Hilti DCG 500-S User manual

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DCG 500-5 angle grinder
It is essential that the operating instructions
are read belore the power tool is operated
tor the tirst 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
pers0ns.
Gonlents Paqe
1. General information
2. Safetv rules
3. Description
4. Technical data
5. Belore use
conlrols and componenls E
Ventilation slots
0n / ofl switch
Vibration-absorbing side handle
Spindle lockbutton
Guard release button
Drive spindle
G uard
Clamping flange
Cutting disc / grinding disc (not supplied)
Clamping nut
Pin wrench
Non-slip grip surface
6. 0peration 10
8. Insert tools, accessories 1 1
9. Troubleshootino 12
10. Disoosal 12
11. Manufacturer's warranty - tools 12
1.1 Safety nolices and lheir meaning
DANGER
Draws attention to imminent danger that could lead
to serious bodily injury or fatality.
WAFNING
Draws attention to a potentially dangerous situati0n
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
Used to draw attention to an instruction or other
useful information.
1.2 Explanalion of the pictograms and olhel
informalion
Warning signs
/\/\/\
/?\ /h\ .((N
/a\ /r\ t)))\
Er l-
-
General Warning; Warning: lrot
warning electricity surface
Wear ear
protectlon
0bligation
^t\
4H
v
Wear eye
protection
signs
Iv.l
v
Wear a hard
hat @s
Wear
protective
gr0ves

25
Y
o,[iiln
protection
Symbols
m
Read the Reiurn waste
operating material for
nstructions recycling.
Delore use.
^/ ng
Alternatinq Rated speed
cutrent under no load Double
ins!lated
2.1 General safety rules
Warning! Read and undelstand all insttuctions.
Failure to follow all instructions listed below may
result in electric shock, fire and/or serious personal
injury. SAVE THESE INSTRUCTI0NS.
2.1.1 Wqrt area sale$
a) Keep yourworkarea clean and well lit. Cluttered
benches and dark areas invite accidents.
b) Do not 0perale power tools in explosive almo-
spheres, such as in the presence of flammable
liquids, gases 0r dusl. Power tools create sparks
which may ignite the dust or f umes.
c) Keep bystanders, children and visilors away
while operating a power tool. Distractions can
cause you to lose control.
2.1.2 Electrical Satety
a) Grounded lools musl be plugged into an outlet
properly installed and grounded in accordance
wilh all codes and ordinances. Never remove
lhe grounding prong 0r modity the plug in any
way. Do nol use any adapter plugs. Gheck wilh
a qualified eleclrician if you are in doubt as
l0 whether the outlet is properly grounded. If
the tools should electricallv malfunction or break
E These numbers refer t0 the corresponding illustra-
tions. The illustrations can be found on the fold-out
cover pages. Keep these pages open while studying
the operating instructions.
ln these operating instructions, the designation "the
power tool" always refers to the DCG 500-5 angle
grinder.
Location of identification data on the power tool
The type designatlon can be found on the type identi-
fication plate and the serial number on the side of the
motor housing. The serial no. can be found on the
underside of the motor housing. Make a note of this
data in your operating instructions and always refer to
it when making an enquiry to your Hilti representative
or service department.
Type:
Serial no.:
&
down, groundrng provides a low resistance path
t0 carry electricity away from the user.
b) Double-insulated tools are equipped wilh a po-
larized plug (one blade is wider than lhe other).
This plug will lit in a polarized oullet only one
way. lf the plug does not fit fully in the oullet,
reverse lhe plug. ll il slill does not lit, contact
a qualified electrician to install a polarized out-
let. Do nol change lhe plug in any way. Double
insulation eliminates the need for the three-wire
grounded power cord and grounded power supply
system.
c) Avoid body contact with grounded surlaces such
as pipes, radialors, ranges and relrigeralors.
There is an increased risk of electric shock if your
body is grounded.
d) Don't expose power tools lo rain or wel condi-
tions. Water entering a power tool will increase
the risk of electric shock.
e) Do not abuse lhe cord. Never use the cord to
carry the t00ls 0r pull the plug from an outlel.
