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Original operating instructions

Information about the documentation

Explanation of signs used

Warnings

Warnings alert persons to hazards that occur when handling or using the product. The following signal words are used in combination with a symbol:
Image alternative DANGER! Draws attention to imminent danger that will lead to serious personal injury or fatality.
Image alternative WARNING! Draws attention to a potential hazard that could lead to serious personal injury or fatality.
Image alternative CAUTION! Draws attention to a potentially dangerous situation that could lead to slight personal injury or damage to the equipment or other property.

Symbols

The following symbols are used in this document:
Image alternative Read the operating instructions before use.
Image alternative Instructions for use and other useful information

Symbols on the product

The following symbols are used on the product:
Image alternative Wear eye protection.
Image alternative Revolutions per minute
Image alternative Revolutions per minute
Image alternative Rated speed
Image alternative Diameter
Image alternative Protection class II (double-insulated)

Characters in illustrations

The illustrations in these operating instructions are intended to promote a better understanding and may deviate from the actual version of the product.
Image alternative These numbers refer to the corresponding illustrations found at the beginning of these operating instructions.
Image alternative The numbering reflects the order of the work steps in the illustration and may deviate from the numbering of work steps in the text.
Image alternative Item reference numbers are used in the overview illustration and refer to the numbers used in the product overview section.

Product information

Hilti products are designed for professional use and may be operated, serviced and maintained only by trained, authorized personnel. This personnel must be informed of any particular hazards that may be encountered. The product described and its ancillary equipment may present hazards when used incorrectly by untrained personnel or when used not as directed.
  • Make a note of the designation and serial number printed on the identification plate in the following table.
  • Always quote this information when you contact a Hilti representative or Hilti Service to enquire about the product.
    Product information
Product information
Angle grinder
DCG 230-DB
Generation
01
Serial no.

Safety

Safety instructions

The safety rules given in the following section contain all general safety rules for electric tools which, in accordance with the applicable standards, require to be listed in the operating instructions. Accordingly, some of the rules listed may not be relevant to this electric tool.

General power tool safety warnings

Image alternative WARNING
Read all safety warnings and all instructions. Failure to follow the warnings and instructions may 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.
Work area safety
  • Keep work area clean and well lit. Cluttered or dark areas invite accidents.
  • Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
  • Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
Electrical safety
  • Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
  • Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
  • Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
  • Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
  • When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
  • If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.
Personal safety
  • Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
  • Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
  • Prevent unintentional starting. Ensure the switch is in the off‐position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or 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 balance 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.
Power tool use and care
  • Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
  • Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
  • Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
  • Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
  • Maintain power tools. 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.

Safety warnings common for grinding, sanding, wire brushing, polishing or abrasive cutting-off operations:

  • Do not use accessories which are not specifically designed and recommended by the tool manufacturer. Just because the accessory can be attached to your power tool, it does not assure safe operation.
  • The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.
  • The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories cannot be adequately guarded or controlled.
  • Threaded mounting of accessories must match the grinder spindle thread. For accessories mounted by flanges, the arbour hole of the accessory must fit the locating diameter of the flange. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.
  • Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks, backing pad for cracks, tear or excess wear, wire brush for loose or cracked wires. If power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute. Damaged accessories will normally break apart during this test time.
  • Wear personal protective equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and workshop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.
  • Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpiece or of a broken accessory may fly away and cause injury beyond immediate area of operation.
  • Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory.
  • Never lay the power tool down until the accessory has come to a complete stop. The spinning accessory may grab the surface and pull the power tool out of your control.
  • Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.
  • Regularly clean the power tool’s air vents. The motor’s fan will draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.
  • Do not operate the power tool near flammable materials. Sparks could ignite these materials.
Kickback and related warningsKickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or any other accessory. Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncontrolled power tool to be forced in the direction opposite of the accessory’s rotation at the point of the binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may either jump toward or away from the operator, depending on direction of the wheel’s movement at the point of pinching. Abrasive wheels may also break under these conditions.
Kickback is the result of power tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.
  • Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start-up. The operator can control torque reactions or kickback forces, if proper precautions are taken.
  • Never place your hand near the rotating accessory. Accessory may kickback over your hand.
  • Do not position your body in the area where power tool will move if kickback occurs. Kickback will propel the tool in direction opposite to the wheel’s movement at the point of snagging.
  • Use special care when working corners, sharp edges etc. Avoid bouncing and snagging the accessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.
  • Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades create frequent kickback and loss of control.

