Virginia Abrasives FG-11 User manual
Electric Floor Grinding Machine
Model FG-11
Operator’s Manual
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2!
SAFETY INSTRUCTIONS
Before using a new grinder
WARNING: Cutting, grinding, sawing, drilling, sanding,
or polishing construction materials and surfaces
generates dust and particulates which may be harmful if
inhaled. Dust collection, proper respiratory protection
and adequate ventilation should be maintained at all
times while engaging in these activities.
• Read the operator’s manual carefully and make
sure you understand the instructions and proper
applications prior to operating the machine.
• Your FG-11 floor grinder is designed for
concrete floor grinding, flattening concrete
floors, surface removal of coatings, glue, and
adhesive residues.
• This machine can cause serious personal injury.
Read safety instructions carefully. Become
thoroughly familiar with the proper use of the
FG-11. Only thoroughly trained personnel
should operate this equipment.
Always use good judgement
It is not possible to cover every circumstance
that you may face. Always exercise care and
use your good judgement. Avoid all situations
which you consider to be beyond your capability.
If you still feel uncertain about operating
procedures after reading these instruction, you
should consult an expert before continuing.
Do not hesitate to contact your dealer if you
have any questions about the use of the
machine. Virginia Abrasives is willing to provide
you with advice to use your machine both
efficiently and safely.
Maintain your machine frequently. Check the
machine and make proper adjustments and
repairs. All information and data in the
Operator’s Manual were applicable at the time
the Operator’s Manual was printed. Contact the
manufacturer for updates.
Warning! Under no circumstances should you
modify the original design of the machine
without approval from the manufacturer.
Always use original spare parts. Unauthorized
modifications and/or accessories may lead to
severe injury or death to the user or others.
Unauthorized modifications and/or
accessories may void warranty.
Warning! Use of products which cut, grind,
drill, sand, or shape material can generate dust
and vapors which may contain harmful
chemicals. Know the nature of the material
being worked on and use appropriate dust
collection, wear appropriate dust mask or
respirator protection.
Personal)protective)equipment)
)
WARNING!)You)must)use)approved)personal)
protective)equipment)whenever)you)use)the)
machine.)Personal)protective)equipment)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.))
)
• Hearing)Protection)
• Protective)goggles)or)safety)glasses)
)
• NIOSH)approved)dust)mask)or)respirator)
)
)
• Heavy-duty,)firm)grip)gloves)
)
)
• Tight-fitting)heavy-duty)and)comfortable))
clothing)that)permits)full)freedom)of)
movement.))
)
)
• Boots)with)steel)toe)shoes)and)non-slip)sole.))
)
!
• Always)have)a)first)aid)kit)nearby.))
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3!
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Safety Instructions
General safety precautions
• Do not use the machine without first
reading and understanding the contents
of this Operator’s Manual.
WARNING! This section describes basic
safety directions for using the machine.
This information is never a substitute for
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!
Work area safety
• Do not use the machine in inclement
weather, such as dense fog, rain, strong
wind, intense cold, etc.
• Keep the work area clean and well lit.
The machine should not be used in
areas where potential for fire or
explosions exist.
Electrical Safety
WARNING! There is always a risk of
shock from electrically powered
machines. Avoid unfavorable weather
conditions and body contact with
lightning conductors and metal objects.
Always follow the instructions in the
Operator’s Manual to avoid damage.
• Never pull the machine by the cord and
never pull out the plug by pulling the cord.
• Keep all cables away from water, oil and
sharp edges. Make sure the cable is not
pinched. Damaged electrical insulation
can create a shock hazard.
• Check to ensure the cords are in good
condition. Use a heavy duty electrical
cord 12 gauge or greater.
• Never use the machine if any cord is
damaged. Damaged electrical cords
should be destroyed or repaired by an
authorized electrical repair shop.
• The machine should be connected to a
grounded outlet socket.
• Ensure that the main voltage corresponds
with that stated one electrical rating on
the machine. Be on your guard for
electrical shocks.
To avoid overheating, do not use an
extension cord. Use only a 12-gauge
(minimum) cord.
Ensure the cord remains out of the grinding area
to avoid damage
Personal Safety
WARNING! Over exposure to vibration
can lead to circulatory damage or nerve
damage in people who have impaired
circulation. Contact your doctor if you
experience symptoms of overexposure to
vibration. Such symptoms include
numbness, loss of feeling, tingling,
pricking, pain, loss of strength, changes
in skin color condition. These symptoms
normally appear in the fingers, hands, or
wrist. These symptoms may be
increased in cold temperatures.
• Wear personal protective equipment. See
instructions under the heading “Personal
protective equipment”.
• Never use the machine if you are tired, or
under the influence of drugs, alcohol, or if
you are taking medication that could
cause impairment.
• 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. Always remain focused on the
task.
• Clothing, long hair, and jewelry 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
machine, so that you can call for help
should an accident occur.
• Always ensure you have a safe and
stable working position
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4!
SAFETY INSTRUCTIONS
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Use and Care
• Only use the machine for the purpose for
which it was intended.
