Irontite products Van norman fg5000 User manual

By Irontite Products Inc.

Instruction Manual and Parts List

MANUFACTURER OF IRONTITE, VAN NORMAN, AND KWIK-WAY BRAND PRODUCTS

Irontite Products Inc. PO Box 9877, Cedar Rapids, IA 52409 USA 800-553-5953 319-377-9101 (FAX)

Equipment specifications, options and accessories subject to change without notice.

Flywheel Grinders

Models FG5000 / FG10000

Warranty for Flywheel Grinders

Irontite Products Inc. (“IRONTITE”) warrants to the original purchaser (the “Purchaser”), other than a purchaser for resale (the

“Distributor”), that IRONTITE’s machine tools shall be free of defects in materials and workmanship, for a period of one (1) year

from completion of installation, or for a period of fifteen (15) months from date of shipment, whichever is earlier. IRONTITE will, at

its sole and exclusive discretion, either replace or repair any machine or part thereof defective in workmanship or material, at no

charge to the Purchaser.

All warranty repairs must either be performed by or authorized by an IRONTITE Authorized Service Organization. To obtain

warranty service, Purchaser must contact IRONTITE. Purchaser must provide verification of date of delivery or installation (dated

installation report) when requesting warranty service. Ground freight charges (UPS regular or common carrier truck) for all

warranty replacement parts are paid by IRONTITE. Materials or parts alleged to be defective shall be returned to IRONTITE at

IRONTITE’s request, transportation charges prepaid. After the warranty repair or replacement of a defective part, IRONTITE’s

warranty for such part shall continue for ninety (90) days or for the remainder of the original Limited Warranty, whichever is longer.

WARRANTY LIMITATIONS

This warranty shall remain in effect only if the machine is used and maintained in accordance with all operating and maintenance

instructions set forth in the manuals and instruction sheets furnished by IRONTITE. IRONTITE shall have no liability to repair or

replace defective parts until the Purchaser has fulfilled its payment obligations. No allowance will be made for repairs or

alterations made without IRONTITE’s prior written consent or approval. The Limited Warranty provided by IRONTITE excludes the

following:

1. Damage, malfunction, or failure caused by or resulting from improper maintenance, misuse, neglect, accident or any other

cause beyond the control of IRONTITE.

2. Damage, malfunction, or failure caused by or resulting from modification of the machine (mechanical or electrical) without

written authorization by IRONTITE.

3. Damage, malfunction, or failure caused by or resulting from installation or use of accessories or peripherals not purchased

through or authorized in writing by IRONTITE.

4. Paint, batteries, filters, fluids, fuses, light bulbs, or any commonly expendable items.

5. Damage to machines and/or components while being transported from IRONTITE’s warehouse or facility to destination.

6. Accessories or peripherals not manufactured by IRONTITE, which shall be subject to only whatever warranty that is supplied

by the manufacturer of such product.

7. Controls, spindle and servo motors, spindle and servo drives, gear motors and gearboxes which shall be subject to only

whatever warranty that is supplied by the manufacturer of such product.

No person, agent, distributor, dealer or company is authorized to change, modify or amend the terms of this Limited Warranty in

any manner. IRONTITE makes no warranties, guarantees or representations, express or implied with respect to the machine tool,

or parts thereof, except to the extent such warranty is set forth herein. The equipment covered does not necessarily comply with

any codes or standards unless specifically quoted, ordered, and so accepted.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION

WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR USE OR PURPOSE. IRONTITE’s LIABILITY

UNDER THIS WARRANTY IS EXPRESSLY LIMITED TO ITS PROMISE TO REPAIR OR REPLACE THE DEFECTIVE

GOODS. IRONTITE SHALL HAVE NO FURTHER LIABILITY IN CONTRACT OR NEGLIGENCE OR UNDER ANY OTHER THEORY

OF LAW OR EQUITY FOR ANY DAMAGES, DIRECT OR INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL, OR ANY

DELAY RESULTING FROM THE DEFECT.

Because of Irontite Products Inc.’s constant program of product improvement, specifications are subject to change without notice.

For further information or questions, please contact

Irontite Products Inc. at: 800-553-5953 or fax 319-377-9101.

