Marshalltown SP684 User Manual

OPERATOR’S MANUAL
Includes Safety, Service and Replacement
Part Information
Model SP684
SURFACE SHARK™
Surface Planer
Do not discard this manual.
Before operation, read and comprehend its contents. Keep
performing any service related function. When ordering
replacement parts, please supply the following information:
model number, serial number and part number.
Marshalltown, IA
Phone 800-888-0127 / 641-753-0127
Fax 800-477-6341 / 641-753-6341
www.marshalltown.com
MARSHALLTOWN SURFACE SHARK
SURFACE PLANER WARRANTY PROGRAM
PURPOSE
It is the intention of Marshalltown Company to supply products to the marketplace that reflect the highest standards for materials, design and manufacture. Each original customer is entitled to receive coverage as described by the current limited warranty program for the product(s) purchased, regardless of where it (they) was (were) originally purchased. This program is intended to serve as a method to facilitate the proper communication procedures for the purpose of obtaining applicable coverage for a product.
WHAT THE LIMITED WARRANTY COVERS
Marshalltown Company warrants that each new and unused product and/or accessory sold by it shall be:
1) Free from defects in material and workmanship under normal use and service for a period of two (2) years from the original date of purchase.
2) To warrant the labor expenses associated with the defects in material and workmanship for a period of one (1) year from the original date of purchase.
The warranty period for materials workmanship and labor expenses shall run concurrent from the original date of purchase (invoice date). No exception to this policy will be made.
The obligation under this warranty program is limited to the current, flat labor rates allowed by it and the replacement and/or repair at its Fayetteville, Arkansas, factory site, or at an authorized dealer designated by it, of such part or parts as shall appear upon inspection to have been defective in material and/or workmanship at the time sold. The part or parts claimed to be defective must be returned to the inspection point, with reasonable transportation charges prepaid. In the event that the part or parts are determined to be covered by the terms of the warranty program, Marshalltown Company will reimburse the original purchaser for reasonable transportation charges. The amount designated, as reasonable transportation charges shall be the sole discretion of Marshalltown Company. Any part or parts replaced under the terms of the warranty program will carry the applicable new product warranty. At the time of requesting warranty service, the original purchaser must present evidence of the purchase date of the part or parts submitted for warranty inspection.
ALLOWABLE FLAT LABOR RATES
Marshalltown Company will pay shop labor repair on warranty at the Marshalltown Company Shop Labor Rate in existence on the date of the warranty claim. A Marshalltown Company Labor Chart will determine the time allowed to complete a repair and will govern the shop labor hours that will be allowed.
Marshalltown’s warranty policy will not cover the following; taxes, shop supplies, environment surcharges, air freight, travel time, loss of rental revenue, or any other charges whatsoever or any liabilities for direct, incidental, or consequential damage or delay.
Please fill out your Marshalltown Company warranty card and place it in the mail within 24 hours of delivery.
TABLE OF CONTENTS
DESCRIPTION PAGE
NOTICE TO OPERATORS .................................................................................................................4
OPERATOR INSTRUCTIONAL DATA SHEET .................................................................................. 6
SAFETY PRECAUTIONS
Preparation .......................................................................................................................................... 7
Operation ............................................................................................................................................. 9
Maintenance, Repair and Storage ......................................................................................................10
ASSEMBLY
Removing the Surface Planer from the pallet ..................................................................................... 11
Filling the Engine Crankcase with Oil ................................................................................................. 11
Filling the Engine Fuel Tank................................................................................................................ 12
OPERATION
California Proposition 65 Disclaimer ................................................................................................... 12
Spark Arrestor Disclaimer ................................................................................................................... 12
Theory of Operation ............................................................................................................................ 12
Flail Design and Application ................................................................................................................ 13
Spacer Washers .................................................................................................................................. 15
Flail Drum Rods ................................................................................................................................... 16
Flail Drum Design and Application ...................................................................................................... 18
Installing Flails on the Two Section Drum ........................................................................................... 19
Installing a Loaded Drum on the Driveshaft ........................................................................................ 22
Transporting the Floor Grinder ............................................................................................................ 22
Starting the Surface Planer on the Job Site ........................................................................................ 23
Operating the Surface Planer on the Job Site .................................................................................... 24
Stopping the Surface Planer on the Job Site ...................................................................................... 28
SERVICE
Preventative Maintenance Check List ................................................................................................. 28
Checking V-Belt Tension and Alignment............................................................................................. 29
Installing a Replacement V-Belt or Pulley ........................................................................................... 30
Installing a Replacement Bearing on the V-Belt Side ......................................................................... 33
Installing a Replacement Bearing on the Outboard Side .................................................................... 35
Lubrication Requirements ................................................................................................................... 37
Aligning the Caster Wheels ................................................................................................................. 38
Checking Driveshaft Run Out .............................................................................................................. 39
Engine Service ....................................................................................................................................40
TROUBLESHOOTING
Engine .................................................................................................................................................40
Operational Problems ......................................................................................................................... 41
STORAGE .......................................................................................................................................... 42
SPECIFICATIONS ............................................................................................................................... 42
REPLACEMENT PARTS DIAGRAMS ................................................................................................43
NOTICE TO OPERATORS
IF YOU CAN NOT READ OR DO NOT FULLY UNDERSTAND THE CONTENTS OF THIS MANUAL, PLEASE CONTACT THE FACTORY FOR PROPER ASSISTANCE BEFORE ATTEMPTING TO OPERATE THIS PRODUCT.
SI TU NO PUEDES LE’ER O NO COMPRENDES EL CONTENIDO DE ESTE MANUAL FAVOR DE PONERSE EN CONTACTO CON LA. FABRICA PARA ASSISTENCIA- A PROPIA ANTES DE INTENTAR PARA OPERAR ESTE PRODUCTO.
SOLLTEN SIE DIESE GEBRAUCHSANWEISUNG NICHT LESEN KOENNEN ODER ES NICHT VOLLKOMMEN VERSTEHEN, WENDEN SIE SICH BITTE AN DEN HERSTELLER FUER RICHTIGE HILFE EHE SIE VERSUCHEN DIESES PRODUKT ZU OPERIEREN.
