proth psgs manual

7/24/2019 Proth Psgs Manual

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PROTH INDUSTRIAL CO., LTD.

PSGS INSTRUCTION MANUAL

SURFACEGRINDERS

PSGS INSTRUCTION MANUAL AND PART LISTS


No. 20, 9thRd., Taichung Industrial District, Taichung 407, Taiwan

TEL: +886-4-2358-3131

FAX: +886-4-2350-3131

E-MAIL:[email protected]

WWW.PROTH.COM.TW
mailto:[email protected]:[email protected]:[email protected]://www.proth.com.tw/http://www.proth.com.tw/http://www.proth.com.tw/mailto:[email protected]


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PSGS INSTRUCTION MANUAL P.2 OF 57

PREFACE

1. This instruction manual is for PROTH PSGS series ONLY.

Please keep this manual in a safe place where operators can

easily access to when necessary. Please read this

instruction manual carefully before operating PROTH

machine.

2. Please check the serial No. of machine which should be the

same as the number indicated on the accuracy table of th is

manual.

3. Please follow the instruction manual for operation and

maintenance. Do not change any ci rcuits, functions and

parts of machine without approvals from PROTH. Please

note that PROTH will not take any responsibili ties for these

faults.

4. Since PROTH subscribes to a process of continuous

improvement for our products, designs and specifications

are subject to change without notices.

5. Please check the machine and its accessories right away

after unpacking. If there are any problems, please do not

hesitate to contact us directly.


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SAFETY INSTRUCTIONS

1. Avoid using any improper work pieces.2. The grinder can only be operated or maintained by eligible persons who

have trained for handling grinding machines.

3. On-site safety training is required for both operators and troubleshooters.

4. The buyer shall remind their operators to follow the safety instructions at

all times.

5. Please read the instruction thoroughly before using the machine. If there

are any queries about the machine, please contact our local

representatives or us directly. Do not attempt to overcome any machine

problems by yourself.

6. Make sure the main power source of machine is properly shut down during

maintenance.

7. Do not measure, move or exchange work pieces when a work ing table is

moving or the wheel is rotating / approaching to the work pieces.

8. DONT remove grits or dirt from machine until the grinding process is fully

finished.

9. Before turning on the spindle, make sure the grinding wheel is fastened on

the spindle and the rotating direction of wheel is matching the direction on

the cover. Let the wheel run idly for at least 5 minutes before grinding any

work pieces.

10. Be famil iar to all switches, especially the emergency stop button.

11. Goggles, masks and working boots are required whi le operating

machines.

12. Neckt ies, gloves, and unsuitable work suits like long sleeves and loose

garments are not allowed whi le operating the grinder.

13. Hair tie or hat is required for longhaired operators .

14. Keeping a clean and dry environment around machine can prolong the

machine service life.

15. Keep the chuck surface clean. If it is scratched, re-grind it immediately.

16. It is obligated to wear gloves whi le loading sharp work pieces. Please use

cranes for loading bigger-sized work pieces, especially the ones are over


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25 kg.

17. DONT make any table adjustments whi le machine is stil l funct ioning.

18. Stabilize work pieces before grinding.

19. To avoid any accidents, once a wheel starts functioning, keeping a safety

distance between the work piece and the wheel is obligatory.

20. DONT leave the operating gr inder unattended.

21. Only firmed work pieces are allowed to put on the machine during grinding.

22. DONT attempt to stop the running wheel by hands or other outer forces.

23. DONT use compressed air / flu id to c lean the machine at any time, since it

will cause fallen grits and dusts uncontrolled.

24. DONT use compressed air / fluid to clean the drain ditch of machine in

order to prevent the dir t from entering the slideways.

25. DONT adjust the nozzle after the wheel starts up. Close down the coolant

before turning off the wheel.

26. DONT change any appl ications or machine capacity such as using

overloaded work pieces or oversize wheels, installing a vertical spindle

head and so on without confirming.

27. Before installing the wheel onto spindle, first to c lean up the flange cone

bore and spindle taper. Never knock on the wheel or flange if it is difficul t

to remove wheel. Please use the wheel spindle screw nut to remove wheel

instead.

28. Except for trained operators, others are not allowed to access the machine

during the grinding process. Leaning on the machine is prohibited.

29. ONLY professional electro-engineers are elig ible to maintain the electrical

devices.30. Please read the warning signs carefully before checking the power source.

31. Any machine modif ications should be approved by PROTH.

32. All electrical components must be properly grounded and comply with the

related regulations for the safety concern. Failure to do so will void the

warranty.

33. Avoid wearing metal adornments like eyeglasses frames, bracelets and

bangles while repairing or maintaining electrical parts.34. Please do not approach to the sparking zones while grind ing.


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35. DONT grind flammable metals like aluminum, magnesium and unhealthful

substances which will easily generate dusts, gases, liquids or vapors

during grinding.

36. The interlock swi tches installed on wheel guard and control box are for the

purpose of power interruption.

37. Please calculate peripheral speed before adjusting the frequency of spindle

motor inverter (if installed this optional accessory). Please check page 50

for more details.

38. PROTH warranty of each machine is based on an 8-hour s tandard operation

per day. If the machine is operating more than 8 hours per day, please

note that PROTH has the right to shorten the warranty period to 6-month.

39. After an 8-hour operation, please rest the machine for at least 1 hour.

40. Please dont touch the directional control arm either by hand or by any

outer forces during table movement.


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UNLOADING INSTRUCTIONS

(A) Using Fork-lift Trucks

Note:

The capacity of fork-lift trucks depends on the gross weight of machines.

Release the wooden case from the

fixative devices.

Unload the wooden case by the fork

lift.

Uncrate the machine.

Position the machine at the desirable

position.

Unpack and install the machine.


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(B) Using Cranes or Elevating Platforms

Note:

The capacity of cranes or elevating platforms depends on the gross weight of

machines.

Release the wooden case from the

fixative devices.

Unload the wooden case by the crane or

elevating platform.

Uncrate the machine.

Position the machine at the desirable

position.

Unpack and install the machine.


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N O T E S

All PROTH machines have been undertaken a 4-hour running test for

small machines and an 8-hour test for bigger machines before

delivery, to insure their excellent condition. Please contact us

immediately if there are any questions related to our machines.

We would like to emphasize PROTH three prominent features as:

1. Smooth table traverse running

2. Quiet machine operations

3. Simple and modern machine-design without much maintenance

required

Thank you for using PRTOH surface grinding machines and sincerely

hope PROTH machines can grind you a bright future. Please enjoy it!


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W A R I N G

W A R N I N G

1. Turn the wheel spindle CLOCKWISE.

2. The peripheral speed of the wheel should be 2300 m/min or up.

3. The spindle rotation speed should be 1800/1500 (60Hz/50Hz) min .

4. Max wheel dimension:

(GS-25, 30) OD406mm x ID127mm x W25mm.

(GS-30B, 40) OD406mm x ID127mm x W38mm.

(GC, GO) OD406mm x ID127mm x W50mm.

1. No cleaning or removing any workpieces or tools before the wheel

fully stops.

2. The wheel cover must remain close while the wheel is in operation.

1. Avoid improper operations causing wheel cracked.

2. Machine should be operated by trained employees.

3. No compressed fluid or air cleaning the spindle anytime.

1. Keep a safe distance from the working table while the table is in

motion.2. Avoid grinding unhealthful substance to reduce the causes of dusts,

gases, liquids or vapors.

3. Avoid grinding flammable or explosive metals like aluminum and

magnesium.

HYDRAULIC SYSTEM

1. Keep oil pressure around 10~25 bar.

2. Use MOBIL Vacuolinel oil 1409, SHELL

Tonna oil S-68, BP Energol GHL-68,

ARAL Vitam GF-68, ESSO Nuto H-68.

3. Always keep the oil above the minimum

red warning line.

4. Change new oil and clean oil tank after

3-month of the first usage, then repeat this

cleaning process once a year.

