Hilti 3490198 Use and Care Manual
Contents
1. 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 spe cialists Check all external parts of the power tool for damage at regular intervals and check that all controls operate faultlessly 8 3 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 9 Troubleshooting Fault The battery runs down more quickly than usual Possible cause Battery condition is not optimal Remedy Have battery condition diagnosed by Hilti Service or replace with a new battery The battery doesn t engage with an audible click The retaining lugs on the battery are dirty Clean the retaining lugs and check that the battery engages securely Contact Hilti Service if the problem persists LED 1 blinks The power tool doesn t run and 1 LED blinks The battery is discharged Charge the battery The power tool has been overloaded application limits exceeded The battery is discharged Use the right power tool for the job don t use a low powered tool for heavy work Change the battery and recharge the discharged battery The battery is too hot or2. Am AG 500 A18 Operating instructions Mode d emploi Manual de instrucciones Manual de instru es MEM 5 ORIGINAL OPERATING INSTRUCTIONS AG 500 A18 angle grinder It is essential that the operating instruc tions are read before the power tool is op erated 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 Contents Page 1 General information 1 2 Description 2 3 Insert tools accessories 4 4 Technical data 5 5 Safety instructions 5 6 Before use 11 7 Operation 14 8 Care and maintenance 14 9 Troubleshooting 15 10 Disposal 16 11 Manufacturer s warranty tools 16 1 General information Hi These numbers refer to the corresponding illustra tions 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 tool always refers to the AG 500 A18 cordless angle grinder Operating controls and parts EN D Ventilation slots 2 On off switch 3 Switch on interlock 4 Vibration absorbing side handle 5 Spindle lockbutton 6 Guard release button Spindle Guard 9 Clamping flange with O ring Cutting disc grinding disc
3. 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 5 3 Additional safety instructions 5 3 1 Personal safety Wear ear protectors Exposure to noise can cause hearing loss Always hold the power tool securely with both hands on the grips provided Keep the grips dry clean and free from oil and grease Breathing protection must be worn if the power tool is used without a dust removal system for work that creates dust Do not operate the power tool without the pro tective devices that belong to it Operate the power tool only as intended and when it is in faultless condition Improve the blood circulation in your fingers by relaxing your hands and exercising your fingers during breaks between working Switch the power tool on only after bringing it into position at the workpiece Remove the battery before storing or transport ing the power tool Never brake the tool by applying lateral pressure to the grinding or cutting disc Do not touch the clamping flange or the clamp ing screw while the power tool is running Never press the spindl
4. Permissible tool overload cannot be given as a specific value as it depends on the temperature of the motor If the power tool has been overloaded release the pressure applied and then allow it to run under no load for approx 30 seconds 2 6 DC EX 125 5 C compact dust removal hood for cutting For cutting concrete and masonry 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 grinding and slitting work on mineral materials such as concrete or stone These serve to protect the operator and increase the life of the power tool and disc used 2 7 Guard with front cover A CAUTION When using cutting discs to cut metals the guard with front cover must be fitted 2 8 DG EX 125 5 dust removal hood for grinding The power 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 cutting grinding and slitting work on mineral materials such as concrete or stone These serve to protect the operator and increase the life of the power tool and disc used 2 9 Lithium ion battery charge status When a lithi
5. 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 ap propriate for the type of dust generated and designed to filter out microscopic particles and direct dust away ftom 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 5 3 2 Power tool use and care 10 Grinding discs must be stored and handled care fully in accordance with the manufacturer s in structions Check that the grinding disc is fitted in accor dance with the manufacturer s instructions 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 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 Never use the power
6. GD Clamping nut 2 Kwik Lock quick release clamping nut op tional 3 Wrench Battery 5 Release buttons with additional function charge status display activation 1 1 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 1 2 Explanation of the pictograms and other information Warning signs Warning caustic substances General warning Warning electricity Warning hot surface Obligation signs Location of identification data on the power tool am S SER an The type designation and serial number can be found on the type identification plate on the machine or tool Make a note of this data in your operating instructions and always refer to it when making an enquiry to your Wear eye Wear a hard Wear ear Wear protection hat protection protective Hilti representative or service department gloves Type Generation 01 Wear Serial no breathing protection Symbols O amp v Read the Return waste Volts Direct current operating material for instructions recyc
