WSG1640AHD SURFACE GRINDING MACHINE

OPERATING    MANUAL 

Operating manual

QUALIFIED CERTIFICATE

Ex-factory record:

The machine is performing GB4022-83

《Horizontal Shaft &Rectangular Table Surface Grinder Precision》

standard

Model of machine: WSG1640AHD

Width of worktable: 16 in

Length of worktable: 40 in

The machine has been inspected being up to the standard and

approved for delivery.

Serial No.:

Inspector:

Date :

Operating manual

Precision Inspection Register

Geometrical precision

No. Items Diagram Permissible deviation

Actual deviation

1 Flatness of the table surface

Full length: 0.01

Local: 0.005/300

2

a. Parallelism of the table surface to its longitudinal movement b. Parallelism of the table surface to its transverse movement

a. Full length:

0.015 Local:

0.008/300 b.

Full length: 0.01

3 Parallelism of the median slot to the longitudinal movement of table

Full length: 0.015

Local: 0.008/300

4 Verticality of the table transverse movement to the longitudinal movement

0.03/300

5 Verticality and straightness of the wheel head up and down to the table surface

0.03/300

Operating manual

6 Radial run out of the wheel spindle nose

0.004

7 Axial run out of the wheel spindle 0.004

8 Parallelism of the spindle center line to the table surface

0.025/300

9 Verticality of the spindle center line to the medina slot

0.015/300

Machining precision

No. Inspection items Permissible deviation Actual deviation Remark

P1 Grinding five columned test blocks

Tolerance in thickness: 0.005/300

Test pieces are 45#steel φ50

P2 Grinding completed test block

Tolerance in thickness: 0.005/300

The material test piece is iron HT200, the length is half of table, width is three times of wheel width ,the thickness is 60mm

Operating manual

DISTRIBUTOR

Do not transport the machine and start operation before reading

the safety directions and the instruction manual.

The below mentioned persons herewith confirm that they have read

and comprehended the operation instructions before transport and

appropriate use of the machine for their security and of third persons

and the safety of the machine. For achieving best grinding results it is

in the user’s own interest to follow the technical directions for

grinding.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

(Name) (Signature)

Operating manual

SAFETY DIRECTIONS

To guarantee an optimal, trouble-free operation at lowest possible endangering this machine should only be operated, maintained and repaired by persons familiar with it and list operation.

For these reasons the instruction directions must be read and be followed exactly before transport and start of operation.

Especially important safety directions are marked with symbols in front of them.

Comments on indicative symbols

= Safety directions must be followed exactly.

Not noting them causes danger for the operator

= Caution advices must be remembered exactly

Not noting them may entail operation trouble or

damage of the machine

= Important directions should be noted in order to

reach good working results.

Operating manual

INDEX

Description page

Chapter 1. Safety instruction

1.1 general safety instruction 1 1.2 safety regulation of the machine 2

Chapter 2. Summary of the machine

2.1 concise statement on the machine 4 2.2 field of application 4 2.3 construction identification 5 2.4 main specification 6

Chapter 3. Machine installation instruction

3.1 Diagram of machine floor space 7 3.2 demand of foundation 9 3.3 foundation construction and machine setting 9 3.4 Carriage and lifting machine 11 3.5 Remove the setting plates 11 3.6 Clean the machine 12 3.7 Placement of Hydraulic system and coolant tank 12 3.8 power supply 15

Chapter 4. Trial running

4.1 preparation before trial running 18 4.2 safety inspection before operation 20

Chapter 5. Operation instruction

5.1 control panel instruction 22 5.2 operating caution 37 5.3 correct operation of wheel 38

Operating manual

INDEX

Description page

5.4 select perfect method of variously grinding 43 5.5 inspection of the grinding wheel 44 5.6 wheel dressing & correct use of wheel dresser 47 5.7 Balancing wheel 49

Chapter 6. Daily maintenance

6.1 daily inspection (oil & water) 51 6.2 daily inspection (test list before operating) 52 6.3 daily inspection (test list after work) 53

Chapter 7. Setting, Adjusting and trouble shooting

7.1 There are ripples on the work piece 54 7.2 Accuracy of the work-piece ground is not so good 54 7.3 The spindle don’t run 55

Appendix

Electrical parts list 56 Circuit diagram 58 Hydraulic system principle diagram (1page) 66 Main function structure drawing ( 10 pages) 67

PACKING LIST

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Chapter 1 Safety instruction

1.1. general safety instruction

(1) The operator must be trained and passed the operating and

maintaining test.

(2) The user should educate the operator according to local law of

industrial safety and hygiene.

(3) The user should warn operator about unsafe operating.

(4) Read the manual before using the machine, and note danger mark and

content stuck on the machine.

(5) The operator whose hair is too long must wear hat before operating

and maintain machine.

(6) When operating, the operator must wear glasses protecting eyes, wear

mask and safe industrial shoes.

(7) Keep machine and around surroundings clean and, avoid the floor

being wet and slippery, and clean unnecessary goods.

(8) In order to prevent compression, please retain 600mm space out of

machine’s limit position, mark the working range with yellow line and

forbid any other person to enter in when operating.

(9) Always shut all guard shied and the door of electrical box unless

maintain the unit.

(10) Shut off the power before maintain the machine.

Forbidden Items:

(1) Don’t operate or maintain the machine with long sleeve clothing, tie,

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and glove.

(2) Don’t lean against the machine in working range

(3) Don’t adjust the grinding wheel cover, right or left travel limit control

block, nozzle with hand or tools when the machine is running.

(4) Don’t blow out scrap or dust with compressed air to protect operator’s

eyes.

1.2. safety regulation of the machine

(1) Be sure that the allowable maximum fringe speed of wheel is 35m/s or

higher.

(2) Pay attention to correlative warning instructions before inspecting and

maintaining.

(3) When inspecting electrical parts, must wear nonconducting protector

such as insulating gloves, rubber shoes and so on..

(4) All the electrical parts needing earth should be properly earthed

according to circuit diagram.

(5) Be sure that circuit is turned off with appropriate instrument before

inspecting circuit

(6) Only certified operator can open the electrical box and inspect circuit

when there is fault.

(7) If the hardness of work-piece is more than HRC65 and grinding is

difficult, Please connect with wheel manufactory and choice a proper

kind of wheel.

(8) The grinding wheel should be installed after balanced, the wheel

should be balanced by trained worker. Before fixing the wheel on the

spindle, cleaning contact surface between flange and front end of

spindle.

(9) Should confirm the position and performance of emergency switch

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before driving the machine.

(10) Must inspect if the spindle rotating direction is correct before driving the

spindle motor. Begin to grind work-piece after not less than 5 minutes

since driving the machine.

(11) Please clean the magnetic chuck surface before using, if there is

scuffing or scar on the surface, please grind it again.

(12) When grinding antimagnetic material such as aluminum alloy, graphite

and so on, please use suitable chuck block to fix the work piece and

make sure it could not touches the wheel.

(13) By hands before wheel turning, the operator should confirm if magnetic

chuck holding work-piece fast and hard.

(14) The work table must be motionless when operator adjusts right or left

travel limit control block.

(15) When wet grinding, should shut off cooling device before braking the

spindle motor.

Forbidden Items:

(1) The machine is forbidden to install near the powder, magazine and

explosive.

(2) Don’t use inflammable liquid as cutting fluid.

(3) The wheel of spindle is forbidden to cut material as rotary sander.

(4) It’s forbidden to alter use & capacity design of the machine and to use

the wheel out of stipulation, also not processing overweight or

overlarge work-piece.

(5) Don’t change circuit before authorized by manufactory avoid damage.

(6) Don’t change interlocked circuit into by pass circuit.

(7) Don’t touch the parts at random where stuck heat lightning mark.

(8) Should avoid touching electrical box and circuit when body and hands

are wet.

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(9) Must not wearing metal garnish to avoid electric shock when inspecting

electrical parts, and hang up warning mark to avoid someone operating

the machine.

(10) Forbid to fixed short & over-thin work-piece or complicated shape,

precarious CG work-piece directly on the magnetic chuck.

(11) When grinding, any other goods are permitted to place on the table but

the fixed work piece.

(12) Don’t adjust nozzle after the spindle has been driven, when wet

grinding.

(13) Don’t stop the wheel with hands or other things, after the motor is shut

off.

