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OPERATING INSTRUCTIONS (Continued)

1. 10118 18 SINLLIS NIW Add MY SHE 1 JOLSv c JOL9b OND 01 b 210181 11 20109 LI ir 6 B 1 0X OF OA a 20REL LI jew 1 i E CROOK ME nalen Mes CO AS ES 2 Vir Ae I ORL Y ung j 00 6 ZH 09 05 Aly a OOOD8O O2FIRBL OIFTRER DE E t3 OE B 0E 8 dS JW JN Mi 5 27402 WIRING DIAGRAM 999 START ursa LI L1 085 3 25 105LP5 5 ES Tt 36H es 35 12 5015 136 STOP A IN uec C 2 AMP 12 AMP CBI CIRCULT BREAKER 1 SSS SYSTEM START SWITCH B2 CIRCUIT BREAKER 2 TBI TERMINAL STRIP 1 DSS D00R SAFETY SWITCH TB2 TERMINAL STRIP 2 ESS EMERGENCY STOP SWITCH TBG TERMINAL BLOCK GREY FTR LINE FILTER TER TERMINAL BLOCK WHITE GMS GRINDING MOTOR SWITCH TSP TRAVERSE SPEED POT LVP LOW VOLTAGE PELAY TOC TRAVERSE DRIVE CONTROL MAG NAGNETIC STARTER PXL LEFT PROXIMITY SWITCH PX2 RIGHT PROXIMITY SWITCH REL GRINOING MOTOR RELAY 55 115 VAC NEUTRAL MEB o oN LINE
2. MANTENERLA RIGIDA CUCHILLAS CON FILOS CORTANTES DOBLES Algunos fabricantes de unidades segadoras y de cuchillas de mercado secundario producen una cuchilla con filos cortantes dobles como lo muestra la Fig 24 Debido a que las dos superficies que estas cuchillas presentan a los imanes son redondeadas la fuerza de atracci n es minima Por lo tanto para lograr una atracci n firme con los imanes usted debe limar la cara inferior de la cuchilla con una lima bastarda FIG 22 plana como lo muestra la Fig 23 CALIBRE DE CONFIGURACION DE LA CUCHILLA Debe limar de manera uniforme a lo largo de ambos radios Lime hasta que haya logrado una cara plana en el radio que tenga una amplitud de por lo menos 3 32 0 09 2 3 mm y que el ancho sea uniforme a lo largo im n para cada extremo de la cuchilla m m gt mx m 24 19 INSTRUCCIONES DE OPERACI N Continuaci n C MO RECTIFICAR LA CARA FRONTAL NOTA Las instrucciones a continuaci n suponen que usted ya estudi todas las secciones previas de este manual NOTA En algunas mordazas de bancada de segadoras la cara frontal es curva por lo tanto es posible que no sea necesario afilarla ub Ubique la cuchilla un rectificado de
3. PARTS LIST 5 27541 BEDKNIFE SUPPORT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION PA 5NTB160605 8 32x3 8 Flat Head Cap Screw NE 5NTB190805 10 24x1 2 Flat Head Socket Cap Screw 5 190811 10 24x1 2 Socket Head Cap Screw 5 190813 10 24 1 2 Button Head Socket Cap Screw 5NTB250611 1 4 20x3 8 Socket Head Cap Screw 5NTB250816 1 4 20x1 2 Socket Head Cap Screw NE 5NTB251211 1 4 20x3 4 Socket Head Cap Screw D cine 5NTB371216 3 8 16x3 4 Button Head Socket Cap Screw anos ONTZT TUE au Bracket Rotation Decal gem 5NTC310420 5 16 18x1 4 Socket Set Screw Cup Pt AA 5NTC310820 5 16 18x1 2 Socket Set Screw Cup Pt d 5NTH250802 1 4 dia x 1 2 Long Roll Pin 5NTH253202 1 4 dia x 2 Long Roll Pin 5NTJ377000 3 8 16 Locknut ta 5NTK251501 1 4 Lockwasher 5NTK370001 3 8 Washer E 5NTK371501 3 8 Lockwasher O iria 5NT3709327 Rubber Tip 9727508 Tooling ZU insi oNT28181 Center Assy 5 128196 RH Tooling Pivot Block 5728200 LH Tooling Slide Bar po ee 5 28201 Tooling Adj Bl
4. 6 Getting to Know Your Grinder Page 8 14 Operating ASU RR 15 25 DAILY MAINTENANCE BY THE OPERATOR On a daily basis clean the machine by wiping it off On a daily basis remove all grinding grit from the traverse shafts and tooling bar area On a daily basis check coolant tray fluid level Fluid must be above the sump On a daily basis inspect the machine for loose fasteners or components Contact your company s Maintenance Department if damaged or defective parts are found DO USE COMPRESSED AIR CLEAN GRINDING DUST FROM GRINDER SAFETY INSTRUCTIONS PLEASE TAKE SPECIAL NOTE OF THE FOLLOWING WARNING DECALS LOCATED ON THE FRONT AND SIDES OF THE GRINDER GRINDING WHEEL RPM SHARP OBJECTS CAUTION A ATENCI N ACAUTION Avoid Injury To Avoid Injury Para evitar lesiones Keep hands Do not exceed grinding No exceda la velocidad de away from wheel maximum operating funcionamiento maxima de speed of 3600 revolutions 3600 revoluciones por minuto rotating objects per minute de la rueda rectificadora Para evitar lesiones Mantenga las manos alejadas de los objetos giratorios ELECTRICITY A CAUTION To Avoid Injury sure all electrical power to this machine has been disconnected before r
5. 10 24 Nut Traverse LH Prox Assembly oNT27149 Traverse RH Prox Assembly 5NTBG1509502 Control Panel Weldment 5NTBG1509505 Cabinet Weldment 5NT6609044 Coolant Tube 5 3700696 6 x 1 5 Steel Borazon 120G Grinding Wheel 5NT3706022 3 4 NPTF Steel Pipe Plug 5NT3707009 Strain Relief 5NT3707029 Strain Relief 5NT3708121 38 Dia Double Cord Clamp 5NT3708339 Barbed Insert Connector 9NT3708419 8 ID Wave Spring 5NT3708421 5 x 1 0 x 075 T Flat Washer 5NT3708832 HIPOT Test Decal 5NTRG5509004 Frontier Decal 5NT 127300 BG1500 Decal Part of Decal Sheet 5NT 127300 Protractor Decal Part of Decal Sheet nec Electrical Caution Decal See page 7 of the Operators Manual E Machine Caution Decal See page 7 of the Operators Manual Sharp Caution Decal See page 7 of the Operators Manual POR RN Wheel RPM Caution Decal See page 7 of the Operators Manual 3 5 27519 GUARD DOOR ASSEMBLY EXPLODED VIEW 38 PARTS LIST DIAGRAM NUMBER 5 27519 GUARD DOOR ASSEMBLY PART NUMBER DESCRIPTION 5NTB190834 10 32 x 1 2 Button Head Socket Cap Screw 5NTB252811 1 4 20 x 1 3 4 Socket Head Cap Screw SNTBS11213 iii 5 16 18 x
6. diio A T Page 24 25 Grinding Motor Page 26 28 CO OVATION OS er Page 28 Traverse Drive Page 29 33 Mechanical Troubleshooting aaa Page 34 35 ELECTRICAL TROUBLESHOOTING Continued CONTROL PANEL located on the right side of the machine Low Voltage Relay Traverse Drive LVR Control Board FUSES Terminal Strip 2 3A Slow Blow TB2 Kc pen Traverse Drive MAG Control Board TDC Blue Terminal Blocks TBB Grey Terminal Blocks TBG Secondary Circuit Breaker SCB Main Circuit Breaker MCB Grinding Motor Relay REL Termial Strip 1 TB1 Main Ground Lug AC Filter FTR 23 ELECTRICAL TROUBLESHOOTING Continued PROBLEM AC Main Power Controls no electrical power to control panel Verify all wires shown on the wiring diagram are correct and pull on wire terminals with approximately 3 65 force to verify there are no loose terminal connections and or no loose crimps between the wire and the terminal If problem persists test as listed below Possible Cause Checkout Procedure Emergency Stop Button ESS A Pull Up on ESS Button is Depressed You must push the System Start Switch SSS to get power to control Panel Main Power Cord is not plugged in Guard doors must be closed and ALL Switches MUST be turned OFF for contactor to pull in Mai
7. 3 Setthe TRAVERSE speed potentiometer at 10 Set the CARRIAGE TRAVERSE switch ON Traverse the carriage to the left until the contact area of the grinding wheel is about 1 beyond the area to be ground on the bedknife Turn the traverse potentiometer to zero Be prepared to STOP the traverse earlier if there is any interference between the grinding wheel and the bedbar With the carriage still in the position determined in Step 3 above slide the left proximity switch in until the LED lights 23 OPERATING INSTRUCTIONS Continued GRINDING THE TOP FACE Continued Traverse back to the right until the grinding wheel reaches the point where it covers the entire area to be ground and goes past that point by 1 25 mm or more if possible Then set the right proximity switch in the same manner NOTE The area of the grinding wheel which contacts the bedknife is on the left side of the wheel When grinding the left end of the bedknife the area of the wheel which doesn t contact the bedknife will still be over the bedknife See FIG 33 When you go to the right end of the Grinder the wheel traverses completely off the bedknife Infeed the grinding wheel until it very lightly touches the bedknife on the left side Now traverse to the right end of the bedknife to assure that the right side is not closer to the grinding wheel Back the wheel out if necessary until you can traverse full length with a very light touch at the
8. It is suggested that a test be made on a corner of the polycarbonate window with the product selected following the polish manufacturer s instructions Some Important DON TS DONOT use abrasive or highly alkaline cleaners on the polycarbonate windows Never scrape polycarbonate windows with squeegees razor blades or other sharp instruments Benzene gasoline acetone or carbon tetrachloride should NEVER be used on polycarbonate windows DONOT clean polycarbonate windows in hot sun or at elevated temperatures Graffiti Removal e Butyl cellosolve for removal of paints marking pen inks lipstick etc e The use of masking tape adhesive tape or lint removal tools works well for lifting off old weathered paints e Toremove labels stickers etc the use of kerosene VM amp P naphtha or petroleum spirits is generally effective When the solvent will not penetrate sticker material apply heat hair dryer to soften the adhesive and promote removal GASOLINE SHOULD NOT BE USED ADJUSTMENTS CARRIAGE LINEAR BEARING REPLACEMENT LINEAR BEARING STEP 1 the four screws of one linear bearing slide the linear bearing off the end of the carriage shaft STEP 2 Insert a new linear bearing onto the end of the carriage shaft with the tension adjustment screw pointing outward See FIG 7 STEP 3 Adjust the tension screw of the linear bearing so when you radially rotate the linear bearing around the
9. 6009270 Panel Electrical 5 3707589 Circuit Breaker 15 Amp 3707778 Terminal Strip 19 Pole 5NT3707707 Straight Double Spade Terminal ONT3707709 Single 90 Spade Terminal 5NT3707708 Double 90 Spade Terminal oNT3707779 6 Amp Circuit Breaker 5NT3707624 Ground Terminal Block 5NT3707224 Cable Tie Mount Not Shown ONT3707225 Cable Tie 6 5 Long x 18 Wide Not Shown 5NT3707255 Cable Tie 4 Long x 10 Wide Not Shown 5NT3707773 Wire Harness Assembly Common Not Shown 51 5 27549 CONTROL PANEL ASSEMBLY EXPLODED VIEW 52 PARTS LIST 5 27549 CONTROL PANEL ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTD250800 1 4 20 x 1 2 Thread Cutting Screw Hex Head D 5 000536 1 4 Internal Tooth Lock Washer ads 5NTBG1509502 Control Panel Weldment 5NT275468 Electrical Panel Sub Assembly See Pages 66 69 D bens ONT80409 Decal Control Panel 5NT3707093 Strain Relief nae 9NT3707342 Yellow E Stop Ring ES 5NT3707367 Rocker Switch On Off ise E 5NT3707429 Rocker Switch On Off TO 5NT3707442 2 Amp Circuit Breaker 5NT3707
10. Buysnipy yeys JoJeS puj JeuseM NOILdIidISIO YIaNNnN LYVd WNV4OVIA PARTS LIST qouy 92560 lt 1 6 jsnJu JeuseMw V0 60 1NS 0 JeuseM 29060 lt 1 6 62 Bulids 8G980 ELNS 92 99A enq Ja 10y S980 1NS ZZ e pueH ejqeisn py LOS8OZELNS 92 Bulids GG80ZELNS GZ yog EIGSOJELNS vz eqn duelg LZLSOZELNG ez Jasseiq puoweig 980Z0ZELNG lt lt 01 NZg SL X 9 dn9 ys jeeuM 96900 lt 1 6 1994 M UOZEJOg Bulysng 60700 1 6 02 JeuseM IND 1814 91 6 LOLOLEMLNG 61 Ja9eds 18068891139 81 uds Jeusew 207 9 LOSLZEMLNS 21 uds Jeysemy907 7 LOSLSZTMLNS 9 105 Jeysemy907 0 ON LOSLELMLNS JeuseM 1e 3 OL ON L0006 LM LNS UO AN 1nUX207 91 B E OOOZZEr INS M8JOS 195 8490S 8 6 X 81 8 9 0901490139 M8JOS 195 8490S 7 X 81 9L G OZVOLEO LNS M8JOS 195 1exoos Z X OZ 7 1 02809201 9 M2JOS 18S JONDOS p L X OZ 7 02709201 9 M8JOS 195 J9A9OS Z L X vc OL 078061 INS peeH PADOS X 9 8 LLOLZEGLNS 6 uonng py L LX OZ p L 9LOZSZJLNS M3J9S ded uopng X Oz b L 9L9LSCS 1NS 6 peeH P E X OZ v L 9LZLSCS INS 6 1exoog uong 2 X OZ v L 9L890SC8 1NS M9J9S 9490S p X yz
11. CAUTION SHOULD BE USED AS ADJUSTING THE TIP WILL AFFECT THE SLIP LOAD AND COULD DAMAGE THE CLAMP TIP BELT OR TRAVERSE DRIVE SYSTEM 20 ADJUSTMENTS Continued POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL TDC Min Speed Factory set at full CCW 8 30 Do not change this setting Right Traverse Forward Torque Factory set at full CW 4 30 Do not change this setting Left Traverse Reverse Torque Factory set at full CW 4 30 Do not change this setting COMP Factory set to 9 00 IR COMP is current 1 resistance compensation COMP IR COMP adjusts the output voltage of the drive which balances load to motor RPM Regulation of a traverse motor may be improved by slight adjustment of the IR COMP trim pot clockwise from its factory set position Overcompensation causes the motor to oscillate or to increase speed when fully loaded If you reach such a point turn the IR COMP trim pot counterclockwise until the symptoms disappear Max Speed Set at 3 30 for maximum voltage of 90 Volts DC to the traverse motor When voltage is above 90 volts DC the traverse motor will start to pulsate and not run smoothly Right Traverse Forward Acceleration Factory set at full CCW 8 30 Do not change this setting Left Traverse Reverse Acceleration Factory set at full CCW 8 30 Do not change this setting DB Dead Band is the potentiometer setting for the 50 or 60 Hz cycle control Factory set to 9 00 works for both
12. For those without that background service can be arranged through your local dealer This section presumes that you are already familiar with the normal operation of the Grinder If not you should read the Operator s Manual or do the servicing in conjunction with someone who is familiar with its operation Persons without the necessary knowledge and skills should not open the control panel or attempt any internal troubleshooting adjustments or parts replacement If you have any question not answered in this manual please call your local dealer WIRE LABELS All wires on the BG1500 have a wire label at each end for troubleshooting The wire label has a code which tells you wiring information The wire label has a seven position code The first two or three digits are the wire number 01 199 The next three numbers or letters are the code for the component to which the wire attaches Example TDC for Traverse Drive Control The last two numbers or letters are the number of the terminal on the component to which the wire attaches TERMINAL BLOCKS To insert or remove a wire from the terminal block insert a small screw driver into the square hole Then insert or remove wire from the round hole Remove screwdriver to lock the wire place Note the square hole can also be used when checking for voltages The probe tip of the multimeter can be inserted into the square hole to take readings TROUBLESHOOTING INDEX AG
13. N REGLAS DE SEGURIDAD DURANTE EL RECTIFICADO EN LA PAGINA 3 NOTA En este punto no sabr las condiciones de la rueda abrasiva despu s del trabajo previo Siempre limpie o labre la rueda antes de rectificar Consulte la secci n sobre C mo limpiar labrar la rueda abrasiva 1 ENCIENDA el interruptor de la RUEDA ABRASIVA 2 ENCIENDA el interruptor de la BOMBA DEL REFRIGERANTE y verifique que la boquilla dirija el refrigerante a la cuchilla Vea la Fig 33 3 Configure el potenci metro de velocidad LONGITUDINAL entre 15 y 20 NOTA Si se debe quitar una cantidad excesiva de material met lico de un extremo vuelva a verificar su configuraci n primero y luego compruebe la linealidad correcta de la cuchilla Si est curvada o torcida reempl cela 4 Con la rueda abrasiva por encima de la cuchilla rote la manivela de avance horizontal en sentido de las agujas del reloj hasta que la rueda apenas rebane metal de la cuchilla Es recomendable que avance alrededor de 0 002 a 0 003 0 05 a 0 075 mm por paso NOTA El indicador de ajuste horizontal est calibrado en incrementos de 0 002 0 05 mm NOTA Durante el proceso de rectificado observe el patr n de chispas a lo largo de todo el rectificado las chispas deber an verse iguales durante todo el proceso NOTA Si se debe quitar una cantidad excesiva de material met lico de un extremo de la cuchilla vuelva a verificar su configuraci n primero y luego compruebe la lin
14. NO PONGA EN FUNCIONAMIENTO LA RECTIFICADORA BAJO LA INFLUENCIA DE DROGAS ALCOHOL O MEDICAMENTOS INSTRUCCIONES DE SEGURIDAD 10 UN USO INADECUADO DE LA RUEDA ABRASIVA PUEDE CAUSAR DANO O UNA LESION GRAVE El rectificado es una operacion segura si siguen las pocas reglas enumeradas a continuacion Estas reglas se basan en el material incluido en el Codigo de seguridad ANSI B7 1 para el Uso cuidado y proteccion de ruedas abrasivas Para su seguridad le sugerimos que aproveche los beneficios de la experiencia de otros y siga estas reglas cuidadosamente LO QUE DEBE HACER LO QUE NO DEBE HACER Siempre MANIPULE ALMACENE las ruedas con 1 NO utilice una rueda agrietada ni una que SE cuidado HAYA CAIDO o que est da ada INSPECCIONE VISUALMENTE todas las ruedas en 2 NO FUERCE una rueda a la m quina ALTERE el busca de da os posibles antes de montarlas tama o del orificio de montaje Si la rueda no encaja en la m quina busque una que s VERIFIQUE LA VELOCIDAD DE LA M QUINA en comparaci n con la velocidad operativa de seguridad 3 NUNCA EXCEDA LA VELOCIDAD OPERATIVA m xima establecida marcada en la rueda M XIMA establecida para la rueda CONTROLE LAS BRIDAS DE MONTAJE a fin de que 4 NO utilice bridas de montaje en las que tengan el mismo di metro y que sea el correcto las superficies de rodamiento NO EST N LIMPIAS PLANAS Y LIBRES DE QUEMADURAS UTILICE SECADORES DE MONTAJE cuando se le sumini
15. OL ELZLGLGLNG M8JoS 1exXoos 8 6 X pZ OL 1190619139 NOILdIYDSAC L4Vd LYVd CARTON ASSEMBLY EXPLODED VIEW 48 PARTS LIST CARTON ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5 1509002 Coolant Pint Pa 5 6709160 Wrench Grinding Wheel 49 EXPLODED VIEW 5 27548 ELECTRICAL PANEL SUB ASSEMBLY 90 PARTS LIST DIAGRAM NUMBER 5 27548 ELECTRICAL PANEL SUB ASSEMBLY PART NUMBER DESCRIPTION 5NTD160666 8 x 3 8 Tapping Screw 5NTD161266 8 X3 4 Self Tapping Screw oNTROOOA90 8 External Tooth Lock Washer 5 3706078 19 Pole Decal 5NT3707073 8 Pin Socket 5 3707163 Primary Ground Decal 9NT3707164 Primary Ground Lug 5NT3707378 Din Rail 14 5NT3707764 Power Line Filter 5 3707850 Traverse Control Board ONT3707556 Magnetic Starter ONT3707558 Voltage Sensor Relay 5 3707625 End Stop Terminal Block 5 3707626 Jumper Adjacent Terminal Block 5NT3707627 End Plate Terminal Block 5NT3707628 Terminal Block 2 Conductor Grey 9NT3707629 Terminal Block 2 Conductor Blue 5 3706079 19 Pole Decal 2 5
16. Operators amp Service Manuals Pint Grinding Wheel Wrench Coolant Concentrate lt a ASSEMBLY Continued ASSEMBLE THE FLOOD COOLANT SYSTEM COOLANT FLOW VALVE 1 The flood coolant system has been fully assembled at the factory The only requirement 15 to fill the coolant tank 2 the coolant concentrate at a ratio of 50 parts water to 1 part concentrate Refer also to the label on the coolant container If the coolant tray is empty this will take about 6 5 gallons of water and one pint of concentrate 24 6 liters of water and 0 5 liter of concentrate USE OF COOLANT OTHER THAN FACTORY SUPPLIED COOLANT CONCENTRATE 15 NOT RECOMMENDED ALTERNATIVE COOLANT CONCENTRATES MAY CAUSE CORROSION GUMMING OR GRINDING PROBLEMS 3 After the mixed coolant has been added your coolant system is ready to operate When you start the coolant pump for the first time you must adjust the coolant flow using the valve on the grinding head See FIG 4 10 ASSEMBLY INSTRUCTIONS Continued IMPORTANT GROUNDING INSTRUCTIONS In case of a malfunction or breakdown grounding reduces the risk of electrical shock by providing a path of least resistance for electrical current This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded according to all local or other appropriate electrical codes and ordinan
17. para verificar que la cuchilla est apenas en contacto en ambos extremos Esto se puede hacer mientras se realiza el rectificado de la cuchilla NOTA Estos ajustes se realizan con la manivela izquierda NO con la manivela de avance del cabezal de rectificado NOTA El m todo recomendado es utilizar el plumin del extremo Utilizar los plumines de los extremos ayudar a mantener la cuchilla alineada con los orificios de montaje de la mordaza de bancada 21 RUEDA ABRASIVA EN EL EXTREMO DERECHO DE LA CUCHILLA FIG 28 RUEDA ABRASIVA EN EL EXTREMO IZQUIERDO DE LA CUCHILLA FIG 29 INSTRUCCIONES DE OPERACI N Continuaci n C MO RECTIFICAR LA CARA FRONTAL Continuaci n Rectifique la cuchilla Cuando est satisfecho con la alineaci n del cabezal de rectificado comience con el rectificado CONSULTE LA SECCI N REGLAS DE SEGURIDAD DURANTE EL RECTIFICADO EN LA PAGINA 3 1 ENCIENDA el interruptor de la RUEDA ABRASIVA 2 ENCIENDA el interruptor de la BOMBA DEL REFRIGERANTE Verifique que la boquilla dirija el refrigerante a la cuchilla Fig 19 3 Configure el potenci metro de velocidad LONGITUDINAL entre 15 y 20 4 rueda abrasiva por encima de la cuchilla rote la manivela de avance horizontal en sentido de las agujas del reloj hasta que la rueda apenas rebane metal de la cuchilla Es recomendable que saque alrededor de 0 002 0 003 0 05 a 0 075 mm por paso NOTA El indicador de
18. posible que no necesite 5 mm Esta linea es paralela la superficie de montaje de la Los ngulos de rectificado adecuados para las dos caras variar n seg n el modelo Siempre siga las especificaciones recomendadas por el fabricante para los ngulos de las cuchillas GUN TIS ngulos de cuchilla t picos Habra angulo de despojo anterior de entre 4 10 grados en la cara superior El angulo habitualmente se mide con relacion a la superficie de montaje de la cuchilla Vea la Fig 11A Esta linea es a Angulo de la superficie re frontal superficie de montaje de la cuchilla fija Habra angulo de despojo anterior de entre 0 30 grados en la cara frontal El angulo 7 bp Superficie montaje 90 habitualmente se mide relacion una linea CUCHILLA perpendicular superficie de montaje la cuchilla Vea la Fig 11B me 09 309 zu FIG 11 13 TERMINOS Cuchilla la lamina estatica de una segadora de carrete Soporte de cuchilla o mordaza de bancada la cuchilla esta montada a este miembro del marco con tornillos y remaches Cara superior la superficie horizontal de base de la cuchilla Angulo de incidencia frontal el Angulo entre la vertical y el Angulo de afilado recomendado por el fabricante Angulo de incidencia superior el Angulo entre la horizontal y el Angulo de afilado rec
