Floorex Satellite 970-6 mkii Troubleshooting guide

FLOOREX PRODUCTS

1800 FLOOREX

1800 356 673

SATELLITE 970-6 MkII

SAFETY & OPERATORS MANUAL AND

PARTS LISTING

22-03-11

Machine Weight Is 360kg including 2 X 15kg weights and 6 disks

SATELLITE 970-6 MkII

1800 FLOOREX

1800 356 673

PAGE 1.

TABLE OF CONTENTS

PAGE 1. TABLE OF CONTENTS

PAGE 2. SAFETY INSTRUCTIONS

PAGE 3. SAFETY INSTRUCTIONS CONT…

PAGE 4. OPERATING INSTRUCTIONS

PAGE 5. AXLE HEIGHT ADJUSTMENT

PAGE 6. OPERATING INSTRUCTIONS CONT...

PAGE 7. OPERATING INSTRUCTIONS CONT...

PAGE 8. TOOLING REMOVAL

PAGE 9. WEIGHTS

PAGE 10. ELECTRICAL SAFETY

PAGE 11. ELECTRICAL SAFETY CONT...

PAGE 12. PROBLEM SOLVING

PAGE 13. DIAMOND TOOLING SELECTION GUIDE

PAGE 14. DIAMOND TOOLING CONT...

PAGE 15. WIRING DIGRAM

PAGE 16. PARTS LISTING

SATELLITE 970-6 MkII

1800 FLOOREX

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PAGE 2.

SAFETY INSTRUCTIONS

1. Read and understand the instructions on the machine and in this

manual and engine manual (if applicable). Different models may

have different parts and controls.

2. Equipment should only be operated by trained personnel, in good

physical condition and mental health (not fatigued). The operator

and maintenance personnel must physically be able to handle the

bulk weight and power of this machine.

3. This is a one person machine. Maintain a safe operating distance to

other personnel. Remember ‘one machine, one operator’.

4. This equipment is intended for commercial use.

5. For the operators’ safety and the safety of others, always keep all

guards and shrouds in place.

6. Never start or run machine when unattended.

7. This machine is intended for use on floor surfaces only.

8. Never start or run machine with handle folded or when disk(s) are

not in contact with the surface.

9. Do not lend or rent machine without the operating instructions for the

machine (and the engine, if applicable).

10. Wear clothing suitable for the job and for the work place including

safety shoes, hard hat, hearing protection, non fogging vented

safety goggles, and dust mask suitable for dust.

11. Keep body parts or any loose clothing away from moving parts.

Failure to comply could result in bodily injury.

SATELLITE 970-6 MkII

1800 FLOOREX

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PAGE 3.

SAFETY INSTRUCTIONS

12. Do not modify machine in any way. Only use genuine SATELLITE

parts and accessories.

13. Repairs should be performed by qualified persons only.

14. Ensure parts have stopped moving and disconnect power or spark

plug when servicing or changing blades or accessories.

15. Never operate machine in rain or if heavy moisture is present.

16. Petrol is extremely flammable and poisonous. Petrol should only be

dispensed in well ventilated areas, and only when engine is cool.

17. WARNING! POISONOUS EXHAUST GASES. Do not operate

petrol powered equipment without adequate ventilation. Carbon

monoxide is and invisible odorless gas that can harm or can kill you.

SATELLITE 970-6 MkII

1800 FLOOREX

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PAGE 4.

OPERATING INSTRUCTIONS

1. Wear clothes suitable for the job and for the work place including,

safety shoes, hard hat, hearing protection, non-fogging vented

safety goggles, and dust respirator suitable for dust.

2. WARNING! POISONOUS EXHAUST GASES. Do not operate

petrol powered equipment without adequate ventilation. Carbon

monoxide is an invisible odorless gas that can harm or can kill you.

3. Be sure all equipment is tested and tagged prior to use on any job.

4. Inspect entire area to be ground before grinding and remove any

bolts or concrete nails (etc) that could damage diamond tooling or

machine which could cause a hazardous situation.

5. Ensure there are no obstacles or existing structures that could

present a hazard to the operator. If so, take necessary action to

eliminate the hazard.

6. Fold handle into upright position (See ‘storage & diamond removal’,

following page) then tilt machine back so handle is resting on the

floor. (See figure 1c).

7. The machine takes a set of six (6) tools. Be sure the tools are of

even height.

8. Install appropriate diamond tooling or other available tooling into the

machine. Only use genuine SATELLITE tooling. Failure to comply

could result in bodily injury.

9. Tilt machine back onto the disk and unfold handle. (See operation

mode previous page)

SATELLITE 970-6 MkII

1800 FLOOREX

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PAGE 5.