(14) Don’t move or exchange work-piece when the work table is moving or

the wheel is turning.

(15) Don’t take a risk clean the scraps on the work piece while grinding or

the wheel is turning.

(16) Specific accessory should be used to takedown the wheel. Forbid to

pound the wheel and pounding maybe make the wheel broken.

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Chapter 2 Summary of the machine

2.1 concise statement on the machine

“十” saddle is adopted in the design, all these three guide way is lined with TF

wearable material and lubricated by intermittent forced oil pump, the column

have double walls. The table right and left moving is driven by variable

displacement vane pump and adopted closed type hydraulic system. All above

make the machine with high rigidity and precision, small thermal distortion,

moving smoothly, low noise and temperature increase, is easy to maintain. The

table is driven by manual or by hydraulic in right or left direction, the speed is

variable changed by adjusting lever located on the saddle, driven by manual or

by motor through driven the ball leading screw. The grinding head could be

driven by lifting motor( AHR model) or servo motor( AHD model), also it be

driven by manual.

2.2 field of application

The machine is used for mid-type & mini-type material processing workshop and

the other maintain & tools workshop in.

The machine is mainly used to grinding the surface with the wheel circle face,

the surface been ground have high precision and low roughness. Also it can

grind the vertical surface with the end face of the wheel. the work pieces can be

placed on the magnetic chuck or fixed directly on the table or with other fixtures

suit to various work pieces.

The machine can be used for grinding steel, cast iron and nonferrous metals.

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2.3 construction identification

No Name No. Name

1 Bed 7 Grind wheel

2 Electro lubricate pump 8 Saddle cross moving hand wheel

3 Table longitudinal moving hand wheel 9 Saddle

4 Table 10 Wheel head lifting hand wheel

5 Column 11 Cabinet

6 Wheel guard 12 Elevating motor (only for R/A model)

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2.4 main specification

Main specification of WSG1640 Series

Model Item Unit AHR AHD

Table size (W×L) In 16×40

Table longitudinal move speed in/min 275.5~906 Max. Distance from table surface to spindle centerline In 23

Max. Loading capacity ( include chuck) kg 500

Table transverse movement

Auto intermittent feed In 0.004~0.3

Rapid speed in/min 39

Feed of Hand-wheel in/div. 0.0008

Vertical movement

Auto feed In - 0.0002/0.0004/0.0008/0.0016/0.002

Rapid Speed in/min 18

Feed of hand-wheel

in/div. 0.0002

in/rev. 0.08

Grinding wheel

Size (OD×W×ID) In 14×1.5×5

Speed rpm 1450 (50HZ) 1750 (60HZ)

Motor

Spindle motor kw 5.5

Oil pump motor kw 2.2

Cooling pump motor kw 0.09

Vertical driven motor kw 0.25 0.5

Transverse driven motor kw 0.04

Gross Weight kg 3800

Floor space (L ×W×H) In 116×89.5×86

1. AH mean: auto feed on transverse, hydraulic transmission on longitudinal, manual

on vertical. 2. AHR mean: auto feed on transverse, hydraulic transmission on longitudinal, rapid

movement on vertical. 3. AHD mean: auto feed on transverse, hydraulic transmission on longitudinal, auto

feed on vertical.

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Chapter 3 Preparation before machine installation

3.1 diagram of machine floor space

size

model A B C

WSG1020 89” 68” 85”

WSG1224 110” 82” 87”

WSG1240 173” 128” 87”

WSG1632 142” 104” 94”

WSG1640 173” 128” 94”

Limit position drawing

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3.2 demand of foundation

1) Installation of the machine will effect deeply efficiency and precision,

don’t place the grinder between the milling machine and planer, etc,

because there is shock when these machine are running, the shock will

be transferred to the grinder and make wave mark on the grinding

surface.

2) The table of the machine must be prevented from insolate for this will

make the table thermal distortion. Don’t install the machine in the field full

of magnet, inflammable dirt, metal dirt and outburst gas.

3) Don’t install the grinding machine on the insubstantiality foundation avoid

distortion.

3.3 foundation instruction and machine setting

1) The machine should be installed on a solid concrete foundation, the

foundation is to be cast in one piece, the concrete should not be lower

than #500, the depth noted on the “Foundation Layout” is the min. value

suitable only for the ordinary solid soil, else it should be accordingly

increased. If the shop is near the sandy river bank or the ground is newly

filled, the foundation should be reinforced with the additional blocks. After

the foundation is finished a curing period of 28days is necessary. During

the first week the foundation should be watered often so that it can be

kept damp. In winter the curing period has to be properly lengthened and

anti-freezing measure should taken into consideration, Installing is not

allowed within the curing period.

2) Don’t use simple “knocking in” type wedges, when the machine is

installed and adjust leveling with wedges. The machine is to be installed

with foundation bolts, the cavities should be grouted with 1:3 cement

mortar around the bolts and then left to dry 3-7 days after the machine

has been pre-leveled up. Following this proceed with fine leveling and

tighten the nuts.

3) Check insulating resistance for electric system, then connection of power

mains to the machine electric cabinet should be made only after it has

been well grounded. Only when the installation has been entirely

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completely and the function of electric circuits proved to be securely safe

and reliable, can the wheel of the machine be tested for geometrical

complete, started and operated.

UNIT: inch

sizemodel A B C

WSG1640 45 30 16

WSG1632 34 30 16

WSG1240 45 22 16

WSG1224 30 22 16

WSG1020 25 21 17

Machine ground diagram

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3.4 Carriage and lifting machine

Use equipment to lift the machine as following.

Lifting: first fasten the sling bolts on the machine base, then set the wire cables

on the sling bolts and the hook.

3.5 Remove the setting plates

In order to avoid damage during transporting, the movable parts have been

locked. When the machine is positioned and no needing to change location

again, uncrating the lock blocks (refer to pictures)

1. Get off the tighten bolt which used to fix the saddle and work table

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3.6 Clean the machine

All the machines are provided with anti-rust treatment. The moving parts are

lubricated with grease and fixture point and dye black portions are applied with

anti-rust oil. Before first running the machine, clean all the slide ways, cylinder, spindle and surface which have been applied with anti-rust oil.

3.7 Placement of Hydraulic system and coolant tank

3.7.1. Placement of Hydraulic system

2. Move up the wheel head then get off the wooden block

3. Remove the antirust paper

covered around the hydraulic

piston rod. Clean the saddle slide

way.

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Connect the hydraulic pipe to oil tank. Right side is the oil Out the tank with high

pressure, left one the oil back to the oil tank.

Each one pipe connecting to the each point is Ok!

Fill in suitable oil (32# Hydraulic oil) through

the top of the tank.(capability of tank is about

110L)

Hydraulic Oil recommended: (32# hydraulic oil )

Brand China Petro MOBIL BP CASTROL ESSO GULF SHELL TOTAL

Model N32G DTE13 NO.2

Energo 1

SHF 32Hyspin AWH 32

UnivisN 32

Hydrasil Multi

Tellus T 32

EquivisZS 32

Note:

1. the hydraulic oil is filled in via the filling top at the oil tank, the pump for

the hydraulic oil will also be lubricated by it and should not run dry

otherwise it will be destroyed.

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2. Fill in oil until marking at oil gauge is reached.

3. Oil types are recommended according to the above list.

4. The oil filter should be changed for the first two month after starting

operation of the machine at the latest. After that changing the filter in the oil

changing cycle of two times a year in case of one shift operation is

sufficient.

5. The pressure of hydraulic system has been adjusted in factory before

delivery. Do not adjust it in normal condition.

6. The wasted oil should be disposed by special treatment procedures to

prevent pollution.

3.7.2. Installation of coolant system

1. Assemble the coolant collect slot box ( fixed by two screws)

2. Assemble the coolant collect pipe and tighten it

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3.8 power supply

Power: 3.7kw (WSG1020 Series)

9.0kw (WSG1224~1640 Series).

For the power supply wire, the 6.00 mm2×4 cable is advised.

3. Assemble the pipe to the

coolant pump and tighten it. You

can put the pipe into hot water for

a few minutes, make it easy to

install

Power wire connect to

the electrical box

Filter box. The coolant should

flow back into the box at first

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The electric connections must be carried through by an approved

electrical engineer only.