LUBRICATION OIL

MOBIL : Vactra No. 2

SHELL : Tonna S-68 (V-68)

BP : Maccurat D-68

ARAL : Deganit BW-68 (B68)

CASTROL : Magna BD-68

ESSO : Fibis K-68


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DO NOTuseCOMPRESSED AIRto clean the coolant

channel and working table because the airborne grits and dusts will damage the slideways.

The chuck surface hasnt been grinded before delivery.

Please grind it after proper installation of the machine.

TO THE COMMISSIONED ENGINEER

1. Due to the improper operation, spindle vibrations would occur because of the

caused damage. Please kindly make sure to provide the best quality of the

spindle to the customer, with no noises and good run out of the taper nose.

2. Clean rusty preventive around the housing channel and throughout the spindle

taper, in order to avoid the grit and dust glued alongside. It can be the major

cause of the spindle noise.


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-- TABLE OF CONTENTS--

(A) INSTALLATION.......................................................................... P.12

(B) STARTING UP THE MACHINE.................................................. P.19

(C) WHEEL...................................................................................... P.34

(D) GRINDING OPERATION............................................................ P.40

(E) THE HYDRAULIC SYSTEM....................................................... P.47

(F) WET GRINDING......................................................................... P.50

(G) PERFECT SURFACE FINISH.................................................... P.51

(H) ELECTRO MAGENTIC CHUCK................................................. P.52

(I) FOR AD3 AUTO DOWN FEED OPERATION............................. P.54

(J) MAINTENANCE......................................................................... P.56


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(A) INSTALLATION

1. LIFTING

1.1 The machine should be lifted by a fork-lift truck or crane.

1.2 There are clamps tightened on the spindle and table to stabilize during

transition, DONT remove these clamps until the machine is completely

installed.

Fig. 1-1 Lifting


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Fig. 1-2 Lifting


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2. INSTALLATION

2.1 Location: It is very important to install the grinding machine at the proper site

to obtain high accuracy. An ideal location is as followings:

2.1.1 The best location for the machine is where has the least temperature

variations.

2.1.2 Avoid installing the machine in a place where the nearby machines may

splash cutting chips.

2.1.3 Install the machine at a vibration-free place, away from compressors,

pressers, planers and other machines which would cause vibrations.

2.1.4 If the ground is not solid enough or very close to the vibrating sources,

please install concrete foundation or setup a vibrant-free protection.

2.2 Foundation and Installation

2.2.1 In case the machine is not installed properly, the result of stripe or

chatter marks can appear. To solve the problem, it is better to place

the machine in a foundation as shown in Fig. 2 with jack bolts.


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3. Mounting the table

3.1 The following procedures are applicable to grinders with ball-rolling

slideways. (Fig. 2a)

3.2 To protect the hardened and ground ball rolling slideways, the table is floated

from steel balls when machine in transportation.

3.3 When the machine is placed in position, mounting the table as follows:

3.3.1 Wind the wire rope on the drum as shown in Fig. 2b, then tight and fix it

temporarily.

3.3.2 Put steel balls and retainers on the slideways (in Fig. 2a), with the longer

one at the rear and the shorter one in the front close to the operator.

3.3.3 Have 2 pieces of wood on both ends of the saddle slide as shown in the

below picture.


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3.4 Put the table on the wood. Lift one end of the table by two hands and take

off the wood. Lay down this table slide on the steel balls carefully, and

repeat the same process for the other end.

3.5 Fix the wire rope on the fixed stand as Fig. 2c.

3.6 The wire rope will be loosen after long usage and may slip on the drum,

and the result is that the table cannot move smoothly. If this situation

happens, please adjust the adjust bolt at the right end of the table until it

gets back to the tighten condition again.


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4. Leveling:

Machines should be carefully leveled by a 0.02/m precision spirit level and

equally load on the jack bolts. The adjusting procedure is as followings:

4.1 Put a spirit level in the middle of the table (or on its magnetic chuck if any) in

longitudinal and transverse direction, adjust jack bolts until the level bulb

indicates within 0.02/m.

4.2 To obtain good accuracy, it is recommended that the machine should be

leveled repeatedly.

4.2.1 The machine should stand still for 24 hours after final installation and it

is better to ensure that the machine temperature is similar to that of the

ambient circumstances.

4.2.2 Start the machine with hydraulic system to let the table running

reciprocally for at least 2 hours, to ensure the machine gets used to the

temperature of its normal operation condition.

4.2.3 Re-check and adjust the leveling condition of the machine, then regrind

the table (or chuck) surface to make it flat.

4.2.4 Every time the machine level is checked, make sure the table (or chuck)

surface should be reground for accuracy.

4.2.5 The machine will lose its level usually due to machine vibration and

other causes, so it is highly recommended that the machine needs to

check leveling periodically.

4.2.6 Although the leveling operation is troublesome, it is essential for getting

good operation results. It is better to have the machine leveled at least

once every month.


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(B) STARTING UP THE MACHINE

1. Take away the clamping plates

1.1 Take away the clamping plates which clamp:

(A) the table with saddle, and

(B) the saddle with machine bases.

1.2 Do not turn the hand wheel before the clamping plates are removed.

2. Turn the table longitud inal control lever L1 to its valve closing position

(Fig.3). Note: L1 correspond to the handle for flow control valve 10a of

Fig.20.

3. Turn the directional arm L2 to its neutral position (L2 in Fig.3), correspond

to the arm for pilot valve 10b of Fig.20.

4. Table dogs T1, T2 (Fig.3) must be well fixed at its proper posit ion (not

exceed its maximum stroke) in table slot.

Fig. 3 Table Dogs

5. Lubricants

Lubricate every sliding surfaces with the recommended lubricants and the oil tank

should be filled with oil to the center line of the level gauge, See the

LUBRICATING INSTRUCATION CHART below:


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LUBRICATION AND MAINTENANCE I

MODELHYDRAUIC

SYSTEM

TABLE

SLIDEWAYS

VERTICAL

SLIDEWAYS &

LEADSCREW

CROSS

SLIDEWAYS &

LEADSCREW

PSGS-2550AH

PSGS-3060AH

PSGS-3060BH

PSGS-4080AHR

PSGS-40100AHR

1. Oil

exchanged

every 1 year.

2. Change new

oil filter every

6 months.

1. Automatic

recirculation

oil lubed.

2. Clean and

check the

slideways

every 6

months.

1. Automatic

non-recirculation

oil lubed.

2. Clean & check

the slideways,

leadscrews and

nut every 6

months.

1. Automatic

non-recirculation

oil lubed.

2. Clean & check

the slideways,

leadscrew and

nut every 6

months.

OIL REQUIRED

MOBIL

SHELL

BP

ARAL

ESSO

VACUOLINE

OIL NO.1409TONNA OIL S68

ENERGOL

GHL-68

VITAM GF-68

NUTO H-68

MOBIL

SHELL

BP

ARAL

CASTROL

ESSO

Vactra NO.2

Tonna S 68 (V 68)

Maccurat D 68

Deganit BW 68

(B68)

Magna BD 68

Febis K 68


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LUBRICATION AND MAINTENANCE II

MODELHYDRAUIC

SYSTEM

TABLE

SLIDEWAYS

VERTICAL

SLIDEWAYS &

LEADSCREW

CROSS

SLIDEWAYS &

LEADSCREW

PSGS-2550M

None. 1. Do not need

lubrication.

2. Clean the ball

rolling

slideways

every 6

months.

1. Manual type one

shoot lubrication

pump and pull 5

times a day.

2. Clean & check

the slideways,

leadscrews and

nut every 6

months.

1. Automatic

non-recirculation

oil lubed.

2. Clean & check

the slideways,

leadscrew and

nut every 6

months.

OIL REQUIRED

MOBIL

SHELL

BP

ARAL

CASTROL

ESSO

Vactra NO.2

Tonna S 68 (V

68)

Maccurat D 68

Deganit BW 68

(B68)

Magna BD 68

Febis K 68


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Soluble Cutting Oils

NO. BRAND SERIES

1 Aral (1) Multronl 400

2 Castrol (1) Syntilo DG 81

3 Cincinnati Milacron(1) Cimtech 100

(2) Cimtech 200

4 Fuchs (1) Ratak Synthan 47

5 Mobil(1) Kuhlschmierst off 166 or 193

(2) Mobil cut 321

6 Oemeta (1) Unimet RD

7 Shell (1)Metalina Fluid GR

Note:

1. The main reason of peeling paint of machines is because of the contained nitrite

and glycol within the soluble cutting oil.