SI VOUS NE LISEZ OU NE COMPRENDRE ENTIEREMENT LES MATIERES DE CE MANUEL, S’IL VOUS PLAIT, CONTACTEZ L’USINE POUR L’ASSISTANCE APPROPRIEE AVANT D’UTILISER LE PRODUIT.
These safety alert symbols identify important safety messages in this manual. When you see these symbols, be alert to the possibility of personal injury and carefully read the message that follows.
Do not allow anyone to operate the Surface Planer without first reading this Operator’s Manual and becoming familiar with its operation. The manufacturer of this Surface Planer has gone to great extremes to provide the owner(s) and/or operator(s) with the finest equipment available for its intended job function of material removal and/or preparation of work surfaces. Yet, the possibility exists that the Surface Planer can be utilized in and/or subjected to job applications not perceived and/or anticipated by the manufacturer. Such misuse and/or misapplication of the Surface Planer can lead to the possibility of serious damage, injury or even death. It is the responsibility of the owner(s) and/or operator(s) to determine that the Surface Planer is being utilized and/or operated within the scope of its intended job function. It is the responsibility of the owner(s) and/or operator(s) to establish, monitor and constantly upgrade all safety programs and/or practices utilized in and for the operation of the Surface Planer. The purpose of such programs is to provide for owner(s’) and/ or operator(s’) safety. Operators must be instructed to recognize and avoid unsafe conditions associated with their work (29 CFR 1926.21 (b)(2)) and/or applicable updated revisions. It is the responsibility of the owner(s) and/or operator(s) to determine that no modifications and/or alterations have been made to the Surface Planer. Modifications and/or alterations can lead to the possibility of serious damage, injury or even death. It is the responsibility of the owner(s) and/or operator(s) to make this Operator’s Manual available for consultation during all phases of operation. Refer to OSHA 2207 and/or applicable updated revisions which contains all OSHA job safety and health rules and regulations (1926 and 1910) covering construction.
PAGE 4 SP684 SURFACE SHARK SURFACE PLANER
The concept of portable, low horsepower type surface planing equipment has been successfully utilized for many years as a practical solution to many types of surface preparation job requirements. The basic concept is proven and well accepted within the associated marketplaces as an alternative method to manual labor and other types of machines and methods. Use of a Surface Planer requires strenuous work activity. This type of work activity can be considered to be greater in magnitude than that experienced with the use of many other types of both light construction and lawn and garden related equipment. This type of work activity should only be attempted by operators of adequate physical size and stature, mental awareness and physical strength and condition. Each operator is required to supply a reaction type force that counteracts/balances and/or resists the forces generated during the surface planing process. The body parts most noticeably affected during the planing process are the arms, hands, wrists, shoulders, lower back and legs. The planing process can also produce excessive stress/strain directly to the back muscles, spinal vertebrae and many other body parts. Back related pain can be a side effect of the planing process. An operator with a chronic back related problem or a history of back and/or other medically related problems should not attempt to utilize the Surface Planer. Use of the Surface Planer may only aggravate this and any other medically related problem. The forces generated and/or encountered correspond to the natural laws of physics and are inherent to the planing process. They can not be changed or totally eliminated with portable hand held and operated, surface planing equipment of this design. Proper operating positions and techniques, as outlined in this manual, can be successfully utilized to minimize the effects of the reaction forces upon the human body. Because of the diverse type of prevailing job applications, job site conditions, operator experience levels and operator physical characteristics, no warranty, guarantee, representation and/or liability is made by the manufacturer as to the absolute correctness or sufficiency of any operational procedure, operational position and/ or technique. There is no absolute guarantee that an operator of any given experience level, physical size and/or physical condition will be immune to the possibility of and/or probable physical side effects of the normal surface planing process. The normal planing process includes the flails striking a wide variety of surface materials and compositions and the resulting reaction forces created. Each potential operator of the Surface Planer must be made aware of and assume the operational and physical liability described and/or associated with the planing process when utilizing the Surface Planer. Each potential operator not willing to assume the operational and physical liability described and/or associated with the planing process should not operate the Surface Planer. Proper levels of operator experience, skill and common sense are essential for maximizing the safe and efficient operation of the Surface Planer.
Record the Surface Planer and engine/electric motor serial numbers in the spaces provided below.
_______________ Model Number
_______________ Serial Number
_______________ Engine Serial Number
_______________ Date of Purchase
Specifications and design are subject to change without notice or obligation. All specifications are general in nature and are not intended for specific application purposes. Marshalltown Company reserves the right to make changes in design, engineering or specifications and to add improvements or discontinue
SP684 SURFACE SHARK SURFACE PLANER PAGE 5
manufacture at any time without notice or obligation. Marshalltown Company and its agents accept no responsibility for variations which may be evident in actual products, specifications, pictures and descriptions contained in this publication.
OPERATOR INSTRUCTIONAL DATA SHEET
The following undersigned operators of the Surface Planer described and/or pertaining to this Operator’s Manual have received formal safety and operational information/instruction from the undersigned owner(s)/ instructor(s) in accordance to OSHA 29 CFR 1926.21 (b)(2) and/or applicable updated revisions pertaining to, but not necessarily limited to the:
1) READING, COMPREHE NSION AN D ACKNOWLEDGEMENT OF THE MATE RIAL COMPRISING THE ENTIRE CONTENTS OF THE APPLICABLE OPERATOR’S MANUAL AND SAFETY AND OPERATIONAL INFORMATION VIDEO FOR THE SURFACE PLANER.
2) FORMALIZED OPERATOR’S SAFETY PROGRAM TO BE DEVISED BY THE OWNER OF THE SURFACE PLANER IN CONJUNCTION WITH THE CONTENTS OF THE APPLICABLE OPERATOR’S MANUAL FOR THE SURFACE PLANER.
3) OSHA RULES AND REGULATIONS RESEARCHED FOR AND/OR BY THE OWNER OF THE SURFACE PLANER AND DEEMED APPLICABLE TO THE SAFE AND PROPER USE AND/OR OPERATION OF THE THE SURFACE PLANER FOR ANY SPECIFIC JOB APPLICATION.