7. Operations for which the power tool was not designed may create a hazard and cause personal injury Do not use accessories which are not specif ically 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 The arbour size of wheels flanges backing pads or any other accessory must properly fit the spindle of the power tool Accessories with arbour holes 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 acces sory 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 acces sories will n
8. handled correctly cleaned and serviced properly and in accordance with the Hilti Operating Instructions and the technical system is maintained This means that only original Hilti consumables components and spare parts may be used in the tool This warranty provides the free of charge repair or replacement of defective parts only over the entire lifespan of the tool Parts requiring repair or replace ment as a result of normal wear and tear are not covered by this warranty Additional claims are excluded unless stringent na tional rules prohibit such exclusion In particular Hilti is not obligated for direct indirect inciden tal or consequential damages losses or expenses in connection with or by reason of the use of or inability to use the tool for any purpose Im plied warranties of merchantability or fitness for a particular purpose are specifically excluded For repair or replacement send the tool or related 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 contempo raneous comments and oral or written agreements concerning warranties ei Ti Hilti Corporation LI 9494 Schaan Tel 423 234 21 11 Fax 423 234 2965 www hilti com Hilti registered trademark of Hilti Corp Schaan W 4081 0112 00 Pos 3 1 Printed in China 2012 Right of t
9. 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 0 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 5 2 2 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 re
10. 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 work piece Let the wheel reach full speed and care fully reenter 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 kick back 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 kick back 5 2 5 Additional safety instructions for sanding operations a Do not use excessively oversized sanding disc paper Follow manufacturers recommenda tions 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 5 2 6 Safety warnings specific for wire brushing a
11. tool without the guard Do not use separate reducing rings or adapters to enable use of grinding discs with a larger mounting hole If the grinding disc or cup wheel etc is equipped with a threaded insert check that the threaded section is long enough to take up the length of the drive spindle The workpiece must be fixed securely in place Do not use cutting discs for grinding Take steps to ensure that flying sparks from the tool do not present a hazard i e by strik ing yourself or other persons or by igniting inflammable substances Adjust the position of the disc guard accordingly When working in dusty conditions check to ensure that the cooling air openings remain unobstructed Should it become necessary to remove dust deposits from the air openings first unplug the tool from the electric supply and then use a non metallic object to remove the dust taking care to avoid damaging parts inside the tool lf the nut securing the disc and flange is not tightened firmly the disc may work loose ftom the spindle due to the braking effect of the motor Tighten the disc flange securing nut in accordance with the directions given in the operating instructions Wait until the disc comes to a standstill 5 3 3 Electrical safety 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 ma
12. amping nut 3 CAUTION The clamping flange is equipped with an O ring The O ring must be replaced if miss ing or damaged Fit the clamping flange onto the drive spindle 4 Fit the diamond disc cutting disc or grinding disc 5 Screw the quick release clamping nut onto the spindle until it contacts the disc the side with the lettering should be visible after the nut is screwed on 6 CAUTION Do not press the spindle lockbutton before the drive spindle has stopped rotating Press the spindle lockbutton and hold it in this position 7 Use the wrench to tighten the clamping nut or respectively rotate the grinding disc firmly by hand in a clockwise direction until the Kwik Lock nut is tight and then release the spindle lockbut ton 6 9 2 Removing grinding cutting discs secured with the Kwik Lock nut 1 Pull the battery out of the tool 2 Release the Kwik Lock nut by turning the knurled ring in a counterclockwise direction Use the pin wrench to release the Kwik Lock nut if very tight Do not use a pipe wrench 13 7 Operation WARNING Wear personal protective equipment 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 30 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 beari