Keep cord away lrom heat, oil, sharp edges or
moving parts. Replace damaged.cords immedi-
ately. Damaged cords increase the risk of electric
snock.

f) When operating a powel tool oulside, use an
ouldoor extension cord marked "W-4" or "W".
These cords are rated for outdoor use and reduce
the risk of electric shock.
2.1.3 Personal Safety
a) Stay alert, watch whal you are doing and use
common sense when operating a powel tool. Do
n0l use l00l while lired or under lhe inlluence
of drugs, alc0h0l 0r medication. A moment of
inattention while operating power tools may result
in serious personal injury,
b) Dress properly. Do not wear loose clothing 0r
jewelry. Contain long hair. Keep your hair, clolh-
ing and gloves away from moving parts. Loose
clothes, jewelry or long hair can be caught in
mOvrng parts.
c) Avoid accidental slarling. Be sure swilch is olf
before plugging in. Carrying tools with your finger
on the switch or plugging in tools that have the
switch on invites accidents.
d) Remove adiusting keys or wrenches belore lurn-
ing the tool on. A wrench or a key that is left
attached to a rotating part of the t00l may result in
personal injury.
e) Do not overreach. Keep proper looting and bal-
ance at all times. Proper footing and balance
enables better control of the tool in unexoected
situatio ns.
f) Use safety equipmenl. Always wear eye prolec-
lion. Dust mask, non-skid safety shoes, hard hat
or hearing protection must be used for appropriate
conditions.
2.1.4 Tool Use and Care
a) Use clamps 0r other practical way t0 secure
and supporl the workpiece to a stable plalform.
Holding the work by hand 0r against your body is
unstable and may lead to loss of control.
b) Do not lorce lool. Use the correct t00l for your
applicalion. The correct tool will do the lob better
and safer at the rate for which it is designed.
c) Do notusel0ol if switch does nollurn iton oroll.
Any tool that cann0t be controlled with the switch
is dangerous and must be repaired.
d) Disconnect lhe plug lrom lhe power source
before making any adiustmenls, changing ac-
cessories, or sloring the tool. Such preventive
safety measures reduce the risk of starting the tool
accid ental ly.
e) Slore idle tools oul of reach of children and other
unlrained persons. Tools are dangerous in the
hands of untrained users.
f) Maintain tools with care. Keep culting t00ls
shatp and clean. Properly maintarned tools with
sharp cutting edges are less likely to bind and are
easier to control.
g) Gheck for misalignment or binding ol moving
pads, breakage 0f parts and any other condition
that may aflecl lhe l00l's operali0n. lf damaged,
have lhe lool serviced belore using. Many acci-
dents are caused by poorly maintained tools.
h) Use only accessories that are recommended by
the manufaclurer lor your model. Accessories
that may be suitable for one tool may become
hazardous when used 0n another t001.
2.1.5 Service
a) Tool service musl be performed only by qual-
ilied repair personnel. Service or maintenance
performed by unqualified personnel could result in
a risk of injury.
b) When servicing a lool, use only identical re-
placement parls. Follow instructions in lhe Main-
lenance section of this manual. Use of unau-
thorized parts or failure to follow Maintenance
Instructions may create a risk of electric shock or
InJury.
2.2 Specilic salety rules
a) Always use proper guard with grinding wheel.
A guard protects operalor lrom broken wheel
f ragments.
b) Accessories must be rated lor at least lhe speed
recommended on lhe tool warning label. Wheels
and other accessories running over rated speed
can fly apart and cause injury.
c) Hold lool by insulated gripping surfaces when
performing an operalion where the cutting tool
may contact hidden wiring or its own cord. Con-
tact with a "live" wire will make exoosed metal
parts of the tool "live" and shock the 0perator.