4) LOCAL LAWS, REGULATIONS AND CUSTOMS RESEARCHED FOR AND/OR BY THE OWNER OF THE SURFACE PLANER AND DEEMED APPLICABLE TO THE SAFE AND PROPER USE AND/OR OPERATION OF THE SURFACE PLANER FOR ANY SPECIFIC JOB APPLICATION.
5) FORMALIZED MAINTENANCE PROGRAM FOR THE SURFACE PLANER TO BE DEVISED BY THE OWNER OF THE SURFACE PLANER IN ACCORDANCE WITH, BUT NOT NECESSARILY LIMITED TO, THE SPECIFICATIONS, GUIDELINES AND OPERATIONAL INFORMATION CONTAINED IN THE APPLICABLE OPERATOR’S MANUAL.
6) COMPREHENSIVE OPERATIONAL INSTRUCTIONS FOR THE CORRECT AND PROPER USE OF THE SURFACE PLANER AS PER THE CONTENTS OF THE APPLICABLE OPERATOR’S MANUAL.
_______________ Operator _______________ Owner/Instructor ________Date
_______________ Operator _______________ Owner/Instructor ________Date
_______________ Operator _______________ Owner/Instructor ________Date
_______________ Operator _______________ Owner/Instructor ________Date
_______________ Operator _______________ Owner/Instructor ________Date
_______________ Operator _______________ Owner/Instructor ________Date
PAGE 6 SP684 SURFACE SHARK SURFACE PLANER
SAFETY PRECAUTIONS
THE FOLLOWING SAFETY PRECAUTIONS PROVIDE SOME COMMON SENSE GUIDES TO PROMOTE SAFETY AND EFFICIENCY WITH THE SURFACE PLANER. NO WARRANTY, GUARANTEE OR REPRESENTATION IS MADE BY THE MANUFACTURER AS TO THE ABSOLUTE CORRECTNESS OR SUFFICIENCY OF ANY INFORMATION OR STATEMENT. THESE SAFETY PRECAUTIONS ARE INTENDED TO DEAL PRINCIPALLY WITH COMMON PRACTICES AND CONDITIONS ENCOUNTERED IN THE USE OF THE SURFACE PLANER AND ARE NOT INTENDED TO BE ALL INCLUSIVE. PROPER LEVELS OF OPERATOR EXPERIENCE, SKILL AND COMMON SENSE ARE ESSENTIAL FOR SAFE AND EFFICIENT OPERATION.
THE ENGINE EX HAUST ALO NG W ITH THE DUSTS/BYPRODUCTS FROM THE COVERING REMOVAL PROCESS ASSOCIATED WITH THE OPERATION OF THE SURFACE PLANER CAN CONTAIN CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. THIS STATEMENT IS MADE IN COMPLIANCE TO CALIFORNIA PROPOSITION 65.
INCORRECT USE OF THE SURFACE PLANER CAN RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR EVEN D EATH. TO REDUCE THIS POSSIBILITY, GIVE COMPLETE AND UNDIVIDED ATTENTION TO THE JOB AT HAND AND FOLLOW THESE SAFETY PRECAUTIONS:
PREPARATION
1) The Surface Planer is a specialized type of powered equipment, designed for a specific job function and requires adequate and thorough instruction BEFORE it is operated. The size, power, complexity and operating characteristics of this type of powered equipment would dictate that each operator must receive adequate, professional instruction regarding the proper operation of the Surface Planer before being allowed to utilize it. BEFORE attempting to utilize the Surface Planer, read this Operator’s Manual to familiarize each operator with its correct operating procedures. Avoid the urge not to take the necessary time to read this Operator’s Manual before operating the Surface Planer. DO NOT OPERATE THE SURFACE PLANER UNTIL EACH OPERATOR COMPLETELY COMPREHENDS THE CONTENTS OF THIS MANUAL , AP PLICABL E SU PPLEMEN TAL INFORMATION AND THE INFORMATION SUPPLIED BY THE ENGINE MANUFACTURER.
2) Develop a comprehensive program for the safe operation of the Surface Planer by its owner(s) and/ or operator(s). Such a program will include, but is not limited to: instructional requirements for operation, applicable OSHA requirements, local laws and regulations, job site safety and a Surface Planer maintenance program. Constantly examine and upgrade this program to guarantee owner(s) and/ or operator(s) safety. Each operator must be fully instructed regarding the specifics of this safety program.
3) Determine that the Surface Planer is in its original, factory configuration and has not been modified in any manner. Many modifications can result in potentially dangerous configurations that can lead to property damage and/or personal injury. If there are any questions about possible modifications made to the Surface Planer, contact the Customer Service Department for specific information BEFORE utilization. There is no charge for this service. Do not operate the Surface Planer without the use of the original equipment V-belt guard. Use of the planer without an approved belt guard can lead to property damage and/or personal injury.
4) Minors should never be allowed to operate the Surface Planer. Bystanders, especially children and animals, should not be allowed in the area where the Surface Planer is in use. The covering removal process can result in flying particles being emitted at high velocity and striking the operator and/or onlookers. This can lead to the possibility of
SP684 SURFACE SHARK SURFACE PLANER PAGE 7
property damage and/or personal injury. Keep all body parts, loose clothing, foreign objects and onlookers clear while equipment is in operation.
9) Flying debris, generated by the planing process, can cause eye injury. Eye protection is required while operating or when near operating equipment
5) Operators must be in adequate physical condition, mental health and not under the influence of any substance (drugs, alcohol, etc.) which might impair vision, dexterity or judgment. Working with the Surface Planer is strenuous. If you have any condition that might be aggravated by strenuous work, check with your doctor BEFORE operating the Surface Planer. Guard against the possibility of back related injuries. Always lift the Surface Planer with leg muscles and not with the back. Use of the Surface Planer requires that the operator be of the proper height, weight and strength to maximize operational efficiency and minimize the possibility of personal injury.
