HILTI DEG 500-D Angle Grinder Instruction Manual
- June 17, 2024
- HILTI
Table of Contents
HILTI DEG 500-D Angle Grinder
ORIGINAL OPERATING INSTRUCTIONS
DEG 500‑D/DEG 600‑D/‑P angle grinder
It is essential that the operating instructions are read before the power tool
is operated for the first time.
Always keep these operating instructions together with the power tool.
Ensure that the operating instructions are with the power tool when it is
given to other persons.
1 These numbers refer to the corresponding illustrations. The
illustrations can be found on the fold-out cover pages. Keep these pages open
while studying the operating instructions.
In these operating instructions, the designation “the power tool” always
refers to the DEG 500 or DEG 600 angle grinder.
Operating controls and parts 1
- Ventilation slots
- On / off switch (hold to run)
- Vibration-absorbing side handle
- Spindle lockbutton
- Guard release button
- Spindle
- Guard
- Clamping flange
- Abrasive cutting disc / abrasive grinding disc
- Clamping nut
- Wrench
General information
Safety notices and their meaning
DANGER
Draws attention to imminent danger that will lead to serious bodily injury or
fatality.
WARNING
Draws attention to a potentially dangerous situation that could lead to
serious personal injury or fatality.
CAUTION
Draws attention to a potentially dangerous situation that could lead to slight
personal injury or damage to the equipment or other property.
NOTE
Draws attention to an instruction or other useful information.
Explanation of the pictograms and other information
Warning signs
-
General warning
-
Warning: electricity
-
Warning: hot surface
Obligation signs
-
Wear eye protection
-
Wear a hard hat
-
Wear ear protection
-
Wear protective gloves
-
Wear breathing protection
Symbols
-
Read the operating instructions before use
-
Return waste material for recycling.
-
Volts
-
Amps
-
Alternating current
-
Rated speed
-
- Rated speed Revolutions per minute
-
Revolutions per minute
-
Diameter
-
Double insulated
Location of identification data on the power tool
The type designation, item number, year of manufacture and technical status
can be found on the type identification plate on the machine or tool. The
serial no. can be found on the left side of the motor housing. 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.
Type:
Serial no.:
Description
Use of the product as directed
The power tool is designed for cutting, grinding and brushing metal and
mineral materials without use of water. Use of a guide carriage is mandatory
for cutting stone.
The working environment may be as follows: construction site, workshop,
renovation, conversion or new construction.
The power tool may be operated only when connected to a power supply providing
a voltage and frequency in compliance with the information given on its type
identification plate.
Working with metals: Cutting, grinding, brushing.
Working with mineral materials: Cutting and slitting using the corresponding
guard (DC-EX), grinding using the corresponding guard (DG-EX).
Use only discs (abrasive grinding discs, abrasive cutting discs, etc.) that
are approved for use at a speed of at least 11000/min, with a maximum
thickness of ¼” (grinding discs) or ¹⁄₈” (cutting discs) and a diameter of
maximum 5″ or, respectively, 6″.
Use only synthetic resin-bonded, fiber-reinforced grinding discs or cutting
discs approved for use at a permissible\ peripheral speed of at least 80
m/sec. The tool may be used only for dry cutting or grinding.
When grinding stone, a vacuum cleaner equipped with a stone dust filter, e.g.
a suitable Hilti vacuum cleaner, must be used.
Working on materials hazardous to the health (e.g. asbestos) is not
permissible.
Nationally applicable industrial safety regulations must be observed.
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.
To avoid the risk of injury, use only genuine Hilti accessories and insert
tools.
Observe the information printed in the operating instructions concerning
operation, care and maintenance.
The power tool 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 encountered. The power tool and
its ancillary equipment may present hazards when used incorrectly by untrained
personnel or when used not as directed.
Modification of the power tool or tampering with its parts is not permissible.
2 Switches
On / off switch (hold to run)
The items supplied in the cardboard box are:
1 Power tool with guard
1 Guard
1 Side handle
1 Clamping flange
2 Clamping nut
1 Wrench
1 Operating instructions
1 Cardboard box
Starting current limitation
The electronic starting current limiter reduces the starting current drawn by
the tool and thus prevents the mains fuse blowing. It also allows the tool to
start smoothly, without a jolt.
Constant-speed electronics
Electronic speed control keeps running speed almost constant irrespective of
whether the tool is idling or running under load. Constant running speed helps
ensure maximum efficiency.
ATC (Active Torque Control)
The electronics of the tool detects situations where the tool body begins to
move too quickly and prevents further rotation of the drive spindle by
switching the tool off (does not prevent kickback). The switch must be
released and pressed again to restart the tool.