2.3 Addilional safety preDaulions
2.3.1 Salety rules applicable lo all applications
Warnings applicable to grinding, sanding, brushing
with wire brushes, polishing and culling:
qI

a) This powert00l is l0 be used for grinding, cutting
and wile brushing. Pay attention to all warnings,
instructions, illustrations and data received with
the power tool. Failure to observe the following
instructions mav lead to electric shock, fire and/or
ft serious iniurv.
r bt This power lool is not suitable for use with
sandpaper or lor polishing. Use of the power t00l
for purposes for which it is not intended may be
hazardous and cause injury.
c) The approved speed of rotation 0f lhe disc t0 be
used must be at leasl as high as the maximum
rated speed given on the power t0ol. Accessories
that rotate at a speed higher than their approved
rating may break and {ly apart.
d) The outside diameter and thickness of the disc
0r accessory musl be compatible with the di-
mensions of the power lool. Discs or accessories
of the wrong dimensions cannot be adequately
guarded or properly controlled.
e) Grinding discs, flanges 0r olher accessories
must lit the drive spindle of the power tool per-
fectly. Discs or accessories which do not fit the
drive spindle perfectly will rotate out of balance,
resulting in strong vibration, and may cause loss
of control of the power tool.
f) Do not use damaged discs or accessories. Check
culting or grinding discs lor chipping, cracking or
excessive wear each lime before use. Check wire
brushes tor broken or loose wires. lf lhe power
tool, disc or accessory has been dropped, check
t0 ensure that it is undamaged. Use only un-
damaged discs and accessories. After checking
and fitting the disc or accessory; keep yourself
and other persons in the vicinity away lrom the
plane ol rolalion of the disc or accessory and
then allow the power lool to run al full speed lor
one minule. Damaged discs or accessories wil
usually break during this test period.
g) Keep the supply cord away from rolating discs
or accessories. Loss of control of the power too
may cause the supply cord to be cut through or
caught up and your hand or arm could be injured
by the rotating disc or accessory.
h) Never lay lhe power tool down until lhe disc or
accessory comes l0 a complete standslill. The
rotating disc 0r accessory may c0me into contact
with the surface on which it is laid, causing you to
lose control of the power tool.
i) Do not allow the power lool lo run while you are
carrying it. Your clothing could become caught
up if it comes into contact with the rotating disc
0r accessory, causing the disc or accessory t0 cut
into your body.
j) Glean the ventilation slols ol the power l00l at
regular inletvals. The motor cooling fan causes
dust to be drawn into the casing of the power
tool . An accumulation of metal dust may present
electrical hazards.
k) Do not use the power lool in the proximity ol
flammable materials. Sparks may cause these
materials to ignite.
l) Do not use discs or accessories that require
liquid coolants. The use 0f water or other liquld
coolants c0uld present a risk of electric shock.
2.3.2 0ther safety rules applicable lo all
applications
Warnings about the risk of kickback
Kickback is the sudden reaction of the power tool
as a result of unexpected sticking or stalling of the
rotating cutting or grinding disc, sanding plate or wire
brush etc. Sticking or stalling causes the rotating tool
t0 come to an abrupt stop. In this situation, loss o1
c0ntrol results rn the power to0l rotating about the
drive spindle axis in the direction opposite to rotation
of the disc. cuo wheel or brush etc.
lf, for example, a grinding disc stalls or catches in
the workpiece, the edge of the disc may cut into
the material, resulting in sticking and damage to the
edge of the disc, or causing the power tool to kick
back. The grinding disc then moves either toward or
away from the 0perator, depending on the direction
of rotation of the disc at the point of sticking. This
may also result in breakage of the grinding disc.
Kjckback is the result of incorrect or inappropriate use
of the power tool. lt can be avoided by application of
suitable precautionary measures, as described below.
a) Hold the power tool securely and bring your
body and arms inlo a posilion in which they are
able to take up the kickback fotces. To ensure
maximum conlrol of kickback forces or reaclion
torque when slarling the power lool, always use
lhe auxiliary handle (if provided). The operator
can control kickback and reaction forces by taking
suitable precautionary measures.
b) Never bring your hand or other parl of your body
close t0 a rotating disc or accessory. In the
event 0f the power tool kicking back, the disc ot
accessory may move toward your hand.