13. ck may create a risk of fire when used with another battery pack Use power tools only with specifically desig nated battery packs Use of any other battery packs may create a risk of injury and fire When battery pack is not in use keep it away from other metal objects like paper clips coins keys nails screws or other small metal objects that can make a connection from one terminal to another Shorting the battery termi nals together may cause burns or a fire Under abusive conditions liquid may be ejected from the battery avoid contact If contact ac cidentally occurs flush with water If liquid contacts eyes additionally seek medical help Liquid ejected from the battery may cause irrita tion or burns 5 1 6 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 5 2 Additional safety instructions 5 2 1 Safety warnings common for grinding a danding 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 polishing are not recom mended to be performed with this power tool
14. e lockbutton while the grinding or cutting disc is still rotating Never direct the power tool toward persons m Adjust the pressure applied to the grinding or cutting disc to suit the material you are working on so that the grinding or cutting disc doesn t stall possibly causing the tool to kick back Avoid touching rotating parts Switch the power tool on only after bringing it into position at the workpiece Touching rotating parts especially rotating insert tools may lead to injury o When grinding with straight grinding discs and cutting with cutting discs in metalworking ap plications use only the guard with cover plate This is available as an optional accessory Children must be instructed not to play with the power tool The power tool is not intended for use by chil dren by debilitated persons or those who have received no instruction or training Do not use the power tool if it starts with a jolt This may be an indication that the electronic control unit is defective Have the tool repaired at an authorized Hilti service center right away WARNING Some dust created by grinding sanding cutting and drilling contains chem icals known to cause cancer birth defects infertility or other reproductive harm or seri ous and permanent respiratory or other injury Some examples of these chemicals are lead from lead based paints crystalline silica from bricks concrete and other masonry products and natural stone
15. echnical and programme changes reserved S E amp O 438685 B
16. ere it can be kept under observation and allowed to cool Contact Hilti Service after the battery has been allowed to cool 5 3 5 Work area safety 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 5 3 6 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 6 Before use WARNING Never use the power tool without the guard 6 1 Battery use and care NOTE Battery performance drops at low temperatures Use the tool only after fully charging the battery This ensures that maximum battery capacity is available Change to a second battery as soon as a drop in performance is noticed Recharge the battery imme diately so that it is ready for reuse Store the battery in a cool dry place Never store the battery where it is exposed to direct sunlight or sources of heat e g on heaters radiators or behind a motor vehicle windscreen Batteries that have reached the end of their life must be disposed of safely and correctly to avoid environmental pollution 6 2 Charging the battery DANGER Only used the specified Hilti battery packs and Hilti battery chargers which are listed under Acces sories 6 2 1 Charging a ne
17. es you full control of the switch function and avoids unintentional restarting 1 Push the safety lock switch on interlock for ward to unlock the on off switch and then press the switch fully 2 The safety lock switch on interlock returns au tomatically to the locked position when the on off switch is released 8 Care and maintenance CAUTION 8 1 Care of the power tool Before beginning cleaning remove the battery from DANGER the power tool in order to prevent unintentional starting 14 Under extreme conditions when used for working on metal conductive dust may accumulate inside the tool In this case use of a stationary dust extraction system and frequent cleaning ofthe ventilation slots are 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 ventilation slots are blocked Clean the ventilation slots carefully using a dry brush Do not permit foreign objects to enter the interior of the power tool 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 power tool Always keep the grip surfaces of the power tool free from oil and grease Do not use cleaning agents which contain silicone 8 2 Maintenance
18. ing 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 2 2 ltems supplied as standard 1 Powertool Side handle Guard Front cover Kwik Lock quick release clamping nut optional Flange Nut Wrench Operating instructions Protective glasses optional 1 1 1 1 asas sa 2 3 Additional items required for operating the tool B18 3 3 or B18 2 6 Li lon battery and C4 36 ACS C4 36 ACS TPS 04 36 C4 36 90 or C4 36 350 charger 2 4 Constant speed electronics automatic brake 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 Disc deceleration time is reduced automatically 2 5 Temperature dependent motor protection The temperature dependent motor protection system prevents the power 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 power tool may stop running avoid stalling the power tool in this way
