KNECHT KLA 220 User manual

Status 08.2018 ■Version 1.3 | Translation
Operating Instructions
KLA 220 - HV 153
Honing Machine for Circular Knives

3
Honing Machine for Circular Knives KLA 220 – HV 153
Manufacturer
KNECHT Maschinenbau GmbH
Witschwender Straße 26
88368 Bergatreute
Germany
Phone [phone]
Fax [phone]
[email protected]
www.knecht.eu
Documents for the machine operator
Operating Instructions
Date of issue of the operating instructions
August 16, 2018
Copyright
The copyright for these operating instructions as well as other documents for the machine operator is held
by KNECHT Maschinenbau GmbH. These documents will be delivered only to our customers and to opera-
tors of our products and are a part of the machine.
These documents may neither be reproduced, nor made accessible to third parties, including rival firms,
without our express permission.
Operating Instructions

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1. Important notes 7
1.1 Foreword 7
1.2 Warnings and symbols in the operating instructions 7
1.3 Warning plates and their meaning 8
1.3.1 Warning and prohibition signs on/in the honing machine 8
1.4 Rating plate and machine serial number 9
1.5 Figure and item numbers in the operating instructions 9
2. Safety 10
2.1 Basic safety instructions 10
2.1.1 Observe notes in the operating instructions 10
2.1.2 Operator's duty 10
2.1.3 Obligations on the part of the personnel 10
2.1.4 Hazards associated with handling the honing machine 10
2.1.5 Malfunctions 11
2.2 Use as intended 11
2.3 Warranty and Liability 11
2.4 Safety regulations 12
2.4.1 Organizational measures 12
2.4.2 Protective devices 12
2.4.3 Informal safety measures 12
2.4.4 Selection and qualifications of the personnel 12
2.4.5 Machine control system 13
2.4.6 Safety measures in normal operation 13
2.4.7 Dangers due to electrical power 13
2.4.8 Particular danger zones 13
2.4.9 Servicing (maintenance, repair) and fault rectification 13
2.4.10 Structural modifications of the honing machine 14
2.4.11 Cleaning the honing machine 14
2.4.12 Oils and greases 14
2.4.13 Relocation of the honing machine 14
3. Description 15
3.1 Intended use 15
3.2 Technical specifications 15
3.3 Functional description 16
3.4 Description of the assemblies 17
3.4.1 Switch box 18
3.4.2 HV 156 Dressing device 19
3.5 Construction 20
Table of Contents

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4. Transport 21
4.1 Transport aids 21
4.2 Transport damage 21
4.3 Transport to another installation site 21
5. Installation 22
5.1 Selection of qualified personnel 22
5.2 Installation site 22
5.3 Supply connections 22
5.4 Settings 22
5.5 Initial commissioning of the grinding machine 23
6. Commissioning 24
7. Operation 25
7.1 General principles of grinding technology 25
7.2 Switching on the grinding machine 26
7.3 Grinding of circular knives with d. 180-475 mm 26
7.3.1 Single side grinding 29
7.4 Grinding of circular knives with d. 60-180 mm 30
7.5 Water tray 32
7.6 Adjusting the grinding angle 33
7.7 Dressing of grinding wheels 35
7.8 Safety slides 36
7.9 Changing the safety slides 37
8. Care and maintenance 38
8.1 Cleaning 38
8.2 Lubrication 38
8.3 Lubrication schedule and lubricant table 38
9. Malfunctions 39
9.1 Faults 39
Table of Contents

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10. Disassembly and disposal 40
10.1 Disassembly 40
10.2 Disposal 40
11. Service, spare parts and accessories 41
11.1 Postal Address 41
11.2 Service 41
11.3 Spare parts 41
11.4 Accessories 42
11.4.1 Abrasives used 42
12. Appendix 43
12.1 EC Declaration of Conformity 43
Table of Contents

