866-688-1032 DIAMOND TOOLS & EQUIPMENT Operators ... · Polishing and Honing a slab surface follows...

DITEQ Corporation9876 PflummLenexa, KS 66215Phone: 816-246-5515Fax: 816-246-1530www.DITEQ.com

Operators Instruction Manual

TG18 18" Grinder/Polisher P/N (Power) G00066 (Electric 5 HP 1 PH 220V) G00067 (Electric 5 HP 3 PH 240V) G00068 (Electric 5 HP 3 PH 480V) G00069 (Electric 3 HP Variable Speed) G00070 (Gasoline 11 HP) G00116 (Propane 18 HP)

Serial Number

HPManual No. 161241 (rev 2/17)©2017, Printed in USA

DIAMOND TOOLS & EQUIPMENT866-688-1032

DIAMOND TOOLS & EQUIPMENT

Toll-Free: 866-688-1032 • Fax: 877-220-4777 • Website: www.DITEQ.com2

Completely read and fully understand the contents of this Operators Instruction Manual before attempting to operate this equipment. Death or serious injury could result from the improper use of this equipment.

Safety Message Alert SymbolsSome of the safety message in the manual are emphasized with a graphic safety message alert symbol of DANGER, WARNING or CAUTION.

Indicates an imminent hazardwhich, if not avoided, will result in death or serious injury

Indicates an imminent hazardwhich, if not avoided, can result in death or serious injury

Indicates hazards which, if notavoided, could result in serious injury and or damage to the equip-ment

Hazard SymbolsAdditional information as to the nature of the hazard is provided by the following hazards symbols which appear throughout the manual in conjunction with safety message alert symbols

Read the OperatorsInstruction Manual

Safety Glasses are required to protect eyes from flying debris.

Use the appropriate Respirator for the dust exposure.

Wear the appropriate Hearing protection for the sound pressurelevels generated

Wear the appropriate head protection

Table of Contents

Section Page(s)

Safety Symbols 2

General Instructions 3

Unpacking and Assembling 4-5

Grinding and Polishing 6

Tips to increase Performance 6-7

Gas and Electric Power Options 8

Propane Power 9-23

Changing Accessories 24

SMI Silica Dust Warning 25

Hoisting / Lifting 26

Maintenance Instructions 26-27

Trouble shooting 28

Parts List/ Wiring Diagrams 29-31

Warranty BC

Wear boots with nonslip soles to prevent slipping

Operation of this machine produces lethal gases, dust and fumes.

Explosion Hazard

ALERT

Electrical shock and electrocution hazard

Keep Guards in placeduring operation

Properly lockoutmachine power sourceduring maintenanceand cleaning.

Burn Hazard and hotsurface.

Pinch Point from beltand pulley.

Properly dispose ofthe dust generated bythe operation of thismachine.

Toll-Free: 866-688-1032 • Fax: 877-220-4777 • Website: www.DITEQ.com 3

General InstructionsFor your safety and the safety of others around you, you must only operate this machine in the way it was intended.

Before operation the machine must be inspect-ed by the operator for damaged components or loose hardware to be certain the machine is in good working order.

Before operation the job site must be inspected by the operator to identify and resolve potential hazards. The work area needs to be defined and appropriately marked.

The operator must be physically able to handle the bulk weight and power of the equipment. The operator must not be in an impaired mental state so they can exercise good judgment to maintain a safe working environment.

This Grinder/Polisher is a ‘one person’ machine. All others must keep a safe distance from the machine during operation to protect them from flying debris, noise and dust.

This Grinder/Polisher must be used with the appropriate dust control methods for the job at hand. It can be used with water and a slurry/wet vacuum or dry with a fine dust vacuum with a minimum of 150CFM.

The work team must be appropriately instructed to be certain they can shut off the machine in an emergency and provide help to the operator.

Be certain the guards are in place and properly secured before the machine is deemed operational.

The Grinder/Polisher must be properly maintained following (at a minimum) the recommended main-tenance schedule in this manual and the Engine/Motor manual also supplied with the machine.

Use only genuine DITEQ parts and accessories with this equipment.

Never leave the machine running unattended.

Wear appropriate Personal Protective Equipment(PPE) including safety glasses, boots, head protection and respiratory protection.

Gasoline Powered EquipmentThe engine exhaust from thisproduct contains chemicalsknown to the State of Californiato cause cancer, birth defects orother reproductive harm.

Do not operate gasoline poweredequipment without adequateventilation. Carbon monoxide isan invisible, odorless gas that cancause death if inhaled.

Gasoline is extremely flammableand its vapors can explode if ignit-ed. Store gasoline only in approved containers, in well ventilated, un-occupied areas, away from sparks, flames or direct sunlight. Do not use gasoline as a cleaning agent. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with engine sparks or hot parts.

Parts of the engine can becomeextremely hot during use. Toprevent severe burns, do not touchthe engine until after it has cooled.

Never tamper with the governorcomponents or settings on theengine to increase the maximumspeed. Engine RPM speeds greater than the engine rating can be dan-gerous and damage the equipment.

Electrical Powered Equipment Be certain the equipment is proper-ly grounded and a Ground-FaultCircuit Interrupter (GFCI) is usedto protect the operator from Electri-cal Shock or Electrocution.

Be certain all electrical cables andconnectors are in good conditionand correctly sized for both theoperating current and the voltageof this equipment.

Adhere to all applicable electrical codes


Unpacking and AssemblingThe TG18 Grinder is a very versatile machine that can be equipped with a variety of different types of accessory mounting styles including TEQ-LOK, cup wheels and velcro-backed accessories. There are a multitude of different accessories within each of these mounting types to make this a very customizable machine capable of stripping coatings, preparing the slab surface for new coatings, grinding and polishing the slab surface. This machine also has many power options available including gasoline and propane engines, single and three phase electric, variable speed electric, voltage friendly options in 120V, electric models with soft start capability and higher horsepower machines that can offer more aggressive performance. For the electric motor options, it is important to note that there is a performance tradeoff between a voltage friendly lower horsepower motor over a larger electric motor that will require a larger electric power source to generate the higher voltages and currents. It is also important to note that an electric motor requires good clean power to operate effectively. That includes the voltage drop from the power cords and the appropriate sizing of a generator and/or circuit to accommodate the motor starting loads.

The TG18 Grinder is typically shipped from the factory in a completely assembled state. For gasolineengine models, they are usually shipped dry, without oil or gasoline. Be certain to check the oil level on a fl at surface per the engine manufacturers instructions. DO NOT OPERATE a gasoline engine without the proper oil level or permanent damage to the engine will occur.

On all models, the operator will need to verify no damage to the machine occurred during transport/shipping and that all hardware is secured, check/adjust the handle for the operators ergonomic comfort, be certain the desired accessories are appropriately installed and properly adjusted for the accessory height, to be certain the dust skirt is properly adjusted for the desired dust capture and to be sure the operator is properly trained.


To adjust the grinder dust skirt simply reposition it with a desired air gap at the bottom to allow some air to pull in while the machine is in use. The amount of air gap will depend on the accessory and the size of the vacuum. This rubber dust skirt is also good for minimizing the splash when grinding wet. For some coatings it might be wise to increase the air gap to keep machine from filling with debris.

Keep the dust skirt clean so it will have a friction hold on the machine to keep it from slipping down.

To adjust the handle for the operators ergonomic comfort, loosen the two hex head cap screws just enough to allow the handle to pivot but still tight enough for the handle to remain in the position it is moved to. Then move the handle to the desired position and tighten the hex head cap screws.

