OPERATION AND SERVICE MANUAL
Contents
1. Front of Machine Leveling Screw At Back Of Machine C Unblocking the Grinding Heads Figures 3 4 and 5 on page 4 The top and bottom motor spindles are blocked for shipment Remove the wood blocks from beneath the bottom motor plate and between the top and bottom 18 grinding wheel mounting plates The spindle motors are moved via stepper motors thru gearboxes The gearboxes have clutches that should be loosened to move the motor spindles The clutch for the top spindle is located on the top of the machine in the back The clutch for the bottom can be accessed thru the panel on the computer side of the machine Raise the top spindle by turning the top hand wheel clockwise to remove the wood blocks After the wood blocks are removed between the grinding wheel mounting plates raise the bottom spindle by turning the lower hand wheel clockwise Inner Guards Wood Blocks NEVER REMOVE ma N Figure 4 Figure 5 Clutch Shaft Top Spindle Motor Clutch Shaft For Bottom Spindle Motor Electrical Air and Dust Collector Hookup Electrical Have a qualified electrician run electrical power to the disconnect making sure that their is an earth ground and that wiring is in conformance with all local and national codes The machine requires 40 amps at 240 volts and 25 amps at 480 volts Electrical schematics are located in the enclosure Compressed Air The air regulator located on the right side of the machine as one faces the carrier drive sys2. To 5 N 2 Ta J E K Figur 4 Figure 5 ba Dresser Head BB10 Bearing Assembly Hex Bushing Screws And Locking Nuts Stars are tight on cutter bushing with cutter are tightened to the dresser head using spacer washers between stars the BB wrenches Figure 6 Figure 7 Spanner Wrench Cutter Lock Washer ForTightening After Stars Are Tight On Cutter Bushing Nut Bushing Bend A Tab On Cutter Dresser Unit Dresser Mounting Lock Washer Support Figure 8 Hold Downs Lock Handle Hand Wheel For Panic Buttons Hand Wheel For Swing Out Carrier Raising Lowering setting Hold Downs Carrier D General Safety Instructions Figure 8 on page 8 1 Front Guards Prior to operating the grinder insist that all guards are in place and bolted to the machine Ensure that the black lock handle that locks the front carrier swing plate is always SCREWED IN TIGHT as this plate is part of the guard system Insist that the front top guard is moved down in front of the top wheel prior to running machine 2 Safety Glasses Insist that safety glasses be worn by all employees operating and loading the grinder 3 Instructions to the Operator Review the operation of the machine and make sure that employees know the location and operation of the panic stop buttons on the console face and under the sub plate Do not allow operators to load springs too close TO THE ENTRANCE HOLD DOWN AREA as their hand could be caught be
3. grinder The reading should not vary more than 0 006 progressively thru the path To check the parallelism toward the back of the machine use a precision straight edge with precision blocks This is a two man operation One person holds the straight edge tight against the carrier hub shaft while the 2 person checks the back position using shims If the readings vary more than 006 the cone drive must be shimmed Figure 20 Figure 21 Note These two pictures are from a different machine However the procedure is the same 4 Adjusting The Carrier Drive If the check performed in Figure 21 is off the gearbox must be shimmed to set the the front to back position Loosen the bolts holding the large carrier gearbox to the swing plate Adjust the gearbox using shims under the feet of the gearbox and retighten Repeat this procedure until the 0 006 is achieved If the check performed in Figure 20 is off there is enough room around the bolts holding the gearbox to twist the gearbox so that the entrance and exit side of the grinding plate are within 006 with the cone drive 15 F Sub plate Alignment Figures 22 amp 23 on page 16 Mount a carrier onto the carrier hub Using shim stock check the space between the carrier and the sub plate at several places around the carrier Adjust the sub plate to get an equal distance between the carrier and the sub plate The sub plate is adjusted by the turnbuckles under the front of the sub plat