• Keep all parts in good working order and
ensure that all parts are properly
secured.
• Never use a machine that has been
damaged. Inspect, maintain and service
as instructed in the owners described in
this manual. Maintenance and service
measures must be carried out by trained
and qualified specialist. See instructions
under Maintenance.
• Do not modify safety equipment. Check
regularly that they function as they
should. The machine must not be run
without all safeguards in place and
properly operating.
• Never use a machine that has been
modified in any way from its original
specification.
• Machinery should only be started when
grinding heads are lightly resting on the
ground unless carrying out a testing
procedure as outlined in this manual.
• The machine should not be started
without the flexible dust shroud attached.
For proper dust control, it is important to
maintain a close proximity between the
dust shroud and the floor when operating
in dry grinding applications.
• During dry grinding, the machine must be
connected to an industrial grade vacuum.
• When changing the grinding tools,
ensure power supply to the unit is off by
engaging the STOP BUTTON and
unplugging the FG-11 from the power
source.
• After each grinding/polishing operation,
always remove the diamond tools.
• Make sure that the dust shroud is intact
and clean and that it seals tightly against
the floor. Damaged or worn dust shroud
should be replaced.
• The grinding disc continues to rotate after
the stop button has been depressed.
Maintain grinding action until the motor
has come to a complete stop. Make sure
the grinding head has stopped rotating
before raising the machine.
• 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 hot after use.
Allow the machine to cool off before
removing the diamond segments.
Always use protective gloves.
• Always use the machine-mounted lifting
handles when lifting.
• Always carry the machine by the carrying
handle and the handle.
Transport and Storage
• Do not expose the FG-11 to rain or snow.
• Store the equipment in a secured area
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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5!
OPERATING DIMENSIONS
Model
FG11
Length
35.4” (900mm)
Width
27.2” (690mm)
Height
30.3” (770mm)
Weight
143 lbs./65kg
Note: All dimensions and weight are all for reference only and subject to change at any time.
HOW TO ORDER REPAIR PARTS
-To ensure produce safety and reliability, always use the original equipment replacement parts
when making repairs.
-When ordering parts, please specify the MODEL and SERIAL NUMBER of the machine as given
on the NAME PLATE.
-Provide the part number, description and quantity as listed on the parts list.
-Please note: Due to improvements and changes in the equipment the illustrations shown may be
different from the actual machine.
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6!
Diamond Tooling Selection
Diamond
Diamond abrasives usually consist of 2 components,
•Diamond powder (also known as diamond crystals or grit)
•A bonding agent
The following are general rules regarding diamond segments in grinding applications.
A. Diamond grit size
Changing the size of the diamond grit to a smaller particle/grit size will affect the performance of
the diamond tool in the following ways.
•Create a finer scratch pattern
•Increase life of diamond tool
•Reduce the production rate
The opposite will occur when changing to a larger particle/grit size
B. Bond
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 bond softer.
Determining the hardness of concrete
The greater the compressive strength rating, the harder the concrete and therefore, the more difficult it
will be to grind.
However, other factors besides compressive strength ratings determine how hard the floor will be, and
therefore, will determine the correct diamond selection. Since grinding normally only deals with the
surface of concrete (top 5mm or ¼ 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 concrete surface is very smooth (heavily troweled) the concrete will behave as if it has a high
compressive strength and therefore, require a soft bond segment
If the concrete surface is coarse/aggressive (rain-damage, shot blast, scarified, exposed aggregate
broom finished) the concrete will behave as if it has low compressive strength and will require a hard
bond segment. Surface coatings and contaminants (epoxy, coatings, thin-set, adhesives, leveling
compound) will often have a bearing on the diamond to select for the application.
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7!
DIAMOND PCD & CUBOIDS
PCD - POLYCRYSTALLINE DIAMOND: Aggressive
removal of heavy coatings, resin, mastics, paint, urethane
and thinset.
Grit: Very Coarse
PCD + Diamond: Moderate removal of hard coatings.
Leaves moderate scratch marks and surface texture.
Diamond prevents PCD from gouging.
Grit: Coarse
Diamond Trapezoids: Coatings and concrete removal.
Light leveling and smoothing of concrete surface. Leaves
smooth surface with no gouges.
Grit: Coarse / Medium & Medium / Fine
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8!
Operating Instructions
Connect the industrial rated dust collector
Make sure that the filters in the dust collector are intact and clean. Monitor proper dust collection during
operation.
Attach the skirt
Adjust the rubber skirt to be in close proximity to the floor to ensure efficient dust collection
(lightly touching the floor or nearly touching the floor).
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9!
Transport
The handle of the FG-11 can be folded for transport. Loosen bolts on each side of the handle then
carefully fold handle forward. Placing padding between the motor and the electric box is recommended to
prevent damage. Snug bolts while handle is in folded position to ensure bolts are not lost in transport.
Select the correct grit size diamonds for your application
Please refer to the following guide for to the basic application of Virginia Abrasives’ diamond tooling.
