Express Dual 3000 Membrane Panel (ENG)
Contents
1. 1 2 Adjustable Mtg Brkt V Base 2 3 Adjustable Mtg Brkt Base R H 1 4 Upright Mounting Brkt 1 5 Upright Mounting Brkt L H 1 6 Adjustable Mtg Brkt Horizontal 2 7 Mounting Brkt Clamp L H 1 8 Mounting Brkt Clamp 1 9 C Clamp 0 2 10 V Bracket Clamp Finger 7 2 11 Kip Lever M10 x 202 tete docete tede 4 12 V Bracket Stud M16 2 13 Kip Lever M12 x 30 4 14 Slide Nut M O ic etre ee itte t ATO 2 15 Nut M16 ine ie tete 2 16 Wing Nut M10 tec cte eed re im se ea 2 17 Cap Head Skt Screw M10 x25 4 18 Washer M12 2222 4 19 Washer 10 4 4 2255 4 20 Base Scale 2 21 Button Head Skt Screw x 8 isseseseeseerrrsrrierrrerrerrens 4 22 Multifix Channel not shown 2 23 Handwheoel ui iet eee tetas 2 24 Quick Nuts iiie tta dere eio ee eee 2 25 Adjustable Bracket Link Bar d 26 0 7 2 Retro fit Universal Mounting Bracket Kit Multi Fix Bracket set complete Part A4012 A3086 A4012 A4010 A4009 A4016 A4006 A4007 A9221 4003 A6118 A5401 A6121 A4180 A5508 A5509 A5116 A5315 A5310 A6601 A5125 A4087 A6186 A3166 A3061 A3072 A9500 E2. 2 5110 8 5 8 Washer 5305 9 Bush included with item 2 4 10 0 2 A4043 11 Spring Coupling 2 A9700 12 i ete ede eter RR 2 8074 13 Saddle Clamp A6851 14 5 x 10 Button Head 4 A5129 15 07 4 5318 FEED ADJUSTMENT Bernhard and Company Limited EXPRESS DUAL 9 Parts List Continued Bernhard and Company Limited Ref Name of Part Qty MAINSHAFT MOUNTING AND MAIN MOTOR DRIVE 1 Side Artri LA hse ii ae 1 2 Side Arm uis oma eae e e m ES 1 3 Rear Shaft c w circlips esses 1 4 Circlip 2 5 Main Motor 220v 6 0 2 1 Main Motor 240v 50 2 1 Main Motor 3 phase eet 1 6 Drive Pulley 60 1 Drive Pulley 50Hz meal Taperlock Bush 1108 x 19 1 Driven dtl 2 24 1 Taperlock Bush 1610 x 1 1 10 SPZ Drive Belt 60 2 gt gt gt 009 1 SPZ Drive Belt 50Hz IM 11 Drive Belt 12 eee a sc EE 1 13 Grinding gt Ba d etes 1 14 1 15 ms Sleeve and Nut assembly 1 16 Mainshaft Bearing 7 1
3. In frame Grinding Continued When Is The Job Done You will hear the cut begin to run out a rough guide of cutting times will be Fairway Units 12 20 minutes Medium Triple Units 10 15 minutes Greens amp Hand Mowers 8 10 minutes Now take off the cut by simultaneously moving both hand wheels anti clockwise when the stone is at one end of its traverse until the grinding wheel is clear of the reel Push the total E stop button NEVER stop the machine while the grinding wheel and reel are in contact except in an emergency Never allow the grinding wheel and reel to spark out If this does happen put another cut on for a few more passes EXPRESS DUAL 1 7 2 7 3 TA 7 5 7 6 7 7 7 8 7 9 NOTE Bernhard and Company Limited Electrical Fault Finding USE A QUALIFIED ELECTRICIAN In the event of any motor not starting the following procedure should be adopted Check that STOP BUTTON in control panel on top of machine is not permanently in STOP position Check fuses main fuses feeding machine and small fuses on Control PCB in main electrical box Check that reset button on junction box is not making contact with red button on the overload If it is adjust RESET so that it CLEARS THE BUTTON this must be tested with lid held in position on box see service Bulletin no 001 Check voltage in electrical box right hand side of machine
4. FIG 1 OVERALL VIEW WITH COVER REMOVED FIG 2 TABLE HEIGHT ADJUSTING DETAIL ADJUSTER Raises Lowers Left Hand Side ADJUSTER B Raises Lowers Right Hand Side Bernhard and Company Limited 48 EXPRESS DUAL LIFT TABLE EXPRESS DUAL Express Dual Lift Table The Express Lift Table is a carefully designed hydraulic lift table purpose built for attachment to the Express Dual lawn mower reel grinding machine Its robust construction and attention to detail should ensure a long and trouble free life However as with all mechanical handling devices caution is required safe operation can be assured only by constant attention to the operating and maintenance instructions contained in this manual It is therefore essential that the responsible person ensure that this machine is operated and or serviced only by suitably qualified personnel who have read and properly understood this manual If you have any service or operational problems contact your distributor or phone our Technical Helpline USA only 1 888 474 6348 or Bernhard and Company Ltd England 44 1788 811600 or email techsupport bernhard co uk use the technical support feedback form on our web site www expressdual com or www bernhard co uk Contents Safety 50 General Description 51 Operating Procedure 52 Maintenance and Adjustments 53 Fault Finding 54 Parts List and Diagrams 55 BERNHARD AND COMPANY LTD Bi
5. DV H IH 66 0 007 133HS OL 107 73s Ob cma QI H3SWON 750 133HS OL 133HS OL Bernhard and Company Limited 133HS 133HS WO 13365 WOU c 15385 13365 133HS WO 133HS WO L33HS M3Q00N3 1335 1331 4874 13365 v Y oT 3 en eT EXPRESS DUAL ED3000 gt 13365 1335 007 209 13365 WOUS 13365 WOUS 13365 WOUS gt 13365 V T3A DOY vo quvno HHH lagrams Continued D iring 10 Wi 133HS 133HS 133HS 133HS WO 1 Bernhard and Company Limited EXPRESS DUAL o o o o o o Wn n Wn wn IT I T m m f m ae P TY 2 SHEET 3 8 Bernhard and Company Limited 46 lt u Lo d EXPRESS LIFT TABLE MANUAL BERNHARD EXPRESS LIFT TABLE for Express Dual Spin Grinders Users Guide amp Instruction Manual BERNHARD Please read this manual carefully This manual should be kept in a safe place so that it can be used for future reference EXPRESS DUAL LIFT TABLE
6. belt or cover depending on which type of unit is being ground This should be done before the mower is on the grinder see example Fig 6 1 Ensure that the mower is clean and that both reel and roller bearings are in good condition Also ensure that the bedknife has been sharpened if necessary and replaced with a small amount of clearance between it and the reel Fig 6 1 Mounting Mower The mainshaft Grinding stone should be wound down to its lowest position and the unit placed on the table The unit should then be carefully moved towards the multifix brackets or front roller brackets which can be adjusted in any direction to allow the unit to be fixed in such a position that the grinding wheel can be raised towards the reel without coming into contact with either the bedknife or the front roller groomer With the mower correctly positioned the radiused pressure bar is moved forward to rest on the rear of the mower and locked in position by operating the toggle switch on the operator control panel downwards The operator should release the toggle switch as the pressure bar engages the cutting unit thus retaining pressure on the mower until the grinding operation is completed A backing up plate is supplied to protect the rear of the units and to evenly disperse the force of the pressure bar across the width of the mower see Fig 6 2 EXPRESS DUAL 6 In frame Grinding Contin
7. E 1 11 1 12 Large Bridge Handle 4 13 Rear Gas Strut nct EE epe es 2 14 MIGCFOSWITCD eere ces ae E ates 1 15 Shoulder Screw M10x12x25 8 16 M6 x 10 Button Head Socket Screw 7 17 M10 x 16 Button Head Socket 8 18 B18 3 1M 6 x 1 0 x 30 Hex SHCS 4 19 Idus zc tet tee tae etes 16 20 Long hight cate Anton E e A bcc herd 1 Part A03094 A03095 A03096 A03099 A03093 A03098 A06790 A03097 A03100 A06825 A06825 A06108 A08225 A05165 A05142 A05215 A03101 A08239 EXPRESS DUAL Bernhard and Company Limited 28 9 Parts List Continued EXPRESS DUAL ED3000 Ref Name of Part Qty Part FEED ADJUSTMENT 1 Feed Channel L H c w top and bottom cap 1 A4041 Feed Channel c w top and bottom 1 4042 2 Feedscrew c w 4 4044 Feedscrew before Serial No 12586 2 9039 Feedscrew from Serial No 12586 2 9208 4 theese eu 5502 5 Handwheel 150mm dia A6113 9 2 6278 5 8 Double Coil Spring Washer older machines 2 5303 7 5 8 whit x 5 8 Socket
