KENT KGS818AH User manual

INSTRUCTIONMANUALFOR
PRECISIONSURFACEGRINDER
MODEL：KGS818AH/AHD
KGS1020AH/AHD
KENTINDUSTRIAL(U.S.A.) INC
Property of Kent Industrial USA
Please Do Not Reproduce

2
Chapter One Installation Guidelines
General Safety Rules
Do 1. The employer must select trained and qualified personnel to operate machinery.
2. The employer must adhere to local national safety laws and regulations when
teaching operators safety and cleanly procedures.
3. The employer must inform operators to look out for unsafe operating practices.
4. The brightness of the lighting equipment in the workplace must conform to local
government regulations.
5. The machine's fire extinguisher must use non-conducting CO_2 or ABC.
6. The operation manual, instructions, and warning labels must be read before
operating the machine.
7. The operation manual must be kept ready at all times. If an accident occurs, please
contact our company representatives.
8. Hair must be properly restrained. Wear a hat if necessary before operating or
maintaining the machine.
9. Before operating the machine, safety glasses, a filter mask, and work safety shoes
must be worn.
10. The machine and its surrounding area must be kept clean and orderly to prevent
slippery surfaces and unnecessary obstacles.
11. The operator must remain at least 600 mm away from the machine to prevent
contact with the machine and injury. A yellow line should be drawn to mark areas
where personnel are restricted from entering.
12. Operation and maintenance personnel must only work within the designated safe
areas.
13. When moving work pieces that exceed 30 kilograms, use a hoist operated by
licensed personnel to lift and lower these pieces.
14. All protective guards and doors must be closed at all times, except when
maintenance work is being done.
15. Before conducting any maintenance work, the power source should be turned off
and only proper tools should be used.
Don't
1. Persons wearing ties, long sleeves, or loose fitting clothing should not operate or
maintain the machine.
2. Persons within the work area must not lean on the machine while it is running.
3. When the machine is running, the wheel guard, right and left storke adjusters, and
nozzles must not be adjusted by hand or with tools.
4. To prevent eye injury to personnel by dust particles, compressed air should not be
used to clean the machine.
1.1 Safety rules for this machinery
Property of Kent Industrial USA
Please Do Not Reproduce

3
Do 1. Only use grinding wheel with a maximum peripheral speed of 2000 m/min or
greater.
2. Before inspecting or maintaining the power source, make sure you are following the
instructions that are given on the warning signs.
3. If warning or instruction signs should fall off the machine or become illegible, re-
affix with replacement signs or contact your sales representative or this company
for replacements.
4. When inspecting electrical sections of the machine, insulating gloves, rubber or
leather boots, and other non-conducting protective items should be used.
5. Electrical wiring that needs to be grounded, must be done so following the diagrams
provided.
6. Before inspecting electrical circuits, check to make sure that the circuit is turned
off.
7. When the electrical portions malfunction, only qualified personnel should carry our
the maintenance work.
8. Check with the grinding wheel manufacturer about grinding wheel specifications
for work pieces with a hardness of HRC65.
9. The grinding wheel balancing should be done by trained personnel only. After
balancing the grinding wheel, it can be mounted onto the wheel spindle. Before
mounting, wipe the flange and the mounting portion of the wheel spindle clean.
10. Before starting the machine, find the location of the machine stop and emergency
push-buttons.
11. Before starting up the wheel spindle motor, inspect the grinding wheel and the
turning direction of the wheel spindle. After starting the wheel spindle motor, let the
grinding wheel spin freely for at least five minutes before beginning to grind the
work piece.
12. Make sure the surface of the electric magnet chuck is clean before mounting work
pieces. If there are marks on the surface, regrind its surface.
13. Use the proper clamps when mounting non-magnetic material work pieces such as
aluminum, graphite, etc., or work pieces that are difficult to hold onto the magnetic
chuck. These clamps cannot come into contact with the grinding wheel.
14. When the grinding wheel is not turning, the operator should check with his hands to
see whether the work piece is firmly attached to the magnetic plate.
15. Adjust the left or right stroke only when the table is at a stop.
16. For wet grinding, turn off the coolant system before turning off the spindle motor.
17. Wet grinding material that produce dust during the grinding process.
Don't
1. The machine must not be installed in areas with explosive materials.
2. Combustible liquids must not be used as a cutting liquid.
3. The machine should not be used to grind lumber, plastic, or other combustible
materials. Please contact KENT Industrial Co, Ltd. if you wish to use optional or
special equipment provided by the company to grind graphite or porcelain.
4. The grinding wheel on the wheel spindle head cannot be used as a disk sander.
5. Do not haphazardly change the use and/or capacity setting on the machine and do
Property of Kent Industrial USA
Please Do Not Reproduce