Before connecting the supply line, it has to be checked if the stated

operation voltage of the machine corresponds to the available power

supply voltage.

Machine must be connected to the ground in order to compensate the

internal power.

Connect to the suitable power according to the rated voltage

Connect the coolant pump and

oil pump power wire to the

electrical box.

For coolant pump

For oil pump

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In a short starting testing, the grinding wheel spindle must rotate

clockwise.

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Chapter 4 Trial running

4.1 preparation before trial running

4.1.1 Lubrication

A. Lubrication set

1) In order to maintain mechanical performance and life, choice correct

lubrication oil for lubrication system is necessary.

2) When the machine is on work, the lubrication pump auto intermittently

feed oil to all the lubrication points.

3) 32# guide way oil is advised.

4) Pay attention to if the pump motor is running, refill the oil in time.

B. Refill lubricant oil.

1) Open the cover, fill the cleaning oil in the tank through the filtering net

until to the FULL line.

2) Keep the oil clean.

3) If there are some sundries in the oil tank and the oil could be support,

please clean the filtering net right now.

4) If the oil is lower than the lower limit, refill the oil right now, if not, the

machine will stop.

5) Before working, please push the STARTUP button, after the machine

running about 20 minutes and the oil have been supply to all the guide

way, then start to working.

6) Look at the safety inspection items before running the machine.

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No Lubricate point Lubricating

mode Lubricant Times

1 V slide way of saddle Auto lubricating 32＃ slide way oil Adjustable

2 Cross feed screw Auto lubricating 32＃ slide way oil Adjustable

3 Lifting feed screw/nut Auto lubricating 32＃ slide way oil Adjustable

4 Front slide way of

column Auto lubricating 32＃ slide way oil Adjustable

5 V slide way of saddle Auto lubricating 32＃ slide way oil Adjustable

6 Back slide way of

column Auto lubricating 32＃ slide way oil Adjustable

7 Flat slide way of table Auto lubricating 32＃ slide way oil Adjustable

8 V slide way of table Auto lubricating 32＃ slide way oil Adjustable

C. Program of lubricating and oil feed adjusting.

Turn on the power, the lubrication pump is running, and the green DIS lamp

(running timing ) is shinning, this means the pump is running. The “running

timing” is over and the “ stop timing” is on work, and DIS lamp is dark and

the yellow INT lamp is shinning. The “stop timing” program is stopped, then

go to next cycle. If the oil is empty, the red EMG lamp will shine, this time

you should refill oil. The oil-feed adjustment by adjusting the running timing

knob DIS. TIME( the range from 2s to 90s) or the stop timing knob INT.

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TIME(the range from 2min to 30min). the shortest stop time should not less

than 2min. after setting, push the RESET button for confirm. THE TIME HAS

BEEN ADJUSTTED WELL BEFORE DELIVERY.

Lubricant recommended （32＃ slide way oil）

4.1.2 Hydraulic system

1) 32# hydraulic oil is advised for the hydraulic system. The hydraulic oil

tank should be cleaned in the first two month and change the oil, then

change the oil two times a year, when change the oil, cleaning the

filter at the same time.

2) the max. pressure is 3Mpa, the pressure have been adjusted well

before delivery, the operator need not adjusting the pressure.

Hydraulic Oil recommended: (32# hydraulic oil )

Brand China Petro MOBIL BP CASTROL ESSO GULF SHELL TOTAL

Model N32G DTE13 NO.2

Energo 1

SHF 32Hyspin AWH 32

UnivisN 32

Hydrasil Multi

Tellus T 32

EquivisZS 32

4.2 Safety inspection before operation

Be sure inspecting as following items before running the machine.

1) Clean the antirust oil from the machine.

2) Level the machine.

3) Fill in the lubrication oil regarding as the direction.

Brand China petro MOBIL BP CASTROL ESSO GULF SHELL TOTAL

Model 32# Vactra

Oil No.2

Maccruat Magna BD68

Febis K68

Slideway 68

Tonna TX68

Drosera68

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4) Check the spindle rotating and make sure the direction is clockwise.

Before check the spindle rotating direction, please remove the wheel,

because the spindle turning unticlockwisly is very dangerous.

5) Conform the oil tank is full enough.

6) Make sure the speed control valve is taken off.

7) Adjusting suitable travel by adjusting the position of these two “travel

adjusting block”

8) Check if all the fixed blocks have been took out.

9) When working the wheel cover should be never opened.

10) Check the pipes connected to the oil tank.

11) All above items have been checked , then look around and to find if there

is any other person in the working area, let him go to prevent from

danger.

12) The machine operating will be explained in next chapter.

13) Remember the position of the EMERGENCY SWITCH

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Chapter 5 Operation instruction

5.1. Control panel instruction

5.1.1 Control panel

1) AHD Series control panel（WSG818AHD ~ WSG1640AHD）

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5.1.2 control panel instruction：

1) AHD Series

SB0：Emergency switch

SB1：Power on push button / indicator lamp

SB6：Wheel head rapid down push button

SB7：Wheel head rapid up push button

SB8：Table cross rapid moving backward push button

SB9：Table cross rapid moving forward push button

SA2：Table cross movement mode (Manual/ Auto.) selecting knob

SA4：Wheel head down feed mode (rapid elevating/ jog feed /Auto. down

feed) selecting knob

SA5：Electro magnetic chuck ON/OFF knob

SA6：Value of wheel head auto. down feed selecting knob

SA7：Coolant pump/dust collector ON/OFF knob

VR ：Table cross intermittent feed adjusting knob

HL1：Grinding spindle motor working condition indicator (lamp)

HL2：Hydraulic pump motor working condition indicator (lamp)

HL3：Electric magnetic chuck working condition indicator (lamp)

HL4：Alarm light

HL5：Plunge grinding mode indicator (lamp)

HMI：Human machine interface

5.1.3 Switch function instruction：

1. Power on / off

push SB1, power on, lamp is shining. Push SB0, power off. If want to

power on again, first step turning the SB0 and make it up, then push

SB1, power on.

When push SB1, but the spindle could not start, may be cause by:

a. the lubricant is short

b. the circuit breaker is off

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c. creep age

d. transformer is bad.

2. Table longitudinal movement

a） Start the oil pump: turn the SA5 to “ magnetized “ position, the

electric magnetic chuck engaged, waiting for a moment then push Key

F6 on HMI, the oil pump start, Push F2, the oil pump stop.

when push the F6, the oil pump not start, may be cause by:

a. there is error of undercurrent rely in the circuit control chuck

(magnetizable or unmagnetizable) ; b. the oil pump motor circuit is

short

b） Table moving speed is control by an

Adjusting lever located on the top surface of

saddle. Turn the lever clockwise, speed

changing from low to high.

c） Table longitudinal movement reverse

the stroke is adjusted by moving these two

Reversing dog, while direction control arm touch the reversing block, the

table movement would reverse.

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If the table reversing dog D1/D2 bump against table direction control

arm C due to operator’s error operating or an long times using, control

arm will lost the correct position then cause the table unable to travel

automatically. In such case adjusting the control arm position as follows:

1) Turn L (speed controller) to close position to stop table movement.

2) Take away D1/D2 (reversing dog) or move it apart from C (reversing

control arm).

3) Take off the C from the S (shaft), turn S (shaft) making the

induction block against the proxi. Switch until the red lamp shining (on

switch), this means the shaft is on correct position. After that, reset C

(arm) on S make it on right position.

4) Turn L by left hand make the table moving on low speed, turn C right

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and left by right hand (about 15-20 degrees), if this can’t make the table

move right and left, reset C at other position and try again, by this way,

you can find the right position for C.

ATTENTION: be care for not clamping fingers by dogs and control

arm.

5) Then fix C well on S and tighten it.

NOTE: IF THE TABLE MOVEMENT IS NOT SMOOTHLY, MAY BE

THE OIL PIPE HAVE AIR, MAKE THE TABLE MOVE ON HIGH

SPEED FOR A MOMENT, THE AIR WILL GET OUT THE PIPE.

3. Table cross movement

a) Rapid movement

Table cross rapid movement: Rotate the pushbutton SA2 to” ”

“MANUAL” position, depress the pushbutton SB9, the table will move

rapidly to front, depress the pushbutton SB8, the table will move rapidly

to behind.

b) Table cross auto feed

Rotate the pushbutton SA2 to” “AUTO” position, depress SB8 or

SB9, the table will move automatically intermittent to frond or to behind,

Rotate clockwise VR, intermittent feed for saddle transverse can be shift

variably. Cross intermittent feed start and stop point can be set by

distance setting block located on the right side of saddle.