6) Prolonged use of the Surface Planer (or other, similar machines) exposes the operator to vibrations which may produce Whitefinger Disease (Raynaud’s Phenomenon). This phenomenon reduces the hand’s ability to feel and regulate temperature, produces numbness and burning sensations and may cause nerve and circulation damage and tissue necrosis. Antivibration systems do not guarantee that you will not sustain Whitefinger Disease. Therefore, continuous and regular users should closely monitor the condition of their hands and fingers. After each period of use, exercise to restore normal blood circulation. If any of the symptoms appear, seek medical advice immediately.
7) Clothing must be sturdy and snug fitting, but allow complete freedom of movement. Never wear loose fitting jackets, scarves, neckties, jewelry, flared or cuffed pants or anything that could become caught on controls or moving parts. Wear long pants to protect your legs. Protect your hands with heavy duty, nonslip gloves to improve your grip. Good footing is most important when operating the Surface Planer. Wear sturdy boots with nonslip soles. Steel-toed safety shoes are highly recommended. Never wear tennis shoes or other, similar type shoes which afford little or no protection. Wear an approved safety hard hat to protect the operator’(s’) head(s) where there is a danger of head injuries.
8) Noise, generated by the engine of the Surface Planer and/or the actual planing process itself, can damage your hearing. A gasoline engine powered Surface Planer operates with a noise emission greater than 70 dBA. Hearing protection is required while operating or when near operating equipment. Continuous and regular operators should have their hearing checked regularly.
10) Visually inspect the Surface Planer, components, tools and accessories for damaged or worn parts. BEFORE each use:
a) Disconnect the engine spark plug wire.
b) Clean and remove all accumulated foreign matter from the wheels and determine that each rotates freely.
c) Clean and remove all accumulated foreign matter from inside the main frame area.
d) Inspect the V-belt drive for proper tension, wear and general condition. Replace each component as necessary.
e) Inspect the flail drum and flails/spacer washers for for excessive wear and structural integrity. Replace each component as necessary. The flail drum and flails rotate at high speed during the planing process and are subject to high wear rates.
f) Determine that operator controls work freely, all safety devices are operative and information decals are readable.
g) Check to see that the Surface Planer and all related accessories are in good, mechanical condition BEFORE utilization.
h) Re-connect the spark plug wire.
11) Contact appropriate representatives to determine if/ where electrical cables, gas lines and other hazardous items are buried under the work surface BEFORE utilization. The Surface Planer and related accessories are not insulated. Contact with buried electrical cables, gas lines and other hazardous items can result in electrocution and/or an explosion.
12) Know how the controls operate. Know how to stop the engine quickly in an emergency. Always start the engine with the flail drum raised to its maximum height from the work surface to minimize the possibility of unexpected contact with the work surface. Unexpected contact with the work surface can cause loss of machine control, and the possibility of property damage and/or personal injury.
13) When operating the Surface Planer with an electrically powered vacuum system on a surface containing water or other electrically conducting
PAGE 8 SP684 SURFACE SHARK SURFACE PLANER
liquid, special precautions must be taken to minimize the possibility of operator electrocution. One such precaution is to wire and operate the electric motor from a 20 Ampere, 115 Volt AC power source in conjunction with a ground fault circuit interrupter (GFCI). A GFCI is a safety device that disconnects power from a circuit to a load when a potentially dangerous condition occurs. The GFCI opens the circuit when the fault current flow from a power line to a ground exceeds the safe limit for humans. The GFCI protects against harmful electrical shock to a person caused by contact with a defective electrical product. A GFCI differs from a fuse or circuit breaker. A fuse or circuit breaker opens the circuit when the total current flow in the power line exceeds the safe limit of the power line. They are designed to protect against fire caused by overheating. Use of a GFCI gives on the job protection from electrical shock hazards caused by ground faults in commercial, industrial and residential applications. They are simple and easy to use: plug a portable GFCI into any suitable, grounded receptacle and plug the Surface Planer into the GFCI for automatic protection against ground faults. For specific information, consult current National Electrical Code publications and OSHA publications 210-22D (or current revision) for construction sites and 555-3 (or current revision) for use around any area containing water.
14) Never exceed the recommended capacities of the Surface Planer. Refer to the Specifications section of this manual for more detailed information.
OPERATION
1) Give complete and undivided attention to the job at hand. Do not chew gum, smoke and/or use smokeless tobacco while utilizing the Surface Planer. Do not attempt to eat and/or drink while utilizing the Surface Planer. Determine that eyeglasses and/or hearing aid devices are properly secured.Use of the Surface Planer is strenuous and causes fatigue. Help prevent the cause of an accident. Plan to take work breaks as required to help maintain proper mental and physical alertness.
2) This Surface Planer is not sealed or insulated. Do not operate this machine in an explosive atmosphere or near combustible materials. Refer to current OSHA and National Electric Code® rules and regulations.
3) Gasoline is an extremely flammable fuel. Use extreme caution when handling gasoline or mixing fuel. Always utilize UL®, CSA® or CE approved containers for the storage and transportation of fuel. Do not smoke or bring fire or flame near the fuel. Always shut off the engine and allow it to cool before refueling.
Never remove the fuel tank filler cap while the engine is running. Never operate an engine without a fuel tank filler cap. Select bare ground for fueling and move at least 10 feet from the fueling spot before starting the engine. Wipe off any spilled fuel before starting the engine and check for leakage. If a fuel or oil leak is found, do not start or run the engine until the leak is fixed and the spillage has been wiped away. Take care not to get fuel or oil on your clothing. If this happens, change your clothing immediately. Before operating the Surface Planer, refer to the Specifications section of this manual for more detailed information regarding fuel and lubrication requirements.
4) The Surface Planer is designed for use by one operator. Use of the Surface Planer by more than one operator can lead to confusion and loss of control, resulting in property damage and/or personal injury. If it is felt that more than one person is required to operate the Surface Planer, STOP and contact the Customer Service Department for specific operational and service/maintenance information. There is no charge for this service.
5) Do not operate the Surface Planer with onlookers close by. Caution all onlookers to stand clear. The planing process can result in flying particles being emitted at high velocity and striking the operator and/ or onlookers This can lead to the possibility of property damage and/or personal injury. Keep all body parts, loose clothing and foreign objects clear of the rotating drum and flails.
