Van Norman FG5000 User manual

FG5000/10000
Flywheel
Grinder
Instruction Manual and Parts List
Van Norman 500 57th St., Marion, IA 52302 888-855-1789 319-377-9101 (FAX)
Copyright 2005 All Rights Reserved.
Equipment specifications, options and accessories subject to change without notice.

WARRANTY
Flywheel Grinders, 777 and 204C Brake Lathes
Van Norman will repair and/or replace, free of charge (FOB factory) all such defective
parts, only when returned to factory with shipping charges prepaid. This warranty does not
cover parts and supplies (wheel dresser/diamonds/abrasives) consumed in normal
operation of the machine.
Van Norman disclaims all other warranties, expressed or implied, as to the quality of any
goods, including implied warranties of MERCHANTABILITY and FITNESS FOR
PARTICULAR PURPOSES. UNDER NO CIRCUMSTANCES WHATSOEVER, SHALL Van
Norman BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES,
WHETHER BASED ON LOST GOODWILL, LOST RESALE PROFITS, WORK
STOPPAGE, IMPAIRMENT OF OTHER GOODS OR ARISING OUT OF BREACH OF ANY
EXPRESS OR IMPLIED WARRANTY, BREACH OF CONTRACT, NEGLIGENCE OR
OTHERWISE, EXCEPT ONLY IN THE CASE OF PERSONAL INJURY.
Because of Van Norman’s constant program of product improvement, specifications are
subject to change without notice.
VAN NORMAN PROVIDES A LIMITED WARRANTY ON PRODUCTS WHEN
PURCHASED IN A NEW ANDUNUSED CONDITION TO BE FREE FROM DEFECTIVE
MATERIAL OR WORKMANSHIP FROM DATE OF PURCHASE FOR A PERIOD OF ONE
YEAR.
This warranty does not apply to a product that has been purchased in used condition, that
has failed due to improper installation, repairs, service or that has sustained damage
caused by accident, improper use or shipment.
For further information or questions, please contact Van Norman at 888-855-1789 or fax
319-377-9101.
PLEASE RETAIN THIS WARRANTY FOR YOUR RECORDS
Van Norman 500 57th St., Marion, IA 52302 888-855-1789 319-377-9101 (FAX)

5000/10000 FLYWHEEL GRINDER
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/Kwik-Way
Products Inc. immediately. Although Van Norman/Kwik-Way Products Inc. 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/Kwik-
Way Products Inc. 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 1. 888-855-1789

5000/10000 FLYWHEEL GRINDER
SAFETY FIRST
This manual has been prepared for the owner and those responsible for the maintenance of this
machine. It’s 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.
Van Norman 2. 888-855-1789

5000/10000 FLYWHEEL GRINDER
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/Kwik-Way 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/Kwik-Way 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,
Van Norman/Kwik-Way Products Inc. disclaims any real or implied warranty and holds itself
harmless for any injury or loss that may result from such use.
Van Norman 3. 888-855-1789

5000/10000 FLYWHEEL GRINDER
ELECTRICAL REQUIREMENTS — FG5000
AMP SERVICE MINIMUM
PART # DESCRIPTION/ELECTRICALS REQUIRED WIRE SIZE
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
794-8690-03 380V, 50 Hz, 3 Ph 20 14
794-8690-04 575V, 60 Hz, 3 Ph 15 14
794-8690-15 230V, 60 Hz, 3 Ph w/10 Hp Motor
FG5000 w/PowerHead
794-8688-40 208/230V, 60 Hz, 3 Ph 30 12
794-8688-41 208/230V, 60 Hz, 1 Ph 60 8
794-8688-42 380V, 50 Hz, 3 Ph 20 14
794-8688-43 460V, 60 Hz, 3 Ph 20 14
FG5000 w/PowerHead & AutoGrind™
794-8688-50 208/230V, 60 Hz, 3 Ph 30 12
794-8688-51 208/230V, 60 Hz, 1 Ph 60 8
794-8688-52 380V, 50 Hz, 3 Ph 20 14
794-8688-53 460V, 60 Hz, 3 Ph 20 14
ELECTRICAL REQUIREMENTS — FG10,000 STANDARD
AMP SERVICE MINIMUM
PART # DESCRIPTION/ELECTRICALS REQUIRED WIRE SIZE
FG10,000 w/PowerHead
794-8688-22 208/230V, 60 Hz, 3 Ph 60 8
794-8688-36 460V, 60 Hz, 3 Ph 30 12
794-8688-35 380V, 50 Hz, 3 Ph 30 12
FG10,000 w/PowerHead & AutoGrind™
794-8688-06 208/230V, 60 Hz, 3 Ph 60 8
794-8688-38 460V, 60 Hz, 3 Ph 30 12
794-8688-37 380V, 50 Hz, 3 Ph 30 12
Van Norman 4. 888-855-1789

