Birmingham WSG1640AHD User manual

WSG1640AHD
SURFACE GRINDING MACHINE
OPERATINGMANUAL

Operating manual
QUALIFIED CERTIFICATE
Ex-factory record:
The machine is performing GB4022-83
《Horizontal Shaft &Rectangular Table Surface Grinder Precision》
standard
Model of machine: WSG1640AHD
Width of worktable: 16 in
Length of worktable: 40 in
The machine has been inspected being up to the standard and
approved for delivery.
Serial No.:
Inspector:
Date:

Operating manual
Precision Inspection Register
Geometrical precision
No. Items Diagram
Permissible
deviation Actual deviation
1 Flatness of the table surface
Full length:
0.01
Local:
0.005/300
2
a. Parallelism of the table
surface to its longitudinal
movement
b. Parallelism of the table
surface to its transverse
movement
a.
Full length:
0.015
Local:
0.008/300
b.
Full length:
0.01
3
Parallelism of the median
slot to the longitudinal
movement of table
Full length:
0.015
Local:
0.008/300
4
Verticality of the table
transverse movement to the
longitudinal movement
0.03/300
5
Verticality and straightness
of the wheel head up and
down to the table surface
0.03/300

Operating manual
6 Radial run out of the wheel
spindle nose
0.004
7 Axial run out of the wheel
spindle 0.004
8
Parallelism of the spindle
center line to the table
surface
0.025/300
9
Verticality of the spindle
center line to the medina
slot
0.015/300
Machining precision
No. Inspection items Permissible
deviation Actual deviation Remark
P1 Grinding five columned
test blocks
Tolerance in
thickness:
0.005/300
Test pieces are 45#steel
φ50
P2 Grinding completed test
block
Tolerance in
thickness:
0.005/300
The material test piece
is iron HT200, the length
is half of table, width is
three times of wheel
width ,the thickness is
60mm

Operating manual
DISTRIBUTOR
Do not transport the machine and start operation before reading
the safety directions and the instruction manual.
The below mentioned persons herewith confirm that they have read
and comprehended the operation instructions before transport and
appropriate use of the machine for their security and of third persons
and the safety of the machine. For achieving best grinding results it is
in the user’s own interest to follow the technical directions for
grinding.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
(Name) (Signature)

Operating manual
SAFETY DIRECTIONS
To guarantee an optimal, trouble-free operation at lowest possible
endangering this machine should only be operated, maintained and
repaired by persons familiar with it and list operation.
For these reasons the instruction directions must be read and be followed
exactly before transport and start of operation.
Especially important safety directions are marked with symbols in front of
them.
Comments on indicative symbols
= Safety directions must be followed exactly.
Not noting them causes danger for the operator
= Caution advices must be remembered exactly
Not noting them may entail operation trouble or
damage of the machine
= Important directions should be noted in order to
reach good working results.

Operating manual
INDEX
Description page
Chapter 1. Safety instruction
1.1 general safety instruction 1
1.2 safety regulation of the machine 2
Chapter 2. Summary of the machine
2.1 concise statement on the machine 4
2.2 field of application 4
2.3 construction identification 5
2.4 main specification 6
Chapter 3. Machine installation instruction
3.1 Diagram of machine floor space 7
3.2 demand of foundation 9
3.3 foundation construction and machine setting 9
3.4 Carriage and lifting machine 11
3.5 Remove the setting plates 11
3.6 Clean the machine 12
3.7 Placement of Hydraulic system and coolant tank 12
3.8 power supply 15
Chapter 4. Trial running
4.1 preparation before trial running 18
4.2 safety inspection before operation 20
Chapter 5. Operation instruction
5.1 control panel instruction 22
5.2 operating caution 37
5.3 correct operation of wheel 38

Operating manual
INDEX
Description page
5.4 select perfect method of variously grinding 43
5.5 inspection of the grinding wheel 44
5.6 wheel dressing & correct use of wheel dresser 47
5.7 Balancing wheel 49
Chapter 6. Daily maintenance
6.1 daily inspection (oil & water) 51
6.2 daily inspection (test list before operating) 52
6.3 daily inspection (test list after work) 53
Chapter 7. Setting, Adjusting and trouble shooting
7.1 There are ripples on the work piece 54
7.2 Accuracy of the work-piece ground is not so good 54
7.3 The spindle don’t run 55
Appendix
Electrical parts list 56
Circuit diagram 58
Hydraulic system principle diagram (1page) 66
Main function structure drawing ( 10 pages) 67
PACKING LIST

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1
Chapter 1 Safety instruction
1.1. general safety instruction
(1) The operator must be trained and passed the operating and
maintaining test.
(2) The user should educate the operator according to local law of
industrial safety and hygiene.
(3) The user should warn operator about unsafe operating.
(4) Read the manual before using the machine, and note danger mark and
content stuck on the machine.
(5) The operator whose hair is too long must wear hat before operating
and maintain machine.
(6) When operating, the operator must wear glasses protecting eyes, wear
mask and safe industrial shoes.
(7) Keep machine and around surroundings clean and, avoid the floor
being wet and slippery, and clean unnecessary goods.
(8) In order to prevent compression, please retain 600mm space out of
machine’s limit position, mark the working range with yellow line and
forbid any other person to enter in when operating.
(9) Always shut all guard shied and the door of electrical box unless
maintain the unit.
(10)Shut off the power before maintain the machine.
Forbidden Items:
(1) Don’t operate or maintain the machine with long sleeve clothing, tie,