c) Keep your body away from lhe area in which the
power lool may move in the evenl ol it kicking
back. The kickback effect causes the p0wer t0ol
t0 move in the direction opposite to the direction
0f rotati0n of the disc at the p0int at which stalling
OCCU TS.
d) Work wilh parlicular care al corners and sharp
edges etc. Prevenl lhe disc jumping back lrom
lhe workpiece and sticking. The rotating disc or
accessory tends to get stuck at corners, and sharp
edges 0r when it jumps back. This may cause a
loss of control or the power t00l may kick back.
e) Do nol use chains or loothed saw blades. Cutting
tools of this kind cause frequent kickback or loss
of control of the power tool.
2.3.3 Additional salely rules applicable to
qrinding and cutting
Special warnings applicable to grinding and cutling:
a) The guard must be securely attached to the
power tool and adiusted so lhal maximum satety
is achieved, i.e. the part ol the cutting or grinding
disc exposed loward the operator must be kepl
as small as possible. The guard is intended t0
protect the operator f rom f ragments and accidental
contact with the cutting or grinding disc.
b) Gutting or grinding discs may be used onlyforlhe
recommended applicalions. e. g.: Never use lhe
side surlace of a cutling disc lor grinding. Cutting
discs are designed t0 remove materral from the
workpiece at the edge of the dlsc. Application ot
lateral pressure t0 cutting discs may cause them
to break.
c) Always use an undamaged clamping flange of
the correct size and type for lhe selected cutting
or grinding disc. A suitable flange supports the
grinding disc and thus reduces the risk of disc
breakage. Flanges for use with cutting discs may
differ from flanges for use with grinding discs.
d) Do noluseworn grinding discsfrom largerpower
tools. Grinding discs for larger power tools may
break as they are not designed to withstand the
higher speed of rotati0n of smaller power tools.
2.3.4 Additional safety rules applicable to
cutting
Olher special warnings applicable t0 cutting:
a) Avoid stalling the cutting disc or lhe application
0t excessive pressure. Do nol make excessively
deep culs. Application of excessive pressure in-
creases the stress on the cutting disc and the
tendency to tilt or stall the power tool and thus the
possibility of kickback or disc breakage.
b) ll the cutting disc slalls or you need t0 stop
working lor a moment, switch the power tool
oll and hold it still until the disc stops rolating.
Never attempt lo pull the rotating cutting disc oul
of the ked as this may cause lhe power lool lo
kick back. Determine the cause of the disc sticking
and take steps t0 prevent this recurring,
c) Do not use type 27 grinding discs wilh integrated
clamping nut.
d) Do not switch the power lool on again while the
cutting disc is still in the kerf in lhe workpiece.
Allow the cutling disc t0 reach full speed belore
cauliously coniinuing the cut. The cutting disc
may otherwise catch or stick, jump out of the kerf
in the workpiece or cause the power tool to kick
back.
e) Sheets or large workpieces should be supported
in order to avoid lhe risk of the disc sticking
and causing lhe power tool to kick back. Large
workpieces may bend or sag under their own
weight. The workpiece must be supported at both
sides. close t0 the area of the cut and at its
extremities.
f) Take particular care when making cul-ouls in
exisling walls or other areas where concealed
obiects may be presenl. The cutting disc may
c0ntact gas 0r water pipes, electric cables or other
objects, causing the power tool to kick back.
2.3.5 Additional salety rules applicable to
working wilh wire brushes
Special warnings applicable to working with wire
brushes:
Bear in mind that wire brushes lose wires even
during normal use. Do nol overload the wires by
applying excessive pressure. Pieces of wire that fly
off can very easily penetrate light clothing and/or the
skrn.
2.3.6 Pe6oflaf Salety
a) Hold lool by insulated gripping surlaces when
performing an 0peration where the cutting t00l
may conlacl hidden wiring or ils own cord. Con-
tact with a "live" wire will make exposed metal
parts of the tool "live" and shock the 0perator.
b) Keep the grips dry, clean and lree ftom oil and
g rease.

c) Brealhing prolecli0n does nol require t0 be worn
il the power lool is equipped with a dust removal
system.
d) lmprove the blood circulalion in your lingers by
relaxing your hands and exercising your fingers
!fl ourng oreaKs oelween wor*rng.
- e) Avoid touching rotating parts. Switch lhe power
lool on only aller bringing it into position at
the workpiece. Touching rotating parts, especially
rotating drill bits, discs or blades, etc. may lead t0
rn ju ry.
f) Always lead the supply cord and exlension cord
away trom the power tool l0 the rear while
working. This helps to avoid tripping over the cord
while working.
