China Honway Machinery HWG 400 Assembly instructions

China Honway Machinery Co.,LTD
Operator’s Instruction Manual
Floor Grinder HWG 400
China Honway Technology Co.,LTD
5bldg Changhua Park. Yuelu District, Changsha, China
Tel [phone]
Fax [phone]
Cell Phone: [phone]
Email: [e-mail]
Website: www.honwaymachinery.com

KEYTO
SYMBOLS
Symbols on the machine:
WARNING! The machine can be a
dangerous tool if used incorrectly or
carelessly, which can cause serious or
fatal injury to the operator or others.
Symbols in the operator’s manual:
Inspection and/or maintenance should be
carried out with the motor switched off and
the plug disconnected.
Always wear approved protective gloves.
Please read the operator’s manual
carefully and make sure you understand the
instructions before using the machine.
Regular cleaning is required.
Wear personal protective equipment. See
instructions under the heading ”Personal
protective equipment”.
Visual check.
WARNING! Dust forms when grinding,
which can cause injuries if inhaled. Use an
approvedbreathingmask.Alwaysprovidefor
good ventilation.
Protective goggles or a visor must be worn.
Starting: Reduce the pressure between
grinding disc and floor by pushing down on
the handle without raising the grinding unit
off the ground.
Environmental marking. Symbols on the
product or its packaging indicate that this
product cannot be handled as domestic
waste.
By ensuring that this product is taken care of
correctly, you can help to counteract the
potentialnegativeimpactontheenvironment
and people that can otherwise result through
the incorrect waste management of this product.
For more detailed information about recycling this product,
contact your municipality, your domestic waste service or the
shop from where you purchased the product.
Other symbols/decals on the machine refer to special
certification requirements for certain markets.
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CONTENTS
Contents
KEYTO SYMBOLS
Symbols on the machine: .............................................
Symbols in the operator’s manual: ...............................
CONTENTS
Contents ......................................................................
WHAT IS WHAT?
What is what on the grinder? .......................................
SAFETY INSTRUCTIONS
Before using a new grinder ..........................................
Personal protective equipment .....................................
General safety precautions ..........................................
ASSEMBLY
Fit the handle ...............................................................
Changing the diamonds ...............................................
Connect the vacuum cleaner .......................................
Transport ......................................................................
GRINDING GUIDE
Diamonds .....................................................................
Determining the hardness of concrete .........................
Diamond selection .......................................................
The motor’s direction of rotation ..................................
STARTING AND STOPPING
Before starting .............................................................
Starting ........................................................................
Stopping .......................................................................
MAINTENANCE
Faults and trouble shooting ..........................................
Maintenance ................................................................
Service .........................................................................
TECHNICAL DATA
Technical data ..............................................................
EC-declaration of conformity ........................................
WIRING DIAGRAM
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WHAT
IS WHAT?
What is what on the grinder?
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2
3
4
5
6
7
8
9
Electric box
Cover
Crank for adjusting grinding pressure
Lifting eye
Electric motor
Lifting handle
Skirt
Connection for vacuum cleaner
Wheel set
11 Screws, cover
12 Grinding plate
13 Grinding pads
14 Handle / handlebar
15 Control Panel
16 Start button
17 Emergency stop
18 Stop button
19 Locking knob for handlebar adjustment
10 Cover locking knob
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SAFETY INSTRUCTIONS
Before using a new grinder
Personal protective equipment
•
Please read the operator’s manual carefully and make
sure you understand the instructions before using the
machine.
Grinders WGS400E are designed for surface removal of
glue/adhesive residues, putty and the like from concrete
floors and grinding and flattening out concrete floors.
WGS400E has a single disc, fixed speed.
The machine can cause serious personal injury.Read the
safety instructions carefully.Learn how to use the
machine.
Only staff that have received the necessary education,
both practically and theoretically concerning their usage
should operate the machinery.
machine. Personal protective equipment
•
•
•
•
•
Protective helmet
Hearing protection
Protective goggles or a visor
•
Always use common sense
It is not possible to cover every conceivable situation you can
face. Always exercise care and use your common sense.
Avoid all situations which you consider to be beyond your
capability. If you still feel uncertain about operating
procedures after reading these instructions, you should
consult an expert before continuing.
Do not hesitate to contact your dealer if you have any more
questions about the use of the machine.We will willingly be of
service and provide you with advice as well as help you to use
your machine both efficiently and safely.
Let your dealer regularly check the machine and make
essential adjustments and repairs.
All information and all data in the Operator’s Manual were
applicable at the time the Operator’s Manual was sent to print.
