sure the wheel guard (L) is securely locked in place.
Attach the auxiliary handle (H) to the desired handle thread (A) following 4.5 Attaching the auxiliary handle chapter.
Keep both hands on the tool, one the main handle (C) and one on the auxiliary handle (H).
Start the tool, let the grinding wheel (N) reach the desired speed then lower the tool at a 15° angle to the workpiece (Fig. 13).
Keep the tool moving, use short quick strokes and avoid staying on the same spot for a long time.
After grinding, stop the tool and allow the grinding wheel (N) to stop completely.
Lift the tool off the workpiece.

Cleaning and Maintenance

Detach the battery pack before cleaning, maintenance, storage, or transportation.
Do not immerse the tool in water or other liquids. Never hold the tool under running water.

Cleaning the housing

To clean the tool, wipe with a soft, slightly damp cloth.
Wipe the tool dry after cleaning.
Never use corrosive detergents, wire brushes, abrasive scourers, metal or sharp utensils to clean the tool.

The tool may be cleaned most effectively with compressed dry air. When doing so, do not exceed the pressure of 43 PSI (3 bar) and always wear safety goggles.

Certain cleaning agents and solvents damage plastic parts. Some of these are: gasoline, carbon tetrachloride, chlorinated cleaning solvents, ammonia and household detergents that contain ammonia. Do not use cleaning agents and solvents containing these, as they can damage the tool.

Repair

This tool does not contain any parts that can be repaired by the user. Contact a professional repair center or a professional technician to have the tool checked out and repaired.

Transport

Make sure the tool is secured safely for transit.
Avoid vibrations and shocks.

Storage

Clean the tool before storing.
Store the tool in its original packaging in a dry area. Keep away from children and pets.

Spare parts/replacement parts

Risk of injury!
Using parts that are not compatible with the tool may cause accidents that can result in serious injury.

Description	Model no. or Specification
Battery pack	North American market: ABYS 197B-00, ABYS 196B-00

European market and United Kingdom:
ABY5197B-00E,ABY5196B-00E
Battery charger| North American market: ASC5358B-00
European market: ASC5358B-00E
United Kingdom: ASC5358B-00U

Maintenance

Risk of injury!
Maintenance performed by unauthorized personnel may result in misplacing of internal wires and components which could cause a serious injury.

Any other servicing than mentioned in this manual should be performed by a professional repair center.

Frequently Asked Questions

Problem	Solution
The tool does not switch on.

Check if the battery pack has charge.
Check if the battery pack is attached to the tool properly.
Check if battery pack of correct type is connected (model ABY5197B-00, ABY5197B-00E, ABY5196B-00, ABYS 196B-00E).
Burned out switch. Have the switch replaced by a professional repair center.

Excessive vibration.|

Grinding wheel is damaged. Replace with a new grinding wheel.
Workpiece not clamped or supported properly. Clamp or support workpiece properly.

The tool is over-loaded.| Reduce the pressure on the tool.
The battery pack is overheated.| Switch off the tool and allow the battery pack to cool

before trying again.

Excessive sparking visible through the ventilation openings.
The tool binds or skips off from the workpiece.| This may indicate the carbon brushes have worn out. Stop using the tool and dispose of the tool appropriately.

Grinding wheel spins at low speed. Allow the grinding wheel to reach full speed before touching the workpiece.

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