4. more than 0 006 the bottom motor plate must be adjusted Adjust the three bottom ball screws until the reading is 006 or less Prior to putting the chain back onto the ball screw sprockets make sure that each of the screws turn freely Reinstall the chain and make a final check with the chain installed When reinstalling the chains make sure that each of the chains have the excess slack removed but are not so tight that the screws are put on a bind The tension on the chain connecting the three screws is set using a chain tightener Check to see if each of the screws can be rotated a slight amount with the same amount of resistance If one or more ball screws are tighter than others it means that one of the ball screws was moved an excessive amount one way or the other EC IR Mt R S 19 Figure 16 D Checking Parallelism of Bottom Stone Mounting Plate To Top Stone Mounting Plate Figure 17 on page 14 Set the dial indicator between the two stone mounting plates base on bottom tip on top and rotate the two plates together to see if the stone mounting plates are parallel Orient the plates so their locating pins are in line then turn the plates so that the locating pins remain in line If the top stone plate is not parallel with the bottom stone mounting plate remove the chain from the top sprockets and adjust the three screws independently so that the stone plates are slightly closer together at the spring exit point th
5. nuts and back off the bushing screw After the outside bushing screw is removed from the dresser head the cutter assembly BB10 can be removed for replacing stars We recommend Desmond Sharp Tooth Cutters 17 A 21 22 Figure 31 BB10 Bearing Assembly Hex Bushing Screws And Locking Nuts Stars are tight on cutter bushing with cutter are tightened to the dresser head using Spacer washers between stars the BB wrenches Figure 32 Spanner Wrench Cutter Lock Washer ForTightening After Stars Are Tight On Cutter Bushing Nut Bushing Bend A Tab On Cutter 3 To take the worn stars off and replace with new ones bend the tab back out of the slot in the bushing nut Using the spanner wrench remove the bushing nut from the assembly Take off all the worn stars but save the worn stars Put on a new star then put on a worn star until the bushing is full If no worn stars are available use the spacers supplied with the cutter assembly To align the teeth so that they are staggered flip the stars over so that the tooth of the star being put on is in the middle of the two sharp points of the star just put on Reverse the process of putting the cutter assembly back on the dresser head The bushing screw should be tight enough to feel a small resistance when the stars are rotated Reinstall the two jam nuts to hold the bushing screw in place 23 C A Dressing The Grinding Wheels 1 Caution operators that before dressing the stones
6. on the carrier to move it down DO NOT POUND THE CARRIER DOWN IF IT MOVES SO HARD THAT A TAP WILL NOT MAKE IT DROP THE BORE OF THE CONE DRIVE AND THE SHAFT MUST BE CLEANED THE SHAFT WILL PULL UP AND OUT OF THE BORE FOR CLEANING Warn operators and setup personnel not to have their hands under the carrier when adjusting the height When the setscrew in the collar around the carrier drive hub is loosened the carrier can drop immediately to the sub plate To prevent this from happening adjust the jackscrew so that there is pressure on the screw When lowering the carrier slowly back down the screw so that the carrier slowly drops toward the sub plate When the carrier is at the correct height use the long T handle and tighten the setscrew to lock the carrier in position To prevent damage to the jack back off the jack so that it is not touching the shaft of the carrier plate mounting hub prior to running production This adjustment is required to equalize the amount of spring length sticking above and below the carrier s thickness Figure 24 17 2 Entry and Exit Hold downs Figure 8 on page 8 and Figure 25 on page 17 The entry and exit hold downs are fastened to the front plate The heights of both hold downs are adjusted together using the 4 hand wheel on the front of the plate set the entry hold down so that the bottom of the hold down is flush with the top grinding wheel The exit hold down is set at the factory slightly higher
7. plate which works the same as the emergency stop button on the console 10 Vi A B Run outs and Leveling The next step is to check alignments and run outs of the major moving parts of this machine These checks require a machinist s level felt marker and a good dial indicator graduated in the thousandths of inch Leveling the Machine Frame Figure 10 and 11 on page 11 Unlock and swing out the carrier assembly to gain access to the top plate of the base weldment Position a machine level on this frame plate Adjust the four bolts in the leveling pads until the machine is level in the side to side and front to back directions Tighten the jam nuts on the levelers to keep this setting It may be necessary to go thru this procedure several times to get the machine level in both planes It is necessary to verify that the machine is still level after the nuts are tightened The level of the machine may change when the nuts are tightened ure 10 Figure 11 Parallelism between Top And Bottom Frame Plates And Top And Bottom Motor Plates Figure 12 13 and 140n page 12 With the swing out carrier open and with the outer guards removed use a height gage or calipers to check the parallelism between the bottom frame plate and the bottom moveable motor plate at the three ball screw locations If the readings at the ball screws differ by more than 0 010 remove the master link of the bottom chain connecting the three scr