AXLE HEIGHT ADJUSTMENT…

1. Axle Height should be set so that the level eye on the grinder is

centered when the machine is on a flat floor (not on a slope)

SATELLITE 970-6 MkII

1800 FLOOREX

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PAGE 6.

OPERATING INSTRUCTIONS CONT…

2. Connect machine to suitable power outlet. Only use heavy duty

power lead suitable for high current use (preferably 2.5mm² cable),

no longer than 15 meters.

3. If no power is available within the specified distance, have a

qualified person install a suitable power outlet closer to your work.

Alternatively use 4mm² cable for up to 30 meters.

4. Connect a suitable dust extractor to the machine via a 75mm flexible

hose. The machine is also designed to take the standard FLOOREX

50mm hose ends to make connection of dust extractors easy and

hassle free.

5. Keep machine clear of drainage pits and grates or any such hazard.

Failure to comply could result in bodily injury and or could damage

the machine or property.

6. Ensure machine is on a level surface and handle is not folded (see

operating mode previous page).

7. Switch on the dust extractor.

8. Hold the handles firmly and switch the machine on by pushing the

green button.

9. The Machine has overload protection. If it trips it indicates a

problem. (Example; Undersize power lead or poor power to outlet).

Refer to above 10 & 11 for recommendations on power leads.

Rectify problem and/or decrease load on grinder by using tooling

with more surface area or weights on handle. Continuing to use the

SATELLITE 970-6 when constant tripping occurs, VOIDS THE

WARRANTY!

SATELLITE 970-6 MkII

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PAGE 7.

OPERATING INSTRUCTIONS CONT…

10. Do not attempt to make any adjustments while the machine is in

operation. Any adjustments must only be performed when machine

is stopped and power disconnected.

11. In the event of the machine pulling to one side all the time; adjust

the axle height to obtain the best result. (See PAGE 5).

12. After a few minutes of grinding check the wear of the diamond

tooling. This will pay handsomely if the diamonds are wearing out

fast due to soft concrete / abrasive concrete. FLOOREX has a wide

range of diamonds to suit every need. See page 11 &12 for a guide.

13. See the chart on page 10 for tips on how to grind faster on tough

concrete and other ways problems can be rectified.

14. WARNING! Breathable silica may be generated by use and

maintenance of this machine. Silica can cause severe and

permanent lung damage, cancer, and or other serious diseases. Do

not breathe the dust. Do not rely on your sight or smell to determine

if dust is in the air. Silica may be in the air without a visible dust

cloud. If air monitoring for silica is not provided by your employer at

your work site, you must wear appropriate respiratory protection

when operating or maintaining this equipment. Consult your

employer for proper respiratory protection.

SATELLITE 970-6 MkII

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PAGE 8.

TOOLING REMOVAL

15. To remove tooling from the magnetic plugs, Tilt the machine as per

instructions in the operating instructions and grasp hold of the

diamond disk and give it a sharp pull away from the main black disk.

16. To remove the plug from the main black disk strike the black disk

beside the taper insert as shown below.

01.

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PAGE 9.

WEIGHTS

1. Weights are there to increase or decrease the pressure of the

diamonds on the surface and they can be used to ease the pressure

needed to tilt the machine over onto its back

2. The general rule is start with the weights on the bottom rung near the

wheels

3. If the grinder is not cutting you can add weights onto the head to

increase the pressure of the diamonds on the surface causing them

to cut and open up better

4. If the grinder Cuts out on overload or is cutting too fast causing the

diamonds to wear out prematurely, you can add weights one at a

time to the handle brackets until the symptoms stop.

5. It is best to remove the weights when lifting the machine for obvious

reasons

SATELLITE 970-6 MkII

1800 FLOOREX

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PAGE 10.

ELECTRICAL SAFETY

1. All electrical maintenance and repairs to be carried out by qualified

persons only.

2. CAUTION - Line terminals may be alive when main switch is in the

off position. Disconnect all power at source before performing any

maintenance or repairs.

3. WARNING - DO NOT operate the machine with any electrical

panels open.

4. WARNING - The SATELLITE 970-6 has overload protection and will

trip when under excessive load and will not allow the machine to be

switched on if it is overloaded. (Overload will automatically reset

when safe to do so.)Continuing to use the SATELLITE 970-6 when

constant tripping occurs, VOIDS THE WARRANTY!

5. Never operate machine in the rain or if heavy moisture is present.

6. Never connect or disconnect power cables with voltage present or

while under load.

7. The overload is there to protect you and the machine from harm. DO

NOT alter or adjust the over load in any way. If it is faulty, only

replace with original part that is identical to the faulty one.

8. Never bypass over current devices in this machine.

9. Disconnect all power connections and observe lock out / tag out

procedures before attempting to carry out any maintenance or repair

on any equipment.

