TYROLIT Hydrostress FGE 400 Operational manual

1
10999140_en
EN Floor grinding machine FGE 400
Translation of the original operating manual 4...........................

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EN Floor grinding machine FGE 400
4
EN Floor grinding machine FGE 400
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: 10999140_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.
Contents
1 Important notes 5..........................
1.1 Intended use 5.........................
1.2 Liability and warranty 5..................
1.3 Symbols used 5........................
2 Safety 5...................................
2.1 Accident prevention and safety 5.........
2.2 Safety instructions 6....................
3 Operating 7................................
3.1Startingupthemachine 7...............
3.2 Operation 8............................
3.3 Switching the machine off 8..............
4 Maintenance 9.............................
4.1 Customer service and spare parts 9.......
4.2 Attaching/Removing additional weights 9..
4.3 Tilting the machine 9....................
4.4 Mounting and dismantling ETX diamond tools 9...
4.5 Cleaning the machine 9.................
4.6 Checking electrical components 10........
4.7 Final tasks 10...........................
5 Acceptance and transportation 10.............
5.1 Machine acceptance 10..................
5.2 Transporting the machine 10..............
6 Troubleshooting 11..........................
7 Technical data 12...........................
8 Declaration of Conformity 13..................
Key to the illustrations
Pos. Fig. Designation
1A/B/J Guide handle
2A/B Power plug (CEE 16 A)
3A/G Clamping lever
4A/J Drive motor
5A/J Transport wheel
6A/J Connection to the dust extraction
7A/J Safety hood
8A/J Dust cover
9A/J Velcro strip
10 BOFF button
11 BON button
12 BSafety handle
13 C/E ETX diamond tool
14 C/E ETX locating plate
17 EETX holder
18 FCarriage height adjustment
19 FWater level
20 HCarrying bar
21 HKnob screw
22 JLashing gear
15 DMetal bonded diamonds
16 DSynthetic resin bonded diamond
pads
23 KBolt
24 LAdditional weight
25 LRecessed grip

1 Important notes
EN Floor grinding machine FGE 400
5
1 Important notes
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 needs to be provided with the machine
and its importance must be made clear!
1.1 Intended use
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
—Screed
—Natural stone
Any other use of the machine can lead to dangerous
situations and is prohibited!
Risk of damage!
The machine may not be used for milling bitu
men surfaces (e. g. roads, footpaths)!
Bitumen can adhere to the rotor, the housing
and the suction nozzle.
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!
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 safety devices were not used, have been
altered or were removed.
—The specified power supply ratings and surroun
ding 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 also void the warranty.
1.3 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.
2 Safety
This chapter contains a summary of the most import
ant information on safety when handling the machine.
2.1 Accident prevention and safety
The following instructions comply with legislation, di
rectives, and publications including:
—EC Machinery Directive
—EC General Product Safety 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.
Warning Prohibition Direction

2 Safety
EN Floor grinding machine FGE 400
6
The manufacturer and owner of the machine must
respect the contents and regulations of the EC direc
tives. The effectiveness of any measure ultimately
depends on how well all parties, i.e. the manufac
turer, the owner and the machine operators, work
together to uphold safety standards.
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 pos
sible standards of occupational safety are main
tained. However, incorrect use of the machine could
endanger the health and lives of the personnel or
cause material damage.
All laws and regulations (e.g. the valid regu
lations on waste disposal), accident prevention
guidelines and generally recognised safety rules
must be complied with when working on and
with the machine.
The surfaces to be processed by the machine
need to be free of obstacles and loose parts.
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.
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.
Warning signs [!Fig. R] must be in a legible
condition!
Adding to or modifying the machine in any way
that could compromise operating safety is prohi
bited!
Risk of injury if safety devices have been remo
ved or are non‐functional!
The safety devices must be checked for com
pleteness and function before starting up.
The safety devices must be mounted during
operation.
Do not operate the machine in areas where
there is risk of explosion or where flammable
materials are present.
The machine may only be operated by people
who have been assigned to do so and who have
the appropriate training and skills.
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.
Risk of injury from rotating machine parts!
Limbs and clothing can be drawn in.
Proceed with the greatest care and caution!
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!
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!

