HILTI EXO-O1 Overhead Exoskeleton Instruction Manual

: June 3, 2024
: HILTI

Table of Contents

EXO-O1 Overhead Exoskeleton
Information about the documentation
Safety
Description
Technical data
Donning
Adjusting
Removing
Care and maintenance
Transport and storage
Troubleshooting
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

HA EXO-O1
Instruction Manual

EXO-O1 Overhead Exoskeleton

Original operating instructions

Information about the documentation

1.1 About this documentation

Read this documentation before initial operation or use. This is a prerequisite for safe, trouble-free handling and use of the product.
Observe the safety instructions and warnings in this documentation and on the product.
Always keep the operating instructions with the product and make sure that the operating instructions are with the product when it is given to other persons.

1.2 Explanation of symbols used
1.2.1 Warnings
Warnings alert persons to hazards that occur when handling or using the product. The following signal words are used:

DANGER
DANGER !

Draws attention to imminent danger that will lead to serious personal injury or fatality.

WARNING
WARNING !

Draws attention to a potential threat of danger that can lead to serious injury or fatality.

CAUTION
CAUTION !

Draws attention to a potentially dangerous situation that could lead to personal injury or damage to the equipment or other property.

1.2.2 Symbols in the documentation
The following symbols are used in this document:

| Read the operating instructions before use.
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| Instructions for use and other useful information
| Dealing with recyclable materials
| Do not dispose of electric equipment and batteries as household waste

1.2.3 Symbols in the illustrations
The following symbols are used in illustrations:

2| These numbers refer to the corresponding illustrations found at the beginning of these operating instructions
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3| The numbering reflects the sequence of operations shown in the illustrations and may deviate from the steps described in the text
11| Item reference numbers are used in the overview illustrations and refer to the numbers used in the product overview section
| This symbol is intended to draw special attention to certain points when handling the product.

1.3 Product-dependent symbols
1.3.1 Symbols on the product
The following symbols can be used on the product:

| The power tool supports near-field communication (NFC) technology, which is compatible with iOS and Android platforms.
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| Warning: Magnetic field

1.4 Product information

products are designed for professional users and only trained, authorized personnel are permitted to operate, service and maintain the products. This personnel must be specifically informed about the possible hazards. The product and its ancillary equipment can present hazards if used incorrectly by untrained personnel or if used not in accordance with the intended use.
The type designation and serial number are printed on the rating plate.

Write down the serial number in the table below. You will be required to state the product details when contacting Hilti Service or your local Hilti organization to inquire about the product.
Product information****

Exoskeleton	HA EXO-O1
Generation	1
Serial no.

1.5 Declaration of conformity
The manufacturer declares, on his sole responsibility, that the product described here complies with the applicable legislation and standards. A copy of the declaration of conformity can be found at the end of this documentation.
The technical documentation is filed here:
Hilti Entwicklungsgesellschaft mbH | Tool Certification | Hiltistrasse 6 | D-86916 Kaufering, Germany

Safety

2.1 Safety instructions

WARNING Study all safety instructions and other instructions, images and technical data with which this product is provided. Failure to comply with the instructions below can cause serious injuries.
Keep all safety precautions and instructions for future reference.

Personal safety

The catches of the shoulder straps and the arm supports contain magnets. The magnets can affect cardiac pacemakers or comparable implants. A cardiac pacemaker can be switched to test mode and cause indisposition. Under certain circumstances, a defibrillator might cease to function. Wearers of devices of this nature should keep at least 100 mm clear of the magnets. Warn wearers of devices of this nature to keep clear of magnets. These persons are not permitted to use the product.
Wear suitable work clothes. Do not wear jewelry or loose clothing. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be snagged by moving parts.
Avoid unusual body positions. Keep proper footing and balance at all times.
Only persons who are familiar with it, who have been trained on how to use it safely and who understand the resulting hazards are permitted to use the tool.
Keep children and other persons clear when the product is in use.
The product can be used by only one person.
Do not use the product to lower a person by rope or to secure a person. Do not secure a tool tether to the product.
Do not attach to the waist belt objects that could restrict correct operation of the product.
Make sure that you do not snag with the product on fixed or movable objects.
It is not permissible for the product to interfere with the functionality of your personal protective equipment.

Product safety

Avoid overstraining the load-bearing components. A sudden loss of function can lead to injuries. Use the product only within its specified limits.
Always check the product prior to use to ensure that it is in full working order, free of wear and undamaged. Do not continue to use the product after it has been dropped or if it is damaged. Contact Hilti Service.
To avoid damage, do not expose the product to sources of heat. Comply with the stated temperature limits for storage and operation.