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1.1 Foreword
This operator's manual is meant to make it easier to get to know the honing machine and to use it
properly for the intended purpose.
The operating instructions contain important information on how to operate the honing machine
safely, properly and cost-effectively. Observance of these instructions helps to avoid dangers, re-
pair costs and downtimes, and increases the reliability and service life of the honing machine.
The operating instructions must always be accessible at the place of use of the honing machine.
The operating instructions must be read and used by all persons entrusted with working on the
honing machine, e.g. those entrusted with
• Transport, installation, commissioning
• Operation, including troubleshooting in the process flow, as well as
• Servicing (maintenance, repair).
In addition to the operating instructions and the binding accident prevention regulations applica-
ble in the country and place of use of the machine, the generally acknowledged rules of technolo-
gy with regard to safe and professional work practices are to be observed.
1.2 Warnings and symbols in the operating instructions
Heeding the following safety alert symbols/designations used in the operating instructions is
absolutely necessary:
The hazard triangle with the signal word “CAUTION” is used as a work
safety indication for all work which could result in death or physical injury.
Special care and caution must be taken when carrying out such jobs.
ATTENTION
The signal word “ATTENTION” is used to call attention to hazards which
could result in damage and/or destruction of the honing machine or its
environment if special attention is not paid while carrying out particular
jobs.
NOTICE The signal word “NOTE” calls attention to tips on use and useful
information.
1. Important notes
CAUTION

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1.3 Warning plates and their meaning
1.3.1 Warning and prohibition signs on/ in the honing machine
The following warnings and safety alert signs have been affixed to the honing machine:
CAUTION! DANGEROUS ELECTRICAL VOLTAGE
(warning notice on the switch box)
On being connected to the voltage supply (3x 400 V), the honing
machine becomes electrically live and touching its live parts directly
could be life-threatening.
Live machine parts may be opened only by authorized, trained
personnel.
The honing machine must be separated from the mains supply
before carrying out servicing, maintenance and repair jobs on it.
CAUTION! RISK OF INJURY FROM ABRASIVE PARTICLES
(warning notice on the machine hood)
Grinding, polishing, deburing and truing gives rise to abrasive
particles which could enter the eyes.
Wearing safety glasses is mandatory when carrying out such jobs.
CAUTION! RISK OF INJURY FROM KNIFE
(warning notice on the machine hood)
Work on the honing machine involves sharpening of knives which
could cause serious cut injuries due to their sharpness.
Protective gloves must be worn when clamping and unclamping
the knives.
Be careful when transporting blades. Use the protective devices
provided by the knife manufacturer. Wear protective gloves and
apron.
1. Important notes

TYPE KLA 220 Bauj. 1996
Masch.-Nr. 54409 42 220
V380 A0,76
KW 0,24 Hz 50 Sch. Y
Maschinenbau GmbH
88368 Bergatreute • Germany
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1.4 Rating plate and machine serial number
The type plate is located on the rear panel of the
machine.
The machine number is located on the rating plate
and on the bottom left of the water tray.
1.5 Figure and item numbers in the operating instructions
If the text refers to a machine component shown in a figure, then a figure or item number is
added in brackets after the machine component.
Example: (7-2/1) denotes figure number 7-2, item 1.
Place the circular knife with knife guard (7-2/1) on the
grinding device (7-2/2).
Remove knife guard.
1. Important notes
Figure 1-1 Rating plate
Figure 1-2 Machine serial number
Figure 7-2 Placing the knife on the grinding
device
2
1