8. For ideal operation the machine should be accessible from the front rear and at least one side with clearance around it as indicated in the sketch Fig 3 2 1 5m 5 ft Y C FRONT OF MACHINE 1 5m 5 ft ENSURE ADEQUATE SPACE FOR LOADING UNITS AND FOR A LIFT TABLE IF FITTED Fig 3 2 Leveling The machines should ideally be placed on a solid level floor and this should be checked by placing a spirit level on the table Check the level in both directions Steel shims should be placed under the feet as necessary to ensure that the machine is firm and level Bolt holes are provided in the feet which can be used for fixing down if required NOTE Ensure that the packing under the feet is correct before tightening the bolts otherwise Bernhard and Company Limited twisting of the frame may occur EXPRESS DUAL 3 4 3 5 Bernhard and Company Limited Installation Continued Electrical Supply USE A QUALIFIED ELECTRICIAN The EXPRESS DUAL is supplied with a 75 kW 1 HP single phase main grind motor plus 2 fractional HP motors for spin and traverse Power connection to the machine is via plug and socket termination of the lead supplied Connection is at the rear of the main electrical control box on the right hand end of the machine Ensure that any cable or conduit run to the machine does not constitute a hazard to the operator or other personne
9. at PWR plug to Control PCB Check for open circuit on overload terminals 95 and 96 to determine whether or not main motor is faulty If open press red resetting button on overload To determine that all three contactors are OK test each one by pushing the start button on the individual motors the contactors should audibly pull in This can be checked by someone looking in the junction box while the start buttons are pressed Traverse If the contactor is functioning properly check the microswitch If this is found to be OK check capacitor if possible If neither of these is faulty then the motor is probably at fault Reel Drive If the contactor is functioning properly check the Inverter Look for an error code on the display on the front of the unit Disconnect the power to the machine wait 2 minutes then re connect and try again to re set the inverter If the eroor code remains the inverter may have failed If neither are faulty then the motor is probably at fault Main Motor If the contactor is functioning correctly check the load current with an ammeter across terminal on the plug marked MAIN on the Control PCB If this exceeds full load current indicated on the motor identification plate then a new motor is needed If the reading is below full load current then possibly the overload is set too low Before assuming that there is an electrical fault in any of the systems ensure that the mechanical drive assemblies attached
10. finally check the condition of the motor brushes and their freedom to move If the lift fails to lower 1 Check the fuses 2 Check the voltage at the dump solenoid if all is OK then the solenoid has probably failed If not check back check back through the circuit to locate the loss of voltage If the table drifts drops slightly over time 1 Visually check for leaks throughout the system Power pack ram hose possible seal failure 2 Check dump valve solenoid could be debris under the seating or a valve failure TECHNICAL SPECIFICATIONS Hydraulic Oil 1 5 0 32 eg catrol hysol XH Capacity 0 9litre 2 pints USA Max Hydraulic Pressure 140 Bar Full Load Bernhard and Company Limited EXPRESS DUAL LIFT TABLE 6 Parts List Ref Name of Part Qty Part LIFT TABLE 1 cure 1 A4138 2 Power Pack 220v dedi ete eaten 1 A8954 Power Pack 24w sssssssssseeeeeeeeeem enne nnns 1 A8023 Power Pack 12v ern ER RE Ens 1 A8770 3 IH Slider Plate inh hee 1 A4127 4 R HiSliderPlate iode tend et t meg teg 1 4128 5 2 7744 6 2 A7744 7 Slider Plate 2 A4127 8 Plastic End Cap 60 x 60 2 A6194 9 FIM sires erc ctc et 1 A4139 10 Single 2 7209 11 2 7204 12 Hydraulic Cylinder complete 1 A692
11. 17 Oilite Bush 174 bore sssssssssseseeeeeeeennenenneen nennen 2 18 Plastic ei itr re reg 2 19 Hex Nut M12 20 Washer M12 21 Hex Head Bolt M12 x 45 4 22 Hex Head Bolt M8 x 25 4 23 itn to trii npn HR 4 24 Motor Bolt Retaining Plate 2 25 Hex Set Screw M10 x 70 2 26 Lockn t MIO itsik eee her es 2 27 Button Head Socket Screw M5 x 10 2 Part A4122 A4123 A9108 A5601 A6014 A6015 A6016 7202 7203 A7301 A7201 A7303 A7103 A7102 A6334 A9068 A6505 A9116 A9095 A9506 7721 A7701 A6759 A5506 A5315 A5714 A5216 A5321 A4078 A5711 A5503 A5129 EXPRESS DUAL YOLOW LAVHSNIVIN EXPRESS DUAL 9 Parts List Continued Ref Name of Part Qty Part TRAVERSE ASSEMBLY 1 Forkdriver 1 A9512 Forkdriver c w bushings amp seals 1 A9505 2 7 1 A9050 3 Brackets for Forkdriver Shaft 2 A4049 4 Ball Bushing for Forkdriver cccccccccsescececssteeeeessseeeeeseseees 2 A7706 5 Dust Seals for Forkdriver sse 2 A7707 6 Button Head Screw M8 x 30 4 A5164 7 Socket Screw x 6 2 A5156 8 Shaft
12. List Continued Ref Name of Part Qty Part MAIN FRAME 1 1 4050 2 Top Plate 5 o Emm de ARS 1 A4142 3 Upper Front Skirt 1 A6352 4 Rear SKIFE ake nok co a ete dps 1 A6397 not required if Lift Table fitted 5 Front SKirt as sued pep ec eene xe Pete 1 A6328 6 Dr WOet tace xe ed e EE Rat 2 A6321 7 Drawer Handle sse 2 A6110 8 Dust Tray uiu 0 1 6323 9 heehee Lie de 2 111 10 Drawer Runner essen 4 A6742 11 Drawer Runner Drawer sse 4 A6741 12 M5 x 10 Button Socket 8 A5129 Bernhard and Company Limited EXPRESS DUAL 9 Parts List Continued Bernhard and Company Limited Ref Name of Part Qty GUARD 1 RH Guard Support 1 2 LH Guard Support Complete 1 3 Rear Angle Complete sss 1 4 Guard Swing Arm 0 1 5 Parallelogram Guard Front Assembly sssssssssnneessnneeseenneeee 1 6 Rear ue ee peg etuer ated 1 7 Gas Strut Ball End ene eec 8 8 Gas Str t Armee er te Er beds 2 9 2mm Thick Clear Macralon 1 10
13. auto traverse with the stops set so that the stone completely passes the dresser back and forth Apply more feed as necessary to true the stone Dressing in this way should be carried out periodically to keep the stone clean and true BUT remove only the minimum material off the stone to keep long service EXPRESS DUAL 8 Maintenance Continued NOTE When fitting a new sleeve and nut it may appear that the assembly is too tight to fit onto the mainshaft of the Express Dual This is because all replacement sleeve and nut assemblies are shipped with the drive key left very slightly oversize to allow for varying degrees of wear in the mainshaft keyway The key is peened like riveting into the sleeve NOT welded The key needs to be fitted to the mainshaft This may entail filing a small amount of material from both the depth of the key and the sides Remove only a very small amount of material at a time then check the fit until the sleeve and nut assembly slides freely along the length of the mainshaft without any play between key and keyway REMEMBER The mainshaft keyway will be less worn at the ends of the shaft than where the normal traverse of the grindstone occurs do not remove too much metal from the key NEVER grip the sleeve and nut assembly in a vice Fully tighten the nut when the assembly is fitted to the mainshaft Key Sleeve Mainshaft Re