19. 183 x 221 cm The machine operator will 2 operate the unit from the front of the machine Position the base to allow sufficient operating room in front and right side of the machine See FIG 1 2 The base should be placed on a relatively level concrete floor with ample ceiling height to allow for the installation of the unit Do not place the unit across two concrete slab seams or across a large crack 1 FIG 2 ASSEMBLY INSTRUCTIONS Continued LEVEL BASE Place a level on the top of the traverse base and check the unit for level side to side Adjust the leveling feet as necessary until the machine is level See FIG 3 Now place the level across the traverse base from front to rear Adjust the leveling feet as necessary until the machine is level See FIG 3 LOOSEN JAM NUT TO ADJUST FOOT LEVELING FEET LOCATED AT CORNERS OF MAHCINE FIG 3 When both front to back and side to side leveling procedures have been completed thread the hex jam nuts up against the nut that is welded to the bottom of the machine Be careful not to move the leveling feet when tightening the jam nut See FIG 3 Make certain that all four leveling feet are firmly contacting the floor Recheck that the machine is level after locking the four feet into position Remove the carton and remove the contents from the carton onto a workbench The carton includes Product Packet Assembly
20. CLEARANCE 18 OPERATING INSTRUCTIONS CONTINUED MOUNTING A BEDKNIFE FOR GRINDING Continued VERIFY TOOLING IS TIGHT TO BOTH MACHINED SURFACES Mount the Bedknife THE TOOLING BAR 1 Pull both gauge tips forward and rotate the gauge into position straight up Loosen the lock knob and on the right side magnet and center assembly See FIG 21 Set the bedknife bedbar assembly to be ground on the magnets Move the right side magnet assembly until the bedknife setup gauge tips are at both ends of the bedknife then tighten the right side adjustable support lock knob enough to secure the magnet When tightening make certain the mount 15 tight to the tooling bar machined surfaces 2 Position the bedknife so the unworn tips on a used bedknives or the ends of a new bedknife are on the gauge tips See FIG 22 Pull bedknife forward firmly against the gauge tips Install the centers by loosening the arms lock handles only enough to slide the arms and loosening the center lock knobs Position the center into a bedknife hole and tighten the center lock knob and the arm lock handle on both sides See FIG 21 and 22 Rotate the bedknife setup gauge until the gauge RIGHT SIDE ADJUSTABLE SUP retracts to the stored position PORT LOCK KNOB FIG 21 THE CENTER SHOULD LOAD THE BEDBAR IN ANY DIRECTION AND SHOULD BE TIGHTENED INTO THE BEDBAR ONLY CENTER LOCK ENOUGH TO HOLD THE BEDBAR RIGID CENTER KNOB BEDKNIVES WIT
21. FILTER WT TP 35 OM En AK HED E 2 Wo 13 14 TRAV PROX PX2 R H a Iq 2H B3 REL 12 AMP M 7 REL LI TEL de NE pie B4 PS 2 NP a 56 cuchilla 861900 9 i 6 108 Y REV 5 19 2011 TM LISTA DE COMPROBACION DE PREPARACION INSTALACION DEL DISTRIBUIDOR Rectificadora de cuchilla Frontier BG1500 ESTA LISTA DE COMPROBACI N DEBE PERMANECER EN EL MANUAL DEL USUARIO El distribuidor tiene la responsabilidad de realizar los procedimientos que se enumeran a continuaci n y luego revisar la lista de comprobaci n con el cliente en el momento de la entrega o venta de este equipo La capacitaci n sobre la instalaci n cubre las funciones operativas b sicas del equipo Para garantizar una capacitaci n apropiada establecemos como requisito que su distribuidor de John Deere revise los puntos a continuaci n Marque para asegurarse de comprender los puntos a continuaci n antes de completar la capacitaci n sobre la instalaci n O 1 El equipo est completamente montado O 2 Todas las protecciones est n en su lugar y en buenas condiciones O 3 Todas las calcoman as est n en su lugar y son legibles O 4 Se encuentra en buenas condiciones generales es decir pintura soldaduras instalaciones el ctricas O 5 Verifique que haya suficiente sum
22. Lock Support Bar d stus 5NT6609092 Slide Lock Bar RH 49 5NT6609501 Knob Assy T 2 5 1 4 20 x 1 31Long OD oss cedes 5 6609535 Mount Weldment LH E 5NT6609536 Slide Weldment RH DL id 5NT6709021 Tip Gage o5 5NTJ372000 3 8 16 Hex Jam Nut Thin 22 T Spacer 386 IDx 50 0 75 Long 41 EXPLODED VIEW 5 27554 CHANNEL amp TRAVEL ASSEMBLY 42 PARTS LIST DIAGRAM NUMBER 9NT27554 CHANNEL amp TRAVEL ASSEMBLY PART NUMBER DESCRIPTION 5NTB160607 8 32 x 3 8 Button Head Socket Cap Screw 5NTB251211 25 5 1 4 20 x 3 4 Socket Head Cap Screw 5NTB252016 1 4 20 x 1 1 4 Button Head Socket Cap Screw 5NTB252011 1 4 20 x 1 1 4 Socket Head Cap Screw 256411 1 4 20 x 4 Socket Head Cap Screw 5 3708419 Wave Spring 78 ID x 1 00 OD 5NTJ257000 1 4 20 Locknut Thin 5 161501 8 Lockwasher Split ONTK251501 1 4 Lockwasher Split 5NT3708884 Spacer 281 ID x 62 OD x 38 Long 5NT29192 ins Support Travel Pulley ON TZ 196 etis Traverse Base Machined ONT2919T tns Guard Travel RH oNT50309 Shaft Travel Pulley 5 3706056 Pulley Cog Drive ONT6059062 Motor Assembly Travel W34 5 50363 Guard Traverse Pulley
23. MSHA respirators safety glasses or face shields and protective clothing Provide adequate ventilation to eliminate dust or to maintain dust level below the Threshold Limit Value for nuisance dust as classified by OSHA TABLE OF CONTENTS This machine is intended for reel mower bedknife grinding ONLY Any use other than this may cause personal injury and void the warranty To assure the quality and safety of your machine and to maintain the warranty you MUST use original equipment manufactures replacement parts and have any repair work done by a qualified professional ALL operators of this equipment must be thoroughly trained BEFORE o operating the equipment Do not use compressed air to clean grinding dust from the machine This dust can cause personal injury as well as damage to the grinder Machine 15 for indoor use only Do not use a power washer to clean the machine Low Voltage Relay FACTORY ieee The grinder is equipped with a high low voltage relay GREEN LIGHT which is factory preset at 100 140 VAC If the power INDIGATES supply line does not deliver 100 140 VAC power under LOW VOLTAGE load the relay will open and trip out the starter If this FLASHING occurs your power supply line is incorrect and must be RED LIGHT INDICATES HIGH VOLTAGE DELIVERED TO GR correct before proceeding further with the grinder TABLE OF CONTENTS INSHUCLONS Page 2 7 Daily Maintenance
24. ajuste horizontal est calibrado en incrementos de 0 002 0 05 mm NOTA Durante el proceso de rectificado observe el patr n de chispas a lo largo de todo el rectificado las chispas deber an verse iguales durante todo el proceso NOTA Si se debe quitar una cantidad excesiva de material met lico de un extremo de la cuchilla vuelva verificar su configuraci n primero y luego compruebe la linealidad correcta de la cuchilla Si est curvada o torcida reempl cela 5 Contin e rectificando la cuchilla de esta manera hasta que est satisfecho con el rectificado de la cara frontal Labre la rueda cuando sea necesario consulte C mo limpiar labrar la rueda abrasiva 6 Si utiliza una rueda abrasiva vitrificada labre la rueda antes del rectificado final en vac o Para el procedimiento de rectificado en vac o consulte la parte superior de la p gina 25 Al rectificar parcialmente ambas superficies la cara superior y la frontal como se muestra en la Fig 30 usted volver a afilar una cuchilla usada con la menor remoci n de metal posible La Fig 30 tambi n muestra cu nto material se quitar si rectifica la cara superior hasta que est afilada El rectificado parcial de ambas superficies es el m todo preferido para un uso de por vida de la cuchilla FIG 30 CIERRE EL INTERRUPTOR DE LA BOMBA DE REFRIGERANTE ANTES DE APAGAR LA RUEDA ABRASIVA PARA PERMITIR QUE LA RUEDA GIRE EN SECO SI LA RUEDA RETIENE DEMASIADO REFRIG
25. bottom of the carriage See FIG 51 To adjust the clearance loosen one of the hex nut and tighten the other FIG 15 3 16 Proximity Proximity Switch Switch Nut 19 ADJUSTMENT Continued A lt a TRAVERSE BELT TENSION em Emil LL OH To adjust the tension on the traverse belt tighten the ll _ screws nuts located at the left side of the traverse RN E belt Tighten until the compression springs measure 3 4 19 mm See FIG 16 If the springs are not tensioned equally uneven loading on the traverse system may cause premature failure of the components DO NOT OVERTIGHTEN OVERTIGHTENING COULD DAMAGE THE BELT OR TRAVERSE FIG 16 DRIVE SYSTEM TRAVERSE CLAMP FORCE CLAMP TIP If the traverse clamp is slipping during regular operation it may become necessary to adjust the clamp tip location To adjust the clamp tip loosen the jam nut and rotate the clamp tip The clamp tip should be adjusted to the dimension specified in FIG 17 To measure move the traverse belt out of the way Measure the clamped distance from the clamp tip to the clamping block shoe To secure the new position jam the nut against the clamp being careful not to move the clamp tip JAMNUT E 10 THE HAS BEEN FACTORY SET SO THAT IT WILL SLIP IF THE GRINDING HEAD ASSEMBLY COMES IN CONTACT FIG 17 WITH SOMETHING
26. coolant will then also be deflected onto the grinding wheel Adjust the flow valve so there is a steady stream of coolant Avoid a stronger flow than needed excessive coolant doesn t cool more and increases splattering Fluid Level in Coolant Tank Check the fluid level in the Coolant tray daily to avoid running out while grinding Keep the coolant level between 25 50 inches 6 12 mm above the top of the coolant sump The pump inlet must always be completely submerged in water Never add plain water to the coolant when the level is low Always add water and concentrate in the correct proportions It is recommended to pre mix coolant and water in a separate container for this purpose OPERATING INSTRUCTIONS CONTINUED MOUNTING A BEDKNIFE FOR GRINDING Inspect and Clean the Bedknife Inspect the bedknife for damage cracks warping bushing wear excessive bedknife wear Replace or repair if necessary see the mowing unit manufacturer s manual Thoroughly clean the bedknife especially on the bottom where the magnets will attach It is recommended that you thoroughly wire brush the bottom of the bedknife before mounting Prepare the Machine for Mounting the Bedknife Position the grinding head all the way to the right then move the grinding wheel back away from the magnets to gain clearance for the bedknife Pivot the tooling assembly to the horizontal position Front face grinding position and set the bedknife angle to 0 front
27. face angle Always wipe any grindings dirt etc from the magnets and the tooling bar right side slide area before mounting the bedknife USING A FLARE CUP WHEEL FOR ADDED CLEARANCE WHEEL GUARD LOCK KNOB The shape of some bed bars requires using an optional flare cup grinding wheel to clear the end supports See FIG 20 TA Flare cup wheels can be ordered in several 6 150 mm diameter versions For most applications the 6 borazon straight cupped wheel is used However if the end 22 mounting flanges of the bedknife more than 2 50 mm Ty high or near the front face of the knife you may need the gt gt optional 6 flared cup wheel IQ NN SS gt gt For Part Numbers and descriptions of available grinding MC CAO wheels refer to the Grinding Wheels list on Page 15 FLARED CUP WHEEL FIG 20 ROTATING THE WHEEL GUARD Some bedknives and bedbars have mounting ears so close to the bedknife top face that there is no clearance for the wheel guard For these applications generally a flared cup grinding wheel should be used and the grinding wheel guard can be loosened and rotated so the clearance area of the guard allows the bedknife to be ground without interference When completed ALWAYS reposition the guard to its normal position with the clearance notch down See FIG 20 FOR OPERATOR SAFETY THE GRINDING WHEEL GUARD MUST BE USED WITH THE CLEARANCE AREA UP ONLY WHEN REQUIRED FOR BEDBAR
28. face of the bedknife With the vertical cam and lock lever see Fig 26 adjust the grinding head LOCK LEVER VERTICAL CAM so the grinding wheel rim extends 1 2 12mm or as much LEVER as possible above the front face to be ground EXTEND OVER THE BEDKNIFE FACE IT WILL GRIND UNEVENLY AND CAUSE GROOVES ACROSS THE SURFACE OF THE BEDKNIFE IF THE GRINDING WHEEL DOES Check for interference 1 Back out the grinding head so the wheel no longer touches the front face of the bedknife 2 Slide the left and right proximity switches to the far ends of the rail 3 Set the TRAVERSE speed potentiometer to slow Set the CARRIAGE TRAVERSE switch to ON Traverse the carriage to the left until the contact area of the grinding wheel is about 1 beyond the area to be ground on the bedknife then turn the traverse potentiometer to zero Be prepared to STOP the traverse earlier if there is any interference between the grinding wheel and the bedbar With the carriage still in the position determined in Step 3 above slide the left proximity switch in until its LED lights Traverse back to the right until the grinding wheel reaches the point where it covers the entire area to be ground and goes past that point by 1 25 mm or more if possible Then set the right proximity switch in the same manner NOTE The area of the grinding wheel which contacts the bedknife is on the left side of the wheel When grinding the left end of the
29. gringing wheel height adjustment 5 Verify there is sufficient electrical power to operate O 11 Discuss grinder flood coolant system the machine O 12 Review cleaning dressing the wheel O 6 Review Operators Assembly amp Service Manuals 13 Review General Maintenance and any additional training material if available Dealer s Signature Purchaser s Signature Safety A IMPORTANT SAFETY MESSAGE FOR OWNERS OPERATORS OF BEDKNIFE GRINDERS Safety is a primary concern in the design manufacture sale and use of bedknife grinders As manufacturer of bedknife grinders we want to confirm to you our customers our concern for safety We also want to remind you about the simple basic and common sense rules of safety when using a bedknife grinder Failure to follow these rules can result in severe injury or death to operators or bystanders It is essential that everyone involved in the assembly operation transport maintenance and storage of this equipment be aware concerned prudent and properly trained in safety Always use proper shielding as specified by the manufacturer Our current production machines include as standard equipment guards or shields for the grinding wheel safety signs and an operators manuals Never bypass or operate the machine with any of the guards or safety device removed Read and fully understand all the safety practices discussed on pages 4 and 5 of this manual safety rules must be understoo
30. im n y centro de la derecha Vea la Fig 21 Configure el montaje de cuchilla mordaza de bancada para que se rectifique sobre los imanes Mueva el montaje de im n de la derecha hasta que las puntas del calibre de configuraci n de la cuchilla est n en ambos extremos de la cuchilla y luego ajuste la perilla de bloqueo del soporte ajustable de la derecha lo suficiente como para asegurar el im n Cuando realice el ajuste aseg rese de que el montaje est bien ajustado a las superficies maquinadas de la barra de mecanizado 2 Ubique la cuchilla de manera que las puntas no desgastadas de una cuchilla usada o los extremos de una cuchilla nueva est n sobre las puntas del calibre Vea la Fig 22 Empuje la cuchilla firmemente hacia adelante contra las puntas del calibre Instale los centros al aflojar las manivelas de bloqueo de los brazos solo lo suficiente como para deslizar los brazos y soltar las perillas de bloqueo de los centros Ubique el centro dentro del orificio de la cuchilla y ajuste la perilla de bloqueo del centro y la manivela de bloqueo del brazo en ambos lados Vea las Fig 21 y 22 Rote el PERILLA DE BLOQUEO DEL calibre de configuraci n de la cuchilla hasta que el calibre est SOPORTE AJUSTABLE DEL FIG 21 retra do en la posici n almacenada LATERAL DERECHO EL CENTRO NO DEBE CARGAR LA MORDAZA DE BANCADA EN NINGUNA DIRECCI N Y PERILLA DE DEBE ESTAR AJUSTADO A LA MORDAZA BLOQUEO CENTRAL SOLO LO SUFICIENTE COMO PARA
31. m nimo inicie las otras funciones y luego lentamente incremente la velocidad para observar que tanto la operaci n como la configuraci n sean correctas CONOZCA SU RECTIFICADORA CONTINUACION MANECILLA DE ACOPLE LONGITUDINAL ACOPLE Y DESACOPLE LONGITUDINAL ARRIBA PARA ACOPLAR LA CORREA ABAJO PARA La correa que traslada al carro de izquierda a derecha se DESACOPLARLA puede acoplar y desacoplar al rotar la manivela de la 71 abrazadera roja ubicada en la parte frontal izquierda del carro Al mover la manecilla hacia arriba acoplara la correa y al rotarla hacia abajo la desacoplara La punta de la abrazadera puede ajustarse de ser necesario para aumentar disminuir la tensi n sobre la correa Consulte los ajustes en el manual de servicio para obtener m s r Z r detalles 4 uE DE SER NECESARIO LA PUNTA DE LA ABRAZADERA DE LA CORREA SE DEBE oo AJUSTAR COMO LO ESPECIFICA EL MANUAL DE SERVICIO SI LA ABRAZADERA SE AJUSTA EN EXCESO ES POSIBLE QUELACORREANOSE 5A EOANTIFR 1 18 DESLICE LO QUE PUEDE CAUSAR PUNTA DE LAABRAZADERA DE FIG 2 DA O A LA M QUINA O A LA LA CORREA CUCHILLA INTERRUPTORES DE PROXIMIDAD LONGITUDINALES Dos interruptores m viles determinan los l mites izquierdo y derecho del recorrido longitudinal del carro Vea la Fig 3 Se enciende un LED en el interruptor cuando el soporte del accionador del interruptor en la parte inferior del carro
32. not light when flag is under prox B Proximity switch is not working properly or wire connections are loose If incorrect adjust per adjustment section of manual Yes end troubleshooting No go to Step B next First check to see if proximity light comes on When the light is on it means that there is electricity coming to proximity switch Actuate prox switches with steel tool to take measurements Left proximity PROX 1 check Traverse drive Control TDC between terminals 13 black wire and 15 brown wire Right proximity PROX check 14 black wire and 15 brown wire 31 The light coming on shows the proximity is getting electrical contact Proximity light on 0 Volts DC Proximity light off 12 Volts DC Proximity light on 0 Volts DC Proximity light off 12 Volts DC Replace proximity switch if the voltages do not read as above ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse speed control goes at one speed only Possible Cause Defective speed control potentiometer Wiring hookup to potentiometer is improper If components have been replaced Main circuit board dial pot settings not correct If board has not been replaced Checkout Procedure A Check potentiometer on control panel B Check potentiometer for 10 000 ohms Remove three wires from Traverse Drive Control red from term 8 white from term 7 black from term 9 C Check potentio
33. of the threaded joint between the adjustment shaft and the tooling bar slide block Tighten the setscrew unitl this is zero freeplay in the shaft DO NOT over tension the setscrew as the adjuster will be difficult to turn 16 FIG 9 Setscrew with nylon ball Infeed amp Handwheel Wave and flat washers gt gap FIG 10 ADJUSTMENTS Continued TO ELIMINATE ALIGNMENT ADJUSTMENT BACKLASH If there is backlash in the alignment adjustment handwheels FIG 47 verify the following adjustements are correct 1 2 Washers behind the handwheel A Loosen the handwheel setscrew about half a turn B Hold the handwheel and torque the hex lock nut which secures the handwheel to 100 in Ibs 1 15 kg m then back off 1 2 turn C Verify that the gap between the wave washer and flat washer is 015 in 04mm See FIG12 Adjust the hex lock nut if necessary D Tighten the setscrew holding the handwheel to the shaft Check the nylon ball tension On the tooling bar adjustment block there is a nylon ball setscrew combination used to set the tension on the shaft slide block See FIG 11 When you turn the handwheel the tooling bar block slide should move without any freeplay If there is free play tighten the set screw that pushes the nylon ball against the acme thread on the adjustment shaft Thenylon ball adjusts the freeplay between the adjustment shaft and the tooling bar slide block Tight
34. rectificar y el diamante se puede soltar Rote el reavivador de punta de diamante a lo largo del ancho completo de la rueda dos veces Cuando haya finalizado rote la manivela en sentido de las agujas del reloj contra el soporte de bloqueo al retraer y reemplazar el brazo de movimiento del reavivador en el soporte Vea la Fig 15 NOTA Un labrado excesivo acortar la vida til de la rueda Muy poco labrado no posibilitar un rectificado adecuado REAVIVADOR ARO DE AJUSTE BRAZO DE MOVIMIENTO DEL REAVIVADOR SOPORTE DE BLOQUEO FIG 15 Reavivador bloqueado FIG 16 Reavivador desbloqueado C mo reemplazar la rueda RUEDA DE BORAZON Hay aproximadamente 1 8 3 2 mm de material de rectificado en el extremo de la rueda Cuando reste un m nimo de material de rectificado se debe A reemplazar la rueda rus 075 RUEDA VITRIFICADA Una rueda vitrificada nueva es 2 51 mm de profundidad mn Cuando se gasta hasta una profundidad de 0 75 19 mm se debe reemplazar 19 mm FIG 17 Vea la Fig 17 16 INSTRUCCIONES OPERACION CONTINUACION COMO UTILIZAR REFRIGERANTE DE INUNDACION Para un rectificado de calidad recomendamos el uso de refrigerante de inundaci n para evitar la acumulaci n de calor en el filo de la cuchilla SI REALIZA RECTIFICADO EN SECO NUNCA PERMITA QUE EL FILO DE LA CUCHILLA CAMBIE DE COLOR O PUEDE PERDER SU TEMPLADO SIEMPRE LEA LA HOJA DE INFORMACI N SOBRE LA SEGURIDAD DE