Restart interlock
The tool does not restart by itself when the switch is locked in the “on”
position and the power returns after an interruption in the electric supply.
The switch must first be released and then pressed again to restart.
Temperature-dependent motor protection
The temperature-dependent motor protection system prevents the tool
overheating by monitoring current input and motor temperature.
In the event of motor overload due to application of excessive pressure to the
disc, performance will drop noticeably
or the tool may stop running (avoid stalling the tool in this way).
Permissible tool overload cannot be given as a specific value as it depends on
the temperature of the motor.
In the event of the tool being overloaded, release the pressure applied and
allow the tool to run under no load for approx. 30 seconds.
Using extension cords
Use only extension cords of a type approved for the application and with
conductors of adequate cross section. The power tool may otherwise loose
performance and the extension cord may overheat. Check the extension cord for
damage at regular intervals. Replace damaged extension cords.
Recommended minimum conductor cross section and max. cable lengths
Conductor cross section | 14 AWG | 12 AWG |
---|---|---|
Mains voltage 110-120 V | 75 ft | 125 ft |
Do not use extension cords with 16 AWG conductor cross section.
Using extension cords outdoors
When working outdoors, use only extension cords that are approved and
correspondingly marked for this application.
11 Using a generator or transformer
This power tool may be powered by a generator or transformer when the
following conditions are fulfilled: The unit must provide a power output in
watts of at least twice the value printed on the type identification plate on
the power tool. The operating voltage must remain within +5% and -15% of the
rated voltage at all times, frequency must be in the 50 – 60 Hz range and
never above 65 Hz, and the unit must be equipped with automatic voltage
regulation and starting boost.
Never operate other power tools or appliances from the generator or
transformer at the same time. Switching other power tools or appliances on and
off may cause undervoltage and / or overvoltage peaks, resulting in damage to
the power tool.
DG-EX 125/5″ dust removal hood for grinding 2
The tool is suitable only for occasional use with diamond cup wheels for
grinding mineral materials.
CAUTION
Use of this guard for working on metal is not permissible.
NOTE
It is recommended that a dust removal system consisting of matched components,
i.e. dust removal hood and a suitable Hilti vacuum cleaner, are used for
grinding mineral materials, such as concrete or stone. These serve to protect
the operator and increase the life of the power tool and disc used.
DC‑EX 125/5″‑M dust removal hood with guide carriage for cutting and
slitting 3
Cutting and slitting work on mineral materials may be carried out only when
the power tool is equipped with a dust removal hood with guide carriage.
CAUTION
Use of this guard for working on metal is not permissible.
NOTE
It is recommended that a dust removal system consisting of matched components,
i.e. dust removal hood and a suitable Hilti vacuum cleaner, are used for
cutting and slitting mineral materials, such as concrete or stone. These serve
to protect the operator and increase the life of the power tool and disc used.
DC‑EX 125/5″‑C compact dust removal hood for cutting 4
For cutting masonry and concrete.
CAUTION
Use of this guard for working on metal is not permissible.
NOTE
It is recommended that a dust removal system consisting of matched components,
i.e. dust removal hood and a suitable Hilti vacuum cleaner, are used for
cutting and slitting mineral materials, such as concrete or stone. These serve
to protect the operator and increase the life of the power tool and disc used.
Guard with side cover 5
CAUTION
When grinding with straight grinding discs and cutting with cutting discs in
metalworking applications, use the
guard with cover plate.
Front cover for the guard (DEG 500-D) 6
CAUTION
When grinding with straight grinding discs and cutting with cutting discs in
metalworking applications, use the guard with front cover.
Consumables
Discs with a max. diameter of 125 mm / 5″, for a speed of 11000/min, discs with a max. diameter of 150 mm / 6″, for a speed of 9300/min and a peripheral speed of 80 m/sec, and a max. disc thickness of ¼” (abrasive grinding discs) or ¹⁄₈” (abrasive cutting discs).