To adjust the grinder to the proper accessory height, simply rotate the big knob located between the two wheels (see picture below). If the height is not properly adjusted, the machine will tend to pull to one side or the other because it is a single rotating disc and with an uneven force on either the front or back of the rotating disc with cause a reaction force that with push the machine to one side.

Handle Adjustment Hex Head Cap Screws

Accessory Height Adjustment Knob


GrindingThe grinding process involves aggressive diamond tools to cut through the slab surface. The more aggressive diamonds leave a scratch pattern that is highly visible. The higher the diamond grit acces-sory number equates to a smaller physical size of the diamond crystal, and smaller crystals are less aggressive but leave a less visible scratch pattern. Some slab surfaces are treated with cure-n-seals that are invisible to the human eye, or are hard troweled finishes that are equally difficult to penetrate without using large diamond crystals (ie lower grit sizes like 16G or 24G). Some cure-n-seals melt with high temperatures and coat the diamonds. It is sometimes best to use a little water to create a slurry or to slow the disc speed down on the variable speed models, when grinding these types of cure-n-seals.

To remove the deeper scratches from a previous grit and replace them with a shallower scratch pat-tern of a higher grit simply double the grit number of the first step (for example, 30G to 60G).

The rotary grinders with the right tooling can be very aggressive and if used improperly can damage the slab surface. Be certain to keep the machine moving at all times while the disc is turning (until the disc comes to a complete stop). To prevent ‘corn rows’ it is best to move in a slight sweeping motion to blend the newly ground area with the previously ground area.

Polishing and Honing a slab surface follows the grinding process. To transition from metal bonds in the grinding process to semi-metal or resin bonds is to divide the number of the last grinding step grit by two and start with that grit number accessory semi-metal or resin bond (example from 100G metal to 50G resin or semi-metal).

The typical progression is to double the grit number to remove the scratches from the previous step.Semi-metals can be treated like a resin bond for the step in the progression process but unlike the resin bonds, they are much more aggressive tools and act much like a metal hybrid.

Accessories can be very hot after grinding. Burn hazard- Do not touch hot accessories until they have enough time to cool down.

Tips to Increase PerformanceThe TG18 Grinder can be a versatile machine because of all the types of accessories and the variety of accessories available to use on this machine. There are many choices that will impact the performance of the machine. Six very common ones include:

(1) Contact Pressure.

(2) “Floating” vs “Rigid” tooling.

(3) Keeping the Diamonds Open.

(4) Using the Optimum size Diamond.

(5) Do not exceed the practical working limits of the machine.

(6) Selecting the best type of tooling for the job at hand.


(1) Contact Pressure - A rule of thumb for contact pressure is that the higher the contact pressure the faster the grinding. Most folks mistake contact pressure for weight. Basically the contact pressure is the weight on the accessories divided by the entire area of all the accessories. An analogy to this is walking on snow, with the same weight of a person wearing snowshoes to spread the weight over a large area might be able to walk on the crusted snow verse the same person using a pogo stick would probably break through the crust on the snow. The lesser area will increase the contact pres-sure on the accessories. The TG18 Grinder can accommodate 8 TEQ-Lok accessories. A simple way to increase the contact pressure, is to only use 4 of the 8. Be certain to keep the accessories equally spread out on the disc so the disc remains rotationally balanced. This is also true for the CupWheels and Velcro Backed Accessories, except the TG18 Grinder can accommodate 6 each of those type of accessories, therefore the machine can be set up to use 3.

(2) “Floating” vs “Rigid” tooling - At first blush, this concept is harder to grasp. The TG18 grinder has a working disc that measures close to 18 inches in diameter. The TEQ-Lok tooling rigidly mounts to that disc thus the slab would need to be fl at across the working width of the disc to effectively grind the entire area. The Cup Wheels are mounted loosely on the disc so they “Float” to follow the contours in the slab surface.

(3) Keeping the diamonds open - if the diamond tooling gets coated or glazed, typically from getting too hot, they will not be effective at grinding or polishing. Depending on the slab conditions and the capability of the particular machine model, the operator can vary the bond hardness by going to a softer bond (harder bonds to increase the life of the accessory), slowing down the disc speed and/or use water by either frosting or flooding the floor depending on the amount of water used. Frosting is a term used to describe using just enough water to create a slurry (looks like frosting on a cake). The slurry is abrasive and will help keep the diamonds open/exposed.

(4) Using the optimum size diamond - Typically the larger the diamond crystal (ie- small mesh/grit size) the faster the grinding. Some thin coatings and for polishing concrete, it might be best to start with a small diamond crystal to minimize the number of grinding steps for the complete job. The rule of thumb on selecting the size of diamond for the initial grinding is to start with the smallest diamond crystal (highest grit size) that the slab will let you start with. For example, if a 50Grit metal diamond will not effectively penetrate the slab skin or coating than you would want to consider starting with a 30Grit.

(5) Do not exceed the practical working limits of the machine - the laws of physics are not an option. Each little diamond crystal is a small grinding tool. If the concentration of the diamonds or the number of accessories on the machine put to many diamond crystals on the slab for the size motor/engine, than the performance of the machine will greatly suffer. For the Gasoline powered machines, the torque of the engine at a lower throttle will be less than full throttle. For electric powered machines, it is very important that the machine be supplied with good clean power. Small AWG and long extension cords will increase the voltage drop and decrease the machine performance.

(6) Selecting the best type of tooling for the job at hand - The TEQ-LOK accessories are very fast to change from one grinding step to the next ranging from large PCD’s for coating removal to TEQ-LOK velcro drivers for 2” and 3” velcrobacked polishing pads. However the 18" working width of the tooling plate exceeds the minor contours on a typical slab surface and will increase the grinding time on the initial grinding step. The cup wheels fl oat to follow the contours in the slab. Smaller cup wheels have more fl oat and larger cup wheels have longer life. There is a large variety of velcrobacked tooling for the TG18 Grinder using velcro pad drivers including vacuum brazed coarse diamonds, metal bonds, semi-metals and resin pads. If the accessory is a smaller diameter than the pad driver, be certain to center it on the pad driver to keep from having uneven wear on the accessory. It is also important to note that some tools can create higher grinding temperatures that might exceed the adhesive temp rating on the pad driver and damage it. See number-3 above for ideas on controlling heat.


Gasoline Engine Models Do not operate gasoline powered equipment without adequate ventilation. Carbon monoxide is an invisible, odorless gas that can cause death if inhaled.

Never leave the engine running unattended.

Read the Engine Operators Manual to familiarize yourself with the engine controls.

Electric Motor ModelsThe model G00066 is a 5 HP single phase induction motor wired for 220V, This machine requires a dedicated 20A outlet that is properly grounded. They are supplied with an extension cord attached to the machine and additional cords should not be used unless they are properly sized for the applica-tion by a qualified electrical service technician or electrician to be certain the machine is supplied with an adequate power to prevent damage to the motor and/or switch.

If using a generator power source, be certain it is properly sized for the motor with enough startup capacity to prevent damage to the motor.

The 3 HP Variable Speed model, G00069 uses a motor speed controller that has a forward and reverse switch (some accessories like PCD’s are directional) with a neutral between the settings. Do not change directions while the disc is spinning. To start the machine, select the rotation direction (Forward/Reverse), turn the speed control to desired disc speed and toggle the start/stop switch to start (the start is a momentary action switch to start the disc and settles to the on position). To stop the machine, simply toggle the start/stop switch to stop.