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The cross intermittent feed is control by AC motor controller in the

cabinet. On the Ac motor controller Panel, the “ set” key is for set the

feed rate. There are 4 shift !~4, feed rate: shift 1: 0.08~6mm; shift 2:

0.3~12mm; shift 3: 1.3-18mm; shift 4:2.7-24mm. if more than two or

three shift is on “ON” position, the low shift is working and others is no

work.

The AC motor controller has been adjusting well and is suitable for

the confirmed machine, please don’t reset it without the engineer’s

advising.

NOTE: for AHD model, only the grinding mode is set to “SURFACE

GRINDING” mode, the table can make cross rapid or intermittent

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feed. if the grinding mode is set to “PLUNGE GRINDING” mode the

table couldn’t make cross rapid or intermittent feed.

4. Wheel head vertical up / down movement

a) AH model: the wheel head can only up/down by manual and handwheel.

b) AHR model:

push the SB6 “ ” , the wheel head make step down feed

NOTE: when the spindle rotating, the function is no use.

Push the SB7 “ , the wheel head make step up feed.(on the up

limit position, there is an protect switch)

c) AHD model: rapid up/down feed, step-feed and auto down feed control.

1. Rapid feed:

turn the SA4 (Wheel head vertical movement mode selecting knob

(Jog-feed, rapid-feed, Auto feed) to “ rapid feed ” keep push on

the SB6 “ ” , the wheel head make rapid down moving

Push the SB7 “, the wheel head make rapid up moving.(on the up

limit position, there is an protect switch).

2. Jog-feed:

turn the SA4 to “Jog-feed ”, one push SB6 “ ” , the wheel head

make one step down feed, the feed value could be set by SA6

(Wheel head down feed value adjusting knob) from

0.0002/0.0004/0.0008/0.0016/0.002 in. push down SB7, the wheel head

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make rapid up moving.

Note: the when the machine is set on “ Jog-feed “ function, the

elevating Servo motor will be “ power on”, IT IS FORBIDED MOVING

THE WHEEL HEAD BY MANUAL (HAND WHEEL) !

3. Auto feed

Turn the SA4 to “ auto feed “ position, the wheel head will make

auto down feed, this function have two mode: “Surface grinding” or

“Plunge grinding” mode ( select by F3 and F7)

Note: the when the machine is set on “ auto feed “ function, the

lifting Servo motor will be “ power on”, IT IS FORBIDED MOVING THE

WHEEL HEAD BY MANUAL (HAND WHEEL) !

”SURFACE GRINDING” mode operating instruction

push F11 and select Surface grinding mode , turn SA4 to rapid feed

position → set feed rate and feed times by HMI F8F7F5 F6

F4F3F2F1

F16F15F14F13

F12F11F10F9ESC

ENTERSHIFT

TD400CSIEMENS

→ set

spark out feed by HMI F8F7F5 F6

F4F3F2F1

F16F15F14F13

F12F11F10F9ESC

ENTERSHIFT

TD400CSIEMENS

→ start the oil pump →turn the table

speed control lever make the table longitudinal moving→ start the

wheel head spindle → move the saddle and spindle head to the start

working position → turn the SA4 to Auto feed → push SB6

then the auto feed is start, the wheel head will make first down feed as

soon as the saddle inversing, until finish all steps down feed, then the

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30

wheel head make Spark out grinding, when all the feed is finished, the

wheel head would lift up (the travel can be set) auto and the spindle

motor and hydraulic pump motor are power off.

During the auto feed working, push “emergency switch” end the program,

the new auto down feed working should be reset again.

During the auto feed working, change to the manual mode to lift or down

the grinding head, then can go on the program.

”PLUNGE GRINDING” mode operating instruction（while Plunge

grinding mode is select, the lamp HL5 will light for warning）

press the Key F15 to Plunge grinding mode (the HL5 alarm lamp

will light), turn SA4 to rapid feed position → set feed rate and feed times

by HMI F8F7F5 F6

F4F3F2F1

F16F15F14F13

F12F11F10F9ESC

ENTERSHIFT

TD400CSIEMENS

→ set spark out feed by HMI F8F7F5 F6

F4F3F2F1

F16F15F14F13

F12F11F10F9ESC

ENTERSHIFT

TD400CSIEMENS

→ start the oil

pump →turn the table speed control lever make the table longitudinal

moving→ start the wheel head spindle → move the saddle to the start

working position ( for safety, the SB8 and SB9 is no used, you could

only move the saddle by manual) → move the wheel head to the

start working position → turn the SA4 to Auto feed → push SB6

then the auto feed is start, the wheel head will make first down

feed as soon as the table inversing, until finish all steps down feed, then

the wheel head make Spark out grinding, when all the feed is finished,

the wheel head would lift up auto and the machine is power off.

during the auto feed working, push “emergency switch” end the program,

the new auto down feed working should be reset again.

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31

4. Auto down feed stop and reset

while the autodown feed program is going, stop the working table by

speed control lever , the table and wheel head move stop, restart the

workig table longitudinal moving, the program resatart too.

While the autodown feed program is going, turn the knob SA4 to “jog

feed” position, the program is stop, and then the operator can

make grinding head down feed by SB6 , and if turn SA4 to “auto down

feed” mode again, push the button SB6 , the program will going on

again.

While the auto down feed program is going, push soft KEY F8, the

program will be cancel, and the grind head will lift up auto.

NOTE: WHEN USE THE PLUNGE GRINDING, MUST NOT MOVE THE

SADDLE AVOID WHEEL BROKEN AND THE CHIP ON HIGH SPEED

WILL DAMAGE THE PEOPLE!

Must not press the KEY F11 OR F15 by mistake while the auto.

down feed working in process

5. how to use the HMI

F8F7F5 F6

F4F3F2F1

F16F15F14F13

F12F11F10F9ESC

ENTERSHIFT

TD400CSIEMENS

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32

On the HMI panel there are 16 soft keys, F1~F8 can take effect by pressing

directly, F9~F16 take effect by pressing “SHIFT” key at first and then

pressing one key of them.

“SHIFT”: shift key, used to make F9~F16 take effect

1) Functions of soft keys:

F1—spindle motor stop F5--- spindle motor start

F2—hydraulic pump motor stop F6—hydraulic pump motor start

F11—surface grinding mode F15—plunge grinding mode

F4—set key used to set times of grinding feed and spark out grinding feed

F8—Reset key( fault resetting) F16—data setting confirm

2) Operating process

HMI start

When the machine is power on, the display of HMI will shining

F13 F14 F15 F16

F12F11

F8

F4F3

F7F6

F10F2

F9F1

SHIFT

ESC

ENTERF5

SIEMENS TD 400C

The system start-upplease for a moment.

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33

F13 F14 F15 F16

F12F11

F8

F4F3

F7F6

F10F2

F9F1

SHIFT

ESC

ENTERF5

SIEMENS TD 400C

F R C N Csurface grinder.

(default menu)

Set feed times for different feed rate 

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34

Press F4, HMI will show above menu, press arrow↑、↓to turn page,

press “ENTER”, the fist data will shining, the feed times can be set by

press arrow↑、↓ to increase or decrease times. Pressing “ENTER” to

confirm the data and then the second data shining, repeat the same

operating step to set the grinding times. And press “ ENTER” to confirm

until all the data was set. Then press F16 to make the data setting

effective.

Press “ENTER” directly without data reset, the cursor will move to

next data

Press “ESC” key, the date will be reset, and then press “ ENTER”, the

cursor will move to first data.

Program stop and cancel

while the autodown feed program is going, stop the working table by

speed control lever , the table and wheel head move stop, restart the

workig table longitudinal moving, the program resatart too.

While the autodown feed program is going, turn the knob SA4 to “jog

feed” position, the program is stop, and then the operator can

make grinding head down feed by SB6 , and if turn SA4 to “auto down

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35

feed” mode again, push the button SB6 , the program will going on

again.

While the auto down feed program is going, push soft KEY F8, the

program will be cancel, and the grind head will lift up auto.