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2
and glove.
(2) Don’t lean against the machine in working range
(3) Don’t adjust the grinding wheel cover, right or left travel limit control
block, nozzle with hand or tools when the machine is running.
(4) Don’t blow out scrap or dust with compressed air to protect operator’s
eyes.
1.2. safety regulation of the machine
(1) Be sure that the allowable maximum fringe speed of wheel is 35m/s or
higher.
(2) Pay attention to correlative warning instructions before inspecting and
maintaining.
(3) When inspecting electrical parts, must wear nonconducting protector
such as insulating gloves, rubber shoes and so on..
(4) All the electrical parts needing earth should be properly earthed
according to circuit diagram.
(5) Be sure that circuit is turned off with appropriate instrument before
inspecting circuit
(6) Only certified operator can open the electrical box and inspect circuit
when there is fault.
(7) If the hardness of work-piece is more than HRC65 and grinding is
difficult, Please connect with wheel manufactory and choice a proper
kind of wheel.
(8) The grinding wheel should be installed after balanced, the wheel
should be balanced by trained worker. Before fixing the wheel on the
spindle, cleaning contact surface between flange and front end of
spindle.
(9) Should confirm the position and performance of emergency switch

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3
before driving the machine.
(10) Must inspect if the spindle rotating direction is correct before driving the
spindle motor. Begin to grind work-piece after not less than 5 minutes
since driving the machine.
(11) Please clean the magnetic chuck surface before using, if there is
scuffing or scar on the surface, please grind it again.
(12) When grinding antimagnetic material such as aluminum alloy, graphite
and so on, please use suitable chuck block to fix the work piece and
make sure it could not touches the wheel.
(13) By hands before wheel turning, the operator should confirm if magnetic
chuck holding work-piece fast and hard.
(14) The work table must be motionless when operator adjusts right or left
travel limit control block.
(15) When wet grinding, should shut off cooling device before braking the
spindle motor.
Forbidden Items:
(1) The machine is forbidden to install near the powder, magazine and
explosive.
(2) Don’t use inflammable liquid as cutting fluid.
(3) The wheel of spindle is forbidden to cut material as rotary sander.
(4) It’s forbidden to alter use & capacity design of the machine and to use
the wheel out of stipulation, also not processing overweight or
overlarge work-piece.
(5) Don’t change circuit before authorized by manufactory avoid damage.
(6) Don’t change interlocked circuit into by pass circuit.
(7) Don’t touch the parts at random where stuck heat lightning mark.
(8) Should avoid touching electrical box and circuit when body and hands
are wet.

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(9) Must not wearing metal garnish to avoid electric shock when inspecting
electrical parts, and hang up warning mark to avoid someone operating
the machine.
(10) Forbid to fixed short & over-thin work-piece or complicated shape,
precarious CG work-piece directly on the magnetic chuck.
(11) When grinding, any other goods are permitted to place on the table but
the fixed work piece.
(12) Don’t adjust nozzle after the spindle has been driven, when wet
grinding.
(13) Don’t stop the wheel with hands or other things, after the motor is shut
off.
(14) Don’t move or exchange work-piece when the work table is moving or
the wheel is turning.
(15) Don’t take a risk clean the scraps on the work piece while grinding or
the wheel is turning.
(16) Specific accessory should be used to takedown the wheel. Forbid to
pound the wheel and pounding maybe make the wheel broken.

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Chapter 2 Summary of the machine
2.1 concise statement on the machine
“十” saddle is adopted in the design, all these three guide way is lined with TF
wearable material and lubricated by intermittent forced oil pump, the column
have double walls. The table right and left moving is driven by variable
displacement vane pump and adopted closed type hydraulic system. All above
make the machine with high rigidity and precision, small thermal distortion,
moving smoothly, low noise and temperature increase, is easy to maintain. The
table is driven by manual or by hydraulic in right or left direction, the speed is
variable changed by adjusting lever located on the saddle, driven by manual or
by motor through driven the ball leading screw. The grinding head could be
driven by lifting motor( AHR model) or servo motor( AHD model), also it be
driven by manual.
2.2 field of application
The machine is used for mid-type & mini-type material processing workshop and
the other maintain & tools workshop in.
The machine is mainly used to grinding the surface with the wheel circle face,
the surface been ground have high precision and low roughness. Also it can
grind the vertical surface with the end face of the wheel. the work pieces can be
placed on the magnetic chuck or fixed directly on the table or with other fixtures
suit to various work pieces.
The machine can be used for grinding steel, cast iron and nonferrous metals.