KEEP THIS WARRANTY FOR YOUR RECORDS

Model #: Serial #: __________ Purchase Date: _____________

Van Norman FG5000/FG10000 Flywheel Grinders

RECEIVING SHIPMENT

Upon taking delivery of your machine, carefully inspect the assembly before removing the crating and

packing materials.

If evidence of damage exists, contact the shipper and Van Norman immediately. Although Van Norman is

not responsible for damage incurred during transit, you will be provided assistance in preparation and filing

of any necessary claims.

CAREFULLY READ THIS MANUAL BEFORE ATTEMPTING TO SETUP OR OPERATE THIS MACHINE.

IMPORTANT NOTE

Always have your serial number ready when communicating with Van Norman regarding parts or service.

Keep this manual in a safe place.

Date Received:

Serial Number:

(Serial Number location: Upper left corner at rear of unit)

Van Norman

Manufactured by Irontite Products Inc.

PO Box 9877, Cedar Rapids, IA 52409

800-553-5953 319-377-9421

(FAX) 319-377-9101

Van Norman FG5000/FG10000 Flywheel Grinders

SAFETY FIRST

This manual has been prepared for the owner and those responsible for the maintenance of this machine. Its purpose aside from

proper maintenance and operations, is to promote safety through the use of accepted practice. READ THE SAFETY AND

OPERATING INSTRUCTIONS THOROUGHLY BEFORE OPERATING THE MACHINE.

In order to obtain maximum life and efficiency from your machine, follow all the instructions in the operating manuals carefully.

The specifications put forth in this manual were in effect at the time of publication. However, owing to Van Norman’s policy of

continuous improvement, changes to these specifications may be made at any time without obligation.

SAFETY INSTRUCTIONS

1. Read, understand and follow the safety and operating instructions found in this manual. Know the limitations and hazards

associated with operating the machine.

2. Eye Safety: Wear an approved safety face shield, goggles or safety glasses to protect eyes when operating the machine.

3. Grounding the Machine: Machines equipped with three prong grounding plugs are so equipped for your protection against shock

hazards and should be plugged directly into a properly grounded three-prong receptacle in accordance with national electrical

codes and local codes and ordinances. A grounding adapter may be used. If one is used, the green lead should be securely

connected to a suitable electrical ground such as a ground wire system. Do not cut off the grounding prong or use an adapter

with the grounding prong removed.

4. Work Area: Keep the floor around the machine clean and free of tools, tooling, stock scrap and other foreign material and oil,

grease or coolant to minimize the danger of tripping or slipping. Van Norman recommends the use of anti-skid floor strips on the

floor area where the operator normally stands and that each machine's work area be marked off. Make certain the work area is

well lighted and ventilated. Provide for adequate workspace around the machine.

5. Guards: Keep all machine guards in place at all times when machine is in use.

6. Do Not Overreach: Maintain a balanced stance and keep your body under control at all times.

7. Hand Safety: NEVER wear gloves while operating this machine.

8. Machine Capacity: Do not attempt to use the machine beyond its stated capacity or operations. This type of use will reduce the

productive life of the machine and could cause the breakage of parts, which could result in personal injury.

9. Avoid Accidental Starting: Make certain the main switch is in the OFF position before connecting power to the machine.

10. Careless Acts: Give the work you are doing your undivided attention. Looking around, carrying on a conversation and horseplay

are careless acts that can result in serious injury.

11. Job Completion: If the operation is complete, the machine should be emptied and the work area cleaned.

12. Disconnect All Power and Air to Machine before performing any service or maintenance.

13. Replacement Parts: Use only Van Norman replacement parts and accessories; otherwise, warranty will be null and void.

14. Misuse: Do not use the machine for other than its intended use. If used for other purposes, Irontite Products Inc./Van Norman

disclaims any real or implied warranty and holds itself harmless for any injury or loss that may result from such use.

Van Norman FG5000/FG10000 Flywheel Grinders

* 380V, 50 Hz, 3 Ph – Available for special orders

* 415V – Available for special orders

SPECIFICATIONS - FG5000 / FG10,0000

ELECTRICAL REQUIREMENTS

FG10,000 STANDARD

PART

NUMBER

DESCRIPTION/

ELECTRICALS

AMP

SERVICE

REQD.

MIN.