Be certain the electrical service to the machine is properly grounded.

The branch circuit must have over-current protection appropriately sized to prevent the branch circuit from overheating and causing an electrical fire.


Propane Engine Models

READ & UNDERSTAND OPERATOR'S MANUAL BEFORE USING THIS MACHINE

This symbol is used throughout this manual to warn of hazards or unsafe practices which could result in personal injury to yourself or others.

This manual is furnished with each new propane powered machine. It provides necessary operation and maintenance instructions. Read and understand the information in this manual before operating or servicing this machine.

• Check fuel cylinder for overfill before taking it into the building or placing in storage.

• Install fuel cylinder in a well ventilated place.

• Be aware of possible leaks of propane gas if odor is present.

• Check carburetor air filter for cleanness before starting engine.

• Never run engine with throttle in choke position.

• Never allow water to contact hot engine.

• Never leave the machine unattended while engine is running.

• Remove fuel cylinder and store outside in an approved cabinet.

• Secure fuel cylinders when being transported. If installed on the machine service valve must be OFF.

• Never store fuel cylinders in your van where they may be exposed to high temperatures.

• Maintain the machine as directed by the manufacturer.

• Only trained operators should be allowed to operate propane powered machines.

This publication is designed to provide accurate and authoritative information in regard to the subject matter covered. It is provided with the understanding that the publisher is not engaged in rendering legal or other professional services.

WARNINGWARNING!WARNING!WARNING!

WARNING!WARNING!WARNING!


• This propane fueled machine is intended for commercial use only. Do not use this machine other than described in this operator's manual. • All operators must read, understand and practice the safety precautions in this section as well as the "Safety Awareness Manual" included in this manual.

• Only trained and authorized operators should operate propane powered floor machines.

• Check fuel cylinders for overfill before taking them into the building or your van. Propane Safety Awareness section of this manual).

Before Operating the Machine • Check oil level. • Check Carburetor air filter. • Check abrasives and holders. • Adjust handle height. • Install fuel cylinders in a well ventilated area.

While operating the Machine

If you smell the odor of propane, stop the engine, remove the cylinder and take it outside for inspection.

Be aware of odors other than propane. Toxic emissions are produced by internal combustion engines.Properly maintained engines produce a small amount of these gases including carbon monoxide.Although carbon monoxide has no odor, the hydrocarbons do and an elevation of odor may indicateincreased CO as well.

Exhaust parts are extremely HOT. Be careful not to allow them to come into contact with anything oranyone.

Machine Storage • Stop the engine by closing the service valve on the fuel cylinder. • Remove the key from the switch, if applicable. • Remove the fuel cylinder from the machine and store it outside in a secure approved cabinet (See Propane Safety Awareness section of this manual). • Clean and inspect air and dust filters.

PROPANE SAFETY PRECAUTIONS



Starting Machine

1. Check fuel for overfill (See Propane Safety Awareness section of this manual).2. Install cylinder on machine.3. Place machine in "OPERATING POSITION" on level surface and check for correct oil level.4. Slowly open the service valve on the cylinder.

NOTE: Opening the service valve too quickly may cause the excess flow valve to stop the flow of propane. If this occurs, close the valve, wait a few seconds and re-open the valve SLOWLY!

5. Depress the e-stop switch.6. Pull the choke lever to the choke position and engage the starter by turning the key switch to start. Do not run the starter for more than 20 seconds at a time. Allow 10-20 seconds between attempts to start the engine.7. When engine starts, depress the choke lever to the off position.

NOTE: Do not run engine with throttle in the choke position! Excessive harmful

Operation Position

Grinding Process:1. Increase throttle to about 3/4 while walking forward very slowly. 2. Follow the grinding with dust or sludge removal ( dispose of properly}.

PROPANE MACHINE OPERATION




WARNING! Exhaust emissions contain harmful toxic gases; the worst being carbon monoxide. Always make certain that adequate ventilation is available. Do not leave machine unattended while the engine is running.

Stopping the Machine1. Put machine in idle mode.2. Close the service valve on the fuel cylinder while the engine is running. This serves to"purge" the fuel system of all flammable gas.3. Allow the engine to run until it stops.4. Turn the key switch to OFF.

Emergency Stopping In case of emergency, the machine can be brought to an instant stop by using the e-stop

Storing the Machine1. Remove the fuel cylinder and store in properly propane storage cage outside (see Propane Fuel Cylinders).2. After the engine has cooled completely, clean machine thoroughly, to remove all slurry, dust and debris.3. Perform all daily maintenance requirements.4. Store machine in a cool, dry, secure area where it will not be damaged by other traffic.5. Tilt the machine back on the rear caster with the diamonds off the floor.

Transporting the Machine• When transporting the machine from one job to another, secure the machine with the fuel cylinder installed and the service valve OFF!• Allow the engine to cool down before loading it.




The National Fire Protection Association (NFPA) has established standards for the storageand handling of liquefied petroleum gases. This standard is NFP A58 and is recognized inthe United States and Canada as well as some other countries. For other countries theowner must assure that the required regulations are met.

Liquefied propane will expand at 270 times into flammable vapor, which is used as fuel forpropane engines. Proper training is recommended for those operating propane poweredmachines in order to limit the hazards related to handling and storage of propane fuel cylinders(See Propane Safety Awareness section of this manual).

The fuel cylinder supplied with this machine is a D.O.T. 4E240 motor fuel cylinder. Cylindersnot banded with D.0.T. 4E240 on the top collar should never be used on propane poweredStonekor equipment. Never use a cylinder from a gas barbeque, for example, on this machine.The capacity of the 4E240 cylinder is 20 lbs. 80% of the total liquid capacity. Never allow a fuelcylinder to be overfilled. Have a cylinder filled at a reputable propane dealer and check it foroverfill before accepting it.

Checking a cylinder for overfillAlways wear frost proof gloves and a face shield before attempting to check a fuel cylinder foroverfill.

1. Take cylinder to a safe area outside, away from open flames and cigarettes.2. Open the fixed liquid level gauge (bleeder valve).3. Observe the gas exiting from the valve: white cloud= overfill, no cloud= SAFE!4. If overfill, allow to vent until vapor is clear.

Do not attempt to repair a damaged propane cylinder yourself. Return the cylinder to yourpropane vendor for authorized service.

ATTENTION: Propane fuel cylinders, whether full or empty, should be stored outside thebuilding in a secure approved cylinder storage cabinet in accordance with NFPA58. Removecylinder from machine when not in use. Local authorities may have additional requirements forfuel cylinder storage. Always consult with the local fire marshal for local codes.

CAUTION: Propane fuel cylinders used on machines are VERTICAL cylinders and should always remain in the vertical position, even when being transported or stored. This position assures the pressure relief valve and other fittings and in direct contact with the vapor in the cylinder and not the liquid. Liquid escaping from the cylinder as a result of a leak or overfilling will expand to 270 times the volume of flammable vapor.

PROPANE FUEL CYLINDERS


Warning: Before attempting any maintenance procedures on the machine, close the service valve on the fuel cylinder and stop the engine.

Repairs and adjustments to the fuel system must be made by an authorized, properly trained service technician. To keep the machine in good working condition, simply follow the daily, weekly and monthly maintenance procedure.