Discs | Application | Designation | Material |
---|---|---|---|
Abrasive cutting disc | Cutting | AC‑D | metal |
Diamond cutting disc | Cutting | DC‑D | mineral |
Abrasive grinding disc | Rough grinding | AG‑D, AF‑D, AN‑D | metal |
Diamond grinding disc | Rough grinding | DG‑CW | mineral |
Wire brushes | Wire brushes | 3CS, 4CS, 3SS, 4SS | metal |
Assignment of discs to the DEG 500‑D equipment to be used
Item | Equipment | AC‑D | AG-D | AF-D | AN-D | DG‑CW | DC‑D | 3CS/3SS/4CS/4SS |
---|---|---|---|---|---|---|---|---|
A | Guard | X | X | X | X | X | X | X |
B | Front cover (in combination with A) | X | – | – | – | – | X | – |
C | Guard with cover plate (optional for A, B) | X | – | – | – | – | X | – |
D | DG‑EX 125/5″ sur- face guard | – | – | – | – | X | – | – |
E | DC‑EX 125/5″ compact guard | – | – | – | – | – | X | – |
F | DG‑EX 125/5″M mineral cutting guard | – | – | – | – | – | X | – |
G | DC‑EX SL cutting adapter | – | – | – | – | – | X | – |
H | Side handle | X | X | X | X | X | X | X |
I | DC BG 125 hoop handle (optional for H) | X | X | X | X | X | X | X |
K | Clamping nut (not for use with accessories with integrated thread) | X | X | |||||
X | X | X | X | – | ||||
L | Clamping flange (not for use with accessories with integrated thread) | X | ||||||
X | X | X | X | X | – |
Assignment of discs to the DEG 600‑D/-P equipment to be used
Item | Equipment | AC‑D | AG-D | AF-D | AN-D | DG‑CW | DC‑D | 3CS/3SS/4CS/4SS |
---|---|---|---|---|---|---|---|---|
A | Guard | – | X | X | X | X | X | X |
B | Guard with cover plate (optional for A) | X | – | – | – | – | X | – |
C | Side handle | X | X | X | X | X | X | X |
D | DC BG 125 hoop grip (optional for C) | X | X | X | X | X | X | X |
E | Clamping nut (not for use with accessories with integrated thread) | X | X | |||||
X | X | X | X | – | ||||
F | Clamping flange (not for use with accessories with integrated thread) | X | ||||||
X | X | X | X | X | – |
Technical data
Right of technical changes reserved.
Tool | DEG 500-D | DEG 600-D/-P |
---|---|---|
Rated current input | Rated voltage 120 V: 11.5 A | Rated voltage 120 V: 11.5 A |
Rated frequency | 60 Hz | 60 Hz |
Rated speed | 11,000/min | 9,300/min |
Abrasive cutting discs (Ø) | 125 mm (5″) | 150 mm (6″) |
Dimensions (L x H x W) without hood | 360 mm (14.17″) x 103 mm (4.06″) x 80 mm | |
(3.15″) | 360 mm (14.17″) x 103 mm (4.06″) x 80 mm (3.15″) | |
Weight without accessories | 1.9 kg (4.19 lb) | 1.9 kg (4.19 lb) |
Other information about the power tool
Drive spindle thread (arbor size) | ⁵⁄₈”‑11 UNC |
---|---|
Spindle length | ⁶⁄₈” |
Protection class | Protection class II (double insulated) |
Safety instructions
NOTE
The safety rules in section 5.1 contain all general safety rules for power
tools which, in accordance with the applicable standards, require to be listed
in the operating instructions. Accordingly, some of the rules listed may not
be relevant to this tool.
General Power Tool Safety Warnings
a) WARNING
Read all safety warnings and instructions. Failure to follow the warnings and
instructions may result in electric shock, fire and/or serious injury. Save
all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your mains-operated (corded)
power tool or batteryoperated (cordless) power tool.
Work area safety
a) Keep work area clean and well lit. Cluttered or dark areas invite
accidents.
b) Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases or dust. Power tools create sparks which
may ignite the dust or fumes.
c) Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
Electrical safety
a) Power tool plugs must match the outlet. Never modify the plug in any
way. Do not use any adapter plugs with earthed (grounded) power tools. Un
modified plugs and matching outlets will reduce risk of electric shock.
b) Avoid body contact with earthed or grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
c) Do not expose power tools to rain or wet conditions. Water entering a
power tool will increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for carrying, pulling or
unplugging the power tool.
Keep cord away from heat, oil, sharp edges or moving parts. Damaged or
entangled cords increase the risk of electric shock.
e) When operating a power tool outdoors, use an extension cord suitable
for outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
f) If operating a power tool in a damp location is unavoidable, use a
residual current device (RCD) protected supply. Use of an RCD reduces the risk
of electric shock.
Personal safety
a) Stay alert, watch what you are doing and use common sense when
operating a power tool. Do not use a power tool while you are tired or under
the influence of drugs, alcohol or medication. A moment of inattention while
operating power tools may result in serious personal injury.
b) Use personal protective equipment. Always wear eye protection.