14. is held totally firm during the grinding process When in frame grinding the front of the unit must be held firmly in the multifix brackets or on the front roller brackets The rear of the unit will be held by the radiused pressure bar at the rear of the grinder 5 3 5 31 5 3 2 5 3 3 5 3 4 5 3 5 Bernhard and Company Limited EXPRESS DUAL Understanding the Machine Continued Machine Functions The EXPRESS DUAL has 3 separate motors driving the different functions of the machine all are controlled from the control panel These functions are as follows Traverse This motor and the accompanying drive mechanism controls the automatic movement of the grinding wheel along the mainshaft Reel Spin drive This motor drives the reel through a flexible shaft driving from a drive mechanism under the table It is a three phase motor controlled by an inverter for varying output speed Grinding Wheel A motor situated under the table drives the mainshaft and grinding wheel at 2200 rpm E Stop Pressing the stop button shuts off all 3 motors and locks into the off position None of the start buttons will operate until the stop button has been unlocked by twisting the knob counter clockwise to release it Otherwise the individual motor buttons toggle Press to turn on press again to turn off The machine must NOT be stopped when there is contact between
15. stones rail wipers safety guard windows electrical capacitors and fuses ED ball bushings for fork driver and traverse pick up seals and reel drive flexible couplings For specific component enquiries please call the warranty technical department at Bernhard and Company Limited on 44 0 1788 811600 or Toll free from the USA 1 888 474 6348 Warranty Terms and Conditions Express Dual 2 June 2003 BERNHARD SHARPER SOLUTIONS If you have any service or operational problems contact your distributor or phone our Technical Helpline USA only 1 888 474 6348 or Bernhard and Company Ltd England 44 1788 811600 or email techsupport bernhard co uk use the technical support feedback form on our web site www expressdual com or www bernhard co uk BERNHARD AND COMPANY LTD Bilton Road Rugby England CV22 7DT Tel 44 1788 811600 Fax 44 1788 812640 Email info Q bernhard co uk USA Toll Free 1 888 GRIND IT 1 888 474 6348 a q
16. the reel and grinding wheel except in cases of emergency Reset Button see also Electrical Fault Finding section If the main motor is subject to a voltage drop or overloading the current being drawn will rise and a safety device will automatically shut the grinder off The overload trip switch is situated behind the blue reset button on the cover of the main electrical control box which is located on the right hand end of the machine looking from the front The trip setting will vary with the electrical specification of each machine and is normally set to the full load current of the motor If the overload trip has shut off the grinder it can be reset by pushing the reset button after a few minutes delay This will allow the grinder to be re started The reset button and overload are both variable and should be adjusted if required as indicated in the appropriate service bulletins The reel drive motor traverse motor and VSD inverter reel spin speed control are protected by individual fuses located in the electrical control box EXPRESS DUAL 6 1 6 2 Bernhard and Company Limited In frame Grinding Mower Preparation Units of up to 36 long can be ground in frame this includes most machines including Greens mowers and Fairway units In order to spin drive the reel one end of the reel shaft drive must be exposed This will require the removal of the hydraulic motor the chain
17. to a particular motor are moving freely and have not got increased resistance due to damage or the build up of dirt This can best be done by detaching the motor drive and ensuring that the mechanism is moving freely EXPRESS DUAL 8 Maintenance 8 1 Grinding Wheel Replacement NOTE Grinding wheels should always be fitted by competent trained personnel 811 grinding wheel stone is held on the carrier by a nut which should be loosened using the Spanner provided before the assembly is removed from the mainshaft 8 1 2 Slide the grinding wheel to the left hand side of the machine viewed from the operator position 8 1 3 Release the 2 allen screws in the bearing flange ring on the left hand end of the main shaft 8 1 4 Raise the mainshaft to its maximum height maintaining the shaft as horizontal as possible until the right hand side comes up against the stop in the feed column and the left hand side is at its maximum height At this point the fork will drop away from the grinding wheel assembly 8 15 Place a wooden block under the mainshaft to the right hand side of the grinding wheel assembly bridging the front bed and front channel to take the weight of the mainshaft when the side arm is removed see Fig 8 1 5 Bernhard and Company Limited c EXPRESS DUAL 81 10 8 1 12 8 1 13 8 1 14 8 1 15 8 1 1
18. 1 5460 5109 5146 A6737 5503 6744 5106 4134 EXPRESS DUAL ED3000 REEL DRIVE EXPRESS DUAL 9 Parts List Continued Bernhard and Company Limited Ref Name of Part Qty CLAMP ASSEMBLY SSS 1 Radius Pressure Arm 1 2 Radius Pressure Arm 1 3 Pressure Bar RUDDEGM cccceessecceeesseneeeeeseneeesesseeeenentenees 2 4 Linear Actuator 5 PUG Hep 6 Hex Head Bolt M16 x 170 1 7 Nyloc Nut M1O ot tnde iate 1 8 C s k Socket Screw M10 x 0 4 9 Nut M10 10 Hex Head Bolt M10 x 45 2 11 Nyloc N t M10 icit ee er edes 2 12 Washer MTO E eet ote a ed 6 13 Pressure Plate not shown 1 Part A4101 A4100 A6761 A6013 A8121 A5749 A5524 A5117 A5503 A5706 A5505 A5310 A6342 EXPRESS DUAL CLAMP ASSEMBLY EXPRESS DUAL 9 Parts List Continued Bernhard and Company Limited Ref Name of Part Qty MULTI FIX BRACKET ASSEMBLY 1 Adjustable Mtg Brkt Base
19. 3 13 Chain Screw Tensioner 2 A4119 14 Chain Bottle 2 A4022 15 L H Pulley Mounting Plate 2 A4098 16 Hex Head Bolt x 45 2 1 A5722 17 6 eintreten itt S See S 1 A5517 18 R H Pulley Mounting Plate xd A4099 19 Cover ed dte nn tene teva ele 1 A6319 20 WasherMD tir hc eal S YET 2 A5320 21 Hex Head Screw M6 x 12 2 A5718 22 Ira E 2 A5516 23 Lift Platform Extension vc A4137 24 Washer 2 5321 25 Hex Head Set Screw 8 45 2 5725 26 NylOc NUt M8 ee ee ee e uota 2 A5220 27 Lift Table Lowering Solenoid 220 1 A8943 Lift Table Lowering Solenoid 24v A8392 Lift Table Lowering Solenoid 12v A8391 28 Control Pendant 24v not 5 1 A8018 Mains Control Pendant not 1 A8890 29 Label for Tail Lift Pendant not shown 1 A6552 30 Mains Tail Lift Controller not shown A8904 Bernhard and Company Limited 55 USER MANUAL ADDENDUMI Safety enclosure guard interlocks and service switch Express Dual and Anglemaster models ED3000 ED3000DX ED5000 AM3000 AM3000DX Express Dual and Anglemaster machines are now supplied with safety enclosures as standard These enclosures are fitted with a safety interlock switch so that th
20. 6 8 1 17 NOTE Bernhard and Company Limited Maintenance Continued USING THE C SPANNER PROVIDED loosen the retaining nut Remove the circlip retaining the left hand side arm to the rear shaft The side arm can now be removed from the machine The grinding wheel and sleeve can now be withdrawn Remove the retaining nut and the old wheel Clean sleeve and nut thoroughly Fit the new grinding wheel and replace the collar ensuring that all mating services are clean and undamaged Ensure that the mainshaft and sleeve are perfectly clean and dry Reassemble in the reverse order ensuring that when you replace the grinding wheel assembly onto the mainshaft the nut is on the LEFT HAND side when viewed from the operator s position Tighten nut whilst assembly is on the mainshaft Be careful to guide the assembly into the fork when lowering the mainshaft Make sure that the left hand side arm is centered in the channel Loosen the small allen key in the reel drive support block pull the diamond dresser out a short way and re tighten the screw With the stone NOT running bring the mainshaft and grind stone up horizontally Manually traverse the stone past the diamond making a light scratch to confirm that the shaft is horizontal Move the stone just clear of the dresser then start the grind motor Bring up the shaft equally on each side and manually traverse the stone across the dresser Switch on and engage the