Preventive maintenance is the responsibility of the operator. It includes:• Checking oil level• Checking and cleaning air and dust filters.• Keeping machine clean and lubricated• Repair or replace any damaged or worn parts.• Carefully following servicing intervals and instructions

Service Intervals and Instructions:Daily Maintenance - (every four hours of operation)• Check oil level (use 10W30 or SAE30 oil only)• Check recoil dust filter.• Check and clean carburetor air filter.• Make sure all components (abrasives, holders, fuel cylinder, etc.) are secure and tight. Check diamond holders and diamonds (clean or replace).• Clean machine. If compressed air is available, blow dust from machine and engine, concentrating on the inside of engine shrouds. Wash undercarriage.

CAUTION: Care should be taken to make sure engine is cool before water is used to prevent warping and other damage.

Weekly Maintenance - (every 20 to 50 hours of operation)• All Daily Maintenance Services.• Change oil and oil filters at 50 hours of service. Use 1 OW30 or SAE30 motor oil. Use of non-recommended oil may void the engine warranty (see engine owner's manual).• Check for loose nuts and/or bolts on entire machine.• Examine all propane fuel components for leaks or wear. Replace if necessary.• Grease wheels. Use one pump only of white lithium grease. More grease than recommended may push the seals and dust covers out, allowing dust and other foreign materials to penetrate the bearings, thus shortening their life, as well as allowing grease to drop from the wheels to the floor.

PROPANE MACHINE MAINTENANCE


Monthly Maintenance-(every 80 hours of operation)• Perform all daily and weekly services• Torque cylinder head bolts: Kawasaki: 19 Ft Lb Robin: 30 Ft Lb• Torque valve cover bolts: Kawasaki: 52 Inch Lb Robin: 6.5 Ft lb• Remove engine shroud and clean cooling fans.

Quarterly Maintenance - (every 850 hours of operation)• Perform all daily, weekly and monthly services• Inspect spark plugs. ( Gap.025) Replace if necessary.• Check valve clearance (.006)• Torque valve cover bolts. Kawasaki: 52 Inch Lb Robin: 6.5 Ft lb

Changing the Oil1. The engine manufacturer recommends 10W30 or SAE30 motor oil.2. Run engine for two minutes to warm the oil.3. Make sure machine is on a level surface, with diamond plates resting on the floor. Place a container under the drain and open the oil drain valve. Allow oil to drain completely.4. Close drain valve and add 1 quart of 1 OW30 or SAE30 motor oil. Check level and add if necessary.5. Replace oil-fill cap assembly. Hand tighten only.

ATTENTION: Do not over fill oil and never run engine with low oil level.

Checking the Oil LevelWhen checking the oil, remove dip stick, wipe clean, and then reinsert the dip stick into the engine.DO NOT SCREW IN!Remove dip stick and observe oil level as indicated on the dip stick


PROPANE MACHINE TROUBLESHOOTING

Problem Cause SolutionWill not start No fuel or dirt in fuel line

Blown head gasketEngine overloadDirty air cleanerFaulty spark plugFuel system out of adjustmentDefective ignition

See engine owners manual for servicing

NOTE: Only properly trained Service Technicians should adjust or repair fuel systems!

Hard to start No fuel or dirt in fuel lineEngine overloadDirty air cleanerFaulty spark plugSpark plug or head bolts looseBlown head gasketTiming, coil or valves needadjustingRegulator needs adjustmentInsufficient vacuum

See engine owners manual for servicingNOTE: Only properly trained Service Technicians should adjust or repair fuel systems!

Lacks power Improper valve clearanceDirt in fuel lineFaulty spark plugImproper oil levelWorn rings

See engine owners manual for servicing NOTE: Only properly trained Service Technicians should adjust or repair fuel systems!

Engine overheats Incorrect oil levelEngine overloadBuild up of dirt inside engineshroud

See engine owners manual for servicing

High fuel consumption Faulty spark plugDirty air cleanersImproper fuel system adjust-ment

See engine owners manual for servicingNOTE: Only properly trained Service Technicians should adjust or repair fuel systems!

Engine stops suddenly Out of fuelFaulty spark plugLow oil

Change fuel cylindersClean, adjust/replace spark plugAdd oil (see Changing Oil notes)

Excessive vibration Loose bolts on engine or deckDiamonds not loaded properlyUneven diamondsIncorrect oil levelEngine overloadedDirty filtersFaulty spark plug

Inspect and tighten all boltsInspect and adjust diamondsCheck and reselect diamondsCheck and adjust oil levelSee engine owners manual for servicingClean or replace filtersCheck adjust/replace spark plug


Propane SafetyAwareness Manual

This Safety/Training Manual has been developed to encourage safe working habits of those using engine powered equipment fueled by propane gas. This can be may be generally applied to all ma-chines employing propane gas including small generators, pressure washers, cement finishing power trowels, etc., that are used inside buildings or enclosed spaces.

Please be reminded, this manual is not designed to instruct you on how to polish floors, but is designed to instruct you on how to avoid incidents that could be brought on by unsafe actions, poor maintenance and the lack of accurate knowledge.

Before We Begin Please ConsiderThese Important Points!

• The safety of yourself and those working around you is your responsibility!

• Only Authorized persons are allowed to operate propane powered machines. Read and understand the "Operation Manual" shipped with your machine. Make sure everyone operating the machines reads and understands the basic operation of your particular machine.

• Preventative maintenance (PM) is the responsibility of the operator.

• Regular maintenance by trained service technicians will insure long life and satisfactory performance from your propane powered machine. It will also prevent serious injury to you and others.

• Never alter or adjust the fuel system or carburetion of a propane engine. A trained service technician using the proper emission testing equipment should only do that.

The intent of this manual is that by your reading and meditating on the information contained in this manual you will be better informed and able to perform your duties of operating propane powered ma-chines in a professional and responsible manner and that you actively promote safety in the industry.


For the purpose of accurate knowledge let's examine the real hazards as mentioned on the previous page and see how they can be avoided.

Toxic EmissionsExcessive exposure to carbon monoxide is dangerous, foolish and unnecessary. The symptoms of CO poisoning are sim-ilar to the flu - headache, nausea, dizziness. Extreme exposure could result in loss of consciousness, brain damage and even death. This should not be taken lightly. Read this example.

Example#1An untrained operator was using a propane powered floor machine in a small shop. There was no ventilation and the owner wanted the doors kept shut and locked. By the time the job was completed the operator felt like he had the flu (headache, dizzy, etc.). When he went outside to load his equipment he collapsed. The paramedics were called and he was hospitalized and treated for carbon monoxide poisoning. It is also possible that brain damage may have resulted.

The machine was impounded by the Sheriff's office and tested for the production of excessive CO. It was found to be producing over 50,000 PPM CO. Upon inspection it was noted the machine was very dirty and oily. The air filters looked like a bird's nest, plugged up with dust, lint and oil. The physical appearance of the machine revealed that it was not being maintained in a professional manner. The operator had no training and had not ever seen the operation manual for the machine.

The resulting fine of $7,500 alerted the contractor to pay attention to proper maintenance and training of his work-force. The possible expensive legal problems resulting from this are even more frightening.

OSHA has set a Permissible Exposure Level (PEL) at 50 parts per million (PPM) over a time weighted average of eight hours and a ceiling of 200 PPM. This is generally safe for most industries with industrial trucks, etc., but the environment we work in, such as supermarkets, malls, schools, etc., where the public may be present, calls for a different standard. We should rather be concerned with how much CO the machine we are operating is producing, because many of the places we run these machines are small and have little ventilation. It has been recommended that any machine producing in excess of 1500 PPM CO sampled in the tail pipe should be taken out of service immediately. Most propane engines, without emission controlling systems, can run consistently below 750 to 950 PPM CO. With the addition of catalytic mufflers many record O to 10 PPM.