Protective equipment such as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions will reduce personal
injuries.
c) Prevent unintentional starting. Ensure the switch is in the
off‐position before connecting to power source and/or battery pack, picking up
or carrying the tool. Carrying power tools with your finger on the switch or
energising power tools that have the switch on invites accidents.
d) Remove any adjusting key or wrench before turning the power tool on. A
wrench or a key left attached to a rotating part of the power tool may result
in personal injury.
e) Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewellery. Keep your
hair, clothing and gloves away from moving parts. Loose clothes, jewellery or
long hair can be caught in moving parts.
g) If devices are provided for the connection of dust extraction and
collection facilities, ensure these are connected and properly used. Use of
dust collection can reduce dust-related hazards.
Power tool use and care
a) Do not force the power tool. Use the correct power tool for your
application. The correct power tool will do the job better and safer at the
rate for which it was designed.
b) Do not use the power tool if the switch does not turn it on and off.
Any power tool that cannot be controlled with the switch is dangerous and must
be repaired.
c) Disconnect the plug from the power source and/or the battery pack from
the power tool before making any adjustments, changing accessories, or storing
power tools. Such preventive safety measures reduce the risk of starting the
power tool accidentally.
d) Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate the
power tool. Power tools are dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment or binding of moving
parts, breakage of parts and any other condition that may affect the power
tool’s operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools
with sharp cutting edges are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits etc.
in accordance with these instructions taking into account the working
conditions and the work to be performed. Use of the power tool for operations
different from those intended could result in a hazardous situation.
Service
a) 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.
Safety warnings common for grinding, sanding, wire brushing, polishing
or abrasive cutting-off operations
a) This power tool is intended to function as a grinder, sander, wire
brush or cut-off tool. Read all safety warnings, instructions, illustrations
and specifications provided with this power tool. Failure to follow all
instructions listed below may result in electric shock, fire and/or serious
injury.
b) Operations such polishing are not recommended to be performed with
this power tool Operations for which the power tool was not designed may
create a hazard and cause personal injury.
c) Do not use accessories which are not specifically designed and
recommended by the tool manufacturer. Just because the accessory can be
attached to your power tool, it does not assure safe operation.
d) The rated speed of the accessory must be at least equal to the maximum
speed marked on the power tool. Accessories running faster than their rated
speed can break and fly apart.
e) The outside diameter and the thickness of your accessory must be
within the capacity rating of your power tool. Incorrectly sized accessories
cannot be adequately guarded or controlled.
f) Threaded mounting of accessories must match the grinder spindle
thread. For accessories mounted by flanges, the arbour hole of the accessory
must fit the locating diameter of the flange. Accessories that do not match
the mounting hardware of the power tool will run out of balance, vibrate
excessively and may cause loss of control.
g) Do not use a damaged accessory. Before each use inspect the accessory
such as abrasive
wheels for chips and cracks, backing pad for cracks, tear or excess wear, wire
brush for loose or cracked wires. If power tool or accessory is dropped,
inspect for damage or install an undamaged accessory. After inspecting and
installing an accessory, position yourself and bystanders away from the plane
of the rotating accessory and run the power tool at maximum no-load speed for
one minute. Damaged accessories will normally break apart during this test
time.
h) Wear personal protective equipment. Depending on application, use face
shield, safety goggles or safety glasses. As appropriate, wear dust mask,
hearing protectors, gloves and workshop apron capable of stopping small
abrasive or workpiece fragments. The eye protection must be capable of
stopping flying debris generated by various operations. The eye protection
must be capable of
stopping flying debris generated by various operations. The dust mask or
respirator must be capable of filtrating particles generated by your
operation. Prolonged exposure to high intensity noise may cause hearing loss.
i) Keep bystanders a safe distance away from work area. Anyone entering
the work area must wear personal protective equipment. Fragments of workpiece
or of a broken accessory may fly away and cause injury beyond immediate area
of operation. j) Hold the power tool by insulated gripping surfaces only,
when performing an operation where the cutting accessory may contact hidden
wiring or its own cord. Cutting accessory contacting a “live” wire may make
exposed metal parts of the power tool “live” and could give the operator an
electric shock.
k) Position the cord clear of the spinning accessory.
If you lose control, the cord may be cut or snagged and your hand or arm may
be pulled into the spinning accessory.
l) Never lay the power tool down until the accessory has come to a
complete stop. The spinning accessory may grab the surface and pull the power
tool out of your control.
m) Do not run the power tool while carrying it at your side. Accidental
contact with the spinning accessory could snag your clothing, pulling the
accessory into your body.
n) Regularly clean the power tool’s air vents. The motor’s fan will draw
the dust inside the housing and excessive accumulation of powdered metal may
cause electrical hazards.
o) Do not operate the power tool near flammable materials. Sparks could
ignite these materials.
p) Do not use accessories that require liquid coolants. Using water or
other liquid coolants may result in electrocution or shock.