21. BERNHARD EXPRESS DUAL 3000 MANUAL EXPRESS DUAL SOOO ED3000 Automatic Spin Grinder Users Guide amp Instruction Manual BERNHARD Please read this manual carefully before using the Express Dual This manual should be kept in a safe place so that it can be used for future reference EXPRESS DUAL ANGLEMASTER PRODUCT WARRANTY GUARANTEE REGISTRATION a 2 a ATTENTION This is your guarantee Complete this form NOW and return to Bernhard and Company WARRANTY Satisfactory performance or your money back during the first year Bernhard and Company guarantee the machine against breakdown caused by faulty workmanship or defective components in accordance with the policy schedule for up to 10 YEARS from the date of delivery and warranty includes labour cost for the first 12 MONTHS from the date of delivery Detailed policy terms and conditions are included with your product documentation and are available on request from Bernhard and Company Warranty is at the discretion of Bernhard and Company subject to the specified conditions having been met and verified To register your unit for warranty purposes the following data must be completed and returned to Bernhard and Company Limited within 30 days of delivery of the unit On receipt of this information your warranty will become valid and claims can be speedily processed Please complete the form below and fax it to USA amp Ca
22. Tail Lift Controller not shown A8904 Bernhard and Company Limited EXPRESS DUAL Parts List Continued 9 LIFT TABLE Bernhard and Company Limited EXPRESS DUAL iagrams D iring 10 W Page 44 45 Sheet 1 Sheet 2 46 Sheet 3 YNOH awa SHEET 1 NOLOW AVL YOLOW AD NOLOW 5M1d 9 0 9 t 6 5 9 21335 HOLIMS H2LIMS DNISU3A38 L33HS 133HS OL ro Es GO GO CO 6000 600 GO GO anne wnnown L3N9VW ame m Y3LYJANI amosa 104 NI 101261005 ss 150 3 ANI 9 m EESTI Q 13305 01 flor 9900 dl VOL Es cj E d LLY YOLV1OSI u3MOd 133HS OL 927 71330501 TSY ESY Ez 133HS OL pz lt 133HS OL pz X 133705 01 MOT 1 007 1 66 007 2v 3DVLIOA MOT 661 001
23. Tor PICK Up o en e o qe i ER 1 A9183 9 Traverse RICK Up eei etre rete reete 1 A9518 10 Ball Bushing for Trav Pick Up 2 7702 11 Dust Seal for Trav Pick 2 A7703 12 Hex Head Screw M12 x 25 2 5712 13 Washer M12 2 5315 14 Engagement Screw 7 1 A6112 15 lobed 0 M12 cscs Menard earth 1 A6102 16 Reversing 1 A4111 17 Reversing Bar Stop cccccccccescccecssseeeeseseeeeecsseeeeessneeeeesseaees 2 A4113 18 Cross Knob M8 7 2 A6131 19 Microswitch xs A8111 20 Housing for Microswitch sssseseeeeneeeeeeennne 1 A8113 21 Guard for Microswitch sssssssseeeeeeeeneen 1 A6382 22 Screw 2BAD 194 osten ca d re oe ee CU eq 2 A5404 23 Traverse Motor 60Hz sse 1 A6024 Traverse Motor 50Hz x A6022 24 Idler Sprocket mex ES 1 A7609 25 Oilite Bush for Sprocket nnne 1 A7704 26 Spindle for Idler 1 A9057 27 Drive 1 7603 28 Traverse Chain I A7406 29 Link for Traverse Chain 1 A7502 30 Circlip satis citer Rn eae 1 A5602 31 Hex 0 1 5503 32 0 1 33 Hex Head Screw 6 x 18 4 5719 34 Washer 0 4 5320 35 Capacitor 3uf for Traverse Motor 1 A8148 36 Friction Spring for Reversing 1 A6746 37 Socke
24. Understanding the Machine 10 In Frame Grinding 12 Electrical Fault Finding 20 Maintenance 21 Part Lists and Exploded Diagrams 25 Wiring Diagrams 44 Lift Table Instructions 47 BERNHARD AND COMPANY LTD Bilton Road Rugby England CV22 7DT Tel 44 1788 811600 Fax 44 1788 812640 Email info 6 bernhard co uk USA Toll Free 1 888 GRIND IT 1 888 474 6348 ED a gt a I z amp Express Dual 3000 1002 1 EXPRESS DUAL 1 Identification of Pictograms 250 KG MAX MAXIMUM LIFT PLATFORM LOAD 250 KG 550 LBS TRAPPING FEET OR OTHER OBJECTS WHEN LOWERING LIFT PLATFORM LS N BEWARE HIGH VOLTAGE pes MAXIMUM GRINDSTONE 2200 DIAMETER 150mm MAXIMUM SPEED 2200 Rev Min BEWARE MOVING GRINDSTONE AND SHAFT REEL ROTATING AT BETWEEN 147 AND 255 Rev Min TOTAL WEIGHT OF MACHINE KG Bernhard and Company Limited EXPRESS DUAL 1 Identification of Pictograms Continued POINTS FOR ATTACHING LIFTING EYES BEWARE MOVING COMPONENTS KEEP HANDS AND OTHER OBJECTS CLEAR WEAR EYE EAR AND BREATHING PROTECTION TRAVERSE START CONTROL GRINDSTONE START CONTROL REEL START CONTROL STOP CONTROL ENGAGE DISENGAGE INCREASE REDUCE GRINDSTONE FEED Bernhard and Company Limited Traverse On Off Reel Spin Drive On Off Grindstone On Off Servic
25. XPRESS DUAL MULTIFIX BRACKET ASSEMBLY Bernhard and Company Limited 39 EXPRESS DUAL 9 Parts List Continued Ref Name of Part Qty Part CONTROL BOX 1 Control Boxy cette etre ieee degeret 1 A3486 2 Control Box 0 1 A3487 3 Control Box Arm Not shown 1 A4028 4 Membrane Panel gt 1 A3329 5 Emergency Stop Button sse 1 A8073 6 Contact Block sssssssseeeeeneneenenee 1 A8353 7 1k Potentiometer ssssssseeeneeeneeeneeene 1 A0014 8 Pyxis Membrane Panel Display sees 1 A3502 9 Lyra Membrane Panel 1 A3503 10 Lead Pyxls to iie ete aeterna 1 11 Lead E Stop to Lyra sess 1 12 Lead Potentiometer to 1 A3505 set 13 Lead Service Switch to Lyra 1 14 Lead Comms to Electrical Cabinet Lyra to Vela 1 15 Service Switch 1 EXPRESS DUAL Bernhard and Company Limited EXPRESS DUAL 9 Parts List Continued Ref Name of Part Qty Part ELECTRICAL CABINET with MEMBRANE OPERATOR PANEL ___ 1 Electrical Cabinet cccceeeceeeeeeeeee
26. ction of travel during the grinding processes causing the stone traverse to reverse prematurely it will be necessary to adjust the reversing bar damper as indicated in the service bulletin EXPRESS DUAL 6 5 6 5 1 6 5 2 6 5 3 Bernhard and Company Limited In frame Grinding Continued Linking Up The Reel Drive Unit to the Reel Machines are supplied with the reel drive motor under the table and a flexible drive which can be attached to either end of the machine and do not have to be prepared before the mower unit is placed on the table as the complete drive unit can be moved to either side of the table with a mower unit in place Select the attachment with which to drive the reel If the reel sprocket gear or pulley is secured with a nut it may be easier to use a standard socket together with a 1 2 square end driver Ensure the nut is tight as the direction of rotation may tend to unscrew it Alternatively it may be easier to drive directly onto the sprocket using one of the pin or adjustable type sprocket drivers fitted to the plain drive rod When the cutting unit is in place and firmly fixed into the multifix brackets or front roller brackets and the rear clamped with the radiused pressure bar adjust the drive unit left or right so that the appropriate drive rod will reach the end of the reel shaft Tighten unit in place Adjust the height and position forwards and backwards and up a
27. ding commences Bernhard and Company Limited 6 7 NOTE 6 7 1 6 7 2 6 7 3 6 7 4 6 7 5 6 7 6 NOTE Bernhard and Company Limited EXPRESS DUAL In frame Grinding Continued To Commence Actual Grinding With experience and familiarity setting applying the cut can start here speeding up the set up procedure CLOSE THE GUARDS Start the reel drive motor and check for smooth easy running Start the grinding wheel motor Start the traverse motor first ensuring that the traverse engagement screw is unwound and not connected to the traverse chain Now repeat the adjustment process with the left hand on the control wheel and the right hand on the traverse knob moving the grinding wheel along the reel by hand using the traverse engagement screw winding up the left hand control wheel until the grinding wheel strikes and sparks gently against the reel Repeat this process on the right hand side of the reel raising the shaft with your right hand and moving the grinding wheel along with your left hand Repeat this process until the contact along the reel is even and parallel Screw in traverse knob to engage power traverse Check auto traverse is changing direction at correct point at each end of its movement 677 EXPRESS DUAL In frame Grinding Continued Place hands on the left and right control wheels and move both hand wheels clockw