5000/10000 FLYWHEEL GRINDER
SPECIFICATIONS - FG5000
Table Diameter 18” 450 mm
Flywheel Diameter Capacity 24” 600 mm
Grinding Motor 5 HP 3.5 Kw
Grinding Motor 3500 RPM
Vertical Travel w/2.5” Wheel 8.75” 222 mm
Coolant: Capacity, Std. 9.5 gal. 36 liters
Capacity, Opt. 32 gal. 121 liters
Coolant Flow per Minute 19.5 gal. 475 liters
Height, Overall 67“ 1600 mm
Height to Table 34.5” 876 mm
Space Required 35 x 38” 889 x 965 mm
Shipping Weight
FG5000 1500 lbs. 675kg
FG5000PCA 1550 lbs. 698kg
SPECIFICATIONS - FG10,000
Table Diameter 18” 450mm
Grinding Capacity 24” 600mm
Grinding Motor @ 3500 RPM 10HP 7Kw
Vertical Travel/Clearance 10.5” 267mm
Coolant: Capacity, Std. 9.5 gal 36 liters
Capacity, Opt. 32 gal 121 liters
Coolant Flow per Minute 19.5 gal. 475 liters
Height to Table 34.5” 876 mm
Height, Overall 69” 1753 mm
Floor Space 35 x 38” 889 x 965 mm
Machine Weight 1550 lbs. 703 kg
Shipping Weight 1700 lbs. 771 kg
Van Norman 5. 888-855-1789

5000/10000 FLYWHEEL GRINDER
STANDARD EQUIPMENT — FG5000/ FG10,000
ITEM PART # DESCRIPTION
1 794-8010-64 Centering Cone Bolt 1.875" (47.6 mm)
2 794-8010-65 Centering Cone Bolt 2.375" (60.3 mm)
3 794-8010-66 Centering Cone Bolt 3.375" (87.8 mm)
4 794-8010-72 Centering Cone 1"-1.75" (25.4-44.5 mm)
5 794-8010-74 Centering Cone 1.312"-2" (33.3-50.8 mm)
6 794-8010-76 Centering Cone 1.75"-2.5" (44.5-63.5 mm)
7 794-8017-93 Centering Cone 2"-2.625" (50.8-66.7 mm)
8 794-8010-78 Centering Cone 2.25"-3" (57.2-76.2 mm)
9 794-8010-80 Centering Cone 2.75"-3.5" (69.9-88.9 mm)
10 794-8010-90 Flange Adaptor 3" (76.2 mm)
11 794-8010-92 Flange Adaptor 4" (101.6 mm)
12 794-8010-94 Flange Adaptor 5" (127 mm)
13 794-8010-97 Flange Adaptor 5.875" (149.2 mm)
14 794-8124-71 Wheel Spacer 1.5" (38.1mm)
15 794-8011-28 Grinding Wheel 4" (101.6 mm) Flaring Cup
16 794-8011-12 Grinding Wheel 6" (152.4 mm) Flaring Cup
17 794-8011-30 Grinding Wheel 6" (152.4 mm) Flaring Cup
18 794-8011-88 Lower Wheel Flange
19 794-8017-44 E-Z Lok Inserts (2)
20 794-8011-52 Leadscrew Lubricant
21 794-8011-40 Coolant Additive, 1 Qt (.946 liter)
22 794-8011-55 Table Lubricant, 2 Qts (.946 liter)
23 794-8033-21 Leveling Bolts (4)
24 000-1035-35 Leveling Bolt Lock Nuts (4)
25 794-8030-58 Leveling Pads (4)
26 794-8639-45 E-Z Lok Insert Extractor
27 794-8013-73 Table Oil Level Gage
28 794-8017-32 T-Handle Hex Wrench
29 794-8017-37 Wrench Set
30 000-0170-60 Wheel Mounting Bolt, 2.75"
31 000-0170-55 Wheel Mounting Bolt, 2.50"
32 000-0170-35 Wheel Mounting Bolt, 1.25"
33 000-0170-27 Wheel Mounting Bolt, 1.00"
34 794-8013-12 O-Ring
Van Norman 6. 888-855-1789