The one thing that determines the production of toxic emissions is the air-fuel ratio of the fuel system. If adjusted correctly it minimizes the production of CO. This is the reason it is recommended that only trained service technicians adjust the fuel system and that they use proper instruments to detect the amount of CO in the exhaust. This should be checked regularly, at least every three months.

The air fuel ratio will be affected if the air filters are dirty or oily. An imbalance in this restricts the volume of air mixed with the propane and increases the production of toxic emissions. The operator is responsible to check and correct dirty air filters every time he uses the machine. A good practice is to check this after every work shift, along with cleaning the exterior of the machine.

Something that has been overlooked by many is the effect overfilling the oil has on the production of harmful emissions. When the oil level is too high, the vacuum effect of the engine over the oil pan pulls oil vapor off the oil and distributes it on the carburetor air filter. This in tum collects dust and restricts the free flow of air to the fuel mixture. In tum, it increases the production of CO. Operators should faithfully check the oil level and keep it at the recommended level. This also is the reason it is suggested that a machine should not be left idling while tilted back for more than a few minutes.

When checking the oil level, be aware that different engine manufacturers have different instructions for checking the oil level. Some instruct to unscrew the dipstick, wipe it off and reinsert it without screwing it in, then extracting it to read the level. Others instruct the dipstick to be screwed in before reading the level. Because of the importance of maintaining the correct level you can see why you should consult the operation manual for your engine for the correct information. At all times the machine should be setting level on the floor when checking the oil.

PROPANE HAZARDS


Keep in mind that carbon monoxide has no odor at all. Generally, the slight odor you experience while operating is hydrocarbons or perhaps oil smoke from a worn engine. If the odor seems to be stronger than before the machine should be checked by a service technician to insure that it is safe. Occasionally an untrained operator will turn the machine over on the carburetor side to change the diamonds. This may allow oil to drain into the carburetor and /or the air filter. The result will be oil smoke and increased toxic emissions when the engine is restarted. Always tip the machine over, if necessary, with the carburetor on the topside.

Some manufacturers have developed machines with sensing devices that either control or monitor the emissions. Many of these use catalytic mufflers to burn off some of the toxic emissions. Some even shut the engine down if set limits are ex-ceeded. These devices have reduced, but not eliminated, incidents associated with the production of harmful emissions. If your machine has this advantage, do not try to circumvent it by disconnecting it, as some have done, and if it gives you a warning of high emissions, pay attention to it. First check the air cleaners to see if dust or oil has contaminated them. If that is not the case have the machine checked by a service technician. Do not continue to operate the machine!

Keep in mind that engines using catalytic mufflers and electronic emissions controls have no ability to reduce the toxic emissions when they are first started. Most of these machines use an oxygen sensor to detect excess emissions. The oxygen sensor, as well as the catalytic muffler, needs a few minutes running time (approximately 12 to 15 minutes) to heat up enough to be effective. So when preparing to operate machines equipped in this manner in a small store or in a large market where a census of the public is present it is suggested the engine be started outside and allowed to warm up before bringing it inside. It is not considered dangerous, but being considerate of others is always a good practice.

Fire Related HazardsAs was mentioned earlier, nearly all fire related incidents are the result of overfilled fuel cylinders or improper storage of cylinders and machines.

The Federal Department of Transportation (DOT) has set regulations, included in the National Fire Protection Association's (NFPA) standards for design, construction, marking and use of propane fuel cylinders. Included in these standards are the proper filling procedures and the propane capacity of each cylinder. This capacity is approximately 80% of the liquid capacity. The 20% not filled is for the expansion of the liquefied propane as temperatures increase. This also is the space in which vapor is generated for use as fuel for the vapor draw engines used on floor maintenance machines.The fuel cylinder is equipped with a "Fixed Liquid Level Gauge" (see fig 8.1) that can be used to determine if the cylinder is overfilled. This is a valve, with a small knurled knob on top that is connected to a "dip tube,"extending down into the cylinder about four inches, or 20% of the liquid volume. When opened, the vapor is hardly visible if properly filled. If the vapor is a white cloud spewing out, the level of the liquefied propane is above the lower end of the dip tube and liquid propane is being exhausted. If liquid propane is drawn into the regulator of the fuel system it will first of all frost up the regulator and possible damage will result to the diaphragm of the regulator. Excessive emissions will also result from the rich mixture of fuel. This would never be the case if the cylinder is checked for overfill before bringing itinto the building or attaching it to the machine. Liquefied propane gas is concentrated, or liquefied, by pressure. It is not flammable in this state (the air-fuel ratio for flammable propane gas is between 2 and 10% ). If the pressure is released, one cubic foot of liquid propane will expand to 270 cubic feet of flammable vapor, so it is plain to see that fire from over-filled fuel cylinders is 270 time likely to cause serious damage. Let's look at another example.

Example#2An operator had a fuel cylinder filled as a spare before going to the job site. It was left in his van while he stripped a floor in a large supermarket. After the stripping was complete and the buffing started the operator needed the spare fuel cylinder. He went outside to get the extra cylinder, and at the same time he opened the door to the van, he lit a cigarette. The fuel cylinder in the van had been overfilled and while sitting in the van in the hot sun the propane ex-panded to the point the pressure relief valve vented liquid propane inside the van. It quickly vaporized into flammable vapor. When the door was opened the propane gas ignited, either from his cigarette or the light in the van, and badly burned the operator. It continued to burn from the pressure relief valve and other flammable items in the van. The ex-cessive heat continued to expand the liquefied propane gas in the cylinder faster than the pressure relief valve could vent it. The cylinder exploded sending the top of the cylinder through the top of the van, coming down nearly 200 feet away. Needless to say the van was a loss. The only one hurt was the operator. Checking the fuel cylinder for overfill and venting it properly and being aware of the properties of propane and the need for proper storage could haveprevented it all. That calls attention to the need to understand an additional precaution.


ADDITIONAL CAUTION FOR PROPANE MACHINES!

In some areas your propane supplier or vendor may offer an "exchange service" where they set up asecurity storage cage/rack and exchange filled cylinders for empty ones or fill them on sight from adelivery truck. If you subscribe to that type of service be very careful to:

Make sure the vendor installs a VERTICAL cylinder rack for vertical cylinders.Check each cylinder for overfill.Check each exchanged cylinder to be assured it is a VAPOR DRAW cylinder.Check the manufacturing date on the collar to be assured it has not passed its recertification date(twelve years).

Mechanical Action of Moving and Hot Machine PartsTo some it may seem foolish to consider the danger of mechanical action of moving and hot machine parts,but how many stories have you heard of farmers reaching in to tighten a loose and rattling bolt on a radiator of an old tractor while the engine is running and losing his fingers to the rotating fan blades. The same danger is true of any moving machinery, even floor maintenance machines. Unawareness of the hazards is the cause of many accidents.

Some may feel that the protection of a clutch mounted on a floor machine is an unnecessary expense and does not contribute to the safety of operation. Please note that NFP A 58 8-4 is the standard for "General Provisions for Vehicles Having Engines Mounted on Them (Including Floor Maintenance Machines)." NFPA 58 8-4.4 says "Non-self-propelled floor maintenance machinery (floor polishers, scrubbers, buffers)and other similar equipment shall be listed and shall comply with the following ... " The term "listed" is defined as being listed by an organization like Underwriters Laboratories (UL) stating that it meets appropriate standards for safety. The UL standard for inspection (UL558) requires that the ma-chine be equipped with a clutch. So if the machine does not have a clutch it cannot be UL listed and does not pass thestandard of NFP A. How does a clutch contribute to safety?