28. e Switch Bernhard and Company Limited EXPRESS DUAL Emergency Stop Twist to release EXPRESS DUAL ED3000 Position Value Display Balance Indicator Reset Display Reel Spin Drive Speed Control Unclamp Clamp 21 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 Bernhard and Company Limited EXPRESS DUAL Safety This machine is designed and manufactured ONLY for grinding lawn mower reels rollers groomers and verticut units and MUST NOT be used for any other purpose This machine should be installed operated and maintained by competent personnel who have received adequate training Before carrying out any work on the machine other than grinding ALWAYS SWITCH OFF the main electrical supply or remove the power lead from its socket ALWAYS operate the machine with the guards in position NOISE Owing to the widely varying conditions of use noise emissions may vary considerably There may be occasions when the safe noise level may be exceeded see note on noise emission In this case adequate ear protection MUST be worn NEVER fit or use a grinding wheel or other spares other than those supplied specifically for use on the EXPRESS DUAL Warranty will be invalidated NEVER fit or use a grinding wheel which has been dropped or subjected to any other form of abuse NOTE Grinding wheels should be fitted ONLY by comp
29. e 1 A4127 4 R HiSliderPlate iode tend et t meg teg 1 4128 5 2 7744 6 2 A7744 7 Slider Plate 2 A4127 8 Plastic End Cap 60 x 60 2 A6194 9 FIM sires erc ctc et 1 A4139 10 Single 2 7209 11 2 7204 12 Hydraulic Cylinder complete 1 A6923 13 Chain Screw Tensioner 2 A4119 14 Chain Bottle 2 A4022 15 L H Pulley Mounting Plate 2 A4098 16 Hex Head Bolt x 45 2 1 A5722 17 6 eintreten itt S See S 1 A5517 18 R H Pulley Mounting Plate xd A4099 19 Cover ed dte nn tene teva ele 1 A6319 20 WasherMD tir hc eal S YET 2 A5320 21 Hex Head Screw M6 x 12 2 A5718 22 Ira E 2 A5516 23 Lift Platform Extension vc A4137 24 Washer 2 5321 25 Hex Head Set Screw 8 45 2 5725 26 NylOc NUt M8 ee ee ee e uota 2 A5220 27 Lift Table Lowering Solenoid 220 1 A8943 Lift Table Lowering Solenoid 24v A8392 Lift Table Lowering Solenoid 12v A8391 28 Control Pendant 24v not 5 1 A8018 Mains Control Pendant not 1 A8890 29 Label for Tail Lift Pendant not shown 1 A6552 30 Mains
30. e safety enclosure must be in the closed position before the motors can be started Similarly the motors will shut down if the safety enclosure is opened The control panel for all Express Dual and Anglemaster models 3000 3000DX and 5000 will also be fitted with a key operated service switch This provides a manual override to by pass the interlock switch for relevant service and maintenance purposes only and should only be used by suitably qualified personnel The service key should be removed from the machine for normal operation The service key cannot be removed when the machine is in service mode and an adjacent led illuminates to draw attention to the fact that this mode has been selected E 2 ac EC DECLARATION OF CONFORMITY BERNHARD AND COMPANY LIMITED BILTON ROAD RUGBY ENGLAND CV22 7DT BERNHARD AND COMPANY LTD ATTERTON AND ELLIS LTD Declare that the product Machine Name Type Serial No To which this declaration relates complies with the relevant Health amp Safety requirements of EC Directive 89 392 EEC as amended by 91 368 EEC 93 44 EEC 93 68 EEC and that for the implementation of the Health amp Safety requirements the following standards and or technical specifications have been consulted ISO 7000 1989 BS EN 292 Pt 1 1991 BS EN 292 Pt 2 1991 BS EN 418 1992 Sue J Pol Stephen Bernhard Managing Director Date Bernhard And Compan
31. eeeeeeeeeeneeeeneeeseeeeteneeesieeeeae 1 A3292 2 Electrical Cabinet 1 A3295 3 Main PCB RR 1 8962 4 Mitsubishi Inverter 1 8829 5 24 1 3301 6 Traverse Motor Capacitor 1 A8148 7 Thermal Overload 50 60 Hz 1 A8117 8 24v DC Hours 1 A8206 9 ISolator Switch rece 1 A3303 10 Reset Button eet etiatn 1 A8130 11 00 nente tete dte 1 12 Va Turn oreet pine 4 A5491 13 Vela Membrane Panel IO unit 1 A3509 14 Fuse Holder me npe ties 2 A8174 15 16Amp Fuse supply 2 A8084 ELECTRICAL CABINET FOR MACHINE WITH MEMBRANE OPERATOR PANEL 5 4 ELECTRICAL CABINET LID REMOVED Bernhard and Company Limited EXPRESS DUAL 9 Parts List Continued Ref Name of Part Qty Part LIFT TABLE 1 cure 1 A4138 2 Power Pack 220v dedi ete eaten 1 A8954 Power Pack 24w sssssssssseeeeeeeeeem enne nnns 1 A8023 Power Pack 12v ern ER RE Ens 1 A8770 3 IH Slider Plate inh he
32. etent trained personnel NEVER leave rags or tools on the machine or wear any loose clothing or other articles which could be caught in moving components NEVER allow any combustible materials to be placed on or around the machine ALWAYS ensure that all parts of the cutting unit being ground are securely fixed ALWAYS ensure that all electrical connections are sound and all cables are safely routed ALWAYS carry out cleaning and maintenance of the machine as instructed in this manual Refer to safety note 2 3 STAY ALERT Watch what you are doing NEVER operate the machine when tired or under the influence of drugs or alcohol If a lift table is fitted NEVER attempt to lift in excess of the rated capacity and always ensure that the area is clear before lowering the load 3 1 3 2 3 3 EXPRESS DUAL Set Up and Installation Handling If the machine is crated it can be moved by a suitable fork lift truck or pallet truck under the pallet skid Once the lid and sides of the crate are removed a fork lift truck may be used under the lifting members of the machine chassis The machine can be lifted off the pallet using suitable lifting tackle through 4 lifting eyes provided fitted at the points indicated on the top corners of the machine The total weight of the machine is indicated on the machine plate Location The machine should be located in a well lit environment with adequate headroom
33. ily be included since the tools and equipment supplied will vary according to the machine specification 41 Express Dual 3000 and 3000DxX see illustrated parts list A4066 Long 1 2 AF Ball handled Allen Key A2706 3 16 AF Tee handled Allen Key 2719 Grinding Wheel Nut Wrench A2720 1 2 AF Allen Key A2714 Adjustable Sprocket Driver A9182 Drive Rod Plain short A4134 Drive Rod Square short A4063 2 Pin Drive large A4276 2 Pin Drive small 9181 3 Pin Drive small A4097 Adjustable Plain Shaft Driver A2712 8mm Long Series Allen Key A6161 1 8 Allen Key A4087 Channels for Multifix Brackets A6342 Backing up Pressure Plate not shown A4106 Ransomes 5 7 Driver Standard only on European units A6737 Diamond Dresser 9500 Adustable Front Roller Multifix Brackets Bernhard and Company Limited 5 1 5 2 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 Bernhard and Company Limited EXPRESS DUAL Understanding the Machine General Principles The EXPRESS DUAL is designed to grind reels completely assembled or as a separate loose reel A Loose Reel Kit Available as an optional extra at additional cost is required for this operation The basic principle of the EXPRESS DUAL is to grind mowers in exactly the same conditions that they mow in The grinding wheel takes the place of the grass striking the reel in relatively close proximity to that found in the mowing pos