6) Never start the engine or electric motor without first raising the flail drum to its maximum height from the work surface to minimize the possibility of unexpected contact with the work surface. Unexpected contact with the work surface can cause the loss of machine control and the possibility of property damage and/or personal injury.
7) Start and operate the Surface Planer only in a
well ventilated area. Carbon Monoxide fumes given off by an engine operating from standard fuels are poisonous. Breathing these fumes can result in property damage and/or personal injury.
Operate the Surface Planer only when/where visibility and light are adequate for the job at hand. Work carefully. Always hold the operator handle firmly with both hands. Wrap your fingers around the handle, keeping it cradled between your thumbs and fingers. Always make sure the operator handle is in good condition and free of moisture, pitch, oil or grease. Wear gloves to improve your grip. Never leave the Surface Planer running unattended.
SP684 SURFACE SHARK SURFACE PLANER PAGE 9
8) Special care must be exercised on slippery conditions and on difficult, uneven surfaces. Watch for cracks, high spots and other, surface irregularities. Keep proper footing and balance at all times. The normal use of this machine is on level surfaces. Other terrains can be dangerous and should be avoided. Only properly trained operators should attempt these techniques.
9) Never start the engine with the Surface Planer on cracked, uneven or irregular surfaces. Never start the engine with the flails and/or flail drum in contact with the work surface. Such occurrences can lead to the loss of machine control and the possibility of property damage and/or personal injury.
10) Contact with a hot, engine muffler can cause property damage and/or personal injury. Remain clear of a hot, engine muffler. Do not over speed the engine by altering the governor setting or by disconnecting the engine governor. Serious damage to the engine and/or personal injury can result.
11) Clean and remove all accumulated foreign matter from inside the main frame after each use. This practice will maximize bearing and V-belt service life.
12) Because this Surface Planer is classified as a low cost, hand held, low horsepower, portable type machine, it is limited in the number of practical and/or suitable job applications. A particular job site, actual surface conditions, job specifications and operator skill/common sense may dictate that a different type of machine (with characteristics of higher purchase cost, being mounted to a carrier vehicle, with greater horsepower and less mobility), method and/or process be utilized to properly complete the job with the degree of efficiency and safety required. Contact the Customer Service Department for specific information regarding suitable job applications, job site surface conditions and operator experience/skill/common sense recommendations for this Surface Planer BEFORE utilization. There is no charge for this service.
MAINTENANCE, REPAIR AND STORAGE
1) Use only genuine, approved replacement parts and accessories for maintenance and repair. Use of parts and accessories manufactured by others can result in property damage and/or personal injury.
2) Follow the Service instructions as outlined in the appropriate section of this manual.
4) Always properly maintain the Surface Planer. Frequently check all fasteners and individual parts. Built in safety features are effective only if they are maintained in good working condition. Replace any questionable part or assembly with a genuine, factory approved, replacement part. Do not forsake proper maintenance for the price of a few replacement parts. Proper maintenance does not cost... it actually pays dividends. Do not attempt any maintenance repair work not described in this manual. Have such work performed at your dealer’s service facility.
5) A worn or damaged engine muffler is a fire hazard and may cause loss of hearing. Check to see that the muffler is in good condition. If the muffler is equipped with a spark arresting device, determine that it is in proper working condition at regular service intervals. Replace the spark arresting device with an approved replacement if there is any question of its integrity. It is the responsibility of the owner(s) and/or operator(s) to provide for and properly maintain a USDA approved, spark arresting muffler in an operating area specified by law. Check with appropriate governing agencies for more specific information. The Surface Planer must not be operated if the muffler is faulty or has been removed. Contact with a hot engine muffler can cause property damage and/or personal injury.
6) Do not operate the planer without the use of a factory approved V-belt guard that is maintained in proper structural condition. Frequently inspect the belt guard for signs of wear, cracks and other signs of fatigue. If there is any question regarding the structural integrity and/or condition of the belt guard, properly dispose and replace with a genuine, factory approved, replacement part only.
7) Maintain all safety and operation decals in proper condition. If any decal becomes damaged and/or unreadable, replace with genuine, factory approved, replacement parts only.
8) The Surface Planer utilizes self locking hexagon head nuts to minimize the effects of vibration. Replace all self locking hardware with genuine, factory approved, replacement parts only.
9) Consult the material supplied by the engine or electric motor manufacturer for specific information relative to proper operational, lubrication and storage requirements.
3) Always stop the engine and disconnect the spark plug wire BEFORE checking or working on the Surface Planer.
PAGE 10 SP684 SURFACE SHARK SURFACE PLANER
ASSEMBLY
The SP684 SURFACE SHARK Surface Planer is shipped from the factory secured on a specially designed wooden pallet and protected from external damage by a corrugated carton or wood crate. If shipped with a corrugated carton, the Surface Planer can be secured to the pallet by wood laths nailed to the pallet body. Remove the carton or crate immediately upon receipt using suitable tools to remove the nails.
WEAR SAFETY GLASSES AND OTHER APPROPRIATE SAFETY APPAREL WHEN CUTTING THE STEEL BANDING AND/OR REMOVING THE CORRUGATED/WOOD SHIPPING CRATE.
Check all fasteners for security. Consult a fastener torque chart for the proper torque value if any fastener is found to require retorquing.
FILLING THE ENGINE CRANKCASE WITH OIL
Application: SP684 Surface Planer
Note: The Surface Planer is test run at the factory and is subject to a number of operational tests before shipment. This requires the engine crankcase to be filled with oil to the proper level. No further addition of oil is required prior to placing a new unit in service. In normal operational service, to fill the engine crankcase with oil after first draining the crankcase, proceed as follows:
Tools Required:
1 each, small, clean funnel
REMOVING THE SURFACE PLANER FROM THE
PALLET
Application: SP684 Surface Planer
Tools Required:
1 each, pliers 1 each, claw hammer or hammer and an appropriate pry bar 2 each, 1/2 inch wrenches
The Surface Planer is secured to the pallet with steel banding. Using the pliers, cut and remove the banding. The Surface Planer is secured to the pallet with a tie­down clamp. Using the 1/2 inch wrenches, remove the tie-down clamp. The Surface Planer can then be removed from the pallet.