2.3.7 Tool Use and Care
a) Grinding discs must be slored and handled care-
lully in accordance wilh the manulaclurer's in-
slructions.
b) Check lhat the grinding disc is fitted in accord-
ance with the manulacturer's inslruclions.
c) ll use ol a spacer ring or olher intermediale parl
is specified and the pail is supplied with the
grinding disc, check t0 ensure that the part is
titted.
d) Never use lhe power tool without the guard.
e) Do not use culting discs for grinding.
f) Take steps l0 ensure that flying sparks lrom
lhe power lool do nol presenl a hazard, i.e.
by striking yoursell or other persons. Adiust the
position ol the guard accordingly.
a) Before beginning work, check lhe w0rking area
(e.9. using a melal detector) to ensure lhat n0
concealed eleclric cables or gas and water pipes
are presenl. External metal parts ofthe powertool
may become live, for example, when an electric
cable is damaged accidentally. This presents a
serious risk of electric shock.
b) Check the power tool's supply cord al regular
intetvals and have it replaced by a qualified
specialist if found lo be damaged. Gheck ex-
tension cords at regular inlervals and replace
lhem if lound lo be damaged. Do nol touch the
supply cord or extension cord if it is damaged
while working. Disconnect the supply cord plug
from lhe power outlet. Damaged supply cords or
extension cords present a risk of electric shock.
c) Dirty 0r dusty power lools which have been
used frequenlly for work on conduclive materi-
als should be checked at regular interyals at a
Hilti Seruice Genter. Under unfavorable circum-
stances, dampness or dust adhering to the surface
of the power tool, especially dust from conductive
materials, may present a risk of electric shock.
d) When working outdoors with an electric t00l
check to ensure lhal lhe tool is connected to lhe
eleclric supply by way of a ground laull circuil
inlerupter (GFCI) wilh a raling of max. 30 mA
(tripping current). Use of a ground fault circuil
interrupter reduces the risk of electric shock.
e) Use ol a ground fault circuit interrupter (GFCI)
with a maximum lripping curenl 0f 30 mA is
recommended.
2.3.9 Work area
a) Ensure that the workplace is well lit.
b) Ensure that the workplace is well ventilated.
Exposure to dusi at a poorly ventilated workplace
may result in damage to the health.
2.3.10 Personal protective equipment
o@s
The user and any other persons in the vicinily mu$
wear suilable eye proteclion, a hald hal, ear pr0
tecti0n, protective gloves and breathing proteclior
while the power lool is in use.
2.3.8 Eleclrical Salety
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3.1 Use of tfie produrt as directed
The power t00l is designed for cutting, grinding and brushing metal 0r mineral materials (concrete, stone,
etc.) without use of water. Use of a guide carriage is mandatory for cutting stone.
The working environment may be as follows: c0nstruction site, workshop, renovation, conversion or new
construction.
The power t00l may be operated only when connected t0 a power supply providing a voltage and frequency in
compliance with the information given on its type identification plate.
Working with metals: Cutting, rough grinding, fine grinding, brushing
Use only grinding discs, cutting discs and other accessories that are approved for use at a speed of at least
11000 r,p.m. at 5" diameter.
Use only synthetic resin-bonded, fiber-reinforced grinding or cutting discs or diamond cutting discs approved
f0r use at a peripheral speed of 80 m/sec.
The power to0l may be used only for dry cutting or grinding.
Cutting or grinding materials containing asbeslos is not permissible.
When grinding stone, a vacuum cleaner equipped with a stone dust filter, e.g. the Hilti VCU 40 / VCD 50
vacuum cleaner, must be used.
Changes or modifications t0 the power tool are not permissible.
To avoid the risk of injury, use only genuine Hilti accessories and insert tools.
0bserve the information printed in the operating instructions concerning operation, care and maintenance.
The powertool is designed for professional use and may be operated, serviced and maintained only bytrained,
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.