34. ise the same amount to apply an even cut The Light Emitting Diode LED feed balance system fitted to the Express Dual 3000 spin grinding machine is designed to ensure that the operator has a simple visual indication that ensures that feed of cut is applied parallel across the length on any reel Set the grind stone to the reel as with any other Express Dual adjusting the independent handwheels until there is a light and steady contact between reel and grind stone across the entire length of the reel Press the red reset button to zero the display zero the grinder to the reel The central green LED illuminates and both counters zero Winding the right hand handwheel will make the amber LED to the right of display centre illuminate further winding would then illuminate the red led to the right of the display counter readout increases in value Winding the left hand handwheel will extinguish red and or amber LED s and return to the green LED illuminated Both counters now read the same Equal feed has now been applied to both sides and the feed is balanced PARALLEL no taper has been applied EXPRESS DUAL BERNHARD NOTE It is important that the control wheels are moved equally 6 7 8 Apply a good hard cut Do not be afraid of the aggressive nature of the grinding process Bernhard and Company Limited 6 8 6 8 1 6 8 2 6 8 3 NOTE Bernhard and Company Limited EXPRESS DUAL
35. ition Basic Requirements It is important that grinding the cutting unit when it remains completely assembled takes place under the following conditions The reel bearings MUST be in good condition adjusted correctly and if the roller is to be located on the roller mounting brackets or the multifix brackets the roller bearings MUST also be in good condition The bedknife must be ground separately on a machine such as the ANGLEMASTER bedknife grinder which can guarantee that the blade will be perfectly STRAIGHT and flat whilst mounted on the bedbar During the reel grinding process it is advisable that the bedknife bedbar assembly is replaced in the unit after having been ground On many units the bedknife bedbar is an integral part of the frame and contributes to its strength and rigidity The reel or bedknife must be adjusted away from one another to allow free rotation There should be no reel to bedknife contact It is essential that all work to be carried out on the mowing unit all mower repairs bearings seals roller work etc has been completed prior to grinding the reel The last operation of all apart from final setting reel to bedknife is the actual grinding of the reel in frame It is essential that the unit is held totally firm during the grinding process When in frame grinding the front of the unit must be held firmly in the multifix brackets or on the front roller brackets It is essential that the unit
36. l Machine should be connected to the supply via a 20A breaker The top of the reel and the top of the grinding wheel should both move away from the front of the machine i e both rotate clockwise when viewed from right hand end of the machine In this way the reel and grinding wheel are moving in OPPOSITE DIRECTIONS at the point of contact Preparation If the machine has been received in a crate the handles on the control wheels should be removed from the underneath of the control wheels and refitted to the top see Fig 3 5 It is important that the protective film on the main shaft is removed prior to using the machine This can be done using a WD40 or similar product not gas petrol and then drying the shaft with a clean dry cloth so that the grinding wheel assembly moves freely along the whole length of the shaft Fig 3 5 A spray lubricant such as WD40 should be applied to all bare metal surfaces and moving parts this includes the reversing bar and the shafts along which the fork assembly traverse but NOT THE MAINSHAFT The mainshaft should be washed down as instructed in the maintenance section of this manual The feed control screws are normally coated with molycote and may be washed down with WD40 if required and recoated with molycote or similar anti friction coating when dry EXPRESS DUAL 4 Identification of Tools and Equipment The items below may not necessar
37. lton Road Rugby England CV22 7DT Tel 44 1788 811600 Fax 44 1788 812640 Email info bernhard co uk USA Toll Free 1 888 GRIND IT 1 888 474 6348 49 a q EXPRESS DUAL LIFT TABLE 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 Bernhard and Company Limited Safety Never load the lift table with more than the rated weight The rating is shown on a label on the rear of the cover plate visible when the lift platform plate is in it s lowered position Always ensure that any load is placed as near as possible in the centre of the table Never ride on the left lift Never attempt to lift an unstable load Never use the table to try to assist another lifting device to lift a large load Always carry out routine checks and maintenance as instructed in this manual and at the correct intervals When lowering the platform from the vertical position do not let it fall under its own weight When not in use always latch the platform into the vertical position or leave it horizontal at ground level When lowering a load ensure that the floor space below the table is clear of all objects EXPRESS DUAL LIFT TABLE Bernhard and Company Limited General Description The Express Lift table consists of a fabricated steel mainframe assembly with two vertical rolled steel channels in which the platform carriages are located The hinged platform is constructed from al
38. ly check the complete unit confirm that all fixings are secure that all electrical connections are tight and that the hydraulic fluid is at the correct level with no visible hydraulic leaks 3 MONTHLY In addition to the monthly checks ensure that the lift platform is level with the Express Dual table at the top of its travel Adjust if required using the two adjusters part 14 on exploded parts diagram 12 MONTHLY In addition to the above checks ensure that all parts are clean and free from any damage or obvious wear Raise the table to the top of its travel and apply a small amount of grease over the whole length of both chains On DC powered units visually check the motor brushes for wear When any moving parts have been replaced or cleaned with a degreasing agent ensure that they are re assembled with an adequate quantity of medium grease EXPRESS DUAL LIFT TABLE 5 Fault Finding In the event of faulty operation the following procedure is recommended Check that all moving components are clean and able to move freely and that they free from any obvious damage or wear If the lift fails to raise 1 Check the fuses 2 Use a test meter to check that the correct voltage is present at the motor terminals when the control buttons are operated If the voltage is low missing check back through the circuit to locate the loss of voltage usually a loose or dirty connection is the cause on DC units
39. move minimal material from sides and bottom of key 2nd Key Bernhard and Company Limited 23 EXPRESS DUAL 8 2 8 2 1 NOTE 8 2 2 8 2 3 8 2 4 Bernhard and Company Limited Maintenance Continued Lubrication Daily Mainshaft Wipe off any deposits of grinding dust with a dry cloth or brush ensuring the keyways are kept clean Using a fine spray oil such as WD40 spray the whole shaft Use an excess of WD40 one place and slide the grinding wheel assembly backwards and forwards over that area in order to wash out thoroughly the inside of the sleeve This will remove any build up of material and ensure the free movement of the assembly along the shaft After thoroughly cleaning the shaft dry and ensure that no oil remains at all before use It is essential that the grinding wheel sleeve and nut can be moved freely along the entire length of the mainshaft at all times Occasionally lubricate the contact areas of the fork driver with the sleeve and nut with MOLYCOTE Molybdenum Disulphide this will impregnate the surface Excess lubricant propellant should be wiped off again after a short time Never apply nor leave any oil or grease on the mainshaft during use For extended periods of down time spray on bright areas with Bernhard s Protective oil clean off with Bernhard s Clean and Lube spray or WD40 before use Weekly Spray 40 or equivalent ont