8. should receive brushing to remove any grit B 1 a Pehl MEELEL IE TEEEEEKEEEKI KEETE ERRAR RRERONAN H phi Figure 37 Roller Chain Top Head Two of the Ball Screws For Top amp Bottom Heads 29 30
9. so that one of the dowels is in an area that can be easily seen Mark the outside of the bottom stone mounting plate for the dowel location 3 Clean the mounting surface of the grinding wheel making sure that the aligning holes are free of any foreign material Mark the outside of the grinding wheel showing the dowel hole location Slide the grinding wheel across the stone mounting plate so that the aligning holes in the grinding wheel and the dowels in the stone mounting plate line up Use a screw driver to raise the wheel up so that it rests on the dowels When the dowels and the holes in the stone mounting plate ine up the grinding wheel will drop onto the stone mounting plate Bolt the wheel into place 4 Inspect stones for ANY Cracks or Defects before mounting Be sure the stone is sitting flush onto its plate Dowels MUST be used to ensure proper centering Using the 3 8 16 SHCS bolts provided for the machine bolt the grinding wheels to the grinding wheel mounting plate BOLTS MUST NOT STICK INTO THE GRINDING WHEELS MORE THAN 3 8 BUT HAVE ENOUGH THREAD CONTACT TO HOLD THE WHEELS ONTO THE STEEL MOUNTING PLATES Do not force the bolts They should be tight but over tightening will crack the stone Reference the grinding wheel supplier for the correct torque 5 Lay the wheel for the top grinding wheel mounting plate on top of the bottom grinding wheel Lower the top stone mounting plate making sure that the alignment holes in the g
10. they need to inspect the dresser to make sure the stars are tight on the cutter bushing The BB10 bearing assembly with the stars should be tight to the dresser head but spin freely when rotated The BB10 bearing assembly is assembled to the dresser head by the hex bushing screws and hex locking nuts The dresser head must be tight on the dresser shaft The dresser unit must be held securely in the dresser mounting support Stars should be staggered If points line up on stars turn the star over and put on bearing assembly 2 Move the grinding wheels closer to the teeth of the dresser by moving the dresser into the grinding area until contact is made Start the motors and dress both heads at the same time or individually While dressing slowly move the top and bottom wheel into the dresser as the dresser is moved between the wheels Mounting Carrier Plate Prior to mounting the carrier plate clean the two mounting surfaces to ensure that the two surfaces are clean Any dirt on these surfaces can make the spring carrier plate run through the grinder on such a tilt that the springs may not grind square After this cleaning set the carrier gently onto the carrier plate mounting hub If fixtures or tubes are used make sure that they are set at the same height and that they are set perpendicular to the grinding wheels Basic Setup Procedure Positioning Stones 1 The bottom stone s height should be positioned right at or a slight bit bel
11. to the chart on page 18 for shim thickness Position two shims 1 2 the thickness of the first shim 90 degrees to the left and right of the first shim Let the motor down on the motor plate using the jack bolt then tighten the four bolts holding the top motor to the top motor plate Tighten one bolt then move diagonally across the motor and tighten that bolt Continue moving from bolt to bolt in this X pattern until all bolts are tight To go back to a parallel grind reverse this process If the first shim is positioned 90 degrees to the dresser the shims do not have to be removed before dressing the wheels A starting point for canting is one half a wire size THICKNESS OF SHIMS Machine Desired Amt of Cant Shim Thickness 18 050 100 Or Twice The Amount of Cant 30 050 075 Or A 1 to 1 5 Relationship 36 050 090 Or A 1 to 1 8 Relationship Figure 26 Access Panel Figure 27 Two ofthe three shims Jack Bolt 19 VIII Mounting Grinding Wheels And Dressing A Changing and Mounting Stones 1 Loosen the black handle under the sub plate and swing the carrier out to have access to the stone mounting plates Using the hand wheel raise the front guard plate Lower the bottom stone mounting plate to a position that the grinding wheel can be put on the bottom grinding wheel mounting plate 2 Clean the bottom stone mounting plate by wiping it off with your bare hand until all the grit is removed Rotate the bottom stone mounting plate