WIRE

SIZE

FG10,000 WITH POWERHEAD

794-8688-22 208-230V, 60 Hz, 3 Ph 60 8

794-8688-36 460V, 60 Hz, 3 Ph 30 12

FG10,000 WITH POWERHEAD

AND AUTOGRIND™

794-8688-06 208-230V, 60 Hz, 3 Ph 60 8

794-8688-38 460V, 60 Hz, 3 Ph 30 12

ELECTRICAL REQUIREMENTS — FG5000

PART

NUMBER

DESCRIPTION/

ELECTRICALS

AMP

SERVICE

REQD.

MIN.

WIRE

SIZE

FG5000

794-8690-00 208-230V, 60 Hz, 3 Ph 30 12

794-8690-01 208-230V, 60 Hz, 1 Ph 60 8

794-8690-02 460V, 60 Hz, 3 Ph 20 14

FG5000 WITH POWERHEAD

794-8688-40 208-230V, 60 Hz, 3 Ph 30 12

794-8688-41 208-230V, 60 Hz, 1 Ph 60 8

794-8688-43 460V, 60 Hz, 3 Ph 20 14

FG5000 WITH POWERHEAD AND AUTOGRIND™

794-8688-50 208-230V, 60 Hz, 3 Ph 30 12

794-8688-51 208-230V, 60 Hz, 1 Ph 60 8

794-8688-53 460V, 60 Hz, 3 Ph 20 14

FG5000

FG10,000

Work Piece Capacity 24” (600 mm) 24” (600 mm)

Table Diameter 18” (450 mm) 18” (450 mm)

T-Slots in Table 6 6

Table Support Diameter 15” (381 mm) 15” (381 mm)

Column Diameter 4.44” (111.8 mm) 5.5” (139.7 mm)

Vertical Head Travel 8.75” (222.3 mm) 10.5” (266.7 mm)

Max. Height Table/Wheel 8.75” (222.3 mm) 10.5” (266.7 mm)

Grinding Motor @ 3500 RPM 5 Hp (3.5 Kw) 10 Hp (7 Kw)

Table Motor @ 16 RPM 1/3 Hp (0.233 Kw) 1/3 Hp (0.233 Kw)

Coolant Capacity, Standard 9.5 Gal (36 Liters) 9.5 Gal (36 Liters)

Height (overall) 69” (1752 mm) 69” (1752 mm)

Height (to table) 34.6” (878 mm) 34.6” (878 mm)

Width 34.5” (876 mm) 34.5” (876 mm)

Depth 36” (914.4 mm) 36” (914.4 mm)

Net Weight 1350 Lbs (612.4 kg) 1550 Lbs. (703.1 kg)

Ship Weight 1500 Lbs. (680.4 kg) 1700 Lbs. (771.1 kg)

Van Norman FG5000/FG10000 Flywheel Grinders

STANDARD EQUIPMENT — FG5000/ FG10000

(Image on next page)