40. nada 800 393 4841 UK 01788 812640 Rest of World 44 1788 812640 or mail to Bernhard and Company Limited Bilton Road Rugby England CV22 7DT MACHINE REGISTRATION GUARANTEE CERTIFICATE a 5 2 Machine Type Course Company a Model Address MIC Serial No Distributor i County State Salesman Post Code Purchase Date Country Telephone Installed Check Tick as applicable E Mail By Distrib Mechanic Superintendent With Good Training Mechanic Please quote this serial number on all correspondence Serial EXPRESS DUAL EXPRESS DUAL ED3000 Precision Reel Cylinder Grinder You are now the owner operator of a Bernhard s Express Dual 3000 which if cared for and operated correctly will give you years of good service This manual will enable you to obtain the best results from your Express Dual so please read it thoroughly before using your machine If you have any service or operational problems contact your distributor or phone our Technical Helpline USA only 1 888 474 6348 or Bernhard and Company Ltd England 44 1788 811600 or email techsupport bernhard co uk use the technical support feedback form on our web site www expressdual com or www bernhard co uk Contents Identification of Pictograms 3 Safety 6 Installation 7 Identification of Tools and Equipment 9
41. nd down of the cable drive drive support so that the shaft is square with the driven end of the reel and tighten clamps to hold it in place The black lobed hand screw allows the drive head to be moved along the square support shaft to adjust the height of the drive while the 5 8 hex headed socket screw allows the support shaft to be clamped at any desired angle and also allows the whole assembly to be moved left or right along the machine bed to engage in the drive mechanism on the reel The drive head of the shaft can also be slid through it s support for further adjustment or final connection disconnection of drive Tighten the drive rod via the allen screw in the flexible coupling onto the flat of the drive shaft EXPRESS DUAL 6 In frame Grinding Continued 6 5 4 Moving the flexible Shaft There is layshaft socket at both ends of the machine into which the flexible drive can be engaged as required The other end of the flexible shaft can be disconnected if required but this would not generally be necessary as the bracket and shaft would normally be moved as an assembly The flexible drive shaft can be detached from its socket on the end of the machine by pulling sharply on the shaft to release it from a spring loaded ball detent Earlier units by first removing the spring retainer R pin and withdrawing the complete shaft When replacing the shaft ensure that it is properly e
42. ngaged in the layshaft socket and if appropriate the spring retainer securely replaced By loosening the socket screw and allowing the clamp nut under the table to twist through approximately 90 degrees the whole assembly can be lifted clear of the table and moved to the other side of the mower unit if required 6 6 Applying the Cut Before starting any of the motors it is necessary to bring the grinding wheel into its approximate cutting position 6 6 1 With the stone positioned at the left hand end of the reel place the left hand on the left hand control wheel and the right hand on the reel wind the control wheel clockwise while slowly rotating the reel until the reel gently rides across the grinding wheel 6 6 2 Unwind a complete turn to move the stone away from the reel 6 6 3 Move the grinding wheel to the right hand end of the reel and using the right hand on the right control wheel and the left hand on the reel raise the shaft until the reel again can be gently rotated against the top of the grinding wheel 6 6 4 Unwind half a turn 6 6 5 Go back to the left hand end and repeat the process but this time after contact has been made unwind only sufficiently to release the contact 6 6 6 Go back to the right hand end and repeat the process and again release the contact only slightly NOTE It is important that the grinding wheel should clear the highest blade along the full length of the reel before grin
43. o all moving parts the mainshaft must be completely dried before any grinding is carried out This includes the threads under the feed column handwheels the reversing bar and the shafts on which the fork and pickup assembly run The majority of bearings are either oil impregnated or are ball races and apart from those mounted in special sealed housings or fitted with grease nipples require the occasional drop of oil These include the reel drive coupling bearings and the pressure lever pivot bearings 6 Monthly Chain and idler sprocket require cleaning and oiling Check chain tension Examine belts for wear and tension DO NOT OVER TIGHTEN Examine fork assembly for wear some slight discolouration may occur this is not a problem Yearly Mainshaft bearings are pre packed with grease IF grease nipples are fitted ONLY 1 SMALL SHOT of grease should be applied annualy These bearings run warm hot that IS OK Extra grease will not reduce the temperature more likely the reverse the seals and subsequently the bearings may fail prematurely Bernhard and Company Limited EXPRESS DUAL ED3000 Parts List Page MAIN FRAME 26 GUARD 27 FEED ASSEMBLY 29 MAINSHAFT MOUNTING AND MAIN MOTOR DRIVE 30 TRAVERSE ASSEMBLY 32 REEL DRIVE 34 CLAMP ASSEMBLY 36 MULTI FIX BRACKET ASSEMBLY 38 CONTROL BOX 40 ELECTRICAL CABINET 41 LIFT TABLE 42 EXPRESS DUAL 9 Parts
44. rsing bar is located in the aperture to the front panel of the machine Rotate hand wheels anti clockwise to move grinding wheel away from reel unscrew the traverse engagement screw until it is released from the traverse chain traverse the grinding wheel by hand using the Traverse Engagement Screw until it is at the extreme point of desired travel Ensure that the traverse reversing bar is also moved in that direction and slide the reversing stop up to the grinding wheel traverse assembly and tighten Move the grinding wheel to the opposite end of the desired travel and repeat the operation ensuring that the reversing bar has also been moved in the opposite direction This is critical where the grinding wheel cannot pass beyond the end plates if they protrude below the maximum diameter of the reel On the EXPRESS DUAL it is not necessary for the whole width of the grinding wheel to pass the end of the reel and it SHOULD NOT DO SO EVEN IF SPACE PERMITS see Fig 6 4 Ensure that the leading edge of grinding stone passes the end of the reel but clearance must be maintained between stone and end frame of unit Fig 6 4 The reversing bar will move approximately 1 2 13mm before the direction of travel is reversed and will allow the grinding wheel to move with it It is therefore ESSENTIAL that this is taken into account when setting the maximum point of travel Should the reversing bar be dragged by the traverse assembly in the dire