2. Please use the brands of soluble cutting oil as Mentioned above only.


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6. The procedures for checking the electrical connection.

6.1 For safety reason, remove the grinding wheel from spindle.

6.2 Fix power source lead wire to the terminal board R.S.T

6.3 Press push button SB1 for power source on

6.4 Press push button SA1 for spindle on the spindle must be rotated in

clockwise direction, if not, please change any 2 wires on R.S.T terminals.

6.5 Press push button SA2 for pump motor on, it must be rotated in

clockwise direction, if not, please change any 2 wires on U2, V2, W2

terminals.

6.6 Turn the selector switchSA31 to left, and turn the switch SA3 to the left,

the saddle must be moved forward to the operator; if not, please change

any 2 wires on U3, V3, W3 terminals.

In case the machine wiring voltage is different from that of power source.

6.7 Change the terminal on transformer Tr1, Tr2 to coordinate the machine

wiring voltage with the power source voltage.

6.8 Change wire connection of the following motors: spindle motor, pump

motor, coolant motor.

6.9 Cross feed motor is of constant voltage 220V, so neednt to change its

wiring connection.

6.10 After changing the connections of the above mentioned transformer and

motors, it requires to test the directions of rotation of all motors following

the same procedure as in 6.1 to 6.6.


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7. Table longi tudinal traverse (Fig. 7a, 7b, 7c)

7.1 Switch on power source SB1

7.2 Switch on hydraulic pump motor, SA2

7.3 The table directional arm L2 should be able to turn for left of right an angle

about 15 degrees from its neutral position.

7.4 Turn clockwise the table longitudinal control level L1 slowly until the table

starts to move, the table will get its maximum speed when it turns to 90

degree.

7.5 If the table starts jerkily, there may be some air bubbles in the hydraulic

system. The air bubbles can be removed easily if you operated the table at

slow speed with its full stroke and stop a little while at both ends, repeat

these processes several times.

7.6 If the table dogs T1, T2, fixed on the table T-slot, bump against table

directional arm L2 due to some causes, L2 will slip out an angle from

direction control shaft L3 (see Fig. 5a) and cause the table unable to travel

automatically. In such case, the remedy is as followings:

7.6.1 Turn L1 to its valve closing position (pump is in operation) to stop table

moving.

7.6.2 Take away table dogs T1, T2 or move it apart from L2, this is necessary

for avoiding fingers being clamped by table dogs and L2.

7.6.3 Take off arm L2 from its shaft L3 (Fig.5d) and turn L3 to a position with

its marked line in a perpendicular direction as shown in Fig.5b. then

re-put L2 on L3 in its correct position (as Fig.3)

7.6.4 Turn L1 by left hand about 60 degrees for low table speed.

7.6.5 Turn L2 right and left (about 15-20 degrees) by right hand, if still cantmake the table move right and left, adjust L2 to other position on L3 and

try turn L2 right and left again. Time after time you can find the right

position for L3.

7.6.6 Disassemble L2 from L3 (Fig.5d) and adjust L2 at its right position and

then secure it firmly on L3.

7.6.7 During this adjusting process, it needs that with left hand to control L1,

and right hand to turn L2 simultaneously.7.6.8 This is a troublesome work, and requires lots of patience to try again


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and again.

7.6.9 Please dont touch the directional control arm either by hand or by

something else during table movement.

8. Automatic cross feed traverse (Intermi ttent)

8.1 With the following operations, it needs that the table longitudinal traverse

must be in actuated condition.

8.2 Turn change-over switch SA3 to left and then release the switch

8.3 SA31 for automatic operation, the cross feed will soon be actuated and the

wheelhead will move forward to the operator.

8.4 Turn SA3 to right, wheelhead will automatically move backward to rear side.

8.5 Automatic cross feed traverse will reverse its direction when the limited

switch LS3 or LS4 are actuated by trip dogs. (Fig.6)

8.6 The magnitude of cross feed is infinitely variable by the regulating

knob RP32 .

8.7 By turning switch SA31 to left, or pressing down the limit switch LS1, the

automatic cross feed traverse can be interrupted at once.

9. Automatic cross feed traverse (Continuous)

9.1 This function is available whenever the table longitudinal traverse is in

actuation or not.

9.2 Turn selector switch SA31 to left position.

9.3 Turn SA3 to left, the wheelhead will move approach to the operator.

9.4 Turn SA3 to right, the wheelhead will move backward to the rear side.

9.5 This function will be stopped if limit switch LS1 or LS2 is pressed by stopper.But LS3 and LS4 are not able to reverse the direction or stop this function.

10. For criss-cross grinding (Optional)

10.1 Turn the selection switch SA31 to right.

10.2 Turn the selection switch SA3 to right (or left), with the hand released and

the criss-cross travel will be engaged.

10.3 Adjust the knob RP32 for the rate of feed movement.


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Fig 6. Automatic cross feed


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CONTROL PANEL

Fig. 7a

For PSGS-2550M/2550H/3060H ModelsM: All manual operated.

H: Hydraulic longitudinal traverse.


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CONTROL PANEL

MACHINE WITH AD3

MACHINE WITHOUT AD3


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SB1: Power ON button

SA0: Power OFF button

SA1: Grinding wheel ON-OFF switch

SA2: Hydraulic pump on-off switch

SA5: Switch of dust suction

SA6: Switch of coolant system

SA3: Switch, cross feed backward or forward

SA31: Switch, cross feed auto/manual

: Criss cross grinding (option)

RP31: Cross feed engaged time

RP32: Cross feed rate adjusting knob

SA4: Switch rapid, up/down operation

SA100: Switch of electro-mag. Chuck

RP101: Demagnetizing time

RP102: Chucking power adjustment

HL100: Power display lamp

SB110: On-off switch for auto down feed

SA111: Selector switch for surface grinding or plunge grinding

SB120: Button switch for automatic parallel dressing attachment

PC111: Downfeed increments counter

PC112: Spark out passes counter

SA112: Wheel up traverse time, while auto cycle grinding is finished.


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Functions of Panel

SA0: Emergency stop.

SB0: Main power ON.

SB1: Main power OFF.

SA9: AD1 On/Off

SB11: Grinding wheel ON

SB10: Grinding wheel OFF .

SB21: Hydraulic motor ON.

SB20: Hydraulic motor OFF.

SA31: Auto/manual cross feed selections.

SB31: Criss-Cross grinding switch.

SB32: Cross feed forward button.

SB33: Cross feed backward button.

RP31: Cross feed stroke adjuster by electronic one touch system.

SB34: Criss-Cross speed adjuster.

SB39: Cross feed rate adjuster.

SA40: Button for grinding wheel downward movement (press SB40 & SB44 together).

SB43: Button for grinding wheel upward movement.

SB44: Button for grinding wheel downward movement (press SA40 & SB44 together).

SA5-6: Dust suction/ coolant system.

SB35: Auto dressing time adjuster

SB36: NC intermittent feed switch.

SA100: Electro magnetic chuck switch for magnetization, chuck power off, and

demagnetization.

SB26: Demagnetization time

SB28: Adjustment for magnetic attraction

HL100: Chuck magnetization/ demagnetization display.


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(C) WHEEL

1. Wheel Mounting

1.1 The grinding wheel should be checked carefully before mounted by tapping it

with a wood hammer to ensure that a clear sound is detected. A wheel

having a crack inside it may result a sonant sound. Be sure that no crack is

detected.

1.2 Two pieces of paper washers should be placed on each side of wheel and

serve as elastic packing between wheel and flange.

1.3 The screws for fixing the flange should be tightened gradually and in

diagonal sequence, the wrench should be applied step by step to each screw

in turn.

1.4 When the wheel runs under coolant for some time the paper packing

washers may be damaged, the fixing screws should be retightened in

diagonal sequence again.

