HILTI AG 500-12D Angle Grinder Instruction Manual

HILTI AG 500-12D Angle Grinder

Information about the documentation

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.

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

DANGER

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

WARNING

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

CAUTION

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

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

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

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

| These numbers refer to the corresponding illustrations found at the beginning of these operating instructions
---|---
| The numbering reflects the sequence of operations shown in the illustrations and may deviate from the steps described in the text
| 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.
| Wireless data transfer

Product-specific symbols

Symbols
The following symbols are used on the product:

| Wear eye protection
---|---
| Revolutions per minute
| Revolutions per minute
n| Rated speed
o| Diameter
| Protection class II (double-insulated)

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

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

General Power Tool Safety Warnings

WARNING – 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.
Keep all safety instructions and information for future reference! The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

Work area safety

• Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• 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.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical safety

• 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. Unmodified plugs and matching outlets will reduce risk of electric shock.
• 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.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• 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.
• 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.
  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

• 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.
• 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.
• 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 energizing power tools that have the switch on invites accidents.
• 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.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
• 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.
• Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless
  action can cause severe injury within a fraction of a second.

Power tool use and care

• 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.

• 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.
  Disconnect the plug from the power source and/or remove the battery pack, if detachable, 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.

• 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.

• Maintain power tools and accessories. 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.

• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

• 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.

• Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

Battery tool use and care

• Always charge the batteries only in chargers recommended by the manufacturer.
  Chargers designed for a specific type of battery may pose a fire hazard when used together with other battery types.

• Use only the batteries provided for this purpose in the power tools. Using other batteries may cause injuries and pose a fire hazard.

• When not in use, keep batteries away from paper clips, coins, nails, screws or other small metal objects that could bridge the contacts.
  Short circuits between battery contacts can cause burns or fires.

• Fluid may escape if batteries are used inappropriately. Avoid all contact with this fluid. In the event of accidental skin contact, rinse the affected area thoroughly. If the fluid enters your eyes, seek immediate medical assistance. Escaping battery fluid can cause skin irritation or burns.

• Do not use damaged or modified batteries. Damaged or modified batteries may behave unpredictably and lead to fire, explosion or risk of injury.

• Do not expose the battery pack to fire or excessive temperatures. Fire or temperatures above 130 °C can cause an explosion.
  Follow all instructions on charging and never charge the battery or the cordless tool outside the temperature range indicated in the operating instructions. Incorrect charging or charging outside the permitted temperature range may destroy the battery and increase the risk of fire.

Service

• Have your power tool serviced by a qualified technician using only original replacement parts. This will ensure that the safety of the power tool is maintained.
• Never service damaged batteries. Any servicing of batteries should only be carried out by the manufacturer or authorized customer service points.

Safety warnings common for grinding, sanding, wire brushing, polishing

or abrasive cutting- off operations

• 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.
• Operations such as 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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 dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• Do not operate the power tool near flammable materials. Sparks could ignite these materials.
• 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.

• 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.
• Never place your hand near the rotating accessory. Accessory may kickback over your hand.
• 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.
• 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.
• 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:

• 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.
• The grinding surface of center 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.
• 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 the operator from broken wheel fragments, accidental contact with wheel and sparks that could ignite clothing.
• 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.
• 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.
• 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:

• 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.
• 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.
• 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.
• 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.
• 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.
• 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 sanding operations:

• Do not use excessively oversized sanding disc paper. Follow manufacturers recommendations, when selecting sanding paper. Larger sanding paper extending beyond the sanding pad presents a laceration hazard and may cause snagging, tearing of the disc or kickback.