•
Breathing mask
•
Heavy-duty, firm grip gloves.
•
Tight-fitting, heavy-duty and comfortable clothing that
permits full freedom of movement.
you modify the original design of the
machine without approval from the
!
drill, sand or shape material can generate
•
Boots with steel toe-caps and non-slip sole.
•
Always have a first aid kit nearby.
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WARNING! Use of products which cut, grind,
dust and vapors which may contain harmful
chemicals. Know the nature of the material
being worked on and wear appropriate dust
mask or respirator protection.
WARNING! Under no circumstances should
!manufacturer. Always use original spare
parts. Unauthorized modifications and/or
accessories may lead to serious injury or
death to the user or others.
WARNING!You must use approved personal
!protective equipment whenever you use the
cannot eliminate the risk of injury but it will
reduce the degree of injury if an accident
does happen. Ask your dealer for help in
choosing the right equipment.
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SAFETY INSTRUCTIONS
General safety precautions
Personal safety
!
lead to circulatory damage or nerve damage
information is never a substitute for
symptoms of overexposure to vibration.
feeling, tingling, pricking, pain, loss of
condition.These symptoms normally appear
• Do not use the machine without first reading and
understanding the contents of this Operator’s Manual.
Work area safety
•
Wear personal protective equipment. See instructions
under the heading ”Personal protective equipment”.
Never use the machine if you are tired, if you have drunk
alcohol, or if you are taking medication that could affect
your vision, your judgment or your co-ordination.
Never allow anyone else to use the machine without first
ensuring that they have understood the contents of the
operator’s manual.
All operators shall be trained in the use of the machine.
The owner is responsible for ensuring that the operators
receive training.
People and animals can distract you causing you to lose
control of the machine.For this reason, always remain
concentrated and focused on the task.
Be careful as clothing, long hair, and jeweler can get
caught in moving parts.
Never leave the machine unsupervised with the motor
running.
Make sure that there is always another person close at
hand when you use the machines,so that you can call for
help if an accident should occur.
Always ensure you have a safe and stable working
position.
•
Do not use the machine in bad weather, such as dense
fog, rain, strong wind, intense cold, etc.
Keep work area clean and well lit.Cluttered or dark areas
invite accidents.
The machine should not be used in areas where potential
for fire or explosions exist.
•
•
•
•
Electrical safety
•
•
unfavourable weather conditions and body
•
•
•
Never drag the machine by means of the cord and never
pull out the plug by pulling the cord.
Keep all cables away of water, oil and sharp edges. Make
sure the cable is not pinched in doors, fences or the like.
It can cause the object to become live.
Check that the cables are intact and in good condition.
Use cable intended for outdoor use.
Never use the machine if any cable is damaged, but hand
it in to an authorized service workshop for repair.
The machine should be connected to an earthed outlet
socket.
Checkthat themainsvoltagecorresponds with thatstated
on the rating plate on the machine.
Be on your guard for electrical shocks.Avoid having body
contact with lightning-conductors/metal in the ground.
Do not use an extension cord while it is rolled up to avoid
overheating.
Ensure the cord is behind you when you start to use the
machine so that the cord will not be damaged.
•
•
•
•
•
•
•
•
•
•
WARNING!There is always a risk of shocks
!from electrically powered machines. Avoid
contact with lightning conductors and metal
objects. Always follow the instructions in the
Operator’s manual to avoid damage.
WARNING! Overexposure to vibration can
in people who have impaired circulation.
Contact your doctor if you experience
Such symptoms include numbness, loss of
strength, changes in skin color or
in the fingers, hands or wrists.These
symptoms may be increased in cold
temperatures.
WARNING!This section describes basic
!safety directions for using the machine.This
professional skills and experience. If you get
into a situation where you feel unsafe, stop
and seek expert advice. Contact your dealer,
service agent or an experienced user. Do not
attempt any task that you feel unsure of!
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SAFETY INSTRUCTIONS
Use and care
•
•
Only use the machine for the purpose it was intended for.
Keep all parts in good working order and ensure that all
fixtures are properly tightened.
Never use a machine that is faulty.Carry out the checks,
maintenance and service instructions described in this
manual. Some maintenance and service measures must
be carried out by trained and qualified specialists. See
instructions under the heading Maintenance.
Do not modify safety equipment. Check regularly that they
function as they should.The machine must not be run with
defective or disassembled safety equipment.
Never use a machine that has been modified in any way
from its original specification.
Machinery should only be started when grinding heads
are resting on the ground unless carrying out a testing
procedure as outlined in this manual.