2. Check wheel mounting before operation. It is essential to check the

following points before start for grinding operations.

2.1 Wheel guard is in its right position.

2.2 Turn the wheel in no load condition for a few minutes.

3. Wheel Balancing

3.1 Efficient balancing is essential to eliminate the unnecessary and additional

stress to be build-up in the wheel. High-quality grinding results, such as

grinding accuracy, surface finish as well as the extended life of grinding

wheel, wheel spindle and bearings, depend to a considerable extent oncareful balancing.

Usually the static balancing will be sufficient. The grinding wheel together

with its mounting flange should be fitted to balancing arbor and then place it

on the wheel balancer. And the balancing operations proceed as following:

3.1.1 The wheel balancer must be leveled first (Fig.9), and check it by a

spirit.

3.1.2 Lay the wheel to oscillate, in order to find out the center of gravity,

then mark its downward position S with chalk. (Fig.14)


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3.1.3 Move the first balance weight G opposite to point S and set it.

(Fig.15)

3.1.4 Move two correction weights K anywhere round the periphery, but at

equal distance a from weight G. (Fig.16)

3.1.5 Turn the wheel through 90 degree and to see whether it is in balance.

If not, the correction weight K must change place until no oscillation

occur in every position or the wheel is in balance. (Fig.17)

3.1.6 Dressing: Mount the wheel onto the spindle, dressing it (especially for

new wheel), make it concentric with rotation center.

3.1.7 Rebalance: after dressing, the wheel may lose its balance, so that the

rebalancing operation is necessary.

3.1.8 After balancing, the wheel must be given a test run of grinding

operation at least five minutes at full working speed before it is being

used.

3.2 Mount the wheel flange assembly:

Prior to get the flange-mounted grinding wheel to the grinding spindle,

operators must be taken to ensure the flange cone bore and spindle taper

are in absolutely clean condition. After that the wheel is pushed by hand onto

the spindle taper, and subsequently, tighten wheel flange assembly securely

with fixed bolt (Fig.12). Release wheel flange assembly from spindle taper

will be effected by using jack bolt (Fig.13).

3.3 How to check the wheel vibration:

If the spindle vibrates significantly please take off the wheel assembly first,and then switch on the spindle and proceed to check with the following

precautions:

3.3.1 If no vibration occurred it means the wheel balance is no good,

please rebalance it.

3.3.2 If the spindle is still vibrate, please disassemble the motor and

spindle cartridge, and check the rubber coupling and coupling refer

SD 50008A Index NO. 1, if the rubber coupling is found broken,change a new one, if couplings found loosen set it well.


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3.3.3 The spindle cartridge assembly are designed to have a life of

operation more than 10 years under normal operation, please should

not disassemble it without our advice.

3.3.4 Because of the very high spindle running speed, the wheel must be

well balanced. Otherwise spindle vibration will be resulted and unable

to get good surface finish. A balanced wheel assembly will lose its

balance during grinding operation owing to its wear. It is advisable to

rebalance the wheel assembly periodically.

Grinding wheel is intended to absorb humidity and coolant, it is advisable not

to start coolant supply when the wheel is not running. Otherwise the wheel

will absorb liquid on its bottom side only and make it out of balance. If the

wheel is allowed to stand for any length of time coolant will be collected at its

lowest side. Unbalance will also be resulted, if the wheel is not allowed to idle

running some length of time after the completion of grinding operation. The

purpose of idle running is essential to throw-off coolant by centrifugal force.


37/106



3.4 The wheel dressing can be done either by diamond dresser mounted on the

magnetic chuck (Fig.18b) or on the parallel dressing attachment (Fig.18a)

which mounted beside spindle cartridge.

3.4.1 The diamond tool should be located at an angle to the center line of

the wheel as shown on Fig.18a, so that when the diamond loses its

keenness (Fig.18c) it can be turned an angle, and another sharp

edge can be utilized (Fig.18d).

3.4.2 The wheel dressing should begin from the middle of the width, as

shown on (Fig.18e), due to two edges are usually worn out. If

dressing begins at the edges, there may result in a danger of the

higher pressure in the middle, so as overstress the diamond tool and

chattering it. As far as the life of the grinding wheel and diamond is

concerned the light dressing with more time is better than a heavy

dressing.

3.4.3 Various degrees of roughness can be produced by varying the feeds

and speeds of the diamond dressing. For a 0.2mm or 0.3mm stock

removal, it is advisable to roughen the wheel, this is done by feeding

the diamond in about 0.03mm and let the diamond moves quickly

over the wheel, this will makes the wheel bite well and the stock

removal good. If the workpiece is to be finish-ground to size with the

same wheel, the wheel must be redressed in different ways. In this

time, the dressing operation should be proceed slowly in two or three

passes, with the diamond dressing feed limited to 0.01mm.

3.4.4 Experience has shown that, with highly accurate grinding or better

surface finish is required, the dressing operation with the diamonddresser mounted on the magnetic chuck is better than which mounted

on the spindle housing. The former is more stable than the latter and

the latter condition will causes light undulation in the surface of the

wheel.

3.4.5 Sufficient coolant supply spray to contact point of wheel and diamond

is necessary.

3.4.6 A 250mm/min to 1000mm/min wheel travel to pass through diamondis recommended. For rough grinding higher travel speed is better.


38/106




39/106




40/106



(D) GRINDING OPERATION

1. The grinding results obtained depend to a very large extent on the choice of

the correct grinding wheel and suitable operation.

1.1 For stock removal efficiency

For intensive stock removal a coarse grain (about 30-60) wheel should be

used. The wheel is dressed by passing over the diamond quickly, so that the

surface of the wheel is roughened and bites well.

1.2 Surface finish is required

If fine finish is to be produced, a finer grain wheel is required (40-80). In this

case the diamond is passed slowly over the wheel, so as to break up the

grain.

1.3 Distortion of the workpiece

If the workpiece shows too much distortion as it is being ground, it

announces that the stock removal is too great and the longitudinal and cross

movements of the table are too slow, or the grinding wheel is blunt or

clogged.

1.4 If the workpiece appears undesirable burns and grinding cracks, it

announces that the wheel is too hard, or the wheel is blunt or clogged.

2. Selection of suitable grinding wheel:

Grinding wheel are usually characterized by the kind of abrasives, the grain size,

the grade of bond, the structure and the type of bond which they selected. The

different symbols of each item format the expression of a grinding wheel. We are

in need to familiar with them.

For instance, the expression WA 46K8V of a wheel which denotes:WA: Kind of abrasive

46: Grain size

K: Grade

8: Structure

V: Bond type


41/106



2.1 Kinds of abrasive

A: For grinding common annealed steels

WA:

For grinding steels with higher hardness, such as heat-treatedcarbon steel, alloy steel, etc.

H: Suitable for higher hardness steel, particularly high-speed steel

C: For grinding with cast iron and non-ferrous materials.

GC: For super-hard metal grinding such as tungsten carbide

2.2 Grain size:

Coarse: 10, 12, 14, 16, 20, 24

Medium: 30, 36, 46, 54, 60

Fine: 70, 80, 90, 100, 120, 150, 180.

Coarse Fine

Stock removal much little

Surface roughness rough fine

Workpiece hardness soft hard

Surface contacted wide narrow

Dia. of the wheel big small

Grain

SizeGrindin

Condition


42/106



2.3 Grade: It indicates the strength of the bond which hold abrasive.

Soft: A-H

Medium: I-P

Hard: Q-Z

Soft Hard

Workpiece hardness hard soft


Movement of workpiece slow quick

Wheel speed high slow

2.4 Structure: The structure number of a wheel refers to the relative spacing of

abrasive grains, the larger the number, the wider the grain spacing.

