Festool DSG-AG 125 User manual

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Dia grinding system DSG-AG 125
1 Technical data
Exhaust Cover DCG-AG 125
Exhaust hose 27/36 mm
Weight 0.38 kg
Angular grinder AG 125-14 DE
Voltage 220 – 240 V~
Frequency 50 / 60 Hz
Input 1400 W
Idle revolutions 3500 – 11000 min–1
Circumferential speed 80 m/s
Grinding wheel max. 125 mm
Grinding spindle thread M 14
Limits to interaction current •
Revolutions pre-setting •
Constant electronics •
Heat protection •
Weight 2,3 kg
Protection level II /
2 Symbols
Double insulation
Warning of general danger
Risk of electric shock
Use protective goggles!
Wear ear protection!
Read the instructions
Not to be included in municipal refuse
 Advice or tip
3 Control elements
[1-1] Exhaust Cover
[1-2] Bar guide
[1-3] Threading for clamping and additional
handle
[1-4] Revolutions pre-setting
[1-5] Power cable
[1-6] Angular grinder
[1-7] On/off switch
[1-8] Additional handle
[1-9] Spindle locking plunger
[1-10] Brush ring
[1-11] Sliding front segment
[1-12] Lever
Accessories that are illustrated or described here
are not always included in the scope of delivery.
The specifi ed illustrations can be found at the be-
ginning of the operating instructions.
4 Intended use
The Dia grinding system consists of an angle
grinder and extraction hood, and is designed for
dust-free grinding of mineral materials, smooth-
ing unevenness, removing paint, concrete, adhe-
sive and plaster as well as preparing surfaces for
new coatings.
The user proper is responsible for improper us-
age.
5 Notes on Safety Prevention
5.1 General safety instructions
WARNING! Read all safety warnings and
all instructions. Failure to follow the warn-
ings and instructions may result in electric
shock, fi re 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 bat-
tery-operated (cordless) power tool.
5.2 Safety instructions for all operations
General safety instructions for grinding:
a) This power tool is intended to function as a
grinder. Read all safety warnings, instruc-
tions, illustrations and specifi cations provided
with this power tool. Failure to follow all in-
structions listed below may result in electric
shock, fi re and/or serious injury.
b) Operations such as sanding, wire brushing,
polishing or cutting-off are not recommended
to be performed with this power tool. Opera-
tions for which the power tool was not designed
may create a hazard and cause personal injury.
c) Do not use accessories which are not specifi -
cally designed and recommended by the tool
manufacturer. Just because the accessory can
be attached to your power tool, it does not as-
sure safe operation.
GB

14
d) The rated speed of the accessory must be at
least equal to the maximum speed marked
on the power tool. Accessories running faster
than their rated speed can break and fl y apart.
e) The outside diameter and the thickness of
your accessory must be within the capacity
rating of your power tool. Incorrectly sized
accessories cannot be adequately guarded or
controlled.
f) The arbour size of wheels, fl anges, backing
pads or any other accessory must properly fi t
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 bal-
ance, vibrate excessively and may cause loss
of control.
g) Do not use a damaged accessory. Before each
use inspect the accessory such as ABRASIV
wheels for chips and cracks, backing pad for
cracks, tear or excess wear, wire brush for
loose or cracked wires. If power tool or ac-
cessory is dropped, inspect for damage or
install an undamaged accessory. After in-
specting 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 min-
ute. Damaged accessories will normally break
apart during this test time.
h) 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
workshop apron capable of stopping small
ABRASIV or workpiece fragments. The eye
protection must be capable of stopping fl ying
debris generated by various operations. The
dust mask or respirator must be capable of
fi ltrating 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 acces-
sory may fl y away and cause injury beyond im-
mediate area of operation.
j) Hold 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 shock the operator.
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.
l) Never lay the power tool down until the acces-
sory has come to a complete stop. The spin-
ning 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 hous-
ing and excessive accumulation of powdered
metal may cause electrical hazards.
o) Do not operate the power tool near fl ammable
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.
Further safety instructions for all operations
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 ABRASIV 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. ABRASIV wheels may also break under
these conditions.
Kickback is the result of power tool misuse and/
or incorrect operating procedures or conditions
and can be avoided by taking proper precautions
as given below.
a) Maintain a fi rm 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 ac-
cessory. Accessory may kickback over your

