TYROLIT Hydrostress HYDROSTRESS FGE 450 Operational manual

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10999145_en
EN Floor grinding machine FGE 450
Translation of the original operating manual 4...........................

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Fig. B
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EN Floor grinding machine FGE 450
3
EN Floor grinding machine FGE 450
Translation of the original operating manual
Manufacturer: TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon ZH
Telephone: [phone]
Telefax: [phone]
URL: www.tyrolit.com
Document: 10999145_en
Publishing date: 16.01.2018
TYROLIT Hydrostress AG
TYROLIT Hydrostress AG reserves all rights. Any
reproduction, use or distribution of this original opera
ting manual or the translations of the original opera
ting manual, in whole or in part, is prohibited without
the express written permission of TYROLIT Hydrost
ress AG. If the product described here is altered wi
thout the consent of the manufacturer, then said ma
nufacturer is not responsible for any damage that
may be incurred. Any such actions will void the war
ranty.
Contents
Key to the illustrations 3.......................
1 Important notes 4..........................
1.1 Symbols used 4........................
1.2 Liability and warranty 4..................
2 Safety 4...................................
2.1 Accident prevention and safety 4.........
2.2 Safety instructions 5....................
3 Operating 6................................
3.1Startingupthemachine 6...............
3.2 Operation 7............................
3.3 Switching the machine off 7..............
4 Maintenance 8.............................
4.1 Customer service and spare parts 8.......
4.2 Tilting the machine 8....................
4.3 Mounting and dismantling ETX diamond tools 8...
4.4 Mounting and dismantling surface mills 8..
4.5 Mounting the ETX locating plate 8........
4.6 Cleaning the machine 8.................
4.7 Checking electrical components 9........
4.8 Final tasks 9...........................
5 Acceptance and transportation 9.............
5.1 Machine acceptance 9..................
5.2 Transporting the machine 9..............
6 Technical data 10...........................
7 Declaration of Conformity 11..................
8 Troubleshooting 12..........................
Key to the illustrations
Pos. Fig. Designation
1A/B Guide handle
2A/I Switch box
3A/D Clamping lever
4A/I Tank
5A/I Drive motor
6A/F Carrier handle
7 A Safety hood
8 A Dust cover
9 A Velcro strip
10 A/I Transport wheel
11 BLever (water supply)
12 BSafety switch
13 BPower plug (CEE 16 A)
14 B Pole reverser
15 BON switch (green)
16 BOFF switch (red)
17 CWater connection
18 CPlug connection
19 CConnection to the dust extraction
20 FScrews
21 GBolt
22 JPolycrystalline diamonds (PCD)
23 JMetal bonded diamonds
24 JSynthetic resin bonded diamond pads
25 KETX locating plate
26 K Recess
27 KETX diamond tool
28 K Fixing screw (ETX)

1 Important notes
EN Floor grinding machine FGE 450
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1 Important notes
The machine may be used only with the accessories
supplied by the manufacturer for stripping, wet grin
ding, and dry grinding of even, level floor surfaces
such as:
—cement
—screeds
—synthetic resin screeds / asphalt
—natural stone floors
—residual adhesive or filling compound
—floor remnants (e.g. foam backing)
Any other use of the machine can lead to dangerous
situations and is prohibited!
To ensure correct use of the machine, follow the in
structions in the operating manual, paying particular
attention to any warnings and instructions relating to
operation and maintenance!
Before using the machine, the opera
ting personnel must carefully read and
understand this operating manual!
Keep this operating manual close at
hand for easy reference!
Read and observe documents and
operating manuals provided by sup
pliers!
If the machine is on loan to other parties, the opera
ting manual must be provided with the machine and
its importance must be made clear!
1.1 Symbols used
The following symbols are used in this documentation:
Safety instructions
This symbol indicates warnings, prohibitions and
instructions regarding potential hazards. These
instructions must be obeyed and closely
observed.
Some safety instructions are accompanied by
corresponding symbols.
Additional information
This symbol indicates additional information.
1.2 Liability and warranty
TYROLIT Hydrostress AG
All rights, including those pertaining to translation, lie
with TYROLIT Hydrostress AG.
Liability or warranty is excluded if:
—The instructions in the operating manual have
not been observed.
—The machine or its attachments were improperly
operated.
—The maintenance was carried out inadequately
or incorrectly.
—Specified spare parts were not used.
—The protective equipment was not used, has
been altered or was removed.
—The specified power supply ratings and
surrounding conditions have not been observed.
The manufacturer is not liable for any damage that
may result if the user makes any changes to the ma
chine without the manufacturer’s permission. Any
such actions will void the warranty.
2 Safety
This chapter contains a summary of the most important
information on safety when handling the machine.
2.1 Accident prevention and safety
The following instructions comply with legislation, di
rectives, and publications including:
—EU Machinery Directive
—EU Product Liability Directive
—Law governing technical materials
—Law governing equipment safety
—Law governing product liability
This operating manual is intended for operators and
tool setters, as well as for the personnel that service,
maintain and repair the machine. Together with all
the technical documentation, it is intended to help
—avoid hazardous situations
—use the machine for its intended applications
—avoid downtime and repair costs
—maintain the function of the machine
—extend the service life of the machine.
The manufacturer and owner of the machine must re
spect the contents and provisions of the EU directives.
The effectiveness of any measure ultimately depends
on how well all parties, i.e. the manufacturer, the owner
and the machine operators, work together to uphold
safety standards.
Warning Prohibition Direction