ITEM

PART #

DESCRIPTION

QTY

1 794-8010-64 Centering Cone Bolt 1.88" (47.6 mm) 1

2 794-8010-65 Centering Cone Bolt 2.375" (60.3 mm) 1

3 794-8010-66 Centering Cone Bolt 3.375" (87.8 mm) 1

4 794-8010-72 Centering Cone 1"-1.75" (25.4-44.5 mm) 1

5 794-8010-74 Centering Cone 1.312"-2" (33.3-50.8 mm) 1

6 794-8010-76 Centering Cone 1.75"-2.5" (44.5-63.5 mm) 1

7 794-8017-93 Centering Cone 2"-2.625" (50.8-66.7 mm) 1

8 794-8010-78 Centering Cone 2.25"-3" (57.2-76.2 mm) 1

9 794-8010-80 Centering Cone 2.75"-3.5" (69.9-88.9 mm) 1

10 794-8010-90 Flange Adaptor 3" (76.2 mm) 1

11 794-8010-92 Flange Adaptor 4" (101.6 mm) 1

12 794-8010-94 Flange Adaptor 5" (127 mm) 1

13 794-8010-97 Flange Adaptor 5.875" (149.2 mm) 1

14 794-8124-71 Wheel Spacer 1.5" (38.1mm) 1

15 794-8011-28 Grinding Wheel 4" (101.6 mm) Flaring Cup (FG5000) 1

16 794-8011-12 Grinding Wheel 6" (152.4 mm) Flaring Cup (FG5000) 1

17 794-8011-30 Grinding Wheel 6" (152.4 mm) Flaring Cup (FG5000) 1

18 794-8011-88 Lower Wheel Flange 1

19 794-8017-44 E-Z Lock Inserts 2

20 794-8011-52 Leadscrew Lubricant 1

21 794-8011-40 Coolant Additive, 1 qt. (.946 liter) 1

22 794-8011-55 Table Lubricant, 1 qt. (.946 liter) 2

23 000-0110-37 Leveling Bolts (Hex Head Cap Screws 4

24 000-1035-35 Leveling Bolt Lock Nuts 4

25 794-8030-58 Leveling Pads 4

26 794-8637-45 E-Z Lock Insert Extractor 1

27 794-8013-73 Table Oil Level Gauge 1

28 794-8017-32 T-Handle Hex Wrench 1

29 794-8017-37 Wrench Set (Includes): 1

000-0600-18 3/8” Hex Wrench 1

000-0600-20 5/16” Hex Wrench 1

000-0600-54 1/8” Hex Wrench 1

000-0600-62 5/32” Hex Wrench 1

000-0600-70 3/16” Hex Wrench 1

794-8017-42 1” Combination Wrench 1

N/S 000-0601-00 ¼” Hex Wrench 1

30 000-0170-60 Wheel Mounting Bolt, 2.75" 1

31 000-0170-55 Wheel Mounting Bolt, 2.50" 1

32 000-0170-35 Wheel Mounting Bolt, 1.25" 1

33 000-0170-27 Wheel Mounting Bolt, 1.00" 1

34 794-8013-12 O-Ring 1

Van Norman FG5000/FG10000 Flywheel Grinders

STANDARD EQUIPMENT — FG5000/ FG10000

TOOL BOARD ASSEMBLY

(794

-

8688

-

04)

PART # DESCRIPTION QTY

000-1145-02 Wrought Iron Washer Zinc Plated 2

000-8000-91 Wood Dowel Pins inserted into bottom

back of board

2

794-8015-98 Mounting Screw, .25 X 20 X 1.5” 2

794-8688-03 Main Tool board base with dowel pegs

(small shelf sold separately below)

1

794

-

8044

-

43

Tray Assembly with mount screws

(Sold Separately)

1

2 qt of Table Lube

1 qt of Coolant Additive

A new flywheel grinder comes with a complete

tool board and tray ready to be mounted on the

side of your machine. These items are listed

here in case replacement parts are ever needed.

Van Norman FG5000/FG10000 Flywheel Grinders

COMMON OPERATING SUPPLIES

(A listing of commonly re-ordered items for machine operation)

PART # DESCRIPTION QTY

794-8010-64 Centering Cone Bolt 1.88" (47.6 mm) 1

794-8010-65 Centering Cone Bolt 2.375" (60.3 mm) 1

794-8010-66 Centering Cone Bolt 3.375” (87.8 mm) 1

794-8010-67 Centering Cone Bolt 3.5"(88.9 mm) 1

794-8011-40 Coolant Additive, 1 Qt. (.946 liter) 1

794-8011-41 Coolant Additive, 1 Gal. (3.8 L) 1

794-8011-42 Coolant Additive, 5 Gal. (18.9 L) 1

794-8017-44 E-Z Lock Inserts 1

794-8017-45 E-Z Lock Inserts (5 pack) 1

794-8011-55 Table Lubricant, 1 qt. (.946 liter) 1

794-8011-52 Leadscrew Lubricant 1

GRINDING WHEELS

794-8011-12 Grinding Wheel 6" Flaring Cup (for harder metals) 1

794-8011-30 Grinding Wheel 6" Flaring Cup (general purpose formula) 1

794-8011-28 Grinding Wheel 4" Flaring Cup 1

794-8687-01 Grinding Wheel 3" Flaring Cup (Requires 794-8686-97 Mounting Flange) 1

794-8030-00 CBN Wheel 3” Formula X (Requires 794-8686-97 Mounting Flange) 1

794-8040-00 CBN Wheel 3.75” Formula X 1

794-8060-00 CBN Wheel 6.0” Formula X 1

Van Norman FG5000/FG10000 Flywheel Grinders

The Unique Table Design

The Van Norman Flywheel Grinders use a “floating” table design as illustrated

above. The vast majority of the downward force is displaced over a large pool of

special lubricating oil. This allows the table to be rotated without much force and

eliminates deflection. No need to replace table bearings and you can grind with

closer tolerances and greater pressures.