12. 1OPERATION AND SERVICE MANUAL for MOYER 18 INCH CRUSH DOWNFEED GRINDER MODEL 5 18 2VCD February 1996 Revised February 2003 MOYER MANUFACTURING COMPANY INC 2862 W US HWY 20 Mail P O Box 422 ANGOLA IN 46703 FREMONT IN 46737 Phone 260 665 2363 Fax 260 665 2393 MOYER PROCESS amp CONTROL CO INC P O BOX 935 6045 N WAYNE STREET FREMONT IN 46737 Phone 260 495 2405 Fax 260 495 1290 READ SAFETY INSTRUCTIONS PRIOR TO SET UP AND OPERATING THE GRINDER IMPORTANT OPERATIONAL NOTES ONLY TURN OFF THE COMPUTER WHEN IT IS IN THE MAIN MENU IF IT IS TURNED OFF IN ANY OTHER MENU THE HEAD POSITIONS WILL BE LOST When adjusting the carrier height using the jackscrew back off the jack screw via the hand wheel after the carrier is locked in place with the setscrew Failure to lower the jackscrew will cause an early failure of the jack The jack is not affixed to the shaft hence it will always raise the carrier It never lowers the hub Gravity lowers the carrier as the jack is backed away from the carrier shaft hub Turn the hand wheel clockwise to raise the carrier If the carrier does not go down when the hand wheel is backed away from the shaft of the carrier plate mounting hub tap on the carrier to move it down DO NOT POUND THE CARRIER DOWN IF IT MOVES SO HARD THAT A TAP WILL NOT MAKE IT DROP THE BORE OF THE CONE DRIVE AND THE SHAFT MUST BE CLEANED THE SHAFT WILL PULL UP AND OUT OF THE BORE FOR CLEANING INDEX
13. 7 Figure1 Figure 2 Receiving Damage Check the crates and machine for any signs of damage If damaged advise the driver immediately that you suspect damage to the machine and note this fact on the bill of lading Call the shipper for instructions before unloading and uncrating Uncrating and Locating The Machine Uncrating Remove one of the plywood sides Remove the top piece of plywood The remaining sides and the 2x4 s can be removed together Remove the four screws holding the grinder to the skid Two of the screws are on the front lip of the grinder under the carrier The other two screws are inside the base weldment Remove the two back access plates to remove the screws The machine weighs approximately 2 700 pounds Hence size the forklift accordingly Installation of Leveling Pads Figures1 and 2 on page 3 After the machine is moved to its final location and before setting it down the 4 round leveling pads will need to be put under the machine The leveling pads are shipped in a box with other accessories The pads are installed under the holes from which the screws were removed in the step above Holding the pads under the weldment push the machine screws with the jam nuts on top through the hole and screw into the pads approximately 1 BLOCK THE MACHINE UP PRIOR TO HOLDING THE PADS UNDER THE WELDMENT DO NOT DEPEND UPON THE FORK LIFT HOLDING THE MACHINE DURING THIS PROCEDURE ane iia Leveling Pad At
14. FOR MOYER 18 CRUSH GRINDER MODEL 5 18 2V Section l ILA II B II C II IV IV B IV C IV C 3 IV D V VI VI A VI B VI C VI D VIE VI F VII VILA 1 VILA 2 VILA 3 VILA 4 VAIL VIILA VIILB VIIIC VIIL D IX A IX B Xl XII Description Receiving Machine Uncrating Machine Installation of Leveling Pads Unblocking Grinding Heads Electrica Air And Dust Collector Safety Issues Hazardous Voltages Setup Stone Change and Dressing Changing Stars General Safety Issues amp Machine Controls Power Tests Run outs and Final Leveling Leveling The Machine Frame Parallelism Between Top amp Bottom Frame Plates With Top And Bottom Motor Plates Dresser Alignment Parallelism Of Bottom Stone Mounting Plate Setting Carrier Drive In Same Plane As Bottom Stone Mounting Plate Sub Plate Alignment Manual Controls Carrier Adjustment Vertically Note Warning On Jack Adjustment Spring Hold Down Head Position Using Hand Wheels Canting Top Head Mounting Grinding Wheel And Dressing Changing And Mounting Stones Changing Star Cutters Dressing The Grinding Wheels Mounting Carrier Plate Basic Setup Procedure Positioning Stones Positioning Carrier Plate And Hold Down Running Production Design of Carrier Plates Maintenance Figures 1 2 3 3 4 5 6 7 8 8 9 10 11 thru 23 11 12 13 14 15 16 17 18 thru 21 22 23 24 thru 32 24 25 8 26 27 28 thru 32 33 3
