Multiquip DFG User Manual
)
OPERATION AND PARTS MANUAL
Electric, Gasoline and Propane Converted
Electric and Gasoline
Crack Saw
Model CS8 Series
Surface Grinders
Model DFG Series
Revision #4(05/28/09
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
TABLE OF CONTENTS
MULTIQUIP DFG SERIES SURFACE GRINDERS
Table Of Contents................................................................................................................................. 3-4
Parts Ordering Procedures ................................................................................................................... 6
Notice to Operators............................................................................................................................... 7-8
Operator Instructional Data Sheet ........................................................................................................ 9
Safety Precautions................................................................................................................................ 10
Preparation ........................................................................................................................................10-11
Operation ........................................................................................................................................... 12-13
Maintenance, Repair and Storage..................................................................................................... 13-14
Assembly .............................................................................................................................................. 15
Removing the SURFACE GRINDER from the Pallet ........................................................................15
Installing the SSG24-1000 Safety and Dust Shield Assembly Kit..................................................... 16
Before Starting the Engine.................................................................................................................... 17
Filling the Engine Crankcase with Oil ................................................................................................ 17
Filling the DFG/G Series Engine Fuel Tank ......................................................................................17
Assembly Instructions/Operation.......................................................................................................... 18
Theory of Operation........................................................................................................................... 18
Multi-Accessory Attachments and Applications................................................................................. 19-26
Installing a Multi-Accessory Attachment (not including multi-segmented, dry diamond discs)
in the counter-rotating discs............................................................................................................... 26-27
Removing a Multi-Accessory Attachment (not including multi-segmented, dry diamond discs)
from the counter-rotating discs .......................................................................................................... 28-29
Transporting the Surface Grinder ...................................................................................................... 29
Adjusting the Operator Handle Height............................................................................................... 30
Starting the DFG/E Series Electrically Powered Surface Grinder On the Job Site ........................... 30-32
Starting the DFG/G Series Gasoline Powered Surface Grinder On the Job Site ............................. 32-33
Operating the Surface Grinder on the Job Site .................................................................................33-36
Stopping the DFG/E Electrically Powered Surface Grinder ..............................................................36
Stopping the DFG/G Gasoline Powered Surface Grinder ................................................................. 36
Operational Parameters and Techniques for DFG Series Surface Grinder’s ...................................36-39
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV. #4 (05/28/09) PAGE 3
Maintenance/Service ............................................................................................................................40
Preventative Maintenance Check List ............................................................................................... 40
Checking V-Belt Tension and Alignment ........................................................................................... 40
Installing a Replacement V-Belt or Centrifugal Clutch or Pulley .......................................................41-43
Replacing the LORD® Type Elastomeric Mounts on the Multi-Accessory Discs.............................. 44
Lubrication Requirements.................................................................................................................. 45
Electric Motor Service........................................................................................................................ 46
Engine Service................................................................................................................................... 46
Troubleshooting .................................................................................................................................... 47
Electric Motor..................................................................................................................................... 47
Gasoline Engine.................................................................................................................................... 47-48
Storage ................................................................................................................................................. 49
Specifications........................................................................................................................................ 50
Explanation of Code In Remarks Column ............................................................................................ 52
Suggested Spare Parts......................................................................................................................... 53
Component Parts Drawings
Operator Handle Assembly (Electric) ................................................................................................ 54-55
Operator Handle Assembly (Gasoline).............................................................................................. 56-57
Electric Motor Assembly .................................................................................................................... 58-59
Gasoline Engine Assembly................................................................................................................ 60-61
Wheel Assembly ................................................................................................................................ 62-63
Transmission Assembly..................................................................................................................... 64-65
Head Assembly.................................................................................................................................. 66-67
Safety and Shield Assembly.............................................................................................................. 68-69
Scarifier Assembly ............................................................................................................................. 70-71
SCRAPE-R-TACH ............................................................................................................................. 72-73
Grinder Block Assembly .................................................................................................................... 74-75
Decals ................................................................................................................................................ 76-77
Terms and Condition of Sale —Parts ................................................................................................ 78
TABLE OF CONTENTS
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV. #4 (05/28/09) PAGE 4
NOTE PAGE
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV. #4 (05/28/09) PAGE 5
www.multiquip.com
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Best Deal!
Order via Internet
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specifi cation Information
Goto www.multiquip.com and click on
Order Parts
Choose from three easy options:
(Dealers Only)
to log in and save!
:
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
To obt a in a n MQ Account, contact you r
District Sales Manager for more information.
Effective:
st
January 1
Note: Discounts Are Subject To Change
, 2006
Order via Fax
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
(Dealers Only)
:
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Note: Discounts Are Subject To Change
Order via Phone:
Domestic (US) Dealers Call:
1-800-427-1244
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
❒ Dealer Account Number
❒ Dealer Name and Address
❒ Shipping Address (if different than billing address)
❒ Return Fax Number
❒ Applicable Model Number
❒ Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL
■ Priority One ✓ Tr uck
■ Ground
■ Next Day
■ Second/Third Day
WE ACCEPT ALL MAJOR CREDIT CARDS!
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV. #4 (05/28/09) PAGE 6
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.