The machine should not be started without the rubber
dust skirt attached. It is essential a good seal between
machine and floor be established for safety, especially
when operating in dry grinding applications.
During grinding, the machine must be connected to a
vacuum cleaner to sucking off the dust.
Whenchanging the grinding discs ensure power supply to
the unit is OFF by engaging the Emergency Stop button
and the power-plug disconnected.
Aftereachgrinding/polishingoperationalways removethe
diamond tools.
Make sure that the rubber skirt is intact and clean and that
it seals tightly against the floor. Damaged rubber skirt
should always be replaced.
When removing glue, asphalt, paint etc. always raise the
machine from the surface after use to prevent it from
sticking to the floor due to the heat. Make sure the
grinding head has stopped rotating before raising the
machine.
Diamond tools may be very hot after use.Leave machine
to cool off before removing the diamond segments. Use
protective gloves.
Always use the machine mounted lifting eye when lifting.
Always carry the machine by the carrying handle and the
handle.
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•
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•
•
•
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Transport and storage
•
The machine should always be transported under cover
limiting the exposed to natural elements – in particular
rain and snow.
Store the equipment in a lockable area so that it is out of
reach of children and unauthorized persons.
The machine should always be stored in a dry place when
not in use.
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ASSEMBLY
Fit the handle
Changing the diamonds
•
Remove the screws (A).
Shut down the machine and disconnect the power plug.
Have a set of gloves ready, asdiamond tools can get very hot.
•
Crank up the handlebar to the highest position.
•
•
Remove the locking knobs (B).
Fit the handle in the handle stand-off on the machine.
•
•
Pull back on handle to lift grinding head off the ground.
Lay machine back on the ground.
•
•
Refit screws (A) and locking knobs (B).
The locking knobs should be positioned in-line with the
handlebar to reduce the risk of damaging the knobs when
laying down the machine when changing tools.
•
•
Put on gloves.
Use a hammer to remove the diamond segments.
•
Affix new diamond segments on the grinding disc.
•
Once new diamond segments have been attached,
reverse procedure to lower machine to ground.
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ASSEMBLY
Connect the vacuum cleaner
Connect the vacuum cleaner to the machine. Use a 50 mm
(2 inch) hose.
•
It is highly recommended to use the dust extraction
system for complete dust control.
Make sure that the filters in the vacuum cleaner are intact
and clean. Pay attention to dust during operation.
Adjust the rubber skirt to be in contact with the floor to
ensure efficient dust collection.
•
•
Transport
The machine can be folded to minimize space needed for
transport.
•
Loosen the screws and the lock handle that hold thecover
in place.
•
•
Remove the cover.
Place the crank with the handle pointing straight upwards.
•
Carefully fold the machine forward. Put padding between
the motor and the electric box to prevent damage to the
machine.
•
The cover can be attached to the side of the machine.
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GRINDING GUIDE
Diamonds
•
•
•
•
•
Pressure.
Hardness of bond.
Diamond grit size.
Number of segments under the machine.
Adding an additionalabrasive (e.g.sand, silicone carbide)
on the floor will increase wear.
Background
Diamond abrasives usually consist of 2 components:
• Diamondpowder(also knownasdiamondcrystalsor grit).
By changing the size of the diamond powder or grit, we
can change how coarse or fine the scratches will be that
are left behind from the grinding process.
• A binding agent (metal or resin). Diamond powder is
mixed and suspended in either a metal or resin binding
agent.When suspended in a metal binding agent, the
finished product is referred to as a Metal Bond or Sintered
diamond segment.When suspended in a resin binding
agent, the finished product is referred to as a Resin Bond
diamond segment or pad.By changing the hardness of
the binding agent, we can change how fast or slow the
diamond abrasive will wear.
Generally, thefaster a diamond segment wears, thefaster the
productivity will be. By varying the above factors, changes
can also be made to effect the following:
•
•
•
•
Scratch pattern.
Current draw of machine.
Flatness of floor (see next section).
Ease of operation.
Determining the hardness of
concrete
All concretes are measured by their compressive strength
and depending on which part of the world you are from,
different compressive strength indices (e.g.PSi & MPa) are
used. Generally, the higher the compressive strength rating,
the harder the concrete and therefore, the harder it will be to
grind.
However, other factors beside compressive strength ratings
determine how hard the floor will be, and therefore, the
correct diamond selection.Since grinding normally onlydeals
with the surface of the concrete (top 5mm or 1/4 inch), often
the way the concrete floor has been finished or the condition
of the surface will have a greater bearing on what type of
diamond to select, rather than the compressive strength
rating of the concrete.