4
not use grinding wheels that do not conform to listed specifications or work pieces
that are excessively large or heavy.
6. To avoid the risk of an accident, the user should not modify the electrical circuitry
without prior authorization.
7. Do not change interlocking circuits into bypass circuits.
8. Do not come into contact with those areas of the machine that are labeled with
lightning signs and decals.
9. Do not come into contact with the electrical box or circuits when one's body or
hands are wet.
10. When inspecting or maintaining electrical sections, keep all personal metallic items
away from possible contact. Additionally, hang a warning sign to prevent other
personnel from inadvertently starting the machine.
11. Do not use very thin and short work pieces, or work pieces which have complex
shapes or unstable centers of gravity on the magnetic chuck for grinding.
12. When grinding, make sure the work piece is securely mounted and that no other
object is place on the machine.
13. During wet grinding, the nozzles cannot be adjusted when the wheel spindle is
rotating.
14. When the work table is in motion or when the wheel spindle is rotating, the work
piece cannot be moved or changed.
15. After the wheel spindle motor is turned off, do not use your hand or any other
object to stop or slow down the grinding wheel.
16. During grinding and before the grinding wheel stops rotating after work is finished,
do not attempt to clean the shavings of the work piece or move the work piece.
17. When taking off the grinding wheel, use a flange remover to detach it. Do not use
any method that involves pounding the grinding wheel. This could result in damage
to the grinding wheel.
Property of Kent Industrial USA
Please Do Not Reproduce

5
CONTENTS
MODEL：KGS818AH/AHD........................................................................................1
Chapter One Installation Guidelines ..............................................................................2
CONTENTS........................................................................................................5
A) Transit .................................................................................................................7
B) Unpacking ...........................................................................................................7
(1).Packing Diagram............................................................................................8
C) Choice of Site......................................................................................................8
D) Installation...........................................................................................................9
(1).Power Consumption........................................................................................9
(2).Foundation (Use the leveling pads and screws)...............................................9
(3).Contour and Name of Components...............................................................10
(4).Cleaning Up the Machine.............................................................................11
(5).Mounting the Table......................................................................................11
(6).Leveling the Machine...................................................................................12
(7).Table size and movement scope....................................................................13
(8).Lubrication...................................................................................................15
(9).Hydraulic System.........................................................................................16
(10).Limit Switch Position.................................................................................18
(11).Balancing the Grinding Wheel....................................................................19
E) Putting The Machine Into Operation..................................................................21
(1).Wiring of power source................................................................................21
(2).Control Panel &Description..........................................................................23
(3).Operation .....................................................................................................25
a. Before operation...........................................................................................25
b.Operation......................................................................................................25
Property of Kent Industrial USA
Please Do Not Reproduce

6
F) Grinding ............................................................................................................28
G) Wheel Inspection...............................................................................................28
H) Dressing The Wheel And Correct Treatment Of Dressing Diamond...................29
I) Storage of Grinding Wheel ................................................................................31
J) Selection of Suitable Grinding Wheels...............................................................31
K) Wheel to Be Recommended...............................................................................33
L) Choice of The Grinding Condition.....................................................................33
M) Use of the Optional Attachment.........................................................................35
(1).Parallel Dressing Attachment .......................................................................35
(2).Brief Introduction to Attachment..................................................................35
(3).Sine Bar .......................................................................................................37
(4).Radius Forming Attachment.........................................................................37
(5).Coolant System............................................................................................40
(6).Common cases in Side Grinding...................................................................41
(7).Right Angle Grinding ...................................................................................42
N) Complete Knock Down Drawings & Parts Lists.................................................44
Property of Kent Industrial USA
Please Do Not Reproduce