19. ling before use n min RPM Rated speed Revolutions Revolutions Diameter per minute per minute 2 Description 2 1 Use of the product as directed The power tool is designed for cutting grinding and brushing metal or mineral materials concrete stone etc without use of water The working environment may be as follows construction site workshop renovation conversion or new construction Do not use the battery as a power source for other unspecified appliances Working with metals Cutting rough grinding fine grinding brushing Working with mineral materials Cutting slitting using the corresponding guard DC EX 125 5 C grinding using the corresponding guard DG EX 125 5 Use only grinding discs cutting discs and other accessories that are approved for use at a speed of at least 11000 min at max 5 diameter Use only synthetic resin bonded fiber reinforced grinding or cutting discs or diamond cutting discs approved for use at a peripheral speed of 80 m sec The power tool may be used only for dry cutting or grinding Cutting or grinding materials containing asbestos is not permissible When grinding stone a vacuum cleaner equipped with the appropriate filter e g a suitable Hilti vacuum Cleaner must be used Modification of the power tool or tampering with its parts is not permissible To avoid the risk of injury use only genuine Hilti accessories and insert tools Observe the information printed in the operat
20. must be replaced if miss ing or damaged Fit the clamping flange onto the drive spindle 3 Fit the diamond disc cutting disc or grinding disc 4 Screw on the clamping nut and tighten it 5 CAUTION Do not press the spindle lockbutton before the drive spindle has stopped rotating Press the spindle lockbutton and hold it in this position 6 Use the wrench to tighten the clamping nut securely and then release the spindle lockbutton 6 9 Using the Kwik Lock clamping nut with grinding cutting discs 6 9 1 Fitting grinding cutting discs using the Kwik Lock clamping nut El NOTE The Kwik Lock nut may be used instead of the stan dard clamping nut No tools are then required for changing cutting discs NOTE The Kwik Lock nut cannot be used with cup wheels brushes rubber backing pads tuck pointing discs special discs used for joint repair or with diamond cup wheels CAUTION When operating the power tool take care to ensure that the Kwik Lock nut does not come into contact with the work surface Do not use a damaged Kwik Lock nut NOTE The arrow on the upper surface of the nut must be within the index marks If the arrow is not within the index marks when the nut is tightened it will be impossible to release the nut by hand In this case use the pin wrench to release the Kwik Lock nut do not use a pipe wrench 1 Pull the battery out of the power tool 2 Clean the clamping flange and the quick release cl
21. ng components are cut through Consult the structural engineer architect or person in charge of the building project before beginning the work WARNING Never use the tool without the side handle and the corresponding guard CAUTION Use clamps or a vice to hold the workpiece securely CAUTION Working on the material may cause it to splinter Wear eye protection and protective gloves Wear breathing protection if no dust removal system is used Splintering material presents a risk of injury to the eyes and body CAUTION Breathing protection must be worn if the power tool is used without a dust removal system for work that creates dust WARNING Avoid touching rotating parts Switch the power tool on only after bringing it into position at the work piece Touching rotating parts especially rotating insert tools may lead to injury CAUTION The insert tool may get hot during use Wear protec tive 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 or wheel 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 7 1 On off switch with switch on interlock El The on off switch with safety lock switch on inter lock giv
22. ormally break apart during this test time Wear personal protective equipment Depend ing on application use face shield safety gog gles or safety glasses As appropriate wear dust mask hearing protectors gloves and work shop apron capable of stopping small abrasive or workpiece fragments The eye protection must be capable of stopping flying debris gen erated by various operations The eye protection must be capable of stopping flying debris gen erated 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 sur faces 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 acces sory If you lose control the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory 1 Never lay the power tool down until the acces sory has come to a complete stop The
23. ositioned 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 c 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 ap plied to these wheels may cause them to shatter d 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 e Do notuse 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 5 2 4 Additional safety warnings specific for abrasive cutting off operations a Do not jam the cut off wheel or apply ex cessive pressure Do not attempt to make an excessive depth of cut Overstressing the wheel increases the loading and susceptibility to twist ing 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