Surface factors to consider when making a diamond
selection
Generally, if a concrete surface is very smooth (i.e. Most likely
it has been heavily trowelled/helicopted), the concrete will
behave as if it has a high compressive strength and therefore,
require a soft bond segment.
Accordingly, if a concrete surface is coarse/aggressive (e.g.
rain-damaged, shot blasted, scarified, exposed aggregate
e.t.c.), the concrete will behave as if it has a low compressive
strength and therefore, require a hard bond segment.
Surface coatings/contaminants (e.g.Epoxy coatings, ceramic
tile adhesives, levellingcompounds/screeds) will often have a
larger bearing on what diamond to select, than will the
compressive strength of the concrete.
As a general rule, when grinding a concrete slab for the first
time and you are unsure about its hardness, always begin
with harder bond diamonds under the machine.This will
ensure the least amount of wear on the diamond segments.If
a hard diamond segment is not suited to the application, all it
has cost is a little amount of time without wearing out the
diamonds.
If performed the other way around (i.e.a soft segment is used
to begin with) and the concrete is soft or possesses an
abrasive surface or surfacecontaminant, it is quite possible to
wear-out a considerable amount of diamond in very short
period of time.
General Principles
The following are general rules regarding diamond segments
in grinding applications.As with all general rules there are
exceptions or cases when it is not the case.
Diamond grit size
Changing the size of the diamond grit to a smaller particle/grit
size will effect the performance of the diamond tool in the
following ways:
• Create a finer scratch pattern.
• Increase life of diamond tool.
The opposite will occur when changing to alarger particle/grit
size.
Binding agent
Increasing hardness of bond will:
•
•
•
Create a finer scratch pattern.
Increase life of diamond tool.
Decrease production rate.
The opposite will occur when making the metal or resin bond
softer.
Number of diamond segments/pads under the
machine
Increasing the number of segments under the machine will:
•
Reduce pressure on each individual diamond segment -
reduce wear rate on diamond segments.
Reduce load on the machine and cause the grinder to
draw less current.
Create a smoother scratch pattern (particularly on soft
floors).
•
•
The opposite will occur when decreasing the number of
segments under the machine.
Summary of diamond principles
Diamond segments need to wear in order to achieve
productivity.Diamond segmentwear can be influenced bythe
following factors:
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GRINDING GUIDE
Diamond selection
They way diamond segments are set-up on the grinding unit will greatly influence the performance of the machine, the productivity
levels and also the finished floor quality.
There are a number of different diamond configurations that can be achieved on WGS400E.
Metal bond diamonds
Full set - inner and outer row
Full set - outer row
Half set - inner and outer row
Half set - outer row
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GRINDING GUIDE
Select the correct metal bond diamonds for your application
The following suggestion cover the basic configurations for metal bonded diamond tools.
outer row
Applications
Metal
bond
Grit size
Full set - inner
and outer row
Full set -
outer row
Half set - inner
and outer row
Half set -
Flatten floor - Hard concrete
Soft
16 or 30
X
Flatten floor - Medium concrete
Medium
16 or 30
X
Flatten floor - Soft concrete
Hard
16 or 30
X
Ceramic tile adhesive removal
Medium
16-30
X
Vinyl or Carpet glue removal -
Hard concrete
Soft
16-30
X
X
Vinyl or Carpet glue removal -
Medium concrete
Medium
16-30
X
X
Vinyl or Carpet glue removal -
Soft concrete
Hard
16-30
X
X
Epoxy paint removal -
Hard concrete
Soft
16-30
X
X
Epoxy paint removal -
Medium concrete
Medium
16-30
X
Epoxy paint removal -
Soft concrete
Hard
16-30
X
Rain damaged concrete
Hard
16-30
X
X
Smoothen exposed aggregate
Hard
16-30
X
X
Lippage removal in terrazzo/stone
tiles
Soft
30 or 60
X
Surface polishing of concrete
floors - Hard concrete
Soft
60
X
X
Surface polishing of concrete
floors - Medium concrete
Medium
60
X
X
Surface polishing of concrete
floors - Soft concrete
Hard
60
X
X
Grinding to exposed aggregate in
concrete - Hard concrete
Soft
16-30
X
X
X
Grinding to exposed aggregate in
concrete - Medium concrete
Medium
16-30
X
X
X
Grinding to exposed aggregate in
concrete - Soft concrete
Hard
16-30
X
X
Flatten undulation in concrete
floors - Hard concrete
Soft
16 or 30
X
X
X
Flatten undulation in concrete
floors - Medium concrete
Medium
16 or 30
X
X
Flatten undulation in concrete
floors - Soft concrete
Hard
16 or 30
X
X
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GRINDING
GUIDE
Resin bond diamonds
Redi Lock resin attachment adaptor
Full set - outer row
Half set - outer row
Selecting the correct resin bond diamond configuration for your application
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Applications
Full set - outer row
Half set - outer row
Polishing terrazzo/stone tiles
X
Resurfacing terrazzo/stone tiles
X
Surface polishing of concrete floors - Hard concrete
X
Surface polishing of concrete floors - Medium concrete
X
Surface polishing of concrete floors - Soft concrete
X
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STARTING
AND STOPPING
Before starting
Stopping
•
•
Position grinder on the working area.