7
*THIS MACHINE HAS BEEN FULLY TESTED, ADJUSTED, AND INSPECTED FOR
CORRECT ALIGNMENT AND OPERATION. PRIOR TO SHIPMENT, IN TRANSIT, OR
INSTALLATION, PLEASE ENSURE THAT THE MACHINE IS NOT BUMPED WHEN
BEING ROLLED OR SET DOWN TO AVOID ANY FAILURE.
A) Transit
By Fork Lift By Hoist or Chain Block
Heavy End
Crate Steel Cable
*Machine weight KGS818 KGS1020
Net 1320kg 1680kg
Gross 1520kg 1930kg
B) Unpacking
1. When unpacking the crate, take apart the upper cover, then follow the sequence of front
and rear board, left and right.
2. Do not use a hammer to break down the crate. Please use a nail puller or pry bar instead.
3. To avoid damaging the machine or paint, be more careful when removing the wooden
covers.
4. Loosen the fixing screws before lifting the machine, then remove the skid-board.
Wooden
Skid-board Remove
Skid-board
Loosen bolt 3 places Center Gravity
Property of Kent Industrial USA
Please Do Not Reproduce

8
(1) Packing Diagram
2 1
3
4
1. Machine
2. standard Accessories
3. Coolant Tank
4. Table and Splash Guard
C) Choice of Site
The output of the machine and the degree of accuracy of the components produced
depend on the correct choice of site for the position of the machine.
Grinding machines are often found between milling, shaping, drilling and even
slotting machines, without any thought of the consequences of such planning.
In such cases, it is impossible to achieve good surface finishes, as the vibrations from the
milling machine or jerks from the reversal of the shaper stroke, etc. are transmitted to the
grinding machine. Chatter marks can be found on the ground surface, which are due to
these extraneous influences. A non-solid floor is unsuitable for supporting the machine as
it can result in distortion of themachine bed.
Property of Kent Industrial USA
Please Do Not Reproduce

9
Y
Floor plan:
KGS818 KGS1020
X 1700mm 2220mm
Y 1430mm 1560mm
X
D) Installation
(1).Power Consumption
Spindle
Motor
Coolant
Motor
Hydraulic
Motor
Dust Collection
Motor
Crossfeed
Motor
KGS818AH/AHD
1.5KW 90W 1.5KW 550W 60W
KGS1020AH/AHD
2.2KW 90W 1.5KW 550W 60W
(2).Foundation (Use the leveling pads and screws)
* Lower the machine slowly into position.
* Insert the leveling pad into the hole of the machine base.
* Adjust the leveling screws 1112 and make the machine leveled.
KGS1020AHD-1112
GB6170-86
M20
GB97.1-86
20
KGS1020AHD-1015
Property of Kent Industrial USA
Please Do Not Reproduce

10
(3).Contour and Name of Components
Spindle
Motor
Flow Lever
Hand Wheel
(Crossfeed)
Hand Wheel
(Longitudinal)
(Auto.)
Downfeed
Gear Box
Column Hand Wheel
(Vertical) Electric
Control Box
Wheel Guard
Grinding
Wheel
Dog(Left)
Table
Lifting
Stud
Bed
Dog(Right)
Saddle
Electric
Cabinet
Property of Kent Industrial USA
Please Do Not Reproduce

11
(4).Cleaning Up the Machine
This machine has been ensured moisture-proof, dust-proof, and rust-proof before packing. Please
cleanup the machine before moving the longitudinal cross and up & down, otherwise it will affect
grinding accuracy.
1
1.Guideway
1
(5).Mounting the Table
a. Mounting the table
1. Put the steel ball and its retainers in the middle of slide ways.
2. Place the table on the steel ball retainers.
3. Install the hydraulic cylinder under the table as shown on the sketch below.
Note: Do not damage guideway, steel ball, or retainer.
Nuts Table Hydraulic Cylinder
Rubber
Saddle Cylinder Rod
1
Property of Kent Industrial USA
Please Do Not Reproduce