UL uses a term we would like to avoid, "Dead-Man Switch", which is a means of stopping the action of the machine in case the operator "drops dead" or loses control of the machine. If the machine would keep on rotating after the operator let loose of the handle it could do damage to others or cause related damage, even fire or disaster to the building and persons in the building. The clutch is the "dead-man switch" that prevents this from happening. Please note the following example:

Example#3An employee of a supermarket was buffing a floor in a very confined area with a non-UL machine (no clutch}. He was overcome with carbon monoxide from the exhaust of the engine that was not properly adjusted. Collapsing, he fell over the machine. The increased weight caused the pad to melt the floor tile from heat generated by the rotating pad. The hot muffler burned the operator. Also,he came in contact with the pad rotating at 2000 RPM and received severe burns on his arms. He was hospitalized and treated for CO poisoning and burns. (The exhaust manifold can reach temperatures exceeding 800 degrees). No need to experience this to realize why a UL listed machine requiring a clutch is recommended.

A head rotating at 640 RPM may create additional hazards in some cases. If the drive plate is not inspected regularly small cracks, from the stress of the rotation or from hitting thresholds or other objects, may break away and throw sharp pieces at ankle level at tremendous speeds. If hitting a person it could do untold damage to them and hitting a window or other objects could be costly. Each time you change diamonds carefully check the drive plate and belt to be assured of safe operation! When cleaning the machine after the job is complete is a good time for this inspection.


PROPANE CYLINDERS

The 20 lb. cylinders used on propane powered floor maintenance machines is classified as a DOT 4E240 cylinder. This cylinder is generally aluminum or steel. Aluminum cylinders are lighter and do not rust.

The service pressure the cylinder is designed for is 20 psi although the pressure in the cylinder at 70 degrees Fahrenheit is approximately 130 psi. As the temperature increases the pressure also increases. The pressure relief valve in the top of the cylinder is set to start relieving the pressure when it reaches 300 psi. This pressure could be reached if the cylinder was exposed to high temperature or was overfilled. Obviously this would seldom occur.

In the event that the pressure relief valve started to vent, it is necessary to cool the cylinder as quickly as possible using water or a fire extinguisher on the body of the cylinder. If the propane vapor from the pressure relief valve should ignite do not attempt to extinguish the flame! It is consuming the propane gas as it is relieved. Instead, play the fire extinguisher or water hose on the cylinder to cool it down and lower the pressure in the cylinder. The relief valve will close and the fire will go out. Please note the following experience:

Example#4An operator was buffing a floor in a large mall when the pressure relief valve started to hiss and allowgas to escape from an overfilled fuel cylinder. He stopped the engine and closed the service valveand took the machine with the cylinder attached to the service entrance of the mall trying to get themachine outside. At some point the gas vapor ignited and fire flashed throughout the mall and flameswere coming from the pressure relief valve like a blowtorch. He and a security guard extinguishedthe flame from the pressure relief valve with a fire extinguisher and got the machine outside without itre-igniting. If the extinguisher had been played on the cylinder to cool it down the pressure reliefvalve would have closed and the fire would have been extinguished. Better than that, if the operatorhad checked the cylinder for overfill before bringing it into the building and vented it properly none ofthis would have happened. The operator was badly burned from the flash fire.

It was mentioned earlier that some fuel cylinders have exploded. That is true but seldom happens. It ispossible to heat a propane cylinder up and increase the pressure faster than the pressure relief valve canrelieve it. This generally is the case if the cylinder is overfilled and room for expansion is not available. Notethis example:

Example #5A school building caught fire and burned several classrooms as well as a storage room in whichpaper goods were stored along with a propane floor maintenance machine with a fuel cylinderattached. This was the room where the fire originated. It was discovered that the fire was started byan electrical short in a light fixture and ignited the paper products. When the heat in the room wasgreat enough to increase the pressure in the fuel cylinder, which had just been filled to a 300psi, thepressure relief valve opened and started to relieve the pressure. It obviously ignited and added to theintensity of the fire.

On later inspection, it was found that the fuel cylinder vented successfully and did not explode.Instead, it melted down in a puddle of aluminum, as did the deck of the machine. This cylinder wasnot overfilled! However, the fuel cylinder should never have been stored on the machine! It shouldhave been outside in a storage cage.

The next example involves several fuel cylinders exploding; however, those with overfilling preventiondevices (OPD) did not explode. These are devices that prevent the fuel cylinder from being filled beyond80%. NFP A 58 2-3 .1.5 ( c) stated that after April 1, 2002, no cylinder shall be filled unless it is equipped withan OPD. This, however, does not apply to floor maintenance machines at this time. It should be noted thatDOT E24 fuel cylinders equipped with OPD are available for propane powered concrete grinding andpolishing machines from cylinder manufacturers. Sometime in the future it is expected that they will berequired because of the obvious protection it provides.


PROPER STORAGE AND TRANSPORTING OF FUEL CYLINDERS

Even properly filled fuel cylinders can add to the intensity of a fire originating from a different source. It has been observed that some machines have been stored in the back room of supermarkets with the fuel cylinder attached, some with the service valve open. In one case the machine was parked under an electrical service panel in the boiler room. It does not take much of an imagination to guess what the result would be if a small leak occurred and after a buildup of propane va-por in the room the boiler started or a switch sparked. This would not necessarily be the fault of an overfilled cylinder but would be the responsibility of the operator to understand and obey standards set for safety.

MFPA58 Chapter 5 addresses the storage of portable containers. This standard says, "Containers in storage shall be located to minimize exposure to excessive temperature rise, physical damage, or tampering."

NFP A58 5-3 details what is allowed to be stored in buildings frequented by the public. NOTE: Only cylinders with a maximum LP-Gas capacity of no more than 16.8 ounces shall be permitted to be stored or displayed in buildings frequently by the public.

20 POUND capacity cylinders are not allowed to be stored in buildings frequented by the public. In addition, the standard (NFPA 58 5-4.2.1 (b) says "Containers shall be protected by a lockable, ventilated metal locker or rack that prevents tampering with valves and pilfering of the cylinder." The standard also includes the distance from any doorway or opening in the building "shall be at least 5 feet."

When transporting fuel cylinders it is recommended that the service valve is closed and the cylinders are firmly secured in the vehicle. If installed on a machine, the machine itself should be firmly secured. A fuel cylinder rolling around in the back of a pickup, trailer or van is a candidate for disaster.

Even before loading fuel cylinders that have been recently filled into your vehicle it is the course of wisdom to check the cylinder for overfill. A case in point is the following example.

Example#6Several cylinders had been received from a propane supplier after filling. The cylinders were to bedistributed to stores by a janitorial supply distributor. After sitting in the hot sun outside the warehousethey were loaded into the pickup for delivery. One cylinder started to vent propane gas from thepressure relief valve. The driver jumped up into the pickup and opened the fixed liquid level gauge tovent the excess pressure caused by overfilling. He then realized the cylinders were all overfilled so heopened the fixed liquid level gauges on the remaining ones. A spark ignited the gas combined fromall the cylinders and the heat from the venting gas raised the pressure in the cylinders until thepressure relief valves on all the cylinders opened. The heat from the additional fuel raised thepressure in the cylinders faster than the relief valves could relieve it. This resulted in an explosion ofmost of the cylinders, destroying the vehicle and damaging the building, as well as badly burning thedriver. Cooling the cylinders down with a water hose may have changed the accident to an incidentwith a different ending.

