Bernhard EXPRESS DUAL 4000 Manuel utilisateur

EXPRESS DUAL 4000 MANUAL

EXPRESS DUAL 4000

Please read this manual carefully before using the Express Dual.

This manual should be kept in a safe place so that it can be used for future reference.

ED4000 Automatic Spin Grinder

User’s Guide &

Instruction Manual - Issue 01

Machines SN:- 20343 - Onwards

EXPRESS DUAL 4000

NOTES

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EXPRESS DUAL 4000

EXPRESS DUAL

Contents

BERNHARD AND COMPANY LTD

Bilton Road • Rugby • England • CV22 7DT

Tel +44 1788 811600 • Fax +44 1788 812640

Email: info@bernhard.co.uk

USA Toll Free 1-888 GRIND IT (1-888 474 6348)

ED4000 Precision Reel/Cylinder Grinder

You are now the owner/operator of a Bernhard’s Express Dual 4000 which, if cared

for and operated correctly, will give you years of good service.

This manual will enable you to obtain the best results from your Express Dual so

please read it thoroughly before using your machine.

If you have any service or operational problems contact your distributor,

or phone our

Technical Helpline (USA only) – 1-888 474 6348

or

Bernhard and Company Ltd, England – (+44) 1788 811600

or email

[email protected]

use the technical support feedback form on our web site

www.expressdual.com or www.bernhard.co.uk

Identication of Pictograms 4

Safety 7

Installation 8

Identication of Tools and Equipment 10

Understanding the Machine 11

In Frame Grinding 13

Electrical Fault Finding 21

Maintenance 23

Part Lists and Exploded Diagrams 26

Wiring Diagrams 44

Lift Table Instructions 51

Express Dual 4000 – 1012.4

Please quote this serial number on all

correspondence:

Serial #:

EXPRESS DUAL 4000

BEWARE! HIGH VOLTAGE

1. IdenticationofPictograms

1

5

4

7

6

8

9

10

811

11 10

12

2

5

3

6

7

13

14

15

16

17

20

18

19

21

20

23

24

25

24

22

26

30

MAXIMUM LIFT PLATFORM

LOAD - 250 KG (550 LBS)

BEWARE!

TRAPPING FEET OR OTHER OBJECTS

WHEN LOWERING LIFT PLATFORM

MAXIMUM GRINDSTONE

DIAMETER 150mm

MAXIMUM SPEED 2200 Rev/Min

BEWARE!

MOVING GRINDSTONE AND SHAFT

REEL ROTATING AT BETWEEN

147 AND 255 Rev/Min

TOTAL WEIGHT OF MACHINE (KG)

EXPRESS DUAL 4000

WEAR EYE, EAR AND BREATHING

PROTECTION

1. IdenticationofPictograms (Continued)

POINTS FOR ATTACHING

LIFTING EYES

BEWARE!

MOVING COMPONENTS KEEP HANDS

AND OTHER OBJECTS CLEAR

GRINDSTONE START CONTROL

REEL START CONTROL

STOP CONTROL

TRAVERSE START CONTROL

ENGAGE / DISENGAGE (INCREASE /

REDUCE) GRINDSTONE FEED

EXPRESS DUAL 4000

Emergency Stop

(Twist to release)

Unclamp

Clamp

Reset Display

Traverse

On/Off

Reel (Spin)

DriveOn/Off

Grindstone

On/Off

Position

Value

Display

Balance

Indicator

Service

Switch

Reel (Spin) Drive

Speed Control

EXPRESS DUAL 4000

2.1 This machine is designed and manufactured ONLY for grinding lawn mower reels, rollers,

groomers and verticut units, and MUST NOT be used for any other purpose.

2.2 This machine should be installed, operated and maintained by competent personnel who

have received adequate training.

2.3 Before carrying out any work on the machine, other than grinding, ALWAYS SWITCH OFF

the main electrical supply, or remove the power lead from its socket.

2.4 ALWAYS operate the machine with the guards in position.

2.5 NOISE - Owing to the widely varying conditions of use, noise emissions may vary

considerably. There may be occasions when the safe noise level may be exceeded (see

note on noise emission). In this case adequate ear protection MUST be worn.

2.6 NEVER t or use a grinding wheel (or other spares) other than those supplied specically

for use on the EXPRESS DUAL (Warranty will be invalidated).

2.7 NEVER t or use a grinding wheel which has been dropped or subjected to any other form

of abuse.

NOTE: Grinding wheels should be tted ONLY by competent, trained personnel.

2.8 NEVER leave rags or tools on the machine or wear any loose clothing or other articles

which could be caught in moving components.