Note: When installing near interior walls, allow enough room to gain

access to service panels on the side and rear of the machine.

Coolant Tank

13.5” wide x 9” high x 22.5” deep

IMPORTANT: Notice the full and low coolant levels.

There must ALWAYS be coolant flowing over the baffle

panel or the pump WILL burn out from overheating.

Van Norman FG5000/FG10000 Flywheel Grinders

BEGIN OPTIONAL EQUIPMENT SECTION

(Optional Kits and Equipment for Expanding your Grinders Abilities)

Note: Individual pieces from the Mitee-Bite kit are not sold separately.

794-8625-27 Radius Cutter Assembly

PART # DESCRIPTION QTY

794-8084-05 Boring Bar, 1.5" (38.1 mm) Dia. 1

794-8084-06 Boring Tool – Carbide 1

794-8011-99 Spacer, Power Column Washer (3) 3

794-8621-28 Mounting Plate 1

794-8084-07 Socket head Set Screw cup point

5/16” 18X.500 1

794-8030-20 Hex Head Cap Screw .500-13X1.75 5 3

000-1150-53 1/2 Washer – Zinc Plated 3

000-0170-27 3/8-16X1 Socket. Head. Cap Screw 2

Van Norman FG5000/FG10000 Flywheel Grinders

Optional Light Assembly (794-8685-50)

PART#

DESCRIPTION

QTY

REQ

000-1118-28 3/8 Metal Conduit Locknut 1

000-1241-41 30-072 (72-B) Wire Nut-BL 2

000-1252-18 Flexible Task Lamp 1

000-2410-24 Elec. Wire 16GA Black-MTW 12.5

000-2410-75 Elec. Wire 16GA White-MTW 12.5

001-1601-76 LED 115v Light Bulb 1

794-8048-43 Terminal 16-14 GA 2

NOTE: Light Assembly attaches to the existing electrical box located on the grinding motor.

Van Norman FG5000/FG10000 Flywheel Grinders

794-8627-83

DIAL INDICATOR / INDICATOR BAR SET

ITEM PART # DESCRIPTION QTY

in 10 000-0485-10 ¼-20X¼ SOC CUP PT SS 1

11 001-0023-75 0 – 1 INCH DIAL INDICATOR 1

In 10 794-8013-17 MOUNTING ADAPTER 1

10 794-8013-20 INDICATOR BAR 1

9 794-8013-21 SPACER 13/32 X ¾ X 2 ¼ 1

1 794-8013-22 CONVEX POINT 1

12 794-8013-24 INDICATOR BAR ASSY. 1

8 794-8055-99 3/8 16 X 3 ¼ SOC HEAD CAP SCREW 1

7 794-8627-82 DIAL INDICATOR MAGNETIC BASE 1

13 000-1020-16 ¼ 28 HEX JAM NUT 2

2 794-8011-91 KNOB FL .734 PL KRL .25 1

3 794-8013-33 POINT INDICATOR 1.00 1

4 794-8017-04 ASSY, INDICATOR EXTENSION 1

5 794-8013-30 FOOT LEVELING .500 DIA 1

6 794-8020-53 FOOT ASSEMBLY 1.00 1

WARNING: Always disconnect machine from its main power source before attaching

anything to the grinding motor other than a proper grinding wheel.