3) Other operating

Under the default menu, press “ ESC” two times, the system will go into

“operator menu” and “diagnostic menu)

In the “diagnostic menu”, there are many important data, the operator

must not modify these data, for if the data be modified, the contact

between the PLC to HMI will be interrupt

Factory parameter of TD400 is list as follow

TD400 add. : 1

PLC add. 2

Parameter add. 200

Baud rate 187K( the real value is 187.5K)

HAS 31

GUF 10

Contrast ratio 40

In case of the data be modified by mistake, the engineer can reset the

data according to about parameter

NOTE: while HMI show Servo alarm, make HMI power off and then restart.

6. Wheel head spindle motor start

Turn the SA5 to “ magnetized” position , push F6 (HMI), start the oil

pump, then depress the F5, the spindle motor start (the HL2 alarm lamp will

light); depress F1, the spindle motor stop.

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36

after up steps, if the spindle motor would not start, please check the

undercurrent rely and oil pump control circuit and spindle motor control

circuit.

NOTE: There is a micro switch fixed on the inside of Wheel guard, if

the door have not been closed, the spindle motor could not start.

7. Start coolant pump

Turn the SA7 to position, the coolant pump start, open the valve

located on the right side of the wheel guard, the coolant will flow out. Turn

the SA7 to “stop position, the coolant pump would power off. (the dust

collector is optional equipment, if the machine is special equipped with dust

collector, turn SA7 to position, the dust collector is start)

8. Electro magnetic chuck operating

Turn SA5 to “ magnetized” position , the chuck on working(the HL3

alarm lamp will light); turn the SA5 to “ demagnetized ” position, the

chuck demagnetized; turn SA5 to “ stop” position, the chuck would

work.

NOTE: if the chuck suction force is low, may be caused by: VC is

broken which located in the Rectifier circuit.

If the chuck have no force, may be caused by:

1) the Undercurrent rely is broken

2) electric circuit is take off

3) the chuck is burned.

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37

5.2. Operating caution：

1) Before install of remove the wheel, shut off the power in advanced.

2) Don’t operate the grinding machine which have no wheel cover, it is

forbidden that opening the wheel cover while working.

3) Not move the work piece or put hand on the table before the wheel stop

4) Make sure that work piece is fixed on the table substantially.

5) Must not try to fix the work piece by hands.

6) The length and weight of the work piece must be lower than the rating.

7) Using the suitable wheel, dress the wheel often and keep the wheel

sharp.

8) Make hand and clothes far away from the table and wheel while

working.

9) And not try to connect any wire if you do not know well about the circuit

and electrical parts to prevent from damage.

10) Make the wheel free running about 5 minutes before working, don’t be in

the danger range.

11) The operator should dress the respirator and prevent glass while dry

grinding.

12) Not using the wheel which the speed is higher than rating.

13) Closing the wheel cover fixed before running the grinding head motor.

14) Be sure the feed is suitable, large feed will heat the work piece and

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38

reduce the motor speed.

15) Confirm the direction of wheel turning is same as indicated on the wheel

cover.

16) Confirm all the switch and button are on the shut off position before start

the machine.

17) Stop the table while adjusting the longitudinal travel.

18) Shut off the grinding head motor before cleaning the table after working.

5.3. correct operation of wheel

5.3.1 How to selecting suitable wheel

The wheel have tiny grain which is sharp and rotating at high speed, and

cutting variable kinds of material.

The mainly basic factor is as following

(1) Abrasive —— the cutter

(2) Bond —— make these grains one piece and could turn safely at a

high speed.

(3) Air hole —— the space between these grains, which could expel the

chip and have good processing surface.

All above factor form a whole wheel, it have these chapter as following:

(1) As the cutter, the grain is harden than the work piece, it can process

the tool steel and hard alloy steel, too.

(2) The passivated grains will fall off then the new grains appear.

(3) The grain is tiny and hard, using it can obtain good surface and

accuracy.

5.3.2 Notation of grinding wheel

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39

NOTE:

(1) Max Peripheral cutting velocity of the wheel must be higher than

limit speed of the wheel.

(2) The Peripheral cutting velocity of the grinding wheel (m/s)

=3.14×D(dia. Of wheel, mm)×N(spindle speed, r/min)÷60000

5.3.3 ABRASIVE

All the abrasives have themselves physics character, their hardness and

tenacity is deferent, choice proper wheel according to work-piece material.

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40

Sort of abrasive and using range

Name Code Color Using Range

Brown emery A (GZ) Brown

Grinding carbon steel, general alloy steel, malleable cast iron, hard bronze etc. especially suit grinding steel without quenched & quenched and tempered steel, suit rough grinding too.

White emery WA(GB) White Grinding quenched steel high-speed steel high carbon steel etc., which don’t suit grind roughly as the wheel waste more.

Mono-crystalline emery SA(GD)

White or canary yellow

Grinding stainless steel and high-speed steel & high intension and high tenacity material.

Micro-crystalline emery MA(GW) Brown Grinding stainless steel bearing steel and

special ductile iron

Chrome emery PA(GG) Rosy orMauve

Grinding alloy steel, high-speed steel, manganese steel etc. high intension material and suit the working procedure for high smooth

Black silicon carbide C(TH) Black Grinding iron, brass soft-bronze etc. soft

material.

green silicon carbide GC(TL) Green Grinding carbide, glass fibre reinforced

plastic etc. high hard material.

diamond RVD, MBDMP—SD Grinding carbide, glass fibre reinforced

plastic and pottery & porcelain material.

Cube boron nitride CBN Nigger-

brown

Grinding the high-speed steel, which is complex of quite a few chrome, tungsten, cobalt and series wearproof material .

5.3.4 GRIT SIZE

Express grain as grit size, express grit size as the number of sieve pore on

per inch length of sieve screen.

A general grit size of the wheel, which is used grinding surface, is 36-60, in

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41

general way, the grit size is smaller, the surface ground is better.

APPLICATION RANGE OF SERIES WHEEL GRIT SIZE

Grit size of gain Application range

14-24 Grinding steel ingot, iron burr, cutting off billet

36-60 Grinding general surface

60-100 Fine grinding and grinding edge

120-W20 Fine grinding, hone, screw grinding

below W20 Fine grinding, abrade, mirror grinding

5.3.5 GRADE

The grade of wheel is cohere degree of abrasive adhere to a wheel. The

soft wheel is express that abrasives break off easily from wheel, on the other

hand, the bond among the abrasive not only have cohere function, and fixing

abrasive function. The beat state is that the wheel has been blunted and sharp &

blunt has been balanced by itself, so as to choice grade of wheel is the most

important basic to gain better grinding effect.

THE GRADE OF WHEEL

Grade Over soft

Soft 1

Soft 2

Soft 3

MSoft

1

M Soft

2

M1

M 2

MHard

1

MHard

2

M Hard

3

Hard 1

Hard2

Over hard

Code 0 G H J K L M N P Q R S T Y

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42

GRINDING CONDITION AND CHOICE OF HARDNESS

Soft grad hard

Hard and brittle work-piece material soft and ductile

width interface narrowness

fast linear speed slow

Slow work-piece moving speed fast

Better mechanical precision badness

Experience operator inexperience

5.3.6 STRUCTURE

Express volume proportion among grain, bond, pore, separate three kinds

of structuredense structure, middle structure, open structure, 15 degree. Wheel

structure loosing affects directly grinding efficiency and surface grinding quality.

The pore not only obtain grinding crumb in the grinding process, and bring

cooling water and air into grinding area to cool, and reduce work-piece heating,

deformation, burning. If the pore is too big, grain per area would be less, the

outline of the wheel isn’t better circinal, which would affect surface roughness.

Middle structure is normal chosen.

5.3.7 BOND

The function of bond is to have kept intension cohere grain to the wheel for

long. Ensure the wheel is safe at grinding.

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43

Divide bond into:

(1) Vitrified bond, its purpose is abroad, combine degree and structure is

easy to adjust, chemical performance is better.

(2) Resinoid bond, is propitious to high speed rotate, has a bit stretch.

(3) Rubber bond, has stretch, is propitious to thin wheel

(4) Metal bond, is mainly propitious to make the wheel whose abrasive is

over-hard.