Description

Overview of the product

Image alternative
  1. Spindle lockbutton
  2. Threaded bushing for the side handle
  3. Steadying rib
  4. On/off switch
  5. Release lever (for pivotable grip)
  6. Side handle
  7. Wrench
  8. Kwik lock quick-release clamping nut
  9. Abrasive cutting disc / abrasive grinding disc
  10. Hood
  11. Keyed locating lug
  12. Spindle
  13. Clamping lever
  14. Adjusting screw

Intended use

The product described is a hand-held electric angle grinder. It is designed for cutting and grinding metal and mineral materials without use of water. It may used only for dry cutting / grinding.

The tool may be operated only when connected to a power supply providing a voltage and frequency in compliance with the information given on its type plate.
  • The power tool may be used for cutting, slitting and grinding mineral materials only when equipped with the corresponding guard (optional accessory).

  • 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 working on mineral materials such as concrete or stone. These protect the operator and increase the life of the power tool and accessory tools used.

Items supplied

Angle grinder, side handle, guard, Kwik lock quick-release clamping nut, wrench and operating instructions.
You can find other system products approved for your product at your local Hilti Center or online at: www.hilti.com

Pivotable side handle

To allow the power tool to be used comfortably in all positions, the grip can be pivoted through 90° to the left and the right.

Starting current limitation

The electronic starting current limiter reduces the starting current drawn by the power tool and thus prevents the mains fuse blowing. It also allows the angle grinder to start smoothly, without a jolt.

Active Torque Control (ATC)

The electronics detect potential stalling of the disc and prevent further rotation of the drive spindle by switching off the tool.
If the ACT system has been triggered, restart the tool. Do this by releasing the on/off switch and then pressing it again.
If the ATC system malfunctions, the electric tool will run only at greatly reduced speed and with greatly reduced torque. Have the tool checked by Hilti Service.

Restart interlock

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

DC-EX 230/9" dust hood for cutting, with carriage (accessory)

Image alternative
The power tool may be used for cutting work on mineral materials only when fitted with a dust removal hood and guide carriage.
CAUTION Use of this hood for working on metal is prohibited.

Guard with cover plate

Image alternative
When grinding with straight grinding discs and cutting with cutting discs in metalworking applications, use the guard with cover plate.

Consumables

Only synthetic resin-bonded, fiber-reinforced discs with a maximum diameter of Ø 230 mm which are approved for use at a rotational speed of at least 6500/min and a peripheral speed of 80 m/s may be used.
Disc thickness must not exceed 8 mm.
WARNING! When cutting or slitting with abrasive cutting discs always use the guard with cover plate or a fully enclosing dust hood.
Discs

Application
Designation
Material
Abrasive cutting disc
Cutting, slitting
AC‑D
Metal
Diamond cutting disc
Cutting, slitting
DC‑D
Mineral
Abrasive grinding disc
Rough grinding
AG-D
metal
Suitability of discs for the equipment used
Item
Equipment
AC‑D
AG-D
DC‑D
A
Guard

X
X
B
Guard with cover plate
X

X
C
DC-EX 230/9" cutting guard


X
D
Side handle
X
X
X
E
DC BG hoop grip (optional for D)
X
X
X
F
Kwik lock quick-release clamping flange
X
X
X