Close: 0, 1, 2, 3, 4, 5

Medium: 6, 7, 8, 9

Wide: 10, 11, 12

Wide Close

Surface roughness rough fine


Workpiece hardness soft hard

Grade

Grinding

Condition

StructureGrinding

Condition


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2.5 BOND TYPE

* The symbol of bonds Listed bellows:

V: VitrifiedS: Silicate

B: Resinoid

R: Rubber

E: Shellac

3. Wheel to be recommended

Under 205mm 205-355MM

Carbon

Steel

Under HRC25

Above HRC25

WA 46K or A 46K

WA 46J

WA 46J or A 46J

WA 46I

Alloy

Steel

Under HRC55

Above HRC55

WA 46J

WA 46I

WA 46I

WA 46H

Tool

Steel

Under HRC60

Above HRC60

WA 46I

WA 46H

WA 46H

WA 46J

Stainless steel WA 46J WA 46H

Cast Iron C 46J C 46J

Brass C 30J C 30I

Aluminum Alloy C 30J C 30I

Tungsten Carbide GC 60-100 H, I GC 60-100 H, I

Glass C 60K C 60K

Marble C 36M or GC36M C 36M or GC36M

Wheel

DiameterMaterialTo

BeGround


44/106



4. Choice of the Grinding Conditions

4.1 Down feed of grinding wheel

Down Feed Great Small

Grinding resistance large small

Heat produced much less

Surface finish rough fine

Wheel worn-out much little

4.2 Cross Feed

Cross Feed Great Small


Heat produced less much



Rough grinding: 100-500 mm/min, or under 1/2 of the wheel width.

Fine grinding: Under 50 mm/min, or under 1/4 of the wheel width.

4.3 Table Longitudinal Traverse:

Table traverse Quick Slow


Heat produced less much




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4.4 Suitable speeds of the table traverse: m/min

Workpiece

Material

Soft steelHeat-Treated

steel

Tool steel Cast iron

Speed 6-15 30-50 6-30 16-20

4.5 Suitable Peripheral speeds of wheel: 20-30m/sec.

High Low

Grinding resistance small large

Heat produced much less

Surface finish fine rough

Wheel worn-out small great

Safety bad better

Material Peripheral Speed

Steel 20-30 m/sec

Cast Iron 20-18 m/sec

Tungsten Carbide 8-18 m/sec

Zinc alloy & Light Metal 25-30 m/sec

Wheel

Peripheral

SpeedCondition


46/106



4.6 Down Feed and Feed Chart:

Workpiece

Material

Grinding

Down Feed

CrossFeed

Cast Iron, SoftSteel &

Hardened Steel

Stainless & Heat

Resistant SteelTool Steel

Rough0.0006 0.0012 inch

(0.015 0.03 mm)

0.0008 0.0012 inch

(0.02 0.03 mm)

0.0008 0.0016 inch

(0.02 0.04 mm)

Under 1/2 of

wheel width

Fine0.0002 0.0004 inch

(0.005 0.01 mm)

------------

0.0002 0.006 inch(0.005 0.015 mm)

Under 1/4 of

wheel width

Note:

(A) Before adjusting frequency of spindle motor inverter (option), please

calculate peripheral speed in accordant with a following formula.

V= DN, D= wheel diameter (m), =3.14, N= R.P.M. (spindle motor), V=

peripherial speed (m/min), N= (120xf)/np, f= frequency (Hz), np= polar

number (spindle motor).

(B) The calculated speed can not exceed maximum safe operating speed

indicated on the wheel.


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(E) THE HYDRAULIC SYSTEM

A special hydraulic system for driving the longitudinal traverse of the table is

adapted. The table speed is variable and can be adjusted from 5 m/min to

25m/mn.

1. The hydraul ic oil

For trouble free operation, the specified oil Mobil Vacouline 1409 or its equivalent

one is recommended.

2. Change of new oil

The oil is apt to oxidation contamination and ageing, it is recommended to havethe replacement of new oil after its first three months operation and every one

year operation of the machine.

The mix of new oil with highly aged oil is senseless. The addition of new oil cant

improve the quality of the old oil, but cause the added new oil become useless

rapidly.

3. How to test the hydraulic oilA simple way to test the degree of oxidation contamination and ageing of the oil

is:

Take a drop of hydraulic oil to the filter paper, if it appears light and yellow it

means the oil is clean and good. On the other hand, if it appears a dark spot,

it means the oil has been considerable aged, and has lost its quality.

4. Table shock

4.1 If the hydraulic system particularly in pipe line having contained some air in it,

it will cause the table shock.

4.1.1 If pipe connections do not be fastened well, air will be sucked in.

4.1.2 During the operation of connecting the hydraulic tank to the machine, air

will have chance to enter into the system.

4.1.3 In case the air have already been existed in the system the remedy

process is to run the table with low speed at full stroke, after a long

period of operation the air will be squeezed out.

4.2 A too high pressure will cause the table to shock also.


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5. Oil capacity

MODEL HYDRAULIC MOTOROIL TANK

CAPACITY

LUBRICANT

CAPACITYPSGS-2045H 1HP 60L 3L

PSGS 1HP 60L 2L

PSGS 2HP 90L 2L

PSGC 5HP 120L 20L

PSGO 5HP/7.5HP 150L 20L

PSGP 10HP OR UNDER 550L 50L

PSGP ABOVE 10 HP 1300L 50L


49/106




50/106



(F) WET GRINDING

The wet grinding for most of the workpiece can provide the following advantages:

1. Reduced the possibi lity of distortion of the workpiece caused by heating.

2. Reduce the danger of burning.

3. Prevent wheel from clogging.

4. Shorten the grinding time.

5. Lengthen the wheel life.

6. Protect operator, machine and circumstances from grinding dust.

7. Clear transparent coolant is recommended to replace the milky one,

because:

7.1 The surface of workpiece can be easily watched during g grinding operation.

7.2 The grinding wheel can be kept bite and sharp to a longer time than the milky

one.

8. The recommended oil base coolant having the prefer mixing ratio at oil :

water =1 : 60-80, if it is reduced to less than 1 : 50, the excessive heat make

the workpiece apt to distor tion.

9. The coolant wil l gradually lose its effectiveness, due to lost as spray and

evaporates during grinding, eventually i t wi ll become a thin mixture, so that

new oil must be added to correct the mixing ratio.

10. The coolant delivered from a water pump must be sprayed to the wheel

through a nozzle, to prevent the wheel f rom c logging.

11. An automatic paper strip filter is preferred instead of the simple coolant

system in order to obtain a sound surface finish.


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(G) PERFECT SURFACE FINISH

1. Too hard a wheel or wheel is not correctly chosen.

2. Workpiece is not clamped well.

3. A dir ty mating surface between the spindle taper and wheel flange (adaptor)

bore will make the wheel to vibrate.

4. An unqualified wheel flange, such as poor concentricity and poor

squareness.

5. Wheel and flange not matched well or there have somewhat slippage.

6. An unbalanced wheel or the wheel is not be balanced well.

7. Wheel wont be well dressed.

8. The coupling between motor and spindle become loosen or broken.

9. A defect bearing is used in spindle or motor.

10. Coolant mixing ratio is improper, or too much oil.

< The correct ratio is oil : water=1 : 60-80. >

11. The coolant is dirty. For getting good surface fin ish the automatic paper

strip filter attachment is recommended.


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(H) ELECTRO MAGENTIC CHUCK

The electro magnetic chuck is an indispensable attachment for surface grinding

machine. It require a perfect flat mounting surface to be clamped to the machine

table, otherwise table will be subjected to distortion due to the huge magnetic

attracting force of chuck.

The following practice must be followed to grind the mounting surface of

magnetic chuck before it has to be clamped in machine table.

1. The underside of the magnetic chuck must firstly be ground to perfect flat withgreat care. The chuck is laid upside down on the table, not to be clamped, but

stoppers at both right and left sides are used to prevent chuck from moving.

Caution: the chuck should never be switched on. Wet grinding with max. Coolant

volume and minimum wheel infeed is recommended to avoid excessive heating

and the consequent surface inaccuracy to be resulted.

2. Both the ground area of the machine table and underside of the magnetic chuck

are lightly greased to prevent them from getting dust during their clampingoperation. A very thin grease film is preferred for keeping the mounting accuracy.


53/106



3. Clamp the magnetic chuck to the machine table.

3.1 Rough grinding the chuck surface same as the grinding of the underside of

the chuck, but with different clamping method.

3.2 Switch on the magnetic chuck and then fine grinding the surface with

0.005mm wheel infeed.