By the way, the fuel cylinders that did not explode were equipped with Overfilling Prevention Devices(OPD) and were not overfilled.


Propane is a clean burning, efficient fuel. Because of its physical makeup, it burns cleaner than gasoline and therebygenerates less harmful emissions. This is why it is used on engines used indoors and in enclosed spaces.

It is unique because it is a gas at atmospheric pressure and a liquid when stored under pressure. When released toatmospheric pressure, 1 cubic foot of liquefied propane will expand to 270 cubic feet of flammable vapor

The small horsepower propane engines used on Stonekor machines run on propane vapor. The cylinders used are"vapor draw" cylinders.

Propane gas is heavier than air, approximately 1.5 times the specific gravity of air. Knowing this we understand thatif propane leaks from the fuel system or cylinder it will lay close to the floor and seek low places like under doors.

Propane has no natural odor. The odor, ethyl mercaptian, is added for safety to enable most people to recognize itspresence.

Liquefied propane has a boiling point of -44 degrees F. If venting propane from the fixed liquefied level gauge beaware that the plume of gas can frostbite your flesh.

The limits of flammability (air-fuel ratio) of propane are between 2 and 10%.

The ignition temperature (exhaust temperature) is 920 to 1,120 degrees F.

Understanding the properties of propane will assist you in avoiding incidents that may be harmful, hurtful and expensive. For example: Knowing that liquefied propane will expand 270 times to flammable vapor emphasizes the need to avoid the release of and the danger of using overfilled cylinders.

Knowing that propane is heavier than air reminds us that propane leaks will seek to spread in low places like underdoors where it may be ignited and cause damage.

Knowing the cylinders approved by DOT are 4E240 are the only cylinders safe for use on propane powered floormachines prevents us from using cylinders designed for other services like barbecues.

Knowing the boiling point of propane helps prevent personal damage from frostbite.

Knowing the temperature of the exhaust reminds us that the hot exhaust gases can not only bum the operator butalso can cause damage to property.

Knowing that in case of a fire, keeping the fuel cylinder cold with an extinguisher or water hose may prevent aserious fire related incident.

Knowing that fuel cylinders should be stored outside of the building in the vertical position may protect you fromexpensive litigation resulting from fire damage even if it was not caused by your fuel cylinder.

Knowing how to test a fuel cylinder for overfill and knowing how to correct it will prevent most fire related incidents.

Being able to recognize the symptoms of carbon monoxide poisoning may prevent harm to yourself and/or others.

Knowing the value of preventive maintenance (PM) in preventing incidents is of great value.

PROPERTIES OF PROPANE


The TEQ-Lok accessories were created to provide a means for the operator to quickly change between different bonds or grits. It is a wedge locking system that is easy to change, but it requires the proper tools and technique.

To Install the new accessory,simply insert it in the matingwedge on the TEQ-Lok driverplate (see picture on Left).

During the grinding process,the centrifugal forces generatedon the accessory, lock it in place on the wedge to the point that it is typi-cally not removable without tapping the edge to break loose the frictionbond. Be very careful to tap the steel base part and not hit the diamond segment or plastic cup. Use a punch, chisel or screwdriver using a very soft tapping action just enough to break loose the accessory.

(3) Holes for 7" Cup wheels/Backer pads

(6) Holes for 4" or 5"Cup wheels/Backer pads

Changing Accessories

To mount the Backer Pad or the Cup Wheels, it is recommended to remove the accessory tooling plate first, then mount the accessories, and return the accessory tooling plate to the machine.

The Cup wheels mount using a spacer to allow the wheel to float. Use the cup wheels with the7/8-5/8 hole and not the threaded style.

Required Parts for AttachingCup wheels to Accessory Plateinclude:

Description Part No.Bolt - 5/8-11 x 1-3/4" 900001Lock Washer 160257Nut, 5/8-11 160255Spacer 160232

Backer pads can be flexible rubber or rigid aluminum, with a 5/8-11 threaded mount on the backer pad. The Backer pad requires a mounting bolt Part# 160254 to attach to the accessoryplate.

(8) TEQ-LOK slots


SMI Silica and Dust Warning (rev 6-20-06)

Grinding/cutting/drilling of masonry, concrete, metal and other materials can generate dust, mists and fumes containing chemicals known to cause serious or fatal injury or illness, such as respiratory disease, cancer, birth defects or other reproductive harm. If you are unfamiliar with the risks associated with the particular process and/or material being cut or the composition of the tool being used, re-view the material safety data sheets and/or consult your employer, the manufacturers/suppliers, governmental agencies such as OSHA and NIOSH and other sources on hazardous materials. California and some other authorities, for instance, have published lists of substances known to cause cancer, reproductive toxicity, or otherharmful effects.

Control dust, mist and fumes at the source where possible. In this regard, use good work practices and follow the recommendations of the manufacturers/suppliers, OSHA/NIOSH, and occupational and trade associations. Water should be used for dust suppression when wet cutting is feasible. When the hazards from inhalation of dust, mists and fumes cannot be eliminated, the operator and any bystanders should always wear a respirator approved by NIOSH/MSHA for the materials being used.

Grinding/cutting/drilling of masonry, concrete and other materials with silica in their composition may give off dust or mists containing crystalline silica. Silica is a basic component of sand, quartz, brick clay, granite and numerous other minerals and rocks. Repeated and/or substantial inhalation of airborne crystalline silica cancause serious or fatal respiratory diseases, including silicosis. In addition, California and some other authorities have listed respira-ble crystalline silica as a substance known to cause cancer. When cutting such materials, always follow the respiratory precautions mentioned above.

Be certain to use the appropriate vacuum system to control dustexposure.


Do not lift overhead.If it falls, it could killsomeone and damageproperty and themachine.

The TG18 Grinder is a heavy machine that should be lifted by atleast two people by hand or with the proper rigging material to secure itbefore lifting it off the ground.

Use blocks under the frame to fully support the frame before strappingit to cargo hold downs.

Maintenance Instructions

All repairs should be performed by qualified mechanics in accordance with good shop practices.

Keep the machine clean and in good repair. Use only genuine DITEQ parts and accessories to maximize the life of your investment.

The operator must inspect the machine daily for loose hardware and to be certain all guards and controls are properly installed and in good working condition. If, at any time, the operator feels the machine is not safe, it MUST be taken out of service, tagged to keep others from using it and sent to a mechanic for repair.

The machine should be cleaned after every daily use.

Be certain the belts are properly tensioned.

The bearing must be greased every 8 hours of use. Do not overgrease the bearing or it could damage the seals.

All machine adjustments and maintenancemust be performed only when the machineis turned off and the power cord completelydisconnected following the LOTO (Lockout-Tagout) procedures.

See Engine / Motor Operators ManualService the Motor / Engine to the recommendedmaintenance schedule provided in the respectivemanual.

DO NOT remove any guards or clean the machine without first locking out the power source so the machine can’t be started bysomeone else remotely by reestablishingpower (i.e. plugging it back in or turning back on the Circuit Breaker). Death or serious injury can result.