NOTICE TO OPERATORS
DANGER
CAUTION
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 GRINDER without first reading this Operator Manual and
becoming familiar with its operation. The manufacturer of the SURFACE GRINDER 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
removing covering materials from concrete and wood floor surfaces. Yet, the possibility exists that the SURFACE
GRINDER can be utilized in and/or subjected to job applications not perceived and/or anticipated by the
nufacturer. Such misuse and/or misapplication of the SURFACE GRINDER can lead to the possibility of
ma
serious damage, injury or even death. It is the responsibility of the owner(s) and/or operator(s) to determine that
the SURFACE GRINDER 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 GRINDER. 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 a
made to the SURFACE GRINDER. 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 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.
nd/or alterations have been
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV. #4 (05/28/09) PAGE 7
CAUTION
The concept of powered SURFACE GRINDER has been successfully utilized for many years as a practical
solution to many types of surface preparation requirements. The basic concept is proven and well
accepted within the associated marketplaces. Use of a SURFACE GRINDER 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. The body parts most noticeably affected during any
specific process are the arms, hands, wrists, shoulders, lower back and legs. The 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 utilizing a SURFACE GRINDER. 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 GRINDER. Use of the SURFACE GRINDER may only aggravate this and any other
medically related problem. 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 use of the SURFACE GRINDER. Each
potential operator must be made aware of and assume the operational and physical liability described
and/or associated with the use of the SURFACE GRINDER. Improper use of the SURFACE GRINDER can
result in property damage and/or personal injury, including death. Each potential operator not willing to
assume the operational and physical liability described and/or associated with the use of the SURFACE
GRINDER, should not operate it. Proper levels of operator experience, skill and common sense are
essential for maximizing the safe and efficient operation of the SURFACE GRINDER.
Record the SURFACE GRINDER and electric motor serial numbers in the spaces provided below.
_______________ Model Number
_______________ Serial Number
_______________ Electric Motor 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. Multiquip, Inc. reserves the right to make changes
in design, engineering or specifications and to add improvements or discontinue manufacture at any time without
notice or obligation. Multiquip, Inc. and its agents accept no responsibility for variations which maybe evident in
actual products, specifications, pictures and descriptions contained in this publication.
NOTICE TO OPERATORS
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV. #4 (05/28/09) PAGE 8
The following undersigned operators of the SURFACE GRINDER described and/or pertaining to this Operator
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, COMPREHENSION AND ACKNOWLEDGEMENT OF THE MATERIAL COMPRISING THE
ENTIRE CONTENTS OF THE APPLICABLE OPERATOR MANUAL AND APPLICABLE SAFETY AND
OPERATIONAL INFORMATION VIDEO TAPE FOR THE SURFACE GRINDER.
2) FORMALIZED OPERATOR SAFETY PROGRAM TO BE DEVISED BY THE OWNER OF THE SURFACE
GRINDER IN CONJUNCTION WITH THE CONTENTS OF THE APPLICABLE OPERATOR MANUAL AND
THE APPLICABLE SAFETY AND OPERATIONAL INFORMATION VIDEO TAPE FOR THE SURFACE
GRINDER AND THE APPLICABLE MATERIAL INCLUDED IN THE NATIONAL ELECTRICAL CODE®.
3) OSHA AND NATIONAL ELECTRIC CODE® RULES AND REGULATIONS RESEARCHED FOR AND/OR
BY THE OWNER OF THE SURFACE GRINDER AND DEEMED APPLICABLE TO THE SAFE AND
PROPER USE AND/OR OPERATION OF THE SURFACE GRINDER FOR ANY SPECIFIC JOB
APPLICATION.
4) LOCAL LAWS, REGULATIONS AND CUSTOMS RESEARCHED FOR AND/OR BY THE OWNER OF THE
SURFACE GRINDER AND DEEMED APPLICABLE TO THE SAFE AND PROPER USE AND/OR
OPERATION OF THE SURFACE GRINDER FOR ANY SPECIFIC JOB APPLICATION.
5) FORMALIZED MAINTENANCE PROGRAM FOR THE SURFACE GRINDER TO BE DEVISED BY THE
OWNER OF THE SURFACE GRINDER IN ACCORDANCE WITH, BUT NOT NECESSARILY LIMITED TO,
THE SPECIFICATIONS, GUIDELINES AND OPERATIONAL INFORMATION CONTAINED IN THE
APPLICABLE OPERATOR MANUAL.
OPERATOR INSTRUCTIONAL DATA SHEET
6) COMPREHENSIVE OPERATIONAL INSTRUCTIONS FOR THE CORRECT AND PROPER USE OF THE
SURFACE GRINDER AS PER THE CONTENTS OF THE APPLICABLE OPERATOR'S MANUAL, SAFETY
AND OPERATIONAL INFORMATION VIDEO TAPE AND APPLICABLE MATERIAL INCLUDED IN THE
NATIONAL ELECTRIC CODE®.
_______________ Operator _______________ Owner/Instructor __________ Date
_______________ Operator _______________ Owner/Instructor __________ Date
_______________ Operator _______________ Owner/Instructor __________ Date
_______________ Operator _______________ Owner/Instructor __________ Date
_______________ Operator _______________ Owner/Instructor __________ Date
_______________ Operator _______________ Owner/Instructor __________ Date
NOTE: INSERT COPIES OF THIS PAGE WITHIN THE OPERATOR'S MANUAL IF SPACE FOR ADDITIONAL
OPERATORS IS REQUIRED.
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV. #4 (05/28/09) PAGE 9
SAFETY PRECAUTIONS
THE FOLLOWING SAFETY PRECAUTIONS
PROVIDE SOME COMMON SENSE GUIDES TO
PROMOTE SAFETY AND EFFICIENCY WITH THE
SURFACE GRINDER. 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 GRINDER 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 EXHAUST FROM THIS PRODUCT
CONTAINS 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.