12
(6).Leveling the Machine
Procedure:
a) Use longitudinal hand wheel to move table to the left end position. Level the machine
by a Spirit Level in longitudinal and latitudinal direction (Fig.A).
b) Use longitudinal hand wheel to move table to the right end position. Level the machine
in the longitudinal and latitudinal direction (Fig.B).
LEVEL LEVEL
A B
c) Use cross-feed hand wheel to position the table at at front end position. Level the machine
by a Spirit Level in longitudinal and latitudinal direction (Fig.C)
d) Use cross-feed hand wheel to position the table at thr rear end position. Level the machine
in the longitudinal and latitudinal direction (Fig.D)
LEVEL
C
LEVEL
D
Property of Kent Industrial USA
Please Do Not Reproduce

13
MAX530
10
23
(7).Table size and movement scope
a.KGS818AH/AHD
MAX220
200
14
24
SPECIFICATION KGS818AH/AHD
Size of working table
200mm×460mm
Table traverse
Longitudinal traverse
510mm
Cross traverse
250mm
Distance from spindle axis to table surface
70-530mm
Spindle vertical traverse
460mm
Wheel size
200mm×25mm×32mm
Spindle motor
2850r/min 50HZ
Overall dimension(L×W×H)
1570mm×1990mm×2120mm
Property of Kent Industrial USA
Please Do Not Reproduce

14
MAX535
10
23
b.KGS1020AH/AHD
MAX276
255
14
24
SPECIFICATION KGS1020AH/AHD
Size of working table 250mm×510mm
Table traverse Longitudinal traverse 575mm
Cross traverse
280mm
Distance from spindle axis to table surface 70-535mm
Spindle vertical traverse
460mm
Wheel size
200mm×25mm×32mm
Spindle motor
2850r/min 50HZ
Overall dimension(L×W×H)
1680mm×2030mm×2110mm
Property of Kent Industrial USA
Please Do Not Reproduce

15
0
0
2
(8).Lubrication
Lubrication Flow Chart
Elevation slideways Saddle "V" groove
Saddle plane
0 0 0
0 0 0
0
PJ-4
2
groove
PJ-9S Vertical leadscrew
2
Crossfeed leadscrew
Bed "V" left groove
Bed "V" right groove
0 0 0
PJ-7S
Auto .lubrication pump
MMXL-Ⅲ-6/5.5-AC220
Reliability and efficiency of the machine are ensured only by the correct choice of lubricant
for the individual lubricating points.
1) Lubrication pump: Auto lubrication pump will work automatically and 2.5cc lube
oil (adjustable) every 15 minutes.
2) Type of lubricant: BP, ESSO, MOBIL or SHEEL.
3) Lubricant tank:1.8 liters.
4) Lubricating points: "V" base (2) Cross-feed lead-screw(1) Vertical lead-screw, gear
Property of Kent Industrial USA
Please Do Not Reproduce

16
(9).Hydraulic System
a)Hydraulic Diagram
1
5
2
3 6
4
12
7
8
M
10
9
11
1. Table Cylinder
2. Control Valve
3. Downfeed Cylinder
4. Downfeed Solenoid Valve
5. Clutch Engage Cylinder
6. Clutch Engage Solenoid Valve
7. Pressure Gauge
8. Check Valve
9. Hydraulic Pump
10. Hydraulic Motor
11. Hydraulic Tank
12. Sequence Valve
Property of Kent Industrial USA
Please Do Not Reproduce

17
b) Hydraulic Oil
Hydraulic tank volume: 51.3 liters
Re-fill frequency:
After the first month, clean the hydraulic tank and change the oil every six months.
Hydraulic oil:
CPC
BP
ESSO
MOBIL
MOBIL
R-68
ENGRGOL
ESSTIC 50
D.T.E OIL
SHELL
HL100
Medium
Tellus oil 29
4.5 E/50 C 4.7 E/50 C 3.93 E/50 C 4.0 /50 C
33cst/50 C
35cst/50 C
28.9cst/50 C
29cst/50 C
*Fill up the oil tank before starting the hydraulic motor.
*Please ensure that there are no people or objects within the range of the table movement
before starting the longitudinal travel.
*Maximum hydraulic pressure: 22 kgs/cm ².
*Filter must be cleaned when changing oil. If broken, the filter must be replaced.
Property of Kent Industrial USA
Please Do Not Reproduce