Hoisting and Lifting

Textured surface for tilting machine back

Lock out Power source before performing any maintenance


Changing and/or tensioning the beltsBelts must be properly tensioned. If the belts are undertensioned it will reduce the power transmitted from the motor to the grinding head and shorten the life of the belts and pulleys. If the belts are over-tensioned it will reduce the life of the belts, bearings, pulleys and motor/engine. Be certain to properly tension the belts.

The proper tension of the belts are established by the belt manufacturer. A rule of thumb is that if you can squeeze the belts with a deflection about the thickness of the belt, it is probably close to the proper tension.

Secure the belt tensioning hardware.

Tighten all the loose hardware.


Troubleshooting Guide

If the electric motor keeps tripping circuit breakers or thermal overloads - Check to see if the machine is being overloaded. Perhaps to many accessories or too much weight for the motor size. - Check to see if the machine is being supplied the proper voltage and current. Long extension cords or small wire gauge (AWG) can cause large voltage drops and starve the motor for incoming power. - Check to see if the circuit is properly sized for the machine. These machines must be operated on the appropriate sized circuit breaker, at a minimum of 20Amps. - Check to see if the motor is damaged or the capacitors cooked. This is something that should be looked at by a qualified motor center.

If the electirc motor will not start - Check to see if the motor Thermal Overload is tripped. It must be reset before it can be restarted. On the 5HP models, the overload is in the motor starter box and will require the operator to push the stop button to reset the overload. - Check to see that the power supplied to the machine is still active. - On the Variable Speed models, the start switch is a momentary toggle. Also note that there is a neutral (or STOP) position between the forward/reverse settings that must be in one of those directions to operate. Also note that the speed adjustment must be set to a speed above zero for the motor to turn.

If the accessory looses performance - Check to see if the accessory is not worn out - Check to see if the accessory is not coated or glazed.

If the machine pulls to one side or the other - Check/Adjust the level of the machine to accommodate for the accessory height.

If the machine vibrates excessively - Check to be certain the accessories are equally spread on the accessory tooling plate to keep it rotationally balanced. - Check the bearings to be certain they are not damaged or worn and that they are properly greased. - Check to be certain the correct accessory is being used for the slab conditions. - Check the machine for loose hardware or damaged parts

Use this manual as a GuideThe TG18 Grinder may have design variations and customizations that would differ from machine to machine.

Please note the Serial Number when calling DITEQ customer service for assistance.


The electric motors are protected with a thermal overload. On the 5HP motors (both single and 3 Phase) the thermal overload is in the magnetic starter box and is reset by pushing the stop button before restarting. On the Variable speed models, the overload is integrated in the motor speed controller.

Be certain the thermal overload and motor are fully cooled before reseting the overload.

Motor Speed Controller (part no. 161120)

The TG18 Grinder has a Variable Speed model, the G00069 is a 220V single phase input using the 161120 motor speed controller to a 3 phase motor.


TG18

Grin

der


Item No. DITEQ p/n Description1 Fr Weldment,ame TG182 160170 Motor Mounting plate3 Belt Cover4 Handlebar Weldment5 Cover6 160171 Belt Tensioning Plate7 Gasket, Belt Cover8 Disc Cover Weldment9 161131 Dust Shroud, (rubber dust skirt)10 Mounting Velcro, male, dust shroud11 Bearing, 2 Qty12 Key13 161134 Spindle Shaft14 161130 Isolator15 161132 Accessory Tooling Plate17 Rear Axle18 100147 Rear Wheel20 Bearing21 Accessory Height Adjustment shaft22 Accessory Height Adjustment Knob24 Hand Grip25 Vacuum hose inlet26 Y, Vacuum tube27 Vacuum Mounting Plate30 Back Plate31 Spacer34 Large Pulley35 Lift Handle36 161133 Vacuum Hose55 Hex Head Cap Screw56 Washer

160180 Drive Belt, Electric models161177 Clutch, Gasoline Models


GENERAL PROVISIONS – The warranties describedbelow are provided by DITEQ Corporation (“DITEQ”) to the original purchasers of new DITEQ Equipment from DITEQ or authorized DITEQ dealers. Under these warranties, DITEQ will repair or replace, at its option, any covered part which is found to be defec-tive in material or workmanship during the applicable warranty term. Warranty service must be performed by DITEQ or a dealer or service center authorized by DITEQ to sell and/or service the type of product involved, which will use only new or remanufactured parts or components furnished by DITEQ. Warran-ty service will be performed without charge to the purchaser for parts or labor. The purchaser will be responsible, however for any service call and/or transportation and/or freight of product to and from DITEQ’s, the dealer’s or service center’s place of business, for any premium charged for overtime laborrequested by the purchaser, and for any service and/or maintenance not directly related to any defect covered under the warranties below.

WHAT IS WARRANTED – All parts of any new DITEQ Equipment are warranted for the number of months specified below. Component manufacturers offer separate warranties and warranty terms as stated below. Warranty statements required by law covering engine emission-related parts and components are found in the engine operating manual delivered with the machine. Each warranty term begins on the date of product delivery to the purchaser.

TG18 24 MonthsBaldor Motors 12 MonthsLeeson Motors 12 MonthsHonda Gas Engines 12 MonthsKawasaki Propane Engines 36 months

WHAT IS NOT WARRANTED – DITEQ IS NOT RESPONSIBLE FOR THE FOLLOWING:(1) Used products; (2) Any product that has been modified in ways not approved by DITEQ; (3) Depreciation or damage caused by normal wear, lack of reasonable and proper maintenance, failure to follow operating instructions, misuse, lack of proper protection during storage, transporting or accident; (4) Normal maintenance parts and service.

SECURING WARRANTY SERVICE – To securewarranty service, the purchaser must (1) report theproduct defect to DITEQ, an authorized dealer or anauthorized service center and request repair within the applicable warranty term, (2) present evidence of the warranty start date, and (3) make the product available to DITEQ, the dealer or service center within a reasonable period of time.

LIMITATIONS OF IMPLIED WARRANTIES ANDOTHER REMEDIES – To the extent permitted bylaw, neither DITEQ nor any company affiliated with itmakes any warranties, representations or promisesas to the quality, performance or freedom from defectof the equipment covered by this warranty.

IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE,TO THE EXTENT APPLICABLE, SHALL BE LIMITED IN DURATION TO THE APPLICABLE PERIOD OF WARRANTY SET FORTH ON THIS PAGE. THE PURCHASER’S ONLY REMEDIES IN CONNECTION WITH THE BREACH OR PERFORMANCE OF ANY WARRANTY ON THE DITEQ EQUIPMENT ARE THOSE SET FORTH ON THIS PAGE. IN NO EVENT WILL THE DEALER, DITEQ OR ANY COMPANY AFFILIATED WITH DITEQ BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. (Note: Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitations and exclusions may not apply to you.) This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

NO DEALER WARRANTY - THE SELLING DEALERMAKES NO WARRANTY OF ITS OWN AND THE DEALER HAS NO AUTHORITY TO MAKE ANY REPRESENTATION OR PROMISE ON BEHALFOF DITEQ, OR TO MODIFY THE TERMS OR LIMITATIONS OF THIS WARRANTY IN ANY WAY.

If further information is desired, contact DITEQ.

DITEQ Corporation9876 PflummLenexa, KS 66215Phone: 816-246-5515Fax: 816-246-1530www.DITEQ.com

Limited Warranty for New DITEQ Equipment

866-688-1032 DIAMOND TOOLS & EQUIPMENT Operators ... · Polishing and Honing a slab surface follows...

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