Safety warnings specific for wire brushing operations:

• 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.
• 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

• Use the product only when it is in technically faultless condition.
• Never tamper with or modify the tool in any way.
• Always hold the power tool with both hands on the handles provided. Keep the handles clean and dry.
• Avoid touching rotating parts – risk of injury!
• Wear suitable protective glasses, a hard hat, ear protection, protective gloves and light respiratory protection while using the power tool.
• Before beginning the work, check the hazard classification of the dust that will be produced. Use an industrial vacuum cleaner with an officially approved protection class in compliance with the locally applicable dust protection regulations. Dust from materials such as lead-based paint, certain types of wood and concrete/masonry/stone containing quartz, minerals or metal may be harmful to health.
• Make sure that the workplace is well ventilated and, where necessary, wear a respirator appropriate for the type of dust generated. Contact with or inhalation of the dust may cause allergic reactions and/or respiratory or other diseases among operators or bystanders. Certain kinds of dust are classified as carcinogenic such as oak and beech dust, especially in conjunction with additives for wood conditioning (chromate, wood preservative). Material containing asbestos may be handled only by specialists.
• Take breaks between working and do physical exercises to improve the blood circulation in your fingers. Exposure to vibration during long periods of work can lead to disorders of the blood vessels and nervous system in the fingers, hands and wrists.

Electrical safety

• Before beginning work, check the working area for concealed electric cables or gas and water pipes. External metal parts of the power tool may give you an electric shock if you damage an electric cable accidentally.
• Do not touch the supply cord or extension cord if it is damaged while working. Disconnect the mains plug from the power outlet. Check the tool’s supply cord at regular intervals and have it replaced by Hilti Service if damage is found. Check extension cords at regular intervals and replace them if found to be damaged.

Using and handling power tools with care

• Do not use cutting discs for grinding.
• Remove the clamping flange from the arbor before fitting a threaded accessory tool.
• Tighten the accessory tool and flange securely. If the accessory tool and flange are not tightened securely, the accessory tool may work loose from the arbor due to the braking effect of the motor after switching off.
• Comply with the manufacturer’s instructions for handling and storing grinding discs.

Description

Overview of the product 1

1. Spindle lock button
2. Air vents
3. Vibration-absorbing side handle
4. Wrench
5. Clamping nut
6. Kwik lock clamping nut (optional)
7. Cutting disc / grinding disc
8. Clamping flange
9. Guard
10. On/off switch
11. Switch-on interlock release button
12. Spindle
13. Quick locking system
14. Guard release button
15. Threaded bushing for handle

Intended use

The product described is a hand-held electric angle grinder. It is designed for cutting and grinding metal and mineral materials, as well as brushing and sanding, without the use of water. It may used only for dry cutting / grinding.
The tool may be operated only when connected to a power supply providing a voltage and frequency in compliance with the information given on its rating plate.

• The power tool may be used for cutting, slitting and grinding mineral materials only when equipped with the corresponding guard (optional accessory).
• A dust removal hood together with a suitable Hilti vacuum cleaner must be used for working on mineral materials such as concrete or stone.

Items supplied

Angle grinder, side handle, standard guard, front cover, clamping flange, clamping nut, wrench, operating instructions.
Other system products approved for use with this product can be found at your local Hilti Store or at: www.hilti.group | USA: www.hilti.com

Starting current limiter

The electronic starting current limiter reduces the starting current drawn to prevent the line fuse from tripping.
This prevents abrupt start-up of the product.

Constant-speed electronics

Electronic speed control keeps running speed almost constant irrespective of whether the power tool is idling or running under load. Constant running speed helps ensure maximum efficiency.

Active Torque Control (ATC)

The electronics detect potential stalling of the disc and prevent further rotation of the arbor by switching off the product.
If the ATC system has been triggered, restart the product. Do this by releasing the on/off switch and then pressing it again.

If the ATC system fails, the product will run at greatly reduced speed and with greatly reduced torque. Have the product checked by Hilti Service.

Restart interlock

The product does not restart by itself when the on/off switch is locked in the ON position and power is restored after an interruption in the electric supply. The on/off switch must first be released and then pressed again.

Temperature-dependent motor protection

The temperature-dependent motor protection system monitors current draw and motor temperature to prevent the product from overheating.
If the motor is overloaded through application of excessive working pressure, the product’s performance drops noticeably or it might stall completely. A standstill should be avoided. The product’s permissible overload depends on motor temperature and is not a specific value.

Front cover for the disc guard 2

When grinding with straight grinding discs and cutting with cutting discs in metalworking applications, use the standard guard with front cover.

DG-EX 125/5″ dust hood for grinding (accessory) 3

The grinding system is suitable only for occasional use with diamond cup wheels for grinding mineral materials.
CAUTION Use of this hood for working on metal is prohibited.

