Bernhard Express dual ed2000 User manual

EXPRESS DUAL 2000

Please read this manual carefully before using the Express Dual.

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

ED2000 Precison Reel/Cylinder Grinder

User’s Guide &

Instruction Manual

ED2000 2007/01

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EXPRESS DUAL • ED2000

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EXPRESS DUAL • ED2000

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EXPRESS DUAL • ED2000

BERNHARD AND COMPANY LTD

Bilton Road • Rugby • England • CV22 7DT

Tel +44 1788 811600 • Fax +44 1788 812640

Email: info@bernhard.co.uk

USA Toll Free 1-888 GRIND IT (

1-888 474 6348)

ED2000 2007/01

EXPRESS DUAL

Contents

ED2000 Precison Reel/Cylinder Grinder

You are now the owner/operator of a Bernhard’s Express Dual 2000 which,

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

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

please read it thoroughly before using your machine.

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

or phone our

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

or

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

or email

[email protected]

or use the technical support feedback form on our web site

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

Identication of Pictograms 4

Safety 7

Installation 8

Identication of Tools and Equipment 10

Understanding the Machine 11

In Frame Grinding 13

Electrical Fault Finding 20

Maintenance 21

Part Lists, Exploded and Wiring Diagrams 25

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-GENUINE SPARE PARTS.

Please quote this serial number on all

correspondence:

Serial #:

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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 2200 Rev/Min

BEWARE!

MOVING GRINDSTONE AND SHAFT

REEL ROTATING AT BETWEEN

147 AND 255 Rev/Min

TOTAL WEIGHT OF MACHINE (KG)

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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

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Emergency Stop

(Twist to release)

Traverse On

Reel (Spin)

Drive On

Grindstone On

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

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

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

have received adequate training.

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

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

2.4 ALWAYS operate the machine with the guards in position.

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

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

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

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

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

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

of abuse.

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

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

which could be caught in moving components.

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

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

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

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

(Refer to safety note 1.3).

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

under the inuence of drugs or alcohol.

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

ensure that the area is clear before lowering the load.

2. Safety

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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).

  

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     

  

  

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.

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3.4 Electrical Supply

USE A QUALIFIED ELECTRICIAN

The EXPRESS DUAL is supplied with a .55 kW ( HP) single phase main (grind) motor

plus 2 fractional HP motors, for spin and traverse.

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

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

machine.

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

operator or other personnel.

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

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

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

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

at the point of contact.

3.5 Preparation

If the machine has been

received in a crate, the handles

on the control wheels should be

removed from the underneath of

the control wheels and retted to

the top (see Fig. 3.5).

It is important that the protective

film on the main shaft is

removed prior to using the

machine. This can be done

using a WD40 or similar product

(not gas/petrol) and then drying

the shaft with a clean, dry cloth

so that the grinding wheel

assembly moves freely along

the whole length of the shaft.

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

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

traverse, but NOT THE MAINSHAFT).

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

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

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

when dry.

Fig: 3.5

3. Installation (Continued)

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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 2000

A2706 3/16” AF Tee handled Allen Key.

A2719 Grinding Wheel Nut Wrench

A4134 Drive Rod Square (short)

A2712 8mm Long Series Allen Key

Adjustable Front Roller mtg brackets

A4133 Spline driver set

A6737 Diamond Dresser

Also available to order at extra cost

A2714 Adjustable Sprocket Driver

A9182 Drive Rod Plain (short)

A4063 2 Pin Drive (large)

A4276 2 Pin Drive (small)

A9181 3 Pin Drive (small)

A4097 Adjustable Plain Shaft Driver

A6342 Backing up/Pressure Plate (not shown)

A4106 Ransomes 5/7 Driver

Multix brackets

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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 on the front roller brackets or optional

multix brackets.

The rear of the unit will be held by the adjustable clamp that slots into the rear of the

grinder table.

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5. Understanding the Machine (Continued)

5.3 Machine Functions

The EXPRESS DUAL has 2 (or 3) separate motors driving the different functions of the

machine, all are controlled from the control panel. These functions are as follows:

5.3.1 Reel/Spin drive

This motor/gearbox is supported on a bracket on top of the machine table & drives the reel

through a exible coupling. The motor can be swapped to either side of the table and the

output shaft can be tted into the gearbox from either direction.

5.3.2 Grinding Wheel

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

5.3.3 Traverse

(Option where tted. ONLY available in conjunction with the freestanding support frame)

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

the grinding wheel along the mainshaft.

5.3.4 Stop

Pressing the stop button shuts off both (or 3) 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.

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 switch is

situated behind the blue reset button on the cover of the main electrical control box which

is located on the right hand end of the machine (looking from the front).

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.

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6.1 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.

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.

With the mower correctly positioned

the clamp can be slotted into the rear

of the machine table, moved forward

to rest on the rear of the mower and

locked in position retaining pressure on

the mower until the grinding operation

is completed.

6. In-frame Grinding

Fig: 6.1

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6.3 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).

6. In-frame Grinding (Continued)

Fig: 6.3

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

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6.4 Set up of Traverse/Stops

Manual, bench-mounted machine

Rotate hand wheels anti-clockwise to move grinding wheel away from reel. Traverse the

grinding wheel by hand, using the handle xed to the fork-driver until it is at the extreme

point of desired travel (so that one edge of the grindstone is past the end of the reel but not

touching the mower’ side frame). Move the stop collar, on that side of the grinder, against

the fork driver. Move the grinding wheel to the opposite end of the desired travel and

repeat the operation.