5000/10000 FLYWHEEL GRINDER
STANDARD EQUIPMENT — FG5000/ FG10,000
Van Norman 7. 888-855-1789

5000/10000 FLYWHEEL GRINDER
OPTIONAL EQUIPMENT
ITEM PART # DESCRIPTION
1 794-8010-67 Centering Cone Bolt 3.5"(88.9 mm)
2 794-8011-41 Coolant Additive, 1 Gal. (3.8 L)
3 794-8011-42 Coolant Additive, 5 Gal. (18.9 L)
Grinding Wheels
1 794-8011-16 Grinding Wheel 6" Flaring Cup
2 794-8011-32 Grinding Wheel 6" Straight Sided
3 794-8011-34 Grinding Wheel 6" Flaring Cup
4 794-8011-36 Grinding Wheel 6" Straight Sided
5 010-0797-03 Grinding Wheel 3" Flaring Cup (Requires 801173 Mounting Adaptor)
6 794-8011-73 Mounting Adaptor 1.75" to .75"
7 794-8011-12 Grinding Wheel 6" Flaring Cup
8 794-8011-30 Grinding Wheel 6" Flaring Cup
9 794-8011-28 Grinding Wheel 4" Flaring Cup
10 794-8687-01 Grinding Wheel 3" Flaring Cup (Requires 868697 Mounting Flange)
VW/UNIVERSAL FLYWHEEL KIT (#794-8685-49)
ITEM PART # DESCRIPTION
794-8685-49 VW/Universal Flywheel Kit
1 794-8010-58 Tee Nut 375-16 x .500 (3)
2 794-8012-02 Centering Cone
3 794-8012-03 Tooling Support Block (3)
4 794-8012-04 Tooling Clamp (3)
5 804-8012-06 SHCS .375-16 x 2.250 (3)
6 794-8012-07 SHCS .437-14 x .750
7 000-1155-33 Flat Washer, .375 (3)
8 000-0171-40 SHCS .375-16 x 1.5 (3)
Van Norman 8. 888-855-1789

5000/10000 FLYWHEEL GRINDER
OPTIONAL EQUIPMENT (continued)
#794-8686-32
ITEM PART # DESCRIPTION
794-8627-83 Dial Indicator/Indicator Bar Set
1 794-8013-17 Mounting Adapter (not shown)
2 001-0023-75 Dial Indicator
3 794-8013-20 Indicator Bar
4 794-8013-21 Spacer
5 794-8013-22 Convex Point
6 000-0485-18 SSS .250-20 x .250 (not shown)
7 794-8055-99 SHCS .375-16 x 3.25 Long
8 794-8627-82 Dial Indicator Magnetic Base
9 000-1020-16 .250-28 Jam Nut (not shown)
794-8627-83 Indicator Bar Kit
10 794-8011-91 Knob
11 794-8013-25 Indicator Bar
12 804-8013-29 Hex Nut .250-20, Jam (2)
13 794-8013-33 Indicator Point, 1
14 794-8017-04 Indicator Point, 2.5
15 794-8020-52 Foot Assembly, .500 (2)
16 794-8020-53 Foot Assembly, 1.00 (2)
Van Norman 9. 888-855-1789