Kickback and related warnings
Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing
pad, brush or any other accessory. Pinching or snagging causes rapid stalling
of the rotating accessory which in turn causes the uncontrolled power tool to
be forced in the direction opposite of the accessory’s rotation at the point
of the binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the
edge of the wheel that is entering into the pinch point can dig into the
surface of the material causing the wheel to climb out or kick out. The wheel
may either jump toward or away from the operator, depending on direction of
the wheel’s movement at the point of pinching. Abrasive wheels may also break
under these conditions.
Kickback is the result of power tool misuse and/or incorrect operating
procedures or conditions and can be avoided by taking proper precautions as
given below.
a) Maintain a firm grip on the power tool and position your body and arm
to allow you to resist
kickback forces. Always use auxiliary handle, if provided, for maximum control
over kickback or torque reaction during start-up. The operator can control
torque reactions or kickback forces, if proper precautions are taken.
b) Never place your hand near the rotating accessory. Accessory may
kickback over your hand.
c) Do not position your body in the area where power tool will move if
kickback occurs. Kickback will propel the tool in direction opposite to the
wheel’s movement at the point of snagging.
d) Use special care when working corners, sharp
edges etc. Avoid bouncing and snagging the accessory. Corners, sharp edges or
bouncing have a tendency to snag the rotating accessory and cause loss of
control or kickback.
e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such
blades create frequent kickback and loss of control.
Safety warnings specific for grinding and abrasive cutting-off
operations
a) Use only wheel types that are recommended for your power tool and the
specific guard designed for the selected wheel. Wheels for which the power
tool was not designed cannot be adequately guarded and are unsafe.
b) The grinding surface of centre depressed wheels must be mounted below
the plane of the guard lip. An improperly mounted wheel that projects through
the plane of the guard lip cannot be adequately protected.
c) The guard must be securely attached to the power tool and positioned
for maximum safety, so the least amount of wheel is exposed towards the
operator. The guard helps to protect operator from broken wheel fragments,
accidental contact with wheel and sparks that could ignite clothing.
d) Wheels must be used only for recommended applications. For example: do
not grind with the side of cut-off wheel. Abrasive cut-off wheels are intended
for peripheral grinding, side forces applied to these wheels may cause them to
shatter.
e) Always use undamaged wheel flanges that are of correct size and shape
for your selected wheel.
Proper wheel flanges support the wheel thus reducing the possibility of wheel
breakage. Flanges for cut-off wheels may be different from grinding wheel
flanges.
f) Do not use worn down wheels from larger power tools. Wheel intended
for larger power tool is not suitable for the higher speed of a smaller tool
and may burst.
Additional safety warnings specific for abrasive cutting-off
operations
a) Do not “jam” the cut-off wheel or apply excessive pressure. Do not
attempt to make an excessive depth of cut. Overstressing the wheel increases
the loading and susceptibility to twisting or binding of the wheel in the cut
and the possibility of kickback or wheel breakage.
b) Do not position your body in line with and behind the rotating wheel.
When the wheel, at the point of operation, is moving away from your body, the
possible kickback may propel the spinning wheel and the power tool directly at
you.
c) When wheel is binding or when interrupting a cut for any reason,
switch off the power tool and hold the power tool motionless until the wheel
comes to a complete stop. Never attempt to remove the cut-off wheel from the
cut while the wheel is in motion otherwise kickback may occur.Investigate and
take corrective action to eliminate the cause of wheel binding.
d) Do not restart the cutting operation in the workpiece. Let the wheel
reach full speed and carefully
re-enter the cut. The wheel may bind, walk up or kickback if the power tool is
restarted in the workpiece.
e) Support panels or any oversized workpiece to minimize the risk of
wheel pinching and kickback. Large workpieces tend to sag under their own
weight. Supports must be placed under the workpiece near the line of cut and
near the edge of the workpiece on both sides of the wheel.
f) Use extra caution when making a “pocket cut” into existing walls or
other blind areas. The protruding wheel may cut gas or water pipes, electrical
wiring or objects that can cause kickback.
Safety warnings specific for wire brushing operations
a) Be aware that wire bristles are thrown by the brush even during
ordinary operation. Do not overstress the wires by applying excessive load to
the brush. The wire bristles can easily penetrate light clothing and/or skin.
b) If the use of a guard is recommended for wire brushing, do not allow any
interference of the wire wheel or brush with the guard. Wire wheel or brush
may expand in diameter due to work load and centrifugal forces.
Additional safety instructions Personal safety
a) Always hold the tool securely with both hands on the grips provided.