DC-EX 125/5″C dust hood for cutting (accessory) 4

Use the DC-EX 125/5″C dust hood when cutting masonry and concrete.
CAUTION Use of this hood for working on metal is prohibited.

Consumables

Only synthetic resin-bonded, fiber-reinforced discs with a maximum diameter of Ø 5″ and a maximum disc thickness of 1/4″ (grinding discs) or 1/8″ (cutting discs) which are approved for use at a rotational speed of at least 11,500/min and a peripheral speed of 80 m/s may be used.
WARNING! When cutting or slitting with cutting discs, always use the standard guard with additional cover plate.

Discs

| Application| Designation| Material
---|---|---|---
Abrasive cutting disc| Cutting, slitting| AC­D| Metal
Diamond cutting disc| Cutting, slitting| DC-TP, DC-D (SPX, SP, P)| Mineral
Abrasive grinding disc| Rough grinding| AG-D, AF-D, AN-D,

AG-D type 27

| Metal
Diamond grinding disc| Rough grinding| DG-CW (SPX, SP, P)| Mineral
Wire brushes| Wire brushes| 3CS, 4CS, 3SS,

4SS

| Metal
Abrasive resin-fiber disc| Rough grinding| AP-D| Metal

Suitability of discs for the equipment used

Item| Equipment| AC­D| AG­D,
AF­D, AN­D| DG-CW (SPX,
SP, P)| DC-TP, DC-D (SPX,
SP, P)| AP-D| 3CS,
4CS,
3SS,
4SS| AG-D

type 27

---|---|---|---|---|---|---|---|---
A| Guard| X| X| X| X| X| X| —
B| Front cover (in combination with A)| X| —| —| X| —| —| —
C| DG-EX 125/5″ dust hood for grinding| —| —| X| —| —| —| —
D| DC-EX 125/5″C dust hood for cutting (only in conjunction with A)| —| —| —| X| —| —| —
E| Side handle| X| X| X| X| X| X| —
F| DCBG 125 hoop handle (optional for E)| X| X| X| X| X| X| —
G| Clamping nut (not for use with accessories with integrated thread)| X| X| X| X| —| —| —
H| Clamping flange (not for use with accessories with integrated thread)| X| X| X| X| —| —| —
I| Kwik lock (optional for G)| X| X| —| X| —| —| —
J| Clamping nut for abrasive resin-fiber disc| —| —| —| —| X| —| —
K| Support plate| —| —| —| —| X| —| —
L| Guard type 27| —| —| —| —| —| —| X

Technical data

For rated voltage, rated current, frequency and/or input power, refer to the country-specific type identification plate.

If the device is powered by a generator or transformer, the generator or transformer’s power output must be at least twice the rated input power shown on the rating plate of the device. The operating voltage of the transformer or generator must always be within +5 % and -15 % of the rated voltage of the device.

| AG 500-12D
---|---
Maximum disc diameter| 5 in
Drive spindle thread| 5/8″-11
Weight| 5.7 lb
(2.6 kg)

Before use

CAUTION
Risk of injury. The accessory tool may be hot or have sharp edges.

• Wear protective gloves when fitting, removing or adjusting the accessory tool or other parts and when troubleshooting.

Fitting the side handle

• Screw the side handle into one of the threaded bushings provided.

Guard

• Observe the instructions for fitting the applicable guard.

Installing the guard 5
The guard is keyed to ensure that only guards of a type suitable for use with the product can be installed. The keyed locating lug also prevents the guard from coming into contact with the tool.

1. Fit the guard on to the arbor collar so that the two triangular marks on the guard and on the product are in alignment.
2. Press the guard on to the drive spindle collar.
3. Press the guard release button and turn the guard until it engages in the desired position.
   The guard release button jumps back.

Adjusting the guard 6
Press the guard release button and then rotate the guard until it engages in the desired position.

Removing the guard

1. Press the guard release button and turn the guard until the triangular marks on the guard and on the product are in alignment.
2. Lift off the guard.

Fitting or removing the front cover 7

1. Position the front cover with the closed side on the standard guard and push it on until it engages.
2. To remove it, release the catch for the front cover and then lift the front cover away from the standard guard.