Visually inspect the shipment for freight damage and/or missing parts. If shipping damage is evident, contact the delivering carrier immediately to arrange for an inspection of the damage by their claims representative. Federal law requires that a claim be filed within a specific time period. If missing parts are detected, notify your dealer who will assist you in obtaining them.
1)The SP684 Surface Planer is available equipped with a number of industrial quality, gasoline and diesel engines. Consult the material supplied by the engine manufacturer for the engine that has been ordered with your Surface Planer. Carefully review this material to become familiar with specific operating characteristic, recommendations and service requirements.
2) Determine the location(s) of both the oil filler and oil drain plug(s).
3) Wipe oil, dust and accumulated dirt from the filler plug area.
4) Using the funnel, fill the engine crankcase with a high grade motor oil. Consult the material supplied by the engine manufacturer for proper amount, weight and service classification.
5) Replace the oil filler plug and tighten. Wipe off any excess oil spilled on the engine crankcase and Surface Planer.
6) Do not operate the engine unless proper oil level is maintained as per the material supplied by the engine manufacturer.
The Surface Planer is shipped from the factory completely assembled. If ordered with the Surface Planer, the flail drum and flail kit are normally installed on the flail drum driveshaft. Additional flail drums and flail kits or replacement parts are normally shipped separately.
SP684 SURFACE SHARK SURFACE PLANER PAGE 11
FILLING THE ENGINE FUEL TANK
Application: SP684 SURFACE SHARK.
THE MATERIAL SUPPLIED BY THE ENGINE MANUFACTURER FOR INFORMATION RELATIVE TO PROPER FUELING PROCEDURES.
Tools Required:
1 each, small, clean funnel
Never mix oil with gasoline. Four cycle engines are not designed to be operated with oil mixed with the gasoline.
1) Determine the location of the fuel tank filler cap.
2) Carefully clean the filler cap and surrounding area to insure that no dirt or debris falls into the fuel tank. Remove the filler cap.
3) Fill the fuel tank with fresh, clean, unleaded automotive gasoline. Leaded “regular” grade gasoline is an a acceptable substitute. DO NOT USE GASOLINE CONTAINING METHANOL (WOOD ALCOHOL) Gasoline containing a maximum of 10 percent ethanol or grain alcohol (sometimes referred to as Gasohol) may be used but requires special care when the engine is stored for extended periods.
4) Use of a properly blended gasoline for operation during the intended season will result in easier engine starting. Do not use gasoline left over from the previous season of operation.
5) Do not overfill the tank or spill any fuel. If the fuel tank incorporates a screen mesh to prevent debris from falling into the tank, do not remove to increase the fill rate. Replace the filler cap. Wipe away any excess spilled fuel.
OPERATION
CALIFORNIA PROPOSITION 65 DISCLAIMER
Application: SP684 SURFACE SHARK
THE ENGINE EXHAUST AND BY/PRODUCTS FROM THE OPERATIONAL PROCESS OF THIS PRODUCT CONTAIN CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS, OR OTHER REPRODUCTIVE HARM.
SPARK ARRESTOR DISCLAIMER
Application: SP684 SURFACE SHARK
DO NOT OPERATE THE SURFACE PLANER ON ANY FOREST COVERED, BRUSH COVERED, OR GRASS COVERED, UNIMPROVED AREAS UNLESS AN APPROVED SPARK ARRESTOR IS INSTALLED ON THE MUFFLER. THE SPARK ARRESTOR MUST BE MAINTAINED IN PROPER WORKING ORDER BY THE OWNER AND/OR OPERATOR. IN THE STATE OF CALIFORNIA, THE ABOVE IS REQUIRED BY LAW. OTHER STATES MAY HAVE SIMILAR LAWS. FEDERAL LAWS WILL APPLY ON FEDERAL LANDS. LAWS WILL VARY WITH USE IN SPECIFIC COUNTRIES.
THEORY OF OPERATION
Application: SP684 SURFACE SHARK
The SP684 Surface Planers operate on the principle of various flail configurations being operated at high
DO NOT SMOKE NEAR THE FUEL TANK. DO NOT FILL THE FUEL TANK WITH THE ENGINE RUNNING OR IF IT IS HOT. ANY FUELS ARE EXTREMELY FLAMMABLE. ALLOW AMPLE TIME BETWEEN EACH REFUELING FOR THE ENGINE TO COOL. AN IGNITION SOURCE IN CLOSE PROXIMITY TO THE FUEL TANK CAN BE THE SOURCE OF AN EXPLOSION, RESULTING IN PROPERTY DAMAGE AND/OR PERSONAL INJURY.CONSULT
rotational speeds to make direct contact with a work surface. A series of flails are spaced and aligned on shafts that span a specified width and rotate on a drum that can be raised or lowered at the discretion of the operator. The specific flail configuration and impact rate directly affect the rate of material removal from the work surface, the resulting surface profile and texture.
PAGE 12 SP684 SURFACE SHARK SURFACE PLANER
The planing process is directly controlled by these conditions:
Several Factors Directly Affect the Selection of a Flail Design for a Specific Job Application:
1) The use of a suitable mechanism (flail) of sufficient strength and hardness to impact the work surface and remove material while delivering an acceptable service life.
2) Sufficient static weight supporting the flails which allow them to effectively penetrate the work surface and remove material.
3) Adequate horsepower capable of propelling the rotating flails against the work surface to deliver acceptable productivity rates.
Since no two materials are exactly alike, no two work surface materials can be penetrated and removed by the exact same method. The nature of the planing process, along with operator experience, skill and common sense, would suggest that efficient and productive material removal is a matter of trial and error. Combinations of flail type, condition, configuration, spacing along the width of the flail drum and feed rate are direct factors that will determine the overall success of the job application.
FLAIL DESIGN AND APPLICATION
While individual flail design and configuration may vary, basic operational characteristics are identical: impact a work surface material and remove a percentage of the material. This common operational characteristic has led to the development of two basic flail configurations:
1) High carbon, heat treated, alloy steel designed for direct contact and removal of the surface material. The high carbon content of the flail material also helps to improve service life
1) The type and amount of material to be removed from the work surface. Materials of higher yield and tensile strengths along with the actual volume of material to be removed will generally be the first factors under consideration.