Keep the grips dry, clean and free from oil and grease.
b) Breathing protection must be worn if the power tool is used without a
dust extraction system for work that creates dust.
c) Improve the blood circulation in your fingers by relaxing your hands
and exercising your fingers during breaks between working.
d) 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.
e) Always lead the supply cord and extension cord away from the power
tool to the rear while working. This helps to avoid tripping over the cord
while working.
f) Children must be instructed not to play with the power tool.
g) The power tool is not intended for use by children, by debilitated
persons or those who have received no instruction or training.
h) WARNING: Some dust created by grinding, sanding, cutting and drilling
contains chemicals known to cause cancer, birth defects, infertility or other
reproductive harm; or serious 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 chemicals, the operator and bystanders should work in a
well-ventilated area, work with approved safety equipment, such as respiratory
protection 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 protective clothing and wash exposed
areas with soap and water. Allowing dust to get into your mouth, eyes, or to
remain on your skin may promote absorption of harmful chemicals.
Power tool use and care
a) Grinding discs must be stored and handled carefully in accordance with
the manufacturer’s instructions.
b) Check that the grinding disc is fitted in accordance with the
manufacturer’s instructions.
c) If use of a spacer ring or other intermediate part is specified and
the part is supplied with the grinding disc, check to ensure that the part is
fitted.
d) Never use the power tool without its matching disc guard.
e) The workpiece must be fixed securely in place.
f) Before use, check that the cutting or grinding disc has been fitted
correctly and the clamping nut tightened. Then allow the power tool to run for
30 seconds under no load while holding it securely. Switch off the power tool
immediately if significant vibration or any other faults are noticed. Should
this occur, examine the power tool in order to determine the cause.
g) Do not use cutting discs for grinding.
h) Do not use type 27 grinding discs with integrated clamping nut.
i) After disc breakage, or if the power tool is dropped, falls or suffers
other mechanical damage, it must be checked at a Hilti Service Center.
j) Take steps to ensure that flying sparks from the tool do not present a
hazard, i.e. by striking yourself or other persons or by igniting inflammable
substances. Adjust the position of the disc guard accordingly.
k) In case of an interruption in the electric supply: Switch the power
tool off and unplug the supply cord. This will prevent accidental restarting
when the electric power returns.
Electrical safety
a) Before beginning work, check the working area (e.g. using a metal
detector) to ensure that no concealed electric cables or gas and water pipes
are present. External metal parts of the power tool may become live, for
example, when an electric cable is damaged accidentally. This presents a
serious risk of electric shock.
b) Check the power tool’s supply cord at regular intervals and have it
replaced by a qualified specialist if found to be damaged. If the power tool’s
supply cord is damaged it must be replaced with a specially-prepared supply
cord available from Hilti Customer Service. Check extension cords at regular
intervals and replace them if found to be damaged. Do not touch the supply
cord or extension cord if it is damaged while working.
Disconnect the supply cord plug from the power outlet. Damaged supply cords or
extension cords present a risk of electric shock.
c) Dirty or dusty power tools which have been used frequently for work on
conductive materials should be checked at regular intervals at a Hilti Service
Center. Under unfavorable circumstances, dampness or dust adhering to the
surface of the power tool, especially dust from conductive
materials, may present a risk of electric shock.
d) When working outdoors with an electric tool check to ensure that the
tool is connected to the electric supply by way of a ground fault circuit
interrupter (GFCI) with a rating of max. 30 mA (tripping current). Use of a
ground fault circuit interrupter reduces the risk of electric shock.
e) Use of a ground fault circuit interrupter (GFCI) with a maximum
tripping current of 30 mA is recommended.
Work area
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.
Personal protective equipment
The user and any other persons in the vicinity must wear ANSI Z87.1-approved eye protection, a hard hat, ear protection, protective gloves and breathing protection while the power tool is in use.
Before use
WARNING
Never use the power tool without its matching disc guard.
DANGER
Disconnect the plug from the power source before making any
adjustments, changing accessories, or storing the tool. Such preventive
safety measures reduce the risk of starting the tool accidentally.
CAUTION Wear gloves when fitting or removing parts, when making
adjustments or when remedying malfunctions.
Fitting the side handle
WARNING
The side handle must be fitted for all types of work. The side handle
may be screwed onto the power tool on the right or left.
Guard
CAUTION
Adjust the position of the guard to suit the requirements of the work being
done.
CAUTION
The closed side of the guard must always face the operator.
Fitting the guard or guard with cover plate 7
NOTE
The guard is equipped with locating lugs that ensure only guards of a type
suitable for use with the power tool can be fitted. The locating lugs of the
guard fit into the guard mount on the power tool.
- Fit the guard onto the drive spindle collar so that the two triangular marks on the guard and on the power tool in alignment.