35. rotate to a new angle or to rotate from the front face to top face grasp the tooling rotate handle and then loosen the tooling bar rotate lock handle a TOOLING BAR TOOLING BAR ROTATE Vision fue er as indicated on ADJUSTMENT LOCK HANDLE e decal and tighten the lock handle HANDWHEEL FIG 9 12 OPERATING INSTRUCTIONS WHEN TO SHARPEN THE BEDKNIFE When the grass is not being cut cleanly or the cut ends of the grass appear torn or ragged the edges of the reel blade and bedknife have become rounded and need sharpening See FIG 10A The purpose of sharpening is to restore the sharp edges to the reel and bedknife IMPORTANT To fully sharpen a reel mower you need to grind the reel blades using a Reel Grinder and reshape the cutting edge of the bedknife NOTE New bedknives should be ground before being put into use New bedknives deform and move to match the shape of the bedbar at the time of installation and therefore MUST be ground to a straight surface after installation BEDKNIFE GRINDING ANGLES The bedknife has two faces that normally need to be ground the top face and the front face on some models the front face may be curved and may not need grinding The proper grinding angles for the two faces will vary depending on the model Always follow the manufacturer s recommended specifications for bedknife angles Typical Bedknife angles There will be 4 to 10 degrees clearance angle ground on the
36. se acerca al cabezal del interruptor Tenga en cuenta que debe haber un espacio de 3 16 entre el cabezal del interruptor de proximidad y el soporte del accionador longitudinal FIG 3 INTERRUPTORES DE PROXIMIDAD LONGITUDINALES TUBO FLEXIBLE Y BOQUILLA SISTEMA DE REFRIGERACI N V LVULA DE FLUJO Boquilla del refrigerante Dirige una corriente de refrigerante a la cuchilla y a la rueda abrasiva Para un direccionamiento preciso la boquilla y el tubo de conexi n deben ser completamente flexibles NOTA El tubo de conexi n se puede acortar al quitar segmentos si lo desea V lvula de flujo del refrigerante Controla el volumen de refrigerante que fluye a trav s de la boquilla Utilice solo el flujo suficiente como para refrigerar la cuchilla El exceso de flujo puede causar gran cantidad de salpicaduras y no mejorar el desempe o 10 CONOZCA SU RECTIFICADORA CONTINUACION CABEZAL DE RECTIFICADO TORNILLO DE BLOQUEO DEL MANECILLA DE LEVA PROTECTOR DE LARUEDA VERTICAL Ajuste y bloqueo excentricos y verticales pr Mueve el cabezal de rectificado hacia arriba y hacia Manivela horizontal Mueve el avance del cabezal de rectificado hacia adentro y hacia afuera Escala de ajuste horizontal Calibrada en incrementos de 0 002 in 0 05 mm de manera que pueda mover con precision la rueda abrasiva hacia adentro para cada paso a lo largo de la cara de la cuchilla Tornillos de bloqueo del prote
37. unscrew the mounting flange that holds the grinding wheel THE LOCK FLANGE HAS A LEFT HANDED THREAD HOLD THE WHEEL AND TURN THE WRENCH CLOCKWISE WHILE LOOKING AT THE LOCK FLANGE TO LOOSEN 3 Remove the old wheel and install the new one 4 Screw on the flange finger tight then tighten approximately 1 8 turn further with the wrench The flange will self tighten when motor is turned on VITRIFIED GRINDING WHEELS IF THE WHEEL FLANGE IS OVERTIGHTENED THE GRINDING WHEEL MAY CRACK AND FLY APART 5 VITRIFIED GRINDING WHEELS After you install a new or different wheel it is recommended that you dress it before grinding Dressing trues the grinding surface of the wheel and removes the hard glaze sometime remaining from the manufacturing process Dressing the wheel properly prepares the wheel for grinding GRINDING WHEELS AVAILABLE FOR BG1500 BEDKNIFE GRINDER WHEEL PART NO 9NT3700060 9NT3700062 9NT3700268 9NT3700411 9NT3700670 9NT3700696 COLOR DESCRIPTION SIZE White red ruby flare cup wheel 6 3 1 4 x 2 0 627 inch bore vitrified ruby White flare cup wheel 6 3 1 4 x 2 0 627 inch bore vitrified White red ruby straight cup wheel 6 x 2 x 0 627 inch bore vitrified ruby White straight cup wheel 6 x 2x 1 25 inch bore vitrified Borazon straight cup wheel 6 x 1 1 2 x 0 625 inch bore Borazon straight cup wheel 6 x 1 1 2 x 0 625 inch bore 15 GRINDING WHEEL SHAFT HASALEFT HAN
38. working Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram are correct and pull on wire terminals with approximately 3 lbs force to verify there no loose terminal connections and or no loose crimps between the wire and the terminal problem persists test as listed below Possible Cause Grinding Motor Switch GMS is not on Guard door is not closed 10 Circuit Breaker CB is tripped Grind Motor Switch GMS not working Grinding Motor Relay not working No Power to Relay Contacts A Turn switch on B Close Front guard doors and rear ramp lift option C Check 10 amp CB on front of Control panel Press in if tripped D Check for power to GMS E Check for power from GMS F Check for power to relay Coil Relay should click when GMS is turned on G Verify Power to Relay Contacts 2 Grinding Motor works Yes end troubleshooting No go to Step B next Grinding Motor works Yes end troubleshooting No go to Step C next Grinding Motor works Yes end troubleshooting No go to Step D next GMS term 5 to Terminal Block 4 Blue for 120 Volts AC Yes go to Step E next No With power off check continuity of wires to GMS With GMS ON check GMS Term 6 to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step F next No replace GMS Check for 120 Volts
39. 20 Volts AC Yes Go to Step M next No Check wires 7 amp 3 Check Jumper on Terminal Blocks 1 3 Measure 120 volts AC from GMS Terminal 1 to Term Block 4 Blue Yes Go to Step N next No Flip Switch and check again Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch Measure 120 Volts AC from ESS term 2 to Term Block 4 Blue Yes Go to Step O next No Check wire for continuity then verify switch continuity If bad replace ESS contactor NC Measure 120 Volts AC from 555 term 3 to Term Block 4 Blue Yes Go to Step P next No Check wire for continuity then verify switch continuity If bad replace SSS contactor NO Measure 120 Volts AC from LVR term 8 to Term Block 4 Blue Yes Go to Step Q next No Check for 120 Volts AC from LVR term 6 to term 7 Yes Verify Continuity of term 1 to term 8 on LVR Replace LVR if bad No Verify Continuity of Wires Measure 120 Volts AC from MAG Term A1 to Term A2 Yes MAG Should pull in with clunk if not replace MAG No Verify Continuity of Wires 25 ELECTRICAL TROUBLESHOOTING Continued PROBLEM Machine Shuts off when you turn on Grind motor switch Possible Cause Guard Door is open Low Voltage Relay is tripping Door Safety Switch is not aligned Door Safety Switch is not working properly Checkout Procedure A Close the guard doors B Power delivered to the grinder is inadequate Verify th
40. 2500 11 blade 220 220 E Cut 7500 11 blade 7500 E Cut 11 blade 8500 11 blade ET17533 8500 E Cut 11 blade 15 220 WGM i O EC EEE EEE All 22 GAS 22 Fairway Lo Cut Epi __ _____________ ee eee ee ee All 22 Standard Medium 25008 7 blade 2500E 7 blade 7500 7 blade 7500 E Cut 7 blade 22 Fairway Hi Cut ET17767 8500 7 hlade 8500 E Cut 7 blade A lM 3 0 mm w Hardened Insert 1066 __ __ 5 6 AAR Ie aie 2 5 mm Tournament MT4846 180 AO DA 80 WGM ETTET E 18 OAS 18 Low Cut MT7350 8000 E Cut 11 blade 18 Fairway TCU25299 8000 E Cut 7 blade 250 wm 260B C WGM 26 diia ieee 15 26 Fairway ee _ _ ee mae 22 Standard st rrs _ 7700 8700 amp blade a ae ri All 22 ESP 22 TournamenvLow Cut Fairway 7700 10 ade 8700 5 e gt 227 Tournament Ultra Low Cu CO RE 1 A All 26 26 Standard 17752 2653B 7200 uu 2 All 30 and ESP 30 Standard MT1973 26538 7200 Lo de po die sr 30 ESP for 365 30 ESP for 1905 16 A 2 1 eI MKI MK2 0119 BERNER UNIES unm _____________ _ __ 14 OPERATING INSTRUCTIONS CONTINUED MOUNTING A GRINDING WHEEL To replace the grinding wheel See FIG 12 1 First turn the power off by pushing in the Emergency Stop button 2 Use the grinding wheel wrench supplied with the grinder to
41. 3 4 Button Head Socket Cap Screw 5NTB312013 5 16 18 x 1 25 Button Head Socket Cap Screw 5NTJ167000 8 32 Jam Locknut 5NTJ257100 1 4 20 Locknut 5NTJ317000 5 16 18 Jam Locknut 5NTK190001 10 Flat Washer 5NTK310001 5 16 Flat Washer 5 000453 Flat Washer 31 x 88 x 104 Thick uns Door Frame Bracket Right Hand SNT27 132 zu Door Frame Bracket Left Hand Lower Arm 5 27138 Torque Tube 2 71392 Inside Door Reinforce Right Hand 5NT27140 Inside Door Reinforce Left Hand oNT27144 Safety Switch Key Bracket oNT27142 Polycarbonate Door ONT2TS TT ise Door Arm Weldment Right Hand 5 27918 Door Weldment Left Hand 5NT3707728 Safety Switch 5NT3707372 Straight Key Safety Switch oNT3707563 Strain Relief 5NT3708572 Ball Stud 10MM 5NT3708577 D Handle 5NT3708820 8 32 x 50 Button Head Safety Screw 5NT3708865 8 32 x 1 50 Button Head Safety Screw 5 3708866 Gas Spring ONT 3889045 Spacer 406 x 875 x 38 Long 5 6709071 Handle Ferrule 9NT3708378 Foam Strip 25 Thick Not Shown 39 5 27541 BEDKNIFE SUPPORT ASSEMBLY EXPLODED VIEW
42. 5 tao oNT50310 Tip Belt Clamp oNT803395 Clamp Was 5 3709044 Bearing Ball Bushing Le 5NT3969064 Wiper Foam 45 5 6609529 GRINDING HEAD ASSEMBLY EXPLODED VIEW 46 Assy 9UI JUe 002 108 271 X v b INN 4907 AOJ N OZ p 1 Oc 9 1 MN XoH CVIBOZELNS CO80SCHLNS 000 4 lt 1 6 000cScf LNS OLE60ZELNS LLOSSCELNS S6S60ZELNS CSGBOZOLNS 60S60Z9LNS 086079 1 NG 09609139 50 60 9164 85060 91 64 804609914 56460 lt 1 4 911679 1 NG LLOL6LELNS 20560991585 600 0 lt 1 4 85060 91 64 89806099164 050609914 620609914 860609914 260609914 700609914 770600914 28064091585 8 26009 1 LvO608ELNS SOZ60ZELNS COL8OZELNS M9J9S pH 193906 8 L X OZ p 9 p99N HO MUS SAJEA jueuipjeM jeeuM wy JesseJq SSY 2109999 ssy qouy 291 eBue J Jaysnipy Je 0D Assy JOJOIN paq eg 5 HO MUS 10129Uuu02 M9J9S pH X YZ Ol dH Assy JO 0 Jeijes 5 6609529 GRINDING HEAD ASSEMBLY epinc 4907 JessaJq 1exoeJug HOUS A Bulysng 19108 WAY eseg 99YMPUBH Bury
43. 50 and 60 Hz Do not change this setting Calibrating the DWELL TIME rotary DIP switch adjusts the amount of time the process remains in the stop position after a limit switch is actuated The DWELL TIME range is adjustable from 0 4 seconds A DIP switch setting of sets the DWELL TIME to 0 seconds while a setting of 8 sets the DWELL TIME to 4 seconds Dwell time is preset to 2 setting for a 1 second dwell time when reversing at each end of stroke Diagnostic LED s indicate the function that is currently being performed indicates that ac power is being applied to the control A FORWARD indicates that the process is running in the forward direction traversing left REVERSE indicates that the process is running in the reverse direction traversing right PROX 1 FWD LIMIT lights when the forward limit switch is actuated left prox PROX 2 REV LIMIT lights when the reverse limit switch is actuated right prox DWELL lights when the process remains stopped after a proximity switch is actuated e a E co PROX 2 REV LIMIT PROX 1 FWO LIMIT Potentionmeter REVERSE Clock Orientation c 21 ELECTRICAL TROUBLESHOOTING SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING This Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowledge and skills to reliably test and repair the BG1500 electrical system
44. 543 12 Amp Circuit Breaker AAN 5NT3707446 Potentiometer Knob o NON 5NT3707564 Green Start Pushbutton jp oNT37079565 Normally Open Contact Block is ME ce 5NT3707566 Pushbutton Mounting Latch 5NT3707567 Push Pull E Stop Pushbutton X aa eee eee ee 5NT3707568 Normally Closed Contact Block TO up ONT6059050 Pot Assy euet E 5NT6059054 Main Power Cord Not Shown 5NT3707255 Cable Not Shown TERR 5NT3708378 25 Thick Foam Strip Not Shown 53 5 27402 WIRING DIAGRAM LEM 0009 LEM SEM ow qan VEM ADION 81 AD diid 1212 00 13780 10 114182 7 113182 6 02182 19 Pr rH 60182 02782 18 PF 2382 1 1410 17 FP 22182 1 102182 16 FFA BL 06182 15 FT 2UB2 1 07182 14 PIT 682 1 9 8 1 Ib J 4 3 E rm 93180 1 0 PM 5100 1 3182 13 FTA 07180 0 FIR AT 60182 117680 117181 18 40181 14 37181 13 k 30181 13 118781 6 118181 3 1187B1 4 TEM 040 8199 JM NIW 2 100781 TI 1421805 19 10018 19 OJO O
45. 5NT555539 iius Idler Pulley Assembly 5NT90355 Washer Thrust 75ID x 1 250D 9 ice Belt Cog 5NT3708688 Spring Compression 5NT3709331 Ring Retaining Ext 5NT6509063 Shaft Carrier 43 EXPLODED VIEW 5 27543 CARRIAGE ASSEMBLY 44 PARTS LIST 5 27543 CARRIAGE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Mi 5NTB191211 10 24 x 3 4 Button Head Socket Cap Screw LEN 5NTB250816 1 4 20 x 1 2 Button Head Socket Cap Screw D induce 5NTB252016 1 4 20 x 1 1 4 Button Head Socket Cap Screw d osx 5NTB253216 1 4 20 x 2 Button Head Socket Cap Screw 5NTJ252000 1 4 20 Hex Jam Nut 5NTJ627200 5 8 18 Locknut Jam Nylon ra c oNTK251501 1 4 Lockwasher Split S eet 5 28183 Bracket Travel Clamp O tunas oleadas 5 28187 Block Travel Clamp 5 28188 Spacer Travel Clamp T Pere eee 5NT28189 Block Clamp Support REN oNT28191 Carriage Grinding Head M 2 Bracket Wiper 5 28507 Travel Clamp Assembly 27
46. AC from A1 to A2 of Grinding motor Relay Yes If Relay does not pull in with click re place Relay if it does Go to Step G next No check continuity of wires to Grinding motor Relay REL Term L1 to Term L2 for 120 Volts AC Yes Go to Step H next No Check wires to REL Term L1 amp L2 ELECTRICAL TROUBLESHOOTING Continued Possible Cause Checkout Procedure Bad Contacts in Grinding motor Relay H Verify power out of Grinding Motor Relay With relay pulled in click check REL Term 1 to Term T2 for 120 Volts AC Yes Go to Step I next No Replace Gringing Motor Relay Bad Circuit Breaker Verify Power out of Circuit Breaker Check for 120 Volts AC from ter minals TB2 6 to Terminal Block 4 Blue Yes Go to Step J next No Check circuit breaker for con tinuity Verify wiring and replace if needed Bad Grinding Motor J Verify Power to Grinding mo tor Cord Verify wiring at terminals 1 2 amp 3 on Terminal Strip 1 Check TB1 1 to TB1 2 for 120 Volts AC Yes Check terminals on motor cord If tight replace motor No Check wires from Grinding Motor Relay and Circuit Breaker to Terminal Strip 1 PROBLEM Coolant Pump not working Possible Cause Coolant Pump A Turn switch Coolant Pump works owitch CPS is not on Coolant flow valve closed 2 Amp Circuit Breaker CB is tripped 2 Amp Circuit Breaker CB failed Coolant Pump Switch CPS not working Coolant P
47. CE BY THE OPERATOR On a daily basis clean the machine by wiping it off On a daily basis remove all grinding grit from the traverse shafts and tooling bar area On daily basis check coolant tray fluid level Fluid must be above the sump On a daily basis inspect the machine for loose fasteners or components Contact your company s Maintenance Department if damaged or defective parts are found USE COMPRESSED AIR TO CLEAN GRINDING DUST FROM GRINDER 6 SERVICE DATA SKILL AND TRAINING REQUIRED FOR SERVICING This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the BG1500 Bedknife Grinder For those without the back ground service can be arranged through your local distributor This section presumes that you are already familiar with the normal operation of the Grinder If not you should read the front of this manual or do the servicing in conjunction with someone who is familiar with its operation Persons without the necessary knowledge and skills should not remove the control box cover or attempt any internal troubleshooting adjustments or parts replacement If you have questions not answered in this manual please call your distributor They will contact manufacturer if necessary TORQUE REQUIREMENTS Throughout this manual we refer to torque requirements as firmly tighten or the like For more specific
48. CLUIDO POR EL FABRICANTE LOS CONCENTRADOS DE REFRIGERANTE ALTERNATIVOS PUEDEN CAUSAR CORROSION ENGOMADO O PROBLEMAS EN EL RECTIFICADO 17 FIG 19 Como utilizar el refrigerante Dirija la boquilla de manera que el refrigerante se pulverice sobre la cara de la cuchilla que se esta rectificando Fig 18 19 Algo de refrigerante tambi n se desviara a la rueda abrasiva Ajuste la valvula de flujo de manera que vierta una corriente constante de refrigerante Evite un flujo mayor que el necesario el refrigerante en exceso no enfria mas y aumenta el salpicado Nivel de liquido del tanque de refrigerante Diariamente verifique el nivel de liquido de la bandeja de refrigerante para evitar que se acabe durante el rectificado Mantenga el nivel de refrigerante entre 0 25 y 0 50 in 6 a 12 mm por encima de la parte superior del sumidero La entrada de la bomba debe estar siempre completamente sumergida en agua Nunca agregue agua al refrigerante cuando el nivel este bajo Siempre agregue agua y concentrado en las proporciones adecuadas Es recomendable que mezcle previamente el concentrado con el agua en un recipiente separado destinado a este prop sito INSTRUCCIONES OPERACION CONTINUACION COMO MONTAR LA CUCHILLA PARA SU RECTIFICADO Inspeccione y limpie la cuchilla Inspeccione la cuchilla en busca de da os grietas deformaciones desgaste del casquillo desgaste excesivo de la cuchilla Reemplace o repare de ser neces
49. CTORES EN SULUGAR y 13 en buenas condiciones de operaci n 2 QUITE LAS LLAVES Y OTRAS HERRAMIENTAS 3 CONSERVE EL REA DE TRABAJO LIMPIA 14 A NO UTILIZAR EN UN ENTORNO PELIGROSO No utilice la rectificadora en zonas h medas o mojadas La m quina es solo para uso en interiores 15 Conserve el rea de trabajo bien iluminada 5 TODOS LOS VISITANTES DEBEN MANTENER DISTANCIA Todos los visitantes deben mantenerse a una distancia segura del rea de trabajo 16 6 ACONDICIONE EL AREA DE TRABAJO PARA QUE SEA A PRUEBA DE NINOS con candados e interruptores principales 7 NO FUERCE LA RECTIFICADORA Realizar un 17 trabajo mejor mas seguro si se utiliza segun las especificaciones de este manual 8 UTILICE LAHERRAMIENTA CORRECTA No fuerce la rectificadora ni ninguna pieza adjunta a que realicen 18 un trabajo para el que no fueron dise adas 9 UTILICE LA VESTIMENTA ADECUADA No vista indumentaria suelta guantes corbatas ni alhajas que 19 puedan atascarse en las piezas en movimiento Se recomienda el uso de calzado antideslizante Utilice una redecilla protectora del cabello para contener el cabello largo 20 10 SIEMPRE UTILICE GAFAS DE SEGURIDAD 11 ASEGURE SU TRABAJO Aseg rese de que la cuchilla est trabada en forma segura con los soportes que se brindan antes de poner en funcionamiento 12 NO ADOPTE POSTURAS FORZADAS Mantenga 21 una posici n firme y equilibrada en todo mome
50. CTS A CAUTION A ATENCI N ACAUTION A ATENCI N 5 3 To Avoid Injury evitar To Avoid Injury Para evitar lesiones Keep hands lesiones Do not exceed grinding No exceda la velocidad de away from Mantenga las wheel maximum operating funcionamiento maxima de rotating objects gms manos alejadas speed of 3600 revolutions 3600 revoluciones por minuto de los objetos per minute de la rueda rectificadora giratorios ELECTRICITY CAUTION 0 To Avoid Injury sure all electrical power to this machine has been disconnected before removing any electrical panels or covers for maintenance y ATENCI N Para evitar lesiones Aseg rese de que se haya desconectado por completo el suministro el ctrico de esta m quina antes de retirar los paneles el ctricos o las cublertas para el mantenimiento GENERAL INFORMATION CAUTION To Avoid Injury Read Operator s Manual before operating servicing or repairing equipment Follow all safety rules and instructions Manuals are avallable from your selling dealer Keep bystanders away from equipment during operation Keep all shields in place and in good condition Wear all of the appropriate safety equipment specified in the Operator s Manual while operating this machine Always make sure machine 15 off and all machine movement has stopped before leaving machine Never allow children or untraine
51. D THREAD TURN CLOCKWISE TO LOOSEN uk GRIT 60 46 60 46 60 120 Standard Grinding Wheel OPERATING INSTRUCTIONS CONTINUED DRESSING CLEANING THE GRINDING WHEEL Clean or dress the grinding wheel whenever there Is any coolant on the face of the wheel For best results with a vitrified wheel also dress the wheel before making the final grind REFER ALSO TO THE SAFETY RULES WHEN GRINDING ON PAGE 3 For cleaning or dressing always move the grinding head to the right hand side of the machine FIG 13 so you are clear of the bedknife CLEANING A BORAZON GRINDING WHEEL Do not use the built in diamond dresser on the Borazon grinding wheel If the Borazon wheel is not grinding effectively use the cleaning stick to recondition the wheel To use the cleaning stick thoroughly soak the stick in water Turn on the grinding motor if not already on Once the motor is at full speed turn off the motor As soon as the power is turned off press the cleaning stick STRAIGHT into the grinding surface of the wheel until the wheel skids to a stop Repeat this procedure if necessary until the wheel is grinding effectively DO NOT MOVE THE CLEANING STICK SIDEWAYS MOVING THE CLENAING STICK SIDEWAYS WILL ERRODE THE BONDING MATERIAL ON THE SIDES OF THE GRINDING PARTICALS THIS WILL GREATLY DRECREASE THE LIFE OF THE WHEEL DRESSING A VITRIFIED GRINDING WHEEL With the wheel turning lift the dresser movement arm off i