5.4. select perfect method of variously grinding

1) At first must choice proper wheel when grinding, method as follow:

a. high grinding efficiency

b. low wear of grinding wheel

c. gain perfect precision and machining quality

2) The basic considered choice grinding wheel

Definite basic:

a. the ground work-piece material

b. request precision and roughness

c. area of grinding interface

d. character of operating grinding

Variable basic:

a. speed of grinding wheel

b. feed

c. state of the machine

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44

d. operator’s skill

★ If ground material is steel or alloy, the abrasive usually be oxide, if it is

iron, non-ferrous metal or nonmetal, abrasive would be carbide. Fine grit

size abrasive is propitious to soft, high ductility material. Hard grinding

wheel grinds soft material, soft grinding wheel grinds hard material. The

grinding wheel of Dense structure grinds hard and brittle material, the

grinding wheel of open structure grinds soft and ductile material.

★ About precision and roughness, advise adopt high speed grinding to

gain a bit high precision and a bit low roughness, if use coarse wheel.

Adopt fine grain wheel to gain high precision and low roughness.

★ About interface, dense structure wheel is propitious to small interface,

whose grain is request fine and hard. Open structure wheel is propitious

to big interface.

★ Feed is faster, grinding press is heavier, the grinding wheel is request

harder, the opposite feed would automatically increase with table moving

speed increase at equal absolute feed speed, so as to the grinding

wheel wears fast, the wear would improve using hard grade wheel.

Note: Bigger for feed, more probability for the grinding wheel

breaks.

5.5. INSPECTION OF THE GRINDING WHELL

Must stand to the following safe regulation, the regulation is to assure

operator safe.

1) Should inspect the grinding wheel before fixed. In general way, it is well

to test the voice of the wheel. Use an mandrel passes the center bore of

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45

the wheel and supports the wheel, then lightly knock the wheel with

wooden bar, the wheel would have voices, if the wheel has broken, it

would have different voice, even we don’t see with our eyes. The perfect

wheel’s voice is very clear. The bad wheel must be forbid using.

2) Two absorbing-ink paper on the both side of grinding wheel can be as

spring cushion between the wheel and flange, don’t rip off when fixing.

Slightly slip the wheel to flange with hands, don’t force. The flange must

be cleaned, special orienting surface and fixing surface etc.

3) The grinding wheel is availably balanced, inside stress of the grinding

wheel can be eliminated, grinding precision and life of the wheel, spindle,

bearing are all in contact with whether fine to balance the grinding wheel.

For the purpose, general speaking, static balance is enough.

4) Take the grinding wheel, wheel flange and balance shaft on the balance

stand after have fixed, way of balance the wheel as follow:

a) The grinding wheel balance stand is leveled in one unit of a gradienter.

b) Let the grinding wheel roll freely until stop, then mark the heaviest

place with chalk.

c) Fix the first balancing weight at the place opposite to the mark place,

note it never to be moved again.

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46

d) Then fix two other balancing weights at symmetrically place, which is

at the same periphery and isogonal of the first one position, then rotate

the wheel 90° one times, test the wheel whether balance, if not,

remove the two balancing weight until the wheel comes to an entire

standstill at any place.

e) The wheel which has been balanced at the first time, should be fixed

to the spindle and dressed by a wheel dresser, then take down the

wheel and carefully balance again refer to above way, fix to the spindle,

dress the wheel until accurately. Even the balance better wheel would

be unbalance as wear, so should often test. If it is need the wheel

should be balanced again. The wheel should be trial run for 5 minutes

with normal grinding speed.

f) Don’t open cooling water when the wheel standstills, as the wheel can

absorb cooling water, otherwise the wheel should lose its balance. If

the wheel has been standstill for long, that would lose its balance as

water concentrate at the bottom of the wheel, so the wheel hasn’t turn

for some time after have ground, it would lose its balance too, at the

moment, drive it turn without feed, separate water from the wheel by

centrifugal effect, and come back its balance.

g) Should clean the taper of the spindle and wheel flange before the

wheel has be fixed to the spindle, then fix and lock down.

h) Replace different wheel with grinding different material, to exchange

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47

the wheel by take-down flange is uneconomical. We advise contact

with manufacturer of wheel flange, special order wheel flanges

according your condition.

5.6. WHEEL DRESSING & CORRECT USE OF WHEEL

DRESSER

1) The dresser can be fixed on the magnetic chuck or the table, inclination

between axis of diamond tool and vertical axis of the wheel is 5°, because

the wore part of diamond must be toward rotate direction of the wheel, so as

to the diamond keep sharp.

2) To change dressing speed of the wheel, can exchange grit size of the

wheel. If grinding 0.1-0.2mm thickness, rough grinding is well, that crosswise

moving speed of the wheel head increase, the diamond tool passes by the

wheel fast, so as the wheel can be chipped bigger, if fine grinding, crosswise

moving speed of the wheel head would be slower, dress 2-3 times, feeding

0.01mm per times.

3) The diamond is easy to break, even to be hit lightly, because it is brittle

and hard.

4) When dressing, the diamond tool should dress from middle of the wheel,

because the both side of the wheel wear more, if dressing from both side of

wheel, there would be heavy press to result the wheel break accident.

5) When the diamond has wore, should be rollback, the diamond would

keep sharp, and could be continuously used.

6) If the wheel is not dressed, even the wheel get the great quality which

can not do the high precision on the workpiece. So for the higher grinding

performance, the wheel dressing is very necessary. The operators must

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48

handle the well wheel-dressing technic, and make sure the wheel get the

high performance at any time.

7) The wheel dressing is the process of making the wheel sharp. In this

process, we need to remove the agglutinant and the grains,so that the

grains will come out from the agglutinant and form the sharp tool. The wheel

dressing is also need to remove the macro materials in the holes, so that to

avoid the grinding force increment of the wheel to make the damage on the

workpiece surface.

8) In the wheel dressing, we need the diamond pen, the machine get the

diamond pen base as a standard accessories. The diamond pen is the

optional accessory.

9) The wheel dresser need to be treated very carefully, because it consists

by the diamond which is very sensitive about the shake or crash.

10) The wheel dressing can be done by the diamond pen base or the

parallel dresser (the parallel dresser is the optional accessory)

11) When the wheel dressing is going by

the diamond pen base, we can hold it by

the electro magnetic chuck or clamped on

the worktable. There is 5°-15°angle

between the center of diamond pen and

the wheel, so that can make the diamond

pen very sharp. If the diamond pen is not

sharp, the operator can turn the diamond

pen at 180°and use it. The touch point between diamond pen and wheel is

less than the wheel axial line 0.5-2mm to avoid the diamond pen prick into

the wheel.

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49

12) In the wheel dressing, please let the diamond pen do the movement in

constant speed. If the roughness of the wheel require more low, the speed

will be more slow. The total quantity of the wheel dressing is 0.1mm in single

section, and repeat several times. The rough dressing is about 0.01-0.13mm

every time, and the accurate dressing is less than 0.01mm. Please start the

dressing from the wheel center, because the two edges consumption of the

wheel is more. If the dressing is starting from the two edges, it will cause the

diamond pen break.

13) In the wheel dressing the operators need to add the coolant which can

make the dressing fast and more efficiency. The suitable coolant can remove

much heat from the dresser, and increase the diamond pen working life.

Please make the coolant clean so that the coolant can be used for many

times. Before the off daily work, please turn off the coolant and let the wheel

run few circles so that to avoid the wheel break.

14) In the wheel dressing, please reduce the shake to avoid to make the

scratches on the workpiece surface. That is very important. It is necessary to

make the wheel balance very well. At the same time, please avoid the shake

from the machine so that to make sure the most min. pendency and the

dresser fixed on the base tightly, then the dresser gets the enough stiffness.

If the diamond pen is not fastened very tightly, which will cause the shake

and noisy, then the workpiece will get the some scratches or waves and also

the dresser will get the damages.

5.7. BALANCING WHEEL

The grinding wheel must be dressed before balancing.

The balancing method is according to the operation of the bubble balancing

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50

racket. As shown:

1. Let the wheel rolling on the stand freely to

find out it is gravity center “S” and mark it with

chalk.

2. Insert a balancing weight on the opposite “G” of “S”, rotate

the wheel 90°to find out “S” or “G” side is heavier.

3. Insert another two balancing weights at lighter side points”

K” which are of the same circle surface as “G” point.