Description

3.1 Product overview, front 1

Shoulder strap
Arm support with padding
Parked position, magnetic catch
Strap clip of the shoulder strap
Chest strap
Waist-belt pad
Clip catch
Belt holder, waist belt

3.2 Product overview, rear 2

9. Adjusting knob for assistance
10. Articulation unit (cover not available in all markets)
11. Arm-rail
12. Magnetic catch
13. Pivot stop
14. Expander
15. Cover for expander
16. Locknut
17. Threaded rod| 18. Adjustment unit with ball socket
19. Locking clip
20. Hang-up loop
21. Waist-belt reinforcement
22. Burr fastener, waist-belt pad
23. Back strap
24. Strap clip of the back strap
25. Tensioner
26. Back cross
27. Tension cord
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3.3 Intended use
The product described is a passive exoskeleton. It is to be used only as an assistance system by trades and only by adults. It is designed to relieve the strain on the arms and pectoral girdle during overhead and over-shoulder work.
The product is to be used and maintained only by trained, authorized personnel who have received special instruction regarding the hazards that may be encountered.
The maximum wearing period is 8 hours per working day.
The maximum service life is 10 years.

3.4 Restrictions on use and misuse
Do not use the product in environments where there is a risk of explosion.
Do not use the product without user-specific product fitting.
Do not use the product for performance enhancement and do not use it to lift persons.
The product is not be used by persons

with cardiac pacemaker or comparable active implants
with pre-existing debilitating conditions of the musculoskeletal system in the area of the shoulders, arms, back and hands
with skin diseases/injuries, inflammations; raised scars with swellings
with reddening and above-normal temperature in the body areas affected (arms, shoulders, hips and back)
with pronounced varicose veins, especially with venous insufficiency, lymphatic drainage disorders –also unexplained soft-tissue swelling in parts of the body away from the product
with sensory and circulatory disorders in the area of the upper extremities, hips and back (e.g. diabetic neuropathy)

Do not continue to use the product if you experience discomfort, develop a rash or notice increased sensitivity of the skin.

3.5 Items supplied
Exoskeleton, bag, 4 magnetic adjusting screws, 2 spare clips, operating instructions
Other system products approved for use with this product can be found at your local Hilti Store or at: www.hilti.group

Technical data

Weight	1.99 kg
Ambient temperature for operation	−10 ℃ … 45 ℃
Storage temperature	−10 ℃ … 60 ℃
Dimensions (length x width x height)	850 mm x 400 mm x 200 mm

Donning

CAUTION
Risk of injury if product is worn incorrectly or too tightly. Local pressure points and restrictions of blood vessels and nerves.

Be sure to don and wear the product correctly.

Shrug the product on to your shoulders as if it were a backpack. Slip your arms through the shoulder straps and position the shoulder straps on your shoulders.
Close the clip catch of the waist belt.
Adjust the waist belt. → page 34
Close the clip catch of the chest strap.
Adjust the shoulder straps. Pull the ends of the straps down to tighten the shoulder straps. To loosen the shoulder straps, flip the strap clip up.
▶ The shoulder straps must sit loosely on your shoulders and should not hinder you from raising your arms.
▶ Raising your arms should not cause the waist belt to ride up. If the waist belt changes its position, you have to loosen the shoulder straps.
Tuck the ends of the shoulder straps into the rubberized strap holders. WARNING
Risk of injury caused by arm-rail snapping back.
When under tension, the arm-rail can snap back and injure your head.
▶ When disengaging the magnetic catch, keep your finger hooked into the pull loop until the magnetic catch is securely engaged in the parked position.
Slip the index finger of your right hand into the pull loop of the left magnetic catch.
Pull the pull loop up and carefully disengage the magnetic catch.
Pull the arm support down with the pull loop. As you do so, hold your arm out in front of your body.
Center your upper arm in the arm support.
Use the pull loop to engage the magnetic catch in the hook on the arm support.
▶ Make sure that the magnetic catch engages fully.
Use the burr fasteners to adjust the fit of the armsupport strap round your upper arm. Center the burr fasteners and close them completely.
▶ The arm-support strap is adjustable at both ends.
Secure the arm support on the other side of your body in the same way.
Check that the product is fitted symmetrically. The clip catches do not necessarily have to be centered.
Make sure that the waist belt is correctly seated. Use the padding on the waist belt to make sure that it is seated symmetrically.
Center the back cross between your shoulder blades.
The back cross should not chafe your back.

Adjusting

WARNING
Risk of injury caused by crushing. Risk of crushing the fingers in the articulation unit.