15. an they are at the spring entrance Try to keep the cant between 0 003 to 008 13 Locating pins E Setting the Carrier Drive In The Same Plane As The Bottom Stone Mounting Plate 1 Marking Run Out of Bottom Grinding Stone Mounting Plate Figure 18 on page 14 Place a dial indicator with its base on the bottom motor plate and its tip near the outside edge of the bottom stone mounting plate On the plate mark the run out plus or minus from zero every 3 around its circumference The run outs should not exceed 0 008 If the run out exceeds the 008 contact Moyer Manufacturing Company Inc 2 Run Out of Carrier Hub Figure 19 on page 14 Put the indicator base on the sub plate and the tip onto the shoulder of the carrier hub Rotate the hub using the Dial Jog and mark the run out of the hub which should not exceed 0 002 If this is not within 002 contact Moyer Manufacturing Company Inc for assistance Figure 18 Figure 19 14 3 Checking The Carrier Drive Figures 20 amp 21 on page 15 Rotate the bottom stone mounting plate so that its previously marked run out readings have the same value at the spring entrance and exit points Set the indicator base onto the carrier hub and the tip of the indicator onto the spring entrance point on the bottom stone mounting plate Rotate the carrier hub using the Dial Jog to sweep the indicator across the stone mounting plate in the path that the springs will go thru the
16. e and the slotted angle blocks supporting the sub plate behind the carrier swing plate Figure 23 Figure 22 G Further Setup The chapter Setup and Tooling For A New Job provides the instructions for safely mounting and dressing stones mounting the carrier plate and other topics in setting up a new job 16 Vil Manual Controls A Manual Adjustments Available 1 Carrier Adjustment Vertically Figure 24 on page 16 To adjust the carrier up and down the setscrew in the collar on the cone drive is loosened using the long T handle provided Use the console s dial jog switch to rotate the carrier until the setscrew can be reached using the long T handle Note turn the speed pot all the way counter clockwise so that the dial will not move fast Turn the speed pot up slowly or clockwise until the carrier starts to move slowly After the setscrew is loosened the adjusting hand wheel located at the front of the machine under the carrier plate is used to raise the carrier plate This hand wheel is connected to a jack under the shaft of the carrier plate mounting hub The jack is not affixed to the shaft hence it will always raise the carrier It never lowers the shaft Gravity lowers the carrier as the jack is backed away from the carrier shaft hub Turn the hand wheel clockwise to raise the carrier If the carrier does not go down when the hand wheel is backed away from the shaft of the carrier plate mounting hub tap
17. een holes Make holes at least 0 006 to 0 015 larger than the spring diameter depending upon size of wire squareness required and the length to diameter ratio Longer springs typically can have more clearance Subtract 1 to 2 wire diameters from the free length of the springs Lower rate springs require thinner carriers as they compress more during grinding For springs that are as tall as they are wide or springs with only 1 2 active coil the carrier must be as close to the ground length of the spring as possible without grinding the carrier The mounting hub is 5 00 inches The center hole dimension for the carrier is 5 002 to 5 004 Blanchard ground flat and parallel to 0 002 TIR Plated with electroless Nickel and baked for hardness is also recommended A Material Required Bearings Air Regulator Oil Cone Drive Oil Kendall Super Blue Prior to greasing wipe off grease zerks Marvel Air Tool Oil Mobil SHC 634 Cleaning and Lubrication Figure 33 Figure 34 Filter For Air Air Regulator Keep grit below spun aluminum Conditioner Remove Grinding Build UP 26 1 2 4 Daily General clean off the machine each day to remove grit If using air maintain a low pressure so that grit is not forced into working components of the machine or your eyes Air Regulators Oilers should be filled with oil suitable for pneumatic devices and their seals Commonly available Marvel M
18. ews and adjust them independently to achieve a parallelism of 0 010 or less Repeat this process between the top frame plate and the top motor plate Do not reassemble the chain until later in the process of leveling the machine Hints Adjust one ball screw at a time then check for results If you move more than one ball screw at a time it is difficult figuring out which ball screw must be moved to get the heads parallel with the frame plates Prior to removing the chain rotate the ball screws such that the connectors for the chains are on the sprockets Check to see if each of the screws can be rotated a slight amount with the same amount of resistance If one or more screws are tighter than others it means that one of the screws was moved an excessive amount one way or the other Correct this condition prior to going to the next step Set the parallelism as close as possible without binding the ball screws 11 Figure 13 Outer Guard Removed Top Frame Plate Bottom Motor Plate Top Motor Plate Bottom Frame Plate a oo S Ea Figure 15 Chain and Sprocket For Bottom Spindle Figure 14 Using Height Gage 12 C Dresser Alignment Figure 16 on Page 13 Mount the base of the dial indicator to the dresser head with the tip onto the bottom stone mounting plate Set the dial to zero and move the dresser in and out across the bottom stone mounting plate These readings should be within 0 006 If the reading is