3.? Switohes ' '
Lockable on / off switch with switch-on interlock
3.3The items supplied in lhe mrdboard box are:
1 Power tool with dust removal hood
1 Vibration-absorbing side handle
2 Nuts
1 Pin wrench
1 0peratinginstructions
1 Cardboard box
1 Protective glasses
3.4 Staning ounent limitation :
The electronic starting current limiter reduces the starting current drawn bythe powertool and thus prevents
the mains fuse blowing. lt also allows the power t00l t0 stad smoothly, without a jolt.
S,S Constant-speed eleelronics
Electronic speed control keeps running speed almost c0nstant irrespective of whether the power tool is idling
or running under load. Constant running speed helps ensure maximum efficiency.
q

3.S,ATC $ctive,,Torque,Conlrol) ,.. ,:.. :::.
The electronics in the power tool detect situations where there is a risk of the disc sticking and prevent furth
rotation of the drive spindle by switching the power tool off (does not prevent kickback). The switch must t
released and pressed again to restart the power tool.
3;T Resfart interfock
The power tool does not restart by itself when the switch is locked in the on-position and the power retun
after an interruption in the electric supply. The switch must first be released and then pressed again to resta
3.8 Temperature-dependent motot prolection ',:',', ::,,: ,':.-.. '.,1 ::r::' .. :,..: ..,, j
The temperature-dependent motor protecti0n system prevents the power tool overheating by monitorir
current input and m0t0r temDerature.
In the event of motor overload due to application of excessive pressure to the disc, performance will dr{
noticeably or the power tool may stop running (avoid stalling the power tool in this way).
Permissible overload cannot be given as a specific value as it depends on the temperature of the motor .
lf the power tool has been overloaded, release the pressure applied and then allow it to run under no load 1
aoorox. 30 seconds.
3.9 Using extension cords ' ', ". ',t ",t ":: ',t' n
Use only extension cords of a type approved for the application and with conductors of adequate cross sectic
The power tool may otherwise loose performance and the extension cord may overheat. Check the extensi
cord for damage at regular intervals. Replace damaged extension cords.
Recommended minimum conductor cross seclion and max. cable lengths
Gonductor closs section 14 AWG 12 AWE
Mains voltage 1 1 0-120 V 125 ft
Do not use extension cords with 16 AWG conductor cross section.
3,10 Using extension $ords 0utd00rs :. -: 1,,,,
When working outdoors, use only extension cords that are approved and correspondingly marked for I
application.
3.11 Using a generator'or transl0ffi€f 'r' 'r"r' '."' .': ,.',"' ".' r.l',, i
This power tool may be powered by a generator 0r transformer when the following conditions are fulfill
The unit must provide a power output in watts of at least twice the value printed on the type identificat
plate 0n the power tool. The operating voltage must remain within +5% and -15% of the rated voltage at
times, frequency must be in the 50 - 60 Hz range and never above 65 Hz, and the unit must be equipped v
automatic voltage regulation and starting boost.
Never operate other power tools or appliances from the generator or transformer at the same time. Switch
other power tools 0r appliances on and otf may cause undervoltage and / or overvoltage peaks, resultinq
damage to the power tool.

Rated voltage
current input 11.5A
Rated frequency 50 Hz
Rated speed under no load 11,000 r.p.m.
Cutting disc Diameter 5"
Dimensions(LxHxW) mm (11.9685 in) x 103 mm
82 mm (12 in x 4.1 in x 3.2 in)
(without accessories) 1.85 ks (4.1 lbs)
Inlormalion aboul the power tool and applicalions
Drive spindle thread (arbor size) %Io 11"
m
WARNING
Never use lhe power tool without the guard.
5.1 Filling the side handle
WARNING
The side handle must be fitted for all types of work.
The side handle may be screwed onto the power tool
on the right or left.
5,2 Working with lhe power tool
Take care t0 ensure that the closed side of the guard
is always positioned toward the operator's body.
Adlust the position of the guard to suit the require-
ments of the work being done.
Close the guard adjustment release knob before op-
erating the power tool.
5.2.1 Fitting the guard El
NOTE
The guard is equipped with locating lugs that ensure
only guards 0f a type suitable for use with the power
t00l can be fitted. The locating Iugs of the guard fit
into the guard mount on the power tool.