794-8692-67 STEP COMPARATOR KIT

Item

Part #

Description

QTY

Item

Part #

Description

QTY

1 794-8692-68 Indicator Bar 1 5 794-8692-69 1.00” Standard 1

2 794-8013-19 Dial Indicator 1 6 794-8692-82 2.00” Standard 1

3 794-8017-04 Truck Extension (2.50”) 1 7 794-8011-91 Hand Knob 1

4 794-8013-33 Automotive Ext. (1.00”) 1

794-8685-32 WHEEL TILT SETTING KIT

(Included in 794-8627-83 Dial Indicator / Indicator Bar Set Above)

This kit is minimum requirement for Head Tilt Adjustment on Page 18

Item

Part #

Description

QTY

794-8013-17 Mounting Adapter (not shown) 1

1 001-0023-75 Dial Indicator 1

2 794-8013-20 Indicator Bar 1

3 794-8013-21 Spacer 1

Van Norman FG5000/FG10000 Flywheel Grinders

794-8107-88 HD Universal Centering Cone & Spacer Set

ITEM

PART#

DESCRIPTION

QTY

ITEM

PART#

DESCRIPTON

QTY

1 794-8010-58 Tee Nut .375-16 x .500 (3) 3 8 000-0170-94 SHCS .375-16 x 2.25 1

2 794-8010-59 Hex Stool, 0.5” (12.7 mm) (3) 3 9 000-0170-19 SHCS .375-16 x .75 (3) 3

3 794-8687-12 Hex Stool, 1” (25.4 mm) (3) 3 10 000-0170-35 SHCS .375-16 x 1.25 (3) 3

4 794-8010-82 Centering Cone, 4” (101.6 mm) 1 11 000-0170-51 SHCS .375-16 x 2.00 1

5 794-8010-84 Centering Cone, 4.5” (114.3 mm) 1 12 794-8055-99 SHCS .375-16 x 3.25 1

6 794-8010-86 Centering Cone, 5” (127.0 mm) 1 13 000-0170-65 SHCS .375-16 x 3.00 1

7 794-8011-89 Wheel Spacer, 1” (25.4 mm) 1 14 794-8677-99 Centering Cone Bolt, 4.25” 1

794-8011-90 Wheel Spacer, 2” (not shown) 1

Part #

Description

QTY

794-8627-82 Dial Indicator Magnetic Base

Allows for easy positioning of the Dial Indicator, sold

separately.

1

794

-

8627

-

82 Dial Indicator Magnetic Base

(Included in 794-8627-83 Dial Indicator / Indicator Bar Set Previously Shown)

794-8107-90 Small Bore/VW Centering Cone Set

ITEM

PART #

DESCRIPTION

QTY

1 794-8010-69 VW Rabbit Centering Cone, 1.38” 1

2 794-8010-70 Centering Cone, 1.375” 1

3 794-8010-95 VW Flange Adapter 1

4 794-8015-96 FSHCS, .437-14 x 2” 1

5 794-8016-28 SHCS, .437-14 x 1.5” 1

6 794-8686-99 FSHCS, .437-16 x 2.50” 1

7 794-8687-14 SHCS, .437-14 x 2.25” 1

Van Norman FG5000/FG10000 Flywheel Grinders

Optional Collets

794-8688-55 3/16” Collet (4.75mm) 794-8688-61 4mm Collet

794-8688-60 ½” Collet (12.7mm) 794-8688-64 8mm Collet

794-8688-89 9/16” Collet (14.28mm) 794-8688-65 10mm Collet

CENTERING CONES FOR SPECIFIC COMMON ENGINE MODELS

794-8684-78 Dowel Pin Kit

Popular Automotive Domestic and Import Kit

ITEM

PART#

DESCRIPTION

1 794-8688-44 Slide Hammer

2 794-8688-45 Slide Rod

3 794-8688-46 Tightening Sleeve

4 794-8688-56 ¼” Collet (6.35mm)

5 794-8688-57 5/16” Collet (7.93mm)

6 794-8688-58 3/8” Collet (9.53mm)

7 794-8688-59 7/16” Collet (11.10mm)

8 794-8688-62 5mm Collet

9 794-8688-63 6mm Collet

10 794-8688-47 Removal Stand

11 001-1001-57 Storage Case

794-8684-77 0-4” Optional Micrometer (not shown)

794-8680-18 Heavy Duty Centering Adapter Set

ITEM PART # DESCRIPTION QTY

1 794-8657-37 Ford/Cat 205, 2.040” (51.8 mm) 1

2 794-8657-38 Mack 305, 2.435” (61.8 mm) 1

3 794-8657-39 Ford Truck, 2.495” (63.4 mm) 1

4 794-8657-40 Cum/GMC 306, 2.830” (71.9 mm) 1

5 794-8657-41 Ford 307, 3.149” (79.9 mm) 1

6 794-8657-42 Ford Truck, 3.255” (82.7 mm) 1

7 794-8677-99 4.25" Centering cone bolt assembly 1

7

Van Norman FG5000/FG10000 Flywheel Grinders

Huge Additional Profit Potential!