15
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 fre-
quent kickback and loss of control.
Further safety instructions
-The machine may not be used in damp and wet
spaces, outdoor when it is rainy, foggy or snowy
or in the explosive environment.
-Before use always inspect the fl exible lead and
the plug. Have the defects repaired by a spe-
cialist repair shop.
-Outside the premise use only approved exten-
sion leads and cable connections.
-Apply the machine to the material only when
switched on.
-Do not carry the machine by the lead.
-Do not work on a ladder.
-When operating the tool, use protective gloves
and tough footwear.
-When operating the tool, use goggles and ear
protectors.
-The dust generated during work is harmful to
health. When operating the tool, use the dust
extraction system and the respirator.
-Materials containing asbestos can only be pro-
cessed by qualifi ed individuals. Comply with the
safety regulations that apply in your country.
-Flexible power supply cable always route from
the tool backwards.
-Only use milling rings recommended by the
manufacturer.
-The machine is only allowed be used when pro-
tective guard is in place and additional handle
is fastened.
-Plug in the fl exible power supply cable’s plug
into the wall socket when the machine is off.
-Make yourself sure whether the material that is
going to be machined does not contain electric,
water or gas lines – an injury could occur.
-Do not mill over metal objects, nails or screws.
-The machine is not allowed to be operated by a
person under 16 years of age.
-Only for AS/NZS: The tool shall always be sup-
plied via residual current device with a rated re-
sidual current of 30 mA or less.
-When clamping, be careful about the direc-
tion of rotation marked on the label and/or the
diamond tool, which must be the same as the
direction of the actual rotation of the machine
used.
-The fl ange and fastening nuts must be properly
tightened.
-Use a tool with specifi cations suitable for the
worked material – cf. the information on the
diamond tool and its packaging.
-Avoid mechanical damage to the diamond tool,
whether by force, impact or heat.
6 Emission levels
Measured values determined according to EN
60745.
Typically the A-weighted noise level of the tool
are:
Sound pressure level: 90 dB (A)
Sound power level: 101 dB (A)
Inaccuracy of measurement K = 3 dB (A)
CAUTION
Operating noise
Damage to hearing
Use ear protection!
Measured values determined according to EN
60745.
Vibration emission value ah = 4,0 m/s²
Inaccuracy of measurement K = 1.5 m/s²
The specifi ed emissions values (vibration, noise)
– are used to compare machines.
– They are also used for making preliminary esti-
mates regarding vibration and noise loads during
operation.
– They represent the primary applications of the
power tool.
Increase possible for other applications, with oth-
er insertion tools or if not maintained adequately.
Take note of idling and downtimes of machine!

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7 Safety elements assembly
WARNING
Risk of accident, electric shock
Always pull the plug out of the socket before
performing any type of work on the machine.
CAUTION
Always use the additional handle to guarantee
a safe, non-tiring working posture.
7.1 Exhaust cover
Assembly [2]
Removal [2 a]
7.2 Brush ring
Assembly [3]
Removal [3 a]
7.3 Additional holder
Special construction “VIBRASTOP” regulates the
vibrations with additional holder [1-8].
7.4 Dust extraction
WARNING
Dust hazard
Always work with a dust extractor.
To ensure suction, put the hose of a Festool vacuum
cleaner class M or H into the suction adapter [1-2].
Warning: Always work with the suction connect-
ed. Use exclusively antistatic vacuum cleaners to
prevent discharges of static electricity in dusty
environments.
8 Fastening the grinding wheel
WARNING
Do not use quick-change nuts for clamping the
disc!
WARNING
Only use diamond grinding discs recommended
by the manufacturer and the prescribed fl ang-
es included with the cover and the grinder [4].
-For reasons of safety, always use original Fes-
tool sanding discs!
-If the permissible revolution speed is given on
the disc, it must not be lower than the highest
no-load speed of the grinder.
-Discs with a permissible peripheral speed of
80m/s and higher may be used.
-Test new grinding discs by letting them run for
about one minute with no load.
-Unbalanced or vibrating discs should not be
used and should be discarded.
-Protect grinding discs from shock, impact and
lubricants.
-For diamond discs with inner diameter of
22.2mm, insert spacer ring [4-4].
8.1 Assembly with standard fastening nut
Clean the fl ange [4-2] and fastening fl ange [4-
3] and grinding wheel fastening areas.
Mount the fl ange [4-2] with shoulder out to
grinding wheel [4-1].
Mount grinding wheel. Flange shoulder must
fi t the grinding wheel aperture.
9 Activation
WARNING
Risk of accident if the machine is operated us-
ing unauthorised voltages or frequencies.
The mains voltage and the frequency of the
power source must correspond with the spec-
ifi cations on the machine’s name plate.
In North America, only Festool machines with
the voltage specifi cations 120 V/60 Hz may
be used.
9.1 Switching on – off
Switching on
Slide the on/off switch [1-7] forwards.
Continuous operation: pressing the front part
of the switch at the same time locks the on/
off switch.
The electric power tool starts.
Only make contact with the material once the
machine has reached operating speed.
Switching off
Lift the electric power tool from the processed
material.
Release the on/off switch [1-7].
During continuous operation: press on the
rear part of the on/off switch [1-7].