Power lool DCG 500-S
Protection class Protection class I (grounded) or protection class ll
(double insulated). See type identification plate.
1. Disconnect the supply cord plug from the power
outl et.
2. Fit the guard onto the drive spindle collar so that
the two triangular marks on the guard and on the
power tool in alignment.
3. Press the guard 0nto the drive spindle collar;
press the guard release button and then rotate
the guard until it engages and the guard release
button jumps back to its outset position.
5.2.2 Adiusting lhe guard El
1. Disconnect the supply cord plug fr0m the power
o utlet.
2. Press the guard release button and then rotate
the guard until it engages in the desired position.
5.2.3 Removing th€ guard
1. Disconnect the supply cord plug from the power
o utlet.
2. Press the guard release button and then rotate
the guard until the triangular marks on the guard
and the power tool are in alignment.
3. Lift off the guard.

5.3 Filling lhe cutting / grinding disc E
DANGER
Gheck that the speed rating printed on the cutting
or grinding disc is equal to or higher lhan the rated
speed ol lhe power lool.
DANGER
Gheck lhe condition of the grinding disc before
using it. Do nol use discs that are broken, cracked
or damaged in any way.
1. Disconnect the supply cord plug from the power
outlet.
2. Fit the clamping f lange onto the drive spindle.
3. Fitthe diamond disc, cutting disc or grinding disc.
4. Screw on the clamping nut and tighten it.
5. GAUTION Do nol press the spindle lockbutton
belore lhe drive spindle has slopped rotaling.
Press the spindle lockbutton and hold it in this
position.
6. Use the pin wrench to tighten the clamping nt
securely and then release the spindle lockbuttor
5.4 Botating the gearing section El
NOTE
To allow the power tool to be used safely and withor
fatigue in all positions (e.9. on / off switch facin
upwards), the gearing section can be rotated to 0r
of four positions at 90' intervals.
1. Disconnect the supply cord plug from the powt
o utlet.
2. Clean the power tool.
3. Remove the side handle from the power t001.
4, Removethefourscrewsfromthe gearing sectior
5. Rotate the gearing secti0n t0 the desired positic
without pulling it away from the power tool.
6. Secure the gearing section by inserting and tigh
ening the four screws.
7. Fit the side handle.
lll!/
AA
WARNING
Test new culting 0r grinding discs by allowing lhem
l0 run al maximum speed in a prolecled area f0r al
least 30 seconds.
WARNING
SIits cut in loadbearing walls of buildings or other
structures may influence the statics 0f the structure,
especially when steel reinforcing bars or load-bearing
components are cut through. Consult lhe slruclural
engineer, archilecl, 0r person in charge ol lhe
building project belore beginning the work.
WARNING
The electric supply voltage must comply with the
inlormalion given on the type identification plate
on the oower lool.
WARNING
Always use lhe side handle with lhe power tool.
CAUTION
Use clamps or a vice to hold lhe workpiece securely.
WARNING
Cutting or grinding may cause splintering of tl
material. Wear eye proleclion.
CAUTION
Breathing prolection must be worn if lhe power l0
is used without a dusl removal system lor work tlr
creates dusl.
CAUTION
Wear ear prolectors. Exposure t0 noise can cal]
hearing loss.
WARNING
Avoid louching rotating parts. Switch lhe power to
on only after bringing il into position al the w0
piece. Touching rotating parts, especially rotatr
drill bits, discs or blades, etc. may lead to inlury.
CAUTION
The insert tool may get hot during use. Wear proler
ive gloves when changing insefl lools.
WARNING
Reduce the load on lhe power tool by avoidir
lilling the disc in the kerf when cutting. The d

may otherwise break, or the power tool may kick back
or stall,
CAUTION
lmprove the blood circulalion in your fingers by
relaxing your hands and exercising your lingers
during breaks belween wo*ing.
WARNING
Keep inflammable materials away from the working
area.
6.1 Switching on i ofl
6.1.1 Switching on
1. Plug the supply cord into the power outlet.
2. Press the rear section of the on / off switch.
3. Slide the on / off switch forward.
4. Lock the on / off switch.
6.1.2 Switching off
Press the rear section of the on / off switch. The on /
off switch jumps back to the off-position.