3.3 Spark out grinding with no infeed, 2 to 3 times passes of wheel over the

chuck surface.


54/106



(I) FOR AD3 AUTO DOWN FEED OPERATION

The special arrangement for AD3 auto down feed includes an auto down feed

unit mounted to the shaft of elevating mechanism and two counters (one for down

feed, the other for spark out) to be built-in at the right side of control panel. There

are six increments of feed values, namely 0.005,0.010,0.015, 0.020,0.025 and

0.030mm,which can be selected on the dial regulator C of the auto down feed

unit at your will (see the picture below).

(The function of dial regulator D is replaced by the counters PC111 and PC112 in

control panel, it will not be in use here.)

1. FOR SURFACE GRINDING + AUTO DOWN FEED.

1.1 Turn selector switch SA111 to right for surface grinding.

1.2 Select the required down feed increment on the dial regulator C of auto down

feed unit AD3 and set the number of down feed increments on the lower

portion of PC111 counter (the upper portion of counter shows the actual

number of cross slide passes actuated).

1.3 Set the number of spark-out passes required on PC112 counter.

1.4 Press the power button SB1 ON for power (usually press the power button

for 2-3 seconds is required and then the hand can be released).1.5 Switch ON the hydraulic pump switch SA2 (hydraulic table drive).


55/106



1.6 Turn lever L1 to left for table movement.

1.7 Turn SA31 to right for auto cross feed.

1.8 Turn SA3 to left or right as required (auto cross feed is engaged).

1.9 Push ON the switch SB110 FOR ARTO DOWN FEED.

2. FOR PLUNGE GRINDING + AUTO

2.1 Turn SA111 to left for plunge grinding.

2.2 Select the required down feed increments to the dial regulator C of auto

down feed unit AD3.

2.3 Set the number of down feed increments required on PC111 counter.

2.4 Set the number of spark-out passes on PC112 counter.

2.5 Switch ON the hydraulic pump switch SA2 (hydraulic table drive).

2.6 Turn lever L1 to left for table movement.

2.7 Turn SA31 to left.

2.8 Press ON the switch SB110 for auto down feed.

3. After the auto down feed grinding cycle is finished, should the hydraulic

pump switch SA2 turn to OFF position and the hydraulic system to be

stopped as well as the table control lever L1 run to closed position, so as

the power button SB1 can be engaged for next cycle.

4. RAPID UP/DOWN

4.1 Turn the rapid up/down switch SA4 to right for up movement.

4.2 Turn switch SA4 to left and press button switch SB1 simultaneously for down

movement.


56/106



(J) MAINTENANCE

Interval Maintaining points Remark

Each time

The surface of workingtable.

To keep the clean and oiled surface is a necessityafter working hours.

The grinding wheel. *Re-correct the wheel balance and re-clean up the

inner hole of wheel flange and the spindle.

Daily routine

Hydraulic oil tank. Check the oil level of it whether the oil need to be

re-filled.

Lubricating oil tank. Check the oil level of it whether the oil needs to be

re-filled.Emergency stop. Check the function of switch whether it loses

efficacy or not.

Wheel cover locker. Check the function of switch whether it loses

efficacy or not.

Warm-up. Depending on working environment, we suggest to

warm up the machine when the room temperature

is below 25C.

Longitudinal slide-ways

lubricating advice.

To check lubricating oil is even on slideways.

Cross slideways and

ball screw lubricating

advice.

To check lubricating oil is even on slideways and

the ball screw.

Upward/downward

slideways and the

lead-screw lubricating

device.

To check lubricating oil is even on slideways and

the lead screw.

Machine surface. Wipe it up.

The rear drain ditch. Clean up the dust and grit. Please do not use the

compressed fluid or air.

Weekly

routine

The automatic lub

system.

Check the automatic lub system and fill it up.

Every month The electrical box. Keep the inner of electrical box dry and clean.


57/106



Interval Maintaining points Remark

Every seasonThe machine level. The deviation must be within the range of 0.002

mm/m.

Every year

Hydraulic oil change. The hydraulic oil has to be changed and the oil

deposit located on the bottom of oil tank has to be

cleaned.

Notes:

Do not use compressed fluid or air to clean up the spindle any time.


58/106


PSGS TROUBLE SHOOTING

SURFACEGRINDERS

-PSGS TROUBLE SHOOTING-



TEL: +886-4-2358-3131

FAX: +886-4-2350-3131


WWW.PROTH.COM.TW


59/106


PSGS TROUBLE SHOOTING P. 2 OF 18

--TABLE OF CONTENTS--

I Grinding defects, Causes and Remedy ................................ P.3

II Electronic-related defects, Causes and Remedy ................. P.7

A. General (machines without CE) ......................................... P.7

B. General (machines with AD3) ........................................... P.10

C. Machines with AD1 or CE mark........................................ P.13

III Hydraulic-related defects, Causes and Remedy ................ P.16


60/106



I Grinding defects, Causes and Remedy

No. Defects Causes Remedy

1-1 Chatter marksappeared on the

grinding surface.

1) The foundation is not firmenough for the machine.

Please improve thefoundation.

2) The leveling screws (jack

bolts) in machine base are

loosened.

Check the leveling first and

lock them tight.

3) Work table does not run

smoothly.

Check slideways have

enough lubricant oil. And

cylinders are smoothly

running.

4) Table is not fully supported. Re-scrap the contacted

surfaces of table and bed

slideways.

5) Grinding wheel does not sit

firmly on the wheel flange.

Replace the intermediate

washer between wheel and

flange, make sure to tighten

them well.

6) Flange (with wheel) does

not fit firmly on the grinding

spindle taper nose.

Clean both taper contacted

surfaces, make sure they are

well contacted and fitted

firmly.

7) Wheel and flange are not

well balanced.

Make sure the water-based

fluid on the wheel is dried out

BEFOREre-balancing wheel

and flange.

8) Wheel is asymmetrical. If wheel and flange cannot be

balanced well, dress the

wheel on periphery and both

sides before rebalancing

again. If it still cannot reach

the balance, please replace a

new wheel.


61/106




9) The usage of improper

wheel.

Please select the proper

wheel base on the material of

the workpiece.

10) Wheel is not dressed

correctly.

The angles of the diamond

dresser must be turned

regularly in order to keep

sharp. Replace with a new

one when the diamond

dresser gets dull.

The diamond dresser is not

firmly fixed.

11) Too much play on the

grinding spindle.

Re-adjust the spindle by a

qualified technician.

12) Too much play on the

wheel head guideways.

Clean and adjust the gibs.

13) Vibrations transferred to

machine from outside, such

as rough-running machines,

traveling cranes inside the

buildings, street vehicles etc

Improve the foundation, make

it vibration free or place

machine in a vibration-free

location/position.

14) Couplings of motor and

spindle are loosened or

rubber is broken.

Fix couplings well or replace

with new rubber couplings.

15) Unsteady running of

grinding wheel.

The voltage of 3-phase power

source may be unstable,

please check and make it

stable.

16) Stock removal is too Reduce infeed amount.


62/106




great. Reduce cross feed

movement.

17) Grinding wheel gets too

hard, dull or clogged.

Use softer or coarser wheel.

Increase table speed.

Reduce infeed amount.

Roughen the wheel.

Check the sharpness of the

diamond dresser.

1-2 Small and uneven

flutter marks

appeared on the

workpiece

surface.

1) Traveling cranes or hoists

inside the building.

Improve the foundation.

Change the location/position.

2) Traveling vehicles in the

building or streets.

Improve the foundation .

Change the location/position.

1-3 Obvious ray

pattern parallel

lines that can be

seen by naked

eyes.

1) Bearings of grinding

spindle are defected.

Please see item No.A-1for

more details.

2) Too much play on

wheelhead guideways.

3) Wheel is badly dressed. Dressing the wheel again.

1-4 Comma-shaped

lines appeared

when grinding is

getting a high

surface finish.

1) Coolant gets too dirty. Clean coolant or use

automatic paper strip filter.

2) Grinding wheel chips off. Clean the interior grits of the

wheel cover.