When adjusting the product, keep your fingers well clear of the articulation unit’s mechanism.

6.1 Adjusting assistance

If applicable, attach the magnetic adjusting knob to the articulation unit.
Adjust the assistance by turning the magnetic adjusting knob.
▶ Turn the knob clockwise (+) for more assistance, turn it counter-clockwise (-) for less assistance.
▶ The scale on the articulation unit is merely an indicator marking the position.
Assistance is correct when gravity is enough to make your arms drop, without further exertion on your part. Do not attempt to set assistance to a value higher than this; any lower setting is possible, in accordance with your preference.
Engaging the second expander is an option, if more assistance is necessary. → page 31

6.2 Engaging second expander
Step through the following procedure for each side of the exoskeleton in turn.

If applicable, remove the magnetic adjusting knob.
Open the articulation cover.
Pull the articulation cover off to one side.
Zero the tension on the articulation unit and open the pivot stop.
Turn the product so that the side normally toward the body is up.
Disengage the second expander from the parked position and engage it in the articulation unit opposite the first expander.
The expanders determine the assistance provided.
Try out the assistance provided by only one expander by increasing it step by step. If more assistance is necessary, the second expander can be used as well.
Tension the articulation unit and close the pivot stop.
Slide the articulation cover over the articulation unit.
Close the articulation cover. Make sure that the tension cord is not trapped by the articulation cover.
Engage the magnetic adjusting knob.

6.3 Adjusting waist belt

The waist belt has to sit above the gluteal muscles and level with your pelvis.
▶ It is important to make sure that the waist belt cannot slip while the product is in use.
Flip the strap clips up to loosen the waist belt.
Pull both ends of the waist belt forward to tighten the belt.
Tuck the ends of the waist belt into the belt holders.

6.4 Adjusting articulation unit

You have to remove the exoskeleton in order to adjust the articulation unit.

Squeeze the sides of the locking clip in.
Pull the locking clip out of the adjusting unit.
Move the adjusting unit with the ball socket on the belt web of the waist belt. Use the mark at the top edge to determine the latching position.
Set both sides to the same latching position.
Insert the locking clip to maintain this position.
Slip the product on to your shoulders and check the symmetrical positioning of the waist belt.
▶ The ball sockets must be fixed vertically relative to the shoulder articulations and can be tilted outward (V-shape), depending on the wearer’s upper-body build. The wearer’s hands must be free to swing without hindrance.
Slacken the locknut.
Adjust the height of the threaded rod by hand.
Retighten the locknut.
Slip the product on to your shoulders and check that the articulation units are at the same height.
▶ When the product is worn, the top edge of the articulation unit must match the height of the shoulder.

6.5 Aligning back cross

Flip the strap clip of the back strap up to loosen the strap.
Pull the end of the strap to tighten the strap.
Check the position of the back cross.
▶ The back cross must be centered between the shoulder blades.

6.6 Adjusting tension cord
The tension cord forms a wide-open Vee between the shoulder blades. The tension cord lets you adjust the position of the expander covers. Tightening the tension cord brings the covers closer to your body.

Open the top and bottom parts of the tensioner on the tension cord.
To shorten the tension cord, pull the ends of the tension cord taut and push the top part of the tensioner up.
▶ Make sure that the tension cord is symmetrically positioned.
To lengthen the tension cord, pull the bottom part of the tensioner down.
▶ Make sure that the tension cord is symmetrically positioned.
To secure the tension cord in position, push the top and bottom parts of the tensioner together.

Removing

WARNING
Risk of injury caused by arm-rail snapping back. When under tension, the arm- rail can snap back and injure your head.
▶ When disengaging the magnetic catch, keep your finger hooked into the pull loop until the magnetic catch is securely engaged in the parked position.

Slip the index finger of your right hand into the pull loop of the left magnetic catch.
Slowly pull the magnetic catch up and disengage it from the hook of the arm support.
Draw the pull loop down, keeping the strap taut.
Remove your arm from the arm support and hold it in front of your body.
Slowly guide the arm support up.
Let the magnetic catch engage fully at the parked position on the shoulder strap.
Check that the magnetic catch is correctly seated.
Repeat these steps with your left hand for the right arm support.
Open the clip catch of the chest strap.
Disengage the ends of the waist belt from the belt holders.
Loosen the waist belt.
Open the clip catch of the waist belt.
Shrug the product off your shoulders as if it were a backpack.

Care and maintenance

WARNING
Risk of injury caused by expanders under tension. Injuries during care and maintenance work.

Carry out care and maintenance work only with the expanders at zero tension.