2 Safety
EN Floor grinding machine FGE 450
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All laws and regulations (e.g. the valid regulations on
waste disposal), accident prevention guidelines and
generally recognised safety rules must be complied
with when working on and with the machine.
2.2 Safety instructions
This machine incorporates state of the art technology
and has been built in accordance with recognised
safety regulations. This ensures that the highest possi
ble standards of occupational safety are maintained.
However, incorrect use of the machine could endanger
the health and lives of the personnel or cause material
damage.
The machine may only be operated by people who
have been assigned to do so and who have the ap
propriate training and skills.
If any defects are found in the machine that
could endanger people or damage property,
stop the machine immediately and ensure that it
cannot be used again until all repairs are com
pleted.
The operating and maintenance personnel resp
onsible for the machine must ensure that no one
can enter the machine's danger zone during
operation or maintenance work.
Persons with pacemakers are not permitted to
work with the machine!
Risk of injury if safety equipment has been
removed or is non-functional!
The safety equipment must be checked for com
pleteness and function before starting up.
The safety equipment must be mounted during
operation.
The surfaces to be processed by the machine
must be free of obstacles.
Warning signs [!Fig. E/H] must be in a legible
condition!
Risk of injury from rotating machine parts!
Limbs and clothing can be drawn in.
Proceed with the greatest care and caution!
When working on the machine (set-up, mainte
nance, service, repair, cleaning, etc.), the power
supply of the machine has to be disconnected
from the mains
(disconnect power plug)!
High-voltage electrical current can be fatal!
Only connect the machine to power supplies
equipped with a ground fault circuit breaker
(type B)!.
Connections with mains cables
must be protected from splash water!
Only suitably knowledgeable, qualified profes
sional electricians may perform work on any
electrical parts of the system.
Risk of poisoning due to harmful substances at
the workplace!
Eating, drinking and smoking at the workplace is
not permitted. Always eat in break rooms or
canteen areas!
After completing the work, thoroughly clean
yourself!
A general inspection of the machine must be
conducted before starting up the machine. Parti
cular attention should be paid to damaged or
loose components, and wear.
The machine may only be put into operation in
perfect technical condition.
Adding to or modifying the machine in any way
that could compromise operating safety is prohi
bited!

3 Operating
EN Floor grinding machine FGE 450
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Cleaning and maintenance may be done only by
trained personnel.
Maintenance must be conducted according to
the operation manual.
Do not use high pressure cleaners to clean the
machine!
Do not operate the machine in areas where
there is risk of explosion or where flammable
materials are present.
3 Operating
Risk of injury from parts flung out during grin
ding!
Wear protective clothing and protective goggles.
Wear safety shoes!
Wear safety gloves!
Proceed with the greatest care and caution!
Danger of injury from loud noise during grinding
operation of the machine!
Always wear hearing protection when the ma
chine is in operation!
Risk of injury from dust formation during grin
ding work!
Connect an extractor unit to the machine or feed
in water during the grinding process.
Wear respiratory protection!
3.1Startingupthemachine
Observe the safety instructions in Chapter 2!
The initial start-up of the machine may be car
ried out only by qualified personnel.
A visual inspection of the machine must be car
ried out before starting up the machine.
Particular attention should be paid to damaged
or loose components, wearing and filling levels.
Always use ETX diamond tools or abrasive bonding
for the surface to be machined (e.g. some surfaces
require wet grinding).
1. Disconnect the power plug [13, Fig. B] from the
mains.
2. Check ETX diamond tools for function and con
dition and replace if necessary
(!Chapter 4.3 ‐ page 8).
3. Check the surface to be ground and remove any
protruding objects.
4. Either (dry grinding)
—Attach external dust extraction at the
connection to the dust extraction
[19, Fig. C].
or (wet grinding)
—Check the water level in the tank [4, Fig. A]
and refill if necessary.
5. Grip the guide handle [1, Fig. A/B] or secure
against dropping and open the clamping lever
[3, Fig. A/D].
The guide handle is unlocked.
6. Set the guide handle to the desired position.
Operation begins in the standard position
[Fig. A].
The stretched position is intended for tool
change and for maintenance. The machine can
then be tilted backward.

