Bernhard Express dual 4000dx User manual

EXPRESS DUAL 4000DX

Please read this manual carefully before using the Express Dual 4000DX.

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

Touch Screen Model

User’s Guide &

Instruction Manual

EXPRESS DUAL 4000DX

NOTES

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EXPRESS DUAL 4000DX

EXPRESS DUAL

BERNHARD & CO. LIMITED

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)

ED4000DX Precison Reel/Cylinder Grinder

Welcome to the Bernhard Express Dual 4000DX. If cared for and operated

correctly this machine 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 issues please contact your distributor or

phone our technical support hotline

Technical Helpline (USA only) 1-888 474 6348

Rest of World: UK Head Ofce, England (+44) 1788 811600

Email: support@bernhard.co.uk

Technical FAQs can be found on our web site: www.bernhard.co.uk

When ordering spare parts please quote the machine type and serial number.

THE MANUFACTURERS ACCEPT NO RESPONSIBILITY FOR ANY SITUATION ARISING FROM THE

FITTING AND/OR USE OF NON-ORIGINAL SPARE PARTS.

Contents

Identication of Pictograms 3

Safety 5

Installation 6

Identication of Tools and Equipment 8

Understanding the Machine 9

In Frame Grinding 11

Electrical Fault Finding 21

Maintenance 23

Part Lists and Exploded Diagrams 29

Lift Table Instructions 48

Quick Start Guide 58

ED4000DX Touchscreen – 1003.4/ENG/2017RB

Please quote this serial number on all

correspondence:

Serial #:

EXPRESS DUAL 4000DX

BEWARE! HIGH VOLTAGE

1. Identication of Pictograms

MAXIMUM LIFT PLATFORM

LOAD - 250 KG (550 LBS)

BEWARE!

TRAPPING FEET OR OTHER OBJECTS

WHEN LOWERING LIFT PLATFORM

MAXIMUM GRINDSTONE

DIAMETER 150mm

MAXIMUM SPEED 4000 Rev/Min

RUNS AT 2200 Rev/Min

BEWARE!

MOVING GRINDSTONE AND SHAFT

REEL ROTATING AT BETWEEN

147 AND 255 Rev/Min

TOTAL WEIGHT OF MACHINE (KG)

EXPRESS DUAL 4000DX

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 4000DX

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 ON LY 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 tted 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 4000DX

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 and also at the front of

this manual.

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).

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.

1.5m (5 ft)

ENSURE ADEQUATE SPACE FOR

LOADING UNITS AND FOR A LIFT

TABLE (IF FITTED)

FRONT OF MACHINE

EXPRESS DUAL 4000DX

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

lm 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 4000DX

4. Indenti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).

A9502 Adjustable Mounting Bracket Set (Fitted) ........................1

A6505 Grind Stone (Fitted)..................................................................1

A6737 Diamond Dresser (In Spin Drive Support) .......................1

A2719 Grinding Wheel Wrench..........................................................1

A6342 Pressure Plate ............................................................................1

A4095 Plain Drive Rod Short..............................................................1

A4134 Square Drive Rod Short (Fitted To Cable Drive) ...........1

A4066 Long Ball Handled Allen Key.................................................1

A2720 Large Hex Key............................................................................1

A2706 3/16 T Handled Allen Key.......................................................1

A4097 Plain Shaft Driver ......................................................................1

A4063 Large Two Pin Sprocket Driver.............................................1

A4133 Drive Kit - Female Splines......................................................1

A9535 Adj. Sprocket Driver Complete .............................................1

A9534 Eccentric Pin For Adj Sprocket Driver ...............................3

A2722 Molycote Paste...........................................................................1

A6847 Molycote Brush...........................................................................1

A4087 Multix Channels .......................................................................1

A2712 8mm Allen Key ...........................................................................1

A8786 Pack of Spare Fuses................................................................1

A2708 3mm Allen Key ...........................................................................1

A3306 22mm 1/2 Drive Socket...........................................................1

A6603 Guarantee Certicate ..............................................................1

A6615 Operating Instructions .............................................................1

EXPRESS DUAL 4000DX

5. Understanding the Machine

5.1 General Principles

The EXPRESS DUAL is designed to grind reels completely assembled, or as a separate

“loose” reel. A Loose Reel Kit (Available as an optional extra, at additional cost) is required

for this operation.