52. E EXTIENDE SOBRE LA CARA DE LA CUCHILLA RECTIFICAR EN FORMA DESPAREJA Y DEJAR SURCOS A LO LARGO DE LA SUPERFICIE DE LA A cuchiLLa Verifique si hay alguna interferencia 1 Aleje el cabezal de rectificado de manera que la rueda ya toque la cara superior de la cuchilla FIG 32 2 Siacaba de rectificar la cara frontal el l mite del recorrido deber a seguir siendo el correcto pero es recomendable que de todas maneras verifique que no haya interferencias como se describe a continuaci n Si no rectific la cara frontal siga todo el procedimiento que se enumera a continuaci n Deslice los interruptores de proximidad izquierdo y derecho completamente hasta los extremos del riel 3 Configure el potenci metro de velocidad LONGITUDINAL en 10 Encienda el interruptor de DESPLAZAMIENTO DEL CARRO Desplace el carro a la izquierda hasta que el rea de contacto de la rueda abrasiva est alejada alrededor de 1 25 mm del rea de la cuchilla que se rectificar Gire el potenci metro longitudinal hasta la posici n cero Est preparado para DETENER antes el desplazamiento si hay alguna interferencia entre la rueda abrasiva y la mordaza de bancada Con el carro todav a en la posici n establecida anteriormente en el Paso 3 deslice el interruptor de proximidad izquierdo hacia adentro hasta que se encienda el LED 23 INSTRUCCIONES DE OPERACI N Continuaci n C MO RECTIFICAR LA CARA SUPERIOR Continuaci n Desplac
53. E YOUR WORK Make certain that the bedknife is securely fastened with the mounts provided before operating DON T OVERREACH Keep proper footing and balance at all times Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards Whenever you see these symbols follow their The Caution Symbol identifies special instructions or procedures which if not strictly observed could result in damage to or destruction of equipment 13 14 15 16 17 18 19 20 21 MAINTAIN GRINDER WITH CARE Follow instructions in service section of the Manual for lubrication and preventive maintenance DISCONNECT POWER BEFORE SERVICING or when changing the grinding wheel REDUCE THE RISK OF UNINTENTIONAL STARTING Make sure all switches are OFF before plugging in the Grinder USE RECOMMENDED ACCESSORIES Consult the manual for recommended accessories Using improper accessories may cause risk of personal injury CHECK DAMAGED PARTS A guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced NEVER LEAVE GRINDER RUNNING UNATTENDED TURN POWER OFF Do not leave grinder until it comes to a complete stop KNOW YOUR EQUIPMENT Read this manual carefully Learn its application and limitations as well as specific potential hazards KEEP ALL SAFETY DECALS CLEAN AND LEGIBLE If safety decals become damaged or illegible for an
54. ED FIXED BEDKNIFE SUPPORT LEFT SIDE The bedknife and bedbar is held in position by two magnets and centers The left side magnet and center position is fixed See Fig 7 ADJUSTABLE BEDKNIFE SUPPORT RIGHT SIDE The right side magnet and center is adjustable to match the width of the bedknife See Fig 8 CENTERS BEDKNIFE SETUP MAGNET LOCK KNOB ON BACK OF RIGHT HAD GAUGE RETRACTED ADJUSTABLE SUPPORT FIG 7 Locks the right magnet and center assembly in LOCK KNOB CENTER position on the tooling bar slide See Fig 8 BEDKNIFE SUPPORT CHECK TO SEE THAT IT IS TIGHT TO THE MACHINED SURFACES OF THE TOOLING BAR WHEN TIGHTENING THE ADJUSTABLE BEDKNIFE SETUP GAUGE On the outside of each magnet is a retractable bedknife setup gauge These gauges are used to help align the bedknife to the grinding wheel carriage travel Operation of the gauges will be explained in the operations section of this manual See Fig 7 amp 8 BEDKNIFE SETUP MAGNET GAUGE UP POSITION ig e TOOLING BAR ADJUSTMENT HANDWHEEL ANGLE INDICATOR nie The tooling bar adjustment handwheel moves the tooling bar horizontally The handwheel is used to align the the tooling assembly and bedknife to the grinding head This will ensures maximum life of the bedknife See Fig 9 TOOLING ROTATION To achieve the recommended bedknife angles the BG1500 bedknife grinder has a rotatable tooling bar with an angle indicator and lock handle See Fig 9 To
55. ERANTE ESTAR DESEQUILIBRADA CUANDO VUELVA A ENCENDER EL MOTOR DE RECTIFICADO 22 INSTRUCCIONES DE OPERACI N Continuaci n C MO RECTIFICAR LA CARA SUPERIOR NOTA Las instrucciones a continuaci n suponen que usted ya estudi todas las secciones previas de este manual Ubique la cuchilla para un rectificado de cara superior Vea la Fig 31 Cuando rote del rectificado de la cara frontal al de la cara superior el cabezal de rectificado debe estar retra do tres vueltas completas Rote el montaje del mecanizado hacia la posici n de cara superior hacia arriba y configure el ngulo de cara superior seg n las especificaciones de f brica de la segadora Verifique los m rgenes y establezca los l mites longitudinales FIG 31 Ubique el cabezal de rectificado de manera que la rueda abrasiva apenas toque la cara superior de la cuchilla Compruebe si el aro de la rueda abrasiva est extendido MANECILLA DE 1 2 50 mm por encima de la cara superior de la cuchilla BLOQUEO Si previamente rectific la cara frontal la mayor a de las veces estara correctamente posicionado De no estarlo con la leva vertical y la manecilla de bloqueo ajuste el cabezal de A rectificado Vea la Fig 32 Si la forma de la mordaza de bancada interfiere el protector de la rueda con la rueda abrasiva debera realizar algunos ajustes Consulte la pagina 18 MANECILLA DE LEVA VERTICAL 5 EL ARO DE LA RUEDA ABRASIVA NO S
56. H DUAL CUTTING EDGES Some mowing unit manufacturers and some after market bedknife manufacturers make a bedknife with Dual Cutting Edges as shown in FIG 24 Because of the two rounded surfaces that these bedknives present to the magnets there is minimal holding force Therefore to achieve a solid hold with the magnets you must file the bottom side of the bedknife with a flat bastard file as shown in Fig 23 You must file with a uniform stroke across both radiuses File until you have developed flats on the radius that are a minimum of 3 32 09 2 3mm wide and uniform in width for the length of the magnet on each end of the hedknife er FIG 24 19 OPERATING INSTRUCTIONS Continued GRINDING THE FRONT FACE NOTE The following instructions presume that you have already studied all previous sections of this manual NOTE On some mower bedknives the front face is curved and therefore may not have to be sharpened Position the Bedknife for Front Face Grinding See FIG 25 Loosen the left side tooling rotate lock handle Rotate the tooling assembly to the front face position down and set the front face angle to the mower factory specification Tighten the tooling rotate lock handle Check Clearances and Set Traverse Limits M Position the grinding head so that the grinding wheel just FIG 25 touches the front
57. INTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY S MAINTENANCE DEPARTMENT PERIODIC MAINTENANCE 1 Clean the Traverse Rails by wiping down with CRC3 36 or equivalent on a weekly basis 2 Replace the four foam rail wipers as necessary and at least every 6 months of operation FIG 6 3 Clean the interior of the Coolant Tray as necessary and at least every 6 months 4 Clean and lubricate the traverse bearings per the procedure below as necessary and at least every 6 months Wiper 5 Check the brushes on the traverse drive motor once every 36 months Replace as necessary LUBRICATION OF LINEAR BEARINGS STEP 1 Thoroughly clean the both traverse shafts STEP 2 Flood spray both shafts with CRC 3 36 until the lubricant is dripping off the shafts Do not use a Teflon based lubricant Then run the grinding head assembly back and forth through the full range of travel This will remove the dust and deposits from inside the bearings Repeat spraying the shafts moving the grinding head and wiping the shafts clean until the lubrication is clear of deposits when moving the grinding head back and forth STEP 3 With a clean rag wipe off the excess amount of lubricant from the shafts Run the grinding head assembly through the full range of travel and wipe the shafts after each traverse Repeat until the shafts feel dry This completes the lubrication process IMPORTANT If the unit will be shut down for an extended period of
58. L MATERIAL MSDS DEL REFRIGERANTE QUE UTILICE A CONTINUACI N ENCONTRAR ADVERTENCIAS RELEVANTES PARA LA MAYOR A DE LOS REFRIGERANTES EVITE EL CONTACTO DEL REFRIGERANTE CON LOS OJOS CAUSAR IRRITACI N EN LOS OJOS USE UNA M SCARA O GAFAS PROTECTORAS CUANDO MANIPULE EL CONCENTRADO EN CASO DE CONTACTO ENJUAGUE LOS OJOS CON AGUA DURANTE 15 MINUTOS Y PONGASE EN CONTACTO CON UN M DICO EVITE RESPIRAR EL VAPOR PROPICIE UNA VENTILACI N LOCAL MANTENGA LA BOTELLA DEL CONCENTRADO CERRADA CUANDO NO LA UTILICE UN CONTACTO CONTINUO DEL CONCENTRADO CON LA PIEL PUEDE CAUSAR IRRITACI N LAVE CON JAB N Y AGUA LUEGO DEL CONTACTO NO LO CONSUMA EN CASO DE INGERIRLO CONSULTE CON UN MEDICO Y NO INDUZCA EL VOMITO UN RIESGO POTENCIAL APLICA AL CONCENTRADO Y ES MENOR SI SE UTILIZA LA DILUCI N NORMAL C mo mezclar el refrigerante Mezcle el refrigerante N de pieza SNTBG1509002 con una proporci n de 50 partes de agua y 1 parte de concentrado Consulte tambi n la etiqueta del recipiente del refrigerante Si la bandeja del refrigerante est vac a se utilizar n 6 5 galones de agua y una pinta de concentrado 24 6 litros de agua y 0 5 litros de concentrado DEBE UTILIZARSE LA PROPORCI N DE REFRIGERANTE QUE SE ESPECIFICA UNA CONCENTRACI N DEMASIADO ALTA O BAJA PUEDE CAUSAR CORROSI N Y PROBLEMAS EN EL DESEMPE O NO SE RECOMIENDA EL USO DE REFRIGERANTE DIFERENTE AL CONCENTRADO DE REFRIGERANTE IN
59. O CENTRO derecha sobre la gu a de deslizamiento de la barra de mecanizado Vea la Fig 8 CUANDO APRIETE EL SOPORTE AJUSTABLE DE LA CUCHILLA VERIFIQUE QUE ESTE AJUSTADO ALAS SUPERFICIES MAQUINADAS DE LA BARRA DE MECANIZADO CALIBRE DE CONFIGURACION DE LA CUCHILLA En el exterior de cada iman se encuentra un calibre de configuracion de la cuchilla Estos calibres se utilizan para poder alinear la cuchilla con el recorrido del carro de la rueda abrasiva Se explicar c mo se operan estos cali bres en la secci n de operaciones de este manual Vea las Fig 7 y 8 IM N CALIBRE DE CONFIGURACI N DE LA CUCHILLA POSICION FIG 8 LEVANTADA MANIVELA AJUSTE DE LA BARRA DE MANIVELA DE ROTACION MECANIZADO INDICADOR DE NGULO DEL MECANIZADO La manivela de ajuste de la barra de mecanizado mueve la barra horizontalmente La manivela se utiliza para alinear el montaje del mecanizado y la cuchilla con el cabezal de rectificado Esto asegurar la m xima vida til de la cuchilla Vea la Fig 9 ROTACI N DEL MECANIZADO Para lograr los ngulos recomendados para la cuchilla la rectificadora de cuchilla BG 1500 cuenta con una barra de mecanizado rotatoria con un indicador de ngulo y una manivela de bloqueo Vea la Fig 9 Para rotar a un nuevo ngulo o para rotar de la cara frontal a la superior tome la manivela de rotaci n del mecanizado y luego afloje la manivela de bloqueo de rotaci n de la barra de mecan
60. OPERATOR S MANUAL b O This book consists of three manuals The OPERATORS MANUAL in ENGLISH which contains all the information on operating and doing routine daily maintenance on this equipment ASSEMBLY SERVICE MANUAL which is used by the maintainence department to install the equipment and to do all maintenance except routine daily maintenance The OPERATORS MANUAL in SPANISH which is the same as the English version only translated into Spanish REV 6 16 2011 DEALER PREPARATION INSTALLATION CHECK LIST Frontier BG1500 Bedknife Grinder THIS CHECKLIST IS TO REMAIN INOWNER S MANUAL It is the responsibility of the dealer to complete the procedures listed below then review this checklist with the customer upon the delivery or the sale of this equipment The installation training goes over the basic operational functions of the equipment To ensure adequate training we require that the following items are reviewed by your John Deere Dealer Please check off to ensure that you understand the following items before the installation training is complete O 1 Equipment is completely assembled O 7 Review proper positioning of bedknife O 2 All shields in place and in good condition O 8 Review traverse proximity switch positioning O 3 All decals in place and readable O 9 Explain use of setup flags 4 Overall condition good i e paint welds electrical L1 10 Explain
61. P CONSTANTLY PROPER GROUNDING OF THE RECEPTACLE GROUND IN YOUR BUILDING MUST BE VERIFIED IMPROPER GROUNDING IN YOUR BUILDING MAY CAUSE THE GRINDER TO MALFUNCTION When installing the grinder the following guidelines should be used to establish the wire size between the power panel in your building and the grinder receptacle Note that the wiring in your building must be per code between main power panels and sub panels FOR 15 AMP RATED LARGE MACHINES BUILDING WIRING For 0 to 30 Feet 0 to 9 m from panel to receptacle Use 14 Ga 2 5 m FIG 5 The grinder is equipped with a high low voltage relay which is factory preset at 100 140 VAC If the power supply line does not deliver 100 140 VAC power under load the relay will open and trip out the starter If this occurs your power supply line is incorrrect and must be correct before proceeding further with the grinder FACTORY PRESET FLASHING GREEN LIGHT INDICATES LOW VOLTAGE FLASHING RED LIGHT INDICATES HIGH VOLTAGE DELIVERED US 272 222 Wire For 30 to 50 Feet 9 to 15 m from panel to receptacle Use 12 Ga 4 0mm Wire For 50 to 80 Feet 15 to 24 m from panel to receptacle Use 10 Ga 6 0 mm Wire For 80 to 140 Feet 24 to 42 m from panel to receptacle Use 8 Ga 10 12 O mm Wire MAINTENANCE DAILY MAINTENANCE IS SPECIFIED ON PAGE 6 AND IS TO BE PERFORMED BY THE OPERATOR LISTED BELOW ARE PERIODIC MA
62. R GRINDER WITHOUT FIRST PUTTING ON SAFETY EMEREENEY EYEWEAR STOP EMERGENCY STOP PUSHBUTTON 2 Push to cut all power to the control panel functions CONTROL This removes power from all motors including the grinding motor coolant pump traverse motor etc To restore power pull up on button and press the Start button The large button design allows a quick stop of all power in an emergency situation FIG 1 SYSTEM START PUSHBUTTON The green pushbutton is the system start switch Pushing it will engage the magnetic starter and power the control panel The magnetic starter will not engage unless the emergency stop pushbutton is pulled out and the grinding motor switch is turned off GRIND MOTOR SWITCH The grind motor switch turns the Grinding Wheel Motor on and off COOLANT PUMP SWITCH The coolant pump switch turns the coolant pump on and off There is also a valve on the side of the grinding head to control the amount of the flow TRAVERSE MOTOR SWITCH The travel motor switch turns the traverse motor on and off It controls the side to side movement of the carriage and grinding head TRAVERSE SPEED CONTROL POTENTIOMETER This control knob sets the speed of traverse for the grinding carriage When turned on to minimum the carriage will stop When turned to the maximum the carriage moves back and forth at full soeed When learning to use this machine it is a good idea to set this speed at minimum start the other func
63. ROPPED or has become damaged DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole if wheel won t fit the machine get one that will DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURNS DON T TIGHTEN the mounting nut excessively DON T grind on the SIDE OF THE WHEEL see Safety Code 7 2 for exception DON T start the machine until the WHEEL GUARD IS IN PLACE DON T JAM work into the wheel DON T STAND DIRECTLY IN FRONT of a grinding wheel whenever a grinder is started DON T FORCE GRINDING so that motor slows noticeably or work gets hot AVOID INHALATION OF DUST generated by grinding and cutting operations Exposure to dust may cause respiratory ailments Use approved NIOSH or MSHA respirators safety glasses or face shields and protective clothing Provide adequate ventilation to eliminate dust or to maintain dust level below the Threshold Limit Value for nuisance dust as classified by OSHA TABLE OF CONTENTS This machine is intended for reel mower bedknife grinding ONLY Any use other than this may cause personal injury and void the warranty To assure the quality and safety of your machine and to maintain the warranty you MUST use original equipment manufactures replacement parts and have any repair work done by a qualified professional ALL operators of this equipm
64. SEQUILIBRADA CUANDO VUELVA A ENCENDER EL MOTOR DE RECTIFICADO C MO QUITAR LA CUCHILLA Para quitar la cuchilla rote el montaje del mecanizado hacia la posici n de rectificado de cara frontal hacia abajo Quite el centro del lateral derecho de la mordaza de bancada al retraer el centro hacia atr s tanto como sea necesario NO afloje el bloqueo del brazo Tome la cuchilla y qu tela de los imanes Si la pr xima cuchilla que se debe rectificar es del mismo tipo y tama o que la anterior simplemente m ntela y proceda con la verificaci n del montaje y la nueva alineaci n Si la pr xima cuchilla que se debe rectificar es de diferente tipo o tama o siga el procedimiento de instalaci n completo 25 PART NUMBER NUMERO DE PIEZA 5NTBG1507901
65. Start Inicio El dise o de bot n grande permite una FIG 1 detenci n r pida de todo suministro el ctrico en una situaci n de emergencia PULSADOR DE ARRANQUE DEL SISTEMA El pulsador verde es el interruptor de arranque del sistema Al presionarlo pondr en funcionamiento el arrancador magn tico y suministrar electricidad al panel de control El arrancador magn tico no se pondr en funcionamiento a menos que se tire del pulsador de parada de emergencia y el interruptor de la rectificadora est apagado INTERRUPTOR DEL MOTOR DE LA RECTIFICADORA El interruptor del motor de la rectificadora enciende y apaga el motor de la rueda abrasiva INTERRUPTOR DE LA BOMBA DEL REFRIGERANTE El interruptor de la bomba del refrigerante enciende y apaga la bomba del refrigerante Tambi n hay una v lvula en el lateral del cabezal de rectificado para controlar el volumen del flujo INTERRUPTOR DEL MOTOR LONGITUDINAL El interruptor del motor de carrera enciende y apaga el motor longitudinal Controla el movimiento de lado a lado del carro y del cabezal de rectificado POTENCI METRO DE CONTROL DE VELOCIDAD LONGITUDINAL Esta perilla de control establece la velocidad longitudinal del carro de la rectificadora Cuando se gira hasta el m nimo el carro se detiene Cuando se gira al m ximo el carro se traslada de un lado al otro a m xima velocidad Mientras aprende a utilizar esta m quina es recomendable que confi gure esta velocidad al
66. TERIAL SAFETY DATA SHEET MSDS FOR THE COOLANT YOU ARE USING BELOW ARE WARNINGS THAT APPLY TO MOST COOLANTS AVOID CONTACT OF COOLANT WITH EYES IT WILL CAUSE EYE IRRITATION WEAR FACE SHIELD OR GOGGLES WHEN HANDLING CONCENTRATE IN CASE OF CONTACT FLUSH EYES WITH WATER FOR 15 MINUTES AND CONTACT A PHYSICIAN AVOID BREATHING MIST PROVIDE LOCAL VENTILATION KEEP CONCENTRATED BOTTLE CLOSED WHEN NOT IN USE CONTINUED CONTACT OF CONCENTRATE ON SKIN MAY CAUSE IRRITATION WASH WITH SOAP AND WATER AFTER CONTACT DO NOT TAKE INTERNALLY IF INGESTED CONSULT PHYSICIAN AND DO NOT INDUCE VOMITING HAZARD POTENTIAL APPLIES TO CONCENTRATE AND IS LESS AT NORMAL USE DILUTION Mixing the Coolant Mix Part No 5NTBG1509002 coolant at a ratio of 50 parts water to 1 part concentrate Refer also to the label on the coolant container If the coolant tray is empty this will take about 6 5 gallons of water and one pint of concentrate 24 6 liters of water and 0 5 liter of concentrate THE COOLANT RATIO AS SPECIFIED MUST BE USED TOO HIGH A CONCENTRATION OR LOW A CONCENTRATION WILL CAUSE CORROSION AND PERFORMANCE PROBLEMS e USE OF COOLANT OTHER THAN FACTORY SUPPLIED COOLANT CONCENTRATE IS NOT RECOMMENDED ALTERNATIVE COOLANT CONCENTRATES MAY CAUSE CORROSION GUMMING OR GRINDING PROBLEMS 17 FIG 19 Using the Coolant Direct the nozzle so the coolant sprays onto the bedknife face being ground FIG 18 or 19 Some
67. a capacitaci n adecuada sobre seguridad Siempre utilice la protecci n adecuada como lo especifica el fabricante Nuestras m quinas de producci n actuales incluyen como equipamiento est ndar protectores o protecciones para la rueda abrasiva se ales de seguridad y un manual del operador Nunca pase por alto o ponga en funcionamiento la m quina sin alguno de los protectores o alguno de los dispositivos de seguridad Lea y comprenda completamente todas las pr cticas de seguridad que se especifican en las p ginas 4 y 5 de este manual Toda persona que trabaje con las rectificadoras de cuchilla debe comprender y seguir todas las reglas de seguridad MENSAJE DE SEGURIDAD IMPORTANTE PARA LOS PROPIETARIOS OPERADORES DE LAS RECTIFICADORAS DE CUCHILLA Antes de poner funcionamiento la rectificadora de cuchilla un operador debe leer y comprender toda la informacion en el manual del usuario en las se ales de seguridad que aparecen adjuntas al producto Una persona que no haya le do o comprendido el manual del usuario y las se ales de seguridad no est calificada para poner en funcionamiento la unidad A menudo ocurren accidentes en m quinas que son utilizadas por una persona que no ley el manual del usuario y no se familiariz con el equipo Si no cuenta con un manual del usuario o con las se ales de producci n actualizadas p ngase en contacto con el fabricante o con su distribuidor de inmediato Las rectifica