10. Avoid any contact with any rotating parts or driven parts.

11. Never use equipment that has not been tested and tagged (including

cords).

SATELLITE 970-6 MkII

1800 FLOOREX

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PAGE 11.

ELECTRICAL SAFETY CONT…

12. When connecting the power to the machine, check the condition of

all power leads and cables on or used in conjunction with the

machine. DO NOT USE it if there are any fault(s) cuts; wear marks,

Bare wires out of plugs or sockets, etc…Get qualified persons to

repair and re-tag it as required by regulations in your country.

13. Connect machine to suitable power outlet. Only use heavy duty

power lead suitable for high current use (preferably 2.5 mm cable),

no longer than 15 meters.

14. If no power is available within the specified distance have a qualified

person install a suitable power outlet closer to your work.

Alternatively use 4 mm2 cable for up to 30 meters.

SATELLITE 970-6 MkII

1800 FLOOREX

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PAGE 12.

PROBLEM SOLVING

Diamond Grinding has many variables. When you understand some of these, you can solve a lot of

problems without a lot of bother and expense.

PROBLEM

CAUSE

REMEDY

WHAT IT IS DOING?

Machine will not

start / run.

No power is present

at cable end.

Check the power is present

with another tool.

Using another tool confirms power is

present

Machine is trying to

start on glue or

other sticky

substance.

Clear a patch with a scraper

and grind into the glue a little

at a time.

This means it only tackles a small amount

of glue at a time and keeps the glue residue

coated with dust, preventing glue build-up

on the diamonds.

Power lead is too

small in capacity or

too long.

Upgrade the power lead to

2.5mm² (15meters) max or

4mm² (30 meters max).

The long / small capacity cable is too

restrictive and can’t allow enough power

through for the machine to start / run

properly.

Use weights on the brackets

on the handle.

The weight reduces the load on the

machine thus reducing the current draw.

Machine is not

grinding at all.

No blades /

accessories in unit.

Fit blades. Note; check wear

on machine.

Very hard concrete

or glazed topping on

concrete.

Turn dust extractor down /

restrict flow. Only just control

the dust from escaping.

The extra dust accumulating on the floor

acts as an abrasive between the segments

and the floor thus exposing the diamonds

better.

Place river sand or equivalent

on the floor.

The sand is an abrasive as described

above.

Use softer grade of diamond

tooling.

The softer grade will expose the diamonds

better.

Use coarser diamond tooling.

The coarser diamond tooling can get

through the hard topping without wearing

out the diamonds too fast.

Place weights on the machine

The extra weight exposes the diamonds

better, therefore grind faster

The diamonds

are wearing out

too fast.

The concrete is:

*Soft

*Abrasive

*Rain Damaged

*A rough finish

(Scarified /brushed).

Use a powerful dust extractor

to remove as much dust as

possible.

The dust, as described acts as an abrasive

between the segments exposing the

diamonds prematurely, wasting them.

Use harder diamond matrix.

The harder segments don’t expose as

easily.

Use tooling with more

segments or area² of

segment.

The tooling with more segments or area²

doesn’t have the same weight on them,

reducing wear.

The diamonds are

too soft or too few.

Use weights on the brackets

on the handle.

The weight on the handle reduces the

weight on the diamonds thus reducing the

wear on them.

NOTE: THIS IS A GUIDE ONLY

* Wheels for hard concrete should not be used on soft concrete, and will wear out quickly.

* Wheels for soft concrete will grind very slowly on hard concrete, get hot and glaze.

SATELLITE 970-6 MkII

1800 FLOOREX

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PAGE 13.

DIAMOND TOOLING SELECTION GUIDE

DIAMOND PLUGS

CONTRACTOR RANGE

2PDB 30/40

Soft Bond –Hard Concrete Only

YELLOW

4PDB 30/40

Hard Bond –Soft/Medium Concrete, for production grinding

GREEN

4PDB 16

Hard Bond –Med Concrete –Coarse Grade, fast grinding, epoxies etc.

GREEN

2PDT 30/40

Soft Bond Turbo Plug –Aggressive Removal of glues etc, for hard concrete

YELLOW

4PDT 30/40

Hard Bond Turbo Plug 6 segment, aggressive removal of glues and coatings

ORANGE

4P3DT 30/40

Hard Bond Turbo Plug 3 segment, Extra aggressive removal of glues

WHITE

DIAMOND PLUGS

PREMIUM RANGE –LONG LASTING

2PD 30/40

Soft Bond –Hard Concrete Only

YELLOW

4PD 30/40

Hard Bond –Soft / Medium Concrete

BLUE

4PD 16

Hard Bond –Medium Concrete, Coarse Grade, Fast Removal of epoxies

SILVER

4PD 120