Fitting or removing the discs

CAUTION
Risk of injury. The accessory tool may be hot.

• Wear protective gloves when changing the accessory tool.

Diamond discs must be replaced when their cutting or grinding performance drops significantly. This generally is the case when the diamond segments reach a height of less than 2 mm (1/16″).
Other discs must be replaced when their 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 must be replaced when their expiry date has been reached.

Fitting the grinding disc 8

1. Disconnect the mains plug from the power outlet.
2. Clean the clamping flange and the clamping nut.
3. Screw the clamping flange onto the arbor.
4. Fit the grinding disc.
5. Screw on the clamping nut corresponding to the type of grinding disc fitted.
6. Press the arbor lock button and hold it in this position.
7. Use the pin wrench to tighten the clamping nut securely, then release the arbor lock button and remove the wrench.

Removing the grinding disc

1. Disconnect the mains plug from the power outlet.
   CAUTION
   Risk of breakage and irreparable damage. If the spindle lock button is pressed while the spindle is rotating, this may cause the accessory tool to work loose or detach from the power tool.
   Press the spindle lock button only when the spindle has stopped rotating.

2. Press the spindle lock button and hold it in this position.

3. Release the clamping nut by gripping it with the pin wrench and turning the nut counterclockwise.

4. Release the spindle lock button and remove the grinding disc.

Fitting a grinding disc with a Kwik lock nut 9

CAUTION
Risk of breakage. Heavy wear (abrasion) may cause the Kwik lock nut to break.

• When working with the power tool, make sure that the Kwik lock nut doesn’t come into contact with the working surface.
• Do not use a damaged Kwik lock nut.

The optional Kwik lock nut can be used instead of the standard clamping nut. Grinding discs can then be changed without the need for additional tools.

1. Disconnect the mains plug from the power outlet.

2. Clean the clamping flange and the quick-release clamping nut.

3. Fit the clamping flange onto the drive spindle.

4. Fit the grinding disc.

5. Screw on the Kwik lock nut until it is seated against the grinding disc.
   The name Kwik lock should be visible when the nut is screwed on.

6. Press the spindle lock button and hold it in this position.

7. Turn the grinding disc firmly by hand in a clockwise direction until the Kwik lock nut is tightened securely and then release the spindle lock button.

Removing a grinding disc secured with a Kwik lock nut

1. Disconnect the mains plug from the power outlet.
   CAUTION
   Risk of breakage and irreparable damage. If the spindle lock button is pressed while the spindle is rotating, this may cause the accessory tool to work loose or detach from the power tool.
   Press the spindle lock button only when the spindle has stopped rotating.

2. Press the spindle lock button and hold it in this position.

3. Release the Kwik lock nut by turning it counterclockwise by hand.

4. If the Kwik lock nut cannot be released by turning it by hand, use a pin wrench to turn the nut in a counterclockwise direction.
   Never use a pipe wrench! A pipe wrench could damage the Kwik lock nut.

5. Release the spindle lock button and remove the grinding disc.

Fitting a threaded accessory tool

1. Disconnect the mains plug from the power outlet.
2. Screw the accessory tool onto the drive spindle.
3. Press the spindle lock button and hold it in this position.
4. Use an open-end wrench to tighten the accessory tool securely and then release the spindle lock button.

Removing a threaded accessory tool

1. Disconnect the mains plug from the power outlet.
   CAUTION
   Risk of breakage and irreparable damage. If the spindle lock button is pressed while the spindle is rotating, this may cause the accessory tool to work loose or detach from the power tool.

   • Press the spindle lock button only when the spindle has stopped rotating.

2. Press the spindle lock button and hold it in this position.

3. Use an open-end wrench to release the accessory tool.

4. Release the spindle lock button and remove the accessory tool.

Fitting the wire brush 10

1. Disconnect the mains plug from the power outlet.
2. Fit the side handle. → page 10
3. Install the guard. → page 10
4. Place the wire brush in position and tighten it hand-tight.
5. Press the spindle lock button and hold it in this position.
6. Tighten the wire brush with a suitable open-end wrench.
7. Then release the spindle lock button and remove the open-end wrench.