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WARNING
Risk of injury
Rebound, ejected parts
Before setting down the machine, wait until
the rotating tool has come to a complete stop.
9.2 Motor electronics
Starting current limitation
Electronically controlled continual running se-
cures device acceleration without back thrust.
WARNING
Devices without starting current limitation
need higher protection – at least 16A circuit
breaker.
Switching off during back thrust
During sudden drop of revolutions, for example
blocking in dividing cut, the current input in mo-
tor stops. For re-starting, the device must be fi rst
switched off and again switched on.
Protection against re-starting
Prevent uncontrolled starting of the device after
current supply cut off. For re-starting, the device
must be fi rst switched off and again switched on.
Revolutions pre-setting
Use the revolutions regulator [1-4] for smooth
revolutions pre-setting.
1 3500 min–1 4 7600 min–1
2 4600 min–1 5 8900 min–1
3 6000 min–1 6 11000 min–1
Required number of revolutions depends on ap-
plied grinding wheel and worked material.
Constant electronics
Constant electronics maintains revolutions during
operation and idle run near the constant. Regular
operating shift is achieved.
Protection from overloading dependant on tem-
perature
The safety electronics switches to cooling regime
when the critical temperature is reached. Motor
continues running at approximately 50 % revolu-
tions, constant electronics is deactivated.
After cooling to approximately 10 – 20 s, the device
is fully operational.
Heat protection for devices heated during opera-
tion, reacts adequately sooner.
9.3 Turning the gear box
For special cases, the gearbox can be turned in
steps of 90°. This achieves a better handling posi-
tion of the switch.
For such work, we recommend to use the Festool
service.
Remove four screws.
Carefully, turn the gearbox into required position.
Make sure the gearbox does not separate from
motor box by more than approximately 1mm.
Insert and fasten the four screws [5].
9.4 Sliding front segment [6]
For working close to edges.
10 Service and maintenance
WARNING
Risk of accident, electric shock
Always pull the plug out of the socket before
performing any type of work on the machine.
All maintenance and repair work which re-
quires the motor housing to be opened, must
only be carried out by an authorised service
workshop.
- Wrapped electric tools can be stored in a dry
place without heating, with temperatures not
lower than –5°C. Unwrapped electric tools can
only be stored in dry places with temperatures
not lower than +5°C, without sudden changes
in the temperature.
-To ensure the airfl ow is suffi cient, cooling
openings of the motor must be always clean
and free.
-The machine is equipped with special self-
disconnecting brushes. When the brushes are
worn, the power supply is automatically discon-
nected, and the machine is stopped.
-If the suction fl ange height adjustment system
does not operate smoothly, the fl ange must be
removed and cleaned.
Customer service and repair. Only
through manufacturer or service work-
shops: Please fi nd the nearest address
at: www.festool.com/service
EKAT
1
235
4
Use only original Festool spare parts! Or-
der No. at: www.festool.com/service

18
11 Environment
Do not throw the power tool in your household
waste! Dispose of the machine, accessories and
packaging at an environmentally-responsible re-
cycling centre! Observe the valid national regula-
tions.
EU only: In accordance with European Directive on
waste electrical and electronic equipment and im-
plementation in national law, used electric power
tools must be collected separately and handed in
for environmentally friendly recycling.
Information on REACh:
www.festool.com/reach
12 EU Declaration of Conformity
Dia grinding system Serial no.
AG 125-14 DE
(Basis for DSG-AG 125)
200107
Year of CE mark: 2013
We declare under sole responsibility that this
product comply with all relevant requirements
of the following directives, norms or normative
documents:
2006/42/EG, 2004/108/EG (until 19.04.2016),
2014/30/EU (from 20.04.2016),
2011/65/
EU , EN 62233, EN 60745-1:2009, EN 60745-
2-3:2011+A2:2013, EN 55014-1:2006+
A1:2009+A2:2011, EN 55014-2:1997+Corrigen-
dum 1997+A1:2001+A2:2008, EN 61000-3-2:2006+
A1:2009+A2:2009, EN 61000-3-3:2013.
Festool GmbH
Wertstr. 20, D-73240 Wendlingen
Dr. Johannes Steimel
Head of Research, Development and Technical
Documentation
2015-03-02