DANGER
DANGER
DANGER
INCORRECT USE OF THE SURFACE GRINDER
CAN RESULT IN PROPERTY DAMAGE,
PERSONAL INJURY OR EVEN DEATH. TO
REDUCE THIS POSSIBILITY, GIVE COMPLETE
AND UNDIVIDED ATTENTION TO THE JOB AT
HAND AND FOLLOW THESE SAFETY
PRECAUTIONS:
PREPARATION.
1) This SURFACE GRINDER is 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 this SURFACE GRINDER before
being allowed to utilize it. BEFORE attempting to
utilize this SURFACE GRINDER, read this
Operator's Manual, the applicable Safety and
Operating Information Video Tape and the
material supplied by the engine manufacturer to
fa
miliarize 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
GRINDER. DO NOT OPERATE THE SURFACE
GRINDER UNTIL EACH OPERATOR
COMPLETELY COMPREHENDS THE
CONTENTS OF THIS MANUAL AND THE
APPLICABLE SAFETY AND OPERATIONAL
INFORMATION VIDEO TAPE.
2) Develop a comprehensive program for the safe
operation of the SURFACE GRINDER 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 GRINDER maintenance
program. Constantly examine and upgrade this
program to guara
operator(s) safety. Each operator must be fully
instructed regarding the specifics of this safety
program.
3) Determine that the SURFACE GRINDER 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
GRINDER, contact the Customer Service
Department for specific information BEFORE
utilization. There is no charge for this service.
Do not operate the SURFACE GRINDER
without the use of the original equipment V-belt
ard. Use of the SURFACE GRINDER without
gu
an approved belt guard can lead to property
damage and/or personal injury.
4) Minors should never be allowed to operate the
SURFACE GRINDER. Bystanders, especially
children and animals, should not be allowed in
the area where the SURFACE GRINDER is in
use. The grinding 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, foreign objects and onlookers clear of
the rotating discs, multi-accessory attachments
and flying particles.
5) Oper
ators 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 GRINDER is
strenuous. If you have any condition that might
be aggravated by strenuous work, check with
your doctor BEFORE operating the SURFACE
ntee owner(s) and/or
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 10
SAFETY PRECAUTIONS
GRINDER. Guide against the possibility of back
related injuries. Always lift the SURFACE
GRINDER with leg muscles and not with the
back.
6) Prolonged use of the SURFACE GRINDER (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.
Anti-vibration 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 circul
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, non-slip
gloves to improve your grip. Good footing is
most important when operating the SURFACE
GRINDER. Wear sturdy boots with non-slip
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. Noise, generated by the
engine of the SURFACE GRINDER and the
actual process itself, can damage your hearing.
Wear approved sound barriers (ear plugs or ear
mufflers) to protect your hearing. Continuous
and regular operators should have their hearing
checked regularly.
8) Visually inspect the SURFACE GRINDER,
components, tools and accessories for damaged
or worn parts. BEFORE each use:
a) Disconnect the engine spark plug wire or
power source cable.
b) Clean and remove all accumulated foreign
matter from the wheels and determine that
each rotates freely.
c) Clean a
matter from inside the mainframe area.
d) Inspect the V-belt drive for proper tension,
wear and general condition. Replace each
component as necessary.
nd remove all accumulated foreign
ation. If any of the symptoms
e) Inspect the multi-accessory discs and
gimbal head assemblies for excessive wear
and structural integrity. Replace each
component as necessary. The multiaccessory discs rotating at high speed
during the specific process can be subject to
high wear rates if the installed attachment is
not properly maintained and/or replaced at
regular service interva
f) Determine that operator controls work freely,
all safety devices are operative and
information decals are readable.
g) Check to see that the SURFACE GRINDER
and all related accessories are in good,
mechanical condition BEFORE utilization.
h) Reconnect the spark plug wire or power
source cable as applicable.
9. 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 GRINDER and related
are not insulated. Contact with buried electrical
cables, gas lines and other hazardous items can
result in electrocution and/or an explosion.
10. Know how the controls operate. Know how to
stop the engine or electrical motor quickly in an
emergency. Always start the engine or electric
motor according to the instructions as outlined in
this manual 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.
11. Ground the DFG20E or DFG30E electrically
powered SURFACE GRINDER motors securely.
Determine that any "grounding" wire and/or
device is, in fact, properly grounding the motor.
Failure to properly ground the motor m
an electrical shock and/or electrocution,
resulting in property damage and personal,
injury including death. Electrical wiring and all
connections should be performed by a qualified
electrician. Depending upon the wiring
configuration, the electric motor is designed to
operate from either 115 or 230 volt, AC power
sources. Determine that the electric motor
voltage switch is properly selected according to
the intended and/or available power source.
Operating the electric motor from an improper
voltage/amperage power source can result in
property damage and/or personal injury.
ls.
accessories
ay cause
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 11
SAFETY PRECAUTIONS
12. When operating the DFG20E or DFG30E
electrically powered SURFACE GRINDERs on a
surface containing water or other electrically
conducting liquid, special precautions must be
taken to minimize the possibility of operator
electrocution. Once such precaution is to wire
and operate the electric motor from a clean, 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 of the power line.