19. ge and Dressing Safety Issues 1 Guards Surrounding the stones are thick top and bottom inner guards NEVER remove these inner guards Reference Figure 3 on page 4 2 Grinding Stones Insist that employees changing grinding stones Inspect stones for ANY cracks or defects before mounting Be sure the stone is sitting flush onto its mounting plate Dowels MUST be used to ensure proper centering Bolts MUST NOT stick into the stone more than 3 8 but must have enough thread contact for proper mounting Do not force the bolts They should be tight but over tightening can crack the stone Refer to Grinding Wheel Supplier for proper torque Please read the entire section Changing and mounting stones in the Setup and Tooling chapter VIII on page 19 to all employees performing this function 3 Dresser Figures 4 5 6 and 7 on page 7 Caution operators that before dressing the stones they need to inspect the dresser to make sure the stars are tight on the cutter bushing The BB10 bearing assembly with the stars should be tight to the dresser head but spin freely when rotated The BB10 bearing assembly is assembled to the dresser head by the hex bushing screws and hex locking nuts The dresser head must be tight on the dresser shaft The dresser unit must be held securely in the dresser mounting support Stars should be staggered If the sharp points line up on stars turn the stars over and put back on the bearing assembly
20. gth and make any adjustments to the top grinding wheel as the bottom wheel has been set at the proper height for the sub plate If a large adjustment has to be made to the top wheel adjust the hold down to match the adjustment made to the top wheel After production has started make alternate wheel adjustment for wheel wear Design of Carrier Plates The first concern in setting up a new job is to provide a carrier to push the given springs into the grinder holding them as square as possible Diameter The machine is designed to use up to a 30 diameter carrier and to have a center hole in the grinding stone The center hole will have to be adjusted to match the type and size of carrier being used Contact Moyer for sizing the center hole in the grinding stone based upon the type of carriers that will be used Bollt Circle Using stones with an 8 ID center hole the 30 carrier would require that the outermost holes be on an approximate bolt circle of 28 5 The actual bolt circle is dependent upon the hole size in the carrier The distance between the centerline of the carrier and the grinding wheel is 18 25 If the hole is put on a 28 5 bolt circle of the spring O D will pass over the center hole For small diameter springs the bolt circle should be reduced based upon the diameter of the spring 25 Hole Spacing Hole Size Thickness Center Hole Surfaces XII Maintenance Leave at least 0 125 material betw
21. marked CPU at the center right of the console face The screen should come alive and present you with the Main Menu of the CNC system Use the keypad s down arrow key to highlight Crush grind and press the ENTER key The Crush menu will appear from which you then select dial jog or dial run appearing on the bottom of the window Confirm that this menu selection turns the carrier hub motion on and off and that the dial soeed Knob on the lower center of the console regulates the speed Also confirm that the dial jog knob above it allows you to run the carrier backwards and forwards at half speed Rotation Caution Prior to making this check make sure that nothing is laying loose on either of the grinding wheel mounting plates and that all protective guards are in place Using the start and stop button for the top and bottom spindles jog each motor to check rotation The spindles and carrier should rotate counter clockwise when looking down from the top of the machine As the drive rotation was set at the factory if the rotation is incorrect reverse two of the incoming power lines to the disconnect switch EMERGENCY STOP Pushing in this red mushroom push button stops the carrier and removes spindle power allowing the stones to coast to a stop position To return the machine s functions pull the button back out There is a second emergency stop button mounted to the front of the sub