The basic principle of the EXPRESS DUAL is to grind mowers in exactly the same

conditions that they mow in. The grinding wheel takes the place of the grass, striking the

reel in relatively close proximity to that found in the mowing position.

5.2 Basic Requirements

It is important that grinding the cutting unit, when it remains completely assembled, takes

place under the following conditions:

5.2.1 The reel bearings MUST be in good condition, adjusted correctly and if the roller is to be

located on the roller mounting brackets or the multix brackets, the roller bearings MUST

also be in good condition.

5.2.2 The bedknife must be ground separately on a machine, such as the ANGLEMASTER

bedknife grinder which can guarantee that the blade will be perfectly STRAIGHT and at

whilst mounted on the bedbar.

During the reel grinding process, it is advisable that the bedknife/bedbar assembly is

replaced in the unit after having been ground. On many units the bedknife/bedbar is an

integral part of the frame and contributes to its strength and rigidity.

5.2.3 The reel or bedknife must be adjusted away from one another to allow free rotation (There

should be no reel to bedknife contact!).

5.2.4 It is essential that all work to be carried out on the mowing unit (all mower repairs

– bearings, seals, roller work, etc.) has been completed prior to grinding the reel. The last

operation of all, apart from nal setting reel to bedknife, is the actual grinding of the reel

in-frame.

It is essential that the unit is held totally rm during the grinding process. When in frame

grinding, the front of the unit must be held rmly in the multix brackets or on the front

roller brackets.

5.2.5 It is essential that the unit is held totally rm during the grinding process. When in frame

grinding, the front of the unit must be held rmly in the multix brackets or on the front

roller brackets.

The rear of the unit will be held by the radiused pressure bar at the rear of the grinder.

EXPRESS DUAL 4000DX

5. Understanding the Machine (Continued)

5.3 Machine Functions

The EXPRESS DUAL has separate motors driving the different functions of the machine,

all are turned on and off from the control panel in ‘manual’ mode or by the machine

program in ‘auto’ mode. These functions are as follows:

5. 3.1 Traverse

This motor and the accompanying drive mechanism controls the automatic movement of

the grinding wheel along the mainshaft.

5.3.2 Reel/Spin drive

This motor drives the reel through a exible shaft driving from a drive mechanism under

the table. It is a three phase motor controlled by an inverter for varying output speed.

5.3.3 Grinding Wheel

A motor situated under the table, drives the mainshaft and grinding wheel at around 2200

rpm.

5.3.4 Stop

Pressing the stop button shuts off all motors and locks into the “off” position. None of the

start buttons will operate until the stop button has been unlocked by twisting the knob

counter-clockwise to release it (and the m/c control error warning has been reset).

NOTE The machine must NOT be stopped when there is contact between the reel and grinding

wheel, except in cases of emergency.

5.3.5 Reset Button (see also Electrical Fault Finding section)

If the main motor is subject to a voltage drop or overloading, the current being drawn

will rise and a safety device will automatically shut the grinder off. The overload trip

device (thermal overload contactor) is attached to the main motor contactor in the main

electrical control box which is located within the safety guard on the right hand side of the

machine.(looking from the front). The (red) reset button is on this overload.

The trip setting will vary with the electrical specication of each machine and is normally

set to the full load current of the motor. If the overload trip has shut off the grinder it can be

reset by pushing the reset button after a few minutes delay. This will allow the grinder to be

re started.

NOTE The overload is variable and should be adjusted, if required, as indicated in the appropriate

service bulletin.