45. s will void this warranty including the use of non original grindstones This warranty does not cover machines used for contract grinding services Warranty is at the discretion of Bernhard and Company subject to the specified conditions having been met and verified This warranty does not affect your statutory rights for the sale of goods Warranty Terms and Conditions Express Dual 1 June 2003 WARRANTY SCHEDULE Parts covered by Ten year warranty e All mechanical components not covered below e g chassis guide rails main shaft feed column springs lift table handwheels levers fasteners etc e Electric motors subject to certification by qualified electrician that input voltage at motor terminals is constantly within the specified limits e Fixed electrical wiring e Lifetime telephone technical support Parts covered by Three year warranty e All electrical electronic components e Extensible curly power cables e Bearings and bushes e Drive belts e Drive chains amp joining links e Diamond dresser e Flexible drive shaft e Fork driver for grindstone traverse excluding bearings and seals e Shaft for fork driver e Traverse pick up excluding bearings and seals e Shaft for pick up e Grind stone carrier sleeve amp nut including drive key e Traverse engagement screw e Gas struts guards e Fastenings subjected to removal replacement by operator Normal wearing parts Examples grinding
46. sition the hydraulic power pack will bypass the lifting pressure Release the UP button DO NOT PRESS IT AGAIN WHILST THE TABLE IS IN ITS UPPERMOST POSITION When the unit has been moved onto the Dual table return the platform to its normal storage position to allow better access to the Dual table and avoid the risk of personal injury on the projecting corners of the platform Unload the Dual table in the reverse order EXPRESS DUAL LIFT TABLE 4 NOTE NOTE NOTE Bernhard and Company Limited Maintenance and Adjustment Maintenance and adjustment should be carried out by suitably qualified trained personnel in accordance with the information in this Manual As the conditions and frequency of use will vary greatly the following recommendations should be modified if required to suit the prevailing circumstances The Express Dual Lift Table is designed and constructed to require the minimum of maintenance The 3 main requirements are The correct voltage at the motor terminals when the controls are activated The correct amount of clean hydraulic fluid of an appropriate grade in the hydraulic system No build up of dirt or debris around any of the moving parts When cleaning the Express Dual machine ensure that none of the dust or debris from the grinding process is allowed to enter the Lift table mechanism The following checks should be carried out at approximately the intervals stated MONTHLY Visual
47. t Screw Whit x 1 A5101 Bernhard and Company Limited EXPRESS DUAL AIGINASSV 354 4 Bernhard and Company Limited EXPRESS DUAL 9 Parts List Continued Bernhard and Company Limited Ref Name of Part Qty REEL DRIVE 1 Reel Drive 1 2 Layshaft Long neu tec 1 3 1 4 7 2 5 Socket for Flexible Drive 2 6 Flexible Driv amp Shaft tete etel 1 7 Flexible Drive Bracket Base 1 8 1 9 L Post Drive Hd Support Bar 1 10 Flexible Drive 1 11 Cylinder Drive Motor 1 12 nene 2 13 Ball Spring Plunger sess 2 14 Hd Screw 5 8 Whit x 5 1 2 sssssessesnssnsnrsesrnernsrnsrrsnseee 1 15 Socket Screw x 12 sse 1 16 Diamond Dresser aee tnt pede Sot cepe uten 1 17 es 1 18 Flexible 6 1 19 Grub Screw 3 8 Whit x 3 8 2 20 Short Square Drive sse 1 Part A6011 A9059 A9060 7722 9121 7404 4046 4110 4001 4045 4031 613
48. ued 6 3 To ensure that the correct position for the mower unit has been achieved both control wheels right hand and left hand should be wound in a clockwise direction so that the grinding wheel may be placed to contact each end of the reel evenly If the grinding wheel touches the bedknife or any part other than the reel the whole unit must be moved by adjusting the position of the multifix brackets or roller brackets The exact position required will be easily seen by looking along the mainshaft from one end of the machine as the stone is raised to check that the point of contact is in a suitable position see Figure 6 3 Front Roller position is adjustable Reel ni 0 blades Grind stone has to contact reel blades for sharpening without touching anything else Position of W bedknife is H adjustable Adjustable Front Roller support Fig 6 3 NOTE If the cutting unit has no front roller fitted so that multifix brackets are used then once the correct position for any particular unit has been finalised a set up guide should be completed and filed for future reference so that the identical multifix brackets positions can be used for all subsequent applications on the same type of unit Bernhard and Company Limited GED EXPRESS DUAL 6 4 Bernhard and Company Limited In frame Grinding Continued Set up of Traverse The reve
49. uminium chequered plate to give high strength combined with ease of handling Power is supplied by an electro hydraulic pack with the single hydraulic ram exerting the lift force through a pair of adjustable lifting chains Early units used a power pack with a 12v DC electric motor powered through a transformer wired directly into the Express Dual grinding machine Then from March 1998 units utilised a 24v DC power pack and transformer From March 2003 the lift power unit is now 220v AC All are controlled by a hand held push button panel which controls both the raising and lowering functions 3 1 3 2 NOTE 3 3 NOTE 3 4 3 5 Bernhard and Company Limited EXPRESS DUAL LIFT TABLE Operating Procedure When not in use the lift platform is normally stored in its lowest position with the table clipped in the vertical position To bring into use press the UP button on the control panel until the platform has risen to a convenient height then unclip the platform and lower it into the horizontal position It is advisable not to allow the platform to fall under its own weight When the platform is horizontal press the DOWN button to lower the platform to the floor and place the mower unit onto the platform Ensure that the unit is as central as possible and stable before pressing the UP button to bring the platform to the height of the Express Dual table When the platform reaches its top po
50. y Limited Extended Warranty Policy Terms And Conditions EXPRESS DUAL a LE 2 a a WARRANTY Satisfactory performance or your money back during the first year Bernhard and Company guarantee the machine against breakdown caused by faulty workmanship or defective components in accordance with the attached schedule for up to 10 YEARS from the date of delivery and warranty includes labour cost for the first 12 MONTHS from the date of delivery CONDITIONS OF WARRANTY Register the warranty by returning the MACHINE REGISTRATION GUARANTEE CERTIFICATE to Bernhard and Company Limited within 30 days of delivery of the unit On receipt of this information your warranty will become valid and claims can be speedily processed Satisfactory performance is based on grinding results when the machines are used in accordance with Bernhard and Company best practice guidelines Bernhard and Company reserve the right to perform trials on site to demonstrate performance Money back offer is subject to a deduction for wear and tear This warranty covers the free replacement of major components but excludes normal wearing parts and those with a limited working life Warranty is subject to correct and proper maintenance as described in the instruction manual and any relevant service bulletins All warranty work should be authorised by Bernhard and Company claims department before proceeding Failure to use original manufacturers component
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