22. ow the entrance edge of the sub plate The exit side of the sub plate should be slightly lower than the grinding wheel With this setting the springs will slide easily between the stones to prevent chamfering the stone or the springs At the exit the springs should not get caught against the sub plate upon leaving the stones 2 Bring the top grinding wheel down to the estimated grind length position A gage block or a ground sample spring may be used to determine this position 24 B xI Positioning Carrier Plate And Hold Down 1 Refer to Section VII Manual Controls on pages 16 and 17 to set the height and on of the carrier plate and the hold downs The carrier plate should be moved so that the springs in the holes are equally spaced between the top and bottom grinding wheels Set the hold down so the bottom surface is level with the bottom surface of the top stone RUNNING PRODUCTION Carrier Speed 1 Carrier speed is adjusted from O to 60 Revolutions per hour by a knob on the lower center of the console Adjust the speed so that the holes can be filled Depending upon the results being obtained during grinding the speed should be adjusted to prevent burning the springs and to ensure proper equalization This is a trial and error system The speed should be set to maximize production but provide a quality product Checking first Ground Pieces and Grinding Adjustments 1 At first grind only a few springs check their len
23. r the sub plate on the hold down side of the machine Also clean around the boot where the drive shaft for the carrier goes into the hollow bore of the cone Replace the boot if it is torn This is important If grit gets onto the drive shaft the drive shaft will become stuck in the hollow bore and will not adjust the carrier up and down easily Refer Figure 35 on page 26 2i BE A BA Zerk For Greasing Oil Level Top Bearing Keep Clean 5 Semi annually General Cleaning amp Inspection The outer guards may be removed to clean around the bellows exhaust and dresser area Check all bellows for any holes and replace as needed Flange Bearings Grease the six ball screw flange bearings 3 top and 3 bottom with two pumps of grease Cone Drive Seals Clean the top of the Cone Drive so that any grit laying on the top seal will be removed 6 Annually Carrier Gearbox check oil level in the elbow provided and add Mobil SHC synthetic bearing and gear oil Continued on page 27 28 Ball Screws and Nuts Remove the hose clamps around the top and bottom bellows covering the three top and three bottom ballscrews Using an oiler put a mixture of 50 STP and 50 Kendall Super Blue Grease at the top of each ball screw Prior to reinstalling the bellows clean off any oil off the surfaces of the bellows mount This is important for reassembling the hose clamps around the bellows Refer To Figure 37 on page 27 Roller chains
24. rinding wheel line up with the dowels in the stone mounting plate Don t bring the top head down so that the dowels completely enter the grinding wheel alignment holes Use a small pry bar and lift the top wheel up and start several of the grinding wheel mounting bolts that are next to the dowel Rotate the wheels so that another set of bolts can be started into the grinding wheel next to the dowel located 180 degrees away from the first dowel Insert the remaining bolts and tighten 6 When the stones are installed be sure all tools wood and other foreign objects are removed from the grinder interior Move the grinding wheel so they are close but do not touch the dressing stars CAUTION WITH THE FRONT PLATE UP FOR CHANGING STONES THE ENTRANCE AND THE EXIT HOLD DOWNS ARE CLOSE TO HITTING THE STONE MOUNTING PLATE THE JACK THAT MOVES THE HOLD DOWNS CAN BE DAMAGED IF THE HOLD DOWNS HIT THE STONE MOUNT PLATE Move the hold downs down prior to bringing the top head down 20 Changing Star Cutters Figures 28 29 30 on page 20 Figures 31 amp 32 on page 21 Reference page 6 under Section IV Safety 1 The stars can be changed inside the machine as shown in figure 28 or the dresser shaft can be removed from the dresser block as shown in figures 29 and 30 The dresser is heavy use caution when handling Figure 28 Changing stars inside machine Figure 29 Dresser shaft removed Figure 30 Removing dresser 2 Loosen the two hex locking
25. tem must be connected to a minimum of 60 PSI air source The air is for opening and closing the spring drop out chute and operating the ground length measuring device if this option is purchased This initial setting may have to be modified after set up Adjust the Moyer Exit Mounted Probe pressure depending up on observed performance The probe should move smoothly to measure the parts with a low pressure setting It must have enough pressure to get to the measuring point but should not come down with a lot of force Dust Collector For optimum dust collection and cooling the unit should have at least 1020 CFM The dust collector outlet on the machine has a O D dimension of 8 inches Safety Considerations When The Grinder Arrives Prior to operating the machine please review the safety information with all operators setup personnel and maintenance crew Hazardous Voltages When installing the grinder have a qualified electrician wire the power according to all local and national codes and you must be sure to provide a secure GROUND TO EARTH such as using a 4 wire hookup Caution operators and maintenance personnel that hazardous voltages exist inside the disconnect enclosure the motors the junction box in the base weldment Operator Console and motor terminals The places containing electrical components must not be uncover or serviced without DISCONNECTING ALL POWER first using Company LOCK OUT PROCEEDURES C Setup Stone Chan