2) Purchase costs versus service life. The original purchase cost of plain, heat treated steel flails must be compared against the substantially higher costs of tungsten carbide insert flails. In turn, these costs must be compared to anticipated service life. All flails, whether of high speed steel or tungsten carbide insert design, will eventually wear to the point of requiring replacement. The amount of unproductive time spent to replace worn flails on a job can be substantially greater than the actual replacement cost of many flails. It then becomes a balance between purchase cost, productivity, service life and labor cost.
3) Surface finish and texture. The finest grained surface finish available from the planing process is comparable to a “swept or broomed” like finish. FIGURE 1. If a smooth, flat finish is desired, the planing process must be followed with a grinding or polishing type process. Many job requirements may call for large amounts of material to be removed, but followed with additional specifications requiring a finer surface finish or texture. Many times these jobs dictate the use of an aggressive flail configuration because of productivity and cost considerations. Less aggressive flail configurations can then be utilized for the final finishing sequence. Generally speaking, the more aggressive the flail configuration, the more coarse the resulting finish and texture.
2) High carbon, heat treated, alloy steel with tungsten carbide inserts brazed into the flail body. The tungsten carbide inserts are intended to directly contact the work surface and remove material. The inserts effectively resist wear and usually deliver a substantially longer service life than the plain, heat treated steel types. The flail body is designed to serve as a matrix or support for the tungsten carbide inserts, hence the requirement for heat treatment. The heat treatment process also aids the flail body in resisting wear.
FIGURE 1
SP684 SURFACE SHARK SURFACE PLANER PAGE 13
Many flail configurations are available to meet a wide variety of job application and surface material specifications. To give additional perspective to each configuration a rating system of 1 to 10 (10 being highest) has been devised.
Beam Flail
The beam type flail is manufactured from high carbon, alloy steel that is thoroughly hardened for additional service life. FIGURE 2. It is highly effective for scabbling or scarifying and delivers medium to coarse surface finish texture. Designed for medium to high speed material removal of the work surface.
Pentagonal Flail
The pentagonal flail is manufactured from high carbon, alloy steel that is thoroughly hardened for additional service life. FIGURE 3. Each section of the five sided design features a small, tungsten carbide insert that is first placed in a small hole and then held in position with copper brazing. It is highly effective for scabbling or scarifying and delivers medium to coarse surface finish texture. Designed for high speed material removal of the work surface.
FIGURE 2
Suggested applications:
1) Medium duty asphalt and concrete milling
2) Descaling steel decks
3) Removing thick material build-ups of greases, paints, oils, vegetable powders and resins from non­wood type floors
4) Dried, fully cured, carpet and tile adhesive removal
5) Painted traffic line removal
COST 1 PRODUCTIVITY 5 SERVICE LIFE 2
The beam flail should be replaced when the outside diameter is worn to approximately 1-5/16 inch or the inside diameter elongates to approximately 3/4 inch.
FIGURE 3
Suggested applications:
1) Heavy duty asphalt and concrete milling
2) Milling concrete joints
3) Asphalt and concrete grooving
The pentagonal flail is designed for more aggressive and rapid removal of a surface in comparison to the beam flail. The addition of the tungsten carbide inserts contributes to its long service life and higher production rates. The tungsten carbide is also the main reason for the cost differential between it and the other flails. The design configuration yields a rather coarse surface finish and texture. For many job applications, this finish and texture will be satisfactory. Some applications may require an additional smoothing process. For example: removing high spots or other irregularities from sidewalks. The initial process would utilize pentagonal flails for productivity and service life reasons. If the resulting surface finish is too coarse to meet specifications, it can be smoothed with the use of the beam flails.
COST 10 PRODUCTIVITY 8 SERVICE LIFE 10
PAGE 14 SP684 SURFACE SHARK SURFACE PLANER
The pentagonal flail should be replaced when two successive tungsten carbide inserts break off or the inside diameter elongates to approximately 3/4 inch. In service, the flail body will wear much faster than the tungsten carbide inserts. The copper brazing used to weld the inserts into the body can fail and an insert break off. The flail can still be used in service. It will just wear a little faster and more uneven in that particular area. As a general rule, a pentagonal flail can be utilized until there has been body wear that will no longer support the tungsten carbide inserts.
Milling Flail
The milling flail is manufactured from high carbon, alloy steel that is heat treated for additional service life. FIGURE 4. Each section of the five sided design features a rectangular, tungsten carbide insert that is held in position with copper brazing. The milling flail is primarily designed for “climb” milling applications. This requires that the Surface Planer be pulled toward the operator when being utilized. Removal rates are dependent upon both surface and substrate material composition.
To realize maximum service life, milling flails should not be utilized for the direct removal of concrete and asphaltic work surface materials. Such use will drastically reduce their service life and substantially increase project costs.
SPACER WASHERS
Application: SP684 SURFACE SHARK
Spacer washers are stamped from high carbon, alloy steel that is heat treated for additional service life. FIGURE 5.
FIGURE 4
Suggested applications:
Removing synthetic coatings, thermoplastic and cold plastic marking and lines from concrete and asphaltic surfaces.
COST 10 PRODUCTIVITY 7 SERVICE LIFE 7
Milling flails are designed to remove a variety of traffic line materials from concrete and asphaltic type surfaces. With proper techniques, minimal amounts of parent work surface material will also be removed during the planing process. Milling flails are expensive.
FIGURE 5
The function of spacer washers:
1) Reduce the number of flails required to be mounted on the flail drum, thus reducing purchase and operational costs.
2) Arrange the flails in a sequence or pattern that minimizes “blind” or “open” spots created by the additional support plates of the two section flail drum. Always insert at least one spacer washer between two (2) consecutive flails. The exception to this rule is a configuration where its design does not require the use of spacer washers. A flail drum set up with only pentagonal flails and no spacer washers will not penetrate the work surface at satisfactory rates. Typical configurations minimize the hammering or impact action of the flails. However, this can also be useful when removing traffic lines.