Other motor, VSD inverter (reel spin speed control), and other electrical devices are

protected by individual fuses located on the electrical control panel accessible via key

entry to the enclosure on the right hand side of the guard.

EXPRESS DUAL 4000DX

6.1.1 Mower Preparation

Units of up to 36” long can be ground

in frame, this includes most machines

including Greens mowers and Fairway

units. In order to spin / drive the reel,

one end of the reel shaft drive must be

exposed. This will require the removal

of the hydraulic motor, the chain / belt

or cover depending on which type

of unit is being ground. This should

be done before the mower is on the

grinder (see example Fig. 6.1).

Ensure that the mower is clean and

that both reel and roller bearings are

in good condition. Also ensure that

the bedknife has been sharpened, if

necessary, and replaced with a small

amount of clearance between it and the reel.

FOLLOW THE ILLUSTRATED INSTRUCTIONS IN THE QUICK START

GUIDE AT THE END OF THIS MANUAL

6.1.2 FOLLOW THE SCREEN PROMPTS

Press Auto icon button to progress from the welcome screen to automatic mode

– display advances to next screen

Screen prompts to:

Ensure traverse is not engaged

To mount mower

To engage clamp

6.1.3 Unscrew the traverse engagement screw until it is released from the traverse chain so that

fork/grindstone can be traversed manually along the mainshaft.

6. In-frame Grinding

Fi g: 6.1

EXPRESS DUAL 4000DX

6. In-frame Grinding (Continued)

6.2. Mounting Mower

The mainshaft / Grinding stone should be wound down to its lowest position and the unit

placed on the table. The unit should then be carefully moved towards the multix brackets

or front roller brackets, which can be adjusted in any direction to allow the unit to be xed

in such a position that the grinding wheel can be raised towards the reel without coming

into contact with either the bedknife or the front roller/groomer.

6.3. Clamping

With the mower correctly positioned the radiused pressure bar) is moved forward to rest

on the rear of the mower and locked in position by pressing the key on the operator display

panel on the operator control panel downwards. The operator should release the key as

the pressure bar engages the cutting unit thus retaining pressure on the mower until the

grinding operation is completed. A backing up plate is supplied to protect the rear of the

units and to evenly disperse the force of the pressure bar across the width of the mower

(see Fig. 6.3.1.).

Fi g: 6.3 .1

EXPRESS DUAL 4000DX

To ensure that the correct position for the mower unit has been achieved, both control

wheels (right hand and left hand) should be wound in a clockwise direction so that the

grinding wheel may be placed to contact each end of the reel evenly. If the grinding wheel

touches the bedknife or any part other than the reel, the whole unit must be moved by

adjusting the position of the multix brackets or roller brackets. The exact position required

will be easily seen by looking along the mainshaft from one end of the machine as the

stone is raised to check that the point of contact is in a suitable position (see Figure 6.3.2.)

Rotate hand wheels anti-clockwise to move grinding wheel away from reel. It is important

that the grinding wheel should clear the highest blade along the full length of the reel

before proceeding.

NOTE If the cutting unit has no front roller tted so that the multix brackets are used then, once

the correct position for any particular unit has been nalised a “set up guide” should be

completed and led for future reference so that the identical multix brackets positions can

be used for all subsequent applications on the same type of unit.

6. In-frame Grinding (Continued)

Fig: 6.3.2

Reel

blades

Front Roller position

is adjustable

Grind stone has to contact

reel blades for sharpening

without touching anything else

Adjustable Front

Roller support

Position of

bedknife is

adjustable

EXPRESS DUAL 4000DX

6.4 Linking Up The Reel Drive Unit to the Reel

Machines are supplied with the reel drive motor under the table and a exible drive which

can be attached to either end of the machine do not have to be prepared before the mower

unit is placed on the table, as the complete drive unit can be moved to either side of the

table with a mower unit in place.