2.9 NEVER allow any combustible materials to be placed on or around the machine.

2.10 ALWAYS ensure that all parts of the cutting unit being ground are securely xed.

2.11 ALWAYS ensure that all electrical connections are sound and all cables are safely routed.

2.12 ALWAYS carry out cleaning and maintenance of the machine as instructed in this manual

(Refer to safety note 2.3).

2.13 STAY ALERT. Watch what you are doing. NEVER operate the machine when tired, or

under the inuence of drugs or alcohol.

If a lift table is fitted NEVER attempt to lift in excess of the rated capacity, and always

ensure that the area is clear before lowering the load.

2. Safety

EXPRESS DUAL 4000

3. Set Up and Installation

Fig: 3.2

3.1 Handling

If the machine is crated, it can be moved by a suitable fork lift truck or pallet truck under

the pallet (skid). Once the lid and sides of the crate are removed, a fork lift truck may be

used under the lifting members of the machine chassis.

The machine can be lifted off the pallet using suitable lifting tackle through 4 lifting eyes

(provided) tted at the points indicated on the top corners of the machine.

The total weight of the machine is indicated on the machine plate.

3.2 Location

The machine should be located in a well lit environment with adequate headroom. For

ideal operation, the machine should be accessible from the front, rear and at least one

side, with clearance around it as indicated in the sketch (Fig. 3.2).

1.5m (5 ft)

ENSURE ADEQUATE SPACE FOR

LOADING UNITS AND FOR A LIFT

TABLE (IF FITTED)

FRONT OF MACHINE

3.3 Leveling

The machines should, ideally, be placed on a solid level oor, and this should be checked

by placing a spirit level on the table. Check the level in both directions. Steel shims should

be placed under the feet as necessary to ensure that the machine is rm and level. Bolt

holes are provided in the feet which can be used for xing down if required.

NOTE Ensure that the packing under the feet is correct before tightening the bolts, otherwise

twisting of the frame may occur.

EXPRESS DUAL 4000

3.4 Electrical Supply

USE A QUALIFIED ELECTRICIAN

The EXPRESS DUAL is supplied with a .75 kW (1 HP) single phase main (grind) motor

plus 2 fractional HP motors, for spin and traverse.

Power connection to the machine is via plug and socket termination of the lead supplied.

Connection is at the rear of the main electrical control box on the right hand end of the

machine.

Ensure that any cable or conduit run to the machine does not constitute a hazard to the

operator or other personnel.

Machine should be connected to the supply via a 20A breaker.

The top of the reel and the top of the grinding wheel should both move away from the

front of the machine (i.e. both rotate clockwise when viewed from right hand end of the

machine). In this way, the reel and grinding wheel are moving in OPPOSITE DIRECTIONS

at the point of contact.

3.5 Preparation

If the machine has been

received in a crate, the handles

on the control wheels should be

removed from the underneath of

the control wheels and retted to

the top (see Fig. 3.5).

It is important that the protective

film on the main shaft is

removed prior to using the

machine. This can be done

using a WD40 or similar product

(not gas/petrol) and then drying

the shaft with a clean, dry cloth

so that the grinding wheel

assembly moves freely along

the whole length of the shaft.

A spray lubricant, such as WD40, should be applied to all bare metal surfaces and moving

parts; this includes the reversing bar and the shafts (along which the fork assembly

traverse, but NOT THE MAINSHAFT).

The mainshaft should be washed down as instructed in the maintenance section of this

manual. The feed control screws are normally coated with molycote, and may be washed

down with WD40 if required and recoated with molycote (or similar anti friction coating)

when dry.

Fig: 3.5

3. Installation (Continued)

EXPRESS DUAL 4000

4. IdenticationofToolsandEquipment

The items below may not necessarily be included since the tools and equipment

suppliedwillvaryaccordingtothemachinespecication.

4.1 Express Dual 4000 and 4000DX (see illustrated parts list).

A4066 Long 1/2” AF Ball handled Allen Key

A2706 3/16” AF Tee handled Allen Key

A2719 Grinding Wheel Nut Wrench

A2720 1/2” AF Allen Key

A2714 Adjustable Sprocket Driver

A9182 Drive Rod Plain (short)

A4134 Drive Rod Square (short)

A4063 2 Pin Drive (large)

A4276 2 Pin Drive (small)

A9181 3 Pin Drive (small)

A4097 Adjustable Plain Shaft Driver

A2712 8mm Long Series Allen Key

A6161 1/8” Allen Key

A4087 Channels for Multix Brackets

A6342 Backing up/Pressure Plate (not shown)

A4106 Ransomes 5/7 Driver (Standard only on European units)

A6737 Diamond Dresser

A9500 Adustable Front Roller / Multix Brackets

Bernhard EXPRESS DUAL 4000 Manuel utilisateur

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