APPLICATIONS
GRIT SIZE
Flatten concrete floor,
Ceramic tile adhesive,
Epoxy paint removal,
Rain damaged concrete,
Grinding to expose aggregate in concrete
30/40
Bond determined by concrete
Surface grinding of concrete floors
60/80, 80/100
Bond determined by the concrete
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10!
Starting and Stopping
Wear personal protective equipment. See instructions under the heading “Personal
Protective Equipment”.!
Perform Pre-Start Check
•Visually inspect the equipment for wear or damage.
•Be sure all guards are in place and function properly. Do not operate unless all guards are in
place and secure.
•Perform all daily maintenance.
•Inspect accessories to be sure the correct tooling for the application is installed properly on the
machine.
•Inspect the work area to determine the presence and location of deck inserts, pipes, columns, and
objects producing from the slab surface so that they may be avoided during the grinding operation.
Remove or grind down deck inserts and or other foreign materials to below the surface of the slab
using a right-angle grinder.
•Referencing the bubble level, adjust the tilt of the FG-11 to a level position
•Plug the grinder into the power supply.
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11!
Starting
•Tilt the machine slightly to lift the diamond tooling off the floor surface and start the machine.
•Rotate the switch to the “ON” position to start the machine.
•Allow the machine to achieve full working speed (approximately 20 seconds). Lower the machine
to the surface and do a short touch pass on the concrete. The “touch pass” will show if the tooling
is flat to the floor surface. The grinding pattern on the floor should show a complete circle
abraded. If the pattern is less than a full circle, further level adjustment is required.
•Reduce the pressure between grinding disc and floor by pushing down on the handle without
raising the grinder off the ground.
•You are ready to grind.
•Use a “side-to-side” grinding motion as the FG-11 is worked forward. Using a front to back motion
may stall the motor and cause overheating or cause the breaker to trip.
Stopping)
•Rotate the switch to the “OFF” position to shut down the machine.
•Keep grinding segments in light contact with the floor when stopping. This will help bring the
machine to a complete stop. Do not lift the grinding head off the floor when stopping as this can
create a significant amount of dust in the air.
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12!
MAINTENANCE
Problems and trouble shooting
Machine)will)not)run)
•Check!the!power!supply!(breaker!panel)!and!the
power!cables!and!make!sure!that!they!are!not
damaged.
Machine)is)hard)to)hold)onto)
•Grinding!thick!glue,!coatings!or!soft!floors!will
greatly!increase!the!load!on!grinder!and
operator!accompanied!by!high!current!draw.
Move!the!machine!more!slowly!to!reduce!the
load.!!Work!the!edges!of!a!clean!area.
Machine)is)jumping)around)
•The!rubber!disc!in!the!rigid!drive!coupling!may
be!worn!or!damaged.!!Change!if!necessary.!
•Diamonds!may!not!be!fitted!correctly!or!have
different!heights.!!Check!to!ensure!all!diamonds
are!fitted!correctly!and!are!at!the!same!height.!
Machine)stops)after)short)usage)
•The!machine!is!overloaded!and!the!thermal
overload!protection!has!been!deployed.!!Reduce
the!load!on!the!machine.!!The!machine!will
reboot!after!approximately!one!minute!when
the!thermal!overload!has!cooled!off.
Machine)stops)during)start-up)
•The!electric!motor!has!been!overloaded.!!Allow
the!machine!one!or!two!minutes!to!reset!and!try
again.!!Make!sure!that!the!diamond!tooling!is
not!in!contact!with!the!floor!during!start!up.
Cleaning)
Always remove the plug from the electrical outlet
before loading tooling, cleaning, maintenance or
assembly. Clean all equipment at the end of the
work 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.
Use of an air hose should be avoided to prevent
dust particles from becoming air born.
Rubber shock absorber discs
Check the rubber shock absorbing dics in the
drive coupling every month. Replace if
necessary.
Electrical Feed
WARNING!)Never)use)damaged)cables.)
They)can)cause)serious,)even)fatal,)
personal)injuries.)
Check!that!the!cord!and!the!extension!cord!are!intact!and!
in!good!condition.!!Never!use!the!machine!if!the!cord!is!
damaged.!!Replace!the!cord!or!have!it!repaired!at!an!
authorized!electrical!service!shop.!
Dust)Shroud)
Make!sure!that!the!dust!shroud!is!intact,!clean!and!that!it!
is!in!light!contact!with!the!floor.!!A!damaged!dust!shroud!
should!be!replaced.!
Service)
IMPORTANT!**All*types*of*repairs*may*only*
be*carried*out*by*authorized*repairmen.***
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13!
MAINTENANCE)SCHEDULE)
*
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Before!
operation!
Every!4!
hours!
!!Daily!
Every!50!hours!
of!operation!
As!
required!
Visual inspection
of entire machine
!
!
X!
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Check dust shroud – replace
as needed
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!
X!
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Check for stable handle
position
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X!
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Grease bearings
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!!!!!!X!
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Inspect drive belt
!!!X!
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Inspect diamond tooling
X!
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Check condition of belts
X!
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Check belt tensioning
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!!X!
Clean dust & dirt off machine
!
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X!
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*
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FG-11 Grinder Parts Diagram
Table of contents