4. Rotate the wheel 90° to check the balance of the wheel. If

it is still out of balance, readjust two weights “K” position until

grinding wheel is really balanced. When grinding work pieces

with different materials, change the wheel together with its

flange to save the time required for balancing the wheel.

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51

Chapter 6: Daily maintenance

6.1. daily inspection (oil & coolant)

警告

工作台运动中，禁

止操作人员探头进入工

作区观看工件，以免造

成挤压的危险。

position Oiling model

inspection time Oil advised remark

Lubricate unit oil for guide-way daily 32# oil for guide-way

Hydraulic unit Hydraulic oil monthly 32#hydraulic oil

Spindle Heat-resistant grease Never Need not change

Cooling unit Cutting fluid Every three month

Total composed cutting fluid

Note:

1) The new machines have used for three months, should exchange

hydraulic oil of hydraulic unit, then clean oil tank and exchange

hydraulic oil per year,.

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52

2) Clean oil filter of the oil tank half year. (exchange if need)

3) Clean and exchange cooling water of the coolant tank according your

condition (exchange every three months at least)

6.2. daily inspection (test list before operating)

Item Test content Machine state Test

modelTest

period Test standard Before starting

After starting

1 Lubrication unit √ visual daily Lubricating oil is over lower limit line

2 Table speed control handle √ visual daily Minimal state

3 Grinding wheel √ visual daily 50mm far away to work-piece

4 Hydraulic unit √ visual daily Shut off

5 Cooling unit √ Visual daily Shut off

6 Spindle motor √ Visual daily Shut off

7 Wheel protecting cover √ Visual daily Closed and locked

8 Electric control box √ Visual daily Closed and lock

9 Running Direction √ Visual daily Clockwise

10 Warm-up √ Visual daily About 30minuts

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6.3. daily inspection (test list after work)

Item Test content Machine state Test

way Test

period Test standard Running Power

off

1 Lubrication unit √ visual daily Lubricating oil is over lower limit

2 Spindle motor √ visual daily 50mm more to work-piece

3 Urgent push-button √ visual daily Shut down state

4 Power supply switch √ visual daily Power off

5 Oil pressure unit √ Visual daily Stop

6 Cooling unit √ visual daily Stop

7 Table surface √ visual daily Shut down and clean

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Chapter 7: Setting, Adjusting and trouble shooting

7.1. there are ripples on the work piece

Cause :

1) The wheel is not well balanced — balance again.

2) The abrasive is not suitable to the work piece material — select

suitable wheel again.

3) Space between the grinding head pressboard and the column guide way

— adjusting the slide wedge again.

4) The hook bolt is loosing — tighten again.

5) The table backward or forward feed is not suitable.

6) Oil shortage on guide way.

7) The spindle running out of the way

8) The wheel is too blunt — dressing the wheel again.

7.2. Accuracy of the work piece ground is not so good

Cause:

1) The grind wheel is not suitable to the work piece

2) The machine was not leveled very well

3) The speed of cross and longitudinal moving is not suitable.

4) Space between the grinding head pressboard and the column guide way

5) The guide way need lubricating

6) The surface of the magnetic chuck is not so good.

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55

7.3. The spindle don’t run.

Cause:

1) The electro magnet doesn’t work

2) The fault of the power switch

3) The wheel guard is not closed well.

4) The control wire is loosened.

5) The coupling of the spindle is broken

6) The fault of spindle motor

7) The lubricating pump is short of oil.

8) The hydraulic pump is shut off.

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Parts list of Electrical circuit

No  Code  Name  Spec.  Qty  Remark 

1  QM1  Breaker  3UV1340‐1MN00(14‐20A)  1  Siemens 

2  QM2  Breaker  3UV1340‐1NL00(8‐13A)  1  Siemens 

3  QM3  Breaker  3UV1340‐1MF00(0.6‐1A)  1  Siemens 

4  QM4  Breaker  3UV1340‐1MJ00(2.4‐4A)  1  Siemens 

5  QM5  Breaker  DZ47‐63/2P D6  1  Siemens 

6  QM6‐7  Breaker  DZ47‐63/1P D6  2  Siemens 

7  QM8  Breaker  DZ47‐63/1P C1  1  Siemens 

8  KM1  Contactor  3TB4322‐OXB0  1  Siemens 

9  KM0‐8    Contactor  3TB4022‐OXB0  9  Siemens 

10  KA0 KA4  Middle rely  MY2NJ‐AC24V  2  OMRON 

11  KA1‐8  Middle rely  MY2NJ‐DC24V  5  OMRON 

12    AC motor controller  SQ‐02A  1  Zhuozhuo 

13  EL1  Working lamp  Jl50B  1  Sanying 

14  PLC    6ES7214‐1AD23‐0XB8  1  SIEMENS 

15  TD400  HMI  6AV6 6640‐OAA00‐OAX0  1  SIEMENS 

16    Power switch  S‐100‐24  1  Mingwei 

17  SQ1‐2  Travel switch  TZ‐6004  2  Tend 

18  SQ3‐4  Travel switch  JLXK1‐411  2  Delixi 

19  SQ5  Travel switch  YBLX‐19/001  1  Delixi 

20  SQ7  Travel switch  TZ‐3101  1  Tend 

21  SB0  Emergency switch  LA38‐11MXS/203  1  Changjiang 

22  SB1/6/7  Button with lamp  LA38‐11D/203 绿  3  Changjiang 

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23  SB7‐8  Button  LA38‐11/203绿  2  Changjiang 

24  SA2  Knob  LA38‐31X2/203  2  Changjiang 

25  SA4  Knob  LA38‐21X3/203  1  Changjiang 

26  SA5  Knob(auto reset)  LA38‐20XL3/203  1  Changjiang 

27  SA6  Waveband switch  DPN01N‐30°  1  Dongce 

28  HL1‐3  Indicator lamp  AD11‐16/21‐6GZ(绿)  4  Changjiang 

29  HL4  Indicator lamp  AD11‐16/21‐6GZ(红)  1  Changjian 

30  SQ6  Approach switch Bi2‐M12‐AZ31X 

(AC20‐250V3‐100MA. DC10‐300V63‐100MA) 

1  Tuerke 

31    Servo diver  ASD‐A0421‐AB  1  Taida 

32    Servo motor  ECMA‐E31305ES  1  Taida 

33  QS  Switch  JFD11‐32/300030  1  Yaming 

34  VR  Potentiometer  WTH118‐47KΩ 2W  1   

35  KI  Undercurrent rely  JL18S‐2.5A  1  Tenglong 

36  VC  Rectifier  QL20A‐500V  1   

37  R1 R2  Resistance  ZG11‐50‐T1000Ω  2   

38  TC1  Transformer JBK5‐630VA/220V380V/127V(400VA) 、

110V(50VA)、24V(180VA) 1  Jiuchan 

39  TM2  Transformer  JSG‐1KVA/220V，380V/220V  1  Jiuchuan 

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Circuit diagram

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Table assembly structure

NO. Parts name Machine model Parts Code name Qt.

1 Table extend guard

WSG1225 FSG3063R-30-304

2 WSG1632 FSG4080R-30-308 WSG1240 FSG30100R-30-311 WSG1640 FSG40100R-30-301

2 Splashing guard

WSG1020 FSG2550R-30-303

1 WSG1225 FSG3063R-30-303 WSG1632 FSG4080R-30-301 WSG1240 FSG30100R-30-303 WSG1640 FSG40100R-30-300

3 Table

WSG1020 FSG2550R-30-100

1 WSG1225 FSG3063R-30-100A WSG1632 FSG4080R-30-100 WSG1240 FSG30100R-30-100A WSG1640 FSG40100R-30-100

4 Right transverse adjusting dog All SG Aseries grinders FSG2050M-30-102 1 5 Left transverse adjusting dog All SGAseries grinders FSG2050M-30-103 1

6 Table manual feed rack

WSG1020 FSG2550R-30-300

1 WSG1225 FSG3063R-30-300 WSG1632 FSG4080R-30-300 WSG1240 FSG30100R-30-300 WSG1640 FSG30100R-30-300

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Column structure

No Code Name Qt.