6.4.1 Select the attachment with which to drive the reel. If the reel sprocket, gear or pulley

is secured with a nut it may be easier to use a standard socket together with a 1/2”

square end driver. Ensure the nut is tight as the direction of rotation may tend to unscrew

it. Ensure that the drive shaft is through the exible coupling/driver before setting the

machine on the table and that the whole unit is at the correct end of the table.

Alternatively it may be easier to drive directly onto the sprocket using one of the pin or

adjustable type sprocket drivers tted to the plain drive rod.

6.4.2. When the cutting unit is in place and rmly xed into the multix brackets, or front roller

brackets, and the rear clamped with the radiused pressure bar, adjust the drive unit left or

right so that the appropriate drive rod will reach the end of the reel shaft. Tighten unit in

place.

Adjust the height and position, forwards and backwards and up and down, of the cable

drive support so that the shaft is square with the driven end of the reel, and tighten clamps

to hold it in place.

The black lobed hand screw allows the drive head to be moved along the square support

shaft to adjust the height of the drive, while the 5/8” hex headed socket screw allows the

support shaft to be clamped at any desired angle, and also allows the whole assembly to

be moved left or right along the machine bed to engage in the drive mechanism on the

reel.

The drive head of the shaft can also be slid through it’s support for further adjustment or

nal connection/ disconnection of drive.

6.4.3 Tighten the drive rod via the allen screw in the exible coupling onto the at of the drive

shaft.

6. In-frame Grinding (Continued)

EXPRESS DUAL 4000DX

6. In-frame Grinding (Continued)

6.4.4 Moving the exible Shaft

There is a lay shaft socket at both ends of the

machine into which the exible drive can be

engaged as required. The other end of the

exible shaft can be disconnected if required

but this would not generally be necessary as the

bracket and shaft would normally be moved as

an assembly

The exible drive shaft can be detached

from its socket on the end of the machine by

pulling sharply on the shaft, to release it from

a spring loaded ball detent. (Earlier units by

rst removing the spring retainer (R-pin)),

and withdrawing the complete shaft (see Fig.

6.4.2.2.) When replacing the shaft, ensure that

it is properly engaged in the lay shaft socket.

By loosening the socket screw and allowing

the clamp nut, under the table, to twist through

approximately 90 degrees, the whole assembly

can be lifted clear of the table, and moved to the

other side of the mower unit if required.

Press “next” icon on operator display – display advances to next screen.

Fig. 6.4.4.2

EXPRESS DUAL 4000DX

6.5 Actual Grinding

Screen requests size of mower.

6. 5.1 Press the relevant icon to select size of mower:

nSmaller units (or Greens)

n n Medium sized units (or Tees / Light

Fairway)

n n n Large units (or Fairway)

Display advances to the next screen.

Screen requests type of grind required.

6.5.2 Press the relevant icon to select type of grind required:

n“touch up” (mower needs little

sharpening, probably part of a regular

sharpening regime)

n n “maintain” (blades need just a little more

material removing to get a good edge) or

n n n “rectify” (damaged blades, or a unit rarely

ground or heavily back-lapped)

Display advances to the next screen.

6.5.3 Screen shows selected answers (grind cycle)

CLOSE GUARD FIRST

Press tick (“accept”) icon if OK.(Grind, Traverse and Reel drive motors start – display

advances to the next screen).

or

Press cross (“reject”) icon if you wish to make an alternative selection (display returns to

size of mower question).

6. In-frame Grinding (Continued)

EXPRESS DUAL 4000DX

6. In-frame Grinding (Continued)

6.5.4 Set up of Traverse

With motors running, the screen prompts: “set grind stone to reel” and

“set traverse limit stops”

Traverse the grinding wheel by hand, using the Traverse Engagement Screw until it is at

the extreme point of desired travel. Ensure that the traverse reversing bar is also moved in

that direction and slide the reversing stop up to the grinding wheel traverse assembly and

tighten. Move the grinding wheel to the opposite end of the desired travel and repeat the

operation ensuring that the reversing bar has also been moved in the opposite direction.