26. than the entry hold down The hold downs can be moved relative to the front plate by adjusting the mounting screws The entry hold down alignment is critical in the crush mode The springs should just slide between the two grinding wheels If the hold down is too high the springs will hit the edge of the grinding wheel which will radius the edge of the wheel If the hold down is too low the springs will compress too much and the end coils opposite the tips will compress too much which will adversely affect squareness wheel life and time between dresses Figure 25 Grinding Wheel Hold Down The grinding wheel is not mounted to the steel mounting plate The steel plate shows the grinding wheel location in relation to the entry hold down 18 Head Position Hand Wheels Figure 8 on page 8 The two hand wheels on the left side of the grinder are for manually adjusting the grinding spindles Turning the top hand wheel CLOCKWISE moves the top spindle UP Turning the bottom hand wheel CLOCKWISE moves the botton spindle down One rotation of the hand wheels move the spindles 050 Canting Top Head Figures 26 amp 27 on page 18 Remove the two panels one by the dresser and one by the exhaust pipe to gain access to the top motor spindle Loosen the four bolts holding the top motor to the top motor plate and lift up the motor using the jack bolt in the mounting flange of the motor Insert three shims at 90 degrees to the dresser Refer
27. tween the hold down and carrier plate Insist that operators keep their fingers AWAY FROM THE DROPOUT AREA as 8 they may be injured or pinched between the carrier and side of the dropout Caution operators that while setting up and operating the Moyer Automatic Loading equipment that they should not stick their fingers in between the nozzles and carrier near the positive stop or indexing pin Insist that operators do not stick anything into the grinding stones while the stones are operating do not lay tools on the carrier plate to be dragged inside the grinder and do not work on the machine until the stones have completely stopped Do not allow operators to load springs or work on the machine while wearing loose clothing very long hair necklaces bracelets or rings as springs can catch on these items and pull the operator into the grinding wheel area Warn operators and setup personnel that when adjusting the carrier in the vertical position that the Jackscrew must be moved against the carrier drive hub The jackscrew is adjusted by rotating the jackscrew hand wheel clockwise When the set screw in the collar around the carrier drive hub is loosened the carrier can drop immediately to the subplate unless the jack screw is against the carrier drive hub PAIN nENU n Figure 9 Power Test Console Figures 9 on Page 9 When the power hookup is completed test it by turning on console power using the selector switch
28. ystery Oil is good for this Push in the pin at the bottom of the regulator to drain away all accumulated water and change the filter if its getting dirty Figure 34 Weekly Cleaning Every time that grinding wheels are changed It is very important to clean under the bottom stone mounting plate KEEP THE DUST BELOW THE SPUN ALUMINUM HOUSING AROUND THE STONE MOUNTING HUB Also check the exhaust opening for build up of hard grinding swarth and remove Figure 33 Blower If Purchased Check filter and replace if dirty This blower pumps air thru the spindles The blower can be damaged if any large particles get into the blower NEVER FORCE THE CARRIER UP OR DOWN If the carrier moves hard the Cone drive shaft must be removed Loosen the set screw holding the Cone drive shaft to allow lifting the Cone shaft up and out of the bore in the Cone Drive Some models have a bellows attached to the Cone Shaft Remove the hose clamp on the bellows prior to pulling the shaft out Clean the shaft very good as the slightest amount of grit can make the Cone shaft move up and down hard Every Month Rotary Union If the grinder is equipped with a high velocity pump for pumping air thru the spindles Grease the rotary unions on the top and bottom spindle motors Give each zerk 2 to 3 pumps of Alvania 2 grease or other compatible greases Every 3 Months Cone Drive A zerk is provided to grease the top bearing of the Cone Drive The zerk is located unde
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