18
1
2
5
3
6
4
Description：
（1）. Rear limit:SQ3
（2）. Front limit:SQ2
（3）. Rear reversal limit:SQ1
（4）. Front reversal limit:SQ4
（5）. Auto.down feed switch:SQ5
（6）. Auto.cross feed switch:SQ6
For above-mentioned cord no.,please refer to Circuit
Diagram.
（10）.Limit Switch Position
Description：
（1）. Rear limit:SQ3
（2）. Front limit:SQ2
（3）. Rear reversal limit:SQ1
（4）. Front reversal limit:SQ4
（5）. Auto.down feed switch:SQ5
（6）. Auto.cross feed switch:SQ6
For above-mentioned cord no.,please refer to Circuit Diagram.
1
2
3
4
Property of Kent Industrial USA
Please Do Not Reproduce

19
(11).Balancing the Grinding Wheel
Efficient balancing is essential in eliminating unnecessary stress in the wheel. It can also
help obtain high quality surface finishes, grinding accuracy, and extend the life of the
grinding wheel. In this case, the grinding wheel has to be balanced carefully. Static
balancing can better meet the requirements of machining.
The grinding wheel together with the wheel flange is fitted to balance the arbor and this
assembly is then placed on two accurate parallel knife edges of the wheel balancing base,
and balancing can be effected as follows: (see Fig.2).
•The wheel balancing base must be leveled (Fig.1)
•Allow the wheel to oscillate to find the center of gravity, which is then marked "S"
with chalk (Fig.3)
•Apply the first balancing weight "G" opposite to this point "S" and screw it in. It
cannot be moved again (Fig.4)
•Place two correction weight "K" anywhere around the periphery, but at equal
distance "a" from weight "G" (Fig 5)
•Turn the wheel 90° at a time and see if it is balanced. If it is not, the correction
weight "K" must be moved until the wheel is balanced in any position (Fig. 6)
•After balancing, the wheel must be given a test run of at least five minutes at full
working speed before being used or fine balanced.
Level
Wheel
Flange
Base
Balancing
Arbor
S
Fig.1 Fig.2 Fig.3
G K
G K
Fig.4 S S
Fig.5 Fig.6
Property of Kent Industrial USA
Please Do Not Reproduce

20
After being balanced for the first time, the wheel must be mounted on the grinding
spindle of the machine and dressed. This can be done with the parallel dresser on the spindle carrier or
with one fitted on the table. When dressing the wheel from the table, the table must be locked
longitudinally and then cross-traversed with the hand-wheel. The wheel must be dressed until it runs
dead true. The grinding finish is improved, if any part of the wheel is out-of -truth in the side walls,
the wheel is also removed.
After this first balancing, the wheel must be removed from the spindle again and then carefully re-
dressed. After being fitted to the spindle again and re-dressed, it is ready for use.
As wear can lead to unbalance, the wheel should be re-checked and if necessary,
rebalanced.
Grinding wheel absorbs humidity and coolant, it is therefore advisable not to short the coolant supply
when the wheel is stationary, otherwise the wheel will absorb liquid on one
side only and will then be out of balance. If the wheel is allowed to stand for any length
of time, coolant will collect at the lowest point. Idling is essential to throw-off coolant by
centrifugal force.
Prior to placing the flange-mounted grinding wheel to the spindle, the flange bore and spindle taper
must be absolutely clean, and the wheel is pushed by hand onto the spindle.
Subsequently, tighten the wheel flange securely with a fixed bolt or nut.(Fig.7 or Fig.9)
Use an extractor to release the wheel flange from spindle taper. (Fig.8 or Fig.10)
General type spindle:
Fixed nut Extractor
Fig.7 Fig.8
American type spindle:
Fixed nut Extractor
Fig.9 Fig.10
Property of Kent Industrial USA
Please Do Not Reproduce