Technical data

Angle grinder

When powered by a generator or transformer, the generator or transformer’s power output must be at least twice the rated input power shown on the rating plate of the electric tool. The operating voltage of the transformer or generator must always be within +5% and -15% of the rated voltage of the electric tool.
The information given applies to a rated voltage of 230 V. The data may vary in the event of deviations from the rated voltage and for country-specific versions. Please refer to the electric tool’s type identification plate for details of its voltage, frequency, current and input power ratings.
Rated power input
2,400 W
Rated power input (CH)
2,200 W
Rated speed
6,500 /min
Maximum disc diameter
230 mm
Weight in accordance with EPTA procedure 01/2003
6.8 kg
Drive spindle thread
M14
Thread length
18 mm

Noise information and vibration values determined in accordance with EN 60745

The sound pressure and vibration values given in these instructions have been measured in accordance with a standardized test and may be used to compare one electric tool with another. They may be used for a preliminary assessment of exposure.
The data given represents the main applications of the power tool. However, if the power tool is used for different applications, with different accessory tools or is poorly maintained, the data may vary. This may significantly increase exposure over the total working period.
An accurate estimation of exposure should also take into account the times when the power tool is switched off, or when it is running but not actually being used for a job. This may significantly reduce exposure over the total working period.
Identify additional safety measures to protect the operator from the effects of noise and/or vibration, for example: maintaining the power tool and accessory tools, keeping the hands warm, organization of work patterns.
Noise emission values determined in accordance with EN 60745-2-3
Sound (power) level (LWA)
101 dB(A)
Emission sound pressure level (LpA)
90 dB(A)
Uncertainty for the sound pressure level (KpA)
3 dB(A)
Total vibration (vector sum of three directions), measured in accordance with EN 60745-2-3Other applications, such as cutting, may produce vibration values that deviate from the given values.
Surface grinding with the vibration-absorbing side handle (ah,AG)
5.0 m/s²
Uncertainty (K)
1.5 m/s²

Before use

CAUTION
Risk of injury. The accessory tool may be hot or have sharp edges.
  • Wear protective gloves when fitting, removing or adjusting the accessory tool or other parts and when troubleshooting.

Fitting the side handle

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

Guard or guard with cover plate

  • Observe the instructions for fitting the applicable guard.

Fitting the guard or guard with cover plate

The keying on the guard ensures that only a guard designed for use with the power tool can be fitted. The keyed locating lug also prevents the guard from coming into contact with the disc.
Image alternative
  1. Release the clamping lever.
  2. Fit the guard onto the spindle collar so that the keyed locating lug engages in the recess provided.
  3. Rotate the guard to the required position.
  4. Secure the guard by closing the clamping lever.
    The guard is already set to the correct tension by way of the adjusting screw. If the tension is too low when the guard is fitted, the adjusting screw can be tightened slightly to increase the tension.

Adjusting the guard or guard with cover plate

Image alternative
  1. Release the clamping lever.
  2. Rotate the guard to the required position.
  3. Secure the guard by closing the clamping lever.

Removing the guard or guard with cover plate

  1. Release the clamping lever.
  2. Rotate the guard until the keyed locating lug is aligned with the keyed locating groove and then remove the guard.

Fitting and removing accessory tools

CAUTION
Risk of injury. The accessory tool may be hot.
  • Wear protective gloves when changing the accessory tool.
Diamond discs must be replaced when their cutting or grinding performance drops significantly. This generally is the case when the diamond segments reach a height of less than 2 mm (1/16").
Other discs must be replaced when their cutting performance drops significantly or other parts of the angle grinder (not the disc) come into contact with the material you are working on.
Abrasive discs must be replaced when their expiry date has been reached.

Adjusting the side handle

WARNING
Risk of injury. If the grip position is adjusted while the tool is in operation it is no longer possible to hold the tool in a stable position, resulting in a risk of accident.
  • Do not, under any circumstances, attempt to adjust the grip while the tool is running.
  • Check to ensure that the grip is engaged in one of the three possible positions.
Image alternative
  1. Disconnect the supply cord plug from the power outlet.
  2. Release the locking lever by pulling it back.
  3. Pivot the grip to the left or right as far as it will go.
  4. Secure the grip in position by closing the locking lever.
    The angle grinder cannot be switched on so long as the side handle is not locked in one of the three possible positions.