- Press the guard onto the drive spindle collar; press the guard release button and then rotate the guard until it engages and the guard release button jumps back to its outset position.
Adjusting the guard 8
- Press the guard release button and then rotate the guard until it engages in the desired position.
Removing the guard or guard with cover plate
- Press the guard release button and then rotate the guard until the triangular marks on the guard and the power tool are in alignment.
- Lift off the guard.
Fitting and removing the front cover (DEG 500-P) 9
- Press the front cover onto the standard guard, with the closed side positioned as shown in the illustration, until it engages.
- To remove the front cover, release the catch and then pull the front cover away from the standard guard.
Fitting and removing the disc 10 11
CAUTION
Wear gloves when fitting or removing parts, when making adjustments or when
remedying malfunctions.
DANGER
Check that the speed rating printed on the grinding disc is equal to or higher
than the rated speed of the tool.
DANGER
Check the condition of the grinding disc before use. Do not use discs that are
broken, cracked or damaged in any way.
NOTE
Diamond discs must be replaced when the cutting or grinding performance drops
significantly. This generally is the case when the segments reach a height of
less than ¹⁄₁₆”. Other discs must be replaced when the cutting performance
drops significantly or other parts of the angle grinder (not the disc) come
into contact with the material you are working on. Abrasive discs generally
have to be replaced when the durability date has been reached.
- Clean the clamping flange.
- Fit the clamping flange onto the drive spindle.
- Fit the insert tool.
- Screw on the clamping nut corresponding to the type of disc fitted 11.
- CAUTION Do not press the spindle lockbutton before the drive spindle has stopped rotating. Press the spindle lockbutton and hold it in this position.
- Use the wrench to tighten the clamping nut securely and then release the spindle lockbutton.
- To remove the module from the power tool, follow the instructions for fitting the module but carry out the steps in the reverse order.
Fitting and removing accessories (e.g. discs, brushes) with integrated thread
-
Screw the accessory onto the drive spindle.
-
CAUTION
Do not press the spindle lockbutton before the drive spindle has stopped rotating. Press the spindle lockbutton and hold it in this\ position. -
Use the open-end wrench to tighten the accessory securely and then release the spindle lockbutton.
-
To remove this, follow the instructions for fitting the module but carry out the steps in the reverse order.
Rotating the gearing section 12
NOTE
To allow the power tool to be used safely and without fatigue in all positions
(e.g. on / off switch facing upwards) the gearing section can be rotated to
one of four positions at 90° intervals.
- Disconnect the supply cord plug from the power outlet.
- Clean the power tool.
- Remove the side handle from the power tool.
- Remove the four screws from the gearing section.
- Rotate the gearing section to the desired position without pulling it away from the power tool.
- Secure the gearing section by inserting and tightening the four screws.
- Fit the side handle.
Operation
NOTE
Adjust the position of the guard to suit the requirements of the work being
done.
DANGER
Wear ear protectors. Exposure to noise can cause hearing loss.
WARNING
Test new cutting or grinding discs by allowing them to run at maximum speed in
a protected area for at least 60 seconds.
WARNING
Slits cut in loadbearing walls of buildings or other structures may influence
the statics of the structure, especially
when steel reinforcing bars or load-bearing components are cut through.
Consult the structural engineer, architect, or person in charge of the
building project before beginning the work.
WARNING
The electric supply voltage must comply with the information given on the type
identification plate on the power tool.
WARNING
Always use the side handle with the tool.
WARNING
Never use the power tool without its matching disc guard.
WARNING
Use clamps or a vice to hold the workpiece securely.
WARNING
Cutting or grinding may cause splintering of the material. Wear eye
protection.
DANGER
The operator and bystanders must wear breathing protection if the work causes
dust.
WARNING
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.
CAUTION
The insert tool may get hot during use. Wear protective gloves when changing
insert tools.
WARNING
Reduce the load on the power tool by avoiding tilting the disc in the kerf
when cutting. The disc may otherwise break, or the power tool may kick back or
stall.
CAUTION
Improve the blood circulation in your fingers by relaxing your hands and
exercising your fingers during breaks between working.
WARNING
Keep inflammable materials away from the working area.
CAUTION
In accordance with the applications for which it is designed, the power tool
produces a high torque. Always use the side handle and hold the power tool
with both hands. The user must be prepared for sudden sticking and stalling of
the insert tool.
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.
Rough grinding
CAUTION
Never use abrasive cutting discs for grinding.
Best results are obtained when the disc maintains an angle of 5° to 30° with
the working surface when grinding.
Move the power tool to and fro while applying moderate pressure. This will
avoid overheating and discoloration of the workpiece and ensure an even
surface finish.