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2.1 Basic safety instructions
2.1.1 Observe notes in the operating instructions
The basic prerequisite for the safe handling and uninterrupted operation of this honing machine is
knowledge of the basic safety instructions and regulations.
• These operating instructions contain important notes on how to operate the honing machine
safely.
• All persons carrying out work on the honing machine must follow these operating instructions,
in particular the safety notices.
• In addition, the accident prevention rules and regulations applicable at the place of use of the
machine must also be observed.
2.1.2 Operator's duty
The operator is obliged to allow only those persons to work on the honing machine, who
• are familiar with the basic occupational safety and accident prevention regulations and have
been trained and instructed in the handling of the honing machine,
• have read the operating instructions, particularly the “Safety” section, and have read and
understood the warning notes. They have given a signed confirmation of this in writing.
It is also checked at regular intervals as to whether the worker is fulfilling his employee obligation
to observe safety at work.
2.1.3 Obligations on the part of the personnel
All the personnel working on the honing machine shall be obliged to
• observe the basic occupational safety and accident prevention regulations,
• read the operating instructions, particularly the “Safety” chapter, and the warning notes. They
must provide signed confirmation of this in writing.
2.1.4 Hazards associated with handling the honing machine
The honing machine has been built to the latest technological standards and the acknowledged
rules of technical safety. In spite of that, its use presents inherent risks which could result in bodily
harm or even death of the user or third persons, or impairment of the honing machine or other
property.
The honing machine may be used only:
• for the intended purpose, and
• in faultless condition with regard to safety-relevant aspects.
2. Safety

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Faults that could impair safety must be eliminated immediately.
2.1.5 Malfunctions
If safety-relevant malfunctions occur in the honing machine, or if the processing behavior indi-
cates that such malfunctions may have occurred, the honing machine must be stopped immedi-
ately and until such time as the malfunction has been found and eliminated.
Allow only authorized technical staff to eliminate the malfunctions.
2.2 Use as intended
The honing machine is only meant for sharpening of circular knives with a diameter of 60 to
475 mm.
Before starting work on a circular knife, it must first be checked whether a suitable grinding
device is present. Only then can the circular knife be clamped.
Any other use is considered improper use. KNECHT Maschinenbau GmbH assumes no liability for
damages resulting from improper use. The user alone bears the risk in such cases.
Use as intended includes the observance of all the instructions in the operating instructions.
The honing machine is being used improperly, if, e.g.,
• knives other than those mentioned above are ground.
• knives are ground on grinding devices that do not suit the knives.
• grinding devices are not fastened properly.
2.3 Warranty and Liability
Warranty and liability claims in case of personal injuries or property damage are excluded if such
damage is attributable to one or more of the following causes:
• improper use of the honing machine,
• improper transportation, commissioning, operation and maintenance of the honing machine,
• operating the honing machine with defective safety devices, or improperly attached or
malfunctioning safety and protective equipment,
• ignoring the operating instructions with regard to transportation, commissioning, operation,
maintenance and repair of the honing machine,
• unauthorized structural alterations to the honing machine,
2. Safety

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• unauthorized modification, e.g. of the drive conditions (power and speed), and
• insufficient monitoring of machine parts that are exposed to wear
• use of unapproved replacement and wear parts
Use only original replacement and wear parts. If parts are purchased from external suppliers, it
cannot be guaranteed that they will be constructed and manufactured to withstand the stresses
and provide the required level of safety.
2.4 Safety regulations
2.4.1 Organizational measures
All the existent safety devices must be checked regularly.
Observe prescribed intervals for recurring maintenance work or as specified in the operating
instructions.
2.4.2 Protective devices
Before commissioning the honing machine, it must be ensured that all protective equipment is
properly mounted and in functional condition.
Protective equipment may only be removed after the honing machine has stopped and has been
secured against accidental restarting.
If sub-components are supplied, the protective equipment must be correctly attached by the oper-
ator according to the instructions.
2.4.3 Informal safety measures
The operating instructions must be permanently available at the place of use of the honing
machine. In addition to the operating instructions, the generally applicable as well as the locally
relevant accident prevention regulations must also be made available and observed.
All the safety alert symbols and danger warnings on the honing machine must be complete and
clearly legible.
2.4.4 Selection and qualifications of the personnel
Only trained and instructed personnel may work on the honing machine. The minimum legal age
for employment must be observed.
The responsibilities of the personnel must be clearly assigned, i.e. commissioning, operation,
maintenance and repair, etc.
2. Safety