Operation

Grinding

CAUTION
Risk of injury. The accessory tool may suddenly stick or stall.
  • Use the power tool with the side handle (or optional hoop grip) fitted and always hold the power tool securely with both hands.

Cutting

  • When cutting, apply moderate feed pressure and do not tilt the power tool or, respectively, the cutting disc (hold at approx. 90° to the surface being cut).
    For best results when cutting profiles and square tube, start cutting at the smallest cross section.

Rough grinding

CAUTION
Risk of injury. The abrasive cutting disc could shatter and flying fragments may cause injury.
  • Never use abrasive cutting discs for grinding.
  • Move the power tool to and fro while maintaining a 5° to 30° angle of attack and applying moderate pressure.
    • This will avoid overheating and discoloration of the workpiece and help ensure an even surface finish.

Switch on and off

Switching on

  1. Plug the supply cord into the power outlet.
  2. Slide the on/off switch forward and then press it as far as it will go.
    • The motor runs.

Switching off

  • Release the on/off switch.

Care and maintenance

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

Care of the product

    DANGER
    Electric shock due to breakdown of protective insulation. When working on metal under extreme conditions, conductive dust may accumulate inside the power tool, thereby adversely affecting the protective insulation.
  • Use a stationary dust extraction system when working under extreme conditions.
  • Clean the air vents frequently.
  • Use a ground fault circuit interrupter (PRCD) in the electric power supply line to the power tool.
  • WARNING
    Electrical hazards. Improper repairs to electrical parts may lead to serious injuries.
  • Electrical parts may be repaired only by trained electrical specialists.
  • Never operate the product when the air vents are blocked. Clean the air vents carefully using a dry brush. Do not allow foreign objects to enter the interior of the product.
  • Keep the product, especially its grip surfaces, clean and free from oil and grease. Do not use cleaning agents containing silicone.
  • Clean the outer surfaces of the tool with a slightly damp cloth at regular intervals. Do not use a spray, steam pressure cleaning equipment or running water for cleaning.
    Frequent work on conductive materials (e.g. metal, carbon fiber) may make shorter maintenance intervals necessary. Take your individual workplace risk assessment into account.

Checks after care and maintenance work

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

Transport and storage

  • Do not transport the electric tool with an accessory tool fitted to it.
  • Always unplug the supply cord before storing the electric tool.
  • Store the product in a dry place where it cannot be accessed by children or unauthorized persons.
  • After long periods of transport or storage, check the electric tool for damage before use.

Troubleshooting

If the trouble you are experiencing isn’t listed in this table or you are unable to remedy the problem by yourself, please contact Hilti Service.
Trouble or fault
Possible cause
Action to be taken
The power tool doesn’t start.
Interruption in the electric supply.
  • Plug in another electric tool or appliance and check whether it works.
The supply cord or plug is defective.
  • Have the supply cord and plug checked by a trained electrical specialist and replaced if necessary.
The carbon brushes are worn.
  • Have the power tool checked by a trained electrical specialist and the carbon brushes replaced if necessary.
The restart interlock is active after disconnection or an interruption in the electric supply.
  • Switch the power tool off and then on again.
The tool doesn’t work.
The tool has been overloaded.
  • Release the on/off switch and then press it again. Then allow the power tool to run under no load for approx. 30 seconds.
The tool does not achieve full power.
The extension cord conductor cross section (gauge) is inadequate.
  • Use an extension cord with an adequate conductor cross section.
Malfunction in the ATC system.
  • Have the product repaired by Hilti Service.

Disposal

Image alternative Most of the materials from which Hilti tools and appliances are manufactured can be recycled. The materials must be correctly separated before they can be recycled. In many countries, your old tools, machines or appliances can be returned to Hilti for recycling. Ask Hilti Service or your Hilti representative for further information.
Image alternative
  • Do not dispose of power tools, electronic equipment or batteries as household waste!

Manufacturer’s warranty

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