Fitting the abrasive resin-fiber disc 11

1. Disconnect the mains plug from the power outlet.
2. Fit the side handle. → page 10
3. Install the guard. → page 10
4. Fit the support plate and the abrasive resin-fiber disc, screw on the clamping nut and tighten it securely.
5. Press the spindle lock button and hold it in this position.
6. Use the pin wrench to tighten the clamping nut securely, then release the spindle lock button and remove the wrench.

Types of work

WARNING
A damaged supply cord presents a hazard! Do not touch the supply cord or extension cord if damaged while working. Disconnect the supply cord plug from the power outlet.

• Check the appliance’s supply cord at regular intervals and have it replaced by a qualified specialist if found to be damaged.

Check extension cords at regular intervals and replace them if found to be damaged.

Switching on 12

The on/off switch with built-in safety lock enables the user to check the switch function and prevents inadvertent starting of the product.

1. Plug the supply cord into the power outlet.
2. Slide the safety lock forward to unlock the on/off switch.
3. Fully depress the on/off switch.
   The motor runs.

Grinding

CAUTION
Risk of injury. The accessory tool may suddenly stick or stall.

• Use the power tool with the side handle (or optional hoop grip) fitted and always hold the power tool securely with both hands.

Cutting

• When cutting, apply moderate feed pressure and do not tilt the product or the cutting disc to either side (hold at approx. 90° to the cutting plane).

For best results when cutting profiles and small-section rectangular tubes, start cutting at the smallest cross section.

Rough grinding

• Move the product to and for while maintaining a 5° to 30° angle of attack and applying moderate pressure.
  • This will avoid overheating and discoloration of the workpiece and help ensure an even surface finish.

Switching off

• Release the on/off switch.
• The safety lock jumps back automatically into the locked position and the motor stops.

Care and maintenance

WARNING
Danger of electric shock! Carrying out care and maintenance while the supply cord is connected to the power outlet presents a risk of serious injuries including burns.

• Always unplug the supply cord before carrying out all care and maintenance tasks.

Care

• Carefully remove stubborn dirt from the tool.
• Clean the air vents carefully with a dry brush.
• Use only a slightly damp cloth to clean the casing. Do not use cleaning agents containing silicone as they can attack the plastic parts.

Maintenance

WARNING
Danger of electric shock! Improper repairs to electrical components may lead to serious injuries including burns.

• Repairs to the electrical section of the tool or appliance may be carried out only by trained electrical specialists.
• At regular intervals, check all visible parts and the controls for signs of damage and make sure that they all function correctly.
• Do not operate the power tool if signs of damage are found or if parts malfunction. Have damage repaired immediately by Hilti Service.
• After cleaning and maintenance, refit all guards or protective devices and check that they function correctly.

Checks after care and maintenance work

• After carrying out care and maintenance, check that all protective and safety devices are fitted and that they function faultlessly.

Transport and storage

• Do not transport electric tools with accessory tools fitted.
• Always unplug the supply cord before storing an electric tool or appliance.
• Store tools and appliances in a dry place where they cannot be accessed by children or unauthorized persons.
• Check electric tools or appliances for damage after long periods of transport or storage.

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.

Troubleshooting

power tool or appliance and check whether it works.
The supply cord or plug is defective.| Have the supply cord and plug checked by a trained electrical specialist and replaced if necessary.
The carbon brushes are worn.| Have the power tool checked by a trained electrical specialist and the carbon brushes replaced if necessary.
Product does not work.| Product is overloaded.| Release the on/off switch and then press it again. Then allow the product to run under no load for approx. 30 seconds.
Product does not develop full power.| The extension cord conductor cross section (gauge) is inadequate.| Use an extension cord with an adequate conductor cross section.
Elevated temperatures at the gear housing.| Short braking interval.| Allow the device to run under no load until it has cooled down.

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.

• Do not dispose of power tools, electronic equipment or batteries as household waste!

Manufacturer’s warranty

• Please contact your local Hilti representative if you have questions about the warranty conditions.

References

• Power Tools, Fasteners and Software for Construction - Hilti USA - Hilti USA

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