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2.3 construction identification
No Name No. Name
1 Bed 7 Grind wheel
2 Electro lubricate pump 8 Saddle cross moving hand
wheel
3 Table longitudinal moving
hand wheel 9 Saddle
4 Table 10 Wheel head lifting hand wheel
5 Column 11 Cabinet
6 Wheel guard 12
Elevating motor (only for R/A
model)

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2.4 main specification
Main specification of WSG1640 Series
Model
Item Unit AHR AHD
Table size (W×L) In 16×40
Table longitudinal move speed in/min 275.5~906
Max. Distance from table surface to
spindle centerline In 23
Max. Loading capacity ( include chuck) kg 500
Table
transverse
movement
Auto intermittent feed In 0.004~0.3
Rapid speed in/min 39
Feed of Hand-wheel in/div. 0.0008
Vertical
movement
Auto feed In - 0.0002/0.0004/0.000
8/0.0016/0.002
Rapid Speed in/min 18
Feed of
hand-wheel
in/div. 0.0002
in/rev. 0.08
Grinding
wheel
Size (OD×W×ID) In 14×1.5×5
Speed rpm 1450 (50HZ) 1750 (60HZ)
Motor
Spindle motor kw 5.5
Oil pump motor kw 2.2
Cooling pump motor kw 0.09
Vertical driven motor kw 0.25 0.5
Transverse driven motor kw 0.04
Gross Weight kg 3800
Floor space (L ×W×H) In 116×89.5×86
1. AH mean: auto feed on transverse, hydraulic transmission on longitudinal, manual
on vertical.
2. AHR mean: auto feed on transverse, hydraulic transmission on longitudinal, rapid
movement on vertical.
3. AHD mean: auto feed on transverse, hydraulic transmission on longitudinal, auto
feed on vertical.

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Chapter 3 Preparation before machine installation
3.1 diagram of machine floor space
size
model A B C
WSG1020 89” 68” 85”
WSG1224 110” 82” 87”
WSG1240 173” 128” 87”
WSG1632 142” 104” 94”
WSG1640 173” 128” 94”
Limit position drawing

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3.2 demand of foundation
1) Installation of the machine will effect deeply efficiency and precision,
don’t place the grinder between the milling machine and planer, etc,
because there is shock when these machine are running, the shock will
be transferred to the grinder and make wave mark on the grinding
surface.
2) The table of the machine must be prevented from insolate for this will
make the table thermal distortion. Don’t install the machine in the field full
of magnet, inflammable dirt, metal dirt and outburst gas.
3) Don’t install the grinding machine on the insubstantiality foundation avoid
distortion.
3.3 foundation instruction and machine setting
1) The machine should be installed on a solid concrete foundation, the
foundation is to be cast in one piece, the concrete should not be lower
than #500, the depth noted on the “Foundation Layout” is the min. value
suitable only for the ordinary solid soil, else it should be accordingly
increased. If the shop is near the sandy river bank or the ground is newly
filled, the foundation should be reinforced with the additional blocks. After
the foundation is finished a curing period of 28days is necessary. During
the first week the foundation should be watered often so that it can be
kept damp. In winter the curing period has to be properly lengthened and
anti-freezing measure should taken into consideration, Installing is not
allowed within the curing period.
2) Don’t use simple “knocking in” type wedges, when the machine is
installed and adjust leveling with wedges. The machine is to be installed
with foundation bolts, the cavities should be grouted with 1:3 cement
mortar around the bolts and then left to dry 3-7 days after the machine
has been pre-leveled up. Following this proceed with fine leveling and
tighten the nuts.
3) Check insulating resistance for electric system, then connection of power
mains to the machine electric cabinet should be made only after it has
been well grounded. Only when the installation has been entirely

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completely and the function of electric circuits proved to be securely safe
and reliable, can the wheel of the machine be tested for geometrical
complete, started and operated.
UNIT:inch
size
model A B C
WSG1640 45 30 16
WSG1632 34 30 16
WSG1240 45 22 16
WSG1224 30 22 16
WSG1020 25 21 17
Machine ground diagram

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3.4 Carriage and lifting machine
Use equipment to lift the machine as following.
Lifting: first fasten the sling bolts on the machine base, then set the wire cables
on the sling bolts and the hook.
3.5 Remove the setting plates
In order to avoid damage during transporting, the movable parts have been
locked. When the machine is positioned and no needing to change location
again, uncrating the lock blocks (refer to pictures)
1. Get off the tighten bolt which used to fix the
saddle and work table

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3.6 Clean the machine
All the machines are provided with anti-rust treatment. The moving parts are
lubricated with grease and fixture point and dye black portions are applied with
anti-rust oil. Before first running the machine, clean all the slide ways, cylinder,
spindle and surface which have been applied with anti-rust oil.
3.7 Placement of Hydraulic system and coolant tank
3.7.1. Placement of Hydraulic system
2. Move up the wheel head then
get off the wooden block
3. Remove the antirust paper
covered around the hydraulic
piston rod. Clean the saddle slide
way.