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
extension cord and plug the SURFACE
GRINDER 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
13. Never exceed the recommended capacities of
the SURFACE GRINDER. Refer to the
Specifications sections 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
GRINDER. Do not attempt to eat and/or drink
while utilizing the SURFACE GRINDER.
Determine that eyeglasses and/or hearing aid
devices are properly secured.
Use of the SURFACE GRINDER is strenuous and
causes fatigue. Help prevent the cause of an
accident. Plan to take work breaks as required to
help maintain proper mental
around any area containing water.
and physical alertness.
2) This SURFACE GRINDER is not sealed or
insulated. Do not operate the SURFACE
GRINDER in an explosive atmosphere or near
combustible materials. Refer to current OSHA®
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
GRINDER refer to the Specifications section of
this manual for more detailed information
regarding fuel and lubrication requirements.
4) The SURFACE GRINDER is designed for use
by one operator. Use of the SURFACE
GRINDER by more than one operator can lead
to confusion and loss of control, resulting in
property damage and/or person
felt that more than one person is required to
operate the SURFACE GRINDER, 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 GRINDER with
onlookers close by. Caution all onlookers to
stand clear. The grinding 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) Start the engine or electric motor according to
the instructions a
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.
s outlined in this manual to
al injury. If it is
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 12
SAFETY PRECAUTIONS
7) Start and operate the SURFACE GRINDER only
in a well ventilated area. Carbon Monoxide
fumes given off by an engine are poisonous.
Breathing these fumes can result in property
damage and/or personal injury. Operate the
SURFACE GRINDER 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 GRINDER
running unattended.
Special care must be exercised on slippery
8)
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 or electric motor with the
SURFACE GRINDER directly over cracked,
uneven or irregular surfaces. Start the engine or
electric motor according to the instructions as
outlined in this manual.
10) Contact with a hot, engine muffler can cause
property damage and/or person
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 mainframe area after
each use. This practice will maximize bearing
and V-belt service life.
12) Because this SURFACE GRINDER 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, actua
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 sites surface conditions and
l surface conditions, job
al injury. Remain
operator experience/skill/common sense
recommendations for this SURFACE GRINDER
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 repa
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.
3) Always stop the engine or electric motor and
disconnect the spark plug wire or power source
cable BEFORE checking or working on the
SURFACE GRINDER.
4) Always properly maintain the SURFACE
GRINDER. 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, f
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 it
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
GRINDER 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 SURFACE GRINDER
without the use of factory approved V-belt and
diamond blade guards tha
proper structural condition. Frequently inspect
the guards for signs of wear, cracks and other
signs of fatigue. If there is any question
regarding the structural integrity and/or condition
t are maintained in
ir.
actory
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 13
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 a
genuine, factory approved, replacement part
only.
8) The SURFACE GRINDER utilizes many self-
locking type hexagon head nuts to minimize the
effects of vibration. Replace all self-locking
hardware with genuine, factory approved,
replacement parts only.
9) Consult the ma
electric motor manufacturer for specific
information relative to proper operational,
lubrication and storage requirements.
terial supplied by the engine or
SAFETY PRECAUTIONS
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 14
ASSEMBLY INSTRUCTIONS/OPERATIONS
Assembly
The DFG Series SURFACE GRINDER 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 GRINDER 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.
REMOVING THE SURFACE GRINDER FROM THE
PALLET.
Application: All Models
Tools Required:
1 each, pliers.
1 each, claw hammer or a hammer and an
appropriate pry bar.
The SURFACE GRINDER is secured to the pallet
with steel banding. Using the pliers, cut and remove
the banding. The SURFACE GRINDER ca
removed from the pallet.
DANGER
WEAR SAFETY GLASSES AND OTHER
APPROPRIATE SAFETY APPAREL WHEN
CUTTING THE STEEL BANDING AND/OR
REMOVING THE CORRUGATED/WOOD
SHIPPING CRATE.
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.
The SURFACE GRINDER is shipped from the
factory completely assembled. If ordered with the
SURFACE GRINDER, multi-accessory attachments
are normally shipped separately to minimize the
potential for loss during shipment.
Check all fasteners for proper security. Consult a
fastener torque chart for the proper torque value if
any fastener is found to require retorquing.
After April 1, 1996 all SURFACE GRINDERS are
shipped from the factory with the SG24-1000 Safety
n then be
and Dust Shield Assembly Kit included as a
standard accessory. The kit is included in a separate
package and is not normally installed by factory
personnel. The owner and/ or operator (has) have
the option to install the skirt assembly for any
specific job application. The DFG-1000 Safety and
Dust Shield is designed to perform the following job
functions:
1) To contain loose materials within the platform
area of the SURFACE GRINDER as a direct
result of a
includes materials removed from the surface as
well as any slurry mixture utilized to help
maximize material removal efficiencies.
2) To provide a method for a vacuum system to
help remove airborne dust related materials from
within the skirt assembly. Dust related materials
are usually created as a result of the grinding
process. A specific job application may require
the reduction and/or minimization of airborne
dust related materials from the atmosphere
while the SURFACE GRINDER is being
operated. The kit includes a hose and necessary
hardware to connect the skirt assembly to the 3
inch diameter vacuum attachment fitting located
at the rear of the machine. Use of the kit along
with a suitable vacuum system will not
completely remove all airborne and loose
materials directly from the work surface.