Choose proper wheel.

1-5 Burned marks

and grinding

brunt caused by

over-heating of

the workpiece.

1) Grinding wheel gets too

hard or too thin.

Use softer or coarser wheel.

Increase table speed.

Reduce peripheral speed of

the wheel.

2) Grinding wheel gets dull or

clogged.

Dressing the wheel to make it

rougher and sharper.

3) Stock removal is too great. Reduce infeed amount.

Reduce cross feed

movement.


63/106




4) Table speed is too low. Increase table speed.

5) Inefficient cooling. Increase coolant water.

Use stronger mixture coolant

(filled up with fresh oil)

Fill up new coolant.

1-6 Grinding spark

abnormally.

Cannot be spark out. Using spirit level to align the

machine by adjusting the jack

bolt.


64/106



II Electronic-related defects, Causes and Remedy

A. General (machines without CE)


A-1

Rapid and auto

cross-feed are

not functioning.

1) SA31 doesnt switch on to

the right side.

Please switch it to the right

position.

2) SA3 and SA31 switches

are defective or wires loose.

Fix wires well or replace

new switch.

3) MCU (motor control unit) is

not working.

Or fuse of MCU is defective.

(no power is delivered

because fuse is broken).

Check the terminal block as

following:

1. Short 75 and 76 by a wire.

2. Turn SA3 to either the

right side or the left one

and stay in that position.

(not let it turn back)

3. Check whether the voltage

of 73 and 74 is around

220V10% or not ; if not, itindicates that the MCU is

out of order.

4) Limit Switch LS1 or LS2 for

max stroke safety control is

defective or being pressed.

Check LS1 and LS2

throughout or replace with

new switches.

5) PL-4P (PNP) Proximity

switch is too loose to engage

directional cam or LS5 is not

working.

Fix it well or replace a new

one.

6) The clamping plates for

saddle are not taken off.

Please take off the clamping

plates.

A-2

Automatic cross

feed does not

reverse and runs

to one direction

1) Limit Switch LS3 and LS4

are not working or the trip dog

is too loose to control LS3

and LS4.

Fix trip dog or change to a

new limit switch.


65/106




ONLY. 2) Magnetic contactor for

cross feed motor is not

functioning.

Check contactor wires to

make sure the switch is

working; if not, please change

to a new switch.

A-3

Magnetizing

doesnt work

Fuse of chuck-control is

burnt.

Change a new fuse.

Fuse on TR1 is broken Replace with a new one.

Transformer TR1 is defect 1. Check TR1 primary coil:

take off wires fromterminals a.b. if resistance

show , it means the coil

is broken.

2. Check TR1 secondary

coil: same as above, if

resistance between c.d. is

, the coil is broken.

3. Any coil broken, TR1 must

be replaced with new one.

Switch SA100 is defective 1. Turn SA100 to right

position(magnetizing),

check terminals C1 with

+, C2 and -, all of

them must be in short

circuit(O), otherwise the

switch is defect.

2. Turn SA100 to left

position(demagnetizing),

check terminal C1 and

-, C2 and DE. all of



switch is defect.


66/106




3. Repair or replace with new

switch

The electro magnetic chuck is

defective.

1. Check 2 wires of the

chuck, it must be in short

circuit O. If not, it

indicates the chuck is

broken. Please repair it.

2. Check each wire with

chuck body (earth), it must

be . Otherwise, it

means the insulation is

bad; dry the coil and

improve its insulation.


67/106



B. General (machines with AD3)


B-1Rapid and autocross-feed are

not functioning.

1) SA31 doesnt switch on tothe right side.

Please switch it to the rightposition.

2) SA3 and SA31 switches

are defective or wires loose.

Fix wires well or replace new

switch.


not working.





following:


2. Turn SB31 or SB32 to

either the right side or the

left one and stay in that

position.



220V10% or not ; if not, it

indicates that the MCU is

out of order.




Check LS1 and LS2


new switches.

5) PL-4N (NPN) Proximity



working.


one.




plates.

B-2

Automatic cross

feed does not

reverse and runs

to one direction




and LS4.


new limit switch.


68/106






functioning.




to a new switch.

B-3

Magnetizing

doesnt work


burnt.

Change a new fuse.



take off wires from

terminals a.b. if resistance


is broken.










+, C2 and -, all of



switch is defect.








69/106




switch is defect.


switch


defective.








be . Otherwise, it





70/106



C. Machines with AD1 or CE mark


C-1Rapid and autocross-feed are

not functioning.

1) SA31 doesnt switch on tothe right side.

Please switch it to the rightposition.

2) SB31&SB32, SA31

switches are defective or

wires loose.

Fix wires well or replace

new switch.


not working.





following:


2. Turn SA3 to either the

right side or the left one

and stay in that position.

(not let it turn back)



220V10% or not ; if not, it

indicates that the MCU is

out of order.




Check LS1 and LS2


new switches.

5) PL-4NP (NPN) Proximity



working.


one.




plates.

C-2

Automatic cross

feed does not

reverse and runs

to one direction




and LS4.


new limit switch.


71/106






functioning.




to a new switch.

C-3

Magnetizing

doesnt work


burnt.

Change a new fuse.



take off wires from

terminals a.b. if resistance


is broken.










+, C2 and -, all of



switch is defect.








72/106




switch is defect.


switch


defective.








be . Otherwise, it





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III Hydraulic-related defects, Causes and Remedy

No. Defects Checkup Remedy

3-1 Hydraulic motoris not working

1) Wire lose of hydraulicmotor switch

Check the wire or change themotor switch.

2) Magnetic switch/overload

relay of pump motor are not

working properly.

Check the connecting wires

or change the whole set of

magnetic switch.

3-2 Table longitudinal

movement is

slowing down.

1) Check lubrication oi l on

the slideways

a. Lubricant outlet on the

slideways or lubrication

controlled switch is

blocked.

b. Not enough lubrication oil

in the oil tank.

c. Lubrication pump is in

proper pressure of 3-4 bar

(3~5kgf/cm2).

d. Filter inside the lubrication

oil tank is blocked.

a. Clean up

b. Add Mobil #2 or its

equivalent as

recommended.

c. Adjust to proper pressure

d. Clean the oil tank and add

new oil

2) Move the table to the

extremely end, turn on the

flow control lever at full

speed to see that the

pressure indicator should

stand still.

a. The pressure gauge

indicator downward

movement which means

the leakage inside the

cylinders.

a. Replace the O-ring/seals

of the cylinders.


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b. Using a 5-mm hex key to

adjust the pressure of the

relief valve in clockwise

direction to see if the

pressure gauge indicator

can be upward movement

or it stands still without

moving.

b. Should it stand still without

moving which means the

relief valve was broken.

Please change the new one.

3) Inside hydraul ic tank.

a. The color of hydraulic oil is

creamy white.

b. Abnormal noise from the

pump.

c. Filter block up.

d. d. Not enough oil.

a. Change the hydraulic oil.

b. Change the pump.

c. Clean the oil tank and filter,

then change the hydraulic

oil.

d. d. Add the oil till the upper

limit.

3-3 The transverse

movement of the

table is vibrating

or not stable.

a. The loose or bent of the

cylinder.

b. Not enough oil.

c. The color of hydraulic oil is

creamy white.

d. Abnormal rotation speed of

the motor.

e. Abnormal noise from the

pump.

f. No lubrication oil on the

slideways.

a. Re-adjust the parallelism of

the cylinder. Or replace

with new one if it is bent.

b. Add the new oil till the

upper limit.

c. Change the new hydraulic

oil.

d. Change a new motor.

e. Change a new pump.

f. Examine it following the

above 3-2.


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3-4 The table can not

reverse and runs

to one side

a. Directional control arm is

loose.

b. The trip dogs (T1, T2) are

loose.

c. Unknown body blocks up

inside the cylinder.

d. Hydraulic oil:

1) Brands.

2) Not enough oil.

3) Inferior oil.

a. Adjust directional control

arm following inside

manual.

b. Tighten the trip dog at the

proper position.

c. Cleaning the unknown

body inside the cylinder

tank.

- Use the recommended

brands.