3 Operating
EN Floor grinding machine FGE 400
7
High-voltage electrical current can be fatal!
Only connect the machine to power supplies
equipped with a ground fault circuit breaker!.
Connections with mains cables
need to be protected from splash water!
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)!
Only suitably knowledgeable, qualified profes
sional electricians may perform work on any
electrical parts of the system.
Cleaning and maintenance may be done only by
trained personnel.
Maintenance needs to be conducted according
to the operation manual.
After completing the work, thoroughly clean
yourself!
3 Operating
Follow the safety instructions in Chapter 2.
Risk of injury from parts flung out during grin
ding!
Wear protective clothing and protective goggles.
Wear safety shoes and protective 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!
High-voltage electrical current can be fatal!
Take care not to run over, crush or pull on the
mains cable!
3.1Startingupthemachine
The initial start-up of the machine may be car
ried out only by qualified personnel.
A visual inspection of the machine needs to be
carried out before starting up the machine.
Particular attention should be paid to damaged
or loose components, and wear.
Always use ETX diamond tools or abrasive bonding
that are suitable for the given surface to be machined
(e.g. some surfaces have to be ground wet).
1. Disconnect the power plug [2, Fig. A] from the
mains.
2. Check ETX diamond tools for function and con
dition and replace if necessary.
(!Chapter 4.4 ‐ page 9).
3. Check the surface to be ground and remove any
protruding objects.
4. Attach external dust extraction at the connec
tions to the dust extraction [6, Fig. A].
5. Grip the guide handle [1, Fig. A] or secure
against dropping and open the clamping lever
[3, Fig. G].
The guide handle is unlocked.
6. Set the guide handle to the desired position.
— Operation is carried out in the standard posi
tion [!Fig. A].
—The stretched position is intended for tool
change and for maintenance. The machine can
then be tilted backward.
—For transporting the machine, the guide
handle can be swivelled to the front position
[!Fig. J/M/R].
7. Close the clamping lever.
The guide handle is locked.
8. Place the grinding tool on the surface to be
ground.
9. If necessary, attach additional weights (!
Chapter 4.2).
Alwaysbringthemachinetoastopbeforeac
tuating the carriage height adjustment!

3 Operating
EN Floor grinding machine FGE 400
8
10. Turn the carriage height adjustment [18, Fig. F]
until the machine is aligned horizontally ac
cording to the built-in water level [19, Fig. F].
11. Check the dust cover [8, Fig. A/J] for proper po
sition and function and, if necessary, correct or
exchange.
There should be a 3 ... 4 mm gap between the
dust cover and the grinding surface.
12. Check the safety devices for completeness and
function before starting up.
Risk of damage due to crushing or exerting
tensile strain on the mains cable and the suction
hose!
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.
13. Join the connecting cable (extension cable) with
the proper power socket and plug the connec
tion cable's coupling in the power plug
[2,Fig.A].
3.2 Operation
Follow the safety instructions in Chapter 2.
Risk of damage due to uncontrolled movement
of the machine!
Before actuating the safety handle, grip the ma
chine with both hands on the guide handle!
On a slope, the machine can quickly accelerate
out of the operator's control, and due to the high
centre of gravity, it could also tip over! If ne
cessary, use suitable auxiliary equipment (e. g.
cable winch)!
The machine can suddenly turn to the side
when it is started up! Make sure that it is stan
ding securely and that the guide handle is in the
correct position!
When the machine is in operation, do not touch
any part of the machine outside the gripping
range of the guide handle [1,Fig.A/B]!
1. If necessary, feed in water onto surfaces that
are to be ground wet.
2. Hold the machine by the guide handle.
3. Press the safety handle [12, Fig. B] against the
guide handle and grip in place.
4. Press the ON button [11, Fig. B].
The drive is switched on.
The ETX locating plate rotates [14, Fig. C].
The surface to be ground can now be machined.
3.3 Switching the machine off
Risk of injury from a still rotating ETX locating
plate even after the machine is switched off!
The tool mount can continue to turn in idle (run-
on) for several seconds after switch off!
When the tools have been set down on the floor
and the machine is switched off, even after swit
ching off or releasing the safety handle, the ma
chine can still turn by as much as 60°on its own
axis.
Do not release the guide handle until the ETX
locating plate is no longer turning!
1. Release the safety handle [12, Fig. B] and wait
for the ETX‐locating plate to come to a full stop.
If the ETX locating plate continues to rotate
(defective), press the red OFF button or pull the
power plug.
The drive has been switched off.
The ETX locating plate is no longer rotating.
2. Press the red OFF button [10, 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
(disconnect power plug)!