68. a debe estar alineada con el cabezal de rectificado Utilice la manivela de ajuste izquierda de la barra de mecanizado para alinear la cuchilla con el cabezal de rectificado La alineaci n se logra cuando la rueda abrasiva toca la cuchilla Con la cuchilla configurada en el ngulo correcto mueva el cabezal de rectificado hasta el extremo derecho de la cuchilla Ahora rote la manivela de avance hasta que la rueda apenas toque la cuchilla en el plumin del extremo de la cara de la cuchilla en una cuchilla usada o toda la cara de la cuchilla en una nueva En una cuchilla usada si desea rectificar para que coincida con la cuchilla desgastada entonces ponga en contacto la rueda abrasiva con el plumin del extremo Vea la Fig 28 A continuaci n mueva el cabezal de rectificado al extremo izquierdo de la cuchilla Ahora sin mover el avance del cabezal de rectificado ajuste la manivela de ajuste izquierda de la barra de mecanizado hasta que la rueda abrasiva apenas toque el plumin del extremo de la cuchilla o la cara de la cuchilla en una cuchilla usada Plumin del o toda la cara de la cuchilla en una nueva Nuevamente extremo en una cuchilla usada si desea rectificar para que coincida con la cuchilla desgastada ponga en contacto la rueda abrasiva con el plumin del extremo Vea la Fig 29 Puesto que cuando se ajusta el extremo izquierdo el derecho tambi n se mueve un poco debe volver a los laterales izquierdo y derecho varias veces
69. ancador Si esto sucede la l nea de suministro el ctrico es incorrecta y debe corregirse antes de continuar trabajando con la rectificadora RECTIFICADORA RECIBE ALTO VOLTAJE I WSEAS A ASSSSSSSSSSSSSSSSSSSSSSSSS Ss N INDICE DE CONTENIDOS Instrucclones due Seguridad sli ee Pagina 2 7 Mantenimiento oleada Pagina 6 Conozca su rectificadora caet el Pagina 8 14 Instrucciones de a ie ee dene A A AA A Pagina 15 25 MANTENIMIENTO DIARIO EL OPERADOR Diariamente limpie la maquina con un trapo Diariamente quite toda la arenilla resultante del rectificado de los ejes longitudinales y del area de la barra de mecanizado Diariamente verifique el nivel de liquido refrigerante en la bandeja El liquido debe estar por encima del sumidero Diariamente inspeccione la maquina en busca de sujetadores componentes sueltos P ngase en contacto con el Departamento de mantenimiento de su compa a si encuentra piezas da adas defectuosas NO UTILICE AIRE COMPRIMIDO PARA LIMPIAR EL POLVO DE LA RECTIFICADORA INSTRUCCIONES DE SEGURIDAD PRESTE ESPECIAL ATENCION ALAS CALCOMANIAS DE ADVERTENCIA QUE APARECEN A CONTINUACION Y QUE ESTAN UBICADAS EN LA PARTE FRONTAL Y EN LOS LATERALES DE LA RECTIFICADORA GRINDING WHEEL RPM SHARP OBJE
70. ario consulte el manual del fabricante de la unidad segadora Limpie en profundidad la cuchilla especialmente en la parte inferior donde se adherir n los imanes Es recomendable que cepille cuidadosamente con cepillo de alambre la parte inferior de la cuchilla antes de montarla Prepare la m quina para montar la cuchilla Ubique el cabezal de rectificado en el extremo derecho y luego mueva la rueda abrasiva hacia atr s alejada de los imanes para generar un espacio para la cuchilla Gire el montaje del mecanizado hasta la posici n horizontal posici n de rectificado de cara frontal y establezca el ngulo de la cuchilla en un ngulo de cara frontal de O grados Siempre limpie con un trapo cualquier polvo resultante del rectificado suciedad etc de los imanes y del rea derecha de la gu a de deslizamiento de la barra de mecanizado antes de montar la cuchilla C MO UTILIZAR UNA RUEDA DE COPA C NICA PARA PERILLA DE BLOQUEO DEL UNA DISTANCIA ADICIONAL PROTECTOR DE LA RUEDA La forma de algunas mordazas de bancada requieren la utilizaci n de una rueda de copa c nica opcional para limpiar los soportes de los extremos Vea la Fig 20 Las ruedas de copa c nica pueden solicitarse en diferentes versiones de di metro de 6 150 mm Para la mayor a de las aplicaciones se utiliza la rueda de copa recta de boraz n de 6 Sin embargo si las bridas de los extremos del montaje de la cuchilla tienen una altura mayor a 2 50 mm o est n c
71. arriage from side to side with the belt clamp disengaged The grinding head assembly should have very uniform resistance through its full range of travel BEARING TESTING FORK SNT3 706055 CAN BE USED TOAPPLYTHE CORRECT UPWARD FORCE FOR DIAL INDICATOR ABOVE CHECKING THE BEARINGS BEARING TO ADJUST BEARINGS FIG 8 ADJUSTMENTS Continued TO ELIMINATE INFEED HANDWHEEL BACKLASH If there is backlash in the Grinder Head Infeed handwheel verify the following adjustements are correct 1 Washers behind the handwheel A Remove the calibration ring setscrew and rotating the calibration ring to access the handwheel setscrew Loosen the handwheel setscrew about half a turn B Hold the handwheel and torque the hex lock nut which secures the handwheel to 100 in Ibs 1 15 kg m then back off 1 2 turn C Verify that the gap between the wave washer and flat washer is 015 in 04mm See FIG10 Adjust the hex lock nut if necessary D Tighten the setscrew holding the handwheel to the shaft Install and tighten the calibration ring setscrew 2 Check the nylon ball tension Check the nylon ball tension on the adjustment shaft threads at the grinding head slide See FIG 9 When you turn the handwheel the grind ing head slide should move without any freeplay If there is free play tighten the setscrew that pushes the nylon ball against the acme thread of the adjustment shaft The nylon ball preloads the free play out
72. at adequate power is delivered to the grinder See page 27 of the manual Fix the problem with building power C Check Alignment of Door Safety Switch on guard door D Verify Door Swith is Working properly PROBLEM MAG turns on only with System Start Switch held in Possible Cause No Power to MAG holding Contact MAG holding contact has failed Checkout Procedure A Check voltage to MAG holding contact in B Verify the magnetic starter MAG holding contact is working 26 Machine works Yes end troubleshooting No go to Step B next Machine works Yes end troubleshooting No go to Step C next Check aligment of door switch Yes end troubleshooting No Go to Step D next Disconnect door safety switch cord at terminal 14 and 15 on Terminal Strip 1 Verify Conituity of switch with door closed Yes Reconnect Terminals and verify continuity of wires No Verify continuity of cord and replace cord or switch Measure 120 Volts AC at MAG term T3 to Term Block 4 Blue with E Stop Pulled out do NOT press start button while checking Yes Go to Step D next No Verify continuity of wiring to MAG T3 Disconnect Wire to MAG L3 and Measure 120 Volts AC from MAG term L3 to Term Block 4 Blue Press and hold Green Start button to hold in MAG contacts while checking Yes Verify continuity of wiring from MAG L3 No Replace MAG ELECTRICAL TROUBLESHOOTING Continued PROBLEM Grinding motor not
73. bedknife the area of the wheel which does not contact the bedknife will still be over the bedknife See FIG 27 When you go to the right end of the grinder the wheel traverses completely off the bedknife Follow the alignment procedure on the next page before grinding the bedknife 20 OPERATING INSTRUCTIONS Continued BEDKNIFE ALIGNMENT After securing the bedknife on the tooling support assembly the bedknife face must be aligned to the grinding head Use the left side tooling adjuster handwheel to align the bedknife to the grinding head Alignment is accomplished by touching the grinding wheel to the bedknife With the bedknife set to the correct angle move the grinding head to the right end fo the bedknife Now rotate the infeed handwheel until the wheel just touches the bedknife at the end nib of the knife face on a used bedknife or the full knife face on a new bedknife On used bedknive if you wish to grind to match the worn bedknife then touch the grinding wheel inside the end nib See FIG 28 Next move the grinding head to the left end of the bedknife Now without moving the grinding head infeed adjust the tooling bar left side adjuster until the grinding wheel justtouches the bedknife end nib or the knife face on a used bedknife or the full knife face on a new bedknife Again on a used bedknife if you wish to grind to match the worn bedknife touch the grinding wheel inside the end nib See FIG 29 Because w
74. cara frontal Vea la Fig 25 Afloje la manivela de bloqueo de rotacion de la barra de mecanizado del lateral izquierdo Rote el montaje del mecanizado hacia la posicion de cara frontal hacia abajo y configure el angulo de cara frontal segun la especificacion de fabrica de la segadora Ajuste la manivela de bloqueo de rotacion de la barra de mecanizado Ls N 213 9 Verifique los m rgenes y establezca los l mites longitudinales Ubique el cabezal de rectificado de manera que la rueda abrasiva FIG 25 apenas toque la cara frontal de la cuchilla Con la leva vertical y la manecilla de bloqueo vea la Fig 26 ajuste el cabezal de rectificado MANECILLA DE de manera que el aro de la rueda abrasiva se extienda 1 2 12 mm MANECILLA DE LEVA VERTICAL o tanto como sea posible por encima de la cara frontal que se BLOQUEO rectificar SI EL ARO DE LA RUEDA ABRASIVA NO SE EXTIENDE a Y SOBRE LA CARA DE LA CUCHILLA RECTIFICAR EN FORMA DESPAREJA DEJARA SURCOS ALO LARGO DE e LA SUPERFICIE DE LA CUCHILLA Verifique si hay alguna interferencia 1 Aleje el cabezal de rectificado de manera que la rueda ya no toque la cara frontal de la cuchilla 2 Deslice los interruptores de proximidad izquierdo y derecho completamente hasta los extremos del riel 3 Configure el potenci metro de velocidad longitudinal en velocidad lenta Encienda el interruptor de desplazamiento del carro Desplace el carro a la izquierda hasta qu
75. carriage shaft there should be no free play between the linear bearing and the carriage shaft NOTE Tension is too tight if you feel a cogging action when you rotate the linear bearing around the shaft TENSTON ADJUSTMENT SCREW This cogging is from the skidding of the bearing on the shaft and indicates the tension screw is too tight FACING Sliding the bearing block back and forth should be a smooth uniform motion SETTING THE BEARING TENSION CORRECTLY IS CRITICAL TO PROPER GRINDING BEARINGS WHICH ARE TOO TIGHT OR TOO LOOSE WILL CAUSE POOR GRIND QUALITY ALSO BEARINGS WHICH ARE TOO TIGHT WILL HAVE SUBSTANTIALLY e SHORTER LIVES AND MAY DAMAGE THE SHAFT STEP 4 Slide linear bearing under carriage and attach with the four screws Repeat Steps 1 through 3 with the other two linear bearings STEP 5 After all three linear bearings are secured to the carriage check for correct bearing tension The bearing tension is correct when you try to lift the carriage and can feel no carriage movement If there is movement this means there is up and down free play The most dependable method of checking free play is to use a magnetic base dial indicator attached to the traverse frame weldment and a bearing testing fork 5NT3706055 Read the vertical movement above each bearing This movement should be within 003 07 mm See FIG 8 In addition when there should only be approximately 3lbs 13 Newtons of force required to pull the c
76. ces Before plugging in the Grinder make sure it will be connected to a supply circuit protected by a properly sized circuit breaker or fuse SEE SERIAL NUMBER PLATE FOR FULL LOAD AMP RATING OF YOUR MACHINE Never modify the plug provided with the machine if it won t fit the outlet have a proper outlet and circuit installed by a qualified electrician ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOUR MACHINE AN IMPROPER CONNECTION CAN CAUSE A DANGEROUS ELECTRICAL SHOCK IF YOU ARE UNSURE OF THE PROPER ELECTRICAL GROUNDING PROCEDURE CONTACT A QUALIFIED ELECTRICIAN 11 ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT GROUNDING INSTRUCTIONS 115 Volt Model Only Plug the control box power cord into a standard 115V AC 15 amp grounded receptacle See FIG 5 PERMANENT POWER CONNECTION FROM THE POWER DISTRIBUTION PANEL WITH NO OTHER MAJOR POWER DRAW EQUIPMENT THE SAME LINE 15 RECOMMENDED THAT THIS GRINDER HAS ITS OWN IT IS REQUIRED THAT THE POWER DELIVERED TO THIS GRINDER IS 115 VAC amp 15 AMPS THE TOLERANCE ON THIS POWER REQUIREMENT IS 5 THEREFORE THE MINIMUM VOLTAGE REQUIREMENT IS 109VAC WITH 15 AMPS VOLTAGE MUST BE CHECKED WITH ALL EQUIPMENT UNDER LOAD OPERATING ON THE CIRCUIT DO NOT OPERATE THIS GRINDER WITH AN EXTENSION CORD DO NOT OPERATE THIS GRINDER ON A GROUND FAULT INTERUPTER CIRCUIT THE WILL TRI
77. cia r pida Solicite a todos los operadores que lean este manual con detenimiento y se familiaricen con todos los ajustes y procedimientos operativos antes de intentar poner en funcionamiento el equipo Puede obtener los manuales de repuesto de su distribuidor El equipo que adquiri ha sido dise ado y fabricado cuidadosamente para brindar un uso confiable y satisfactorio Como todos los productos mec nicos requerir limpieza y mantenimiento Lubrique la unidad como se especifica Tenga en cuenta toda la informaci n de seguridad que incluye este manual y las calcoman as de seguridad sobre el equipo Para obtener servicio su distribuidor autorizado John Deere cuenta con mec nicos capacitados piezas de repuesto Frontier genuinas y las herramientas y los equipos necesarios para dar respuesta a todas sus necesidades de servicio Utilice solo piezas de servicio Frontier genuinas INSTRUCCIONES DE SEGURIDAD Los Simbolos de seguridad estan incluidos en este manual para que este alerta de los posibles peligros de seguridad Siempre que vea estos simbolos siga sus instrucciones e El S mbolo de advertencia identifica instrucciones El S mbolo de precauci n identifica instrucciones o procedimientos especiales que si no se siguen procedimientos especiales que si no se obedecen correctamente pueden resultar en lesiones personales estrictamente pueden resultar en da os al equipo e incluso su destrucci n 1 CONSERVE LOS PROTE
78. closest point FIG 33 Grind the Bedknife Align the bedknife per the procedure labeled BEDKNIFE ALIGNMENT NOTE Top face alignment is fully independent of the front face alignment and MUST be done When vou are satisfied with the grinding head travel and alignment begin grinding REFER ALSO TO THE SAFETY RULES WHEN GRINDING ON PAGE 3 NOTE At this point you won t know the condition of the grinding wheel after the previous job Always clean or dress the wheel before grinding See section on Cleaning Dressing grinding wheel 1 Set the GRINDING WHEEL switch to ON 2 Set the COOLANT PUMP switch to ON and check that the nozzle is directing coolant onto the bedknife See FIG 33 3 Set the TRAVERSE speed potentiometer at about 15 to 20 NOTE If an excessive amount of metal stock will have to be removed on one end recheck your setup first and then check the straightness of the bedknife If it is bowed or twisted replace it 4 With the grinding wheel is over the bedknife rotate the horizontal infeed handwheel clockwise until the wheel is lightly removing metal from the bedknife It is recommended to infeed about 002 to 003 05 to 075 mm per pass NOTE The horizontal adjustment dial is calibrated in 002 05 mm increments NOTE During the grinding process watch the spark pattern for the full length of grind the sparks should look equal for the full length of grind NOTE If an excessive amount of metal stock wi
79. ctor de la rueda Una perilla T sostiene el protector en su posicion Afl jela para girar el protector cuando este interfiera con la mordaza de bancada a Reavivador de ruedas abrasivas con punta de nu FIG 5 diamante MANECILLA DE BLOQUEO Le permite labrar la rueda abrasiva La limpieza y el AJUSTE VERTICAL REAVIVADOR DE PUNTA labrado de la rueda abrasiva mejoran la calidad del DE DIAMANTE trabajo de rectificado Br EL REAVIVADOR DE PUNTA DE 4 DIAMANTE SOLO DEBE UTILIZARSE CON RUEDAS ABRASIVAS VITRIFICADAS ESTA RECTIFICADORA SE ENV A UNA RUEDA ABRASIVA DE BORAZON Y UN LADRILLO DE LIMPIEZA NO UTILICE EL REAVIVADOR DE PUNTA DE DIAMANTE INCORPORADO SOBRE LA RUEDA DE BORAZON FIG 6 ESCALA DE AJUSTE HORIZONTAL MANIVELA AJUSTE HORIZONTAL 11 CONOZCA SU RECTIFICADORA CONTINUACION SOPORTE FIJO DE LA CUCHILLA LATERAL IZQUIERDO La cuchilla y la mordaza de bancada se mantienen en su posicion gracias a un par de imanes y centros La posicion del iman y el centro del lateral izquierdo es fija Vea la Fig 7 SOPORTE AJUSTABLE DE LA CUCHILLA LATERAL DERECHO El im n y el centro del lateral derecho son ajustables para que puedan coincidir con la mordaza de bancada Vea la Fig 8 CENTROS CALIBRE DE IMAN PERILLA DE BLOQUEO EN LAPARTE POSTERIOR CONFIGURACION DE LA ES DEL SOPORTE AJUSTABLE DERECHO CUCHILLA RETRAIDO Bloquea la posici n del montaje de im n y centro de la PERILLA DE BLOQUE
80. d and followed by anyone who works with bedknife grinders A Before operating a bedknife grinder an operator must read and understand all of the information in the owner s manual and in the safety signs attached to the product A person who has not read or understood the owner s manual and safety signs is not qualified to operate the unit Accidents occur often on machines that are used by someone who has not read the owner s manual and is not familiar with the equipment If you do not have an owner s manual or current production safety signs contact the manufacturer or your dealer immediately Bedknife grinders are designed for one man operation Never operate the grinder with anyone near or in contact with any part of the grinder Be sure no one else including bystanders are near you when you operate this product Following these simple basic safety rules as well as others identified in the owner s manual and in product safety signs will help minimize the possibility of accidents and increase your productivity in using this product Be careful and make sure that everyone who operates the grinder knows and understands that it is a very powerful piece of machinery and if used improperly serious injury or death may result The final responsibility for safety rests with the operator of this machine THE DEALER Assembly and proper installation of this product is the responsibility of the Deere dealer Read ma
81. d persons to operate equipment ATENCI N BG1500 Para aA Lea el manual del operador antes de la puesta en funcionamiento del mantenimiento de la reparacl n del equipo Siga todas las reglas instrucciones de seguridad Los manuales se encuentran disponibles a traves de su distribuidor Mantenga al personal ajeno alejado del equipo durante el funcionamiento Mantenga todos los protectores en su lugar y en buenas condiciones Durante el funcionamiento de esta m quina utilice todos los equipos de seguridad correspondientes especificados en el manual del operador Aseg rese siempre de que la m quina se encuentre apagada y haya dejado de moverse antes de abandonarla Nunca permita que un ni o o una persona sin capacitaci n pongan la m quina en funcionamiento CALCOMAN A DE HOJA ENGLISH ESPA OL 5NT 127300 CONOZCA SU RECTIFICADORA Interruptores longitudinales Ancho total Altura total Profundidad total Peso Estructura de la base Rieles del carro Motor del cabezal de rectificado Nivel de sonido Desplazamiento automatico Mecanizado Refrigerante Sistema de control ESPECIFICACIONES Interruptores de proximidad sin contacto de estado solido 61 155 cm 58 148 cm con la tapa cerrada 81 206 cm con la tapa abierta 32 82 cm 750 lbs 340 kg peso de embarque 935 Ibs 424 kg Base de acero reforzado soldado para trabajo pesado y de precision Acero endurecido co
82. de rectificado al lateral derecho de la m quina Fig 13 de manera que usted quede alejado de la cuchilla C MO LIMPIAR UNA RUEDA ABRASIVA DE BORAZ N No utilice el reavivador de punta de diamante incorporado sobre la rueda abrasiva de boraz n Si la rueda de boraz n no rectifica en forma eficaz utilice la varilla de limpieza para reacondicionar la rueda Para utilizar la varilla de limpieza humed zcala completamente en agua Encienda el motor de la rectificadora si todav a no est encendido Una vez que el motor est encendido a velocidad m xima ap guelo Apenas lo haya apagado presione la varilla de limpieza DIRECTAMENTE sobre la superficie de rectificado de la rueda y deje que patine hasta detenerse Repita este procedimiento de ser necesario hasta que la rueda rectifique eficazmente MUEVA LA VARILLA DE LIMPIEZA HACIA LOS LADOS HACIA LOS LADOS EROSIONARA EL MATERIAL LIGANTE EN LOS LATERALES DE LAS PARTICULAS DE RECTIFICADO ESTO DISMINUIRA CONSIDERABLEMENTE LA VIDA UTIL DE LA RUEDA COMO LABRAR UNA RUEDA ABRASIVA VITRIFICADA Con la rueda girando levante el brazo de movimiento del reavivador de su soporte y empuje hacia adelante Vire el reavivador en redondo hacia la cara de rectificado de la rueda y gire el aro de ajuste hasta que la punta de diamante APENAS toque la rueda Vea la Fig 16 Si el reavivador se ajusta demasiado profundo en el interior de la rueda el rea que ofrece apoyo al diamante se