5000/10000 FLYWHEEL GRINDER
OPTIONAL EQUIPMENT (continued)
ITEM PART # DESCRIPTION
794-8625-27 Radius Cutter Assembly
1 000-0170-19 SHCS .375-16 x .750 (2)
2 794-8030-20 HHCS .500-13 x 1.750 (3)
3 794-8084-05 Boring Bar, 1.5" (38.1 mm) Dia.
4 794-8084-06 Boring Tool
5 794-8084-07 SSS .312-18 x .500
6 000-1150-53 Washer .562 x 1.375 (3)
7 794-8011-99 Spacer, Power Column Washer (3)
8 794-8621-28 Mounting Plate
794-8107-90 Small Bore/VW Centering Cone Set
1 794-8010-69 VW Rabbit Centering Cone, 1.38"
2 794-8010-70 Centering Cone, 1.375"
3 794-8010-95 VW Flange Adapter
4 794-8015-96 FSHCS, .437-14 x 2"
5 794-8016-28 SHCS, .437-14 x 1.5"
6 794-8686-99 FSHCS, .437-16 x 2.50"
7 794-8687-14 SHCS, .437-14 x 2.25"
Van Norman 10. 888-855-1789

5000/10000 FLYWHEEL GRINDER
OPTIONAL EQUIPMENT (continued)
ITEM PART # DESCRIPTION
794-8010-40 Clutch Tooling Kit
794-8010-01 BHCS .312-24 x 1.00 (4)not shown
000-0592-20 BHCS .312-18 x 1.00 (4) not shown
1 794-8010-03 Clutch Diaphram Fastener (4)
804-8010-05 BHCS .375-16 x .75 (3) not shown
2 794-8010-07 Clamp Plate (3)
3 794-8010-09 V-Plate (3)
4 794-8010-12 Hold Down Bolt Assembly
5 794-8010-16 Center Plate
6 794-8010-19 Parallel Block Assembly (4)
804-8010-23 Flat Washer (4) not shown
7 794-8010-30 Hold Down Bolt Assembly
8 794-8010-32 Clutch Adapter, 9.5
9 794-8010-34 Clutch Adapter, 8.75
10 794-8010-36 Clutch Adapter, 9.0
11 794-8010-38 Clutch Adapter, 7.5
794-8010-58 Tee Nut, .375-16 x .50 (6) not shown
000-0170-19 SHCS .375-16 x .75 (2) not shown
000-0170-27 SHCS .375-16 x 1.00 (4) not shown
000-0171-40 SHCS .375-16 x 1.50 (6) not shown
804-8016-58 BHCS .375-16 x 1.00 (3) not shown
12 794-8047-86 Long Finger, 6" (4)
13 794-8047-87 Long Finger, 4.5" (4)
Van Norman 11. 888-855-1789

5000/10000 FLYWHEEL GRINDER
OPTIONAL EQUIPMENT (continued)
794-8107-88 Heavy Duty Universal Centering Cone & Spacer Set
1 794-8010-58 Tee Nut .375-16 x .500 (3)
2 794-8010-59 Hex Stool, 0.5" (12.7 mm) (3)
3 794-8687-12 Hex Stool, 1" (25.4 mm) (3)
4 794-8010-82 Centering Cone, 4" (101.6 mm)
5 794-8010-84 Centering Cone, 4.5" (114.3 mm)
6 794-8010-86 Centering Cone, 5" (127.0 mm)
7 794-8011-89 Wheel Spacer, 1" (25.4 mm)
8 794-8011-90 Wheel Spacer, 2" (50.8 mm)
9 000-0170-94 SHCS .375-16 x 2.25
10 000-0170-19 SHCS .375-16 x .75 (3)
11 000-0170-35 SHCS .375-16 x 1.25 (3)
12 794-8016-19 Stud .375-16 x 2.875 (2)
13 000-0170-51 SHCS .375-16 x 2.00
14 794-8055-99 SHCS .375-16 x 3.25
15 000-0170-65 SHCS .375-16 x 3.00
16 794-8677-99 Centering Cone Bolt, 4.25"
Van Norman 12. 888-855-1789