DANGER
specific grinding process. This
THE USE OF THE SG24-1000 SAFETY AND DUST
SHIELD ASSEMBLY KIT ALONG WITH A
SUITABLE VACUUM SYSTEM TO REMOVE
HAZARDOUS CLASSIFIED, AIRBORNE
MATERIALS FROM THE WORK SURFACE WILL
NOT ELIMINATE THE REQUIREMENT FOR
PROPER SAFETY RELATED EQUIPMENT,
OPERATING PLAN AND/OR PROCEDURES.
DANGER
USE OF THE SG24-1000 SAFETY AND DUST
SHIELD ASSEMBLY KIT ALONG WITH A
SUITABLE VACUUM SYSTEM WILL NOT
COMPLETELY REMOVE ALL LOOSE
MATERIALS FROM THE WORK SURFACE.
HAZARDOUS CLASSIFIED, LOOSE MATERIALS
MUST BE REMOVED FROM THE WORK
SURFACE BY PROCESSES AND/OR
PROCEDURES MEETING THE APPLICABLE
OSHA AND/OR EPA REQUIREMENTS.
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 15
ASSEMBLY INSTRUCTIONS/OPERATIONS
INSTALLING THE SG24-1000 SAFETY AND DUST
SHIELD ASSEMBLY KIT.
Application: All Models.
Tools Required:
1 each, 5/32 inch Allen wrench.
1 each, 7/16 inch wrench.
2 each, 1/2 inch wrenches.
1 each, flat blade screwdriver.
1) If the SURFACE GRINDER is powered by an
engine, disconnect the spark plug wire. If
powered by an electric motor, properly
disconnect the extension cord or SURFACE
GRINDER from the power source.
2) Using the allen wrench, remove the bumper
guard P/N 29018-016 from the machine.
3) Tilt the SURFACE GRINDER back until the
operator handle comes in contact with the
surface. The SURFACE GRINDER may not be
in a stable position in this configuration. To
minimize the possibility of property damage
and/or personnel injury, properly secure an
appropriate weight to the handle for added
stability. Other means can be utilized to support
the frame and provide proper machine sta
Appropriate wheel chocks are also
recommended. FIGURE 1.
DANGER
bility.
EXERCISE EXTREME CAUTION WHEN
WORKING NEAR OR UNDER THE SURFACE
GRINDER WITH THE OPERATOR HANDLE
TILTED BACK IN THE SERVICE POSITION. IF
THE SURFACE GRINDER IS NOT POSITIONED IN
A STABLE CONFIGURATION, WITH ADEQUATE
COUNTERWEIGHT PROPERLY SECURED,
UNEXPECTED MOVEMENT CAN ALLOW THE
SURFACE GRINDER TO FALL BACK TO THE
WORK SURFACE. THE RESULT CAN BE
PROPERTY DAMAGE AND/OR PERSONAL
INJURY.
4) Using the 7/16-inch wrench, install the wrap-
around rubber skirt P/N 29018-88 around the
outside perimeter surrounding the multiaccessory discs. Secure with cap screws P/N
106499-007 and washers P/N 29018-090. The
original bumper and cap screws can also be
utilized as an alternative attachment method.
The notches in the rubbers skirt are provided as
a means to compensate for multi-accessory
attachment wear (if applicable). Adjust the
location of the rubber skirt to provide the
necessary clearance between it and the work
surface. Improper clearance will accelera
wear. FIGURE 2.
FIGURE 1
FIGURE 2
5) Using the 1/2-inch wrenches, the rectangular
rubber skirt P/N 29018-089 is attached to the
middle support member of the main frame.
Proper installation will have the hose attach
fitting that is riveted to the skirt facing the rear of
the machine. The notches in the rubber skirt are
provided as a means to compensate for multiaccessory attachment wear (if applicable).
Adjust the location of the rubber skirt to provide
the same clearance
rubber skirt P/N 29018-088. The skirt straps PN
29018-092 provide additional support for the
rear skirt assembly. Properly secure with the cap
screws PN 06500-007 and self-locking nuts P/N
08233-005. FIGURE 3.
as with the wrap-around
te skirt
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 16
ASSEMBLY INSTRUCTIONS/OPERATIONS
FIGURE 3
6) Assemble the two each, hose clamps P/N
14821-012 over the PN 290018-093 vacuum
hose. Install the vacuum hose over the vacuum
hose attach fittings. Determine that the
configuration minimizes potential kinks or
depressions, which can reduce the airflow.
Secure the hose clamps tight with the
screwdriver.
7) The DFG-1000 Safety and Dust Shield
Assembly Kit can be removed by reversing the
above procedure and reinstalling the original
bumper P/N 29018-016
8) Return the SURFACE GRINDER to its normal
operating position.
9) If the SURFACE GRINDER is powered by a
gasoline engine, reconnect the engine spark
plug wire. If powered by an electric motor and
the machine is to be used immediately,
reconnect the extension cord or SURFACE
GRINDER to the power source. Determine that
the ON/OFF switch located on the operator
handle is in the OFF position.
DANGER
UNEXPECTED MACHINE START UP CAN
RESULT IN PROPERTY DAMAGE AND/OR
PERSONAL INJURY.
Before Starting the Engine
FILLING THE ENGINE CRANKCASE WITH OIL.
Applications: DFG/G SURFACE GRINDER.
Tools Required:
1 each, small, clean funnel.
The DFG/G Series SURFACE GRINDER is
equipped with a Honda GX340 gasoline engine. This
engine is normally not pre-serviced at the factory
and will require the addition of oil in the crankcase
before being placed in service. Consult the material
supplied by the engine manufacturer for the engine
that has been ordered with your SURFACE
GRINDER. Carefully review this material to become
familiar with specific operating characteristics,
recommendations and service requirements.