1 FSG4080R-12-300 Fixed Guard 1

2 FSG4080R-12-304 Movable guard 2

3 FSG4080R-12-301 Dust-proof plate 1

4 FSG4080R-12-500 Bellow Plastic guard 3

5 FSG4080R-12-303 Dust-proof clamping strip 2

6 FSG2550R-12-100 FSG4080R-12-101 FSG30100R-12-100

Grinding spindle housing 1

7 FSG4080R-12-305 Upper cover-plate 1

8 FSG4080R-12-100 column 1

9 Column rear guard 1

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Table longitudinal manual feed structure

No. Code Name Qt.

1 FSG-30100R-23-302 FSG-4080R-23-305 Gear shaft 1

2

FSG-3063R -30-300 FSG-2550R -30-300 FSG-4080R -30-300 FSG-30100R -30-300A

Rack 1

3 61204－2Z(17×30×7)GB/T276-94 Deep-furrow ball bearing (61204)

2

4 FSG-30100R -23-101 FSG-4080R -23-103

Manual shaft bracket on longitudinal 1

5 FSG-30100R -23-304 FSG-4080R -23-311 Driven shaft sleeve 1

6 FSG-2050M-23-306 Spring 1

7 FSG-2050M-23-202 copper sleeve 1

8 FSG-2050M-10-503 Hand wheel 2

9 M12/J13-2B Acorn nut 1

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Cross feed structure

No Code Name Qt.

1 FSG-4080R-23-313 Washer 1 2 FSG-2050M-23-503 Hand wheel 1 3 FSG-2050M-23-302 Bearing cover 1 4 FSG-4080R-23-316 Feed dial 1 5 M818-10-312 Knurling set screw 1 6 FSG-4080R-23－307 Spacer 1 7 FSG-2050M-23-304 Sleeve 1 8 FSG-4080R-23-104 Vernier dial plate 1 9 M20×1.5/J14-4B Round nut 1

10 3204A (47×20×20.6)/GB/T292-94 Bearing 1 11 FSG-2050M-23-106 Small timing pulley 1 12 FSG-2050M-23－105 Big time pulley 1 13 187L075/GB11616-89 Timing belt 1 14 FSG-2550R-23-300

FSG-4080R-23-300 FSG-30100R-23-300

Cross lead screw 1

15 KT516 Cross feed motor 1 16 FSG-4080R-23-101 Feed nut bracket 1 17 FSG-30100R-23-301

FSG-4080R-23-310 Cross lead screw safe shield 1

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Elevating structure

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Parts list of elevating structure

No Code Name qt. 1 FSG-4080R-23-313 Washer 1 2 17*250/HY8313.7 Hand wheel 1 3 FSG-3063R-10-310 Vertical feed dial 1 4 FSG-3063R-10-315 Vernier dial 1 5 FSG-4080R-10-311 Dial sleeve 1 6 FSG-4080R-10-315 Spacer 1 7 50/GB893.1 Retaining washer 1

9 6204－2Z(20×47×14)GB/T281-94 Deep-furrow ball bearing (6204) 2

10 FSG-4080R-10-314A Bearing base 1 11 Cover plate 1 12 FSG-4080R-10-103 transmission box 1 13 FSG-3063R-10-102 Vertical belt pulley(big) 1 14 203L075/GB11616-89 Timing belt 1 15 FSG-3063R-10-307 Small pulley 1 16 FSG-3063R-10-102 Fixed plate for lifting motor 1 17 YS71M2-6-B5 Motor 1 18 FSG-3063R-10-101 Extension shaft bracket 1 19 M25×1.5/J14-4B Round nut 1 20 FSG-3063R-10-304 Bearing cover 1

21 1205(25×52×15)GB/T301-95 Double-row self-aligning bearing (1205) 1

22 FSG-3063R-10-303 Washer 1

23

FSG3063R-10-302 FSG4080R-10-302A FSG30100R-10-300A FSG40100R-10-300

Vertical shaft 1

24 6204－2Z(20×47×14)GB/T281-94 Deep-furrow ball bearing (6204) 2

25 FSG-2050M-10-305 Bevel pinion 1 26 FSG-4080R-10-303 Vertical screw 1

27 FSG-2050M-10-306 Bevel gear 1

28 6204－Z(55×90×18)GB/T286-94 Deep-furrow ball bearing （6204） 1

29 FSG-4080R-10-105 Drive base 1 30 M40×1.5/J14-4B Round nut 1 31 FSG-2050M-10-200 Vertical nut 1 32 51108(40×60×13)GB/T301-95 Thrust bearing(51108) 1 33 FSG-4080R-10-104 Connecting plate 1 34 FSG-4080R-10-106 Top guard 1

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HYDRAULIC CYLINDER

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HYDRAULIC CYLINDER No Code Name Qt. 1 M16×1.5/J11-1B Hexagonal nut 4 2 SG-4080AHR-53-300 Washer 4 3 SG-4080AHR-53-500 Cushion 2 4 SG-4080AHR-53-301 Driven base 2 5 M12×40/J21-9B Socket head cap screw 8 6 12/J54-1B Spring washer 8

7

SG2550AHR-53-301 SG3063AHR-53A-301 SG-4080AHR-53A-302 SG30100AHR-53-301

Piston rod 2

8 M6×20/J21-9B Socket head cap screw 6 9 6/J54-1B Spring washer 6

10 SG-4080AHR-53A-301 End cap 2 11 AD48-20×28×5.3 Dust-proof ring 2 12 MA30-20×28×6.3 Y-shaped ring 4 13 SG-4080AHR-53A-100 Hydraulic cylinder bracket 2 14 12/J54-1B Spring washer 4 15 8×35/41-2B taper pin 2 16 M12×40/J21-9B Socket head cap screw 4 17 40/G52-2 O-shaped ring 2 18 SG-4080AHR-53A-304 Guard cover 2 19 M6×20/J21-9B Hexagonal socket screw 8 20 6/J54-1B Spring washer 8 21 SG-4080AHR-53A-303 Ring 2

22

SG2550AHR-53-300 SG3063AHR-53A-300 SG-4080AHR-53A-306 SG30100AHR-53-300

Hydraulic cylinder 1

23 6×30/41-2B Taper pin 2 24 SG-4080AHR-53A-305 piston 1 25 K30-40A Hermetic ring 1 26 FUR02-8.1×2.5-40-D24 Guide ring 2

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Spindle unit

Parts list spindle unit

No Name qt. 1 Grinding wheel shield 1 2 Lock screw 3 3 Balancing block 3 4 Grinding wheel 1 5 Spindle 1 6 Plug 2 7 Spindle housing 1 8 Coupling connect to motor shaft 1 9 Gjb

10 Clamping plate 1 11 Motor assembling flange 1 12 AC motor 1 13 Gib 1 14 Plastic insert 1 15 Coupling connect to the spindle 1 16 Gib 1 17 Plug 1 18 Wheel flange base 1 19 Wheel flange clamping cover 1 20 Lock nut 1

Packing List

PACKING LIST 1.

No Name G.W. 1 WSG1640AHD 3800KG

2.

No Name Qt. 1 Oil tank 1pc 2 Coolant tank 1pc

3. Accessories

No. Name Code Qt. Remark

1 Balance arbor FSG2550R-86-301/302 1pc In the tool box

2 Wheel dresser base 1pc In the tool box

3 Wheel Flange Suit for 350*40*120 1 set In the carton

4 Leveling wedge 1set In the tool box

5 Tool box 1pc

6 Wrench body Handle Wheel extractor

FSG2550R-86-303 1pc In the tool box

7 M7130-8016 1pc In the tool box

8 Screw drive 150 1pc In the tool box

9

Wrench for hexagonsocket

head screw

4/S91-7 1pc In the tool box

10 5/S91-7 1pc In the tool box

11 6/S91-7 1pc In the tool box

12 8/S91-7 1pc In the tool box

13 10/S91-7 1pc In the tool box

14 Adjustable wrench 200 1pc In the tool box

15 Wheel P350×40×127 WA46L5V35 1pc In the carton

16 Electro magnetic chuck 400*1000mm 1pc On the

worktable 17 Dust brusher 1pc In the tool box

Packing List

4. Optional accessories No. Name Code Qt 1 Balance stand

2 Parallel wheel dresser

3 Digital readout

4 Magnetic separator

5 Paper filter

6 Diamond pen

5. Documents

No Name Qt 1 Operating manual 1 copy 2 Packing list 1 copy

Inspector：

Y M D