This is critical where the grinding wheel cannot pass beyond the end plates if they protrude

below the maximum diameter of the reel.

NOTE On the EXPRESS DUAL it is not necessary for the whole width of the grinding wheel to

pass the end of the reel and it SHOULD NOT DO SO EVEN IF SPACE PERMITS (see

Fig. 6.5.4).

Ensure that the leading edge

of grinding stone passes the

end of the reel – but clearance

must be maintained between

stone and end frame of unit.

NOTE: The reversing bar will move approximately ½” (13mm) before the direction of travel is

reversed and will allow the grinding wheel to move with it. It is therefore ESSENTIAL that

this is taken into account when setting the maximum point of travel.

Fig: 6.5.4

EXPRESS DUAL 4000DX

6.6.1 With the stone positioned at the left hand end of the reel, place the left hand on the left

hand control wheel and the right hand on the traverse knob, moving the grinding wheel

along the reel by hand using the traverse engagement screw, wind up the left hand control

wheel clockwise until the grinding wheel strikes and sparks gently against the reel.

6.6.2 Unwind a complete turn to move the stone away from the reel.

6.6.3 Move the grinding wheel to the right hand end of the reel and, using the right hand on the

right control wheel, raise the shaft until the reel again can be gently rotates against the top

of the grinding wheel.

6.6.4 Unwind half a turn.

6.6.5 Go back to the left hand end and repeat the process but this time, after contact has been

made, unwind only sufciently to release the contact.

6.6.6 Go back to the right hand end and repeat the process and again release the contact only

slightly.

6.6.7 Repeat this process on the right hand side of the reel, raising the shaft with your right hand

and moving the grinding wheel along with your left hand. Repeat this process until the

contact all along the reel is light, even and parallel.

6.6.8 Screw in traverse knob to engage power traverse.

NOTE: Check auto traverse is changing direction at correct point at each end of its

movement.

6.6.9 Press “next” icon to start grinding cycle

Screen reads “GRINDING”. Pictures on display animate.

Both handwheels will automatically rotate clockwise to apply a parallel cut to the reel.

After a pre-determined number of traverse passes of the stone along the reel a further in

feed will be applied.

According to the program selected a certain number of in feeds / traverse passes will

follow until the cycle is completed. Both handwheels will then rotate counter-clockwise, to

back the stone away from the reel, and all motors will stop.

(Programme will NOT let a reel “spark-out” with factory set programme parameters)

6. In-frame Grinding (Continued)

EXPRESS DUAL 4000DX

6.6.10 Screen reads “PROGRAM COMPLETE

Press “nished” icon if reel is satisfactory

or

Press “re-do” icon if it needs more grinding, to repeat the whole cycle

or

Press “touch-up” icon if reel is almost there but could do with a “touch up” to nish it off.

6.6.11 Press “nished” icon to advance display to the next screen “Grinding completed”-

remove mower from machine”

6.6.12 Press “unlock” icon to undo clamp and remove mower

6.6.13 Press “next” icon to return to the starting screen

6.7 ALTERNATIVES

6.7.1 If “re-do” or “touch up are selected, (close the guard before selection).

After a pause the motors will re-start and the handwheels will return the grindstone to the

position where the grind cycle nished. Further feeds/traverses will follow until the cycle is

completed once more,

6.7.2 At this time the guard can be opened and the condition of the reel checked.

6.7.3 If the blades are sharp enough Press the “nished” icon.

6.7.4 The display will change to “Grinding completed – remove mower from machine”

screen.

6.7.5 If the blades still need some grinding, the “resume” icon can be pressed, after closing

the guard. After a pause the motors will re-start and the handwheels will return the

grindstone to the position where the grind cycle was paused. The cycle will continue to it’s

conclusion.

6. In-frame Grinding (Continued)

Bernhard Express Dual 4000DX User manual

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