1) Determine the location(s) of both the oil filler and
oil drain plug(s).
2) Wipe oil, dust and accumulated dirt from the
filler plug area.
Using the funnel, fill the engine crankcase with a
3)
high grade motor oil. Consult the material
supplied by the engine manufacturer for proper
amount, weight and service classification.
4) Replace the oil filler plug and tighten. Wipe off
any excess oil spilled on the engine crankcase
and SURFACE GRINDER.
5) Do not operate the engine unless proper oil level
is maintained as per the material supplied by the
engine manufacturer.
FILLING THE DFG/G SERIES ENGINE FUEL
TANK.
Tools Required:
1 each, small, clean funnel.
CAUTION
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.
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 17
ASSEMBLY INSTRUCTIONS/OPERATIONS
3) Using the funnel, fill the fuel tank with fresh,
clean fuel according to the specifications
outlined in the material supplied by the engine
manufacturer. 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.
DANGER
MANY FUELS ARE EXTREMELY FLAMMABLE.
DO NOT SMOKE NEAR THE FUEL TANK. DO
NOT FILL THE FUEL TANK WITH THE ENGINE
RUNNING OR IF IT IS HOT. ALLOW AMPLE TIME
BETWEEN EACH REFUELING FOR THE ENGINE
TO COOL.
Operation
THEORY OF OPERATION.
Application: All Models.
The DFG Series SURFACE GRINDERS operate on
the principle of various multi-accessory attachments
being utilized at rotational speeds to make direct
contact with a work surface. Various types of multi-
accessory attachments are secured to recesses
provided in two, counter-rotating, aluminum discs
located on the bottom of the machine. The specific
type of multi-accessory attachment utilized during
the grinding process directly affects the type of
material removed, the material removal rate and the
resulting flatness and smoothness of the surface.
The grinding process is directly controlled by these
conditions:
1) The use of a suitable mechanism (multi-
accessory attachment) of proper design a
configuration to grind the work surface and
remove material while delivering acceptable
service life.
2) Sufficient static weight supporting the multi-
accessory attachment to allow it to effectively
penetrate the work surface and remove material.
3) Adequate horsepower capable of propelling the
multi-accessory attachment 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 n
grinding process, along with operator experience,
skill and common sense, would suggest that efficient
ature of the
nd
and productive material removal is a matter of trial
and error. Combinations of multi-accessory
attachment type, condition, and feed rate are direct
factors that will also determine the overall success of
the job application.
MULTI-ACCESSORY ATTACHMENTS AND
APPLICATIONS.
Application: All Models
While individual multi-accessory attachment design
and configuration may vary, basic operational
characteristics are identical: impact upon a work
surface materi
material. This common operational characteristic has
led to the development of the following popular
multi-accessory attachments:
Grinding Stones
Grinding stones are available in a number of grades,
including: C06 extra coarse, C10 coarse, C24
medium, C80 fine and C120 super fine grade.
FIGURE 4. All stones incorporate silicon carbide as
the abrasive medium and employ a clay binder as
the matrix material. Vitrified type stones utilize an
oven baking process that produces greater service
life over other manufa
material wears away, it exposes new, sharp, edges
of the imbedded silicon carbide material. All stones
have the identical 2" x 2" X 4" dimensions and are
secured to the machine by the use of a plastic
wedge.
FIGURE 4
The designation system for the grinding stones
utilizes a system similarly utilized for most abrasive
products: the larger the number, the finer the grain
structure and usually, the smoother resulting finish.
al and remove a percentage of the
cturing processes. As the clay
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 18
ASSEMBLY INSTRUCTIONS/OPERATIONS
a) The C06 and C10 coarse grade stones are the
most popular utilized stones and result in maximum
material removal rates. They are utilized for general
grinding and the removal of trowel marks, high spots
and rough sections on concrete surfaces. The
average service life is approximately 4 to 10 hours.
b) The C24 medium grade stone will result in lower
material removal rates. It is utilized for finer finish
grinding of concrete and rough grinding on terrazzo
and other types of stone floor configurations. The
average service life is approximately 6 to 10 hours.
c) The C80 fine grade stone will result in still lower
material removal rates. It is utilized for polishing
concrete and medium grinding on terrazzo and other
types of stone floor configur
mixture only. The average service life is
approximately 8 to 20 hours.
d) The C120 super fine grade stone will result in the
lowest material removal rates. It is utilized for final
polishing on terrazzo and other types of stone floor
configurations with a water/slurry mixture only. The
average service life is approximately 40 to 75 hours.
Tungsten Carbide Grinding Block
This multi-accessory attachment is most often
utilized on larger concrete grinding projects where
increased production and service life are required.
The block utilizes tungsten carbide balls
approximately 1/16 inch diameter that are deposited
in a molten matrix material during the manufacturing
process at a controlled r
layer deposit of tungsten carbide balls in the matrix
material. As the softer matrix material wears with
use, it exposes a new layer of fresh tungsten carbide
balls to continue the grinding process. The tungsten
carbide grinding block is considerably more
aggressive than the C10 silicon carbide grinding
stone. With the ability to renew itself during usage,
the normal life expectancy for this accessory can
approach several hundred hours. The nominal
dimensions for the tungsten carbide grinding block is
2" x 2" x 4" and is secured to the machine with a
plastic wedge. FIGURE 5.
ations with a water/slurry
ate. The end effect is a multi
FIGURE 5
Scarifier Blocks
These multi-accessory attachments are comprised
of flails and spacer washers secured in a rigid steel
case. FIGURE 6. Rotation of the two multi-accessory
discs causes the flails to impact against the work
surface with a variety of results. Scarifier blocks are
secured to the machine with plastic wedges.