24. ower 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 the battery pack from the power tool before making any adjustments changing ac cessories or storing power tools Such preven tive safety measures reduce the risk of starting the power tool accidentally Store idle power tools out of the reach of chil dren 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 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 5 1 5 Battery tool use and care a Recharge only with the charger specified by the manufacturer A charger that is suitable for one type of battery pa
25. rage of battery packs Pull the battery pack out of the locked position work ing position and move it into the first click stop position transport position If you disconnect a battery pack from the power tool for transport or storage make sure that the contacts of the battery pack are not short circuited Remove loose metal parts such as screws nails clamps loose screw bits wires or metal swarf from the case toolbox or transport container or prevent these parts from coming into contact with the battery packs 12 Observe national and international transport regula tions when shipping battery packs transportation by road rail sea or air 6 6 Fitting the side handle WARNING The side handle must be fitted for all types of work The side handle may be screwed onto the tool on the right or left 6 7 Working with the power tool Take care to ensure that the closed side of the guard is always positioned toward the operator s body Adjust the position of the guard to suit the require ments of the work being done 6 7 1 Fitting the guard El 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 1 Pull the battery out of the power tool 2 Fit the guard onto the drive spindle collar so that the two triangular marks on the guard and on the power tool are in alignmen
26. sult 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 acces sory Accessory may kickback over your hand c Do not position your body in the area where power tool will move if kickback occurs Kick back 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 5 2 3 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 guard must be securely attached to the power tool and p
27. t 3 Push the guard onto the drive spindle collar press the guard release button 4 Rotate the guard until it engages and the guard release button jumps back into its original posi tion 6 7 1 1 Adjusting the guard 1 Pull the battery out of the tool 2 Press the guard release button and then rotate the guard until it engages in the desired position 6 7 2 Fitting the cutting and grinding guards NOTE Read the instructions for fitting the corresponding guard NOTE If you use the front cover fit it by pushing it onto the guard 6 7 2 1 Fitting the cutting guard I O NOTE Take care to ensure that the on off switch is freely accessible and operable at all times 6 8 Fitting the cutting grinding disc WARNING If the nut securing the disc and flange is not tight ened firmly the disc may work loose from the spindle due to the braking effect of the motor Tighten the disc flange securing nut in accordance with the directions given in the operating instructions Wait until the disc comes to a standstill DANGER Check that the speed rating printed on the cutting or grinding disc is equal to or higher than the rated speed of the power tool see accessories DANGER Check the condition of the grinding disc before using it Do not use accessories e g discs that are broken cracked or damaged in any way 1 Pull the battery out of the tool 2 CAUTION The clamping flange is equipped with an O ring The O ring
28. too cold Bring the battery to the recom mended working temperature The power tool doesn t work and all 4 LEDs blink The power tool has been over loaded briefly The overheating prevention cut out has been activated Release the switch and press it again Allow the power tool to cool down The power tool or the battery becomes very warm Electrical fault Switch the power tool off imme diately remove the battery and contact Hilti Service Fault Possible cause Remedy The power tool or the battery becomes very warm been overloaded application limits exceeded A battery with inadequate capacity The power tool doesn t achieve full power was used The power tool has Use the right power tool for the job don t use a low powered tool for heavy work Use a battery with a capacity of at least 2 6 Ah 10 Disposal ES 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 11 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
29. 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 energising 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 bal ance at all times This enables better control of the power tool in unexpected situations 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 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 5 1 4 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 Do not use the p