6.2 Restart interlock
NOTE
lf the power tool is unplugged from the electric
supply while the on / off switch is locked in the
on-position and subsequently plugged back into the
electric supply, it will not restart. The switch lock must
be released while the power tool is disconnected f rom
the electric supply before the supply cord is again
plugged into the power outlet.
CAUTION
Disconnect the supply cord plug from the power
outlet.
7.1 Care ol lhe power tool
NOTE
The outer casing of the power tool is made from
impact-resistant plastic. Sections of the grip are made
from a synthetic rubber material.
Clean the ventilation slots carefully using a dry brush.
Do not permit foreign objects t0 enter the interior of
the power tool.
Clean the outside of the power tool at regular intervals
with a slightly damp cloth.
D0 not use a spray, steam pressure cleaning equip-
ment or running water for cleaning. This may negat-
ively 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.
7.2 Maintenance
WARNING
Do not operate the power tool if parts are damaged
or when the controls do nol funclion laultlessly.
Have lhe powel l00l repaired by Hilli Service.
WARNING
Repairs lo lhe electrical seclion ol lhe power lool
may be carried out 0nly by lrained eleclrical spe-
cialists.
Check all external parts of the power tool for damage
at regular intervals and check that all controls operate
fau ltlessly.
7.3 Checking the power lool afier care and
mainlenance
After carrying out care and maintenance work on
the power tool, check that all protective and safety
devices are fitted and that thev function faultlesslv.
Discs ol max. S" diameler for max. 11000 r.p.m. and a max. peripheral speed of 80 m/sec
Abrasive cutting disc AC-D Universal Premium
Abrasive cutting disc AC-D Universal Super Premium
Abrasive cuttino disc AC.D INOX
Abrasive grinding disc AG-D Universal Premium

Abrasive grinding disc AG-D Universal Super Premium
Abrasive grinding disc AF-D abrasive flap disc
Diamond cutting disc DC-D 5'
Diamond grinding disc DG-CW 5"
llems not supplied by Hilti
Wire brushes
Rubber backing pads
Accessories for the DCG 500-5
Toolbox
Vacuum cleaner VCU 40 / VCD 50
Faull Possible cause Remedy
The Dower tool doesn't start lnterrupti0n in the electric supply. Plug in another electric appliance
and check whether it works.
The supprv cord or prus is derective XfJj-ll'd'if'l#,lir?ii-:i:fl*
and replaced if necessary.
The carbon brushes are worn. Have it checked by a trained
electrical specialist and replaced il
necgssary.
Theoowertooldoesn'tachieve The extension cord's conductor Use an extension cord with an
adeouate conductor cross secti0n.full power. cross section is inadeouate.
Most of the materials from which Hilti tools or machines are manufactured can be recycled. The materials mu
be correctly separated before they can be recycled. In many countries, Hilti has already made arrangemel
for taking back your old tools for recycling. Please ask your Hilti customer service department or ||
representative for further information.
Hilti warrants that the to0l suoolied is free of defects
in material and workmanship. This warranty is valid
so long as the tool is operated and handled correctly,
cleaned and serviced properly and in accordance with
the Hilti 0perating Instructions, and the technical
system is maintained. This means that only original
Hilti consumables, c0mp0nents and spare parts m
be used in the tool.
This warranty provides the free-of-charge repair
replacement of defective parts only over the ent
lifespan of the tool. Parts requiring repair or replar

ment as a result 0f normal wear and tear are not
covered by this warranty.
Additional claims are excluded, unless slringenl na-
tional rules prohibit such exclusion. In particular,
Hilti is nol obligaled lor direct, indirect, incidenlal
or consequential damages, losses or expenses in
conneclion wilh, or by reason of, the use of, or
inability t0 use the lool for any purpose. lmplied
warranties 0l merchantability or fitness fol a par-
licular putpose 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 marketino or0anizati0n
orovided.
This constitutes Hilti's entire obligation with regard
to warranty and supersedes all prior or c0ntemp0r-
aneous comments and oral or written aoreements
concerning warranties.