Make sure there are diamonds beneath the machine and
that they are firmly attached.
Connect the vacuum cleaner to the machine.
Use locking knobs for handlebar adjustment to set most
comfortable working height.
Plug power supply to machine.
Check that the emergency stop button is not pressed by
turning it clockwise.
•
Use the stop button to shut down the machine.
•
•
•
Keep grinding segments in contact with the floor when
stopping. This will help bring the machine to a complete
stop quickly. Do not lift the grinding head off the floor
when stopping as this can create a significant amount of
dust in the air.
•
•
•
Check the motor’s direction of rotation
Starting
•
Reduce the pressure between grinding disc and floor by
pushing down on the handle without raising the grinding
unit off the ground.
•
Press the start button and keep it pressed a few seconds
to start the machine.
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MAINTENANCE
Faults and trouble shooting
Maintenance
The machine will not run
• Check the power supply and the power cables and make
sure that they are not damaged.
• Check that the emergency stop button is not pressed by
turning it clockwise.
Machine is hard to hold onto
• Not enough diamonds underthe machine (if grinding thick
glue or soft floors, too few diamonds under the machine
will greatly increase the load on grinder and operator).
Usually also accompanied by high current draw by motor.
Increase number of diamonds under machine to reduce
load on grinder and operator.
Used correctly, the machine is anextremely low-maintenance
and reliable product.
Cleaning
Always pull out the plug from the outlet socket before
cleaning, maintenance or assembly.
Always clean all the equipment at the end of the working day.
Do not use a high pressure washer to clean the machine.
In order for the machine to always be cooled sufficiently the
cooling air openings must be kept clear and clean.
Machine is jumping around
• Rubber shock absorber pads ingrinding unit may be worn
out or damaged. Check and change if necessary.
• Diamonds may not be fitted correctly or have different
heights.Check to ensure all diamonds are fitted correctly
and are the same height.
Rubber shock absorber pads
Check the rubber shock absorbing pads every month.
Replace if necessary.
The machine stops after just a while
• The machine is overloaded and the overload protection
has been released.Reduce load.The machine will reboot
after about a minute when the motor has cooled off.
Electrical Feed
The machine stops during start-up
•
The electric motor has been overloaded or a phase is
missing. Allow the machine one or two minutes to
reset and try again.When this does not help, contact
an authorized service workshop.
injuries.
Check that the cord and extension cord are intact and in good
condition.
Never use the machine if the cord is damaged, hand it in to an
authorized service workshop for repair.
Skirt
Make sure that the rubber skirt is intact and clean and that it
seals tightly against the floor. Damaged rubber skirt should
always be replaced.
Service
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IMPORTANT! All types of repairs may only be carried out by
authorized repairmen. This is so that the operators are not
exposed to great risks.
WARNING! Never use damaged cables.They
!can cause serious, even fatal, personal
IMPORTANT! Inspection and/or maintenance should be
carried out with the motor switched off and the plug
disconnected.
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TECHNICAL
DATA
Technical data
Note 1: Noise emissions in the environment measured as sound power (LWA) in conformity with EN 61029-1.
Note 2: Noise pressure level according to EN 61029-1. Reported data for noise pressure level has a typical statistical dispersion
(standard deviation) of 1.0 dB(A).
PG 400 SF
Motor Power, kW/hp
4/5,4
Rated current, A
16
Rated voltage, V
400
Weight, kg/lbs
155/254
Grinding width, mm/inch
400/16
Grinding pressure, kg/lbs
65/143
Speed, rpm
1400
Noise emissions (see note 1)
Sound power level, measured dB(A)
107
Sound power level, guaranteed LWA dB(A)
108
Sound levels (see note 2)
Sound pressure level at the operators ear, dB(A)
89
Vibration levels (see note 3)
Handle right, m/s2
3,4
Handle left, m/s2
3,4
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WIRING
DIAGRAM
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