Cutting
When cutting, apply moderate feed pressure and do not tilt the power tool or,
respectively, the cutting disc (hold at approx. 90° to the surface being cut).
For best results, start cutting at the smallest cross section when cutting
profiles and square tube.
Switching on / off without locking the switch
(DEG 500-D or DEG 600-D)
Switching on
-
Plug the supply cord into the power outlet.
-
Slide the on / off switch forward and then press it as far as it will go.
2 Switching off
Release the on / off switch.
Switching on / off and locking the switch (DEG 600-P)
NOTE
If the tool is unplugged from the electric supply while the on / off switch is locked in the on position and subsequently plugged back into the electric supply, the tool will not restart. The switch lock must be released while the tool is disconnected from the electric supply before the supply cord is again plugged into the power outlet.
Switching on and locking the switch -
Plug the supply cord into the power outlet.
-
Slide the on / off switch forward slightly (3 mm) and, while pressing it down, slide it further forward until it locks in position.
Switching off after locking the switch
Press the front part of the on / off switch down (the lock then releases).
Restart interlock
NOTE
If the power tool is unplugged from the electric supply while the on / off switch is locked in the on-position and subsequently plugged back into the electric supply, it will not restart. The switch lock must be released while the power tool is disconnected from the electric supply before the supply cord is again plugged into the power outlet.
Care and maintenance
CAUTION
Disconnect the mains plug from the power outlet.
Care of the power tool
DANGER
Under extreme conditions, when used for working on metal, conductive dust may
accumulate inside the tool. This may have an adverse effect on the tool’s
protective insulation. Under such conditions, the tool should be plugged into
a ground fault circuit interrupter (GFCI) and use of a stationary dust removal
system and frequent cleaning of the tool’s cooling air slots is recommended.
The outer casing of the power tool is made from impact resistant plastic.
Sections of the grip are made from a synthetic rubber material.
Never operate the power tool when the air vents are blocked. Regularly clean
the power tool’s air vents carefully with a dry brush. Do not permit foreign
objects to enter the interior of the tool. The motor’s fan will draw dust into
the casing and an excessive accumulation of conductive dust (e.g. metal,
carbon fiber) may cause electrical hazards. Clean the outside of the power
tool at regular intervals with a slightly damp cloth. Do not use a spray,
steam pressure cleaning equipment or running water for cleaning. This may
negatively affect the electrical safety of the tool. Always keep the grip
surfaces of the tool free from oil and grease. Do not use cleaning agents
which contain silicone.
NOTE
Frequent work on conductive materials (e.g. metal, carbon fiber) may make
shorter maintenance intervals necessary. Take your individual work place risk
assessment into account.
Maintenance
WARNING
Do not operate the tool if parts are damaged or when the controls do not
function faultlessly. Have the power tool repaired by Hilti Service.
WARNING
Repairs to the electrical section of the power tool may be carried out only by
trained electrical specialists.
Check all external parts of the power tool for damage at regular intervals and
check that all controls operate faultlessly
Checking the power tool after care and maintenance
After carrying out care and maintenance work on the power tool, check that all
protective and safety devices are fitted and that they function faultlessly
Troubleshooting
Fault | Fault Possible cause | Remedy |
---|---|---|
The power tool doesn’t start. | Interruption in the electric supply. | Plug in |
another electric appliance and check whether it works.
Supply cord or plug defective.| Have the supply cord and plug checked by an
electrical specialist and replaced if necessary.
The power tool doesn’t achieve full power.| The extension cord’s conductor
cross section is inadequate.| Use an extension cord with an adequate conductor
cross section.
Disposal
Most of the materials from which Hilti power tools 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 your old power tools or appliances for recycling. Please ask your Hilti customer service department or Hilti representative for further information.
Manufacturer’s warranty – tools
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
replacement as a result of normal wear and tear are not covered by this
warranty.
Additional claims are excluded, unless stringent national rules prohibit
such exclusion. In particular, Hilti
is not obligated for direct, indirect, incidental 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. Implied warranties of
merchantability or fitness for a particular purpose are specifically
excluded.
For repair or replacement, send the tool or related parts immediately upon
discovery of the defect to the address of the local Hilti marketing
organization provided.
This constitutes Hilti’s entire obligation with regard to warranty and
supersedes all prior or contemporaneous comments and oral or written
agreements concerning warranties.
Hilti Corporation
LI-9494 Schaan
Tel.: +423 / 234 21 11
Fax:+423 / 234 29 65
www.hilti.com
References
- Power Tools, Fasteners and Software for Construction - Hilti USA - Hilti USA
- Manual-Hub.com – Free PDF manuals!
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