83. doras de cuchilla est n dise adas para ser operadas por una sola persona Nunca ponga en funcionamiento la rectificadora cuando alguien est cerca de alguna parte de la rectificadora o est en contacto con esta Aseg rese de que nadie m s lo que incluye cualquier persona cercana al rea est cerca de usted cuando ponga en funcionamiento este producto Seguir estas reglas de seguridad simples y b sicas as como tambi n otras especificadas en el manual del usuario y en las se ales de seguridad del producto ayudar a minimizar la posibilidad de accidentes y aumentar su productividad al utilizar este producto Tenga la precauci n y aseg rese de que toda persona que ponga en funcionamiento la rectificadora sepa y comprenda que es una m quina muy poderosa y que de ser utilizada indebidamente puede causar lesiones graves e incluso la muerte La responsabilidad final sobre la seguridad recae en el operador de esta m quina 2 PARA EL DISTRIBUIDOR El montaje y la instalaci n adecuada de este producto son responsabilidad del distribuidor de John Deere Lea las instrucciones del manual y las reglas de seguridad Aseg rese de que se hayan realizado todos los puntos de la Lista de comprobaci n de preparaci n del Manual del usuario antes de entregar el equipo al propietario PARA EL PROPIETARIO Lea este manual antes de poner en funcionamiento su equipo Frontier Conserve este manual al alcance de su mano para tener una referen
84. down Remove the right hand center from the bedbar by backing the center back as far as necessary DO NOT loosen the arm lock grasp the bedknife and pull it off the magnets If the next bedknife to be ground is the same type and size as the previous simply mount it and proceed with verifying mounting and proceed with new alignment If the next bedknife to be ground is a different type or size follow the full installation procedure 25 ASSEMBLY ano SERVICE MANUAL 861900 REV 6 14 2011 DEALER PREPARATION INSTALLATION CHECK LIST IS LOCATED IN THE OPERATOR S MANUAL A Safety is a primary concern in the design manufacture sale and use of bedknife grinders As a manufacturer of bedknife grinders we want to confirm to you our customers our concern for safety We also want to remind you about the simple basic and common sense rules of safety when using a bedknife grinder Failure to follow these rules can result in severe injury or death to operators or bystanders It is essential that everyone involved in the assembly operation transport maintenance and storage of this equipment be aware concerned prudent and properly trained in safety Always use proper shielding as specified by the manufacturer Our current production machines include as standard equipment guards or shields for the grinding wheel safety signs and an operator s manual Never bypass or operate the machine with any of th
85. e de vuelta hacia la derecha hasta que la rueda abrasiva alcance el punto en el que cubra toda el rea que se debe rectificar y que lo sobrepase hasta por 1 25 mm o m s de ser posible Luego configure el interruptor de proximidad de la derecha de la misma manera NOTA El rea de la rueda abrasiva que se pone en contacto con la M cuchilla est en el lateral izquierdo de la rueda Cuando se rectifica ecd el extremo izquierdo de la cuchilla el rea de la rueda que no se pone en contacto con la cuchilla todav a permanecer sobre esta Vea la Fig 33 Cuando se ubica en el extremo derecho de la rectificadora la rueda se aleja completamente de la cuchilla Avance la rueda abrasiva hasta que apenas toque superficialmente el lateral izquierdo de la cuchilla Ahora despl cela al extremo derecho de la cuchilla para h asegurarse de que el lateral derecho no est m s cerca de la rueda abrasiva Retraiga la rueda de ser necesario hasta que pueda desplazarla a lo largo de toda la FIG 33 pieza con apenas un contacto superficial en el punto m s cercano Rectifique la cuchilla Alinee la cuchilla de acuerdo con el procedimiento denominado ALINEACION DE LA CUCHILLA NOTA La alineaci n de la cara superior es completamente independiente de la alineaci n de la cara frontal y SE DEBE realizar Cuando est satisfecho con el recorrido y la alineaci n del cabezal de rectificado comience con el rectificado CONSULTE TAMBI N LA SECCI
86. e el rea de contacto de la rueda abrasiva est alejada alrededor de 1 25 mm del rea de la cuchilla que se rectificar luego gire el potenci metro longitudinal hasta la posici n cero FIG 26 Este preparado para DETENER antes el desplazamiento si hay alguna interferencia entre la rueda abrasiva la mordaza de bancada Con el carro todavia en la posici n establecida anteriormente en el Paso 3 deslice el interruptor de proximidad izquierdo hacia adentro hasta que se encienda su LED Desplace de vuelta hacia la derecha hasta que la rueda abrasiva alcance el punto en el que cubra toda el rea que se debe rectificar y que lo sobrepase hasta por 1 25 mm o m s de ser posible Luego configure el interruptor de proximidad de la derecha de la misma manera NOTA El area de la rueda abrasiva que se pone en contacto con la cuchilla est en el lateral izquierdo de la rueda Cuando se rectifique el extremo izquierdo de la cuchilla el rea de la rueda que no se pone en contacto con la cuchilla todav a permanecer sobre esta Vea la Fig 27 Cuando se ubica en el extremo derecho de la rectificadora la rueda se aleja completamente de la cuchilla Siga el procedimiento de alineaci n de la p gina siguiente antes de rectificar la cuchilla 20 INSTRUCCIONES DE OPERACI N Continuaci n ALINEACI N DE LA CUCHILLA Luego de afirmar la cuchilla sobre el montaje de soporte de la barra de mecanizado la cara de la cuchill
87. e guards or the safety devices removed Read and fully understand all the safety practices discussed on pages 4 and 5 of this and the operator s manual All safety rules must be understood and followed by anyone who works with this bedknife grinders SEE OPERATOR S MANUAL FOR INSTALLTION CHECKLIST It is the responsibility of the dealer to complete the procedures listed in the Operators Manual then review this checklist with the customer upon the delivery or the sale of this equipment The installation training goes over the basic operational functions of the equipment To ensure adequate training we require that the following items are reviewed by your John Deere Dealer Please check off to ensure that you understand the following items before the installation training is complete Safety IMPORTANT SAFETY MESSAGE FOR OWNERS OPERATORS OF BEDKNIFE GRINDERS Before operating bedknife grinder an operator must read and understand all of the information in the operator s manual and in the safety signs attached to the product A person who has not read or understood the operator s manual and safety signs is not qualified to operate the unit Accidents occur often on machines that are used by someone who has not read the operator s manual and is not familiar with the equipment If you do not have an operator s manual or the current production safety signs contact your dealer immediately Bedknife grinders are designed for one man op
88. e prox switches with steel tool to take measurements Left proximity PROX1 check Traverse drive Control TDC between terminals 14 black wire and 15 brown wire Right proximity PROX check TDC between terminals 13 black wire and 15 brown wire Reason The light coming on shows the proximity is getting electrical contact Proximity light on 0 Volts DC Proximity light off 12 Volts DC Proximity light on 0 Volts DC Proximity light off 12 Volts DC Replace proximity switch if the voltages do not read as above PROBLEM Insufficient hesitation at carriage stops prior to reversing traverse The dwell time on the traverse drive control not set properly Reset dwell time as required One increment increases Dwell time by 1 2 second PROBLEM Traverse changes directions erratically while running in traverse cycle Loose wire to proximity Check wire connections from the switch proximity switches and tighten down screws 33 A loose wire connection will give intermittent electrical contact MECHANICAL TROUBLESHOOTING PROBLEM Top face of bedknife is ground ina convex shape high in the center or concave shape low in the center The top face of the bedknife is ground unevenly across the width coarse a grind on bedknife The top face of the bedknife shows burn marks from being too hot POSSIBLE CAUSE A Grinding wheel is loading up with gr
89. e que la m quina se encuentre apagada y haya dejado Label Sheet ado E IAS English and Span ish m quina en funcionamiento Part Number 5NT 127300 English and French Part Number 5NT 127301 Traversing Switches Overall Width Overall Height Overall Depth Weight Base Construction Carriage Rails Grind Head Motor Sound Level Auto Traverse Tooling Coolant Control System GETTING TO KNOW YOUR GRINDER SPECIFICATIONS Solid state non contacting proximity switches 61 155 cm 58 148 cm with door closed 81 206 cm with door open 32 82 cm 750 Ibs 340 kg shipping weight 935 Ibs 424 kg Precision heavy duty reinforced welded steel base Precision Ground Hardened Steel 1 000 Dia 25 4 mm 3 4HP AC Motor 3450 RPM Less than 5 Dba Belt driven with easy to engage clamp system Magnetic Mount for Bed Knife with addition center supports Built in flood coolant system Safety grind motor with door interrupt switches Variable speed traverse control GETTING TO KNOW YOUR GRINDER CONTROL PANEL COMPONENT IDENTIFICATION FOR THE BG1500 Learn the function of each switch and knob on the GRIND control panel As you read and learn about each knob MOTOR SYSTEM you are encouraged to turn that knob on and view that SWITCH START particular operation See FIG 1 PUSHBUTTON ALWAYS WEAR PROPER SAFETY TRAVERSE COOLANT EYEWEAR WHEN OPERATING SWITCH PUMP YOUR GRINDER NEVER TURN SWITCH ON YOU
90. ealidad correcta de la cuchilla Si est curvada o torcida reempl cela 5 Continue rectificando la cuchilla de esta manera hasta que est satisfecho con el rectificado de la cara superior Labre la rueda cuando sea necesario consulte C mo limpiar labrar la rueda abrasiva 6 Siutiliza una rueda abrasiva vitrificada labre la rueda antes del rectificado final en vac o 24 INSTRUCCIONES DE OPERACI N Continuaci n C MO RECTIFICAR LA CARA SUPERIOR CONTINUACI N En los pasos de rectificado al vac o avance la rueda abrasiva solo alrededor de 0 001 0 025 mm y luego permita que la rueda realice el rectificado Para el rectificado al vac o siempre desplace el cabezal de rectificado entre 10 y 20 pasos sin avanzar el cabezal Para obtener el rectificado m s fino de la cara superior configure la perilla LONGITUDI NAL en una velocidad lenta para este rectificado final al vac o Este proceso mejora el acabado superficial del rectificado y la calidad de este NOTA Lo que usted busca es una aproximaci n al rectificado en vac o cerca de un 99 de reducci n de la chispa de rectificado en comparaci n con el rectificado normal No contin e el rectificado al vac o hasta que no haya chispas puesto que esto puede demorar demasiado tiempo CIERRE EL INTERRUPTOR DE LA BOMBA DE REFRIGERANTE ANTES DE APAGAR LA RUEDA ABRASIVA ESTO PERMITIRA QUE LA RUEDA GIRE EN SECO SI LA RUEDA RETIENE DEMASIADO REFRIGERANTE ESTAR DE
91. emoving any electrical panels or covers for maintenance ATENCI N Para evitar lesiones Aseg rese de que se haya desconectado por completo el suministro el ctrico de esta m quina antes de retirar los paneles el ctricos o las cubiertas para el mantenimiento GENERAL INFORMATION CAUTION To Avoid Injury Read Operator s Manual before operating servicing or repairing equipment Follow all safety rules and instructions Manuals are available from your selling dealer Keep bystanders away from equipment during operation Keep all shields in place and in good condition Wear all of the appropriate safety equipment specified in the Operator s Manual while operating this machine Always make sure machine 15 off and all machine movement has stopped before leaving machine Never allow children or untrained persons to operate equipment 4 ATENCI N Para evitar lesiones Lea el manual del operador antes de la puesta en funcionamiento del mantenimiento o de la reparaci n del equipo Siga todas las reglas e instrucciones de seguridad Los manuales se encuentran disponibles a trav s de su distribuidor Mantenga al personal ajeno alejado del equipo durante el funcionamiento Mantenga todos los protectores en su lugar y en buenas condiciones Durante el funcionamiento de esta m quina utilice todos los equipos de seguridad correspondientes especificados en el manual del operador Aseg rese siempre d
92. en the setscrew unitl this is zero freeplay in the shaft DO NOT over tension the setscrew as the ad juster will be difficult to turn 17 1 P E v E lt hy r 4 Y 4 gt ET i Setscrew Nylor ol fee 015 in gap FIG 11 ADJUSTMENTS CONTINUED TO ELIMINATE MOVEMENT IN THE DIAMOND DRESSER ADJUSTMENT COLLAR The adjustment collar on the diamond dresser See FIG 49 has a nylon ball and setscrew to put a holding drag on the diamond dresser shaft If it becomes necessary to increase the collar drag tighten the setscrew If the adjustment collar is difficult to turn reduce the drag by loosening the setscrew Setscrew and FIG 13 Nylon Ball 18 ADJUSTMENTS CONTINUED ADJUSTING THE PRELOAD TENSION ON THE SMALL GRINDING HEAD SLIDE VEE ROLLERS There are 3 vee rollers that support the grinding head The 2 vee rollers on the left side are fixed and the vee roller on the right side is adjustable To set the correct preload on the right side adjuster tighten the setscrew in FIG 14 until the spring is fully compressed solid then back off 1 2 turn Tension Adjust Setscrew TO ADJUST THE PROXIMITY SWITCHES Proximity Sensor Bracket For the proximity switches to work properly a distance of 3 16 in 1 32 4 75 mm 0 75 must be maintained between the top of the switch and the actuator bracket on the
93. ent dial is calibrated in 002 05 mm increments NOTE During the grinding process watch the spark pattern for the full length of grind the sparks should look equal for the full length of grind NOTE If an excessive amount of metal stock will have to be removed on one end of the bedknife recheck your setup first and then the straightness of the bedknife If itis bowed or twisted replace it 5 Continue grinding the bedknife in this manner until you are satisfied with the front face grind Dress the wheel when necessary see Cleaning Dressing the Grinding Wheel 6 If you are using a vitrified grinding wheel dress the wheel before the final spark out grind For spark out procedure see the top of page 25 By partially grinding both surfaces the top face and the front face as shown in FIG 30 you will resharpen a used bedknife with the least metal removal FIG 30 also shows how much stock would be removed if you ground the top face surface until sharp Partially grinding both surfaces is the preferred method for life utilization of the bedknife FIG 30 SHUT OFF THE COOLANT PUMP SWITCH BEFORE YOU SHUT OFF THE GRINDING WHEEL TO ALLOW THE WHEEL TO SPIN DRY IF THE WHEEL RETAINS TOO MUCH COOLANT IT WILL BE UNBALANCED WHEN YOU AGAIN TURN ON THE GRINDING MOTOR 22 OPERATING INSTRUCTIONS Continued GRINDING THE TOP FACE NOTE The following instructions presume that you have already studied all previous sections of thi
94. ent must be thoroughly trained BEFORE operating the equipment Do not use compressed air to clean grinding dust from the machine This dust can cause personal injury as well as damage to the grinder Machine is for indoor use only Do not use a power washer to clean the machine 27 72772229 Low Voltage Relay FACTORY PRESET FLASHING The grinder is equipped with a high low voltage relay GREEN LIGHT which is factory preset at 100 140 VAC If the power INDICATES supply line does not deliver 100 140 VAC power under LOW VOLTAGE i UCM E FLASHING load the relay will open and trip out the starter If this RED LIGHT occurs your power supply line is incorrect and must be INDICATES correct before proceeding further with the grinder HIGH VOLTAGE DELIVERED TO GRINDER TABLE OF CONTENTS Sale UIUC TNA S s a ta Page 2 6 Daly scada a cease eect ele Page 6 lt 7 ASSembly a MMR 8 12 DOT ete 13 14 ted 15 21 Electrical TE 22 33 Mechanical Troubleshooting 34 35 Exploded Views and parts Lists Page 36 53 Wiring Diagram amp Schemallc a en 2 I I Page 54 56 DAILY MAINTENAN
95. eration Never operate the grinder with anyone near or in contact with any part of the grinder Be sure no one else including bystanders are near you when you operate this product Following these simple basic safety rules as well as others identified in the owner s manual and in the product safety signs will help minimize the possibility of accidents and increase your productivity in using this product Be careful and make sure that everyone who operates the grinder knows and understands that this is a very powerful piece of machinery and if used improperly serious injury or death may result The final responsibility for safety rests with the operator of this machine TO THE DEALER Assembly and proper installation of this product is the responsibility of the John Deere dealer Read the manual instructions and safety rules Make sure all items on the Preparation Check List in the Operator s Manual are completed before releasing equipment to the owner TO THE OWNER Read the Operator s Manual before operating your Frontier equipment Keep all manuals handy for ready reference Require all operators to read the Operator s Manual carefully and become acquainted with all adjustments and operating procedures before attempting to operate the equipment Replacement manuals can be obtained from you selling dealer The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactory u
96. erca de la cara frontal de la cuchilla es posible que necesite una rueda de copa c nica opcional de 6 Para obtener los n meros de pieza y las descripciones de las ruedas abrasivas disponibles consulte la Lista de ruedas abrasivas de la p gina 15 RUEDA DE CONICA FIG 20 COMO ROTAR EL PROTECTOR DE LA RUEDA Algunas cuchillas y mordazas de bancada cuentan con aberturas de montaje tan cerca de la cara superior de la cuchilla que no hay margen para el protector de la rueda Para estas aplicaciones por lo general debe utilizarse una rueda abrasiva de copa conica y el protector de la rueda abrasiva puede aflojarse y rotar de manera que el margen del protector permita que se rectifique la cuchilla sin interferencias Cuando haya finalizado SIEMPRE vuelva a ubicar el protector en su posicion habitual con la muesca de margen hacia abajo Vea la Fig 20 PARA LA SEGURIDAD DEL OPERADOR DEBE UTILIZARSE EL PROTECTOR DE LA RUEDA ABRASIVA CON EL MARGEN HACIA ARRIBA SOLO CUANDO SEA NECESARIO PARA EL MARGEN DE LA MORDAZA DE BANCADA 18 INSTRUCCIONES OPERACION CONTINUACION COMO MONTAR UNA CUCHILLA PARA SU RECTIFICADO Continuacion VERIFIQUE QUE EL MECANIZADO ESTE AJUSTADO A AMBAS SUPER C mo montar la cuchilla FICIES MAQUINADAS DE LA 1 Empuje ambas puntas del calibre hacia adelante y r telo hasta BARRA DE MECANIZADO la posici n de manera que mire hacia arriba Afloje la perilla de bloqueo y el montaje de
97. finish grinding pass on each bedknife See Operators Manual Take off about 002 to 003 05 to 075 mm per pass during rough grind See Operators Manual Speed up traverse Visually check the outside diameter runout while slowly rotating the wheel by hand Also check the motor without a wheel installed Replace the wheel if out of round Adjust bearing for proper tension See adjustments section of this manual Flush linear bearing per lubrication proceedure and replace wipers Or replace the three linear bearings and wipers Adjust belt clamping force See adjustment section of manual Adjust traverse belt tension See adjustments section of this manual 35 REASON Wheel will glaze if not dressed often enough If grinding wheel is not extended 1 2 12 mm over bedknife it will glaze more quickly because there is less dressing Too light a grinding cut doesn t permit enough dressing action on the wheel so it glazes Too slow a traverse speed can cause excessive heat buildup in the grinding wheel which glazes the wheel A grinding wheel which isn t properly trued up on outside or inside diameters can vibrate excessively and transfer that vibration to the motor When bearing preload is too tight it causes excessive loading to drive carriage Grinding grit is getting into the linear bearings and causing excessive driving torque of the carriage If the tra
98. hen you adjust the left side the right side also moves a small amount you should go to the right and left sides several times to verify that you just contact the knife at both ends This be done while grinding the knife NOTE These adjustments are done at the left side handwheel NOT at the infeed handwheel on the grinding head NOTE The recommended method is to use the end nib Using the end nibs will help keep the bedknife true to the mounting holes in the bedbar GRINDING WHEEL AT RIGHT END OF BEDKNIFE FIG 28 GRINDING WHEEL AT LEFT END OF BEDKNIFE End Nib 21 FIG 29 OPERATING INSTRUCTIONS Continued GRINDING THE FRONT FACE Continued Grind the Bedknife When you are satisfied with the grinder head alignment begin grinding N REFER TO THE SAFETY RULES WHEN GRINDING ON PAGE 3 1 Set the GRINDING WHEEL switch to ON 2 Setthe COOLANT PUMP switch to ON Check the nozzle is directing coolant onto the bedknife FIG 19 3 Setthe TRAVERSE speed Potentiometer at about 15 to 20 4 With the grinding wheel is over the bedknife rotate the horizontal infeed handwheel clockwise until the wheel is lightly removing metal from the bedknife It is recommended to take off about 002 to 003 05 to 075 mm per pass NOTE The horizontal adjustm