- Add the oil till the upper limit.

- Change new hydraulic oil

and clean the internal and

filter of the oil tank.

3-5 Workable can not

move

1) The electro magnetic

chuck does not switch on, so

that pump motor does not

work.

Switch on the chuck or chuck

control (auto demagnetizer)

switch if it is used on the

machine.

2) Oil pump cannot deliver oil

because air come into the oil

pump and piping (so

called carition)

Fill in oil from the P port of

the Relief Valve, and then

start the hydraulic pump, the

problem will be solved.


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PSGS PART LIST

SURFACE

GRINDERS

- PSGSPART LISTS -



TEL: +886-4-2358-3131

FAX: +886-4-2350-3131


WWW.PROTH.COM.TW


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PSGS PART LIST P.2 OF 31

NAME PLATE:

Please keep 'Model' & 'Serial No.' of this machine

for parts order.

Thank you for your cooperation!


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- - T A B L E O F C O N T E N T S - -

MACHINE ASSEMBLY ........................................................................ P.4

MACHINE BASE STRUCTURE........................................................... P.5

LONGITUDINAL STRUCTURE ........................................................... P.7

CROSS STRUCTURE ....................................................................... P.13

VERTICAL STRUCTURE ................................................................... P.20

SPINDLE ASSEMBLY ........................................................................ P.24

HYDRAULIC SYSTEM ....................................................................... P.27

PARALLEL DRESSING ATTACHMENT .............................................. P.29


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MACHINE ASSEMBLY


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MACHINE BASE STRUCTURE


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PSGS SD10008A

INDEX NO

PART NO

PART NAME

QUANTITY

1 SD9114A* FLYING RING 2

2 SD9115A* FLYING RING 2

3 TURCITE B 2

4 SD9113A* COVER 2

5 SCREW 4

6 SD1111A* MACHINE BASE 1

7 SD9111A* JACK BOLT 3

8 SD9112A* SETTING PLATE 3

9 SD9116A* NAME PLATE 1


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LONGITUDINAL STRUCTURE

(FOR PSGS-2550M BALL ROLLING WAYS)


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PSGS SA20008A (FOR PSGS-2550M BALL ROLLING WAYS)

INDEX NO

PART NO

PART NAME

QUANTITY

1 SCREW 14

2 SA2435A*CONVEX BALL

SLIDEWAY1

3 SA2311A* SPLASH GUARD 1

4 SA1113A* TABLE 1

5 SCREW 2

6 SA2434A*CONCAVE BALL

SLIDEWAY1

7 SA2113A* TRIP DOG 2

8 SA2112A* ADJUSTING NUT 4

9 SA2429A* CABLE 2

10 AA2437A* CABLE FIXED RING 1

11 SA2212A* CABLE FIXED BASE 2

12 NUT 4

13 BALL5/8 45

14 SA2433A*CONCAVE BALL

SLIDEWAYS2

15 SA2431A* SPACER 4

16 SCREW 14

17 SA2432A* BALL RETAINER 9

18 SA2561A* STOPPER 1

19 SA2565A* STOP CUSHION 2

20 SCREW 2


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INDEX NO

PART NO

PART NAME

QUANTITY

21 SA1112A* SADDLE 1

22 SA2423A* TUBE 1

23 SA2422A* DRUM 1

24 BEARING 2

25 SA2421A* DRUM BASE 1

26 SA2424A* DRUM SHAFT 1

27 SA2428A* DRIVE GEAR 1

28 KEY 1

29 BEARING 1

30 C-RING 1

31 SA2436A* SCREW 1

32 C-RING 1

33 BEARING 1

34 C-RING 1

35 SA2425A* NUT 1

36 SA2426A* HOUSING HOLDER 1

37 SA2427A* NUT 1

38 SD2555A* HANDWHEEL 1

39 SD2556A* NUT 1

40 SD2555A* HANDLE 1


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LONGITUDINAL STRUCTURE


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PSGS SD20008A

INDEX NO

PART NO

PART NAME

QUANTITY

1 SCREW 3

2 SD2111A* RACK 1

3 SCREW 2

4 WASHER 2


6 SD2550A* HANDLE 1

7 SD2311A* SPLASH GUARD 1

8 SD2116A* WASHER 2

9 SCREW 2

10 SD2410A* DRIVE 1

11 SD2114A* SLIDER DOG 1

12 SD2112A* SLIDER DOG NUT 4


14 SCREW 4

15 RUBBER WASHER 1

16 SD1112A* SLIDER 1

17 SCREW 4

18 WASHER 4

19 WASHER 4

20 SCREW 4

21 SD2115A* ROD HOLDER 2


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INDEX NO

PART NO

PART NAME

QUANTITY

22 WASHER 2

23 NUT 4

24 SD1113A* TABLE 1

25 SD2210A* CYLINDER 1


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CROSS STRUCTURE

(FOR PSGS-2550M BALL ROLLING WAYS)


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PSGS SA30008A (FOR PSGS-2550M BALL ROLLING WAYS)

INDEX NO

PART NO

PART NAME

QUANTITY

1 SD2550A* HANDLE 1

2 SD2556A* NUT 1


4 SA3116A* GRADUATE DIAL 1

5 SPACER 1

6 WASHER 1

7 BEARING 1

8 BERAING 1

9 SCREW 2

10 SD3115A* DIAL INDICATOR 3

11 SD3114A* SPACER 1

12 SA1112A* SADDLE 1

13 SA3431A* SUPPORTING BASE 1

14 SCREW 2

15 SA2432A* FIXED BASE 1

16 SCREW 4

17 SD3131A* ADJUSTING BASE 1

18 KEY 1

19 SA3110A* LEADSCREW ON

CROSS

1

20 KEY 1


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INDEX NO

PART NO

PART NAME

QUANTITY

21 SD3119A* LEADSCREW NUTHOLDER

1

22 WASHER 4

23 SCREW 4

24 SD3122A* PROTECTION TUBE 1

25 TURCOTE B 4

26 SD1111A* MACINE BASE 1

27 SA2433A* HOLDER 1

28 SA3434A SHAFT 1


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CROSS STRUCTURE


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PSGS SD30008A

INDEX NO

PART NO

PART NAME

QUANTITY

1 SCREW 4

2 SD1111A* MACHINE BASE 1

3 SD3119A*

LEAD SCREW NUT

HOLDER

1

4 SD3122A* PROTECTION TUBE 1

5 WASHER 4

6 KEY 1

7 SD3110A*

LEADSCREW ON

CROSS

1

8 SCREW 2

9 SD3121A* ADJUST BASE 1

10 SCREW 2

11 C-RING 1

12 SD3125A* PULLEY COVER 2

13 TIMING BELT 1

14 SD3113A* PULLEY

1

15 KEY 1


17 BEARING 1

18 SD3115A* DIAL HOLDER 1

19 SCREW 3

20 SD3116A* GRADUATED DIAL 1


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INDEX NO

PART NO

PART NAME

QUANTITY

21 SD3126A* SPRING 1

22 KEY 1

23 SD3117A* CLUTCH HOUSING 1

24 SD3118A* SPRING 3

25 BALL 3

26 BEARING

1

27 WASHER 1

28 SPACER 1

29 SD3555A* HAND WHEEL 1

30 SD2556A* HAND WHEEL NUT 1

31 SD2550A* HANDLE 1

32 WASHER 4

33 SCREW 1

34 SD3123A* MOTOR FOR CROSS 1

35 SD1112A* SLIDER 1

36 SD3124A* PULLEY 1

37 SCREW 2

38 SD3129A* LIMIT DOG 2

39 SD3128A*

SROKE ADJUSTED

RAIL

1

40 SD3132A* FIX SCREW 2


42 SCREW 2


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INDEX NO

PART NO

PART NAME

QUANTITY



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VERTICAL STRUCTURE


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PSGS SD40008A

INDEX NO

PART NO

PART NAME

QUANTITY

1. SD4113A* WAY CPVER SUPPORT 1

2. SD4121A* VERTICAL SLIDEWAY 1

3. SCREW 2

4. SD4111A* CLOUMN COVER 1

proth psgs manual

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