Several factors directly affect the selection of a flail
design for a specific job application:
a) The type and amount of material to be removed
from the work surface. Materials of higher yield and
tensile strengths a
material to be removed will generally be the first
factors under consideration.
b) Purchase cost versus service life. The original
purchase cost of plain, heat-treated steel flails must
be compared against the substantially higher costs
of the tungsten carbide insert flails. In turn, these
costs must be compared to anticipated service life.
All flails 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 ba
between purchase cost, productivity, service life and
labor cost.
c) Surface finish and texture. The finest grained
surface finish available from the scarifying process is
comparable to a "swept or broomed" like finish. If a
smooth, flat finish is desired, the scarifying 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 c
long with the actual volume of
lance
an then be
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 19
ASSEMBLY INSTRUCTIONS/OPERATIONS
utilized for the final finishing sequence. Generally
speaking, the more aggressive the flail
configurations, the more coarse the resulting finish
and texture.
Many flail configurations are available to meet a
wide variety of job applications and surface material
specifications. To give additional perspective to each
configuration, a rating system of 1 to 10 (10 being
highest) has been devised.
FIGURE 6
Star Flail
The star flail is manufactured from high carbon steel
that is through ha
is highly effective for light cleaning or scarifying and
delivers a finer surface finish texture. FIGURE 7.
Suggested Applications:
1) Removal of thin coatings and encrusted
accumulations.
2) Cleaning concrete and asphaltic surfaces
3) Removing thick material build-ups of greases,
paints, oils, vegetable powders and some resins
from floors.
4) Light scarifying prior to the application of
coatings, toppings or sealers.
rdened for additional service life. It
FIGURE 7
COST 1
PRODUCTIVITY 3
SERVICE LIFE 1
The star 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.
Beam Flail
The beam type flail is manufactured from high
carbon steel that is through hardened for additional
service life. It is highly effective for scabbling or
scarifying and delivers medium to coarse surface
finish texture. FIGURE 8.
FIGURE 8
Suggested Applications:
1) Medium duty asphalt and concrete scarifying.
2) Descaling steel decks.
3) Removing thick material build-ups of grea
paints, oils, vegetable powders and some resins
from floors.
4) Dried, fully cured, carpet and tile adhesive
removal.
ses,
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 20
ASSEMBLY INSTRUCTIONS/OPERATIONS
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.
Pentagonal Flail
The pentagonal type flail is manufactured from high
carbon steel that is through hardened for additional
service life. Each section of the five sided design
features a small, tungsten carbide insert that is held
in position with copper brazing. It is highly effective
for scabbling or scarifying and delivers medium to
coarse finish texture. FIGURE 9.
FIGURE 9
Suggested Applications:
1) Heavy duty a
2) Heavy duty descaling of steel decks.
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 use of 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 a
additional smoothing process. If the resulting surface
finish is too coarse to meet specifications, it can be
smoothed with the use of the star or beam flail.
sphalt and concrete scarifying.
n
COST 10
PRODUCTIVITY 8
SERVICE LIFE 10
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 are
can be utilized until body wear will no longer support
the tungsten carbide inserts.
Spacer Washer
Spacer washers are stamped from high carbon steel
and heat-treated for additional service life. FIGURE
10.
FIGURE 10
Spacer washers serve the following functions:
1) Reduces the number of flails required to be
mounted on the scarifier block, thus reducing
purchase and operational costs.
2) Arrange the flails in a sequence or pattern that
minimize "blind" or "open" spots. Normally, at
ast one spacer washer is inserted between two
le
consecutive flails. A scarifier block set up with
only star, beam or pentagonal flails will not
penetrate the work surface at satisfactory rates.
This configuration will minimize the hammering
or impact action of the flails.
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
a. As a general rule, a pentagonal flail
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 21
ASSEMBLY INSTRUCTIONS/OPERATIONS
spacer washer on the scarifier block. By mixing and
matching flails and spacer washers of specific
thicknesses, the required number of components
can be assembled on a block in a minimum amount
of time.
DANGER
USE ONLY FACTORY SUPPLIED SPACER
WASHERS ON THE SCARIFIER BLOCK. OTHER
WASHER TYPES AND/OR CONFIGURATIONS
CAN PRODUCE ABNORMAL WEAR AND
ELONGATION, RESULTING IN COMPLETE
SEPARATION FROM THE SCARIFIER BLOCK.
INADVERTENT SPACER WASHER SEPARATION
CAN LEAD TO PROPERTY DAMAGE AND/OR
PERSONAL INJURY.
Scarifier Block Bushing
Scarifier block bushings are designed to be
discarded whenever the flails are replaced. FIGURE
11. Normal wear should be uniform about the
bushing circumference.
FIGURE 11
Uneven bushing wear would suggest the following
problems:
1) Inadequate free play exists between the
flails/spacer washers and the scarifier block
case. If the flails and spacer washers do not
have complete freedom of movement, they will
not be capable of properly rotating about the
scarifier block bushing. The result is bushing
wea
r usually confined to two locations that are
180 degrees apart. Variances in flail and spacer
washer thicknesses affect free play when
assembled on the scarifier block.