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Personnel that is still in the training or instruction phase may only be allowed to work on the
honing machine under the permanent supervision of an experienced person.
2.4.5 Machine control system
Only trained and instructed personnel are allowed to switch on the machine.
2.4.6 Safety measures in normal operation
Refrain from any method of working which may pose a risk to safety. Only operate the honing
machine if all the safety devices are installed and fully functional.
Check the honing machine for external signs of damage and correct operation of the safety
devices at least once every shift.
Report any changes (including operating behavior) immediately to the competent depart-
ment/person. Where required, shut down the honing machine immediately and secure against
restarting.
Before switching on the honing machine, ensure that no one is exposed to any risk from start-up
of the machine.
If there are any functional faults, stop the honing machine immediately and secure against
restarting. Have the faults eliminated immediately.
2.4.7 Dangers due to electrical power
Work on electrical units or operating materials may only be performed by a qualified electrician in
accordance with electrical rules.
Defects, such as damaged cables, cable connections, etc., must be immediately rectified by an
authorized electrician.
2.4.8 Particular danger zones
In the area of the grinding wheels, there is a danger of pinching and being drawn in (e.g.
clothing, fingers and hair). Suitable personal protective equipment must be worn.
Risk of injury from rotating circular knife.
2.4.9 Servicing (maintenance, repair) and fault rectification
Maintenance work is to be carried out on schedule by trained personnel. Inform operating
personnel before starting repair work. The responsible supervisor must be named.
For all service work, the honing machine is to be disconnected from the power supply and
secured against accidental restarting. Pull out the mains plug. Cordon off the servicing area,
as far as possible.
2. Safety

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After completion of the maintenance work and fault rectification, install all the safety devices and
check whether they are fully functional.
2.4.10 Structural modifications of the honing machine
Modifications, retrofitting or rebuilds of the honing machine are not allowed without the permis-
sion of the manufacturer. This also applies to the installation and adjustment of safety devices.
No alterations may be carried out without prior written permission from KNECHT Maschinenbau
GmbH.
Immediately replace machine parts which are not in perfect condition.
Use only original replacement and wear parts. If parts are purchased from external suppliers, it
cannot be guaranteed that they will be constructed and manufactured to withstand the stresses
and provide the required level of safety.
2.4.11 Cleaning the honing machine
Cleaning agents and materials used must be handled properly and disposed of in an environ-
ment-friendly manner.
Ensure that wear and replacement parts are disposed of in a safe and environmentally friendly
way.
2.4.12 Oils and greases
When handling lubricants/oils and greases, follow the safety regulations for the product. Observe
special instructions for the foodstuffs sector.
2.4.13 Relocation of the honing machine
Even when moving the honing machine a short distance from its site, disconnect it from all exter-
nal power supply sources. Before restarting the honing machine, connect it properly to the current
supply.
When loading or unloading, only use hoisting and load lifting equipment with sufficient
load-bearing capacity. Appoint a qualified banksman (signaller) for the lifting process.
No persons other than those entrusted with this work may be present in the loading and installa-
tion area.
Only lift the honing machine correctly with a suspension device in accordance with the operat-
ing instructions (attachment points for load suspension devices, etc.). Only use suitable transport
vehicles with sufficient load-bearing capacity. Attach the load securely. Use suitable attachment
points. When putting in operation again, proceed only as instructed in the operating instructions.
2. Safety