HEAVY DUTY TRUCK ROTOR KIT

794-8628-00

RESURFACE LARGE TRUCK ROTORS ON YOUR FG5000 OR FG10000 WITH THIS KIT.

Fire Trucks, Ambulances, and all kinds of other service and construction vehicles can now have their brake rotors

resurfaced by you using your FG5000 or FG10000!

Item Part # Description Item Part # Description

1 794-8060-00 6” CBN Formula X Wheel 8 804-7803-01 Arbor Spacer 3.00”

2 794-8628-23 Alignment Pin Assembly 9 804-7803-05 Arbor Spacer 2.00”

3 794-8692-39 SC HD CS 3/8-16X4.25 10 804-7803-02 Arbor Spacer 1:00”

4 794-8628-21 Grinding Wheel Spacer Asm 11 804-8664-59 Centering Cone 4.5-5.5

5 804-7803-35 Arbor Nut Wrench 12 804-8664-60 Centering Cone 5.0-6.5

6 794-7803-03 1-1/4”-12 Nut 13 804-8664-61 Centering Cone 5.875-7.375

7 794-8628-27 Mounting Washer 14 804-8664-62 Centering Cone 6.875-8.125

Van Norman FG5000/FG10000 Flywheel Grinders

SELECTING FLYWHEEL GRINDING STONES

Harder flywheels require softer grinding wheels, and softer flywheels need harder grinding wheels.

Change the stone to match the flywheel being ground. It may be necessary to experiment to find

the best stone suited to a specific application.

STONE

PART #

SIZE/TYPE

WORKPIECE

HARDNESS

REF. NO.

COLOR

HARDNESS

MATERIAL

794-8687-01

3" Diameter

Flared Cup

Gray

For crankshaft mounting flanges, pressure

plate surfaces, automatic trans. pump

bodies and covers.

Requires Adapter 794-8686-97

794-8011-30

6" Diameter

Flared Cup

Black

Best general-purpose wheel for cast iron

and medium steel. Requires very little

dressing.

794-8011-28

4" Diameter

Flared Cup

White/Gray

For small, imported flywheels. Works well

on cast iron and medium steel.

794-8011-12

6" Diameter

Flared Cup

Black

For use on some cast iron and ductile

iron. Special grit tends to be fast cutting

and long wearing.

NOTE: Up to 10% Discount on Grinding Wheels may be available when purchased in Lots of 10 of each size

ADDITIONAL STONES

PART NO.

SIZE/TYPE COLOR

WORKPIECE HARDNESS M

ATERIAL

794-8060-00 6” Diameter CBN Flared Cup Long lasting-High Speed-Low heat transfer

794-8040-00 3.75” Diameter CBN Flared Cup Long lasting-High Speed-Low heat transfer

794-8030-00 3” Diameter CBN Flared Cup Long lasting-High Speed-Low heat transfer

HARD

MED

SOFT

MED.

HARD

Rinse Nozzle Kit

For Flywheel Grinders

For an easy, fast method to clean up each flywheel or

clutch as you finish them. It also makes the chore of

cleaning the machine much easier.

Just close the valve on the back of the coolant shroud.

That will shut off the coolant to the table area allowing all

the pressure to be used for the coolant rinse nozzle.

Rinse Nozzle Option / Kit 794-8690-84

Van Norman FG5000/FG10000 Flywheel Grinders

MACHINE DESCRIPTION

17

13

14 16

12

10

15

11

8

9

1. Emergency Stop

2. Table On/Off

3. Grinder Motor On/Off

4. Coolant Pump Switch

5. PowerHead Up/Down

6. AutoGrind™ On/Off

7. AutoGrind™ Grinding Rate

8. Coolant Pump/Reservoir Access

9. Table

10. Coolant Nozzle

11. Grinding Wheel

12. Grinding Motor

13. Column Lock Handle

14. Micrometer Feed Dial (rear top)

15. Wheel Dresser

16. Fine Feed Hand Knob

17. Manual Feed Hand Wheel

(Switch Part Numbers start on page 33)

Standard Controls

1

2

3

4

PowerHead with

AutoGrind™ Controls

PowerHead Control

1

2

3

4

1

2

3

5 6

5

4

7

FG5000/FG10000 Flywheel Grinder

Figure 4

Figure 3

Figure 2

Figure 1

MACHINE SET

-

UP

1. Remove protective covering from around machine.

Remove bolts from four corner pads to free machine from

skid. Remove all tooling packages from machine and set

aside. Using the fine feed hand knob, raise the grinding

head motor off the wood shipping block and discard.