3 Operating
EN Floor grinding machine FGE 450
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For transporting the machine, the guide handle
can be swivelled to the front position.
7. Close the clamping lever (Fig. E).
The guide handle is locked.
8. Place the grinding tool on the surface to be
ground.
9. Check the dust cover [8, Fig. A] for proper posi
tion and function and, if necessary, correct.
There should be a 3 ... 4 mm gap between the
dust cover and the grinding surface.
10. Check the safety equipment for completeness and
function before starting up.
Risk of damage due to tensile strain exerted by
the power line!
The electric outlet serving as the power supply
should be supported and installed according to
local regulations.
Risk of injury from inadvertent starting of the
machine!
Before plugging in the power plug, make sure
the machine is switched off.
11. Join the connecting cable (extension cable) with
the proper power socket and plug the connection
cable's coupling in the power plug [13, Fig. B].
The machine is ready for operation.
3.2 Operation
Risk of damage and injury from uncontrolled
movement of the machine!
Before pressing the safety switch, the machine
has to be held firmly by the handle of the guide
bar.
High-voltage electrical current can be fatal! Do
not allow the power line to be run over, crushed
or pulled on!
The direction of work always has to be away
from the socket / extractor unit.
1. Hold the machine by the guide handle
[1, Fig. A/B].
The surface to be ground can now be machined.
2. Activate and secure the safety switch
[12, Fig. B].
3. Press the green ON switch [15, Fig. B].
The drive is switched on.
The tool mount rotates.
4. For wet grinding, press the lever (water supply)
[11, Fig. B] according to the required amount of
water (empirical value).
3.3 Switching the machine off
Observe the safety instructions in Chapter 2.
Risk of injury from a still-rotating ETX locating
plate, even after the machine is switched off!
Only switch off the machine with the tools res
ting on the floor.
The tool mount can otherwise still rotate idly
(run-on) for several seconds after being swit
ched off or the safety switch is released.
1. Release the safety switch [12, Fig. B].
2. Press the red ON switch [16, Fig. B].
The machine is switched off
Risk of injury from high voltage!
There is still residual voltage even after the ma
chine has been switched off.
The power supply has to be disconnected to
remove all voltage from the machine.

4 Maintenance
EN Floor grinding machine FGE 450
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4 Maintenance
Observe the safety instructions in Chapter 2!
The operating and maintenance personnel resp
onsible for the machine must ensure that no one
can enter the machine's danger zone during
operation or maintenance work.
Maintenance work may only be performed by
trained specialists! They must be familiar with
the dangers associated with such work, protect
themselves and avoid danger!
When working on the machine (set-up, mainte
nance, service, repair, cleaning, etc.), the power
supply of the machine has to be disconnected
from the mains
(disconnect power plug)!
Perform cleaning and maintenance work in ac
cordance with the operating manual and check
the safety equipment for completeness and
functionality.
4.1 Customer service and spare parts
In case of customer service queries, replacement parts
or repairs, please contact the manufacturer. To ensure
your queries are dealt with as quickly as possible, al
ways quote your machine data. These are located on
the machine’s nameplate.
4.2 Tilting the machine
Before tilting the machine, always make sure
that it is on an even, level floor surface!
1. Disconnect the power plug [13, Fig. B] from the
mains.
2. If necessary, activate the lever [11, Fig. B] and
empty the tank [4, Fig. A/I].
3. Swivel and lock the guide handle [1, Fig. AB]
into the stretched position (!Chapter 3.1).
4. Tilt the machine and place it on the floor
(Fig. HI).
4.3 Mounting and dismantling ETX diamond tools
The consistency of the surface to be ground determines
the type or composition of the tools to be used.
All ETX diamond tools authorised for this ma
chine [Fig. J] are removed and mounted in the
same manner.
Always mount 3 tools of the same type and de
gree of wear per ETX locating plate according to
the processing specifications.
Each ETX locating plate must be equipped with
the same number of tools.
1. Tilt the machine (!Chapter 4.2).
2. Gently tap with a lump hammer to loosen the
tools [27, Fig. K] from the EXT locating
plate [25, Fig. K] and then remove.
3. Insert new tools into the recess [26, Fig. K] of
the ETX locating plate and press firmly in the
direction of the arrow (use lump hammer if ne
cessary).
All locating plates must be equipped with dia
mond tools of the same type and the same
quantity. The heights of the diamond tools (de
gree of wear) must also be the same.
4. Set the machine upright, swivel and lock the
guide handles in standard position (!Chapter
3.1).
4.4 Mounting and dismantling surface mills
1. Tilt the machine (!Chapter 4.2).
2. Fasten the three surface mills with the supplied
screws (3 each, M8) to the ETX locating pla
tes [25, Fig. K].
3. Set the machine upright, swivel and lock the guide
handle in standard position (!Chapter 3.1).
All locating plates must be equipped with com
plete surface mills of the same type. The degree
of wear on all surface mill elements must be
identical.