Care

Carefully remove stubborn dirt from the tool.
Clean the product only with a slightly damp cloth and pH-neutral soap. Do not use cleaning agents containing silicone as they can attack the plastic parts.

Maintenance

Check all visible parts and controls for signs of damage at regular intervals and make sure that they all function correctly.
Do not operate the product if signs of damage are found or if parts malfunction. Have it repaired immediately by Hilti Service.
After cleaning and maintenance, fit all guards or protective devices and check that they function correctly.

To help ensure safe and reliable operation, use only genuine Hilti spare parts and consumables. Spare parts, consumables and accessories approved by Hilti for use with the product can be found at your local Hilti Store or online at: www.hilti.group.

8.1 Cleaning pads

Remove the pads from the arm supports and the waist belt.
Hand-wash the pads in water with pH-neutral soap.
Thoroughly rinse the pads.
Allow the pads to air-dry.
Reinstall the pads.

8.2 Replacing pads

Remove first the inner pad and then the outer pad from each arm support. The pads are held in place in the arm supports by burr fasteners.
Install the new pads in reverse sequence in each arm support. Make sure that the pads are fitted right way round.
The pads and the arm supports are colorcoded, with a blue dot for left and a red dot for right.
Open the burr fasteners of the waist belt pad and remove the pad.
Pass the burr fasteners of the new pad though the openings in the belt web and close the fasteners.

8.3 Replacing arm-support strap

Open the burr fasteners at both ends of the armsupport strap.
Remove the strap from the two tabs of the arm support.
Position the top part of the magnetic catch at the parked position on the arm support.
Starting from below, pass the new strap through the first tab. The burr fastener must face out.
Turn the arm support round.
Pass the strap from above through the metal eye of the magnetic catch.
Pass the strap through the second tab from the inside to the outside.
Close the strap at the burr fastener.

8.4 Checking and cleaning ball socket

Check the movement of the ball end in the ball socket.
Do this by moving the threaded rod.
Result 1 / 2
The ball moves freely.
No action necessary.
Result 2 / 2
The ball is stiff
Undo the two screws in the ball socket and remove the cover.
Remove the ball from the ball socket and clean the ball and the socket with a soft cloth.
Reinsert the ball in the ball socket and place the cover in position.
Tighten the two screws to a tightening torque of 0.5 Nm.

Transport and storage

Transport

Make sure that the equipment is held securely throughout all transport operations.
After transporting, always check all visible parts and controls for signs of damage and make sure that they all function correctly.
Transport and store the exoskeleton only with the expanders at zero tension.

Storage

Store this product in a dry place, where it cannot be accessed by children or unauthorized persons.
After a long period of storage, always check all visible parts and controls for signs of damage and make sure that they all function correctly.

Troubleshooting

If the trouble you are experiencing is not listed in this table or you are unable to remedy the problem by yourself, please contact Hilti Service.

Trouble or fault	Possible cause	Action to be taken
Lack of expander tension	Expander disengaged or incor- rectly installed

Disposal
Most of the materials from which Hilti tools and appliances are manufactured can be recycled. The materials must be correctly separated before they can be recycled. In many countries, your old tools, machines or appliances can be returned to Hilti for recycling. Ask Hilti Service or your Hilti representative for further information.
Manufacturer’s warranty
▶ Please contact your local Hilti representative if you have questions about the warranty conditions.
Further information
For more information on operation, technology, environment and recycling, follow this link: qr.hilti.com/manual?id=2282599
This link is also to be found at the end of the documentation, in the form of a QR code.

EC Declaration of Conformity I UK Declaration of Conformity

HA EX0-01 (01)
Manufacturer:
Hilti Corporation
FeldkircherstraBe 100
9494 Schaan I Liechtenstein
UK Importer:
Hilti (Gt. Britain) Limited
1 Trafford Wharf Road, Old Trafford
Manchester, M17 1BY
Serial Numbers: 1-99999999999
2006/42/EC I Supply of Machinery (Safety) Regulations 2008
EN ISO 10993-5:2009
EN ISO 10993-10:2013

Dr. Tahar Zrilli
Head of Quality and Process Management
Business Area Electric Tools & Accessories| Schaan, 08.12.2021
Johannes Wilfried Huber
Senior Vice President Business Unit Diamond
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http://qr.hilti.com/manual?id=2282599 https://hilti.to/ontrackapp
Hilti Corporation
LI-9494 Schaan
Tel.:+423 234 21 11
Fax:+423 234 29 65
www.hilti.group Hilti = registered trademark of Hilti Corp., Schaan