4 Maintenance
EN Floor grinding machine FGE 400
9
4 Maintenance
Follow 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 the plug) and the drive must be at a
standstill!
Perform cleaning and maintenance work in ac
cordance with the operating manual and check
the safety devices for completeness and functio
nality.
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 pos
sible, always quote your machine data. These are
located on the machine's nameplate.
4.2 Attaching/Removing additional weights
Risk of injury from heavy additional weights!
Only grip the additional weights at the recessed
handles [25, Fig. L]! Work with care!
1. Screw 2 bolts [23, Fig. K, spanner size 13] into
the safety hood [7, Fig. J].
2. As needed, grip 1 ... 3 additional weights
[24, Fig. L] and slide these over the bolts.
The removal is carried out in logical reverse
order.
4.3 Tilting the machine
Before tilting the machine, always make sure
that it is on an even, level floor surface!
1. Disconnect the power plug [2, Fig. A] from the
mains.
2. Swivel and lock the guide handle [1, Fig. A] in
the stretched position (!Chapter 3.1).
3. Remove additional weights (!Chapter 4.2).
4. Tip the machine and place it on the floor
(!Fig. C/N/R).
4.4 Mounting and dismantling ETX diamond tools
The consistency of the surface to be ground de
termines the type or composition of the tools to be
used.
All of the ETX diamond tools [!Fig. D] authori
zed for this machine are removed and mounted
in the same manner.
Always mount tools of the same type according
to the processing specifications. The heights of
the diamond tools (degree of wear) must be the
same.
1. Tilt the machine (!Chapter 4.3).
2. Gently tap with a lump hammer to loosen the
tools [13, Fig. E] from the EXT locating
plate [14, Fig. C/E] in the direction of the centre
and then remove.
3. Insert new tools in the ETX holder [17, Fig. E]
and press toward the outer edge of the ETX lo
cating plate (use lump hammer if necessary).
4. Set the machine upright, swivel and lock the
guide handle in standard position
(!Chapter 3.1).
4.5 Cleaning the machine
Do not use high pressure cleaners or com
pressed air to clean the machine!
1. Tilt the machine (!Chapter 4.3).
2. After use, clean the machine and tools with a
dry method such as a vacuum cleaner with a
suitable filter, a cloth or a brush.
3. Set the machine upright, swivel and lock the
guide handle in standard position
(!Chapter 3.1).

5 Acceptance and transportation
EN Floor grinding machine FGE 400
10
4.6 Checking electrical components
Only suitably knowledgeable, qualified profes
sional electricians may perform work on any
electrical components of the machine.
Risk of fire due to faulty electrical cables!
—Check the mains cable and power plug regularly
for functional safety.
4.7 Final tasks
Either decommission the machine
—Disconnect the power plug [2, Fig. A] from
the mains.
Reduce the projection if necessary:
—Swivel the guide handle into the front posi
tion (over the drive motor) and lock it in
place (!Chapter 3.1, Fig. J/M/R).
or
—Restart the machine
(!Chapter 3.1).
5 Acceptance and transportation
Follow 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!
Risk of injury from heavy loads!
Suspended loads can slide out of place, fall or
tip over and cause serious injuries.
Never walk under or reach under suspended
loads!
Raising and lowering the load must be performed
by two persons!
Do not raise loads any higher than necessary!
Prevent the load from swinging back and forth!
Keep sufficient safety distance.
Devices for transporting the unit have to be
rated to handle its full weight and dimensions.
Observe weight data on packaging or in the ac
companying documentation.
Do not lift any additional loads together with the
machine!
Wear safety shoes!
Wear safety gloves!
During transport, the guide handle [1,Fig.A/J]
must always be locked in posi
tion [3, Fig. G/M/R] with the clamping lever!
The crane hook or lashing gear may only be
attached at the specified position
[!Fig. J/M/R]!
The machine can be fastened to pallets to protect it
against damages. A relocation over shorter distances
is possible on the transport wheels.
1. Switch off the machine (!Chapter 3.3).
2. Fasten any loose parts to the machine.
3. Either
(moving machine over short distances)
—Move the machine to the respective loca
tion with the transport wheels [5, Fig. A/J]
and deposit.