99. inding grit B Too heavy a grind on the final grinding pass C Small Grinding Head Slide Vee Roller loose A Grinding wheel rim is not completely over the top face being ground B Small grinding Head Slide Vee Roller loose C Backlash in infeed handwheel Grinding head is traversing too fast A Coolant not directed onto the bedknife and grinding wheel B Too heavy stock removal during grinding C Grinding wheel is glazing REMEDY Dress the wheel prescribed in the Operators Manual Follow the procedures in the Operators Manual On the final pass infeed only about 001 025 mm Let the wheel spark out for 10 20 passes at about slow speed with no additional infeed Adjust Vee Rollers per procedure on Page 19 The wheel rim must extend over the bedknife top face by 1 2 13 mm whenever possible See Operators Manual If not possible dress the wheel more often Adjust Vee rollers per procedure on Page 19 Eliminate backlash in infeed handwheel see Page 16 Slow down the traversing speed Direct coolant into the grinding wheel at the point of the grind See Operators Manual Take off about 002 to 003 05 to 075mm per pass during rough grind See Operators Manual Dress the wheel before the finish grinding pass on each bedknife See Operators Manual 34 REASON A loaded wheel creates undue pressure on the surface being ground Both ends of bedknife m
100. inistro el ctrico para poner la m quina en funcionamiento O 6 Revise los manuales del operador montaje y servicio y cualquier material de capacitaci n adicional que tenga a disposici n Firma del distribuidor Firma del comprador 7 Revise la posici n adecuada de la cuchilla 8 Revise la posici n del interruptor de proximidad longitudinal Explique el uso de las marcas de configuraci n Explique c mo ajustar la altura de la rueda abrasiva 11 Converse acerca del sistema de refrigeraci n por inundaci n de la rectificadora 12 Revise c mo limpiar labrar la rueda 13 Revise el mantenimiento general Seguridad La seguridad es una de las preocupaciones principales dise o la fabricaci n la venta y la operaci n de las rectificadoras de cuchilla Como fabricantes de rectificadoras de cuchilla deseamos confirmarles a ustedes nuestros clientes nuestra preocupaci n por la seguridad Tambi n deseamos recordarles las reglas simples b sicas y de sentido com n acerca de la seguridad cuando utilicen la rectificadora de cuchilla No seguir estas reglas puede resultar en lesiones graves para el operador o las personas cercanas al rea e incluso la muerte Es esencial que toda persona involucrada en el montaje la operaci n el transporte el mantenimiento y el almacenamiento de este equipo sea consciente y se preocupe por la seguridad sea prudente y cuente con l
101. izado Manualmente rote hasta el ngulo deseado BARRA DE MANIVELA DE BLOQUEO DE como lo indica la calcoman a y ajuste la manivela de MECANIZADO ROTACI N DE LA BARRA DE bloqueo AJUSTE MANIVELA MECANIZADO FIG 9 12 INSTRUCCIONES DE OPERACION CUANDO AFILAR LA CUCHILLA Cuando no realiza cortes limpios a la grama o los extremos del corte de la grama estan rasgados son A Hoja de carrete y cuchilla irregulares los bordes de la l mina del carrete y la fija desafiladas cuchilla se han redondeado y deben afilarse Vea la Fig 10A El prop sito de la afiladura es recuperar los bordes afilados del carrete y la cuchilla IMPORTANTE Para afilar completamente una segadora de carrete debe rectificar las l minas del carrete mediante una Rectificadora de carrete y volver a darle forma al filo cortante de la cuchilla NOTA Las nuevas cuchillas deben rectificarse antes de Hoja de carrete y comenzar a utilizarlas Las nuevas cuchillas se deforman cuchilla fija afiladas y se mueven para que coincidan con la forma de la mordaza de bancada al momento de su instalaci n y por lo tanto DEBEN rectificarse contra una superficie recta luego de ser instaladas FIG 10 ANGULOS RECTIFICADO DE CUCHILLA A nmila de La cuchilla cuenta con dos caras que habitualmente superficie superior necesitan rectificarse la cara superior y la cara frontal en algunos modelos la cara frontal puede ser curva y es 4 10
102. ll have to be removed on one end of the bedknife recheck your setup first and then the straightness of the bedknife If it is bowed or twisted replace it 5 Continue grinding the bedknife in this manner until you are satisfied with the top face grind Dress the wheel when necessary see Cleaning Dressing the Grinding Wheel 6 If you are using a vitrified grinding wheel dress the wheel before the final spark out grind 24 OPERATING INSTRUCTIONS Continued GRINDING THE TOP FACE Continued On the spark out passes infeed the grinding wheel only about 001 025 mm and then let the grinding wheel spark out For sparking out always traverse the grinding head 10 to 20 passes without infeeding the grinding head To get the finest top face grind set the TRAVERSE knob at slow speed for this final grinding sparkout This process improves the surface finish of the grind and improves the grind quality NOTE What you are looking for is a near sparkout about a 99 reduction in grinding spark from a normal grind Don t continue sparking out until you have no sparks because this could be an extremely long time SHUT OFF THE COOLANT PUMP SWITCH BEFORE YOU SHUT OFF THE GRINDING WHEEL THIS WILL ALLOW THE WHEEL TO SPIN DRY IF THE WHEEL RETAINS TOO MUCH COOLANT IT WILL BE UNBALANCED WHEN YOU TURN ON THE GRINDING MOTOR AGAIN REMOVING THE BEDKNIFE To remove the bedknife rotate the tooling assembly to the front face grinding position
103. meter wiring for proper hookup See that speed pot is wired per electrical diagram D Check all pot settings on circuit board as shown in wiring diagram See adjustment section Traverse Motor Control Board Settings 32 Traverse Drive Control Pin 8 to 7 Pot full CCW Pot Full CW 0 VDC 9 75 VDC Pin 8 to 9 Pot full CCW Pot Full CW 9 75 VDC 0 VDC Yes Pot is OK No Go to Step B next Check for 10 000 ohms Red to White wires Full CCW 0 ohms Full CW 10 000 ohms Red to Black wires Full CCW 10 000 ohms Full CW 0 ohms Yes Go to Step C next No replace potentiometer Wiper inside of potentiometer controls speed Wiper may be bad and not making contact Wrong wire hookup effects traverse control Reversing red and orange wires to potentiometer to the D C motor will run at zero speed but maximum will be too slow Reversing red and white wires does not affect speed control Check for Proper function Yes end troubleshooting No Go to Step D next Minimum and maximum pot settings effect traverse speed ELECTRICAL TROUBLESHOOTING Continued PROBLEM If the carriage traverses to one end of stroke or the other and it stops and does not reverse direction Possible Cause Proximity switch is not working properly or wire connections are loose Remedy First check to see if proximity light comes on When the light is on it means that there is electricity coming to proximity switch Actuat
104. minal to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step J next No Flip Switch on MCB to ON Machine works end trouble shooting Machine does not work replace MCB ELECTRICAL TROUBLESHOOTING Continued Possible Causes No 120 Volts AC power to Secondary Circuit Breaker SCB 6 Amp No 120 Volts AC power from Secondary Circuit Breaker SCB 6 Amp 120 Volts AC power not delivered to Terminal Strip Grinding Motor Switch GMS not working Bad Emergency Stop Switch ESS Bad System Start Switch SSS Low Voltage Relay REL not operating Bad Main Contactor MAG Checkout Procedure J Check for 120V to SCB K Check for 120V from SCB L Check for 120 Volts AC at terminal strip M Check for 120 Volts AC at GMS Terminals 1 N Check voltage after the ESS MAKE SURE SWITCH IS PULLED UP O Hold in SSS and Check voltage after the SSS P Hold SSS and Check volt age at LVR LVR must be in stalled in 8 pin socket Q Hold in SSS and Check voltage at MAG A1 amp A2 SCB 03SCB to nuetral blue terminal out of FTR for 120VAC Yes Go to Step K next No Check wires amp replace if needed SCB 67SCB to nuetral blue terminal out of FTR for 120 VAC Yes Go to Step L next No Flip Switch on SCB to ON Machine works end of troubleshooting Machine does not work replace SCB Terminal 11 on Terminal Strip 2 07TB2 11 to Terminal Block 4 Blue for 1
105. n 15 amp outlet circuit breaker has tripped No 120 Volts AC power to Filter FTR No 120 Volts AC power out of Filter No 120 Volts AC power to Main Circuit Breaker MCB No 120 Volts AC power from Main Circuit Breaker MCB B Listen for the Magnetic Starter MAG contacts to pullin with a clunk C Plug in main power cord D Close guard doors and turn off all switches E Check circuit breaker in your building and reset if necessary Check wall outlet with a light to make sure it works F Check for 120V at Cord into FTR Power Cord 32 G Check for 120V out of FTR H Check for 120V to MCB I Check for 120V to MCB 24 Machine works Yes end troubleshooting No go to Step B next Machine works Yes end troubleshooting No go to step C next Machine works Yes end troubleshooting No go to step D next Machine works Yes end troubleshooting No go to step E next Machine works Yes end troubleshooting No but light works in outlet go to Step F next No but light does not work in outlet You must solve your power delivery problem independent of machine FTR Line Terminals for 120 Volts AC Yes Go to Step G next No Replace Power Cord 5NT6059054 FTR Load Terminals for 120 Volts AC Yes Go to Step H next No Replace Filter MCB Bottom Terminal to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step I next No Check wires amp replace if needed MCB Top Ter
106. n adecuada para eliminar el polvo o para mantener el nivel de polvo por debajo del Valor m nimo de polvo perjudicial seg n lo clasifica la OSHA Administraci n para la seguridad y salud ocupacional 5 INDICE DE CONTENIDOS Esta maquina fue disenada SOLO para rectificar la cuchilla de la segadora de carrete Cualquier uso diferente a este puede causar lesiones personales y anular la garantia Para asegurar la calidad y seguridad de su maquina y para mantener la garantia usted DEBE utilizar piezas de repuesto del fabricante del equipo original y encargar cualquier trabajo de reparacion a un profesional calificado TODOS los operadores de este equipo deben estar debidamente capacitados ANTES e de poner en funcionamiento el equipo No utilice aire comprimido para limpiar de la m quina el polvo generado por el rectificado Este polvo puede causar lesiones personales as como tambi n da os a la rectificadora La m quina es solo para uso en interiores No utilice una hidrolavadora para limpiar la m quina 2 A ADVERTENCIA SS Rel de bajo voltaje PREAJUSTE DE F BRICA LA LUZ VERDE INTERMITENTE INDICA BAJO VOLTAJE LA LUZ ROJA INTERMITENTE INDICA QUE LA La rectificadora est equipada con un rel de alto bajo voltaje cuyo ajuste predeterminado de f brica es 100 140 V CA Si la l nea de suministro el ctrico no entrega 100 140 V CA bajo carga el rel se abrir y desenganchar el arr
107. n rectificado de precision 1 000 diam 25 4 mm Motor de 3 4 HP CA 3450 RPM Menos de 75 dBA Accionada por correa con un sistema de abrazaderas de facil enganche Montaje magn tico para la cuchilla de base con agregado de soportes centrales Sistema de refrigeraci n por inundaci n incorporado Motor de la rectificadora de seguridad con interruptores de corte en la tapa Control longitudinal de velocidad variable CONOZCA SU RECTIFICADORA IDENTIFICACI N DE LOS COMPONENTES DEL PANEL DE CONTROL PARA EL MODELO BG1500 INTERRUPTOR Conozca la funci n de cada interruptor y cada perilla del DEL MOTOR panel de control A medida que lea y aprenda acerca de PELA ARRANQUE cada perilla le sugerimos que gire dicha perilla y ob RECTIFICADORA DEL SISTEMA serve la operaci n espec fica que realiza Vea la Fig 1 PULSADOR SIEMPRE USE GAFAS PROTECTORAS ADECUADAS INTERRUPTOR CUANDO OPERA SU LONGITUDINAL ad RECTIFICADORA NUNCA BOMBA DEL ENCIENDA SU RECTIFICADORA REFRIGERANTE SIN HABERSE COLOCADO PRIMERO LAS GAFAS PROTECTORAS PARADA DE EMERGENCIA VELOCIDAD PULSADOR DE PARADA DE EMERGENCIA PULSADOR LONGITUDI Presione para detener todo suministro el ctrico a las funciones NAL del panel de control Esto detiene el suministro el ctrico a todos los motores lo que incluye el motor de la rectificadora la bomba del refrigerante el motor longitudinal etc Para reanudar el suministro el ctrico tire del bot n y presione el bot n
108. nto REALICE EL MANTENIMIENTO DE LA RECTIFICADORA CON CUIDADO Siga las instrucciones de la secci n de servicio del Manual para la lubricaci n y el mantenimiento preventivos DESCONECTE LA ALIMENTACI N EL CTRICA ANTES DE REALIZAR EL SERVICIO o cuando cambie la rueda abrasiva REDUZCA EL RIESGO DE UN ARRANQUE INVOLUNTARIO Aseg rese de que todos los interruptores est n en la posici n OFF Apagado antes de conectar la rectificadora UTILICE LOS ACCESORIOS RECOMENDADOS Consulte el manual para obtener informaci n acerca de los accesorios recomendados Utilizar accesorios inadecuados puede aumentar el riesgo de lesiones personales VERIFIQUE LAS PIEZAS DA ADAS Un protector u otra pieza que est n da ados o no cumplan con la funci n que deben realizar deben repararse o reemplazarse adecuadamente NUNCA DESCUIDE LA RECTIFICADORA AL DEJARLA ENCENDIDA APAGUELA No se aleje de la rectificadora hasta que est completamente detenida CONOZCA SU EQUIPO Lea este manual con atenci n Conozca sus aplicaciones y limitaciones as tambi n como los peligros potenciales espec ficos CONSERVE TODAS LAS CALCOMAN AS DE SEGURIDAD LIMPIAS Y LEGIBLES Si las calcoman as est n da adas o legibles por alguna raz n reempl celas inmediatamente Tome como referencia las ilustraciones de las piezas de repuesto que contiene este Manual para ubicarlas adecuadamente y obtener los n meros de pieza de las calcoman as de seguridad
109. nual instructions and safety rules Make sure all items on the Preparation Check List in the Operator s Manual are completed before releasing equipment to the owner TO THE OWNER Read this manual before operating your Frontier equipment Keep this manual handy for ready reference Require all operators to read this manual carefully and become acquainted with all adjustments and operating procedures before attempting to operate the equipment Replacement manuals can be obtained from your selling dealer The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactory use Like all mechanical products it will require cleaning and upkeep Lubricate the unit as specified Please observe all safety information in this manual and safety decals on the equipment For service your authorized John Deere dealer has trained mechanics genuine Frontier service parts and the necessary tools and equipment to handle all of your service needs Use only genuine Frontier service parts SAFETY INSTRUCTIONS The Warning Symbol identifies special instructions or procedures which if not correctly followed could result instructions in personal injury 1 2 10 11 12 KEEP GUARDS IN PLACE and in working order REMOVE WRENCHES AND OTHER TOOLS KEEP WORK AREA CLEAN DON T USE IN DANGEROUS ENVIRONMENT Don t use Grinder in damp or wet locations Machine 15 for indoor use
110. ock oNT27118 Bracket Tooling pointer ZO Sips dentate 5NTBG1509003 Decal Protractor ZO aida oNT28212 Spacer 39ID x 7500 x 311Long DR 5NT3999030 3 8 16 3 62 LG Thread Stud ZO POE ER 5NT3579109 Nylon Plug 3 16 Dia 5NT 3589106 Washer Flat 39 x 1 38 x 125 DO 5NT3708148 Handwheel 4 5Dia 38 Bore Sl 5 80318 Knob T 1 5 1 2 13 5NT6009555 Knob Assembly T 2 5 3 8 16x1 5 Long dO RER 5NT3709437 Handle Adj 3 8 16 x 1 97 od ideis 5 3708652 Washer Conical 1 2 x 1 83 x 024 OTT oNT 37088396 Spring Compressed 600D 53110 x2 5Long E 5NT3709062 Washer Conical 382 x 75 035 5NT3709304 Washer Thrust 375 812 032 5NT 6009027 Shaft Adjusting Acme LH BO 5NT6309050 Lock Bar LH Adjuster 40 5NT6309091 Lock Bar Threaded LH Adjuster ae 5NT6609087 Base Gage Short C bore AD 5 6609016 Block Slide RH d cnn 5 6609018 Shaft Gage 44 5 6609019 Magnet 5 6609021 Arm Center Adjust AO ones 5NT6609023 Screw Gage Lock A esses 5 6609093
111. ohms Remove three wires from TDC red from term 8 white from term 7 black from term 9 K Inspect Motor Brushes Ah DISCONNECT POWER FROM MACHINE 30 Check TDC terminals A1 to A2 for 90 Volts DC Yes go to Step G next No go to Step H next Remove motor wires from Terminal Strip 1 terminals 7 amp 8 check for 0 ohms across the black and white wires Yes end troubleshooting No go to Step K next TDC Pin 8 to 7 Pot Full CCW Pot Full CW OVDC 9 75 VDC Pin 8 to 9 Pot Full CCW Pot Full CW 9 75 VDC 0 VDC Yes replace the TDC No go to Step J next Check for 10 000 ohms red to white wires Full CCW 0 ohms Full CW 10 000 ohms Red to black wires Full CCW 10 000 ohms Full CW 0 ohms Yes replace the TDC No replace TSP Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Traverse Motor NOTE TRAVERSE MOTOR BRUSHES HAVE SHOWN A VERY LONG LIFE THEREFORE IT IS IMPROBABLE THAT MOTOR BRUSHES ARE BAD ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse does not stop to reverse directions when flag goes under the proximity switch on the left side or right side of machine Possible Cause Gap between flag and prox 15 incorrect Proximity Switch is bad Checkout Procedure A Gap between flag and prox should be 3 16 to 1 4 4 6 mm Prox LED does
112. omendado por el fabricante Angulos de cara y superior recomendados Si su modelo no esta enumerado consulte el manual de John Deere para obtener los angulos de afilado recomendados ngulos de rectificado de la cuchilla John Deere Angulo de rectificacion de la Angulo de superficie rectificaci n Utilizado en Descri ocion i Estandar en frontal superior 1250DB de 11 hojas 2500 de 11 5 220C 220 7500 11 hojas 7500 E Cut de 11 hojas 8500 de 11 hojas 22 est ndar ET17533 850D E Cut de 11 hojas 22 Tournament ET17534 2 1 22 para cortac sped de calle ET17532 12500B 7 blade 2500E 7 blade 7500 7 blade 7500 E Cut 7 Made 8500 7 blade corte alto ET177S7 8500 E Cut 7 blade _____9__6 6 tS 6 _ 3 0 mm c inserto endurecido En MT4846 180C 15 6 MT7350 8000 E Cut de 11 hojas 4 1 amp T Tous les 18 po QA5 18 para cortac sped de calle TCU25299 800D E Cut de 7 hojas 45 6 amp 6 mtem 26 st ndar 47 2500 Lo I 6 23522232 22 est ndar ET17751 17700 8 blade 87 0 8 hojas Todas de 22 7 22 Tournament para cortac sped 192 7700 10 blade 8700 10 hojas Todas de 22 ESP calle corte bajo 22 Tournament corte ultra bajo MT3983 gt E _ Todas de 26 QA7 f26 estandar SET 17752 255387200 002 Todas de 26 ESP 26 Tournament
113. only Keep work area well lit KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area MAKE WORK AREA CHILD PROOF with padlocks or master switches DON T FORCE THE GRINDER It will do the job better and safer if used as specified in this manual USE THE RIGHT TOOL Don t force the Grinder or an attachment to do a job for which it was not designed WEAR PROPER APPAREL Wear no loose clothing gloves neckties or jewelry which may get caught in moving parts Nonslip footwear is recommended Wear protective hair covering to contain long hair ALWAYS USE SAFETY GLASSES SECURE YOUR WORK Make certain that the bedknife is securely fastened with the mounts provided before operating DON T OVERREACH Keep proper footing and balance at all times Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards Whenever you see these symbols follow their The Caution Symbol identifies special instructions or procedures which if not strictly observed could result in damage to or destruction of equipment 13 MAINTAIN GRINDER WITH CARE Follow instructions in service section of the Manual for lubrication and preventive maintenance 14 DISCONNECT POWER BEFORE SERVICING or when changing the grinding wheel 15 REDUCE THE RISK OF UNINTENTIONAL STARTING Make sure all switches are OFF before plugging in the Grinder 16 USE RECOMMENDED ACCESSORIES Consult
114. ove because of this pressure allowing bedknife to rock on the middle support For precise grinding spark ing out process is critical It eliminates excessive final grinding pressure on centers and middle support which helps maintain grinding straightness Looseness in roller causes erratic grind When the rim doesn t extend over the top face it wears unevenly and causes grooves across the bedknife Looseness in rollers causes erratic grind Backlash allows grinding wheel to move under load Traversing speed controls the grinding surface texture A slower traverse produces grind marks closer together When the front face of the bedknife gets too hot the steel loses its temper softens Too much stock removal in one pass creates too much heat and softens the steel Wheel will glaze if not dressed often enough Also as a general rule use a higher traverse speed for the heavy grind MECHANICAL TROUBLESHOOTING Continued PROBLEM POSSIBLE CAUSE Grinding wheel is glazing too quickly A Wheel needs dressing B Too light cut when rough grinding C Grinding head is traversing too slow Grinding motor vibrates excessively Grinding wheel is out of balance Carriage traversing varies speed while grinding A Linear bearings in the carriage do not rotate freely B Belt it slipping C Traverse belt tension is too loose REMEDY Dress the wheel before the
115. rked on wheel DO CHECK MOUNTING FLANGES for equal and correct diameter DO USE MOUNTING BLOTTERS when supplied with wheels DO be sure WORK REST is properly adjusted DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding DO always WEAR SAFETY GLASSES or some type of eye protection when grinding DO TURN OFF COOLANT before stopping to avoid creating an out of balance condition DON T DON T use a cracked wheel or one that HAS BEEN DROPPED or has become damaged DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole if the wheel won t fit the machine get one that will DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURNS DON T TIGHTEN the mounting nut excessively DON T grind on the SIDE OF THE WHEEL see Safety Code 7 2 for exception DON T start the machine until the WHEEL GUARD IS IN PLACE DON T JAM work into the wheel DON T STAND DIRECTLY IN FRONT of a grinding wheel whenever a grinder is started DON T FORCE GRINDING so that motor slows noticeably or work gets hot AVOID INHALATION OF DUST generated by grinding and cutting operations Exposure to dust may cause respiratory ailments Use approved NIOSH or