5Acceptance and transportation
EN Floor grinding machine FGE 450
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4.5 Mounting the ETX locating plate
1. Tilt the machine (!Chapter 4.2).
2. Push the ETX locating plate [25, Fig. K] onto the
guide bolts and screw tight with the central fixing
screw M8x20 [28, Fig. K].
3. Set the machine upright, swivel and lock the
guide handle in standard position
(!Chapter 3.1).
4.6 Cleaning the machine
1. Tilt the machine (!Chapter 4.2).
2. Clean the machine and tools dry with a cloth or
suitable agents.
3. Set the machine upright, swivel and lock the
guide handle in standard position
(!Chapter 3.1).
4.7 Checking electrical components
Only suitably knowledgeable, qualified profes
sional electricians may perform work on any
electrical parts of the system.
Risk of fire due to faulty electrical cables!
—Check the mains cable and power plug regularly
for functional safety.
4.8 Final tasks
Either decommission the machine
a. Disconnect the power plug [13, Fig. B] from
the mains.
b. If necessary, activate the lever [11, Fig. B]
and empty the tank [4, Fig. A/I].
Reduce the projection if necessary:
c. Swivel and lock the guide handle in the
front position (over the drive motor)
(!Chapter 3.1).
or
—Restart the machine
(!Chapter 3.1 Ć page 6).
5Acceptance and transportation
Observe the safety instructions in Chapter 2.
5.1 Machine acceptance
The packaged machine is supplied complete from the
manufacturer.
1. Unpack machine and check the delivery slip to
make sure all parts are delivered.
2. Check for any transportation damage.
3. In case of damage, contact the transport com
pany promptly.
4. Report any problems to the manufacturer imme
diately.
Complaints at a later date cannot be acknowled
ged!
5.2 Transporting the machine
The machine may only be transported if it has
been switched off and the ETX locating plate is
at a standstill!
Do not lift any additional loads together with the
machine!
During transport, the guide handle [1,Fig.A/B]
should always be locked in position [3,Fig.A/D]
with the clamping lever!
Risk of injury from heavy loads!
During transport, the specified threshold values
for lifting and carrying must be observed!
Use devices for lashing and transporting the unit
that have been rated to handle its full weight
and dimensions. Observe weight data on packa
ging or in the accompanying documentation!
The crane hook or lashing gear may only be
attached at the specified position [!Fig. E]!
Wear safety shoes!
Wear safety gloves!