Because free play is also created during the
scarifying 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 bushings and flails. The
specific amount of "tightness" can usually be
determined through trial and error. If the flails
and spacer washers
scarifier block, remove an appropriate flail or
washer and reassemble the block. 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 than a little too tight".
2) Mixing both worn and new flails on the scarifier
block. Proper flail action against the work
surface material requires that the flails be of the
same a
various inside and outside dimensions will not
impact the work surface material with the same
intensity and deliver the same results. Flail
bushing wear is directly proportional to the
amount of force it must supply against each
individual flail. When a bushing can no longer
supply adequate force against the flails, it will
break, allowing the flails to be hurdled against
the inside of the SURFACE GRINDER frame.
The more aggressive flails require greater forces
to keep them contained on the block. These
forces, in turn, create faster and/or uneven
bushing wear rates.
Because sca
component of the actual scarifying process, it is
important that each bushing be inspected on a
regular basis to determine proper structural
integrity.
Wire brushes
Typical applications include light scarifying and
cleaning of concrete, asphalt, steel and tile surfaces.
Wire brushes are secured to the machine with
plastic wedges. FIGURE 12.
FIGURE 12
pproximate dimensions. Flails with
rifier bushings are a critical
appear too tight on the
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 22
ASSEMBLY INSTRUCTIONS/OPERATIONS
Wire brushes are available in a number of flat wire
sizes and resulting configurations. With continuous
use, the flat wire will take a "set" that can limit
effectiveness and overall productivity. FIGURE 13.
For best results, flat wire brushes should be rotated
end for end in the aluminum multi-accessory discs a
minimum of once for every one hour of operation.
External weight applied to the SURFACE GRINDER
will not normally increase productivity rates and only
accelerate flat wire wear rates.
FIGURE 13
Floor Brushes
Eleven inch diameter, silicon carbide impregnated,
floor brushes are availa
designs for general maintenance and cleaning
projects. FIGURE 14. They are especially effective
cleaning soiled concrete floors with the addition of
water soluble solvents. These types of brushes are
directly mounted to the multi-accessory discs with
the included 1/2 inch x 2 inch long Grade 5
capscrews. A kidney shaped drive plate is provided
on the back side of the brush. This drive plate fits
into a recess provided in the multi-accessory disc.
FIGURE 15. To maximize bristle service life, it is
recommended that the silicon impregnated brushes
be rotated between multi-accessory discs a
minimum of once for every one hour of operation.
FIGURE 14
ble in a number of styles and
FIGURE 15
SCRAPE-R-TACH® Industrial Floor Coatings
Removal System
This multi-a
remove many urethanes, epoxies, paints, mastics
and other, similar material accumulations from
concrete floor surfaces. FIGURE 16. Each assembly
utilizes two tungsten carbide inserts set at a precise
angle. The rotating inserts "cut and shave" against
the work surface material with a "scraping" action
that removes materials with highly productive
results. To increase the effectiveness of the inserts,
the scraper block design incorporates a Lord® type
rubber mount that helps absorb damaging shocks
while allowing the inserts to more easily follow local
ations in the surface contour. Units are secured
vari
to the machine with plastic wedges.
FIGURE 16
The productivity of the product is directly dependent
upon the yield and tensile strength of the material
being removed. Material thickness has also shown
to have a direct effect on overall productivity. For
example, the SCRAPE-R-TACH system is a highly
productive method for removing thick paint
accumulations from factory floors. Production rates
ccessory attachment is designed to
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 23
ASSEMBLY INSTRUCTIONS/OPERATIONS
of up to several hundred square feet per hour can be
realized. However, many thin film ( ie: 5 mill
thickness and thinner) urethane coatings present a
much more difficult removal problem. Since removal
rates are also directly affected by applied down
force, up to 300 lbs of external weight can be
applied to the SURFACE GRINDER to increase
productivity. Cement blocks or stacked bags of
cement make excellent weights and can be secured
with "bungy" cords or other means with the provided
holes in the top cover. FIGURE 17.
FIGURE 17
Each insert provides 8 scraping edges. As an edge
become dull and worn, the insert can be turned and
reinstalled to expose a new, sharp edge. FIGURE
18. When all 4 edges of one side become worn and
dull, the insert c
additional 4 edges.
Many materials such as adhesives, rubber deposits
and mastics have the tendency to extrude or smear
rather than shear from the concrete floor material.
The occurrence is also aggravated by higher
ambient temperatures. This problem can be
significantly reduced with the addition of various
amounts of water or a water saturated, fine sand
combination placed on the floor. The use of the
Safety and Dust Shield Assembly with the
SURFACE GRINDER is highly recommended to
contain the water/sand slurry mixture from damaging
surrounding walls and other vertic
FIGURE 19.
an be turned over to expose an
al surfaces.
FIGURE 18
FIGURE 19
To index the tungsten carbide insert, proceed as
follows:
Tools required:
1 each, 5/32 Allen wrench.
1) Clean the SCRAPE-R-TACH unit with a suitable
safety solvent to remove excess material buildup. Remove as much foreign material from the
female hexagon socket area of the capscrew.
This will allow the wrench to make full contact
and maximize the torque transfer to the cap
screw.
DFG-SERIES SURFACE GRINDERS OPERATION AND PARTS MANUAL REV #4 (05/28/09) PAGE 24
Loading...