Unlock the grinding head column lock handle (Figure 1)

and swing the grinding head motor so it is centered over

the table. Relock the motor flange.

2. A forklift is recommended for removing the machine from

the skid and setting in place. Lift only from the base

cabinet from the rear (Figure 2).

3. Locate machine in desired area. Install leveling bolts, lock

nuts and leveling pads in each corner of the machine

(Figure 3). Place a level on the table (Figure 4). Level the

machine side-to-side and front to back adjusting the four

leveling bolts. This is best done by leveling diagonally in

parallel with the corners of the cabinet. Tighten lock nuts

when level.

IMPORTANT: The machine MUST BE LEVEL to operate

correctly and on solid ground.

4. Remove rust preventative from machine using an

approved commercial solvent.

Rear

FG5000/FG10000 Flywheel Grinder

Figure 6

Figure 9

1. Unpack tool board and install the 2 - wooden pegs on the

bottom of the backside of the tool board. This sets the tool

board at a slight angle when mounted on machine. Install the

tool board on right side of machine using the 2 - 1/4" screws

provided. Next, screw the tool tray to the top of the tool board

using the 3 - screws provided (Figure 5).

2. Unpack the Standard Tooling, clean with an approved

commercial solvent, and place on the tool board.

3. Install the plastic handle in wheel dresser (Figure 6)

FILL OIL RESERVOIR

1. Remove the large flat head cap screw from the machine table

(Figure 7). Add approximately one quart Table Lubricant

(P/N: 794-8011-55) to the reservoir through the filler hole

(Figure 8) and replace cap screw. Make certain the small O-

ring is in place on the underside of cap screw.

2. Remove the plastic oil container at the rear of the machine

from its base by turning counterclockwise (Figure 9). Invert

the container and fill with Table Lubricant 794-8011-55

through the bottom tube. Quickly invert and re-install the oil

container, tighten hand tight only.

After installation, the oil level in the plastic container will start

to drop. The base of the oiler has been preset at the factory

to the proper height. When the oil level in the reservoir in the

base casting reaches the preset height the level in the plastic

container will stabilize. It may be necessary to refill the

container after level has stabilized.

NOTE: Avoid large air bubbles in

the tubing between the

plastic oil container and the

table. Tubing is located

under the deck casting.

Figure 5

Figure 8

Figure 7

FG5000/FG10000 Flywheel Grinder

Figure 12

Figure 11

3. A depth gage is provided with the machine for checking the

oil level through the hole in the table that is capped with a hex

screw (Figure 10 and 10A). The overall length of the gage pin

should be set to equal the thickness of the machine table

(Figure 10B). Set pin to bottom of table and tighten setscrew

on side of gage (Figure 10C). The oil level line marked on the

gage pin is 1/16” above the bottom of the table.

4. In the center hole of the table is a 7/16”-14 set screw. This was

installed during shipping of the machine to keep any debris out

of the hole. Remove set screw and discard.

FILL COOLANT TANK

Open front access door and slide coolant tank out of machine

(Figure 11). Pour one quart of (P/N: 794-8011-40) Coolant Additive

into the tank and add water to within approximately one inch of the

top. Slide coolant tank back into machine. Direct coolant drain hose

to the inside of the tank. After machine is wired, turn on coolant

pump and set flow by turning valve located outside the sheet metal

coolant shroud (Figure 12).

Figure 10C

Figure 10A

Figure 10B

Figure 10

CAUTION:

Excessive buildup of

grinding sludge in the

coolant may cause

premature failure of

the coolant pump.

Clean out coolant tank

every 25 flywheels or

more frequently as

needed.

Irontite Products Van Norman FG5000 User manual

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