30. um ion battery is used the charge status can be indicated by gently pressing one of the battery release buttons press until resistance is felt do not release the battery The display on the rear of the battery provides the following information LEDs light constantly LEDs blink Charge status C LED 1 2 3 4 5 C275 LED 1 2 3 3 50 C lt 75 LED 1 2 5 25 C lt 50 LED 1 10 SC lt 25 E LED 1 C lt 10 3 Insert tools accessories Discs of max 5 diameter designed for use at 11000 min and a peripheral speed of 80 m sec Designation Item number description Abrasive cutting disc AC D Abrasive grinding disc AG D AF D Diamond cutting disc DC D Diamond grinding disc DG CW Accessories for the AG 500 A18 Designation Short designation Description Kwik Lock quick release clamp ing nut optional Dust removal hood for grinding DG EX 125 5 Guard with front cover Compact dust removal hood Toolbox Vacuum cleaner recommended by Hilti DC EX 125 5 C Designation Short designation Description Battery B 18 2 6 Li ion Battery B 18 3 3 Li Ion Charger for Li ion batteries C 4 36 C 4 36 ACS or C 4 36 ACS TPS en Charger for Li ion batteries C 4 36 90 Charger for Li ion batteries C 4 36 350 4 Technical data Right of technical changes reserved Power tool AG 500 A18 Rated voltage 21 6V Rated speed 9 500 min Cutting discs grinding discs 125 mm 5 Dimensions L x H
31. w battery for the first time Charge the battery fully before using it for the first time 11 6 2 2 Charging a previously used battery Ensure that the outer surfaces of the battery are clean and dry before inserting it in the corresponding charger Read the operating instructions for the charger for further information about the charging procedure Lithium ion battery packs are ready to use at any time even when only partially charged Charging progress is indicated by the LED display see charger operating instructions 6 3 Fitting the battery CAUTION Check that the power tool is switched off and the switch interlock activated before fitting the battery Use only the Hilti batteries approved for use with this power tool CAUTION Check that the terminals on the battery and in the power tool are free from foreign objects before inserting the battery in the power tool 1 Push the battery into the power tool from the rear as far as it will go and until it is heard to engage with a double click 2 CAUTION If it is not fitted securely the battery could fall out while you are working with the tool CAUTION A falling battery may present a risk of injury to yourself or others Before beginning the work check that the battery is fitted securely to the tool 6 4 Removing the battery from the power tool 1 Press both battery release buttons 2 Pull the battery out of the power tool toward the rear 6 5 Transport and sto
32. x W without hood 351 mm 13 82 x 131 mm 5 16 x 93 mm 3 66 Weight 2 7 kg 5 95 Ib Battery B 18 2 6 Li lon B 18 3 3 Li lon Rated voltage 21 6 V 21 6 V Capacity 2 6 Ah 3 3 Ah Energy capacity 56 16 Wh 71 28 Wh Weight 0 78 kg 1 72 Ib 0 78 kg 1 72 Ib Type of cell Li lon Li lon No of cells 12 12 Deep discharge protection Yes Yes Information about the power tool and applications Drive spindle thread arbor size M14 Spindle length 21 5 mm 5 Safety instructions NOTE 5 1 General power tool safety warnings The safety rules in section 5 1 contain all general a A safety rules for power tools which in accordance WARNING with the applicable standards must be listed in the Read all safety warnings and instructions Fail operating instructions Accordingly some of the rules ure to follow the warnings and instructions may listed may not be relevant to this tool 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 battery operated cordless power tool en 5 1 1 Work area safety a b Keep work area clean and well lit Cluttered or dark areas invite accidents Do not operate power tools in explosive atmo spheres such as in the presence of flammable liquids gases or dust Powertools create sparks which may ignite the dust or fumes Keep children and b
33. y become live for example when an electric cable is damaged accidentally This presents a serious risk of electric shock Dirty or dusty power tools that have been used frequently for work on conductive materials should be checked at regular intervals at a Hilti Service Center Under unfavorable circum stances dampness or dust adhering to the sur face of the tool especially dust from conductive materials may lead to damage to the tool 5 3 4 Battery use and care a Observe the special instructions applicable to the transport storage and use of Li ion batter ies b Do not expose batteries to high temperatures or fire This presents a risk of explosion c Do not disassemble squash or incinerate bat teries and do not subject them to temperatures over 80 C A risk of fire explosion or injury through contact with caustic substances may otherwise result d Do not use batteries other than those approved for use with the applicable power tool or appli ance Use of other batteries or use of the battery for purposes for which it is not intended presents a risk of fire and explosion e Do not charge or continue to use damaged bat teries e g batteries with cracks broken parts bent or pushed in and or pulled out contacts f Ifthe battery gets too hot to touch this may indi cate that it is faulty Place the tool at a location where there is no risk of causing a fire at least 3 meters away from flammable materials wh
34. ystanders away while oper ating a power tool Distractions can cause you to lose control 5 1 2 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 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 con ditions 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 5 1 3 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
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