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3. Description
3.1 Intended use
The KLA 220 - HV 153 honing machine sharpens circular knives with a diameter of 60 to
475 mm.
3.2 Technical specifications
Height ��������������������������������������������������������������������� 750 mm
Width ���������������������������������������������������������������������� 830 mm
Depth ���������������������������������������������������������������������� 820 mm
Space requirement (WxD) ��������������������������������������������� 1000 x 1200 mm
Weight ����������������������������������������������������������������������� 76 kg
Current supply* ������������������������������������������������������������ 3x 400 V
Mains frequency* �������������������������������������������������������������� 50 Hz
Output* ������������������������������������������������������������������� 0.45 kW
Power consumption* �������������������������������������������������������� 0.53 kW
Energy consumption* ��������������������������������������������������������� 1.52 A
Back-up fuse ������������������������������������������������������������������� 16 A
Operating noise at grinding wheels �������������������������������������������� 68 dB (A)
*) This data may vary depending on the electrical power supply.
A circular knife with a diameter of 200 mm was sharpened.

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3. Description
Figure 3-1 Dimensions in mm
3.3 Functional description
The KLA 220 - HV 153 honing machine can be used to clamp and sharpen circular knives with
a diameter of 60 to 475 mm.
The machine is equipped with devices for small knives – d.60-180 mm – and big knives –
d.180-475 mm.
Single side grinds can be applied by tilting the grinding device. The honing angle can be adjusted
between 0° and 40° by rotating the grinding wheels away from each other or towards each other.
Grinding wheels that become untrue can be trued again with the dressing device.
.

4
5
6
8
7
2
1
3
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3. Description
3.4 Description of the assemblies
1 Grinding device, d.60-180 mm
2 HV 156 dressing device
3 Switch box
4 Grinding device, d.180-475 mm
5 Clamping nut
6 Protective hood
7 Grinding wheels
8 Water tray
Figure 3-2 General view of the honing machine

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3. Description
1 Work lamp
2 “Height adjustment” hand wheel
3 “Fine feed” hand wheel
4 Grinding arm
5 Clamping lever for changing the grinding
device
6 Grip for lifting the grinding device
1 Scale for “swiveling”
2 Scale for “lateral shifting”
3 Clamping lever for swivelling the grinding
unit (on the backside of the machine)
3.4.1 Switch box
1 “Control On” button
2 “Hone/Grind” selector switch
3 Rotary knob for controlling the speed of
the right grinding wheel (optional)
4 “Emergency Stop” button
Figure 3-3 Side view
2
6
1
5
4
3
Figure 3-4 Scale
Figure 3-5 Switch box
1
2
3
1 2 3
4

1
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3. Description
Figure 3-6 HV 156 dressing device
3.4.2 HV 156 Dressing device
1 Dressing diamond

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3.5 Construction
Both grinding wheels are driven by one motor each. Force is transmitted via a V-belt on a worm
gear. The left motor can be driven in both directions.
The knife is driven by electric power.
There are two circular knife grinding devices in two different sizes for knives with 60 -180 mm
diameter and for knives with 180-475 mm diameter respectively.
Single side grinds can be applied by tilting the circular knife grinding device. The speed of the
right grinding wheel can be steplessly adjusted according to the equipment.
3. Description

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4.1 Transport aids
Only use adequately dimensioned transport aids for transporting and setting up the honing
machine.
4.2 Transport damage
If damage is detected following unloading after acceptance of the delivery, inform KNECHT
Maschinenbau GmbH and the freight forwarder about it immediately. If required, consult an
independent expert immediately.
Remove the packaging and shipping straps. Remove the shipping straps on the honing machine.
Dispose of the packaging in an environmentally friendly way.
4.3 Transport to another installation site
For transport to another installation site, ensure that the space requirements are fulfilled (see
Chapter 3.2).
A reliable electrical connection must be provided at the new installation site.
The honing machine must be stable and firmly placed.
Installations on the electrical system may only be performed by an
authorized specialist or our customer service staff. Observe the locally
applicable safety and accident prevention regulations.
CAUTION
4. Transport
For transporting the machine, the locally applicable safety and accident
prevention regulations must be observed.
Only transport the honing machine in upright position (with the machine
feet facing downwards).
CAUTION