5000/10000 FLYWHEEL GRINDER
OPTIONAL EQUIPMENT (continued)
ITEM PART # DESCRIPTION
794-8633-33 ATP5000 Transmission Pump Kit
794-8632-07 Centering Hub, Pump Body
794-8633-29 Adaptor Disc, .910
794-8636-23 Adaptor Disc, 2.062 ID
794-8632-22 Adaptor Disc, 2.121 ID
794-8632-21 Adaptor Disc, 2.183 ID
794-8632-20 Adaptor Disc, 2.613 ID
794-8632-27 Adaptor Disc, 2.723 ID
794-8632-19 Adaptor Disc, 2.751 ID
794-8632-26 Adaptor Disc, 2.825 ID
794-8632-25 Adaptor Disc, 2.925 ID
794-8632-18 Adaptor Disc, 2.965 ID
794-8632-24 Adaptor Disc, 2.980 ID
794-8632-28 Adaptor Disc, 2.057 Pilot Dia.
794-8632-09 Alignment Plate
794-8632-17 Brass Wire Brush
794-8632-11 Centering Disc
794-8632-07 Centering Hub
794-8633-30 Counter Boring Tool
794-8105-29 Dressing Stick, Hand Held
794-8664-42 Flanged Nut .5" (12.7 mm)
010-0797-03 Grinding Wheel, 3" (76.2 mm)
794-8633-32 Grinding Wheel, 4" (101.6 mm)
794-8632-13 Hold Down Stud
794-8011-73 Mounting Adaptor
794-8633-31 Peg Board
Van Norman 13. 888-855-1789

5000/10000 FLYWHEEL GRINDER
OPTIONAL EQUIPMENT (continued)
Flywheel Dowel Pin Puller Kit
794-8684-78 Popular Automotive Domestic & Import Kit
1 794-8688-44 Slide Hammer
2 794-8688-45 Slide Rod
3 794-8688-46 Tightening Sleeve
4 794-8688-56 1/4" 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
11 794-8688-48 Storage Case
Optional Collets
794-8688-55 3/16" Collet (4.75mm)
794-8688-60 1/2" Collet (12.7mm)
794-8688-89 9/16" Collet (14.28mm)
794-8688-61 4mm Collet
794-8688-64 8mm Collet
794-8688-65 10mm Collet
794-8684-77 0"-4" Depth Micrometer (0-101.6mm) (Not Shown)
Van Norman 14. 888-855-1789

5000/10000 FLYWHEEL GRINDER
OPTIONAL EQUIPMENT (continued)
794-8680-18 Heavy Duty Centering Adapter Set
1 794-8657-37 Ford/Cat 205, 2.040" (51.8 mm)
2 794-8657-38 Mack 305, 2.435" (61.8 mm)
3 794-8657-39 Ford Truck, 2.495" (63.4 mm)
4 794-8657-40 Cum/GMC 306, 2.830" (71.9 mm)
5 794-8657-41 Ford 307, 3.149" (79.9 mm)
6 794-8657-42 Ford Truck, 3.255" (82.7 mm)
Van Norman 15. 888-855-1789

5000/10000 FLYWHEEL GRINDER
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 NO. SIZE/TYPE WORKPIECE
HARDNESS REFERENCE NO. COLOR HARDNESS MATERIAL
794-8011-34 6" Diameter For soft steel flywheels only.
FG1058 Flared Cup The most free-cutting stone
Ruby on steel.
794-8011-36 6" Diameter Same composition as 801134
FG1058S Straight Side but with straight sides to
Ruby grind flat flywheels only.
794-8687-01 3" Diameter For crankshaft mounting flanges,
FG1059 Flared Cup pressure plate surfaces, automatic
Gray trans. pump bodies and covers.
794-8011-30 6" Diameter Best general purpose wheel for
FG1057 Flared Cup cast iron and medium steel.
Ruby Requires very little dressing.
794-8011-32 6" Diameter Same composition as 801130 but
FG1057S Straight Side with straight sides to grind flat
Ruby flywheels only.
794-8633-32 4" Diameter Best wheel for grinding
FG1060 Flared Cup aluminum.
White
794-8011-28 4" Diameter For small, imported flywheels.
FG1056 Flared Cup Works well on cast iron and
White medium steel.
794-8011-12 6" Diameter For use on some cast iron and
FG1049 Flared Cup ductile iron. Special grit tends to
Ruby be fast cutting and long wearing.
794-8011-16 6" Diameter Best all-around stone for billet
FG1050 Flared Cup steel. Softer wheel requires
White minimum dressing.
NOTE: 10% Discount on Grinding Wheels in Lots of 10 Each
Van Norman 16. 888-855-1789