3) Allow the flails to be arranged on the one section flail drum in configurations of specific widths for many job applications. An example would be the use of pentagonal flails to groove a concrete floor. The spacer washers are used to position the pentagonal flails at the desired width. FIGURE 6.
SP684 SURFACE SHARK SURFACE PLANER PAGE 15
Variances in material thickness and manufacturing processes can affect the final thickness of both flails and spacer washers. Because of this occurrence, trial and error is important for assembling flails and spacer washers on a flail drum. By mixing and matching flails and spacer washers of specific thicknesses, the required number of components can be assembled on a flail drum in a minimum amount of time.
USE ONLY FACTORY SUPPLIED SPACER WASHERS ON THE FLAIL DRUM. OTHER WASHER TYPES AND/OR CONFIGURATIONS CAN PRODUCE ABNORMAL WEAR AND ELONGATION, RESULTING IN COMPLETE SEPARATION FROM THE FLAIL DRUM. SPACER WASHER SEPARATION CAN RESULT IN PROPERTY LOSS AND/OR PERSONAL INJURY.
FIGURE 6
FLAIL DRUM RODS
Application: SP684 SURFACE SHARK
FIGURE 7
Problems Encountered by Uneven Component Wear:
1) Inadequate free play exists between the flails/spacer washers and the support plates of the flail drum. If the flails and spacer washers do not have complete freedom of movement, they will not be capable of properly rotating about the flail drum rod. The result is rod wear confined to two locations that are usually 180 degrees apart. FIGURE 8. Variances in flail and spacer washer thicknesses affects free play when assembled on the drum. Because free play is also created during the planing process due to actual flail and spacer washer wear, a certain amount of “tightness” can sometimes be tolerated without affecting the service life of the drum rods or flails. The specific amount of “tightness” can usually be determined through trial and error. If the flails and spacer washers appear too tight on the drum, remove an appropriate flail or washer and reassemble the drum. If a short, operational test indicates normal component wear patterns, the apparent problem has been solved. A general rule for consideration: it is better to have the flails and spacer washers a “little too loose” on the drum than a “little too tight”.
Flail drum rods are manufactured from 1/2 inch diameter alloy steel. They are heat treated in a two step process that yields a surface hardness that resists wear and extends service life.
Drum rod service life is difficult to predict because of the large number of flail configurations and work surface materials. Normal wear should be uniform about the rod circumference. FIGURE 7.
PAGE 16 SP684 SURFACE SHARK SURFACE PLANER
FIGURE 8
2) Mixing both worn and new flails on the drum. Proper flail action against the work surface material requires that the flails be of the same, approximate dimensions. Flails with various inside and outside dimensions will not impact the work surface material with the same intensity and deliver the same results. Flail rod wear is directly proportional to the amount of force it must supply against each, individual flail. When a rod can no longer supply adequate force against the flails, it will break, allowing the flails to be hurdled against the inside of the Surface Planer frame. The more aggressive flails require greater forces to keep them contained on the rod. These forces, in turn, create faster and/or uneven rod wear rates.
THE MINIMUM ALLOWABLE DRUM ROD DIAMETER IS 3/8 INCH AS MEASURED ALONG ANY PART OF ITS CIRCUMFERENCE AND/OR LENGTH. ANY DRUM ROD NOT MEETING THIS MINIMUM DIMENSION STANDARD SHOULD BE PROPERLY DISCARDED AND REPLACED WITH AN APPROVED, FACTORY REPLACEMENT PART ONLY.
UNDER NO CIRCUMSTANCE IS WELDING AND/OR ANY OTHER TYPE OF METAL BUILD-UP PROCESS ALLOWED TO BE PERFORMED ON A WORN DRUM ROD. TYPICAL MAINTENANCE TECHNIQUES CAN ALTER THE ORIGINAL HEAT TREATMENT PROCESS AND COMPROMISE THE STRUCTURAL INTEGRITY, RESULTING IN PROPERTY DAMAGE AND/OR PERSONAL INJURY.
On occasion, it may be necessary to remove severely worn drum rods from the flail drum by the use of a band saw or similar device. FIGURE 9. Proper preventative maintenance and operational procedures will minimize these occurrences.
Because flail drum rods are a critical component of the actual planing process, it is important that each rod be inspected on a regular basis to determine proper structural integrity.
INSPECT EACH FLAIL DRUM ROD ON A REGULAR INTERVAL TO DETERMINE PROPER STRUCTURAL INTEGRITY. USAGE RATES AND OTHER OPERATING PARAMETERS WILL DETERMINE PROPER INTERVAL RATES. IF THERE IS ANY QUESTION REGARDING THE VISUAL STRUCTURAL INTEGRITY OF A DRUM ROD, PROPERLY DISCARD AND REPLACE IT WITH AN APPROVED, FACTORY REPLACEMENT PART ONLY.
FIGURE 9
SP684 SURFACE SHARK SURFACE PLANER PAGE 17
Utilize proper personal protection devices and exercise caution when attempting this procedure. Secure/stabilize the drum on a solid surface to prevent accidental rotation.
FLAIL DRUM DESIGN AND APPLICATION
Application: SP684 SURFACE SHARK
Flail drums are manufactured from alloy steel and heat treated to extend the service life. Drums are classified by the number of sections between the side plates.
FIGURE 10
The one section flail drum incorporates the four flail rods supported only by the end plates. FIGURE 10. To provide additional stability and structural rigidity for the drum rods, four support straps are included as a standard accessory. These support straps can be installed about the flails in lieu of the standard spacer washers. FIGURE 11. Additional support straps can also be assembled as required to provide for additional rigidity for the drum rods.
FIGURE 11
Never operate the one section drum without the use of a proper quantity of support straps to provide for additional stability and structural integrity. Property damage and/or personal injury can result.
The added flexibility of the one section flail drum can be especially useful on many, specialized job applications. These job applications are usually limited to grooving, or light scabbling and scarifying applications. Example: grooving concrete floors to minimize the chance of animals and humans from falling and sustaining injuries. This end result can be readily accomplished by the correct spacing of flails, spacer washers and support straps on a one section drum. FIGURE 12.
FIGURE 12
PAGE 18 SP684 SURFACE SHARK SURFACE PLANER
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