116. s 9 MT1973 2653 7200 5 6 1 30 ESP 365 ener 5 5 30 ESP para 1905 __ 2 6756 5 6 _ MKI MK2 MI PS UNIDADES BEAVER ce 516 14 INSTRUCCIONES OPERACION CONTINUACION COMO MONTAR UNA RUEDA EL EJE DE LA RUEDA DE RECTIFICACION Para reemplazar la rueda abrasiva Vea la Fig 12 CUENTA UNA ROSCA LEV GIRA 1 GIRE EN EL SENTIDO DE LAS AGUJAS Primero apague la m quina al presionar el bot n Emer DEL RELOJ PARAAFLOJARLA gency Stop Parada de emergencia Utilice la llave para la rueda abrasiva incluida con la rectificadora para destornillar la brida de soporte que sostiene la rueda LA BRIDA DE BLOQUEO CUENTA CON UNA ROSCA LEV GIRA SOSTENGA LA RUEDA Y GIRE LA LLAVE EN SENTIDO DE LAS AGUJAS DEL RELOJ MIENTRAS OBSERVA C MO SE AFLOJA LA BRIDA DE BLOQUEO Quite la rueda vieja e instale la nueva Enrosque la brida con la mano y luego ajuste aproximadamente 1 8 de vuelta adicional con la llave La brida se ajustar sola cuando el motor se encienda FIG 12 RUEDAS ABRASIVAS VITRIFICADAS SI LA BRIDA DE LA RUEDA SE AJUSTA EN EXCESO ES POSIBLE QUE LA RUEDA ABRASIVA SE AGRIETE Y SALGA DESPRENDIDA RUEDAS ABRASIVAS VITRIFICADAS Luego de haber instalado una nueva rueda o una diferente es recomendable que se labre antes de comenzar a rectificar El labrado corrige la superficie de rectificado de la rueda y quita la pel c
117. s manual Position the Bedknife for Top Face Grinding See FIG 31 When rotating from front face grinding to top face grinding the grinding head must be backed out three full turns Rotate the tooling assembly to the top face position up and set the top face angle to the mower factory specifications FIG 31 Check Clearances and Set Traverse Limits Position the grinding head so that the grinding wheel just touches the top face of the bedknife Check to see if the LOCK LEVER rim of the grinding wheel is extended 1 2 50mm above the top face of the bedknife If you have previously ground the front face it most often will be correct If not with the vertical cam and lock lever adjust the grinding head See FIG 32 If the shape of the bedbar interferes with the wheel guard or grinding wheel you will need to make adjustments See page 18 VERTICAL CAM LEVER IF THE GRINDING WHEEL RIM DOES NOT EXTEND OVER THE BEDKNIFE FACE IT WILL GRIND UNEVENLY AND CAUSE GROOVES e ACROSS THE SURFACE OF THE BEDKNIFE Check for interference FIG 32 1 Back out the grinding head so the wheel no longer touches the top face of the bedknife 2 If you have just ground the front face the travel limit should still be correct but you should still verify no interferences as described below If you did not grind the front face follow the full procedure listed below Slide the left and right proximity switches to the far ends of the rail
118. se Like all mechanical products it will require cleaning and upkeep Lubricate the unit as specified Please observe all safety information in the Operator s Manual and safety decals on the equipment For service your authorized John Deere dealer has trained mechanics genuine Frontier service parts and the necessary tools and equipment to handle all of your service needs Use only genuine Frontier service parts SAFETY INSTRUCTIONS instructions The Warning Symbol identifies special instructions or procedures which if not correctly followed could result in personal injury 1 2 10 11 12 KEEP GUARDS IN PLACE and in working order REMOVE WRENCHES AND OTHER TOOLS KEEP WORK AREA CLEAN DON T USE IN DANGEROUS ENVIRONMENT Don t use Grinder in damp or wet locations Machine is for indoor use only Keep work area well lit KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area MAKE WORK AREA CHILD PROOF with padlocks or master switches DON T FORCE THE GRINDER It will do the job better and safer if used as specified in this manual USE THE RIGHT TOOL Don t force the Grinder or an attachment to do a job for which it was not designed WEAR PROPER APPAREL Wear no loose clothing gloves neckties or jewelry which may get caught in moving parts Nonslip footwear is recommended Wear protective hair covering to contain long hair ALWAYS USE SAFETY GLASSES SECUR
119. stren las ruedas 5 NO AJUSTE EXCESIVAMENTE la tuerca de montaje Aseg rese de que el portapiezas est ajustado 6 NO rectifique con el LATERAL DE LA RUEDA adecuadamente consulte el C digo de seguridad B7 2 para conocer las excepciones SIEMPRE UTILICE UNA CUBIERTA PROTECTORA DE SEGURIDAD que cubra por lo menos la mitad de la 7 NO encienda la m quina hasta que el PROTECTOR rueda abrasiva DE LA RUEDA EST EN SU LUGAR Permita que LAS RUEDAS RECI N MONTADAS giren 8 NO ATASQUE la pieza de trabajo en la rueda a la velocidad operativa con el protector colocado en su lugar durante por lo menos un minuto antes de 9 NO SE PARE DIRECTAMENTE DELANTE de la comenzar a rectificar rueda abrasiva cada vez que se encienda una rectificadora Siempre USE GAFAS DE SEGURIDAD o alg n tipo de protecci n ocular cuando rectifique 10 NO FUERCE EL RECTIFICADO de modo que el motor disminuya notablemente la velocidad o la pieza APAGUE EL SUMINISTRO DE REFRIGERANTE de trabajo se caliente antes de detener la m quina para evitar que se genere un desequilibrio EVITE INHALAR EL POLVO generado por las operaciones de rectificado y corte La exposici n al polvo puede causar problemas respiratorios Utilice respiradores gafas de seguridad o m scaras e indumentaria protectora aprobados por el NIOSH Instituto nacional para la seguridad y salud ocupacional y la MSHA Administraci n para la seguridad y salud de los mineros Propicie una ventilaci
120. the manual for recommended accessories Using improper accessories may cause risk of personal injury 17 CHECK DAMAGED PARTS A guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced 18 NEVER LEAVE GRINDER RUNNING UNATTENDED TURN POWER OFF Do not leave grinder until it comes to a complete stop 19 KNOW YOUR EQUIPMENT Read this manual carefully Learn its application and limitations as well as specific potential hazards 20 KEEP ALL SAFETY DECALS CLEAN AND LEGIBLE If safety decals become damaged or illegible for any reason replace immediately Refer to replacement parts illustrations in this Manual for the proper location and part numbers of safety decals 21 DO NOT OPERATE THE GRINDER WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS 10 IMPROPER USE OF GRINDING WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY Grinding is a safe operation if the few basic rules listed below are followed These rules are based on material contained in the ANSI B7 1 Safety Code for Use Care and Protection of Abrasive Wheels For your safety we suggest you benefit from the experience of others and carefully follow these rules DO DO always HANDLE AND STORE wheels in a CAREFUL manner DO VISUALLY INSPECT all wheels before mounting for possible damage DO CHECK MACHINE SPEED against the established maximum safe operating speed ma
121. time more than four weeks then the shafts and other appropriate parts of the unit should be flooded with lubricant and that lubricant left in place until the unit is brought back into service When the unit is brought back into service the full lubrication procedure as stated above should be repeated 13 MAINTENANCE CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE WINDOWS Cleaning Instructions DO NOT USE GASOLINE Adherence to regular and proper cleaning procedures is recommended to preserve appearance and performance Washing to Minimize Scratching Wash polycarbonate windows with a mild dish washing liquid detergent and lukewarm water using a clean soft sponge or a soft cloth Rinse well with clean water Dry thoroughly with moist cellulose sponge to prevent water spots Do not scrub or use brushes on these windows Also do not use butyl cellosolve in direct sunlight Fresh paint splashes and grease can be removed easily before drying by rubbing lightly with a good grade of VM amp P naphtha or isopropyl alcohol Afterward a warm final wash should be made using a mild dish washing liquid detergent solution and ending with a thorough rinsing with clean water Minimizing Hairline Scratches scratches and minor abrasions can be minimized by using a mild automobile polish Three such products that tend to polish and fill scratches are Johnson paste Wax Novus Plastic Polish 1 and 2 and Mirror Glaze plastic polish M G M10
122. tions then slowly increase the speed to observe that your operation and set up are correct GETTING TO KNOW YOUR GRINDER CONTINUED TRAVERSE ENGAGEMENT LEVER TRAVERSE ENGAGEMENT AND RELEASE UP TO ENGAGE BELT DOWN TO DISENGAGE The belt that drives the carriage left and right can be engaged and released by rotating the red clamp handle located on the front left of the carriage Moving the lever to the up position will engage the belt and rotating it down will disengage the belt The clamp tip can be adjusted if necessary to increase or decrease the tension on the belt See adjustments in the service manual for more details IF NECESSARY THE BELT CLAMP TIP Sea A MUST BE ADJUSTED AS SPECIFIED IN 7 tum mme S nem THE SERVICE MANUAL IF THE A CLAMP IS OVERTIGHTENED THE BELT MAY SLIP WHICH MAY CAUSE DAMAGE TO THE MACHINE OR BELT CLAMP TIP FIG 2 BEDKIFE TRAVERSE PROXIMITY SWITCHES Two movable switches determine the left and right limits of carriage traverse See FIG 3 An LED on the switch lights when the switch actuator bracket on the bottom of the carriage gets close to the head of the switch Note there should be a 3 16 gap between the proximity switch head and the traverse actuator bracket FIG 3 TRAVERSE PROXIMITY SWITCHES COOLANT SYSTEM FLEXIBLE TUBE AND NOZZLE FLOW VALVE Coolant Nozzle x Directs a stream of coolant onto the bedknife and grinding
123. top face The angle is usually measured relative to the bedknife mounting surface See FIG 11A There will be 0 30 degrees clearance angle ground on the front face The angle is usually measured relative to a line perpendicular to the bedknife mounting surface See FIG 11B 13 A Dull Reel Blade and Bedknife B Sharp Reel Blade and Bedknife FIG 10 A Top Face Angle 4 TO 109 AA This line 15 aralle to edknife mounting surface Mounting Surface BEDKNIFE This line is parallel to mounting surface B Front Face Angle Ci O Mounting Surface BEDKNIFE TERMS Bedknife the stationary blade in a reel mower Bedknife Support or bedbar the bedknife is mounted to this frame member with screws or rivets Top Face the horizontal ground surface of the bedknife Front Relief Angle the angle between vertical and the manufacturer s recommended sharpening angle Top Relief Angle the angle between horizontal and the manufacturer s recommended sharpening angle Recommended Face amp Top Angles If your model is not listed consult your John Deere manual for the recommended sharpening angles John Deere Bedknife Grind Angles Front Face Top Grind Used on Description Part Number Standard On Grind Angle Angle 25008 11 blade
124. torque values refer to the information GRADE 2 GRADE 5 GRADE 8 below Bolts Going Into a Nut or Into a Thread Hole in SMOOTH 3MARKS 6 MARKS Steel HEAD on HEAD HEAD Refer to the table at the right thread 0 8 kg m 1 25 kg m 1 8 kg m Bolts Going Into a Thread Hole In Aluminum Use the Grade 2 values in the table at the right reag ASO Socket Head Screws Going Into Nut or Steel Unread orm Use the Grade 8 values in the table at the right thread 4 1 kg m 6 9 kg m 10 4 kg m Machine Screws 1 2In 45 ft lbs 75 ft lbs 115 ft lbs 6 screws 11 in Ibs 0 125kg AES 8 screws 20 in lbs 0 23 kg m No 10 screws 32 in lbs 0 37 kg m ASSEMBLY INSTRUCTIONS Remove the sides front and back of the crate Remove the plastic bag shrink wrap and bubble wrap Remove the metal clips that secure the grinder to the crate base With a fork lift raise the grinder from the wood base and set it in its final position See FIG 1 and2 Remove shipping straps THE UNIT WEIGHS 750 LBS 340 kg TO LIFT USE POWER EQUIPMENT 4 POSITION BASE FIG 1 The BG1500 Bedknife Grinder will require an operating area of about 91 W x 72 D x 87 H 231 x
125. ts holder and push it forward Swing the dresser around to the grinding face of the wheel and turn the adjuster ring until the diamond point JUST touches the wheel See FIG 16 If the dresser is adjusted too far into the wheel the area supporting the diamond will be ground and the diamond may come loose Rotate the diamond tip dresser across the full width of the wheel two times When done rotate the handle clockwise against the lock bracket before pulling back and replace the dresser movement arm in the holder See FIG 15 FIG 13 NOTE Excessive dressing will shorten the life of the wheel Too little e dressing will inhibit proper grinding ADJUSTING RING DRESSER MOVEMENT ARM LOCK BRACKET FIG 15 Dresser locked FIG 16 Dresser unlocked Replacing the Wheel BORAZON WHEEL There is approximately 1 8 3 2 mm of grinding material on the end of the wheel When there is minimal grinding material remaining the wheel should be replaced VITRIFIED WHEEL Anew vitrified grinding wheel is 2 51 mm deep When it wears down to a depth of 0 75 19 mm it should be replaced 19mm FIG 17 See FIG 17 16 OPERATING INSTRUCTIONS CONTINUED USING FLOOD COOLANT For quality grinding we highly recommend using flood coolant to prevent heat buildup on the knife edge IF YOU DRY GRIND NEVER ALLOW THE BEDKNIFE EDGE TO CHANGE COLOR OR YOU MAY LOSE THE TEMPER IN THE KNIFE EDGE ALWAYS READ THE MA
126. ula dura que algunas veces queda del proceso de fabricaci n El labrado prepara adecuadamente la rueda para el rectificado RUEDAS ABRASIVAS DISPONIBLES PARA LA RECTIFICADORA DE CUCHILLA BG1500 RUEDA N DE PIEZA COLOR DESCRIPCI N TAMANO GRANO 5NT3700060 Rueda de copa c nica Blanca roja rub 60 Rub vitrificado di metro interior de 6 3 1 4 x 2 0 627 in 5NT3700062 Rueda de copa c nica Blanca 46 Vitrificada di metro interior de 6 3 1 4 x 2 0 627 in 5NT3700268 Rueda de copa recta blanca roja rub 60 Rub vitrificado di metro interior de 6 x 2 x 0 627 in 5NT3700411 Rueda de copa recta blanca 46 Vitrificada di metro interior de 6 x 2 x 1 25 in 5NT3700670 Rueda de copa recta de boraz n 60 Di metro interior de 6 x 1 1 2 x 0 625 in 5NT3700696 Rueda de copa recta de boraz n 120 Rectificado Di metro interior de 6 x 1 1 2 x 0 625 in est ndar Rueda 15 INSTRUCCIONES OPERACION CONTINUACION COMO LABRARILIMPIAR LA RUEDA ABRASIVA Limpie o labre la rueda abrasiva siempre que detecte la acumulacion de alguna pelicula La pelicula es una acumulacion de polvo de roca arenilla de rectificado y refrigerante en la cara de la rueda Para obtener mejores resultados con una rueda vitrificada tambi n labre la rueda antes de realizar el rectificado final DE SEGURIDAD DURANTE EL RECTIFICADO CONSULTE TAMBI N LA SECCI N REGLAS EN LA P GINA 3 Para la limpieza y el labrado siempre mueva el cabezal
127. ump Not Working Open coolant flow valve C Check 2 amp CB on front of Control panel Press if tripped D Check power from CB E Check for power from CPS F Check for power from CPS 28 Yes end troubleshooting No go to Step B next Coolant Pump works Yes end troubleshooting No go to Step C next Coolant Pump works Yes end troubleshooting No go to Step D next Measure 120 volt AC from both sides of 2 amp CB to Terminal Block 4 Blue Yes go to Step E next No With power off check continuity of CB amp wires to CB Replace CB CPS Term 5 to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step F next No replace CPS Measure 120 volt AC from TB1 4 to TB1 5 Yes Replace Coolant Pump ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse Drive not working Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram are correct and pull on wire terminals with approximately 3 165 force to verify there are no loose terminal connections and or no loose crimps between the wire and the terminal If problem persists test as listed below Possible Cause Traverse Motor Switch TMS is not on Traverse Speed Pot TSP set to zero Fuse on Traverse Drive Control TDC has failed Traverse Drive Control TDC is bad Bad Traverse Motor Switch TMS Checkout Procedure A T
128. urn on TMS B Set TSP to 35 on the control panel C Check fuse and replace if failed See Page 23 Too heavy a grind causes grinding head traverse motor to overload and blow the fuse NOTE Fuse can not be checked visually Use Ohm test to check fuse Fuse must be replaced with a slo blo fuse D Check for 120 Volts AC incoming to TDC E Check for 120 Volts AC at TMS Make certain TMS is on 29 Traverse works Yes end troubleshooting No got to Step B next Traverse works Yes end troubleshooting No go to Step C next Traverse works Yes end troubleshooting No go to Step D next On TDC Terminal L1 to L2 for 120 Volts AC Yes Go to Step F No Go to Step E next Measure 120 volts AC from TMS Termi nal 5 to Term Block 4 Blue Yes Verify wiring to TDC No Flip Switch and check again Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch ELECTRICAL TROUBLESHOOTING Continued Possible Cause No DC Voltage from TDC Traverse Drive Control Traverse Motor is bad TSP is not working TSP 10K is bad Worn motor brushes Checkout Procedure F Check for 90 Volts DC across TDC terminals A1 to A2 this voltage drives the DC traverse motor NOTE Traverse must be on and have TSP turned full CW to maximum voltage of 90 VDC G Check traverse motor continuity H Check TSP 10K on control panel J Check TSP for 10 000
129. verse belt clamp is damaged or not adjusted properly the belt will slip If the belt is too loose it will tend to vibrate or the belt tensioning springs may tend to jump when loaded 9NTBG1509504 MAIN BASE ASSEMBLY EXPLODED VIEW 5 7 d A j boop 7 Qu Q SOL T C a IQ Y 4 NF U N IS D amp d 4 A ig i M 36 PARTS LIST DIAGRAM NUMBER 9NTBG1509504 MAIN BASE ASSEMBLY PART NUMBER DESCRIPTION 5 6709209 Coolant Pump Assembly 5NTB1908009 10 24 x 1 2 RHMS 5NTB250816 1 4 20 x 1 2 Button Head Socket Cap Screw 5NTB251016 1 4 20 x 5 8 Button Head Socket Cap Screw 5NTB371201 3 8 16x 3 4 Hex Head Cap Screw 5NTB501601 1 2 13 x 1 Hex Head Cap Screw 5NTC161020 8 32 x 5 8 SSS CPPT oNTK371501 3 8 Split Lockwasher oNTK501501 1 2 SAE Split Lockwasher oNT6609046 Coolant Pump Cover 5NTH371202 375 Dia x 75 Long Roll Pin 9NTH371602 375 Dia x 1 00 Long Roll Pin ONTJ167000 8 32 Nylon Insert Jam Locknut 5NTJ501000 1 2 13 Hex Nut ONTROO0483 10 Int Teeth Lock Washer oNTRO0OO536 1 4 Int Teeth Lock Washer 5NTR000553
130. wheel For precise aiming the nozzle and connecting tubing are completely flexible NOTE The connecting tube can be shortened by removing segments as desired Coolant Flow Valve Controls the volume of coolant flowing to the nozzle Use only enough flow to cool the bedknife Excess flow will cause excess splashing and won t improve performance 10 GETTING TO KNOW YOUR GRINDER CONTINUED GRINDING HEAD WHEEL GUARD LOCK SCREW VERTICAL CAMLEVER Vertical Eccentric Adjustment and Lock Moves the grinding head up and down Horizontal Handwheel Moves the grinding head infeed in and out Horizontal Adjustment Scale Calibrated in 002 in 05mm increments so you can accurately move the grinding wheel in for each pass across the face of the bedknife Wheel Guard Lock Screws A T knob holds the guard in position Loosen it to pivot the guard when the guard interferes with the bedbar Diamond Wheel Dresser Allows you to dress the grinding wheel Cleaning and dressing the grinding wheel improves the VERTICALADJUSTEMENT FIG 5 quality of the grind LOCKLEVER DIAMOND DRESSER ae THE DIAMOND DRESSER SHOULD ONLY BE USED WITH A VITRIFIED GRINDING WHEELS THIS GRINDER IS SHIPPED WITH A BORAZON GRINDING WHEEL AND A CLEANING BRICK DO NOT USE THE BUILT IN DIAMOND DRESSER ON THE BORAZON WHEEL FIG 6 HORIZONTALADJUSTMENT HANDWHEEL SCALE HORIZONTALADJUSTMENT 11 GETTING TO KNOW YOUR GRINDER CONTINU
131. y reason replace immediately Refer to replacement parts illustrations in this Manual for the proper location and part numbers of safety decals DO NOT OPERATE THE GRINDER WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS 10 IMPROPER USE OF GRINDING WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY Grinding is a safe operation if the few basic rules listed below are followed These rules are based on material contained in the ANSI B7 1 Safety Code for Use Care and Protection of Abrasive Wheels For your safety we suggest you benefit from the experience of others and carefully follow these rules DO DO always HANDLE AND STORE wheels in a CAREFUL manner DO VISUALLY INSPECT all wheels before mounting for possible damage DO CHECK MACHINE SPEED against the established maximum safe operating speed marked on wheel DO CHECK MOUNTING FLANGES for equal and correct diameter DO USE MOUNTING BLOTTERS when supplied with wheels DO be sure WORK REST is properly adjusted DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding DO always WEAR SAFETY GLASSES or some type of eye protection when grinding DO TURN OFF COOLANT before stopping to avoid creating an out of balance condition DON T DON T use a cracked wheel or one that HAS BEEN D

OPERATING INSTRUCTIONS (Continued)

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