6 Technical data
EN Floor grinding machine FGE 450
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Suspended loads can fall or tip over, causing
serious injuries!
Raising and lowering the load must be per
formed by two persons!
Do not raise loads any higher than necessary!
Do not stand under suspended loads!
Prevent the load from swinging back and forth!
Keep sufficient safety distance.
Never walk or reach beneath the load while it is
being lowered.
Proceed with the greatest care and caution!
For longer transports or longer storage, the ma
chine must be covered to protect against soiling.
The machine can be separated into 2 parts for transport
and fastened to pallets to protect it against damages.
A relocation over shorter distances is possible on the
transport wheels.
1. Decommission the machine (!Chapter 4.8)
2. Either
a. Fasten all loose parts to the frame.
b. Move the machine to the respective loca
tion with the transport wheels [10, Fig. A/I]
and deposit.
or
a. Unplug the plug connection [18, Fig. C],
water connection [17, Fig. C] and if ne
cessary the connection to the dust extrac
tion [19, Fig. C].
Risk of injury from to tipping carriage!
The following tasks (b. to d.) must be carried
out by 2 persons! One person has to hold the
carriage by the guide handle [1, Fig. A/B].
b. Loosen the 4 screws [20, Fig. F] as far as
possible without removing, so that the bolts
[21, Fig. G] are movable.
c. Push the bolts into the open position
[Fig. G].
d. Disconnect drive from the frame.
e. If necessary (e. g. for lorry transport),
screw the 4 screws [20, Fig. F] tightly and
fasten all loose parts on the frame.
f. Move drive and frame to the respective lo
cation and deposit.
g. If necessary, lift drive and frame onto a sui
table transport device (e.g. a palette). If
necessary, use suitable lashing gear (belts
or ropes).
Always secure the machine according to regu
lations during lifting or transport by a vehicle or
suitable devices and strap down with tension
belts.
6 Technical data
Designation FGE 450
Rated voltage 400 V, 3
Rated frequency 50/60 Hz
Rated current 10 A
Rated power 2,2 kW
Connecting cable 5 x min. 2,5 mm2(max. 25 m)
5 x min. 4,0 mm2(>25 m)
Tool Speed 1200 rpm
Protection rating IP 23
Dust extraction 50
Tank capacity about 10 litres
Dimensions (L x W x
H) ca. 800x 600 x 1050 mm
Working width 450 mm
Edge distance min. 10 mm
Grinding wheel 3x180 mm
Grinding pressure 82 kg
Weight 106 kg
Noise level *) 79 dB
*) determined under standardised manufacturer ope
ration conditions according to measuring method
HARM.

7 Troubleshooting
EN Floor grinding machine FGE 450
11
7 Troubleshooting
Only suitably knowledgeable, qualified profes
sional technicians may perform repairs on the
machine.
Malfunction Cause Rectification
Machine will not start. The voltage supply has not been
properly connected. Join the connecting cable (extension cable) with the proper power socket
and plug the connection cable's coup
ling in the power plug [13, Fig. B].
Connecting cable is defective. Replace connecting cable.
Safety switch [12, Fig. B] is defective. Replace safety switch.
When using an extraction,
the suction housing sucks
itself to the floor.
Distance between rubber ring and the
surface to be ground is too little. Correct the distance between rubber lip and the surface to be ground
(!Chapter 3.1 ‐ page 6).
Grinding pattern is uneven. Tools are loose. Fasten tools.
Tools are damaged or worn. Replace tools.
Machine shuts down
automatically. Machine is overloaded. The drive overload protection (MOP)
has triggered.
—Select other tools if needed
(!Chapter 4.3, 4.4 - page8).
—Reset:
a. Disconnect the power plug
[13, Fig. B] from the mains.
b. Wait 30 seconds.
c. Restart the machine
(!Chapter 3.1 Ć page 6).
Connecting cable (extension cable) is
too long. The minimum cross section and the maximum length of the connecting ca
ble (extension cable) !Chapter 6
Faulty power supply. Check the connecting cable (extension
cable) and replace if necessary.
Use a different power socket if ne
cessary.
Tool mount turning in the
wrong direction. Polarity error Replace the pin with the pole re verser [14, Fig. B] (use a screwdriver).
Use a different power socket if ne
cessary.

8 Declaration of Conformity
EN Floor grinding machine FGE 450
12
8 Declaration of Conformity
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon ZH
Switzerland
We hereby declare that the machine
FGE 450
complies with the provisions described in
— Directive 2006/42/EG
Machine
— Directive 2014/30/EU
Electromagnetic Compatibility
The following harmonised standards apply:
— ISO 12100
Safety of Machinery
— EN 60204‐1
Electrical Equipment of Machines
— EN 61000-6-2/EN 61000-6-4
Electromagnetic Compatibility
This declaration is no longer valid if the machine is
modified or retrofitted without our prior consent and
approval.
Pfäffikon, den 16.1.2018
Pascal Schmid
Development manager and responsible for the
technical documentation

13

TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon ZH
Switzerland
Telefon: [phone]
Telefax: [phone]
URL: www.tyrolit.com