6 Declaration of Conformity
EN Floor grinding machine FGE 400
11
or
(hoisting or carrying the machine over short
distances, 2 people)
a. Remove additional weights (!Chapter
4.2).
b. Loosen the knob screws [21, Fig. H], slide
the carrying rods to the front [20, Fig. H]
and then tighten the knob screws again.
c. Grip the machine by the
guide handle and the carry
ing rods (!Fig. P), move it
to the respective location,
and set it down.
d. Loosen the knob screws, slide the carrying
rods to the back, and tighten the knob
screws again.
or
(for transport over longer distances)
a. Remove the additional weights (!Chapter
4.2) or fasten them securely to the ma
chine (e.g. lash them on with tension
belts).
b. Swivel the guide handle into the front posi
tion (over the drive motor) and lock it in
place (!Chapter 3.1, Fig. J/M/R).
c. Use suitable lashing gear to hoist the ma
chine (!Fig. J/M/R) and lower it onto a
suitable transport device (e.g. a pallet).
The grinding plate and the wheels must rest on
the transport device!
d. When transporting the machine with a ve
hicle or suitable transport device, always
ensure that the machine is secured (e.g.
strapped in with tension belts) according to
regulations.
e. Move the machine to the respective loca
tion and set it down.
For longer transports or longer storage, the ma
chine needs to be covered to protect against
soiling.
6 Declaration of Conformity
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon ZH
Switzerland
We hereby declare that the machine
FGE 400
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

7 Troubleshooting
EN Floor grinding machine FGE 400
12
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 [2, Fig. A].
Connecting cable is defective. Replace connecting cable.
Safety handle [12, Fig. B] is defec
tive.
Repair or replace safety handle.
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).
Grinding pattern is uneven. Tools are loose. Fasten tools.
Tools are damaged or worn. Replace tools.
Machine shuts down by itself. Machine is overloaded.
The drive overload protection (MOP)
has triggered.
—Select other tools if necessary
(!Chapter 4.4 ‐ page 9).
—Reset:
a. Disconnect the power plug
[2,Fig.A]fromthemains.
b. Wait 30 seconds.
c. Restart the machine (!
Chapter 3.1).
Connecting cable (extension cable) is
too long.
The minimum cross section and the
maximum length of the connecting
cable (extension cable)!Chapter 8
Faulty power supply. Check the connecting cable
(extension cable) and replace if ne
cessary.
Use a different power socket if ne
cessary.
Drive motor is turning, but the
ETX locating plate is not tur
ning.
Toothed belt is loose or torn. Tighten or replace toothed belt.
Please contact the manufacturer.

8 Technical data
EN Floor grinding machine FGE 400
13
8 Technical data
Designation FGE 400
Rated voltage 400 V, 3
Rated frequency 50 Hz
Rated current 8,5 A
Rated power (6) 4 kW
Connecting cable 5 x min. 2,5 mm2(max. 25 m)
5 x min. 4,0 mm2(>25 m)
Tool speed 900 rpm
Protection rating IP 23
Dust extraction 50 mm
Dimensions (L x W x H) ca. 650 x 450 x 750 mm
Working width 400 mm
ETX locating plate 400 mm
Edge distance min. 10 mm
Grinding pressure 32 ... 64 kg
Weight 109 kg
Noise level 79 dB(A)
Vibration total value *) ±2,5 m/s2
*) determined under standardised manufacturer operation conditions according to measuring method HARM.

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