Auto traverse machine with free standing support

Rotate hand wheels anti-clockwise to move grinding wheel away from reel. Unscrew the

traverse engagement screw until it is released from the traverse chain, 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 (the shaft that the traverse pick up

and stop collars run on) 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. 6.4).

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 1/2” (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.

Should the reversing bar be dragged by the traverse assembly in the direction of travel

during the grinding processes, causing the stone traverse to reverse prematurely, it will be

necessary to adjust the reversing bar damper.

6. In-frame Grinding (Continued)

Fig: 6.4

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6.5 Linking Up The Reel Drive Unit to the Reel

Machines are supplied with a compact reel drive motor/gearbox that is supported by a

bracket that mounts to the machine table. The support can be mounted on either end of

the table according to where the drive needs to be connected to the mower.

6.5.1 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  inch 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.

6.5.2. When the cutting unit is in place and rmly xed to the

front roller brackets, and the rear clamped. Position the

drive support unit left or right, using appropriate mounting

holes, so that the 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 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 hex socket “allen” screw allows

the support shaft to be clamped at any desired angle to

engage in the drive mechanism on the reel.

Plug the power lead into the socket (on the centre rear

of the machine – OR on the side of the unit that the reel

drive is positioned.)

Route the cable under the hooks provided to keep it clear

of the cutting unit

6. In-frame Grinding (Continued)

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6.6 Applying the Cut

Before starting any of the motors it is necessary to bring the grinding wheel into its

approximate cutting position.

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 reel, wind the control wheel clockwise while

slowly rotating the reel until the reel gently rides across the grinding wheel.

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 and the left hand on the reel, raise the shaft until the reel again can be

gently rotated 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.

NOTE It is important that the grinding wheel should clear the highest blade along the full length of

the reel before grinding commences.

6. In-frame Grinding (Continued)

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6.7 To Commence Actual Grinding

NOTE With experience and familiarity setting / applying the cut can start here, speeding up the

set up procedure.

6.7.1 If the machine has them tted, CLOSE THE GUARDS.

6.7.2 Start the reel drive motor and check for smooth, easy running.

6.7.3 (If the machine has auto-traverse tted, start the traverse motor, rst ensuring that the

traverse engagement screw is unwound and not connected to the traverse chain.)

6.7.4 Now repeat the adjustment process with the left hand on the control wheel and the right

hand on the traverse handle (or traverse engagement knob), moving the grinding wheel

along the reel by hand using the handle (or traverse engagement screw), winding up the

left hand control wheel until the grinding wheel strikes and sparks gently against the reel.

6.7.5. 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 along the reel is even and parallel.

6.7.6 (If traverse is tted, screw in traverse knob to engage power traverse.)

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

6.7.8 Place hands on the left and right control wheels and move both hand wheels clockwise

the same amount to apply an even cut. Apply a good hard cut. Do not be afraid of the

aggressive nature of the grinding process.

6.7.9 Traverse the stone from side to side with a steady, even action to grind the reel, applying

extra in-feed as necessary.

NOTE: It is important that the control wheels are moved equally.

6. In-frame Grinding (Continued)

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6.8 When Is The Job Done

6.8.1 You will hear the cut begin to run out – a rough guide of cutting times will be:

Fairway Units 12–20 minutes

Medium Triple Units 10–15 minutes

Greens & Hand Mowers 8–10 minutes

6.8.2 Now take off the cut by simultaneously moving both hand wheels anti-clockwise, when the

stone is at one end of its traverse, until the grinding wheel is clear of the reel.

6.8.3 Push the total / “E”- stop button.

NOTE NEVER stop the machine while the grinding wheel and reel are in contact except in an

emergency. Never allow the grinding wheel and reel to spark out. If this does happen put

another cut on for a few more passes.

6. In-frame Grinding (Continued)

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USE A QUALIFIED ELECTRICIAN

In the event of any motor not starting, the following procedure should be adopted:

7.1 Check that STOP BUTTON in control panel on top of machine is not permanently in STOP

position.

7.2 Check fuses.

7.3 Check voltage in electrical junction box, low-right hand side of machine. Then in the

control panel box.

7.4 Check for open circuit on overload, terminals 95 and 96, to determine whether or not main

motor is faulty. If open press red resetting button on overload.

7.5 To determine that all three contactors are OK test each one by pushing start button on

the individual contactors, they should noticeably pull in. This can be checked by someone

looking in the junction box while the start buttons are pressed.

7.6 Traverse

If the contactor is functioning properly check the microswitch. If this is found to be OK

check capacitor if possible. If neither of these is faulty, then the motor is probably at fault.

7.7 Reel Drive

If the contactor is functioning properly, check the capacitor.

If neither are faulty then the motor is probably at fault.

7.8 Main Motor

If the contactor is functioning correctly, check the load current with an ammeter across

terminals T2 and T3 on Thermal overload. If this exceeds full load current indicated on

the motor identication plate then a new motor is needed. If the reading is below full load

current then possibly the overload is set too low.

NOTE Before assuming that there is an electrical fault in any of the systems ensure that the

mechanical drive assemblies attached to a particular motor are moving freely, and have

not got increased resistance due to damage, or the build up of dirt. This can best be done

by detaching the motor drive and ensuring that the mechanism is moving freely.

7. Electrical Fault Finding

Bernhard EXPRESS DUAL ED2000 User manual

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