Bernhard EXPRESS DUAL 3000MC User Manual/Instruction Manual Download Page 3

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EXPRESS DUAL 3000MC

EXPRESS DUAL

Contents

BERNHARD & CO. LIMITED

Bilton Road • Rugby • England • CV22 7DT
Tel +44 1788 811600 • Fax +44 1788 812640

Email:

[email protected]

USA Toll Free

1-888 GRIND IT

(1-888 474 6348)

ED3000MC Manual Control Reel Grinder

Identification of Pictograms

Safety

Installation

Identification of Tools and Equipment

Understanding the Machine

In Frame Grinding

Electrical Fault Finding

Maintenance

Part Lists and Exploded Diagrams

Lift Table Manual

Please quote this serial number on all correspondence:

Serial #:

ED3000MC 2012/10/ENG/RB

Welcome to the Bernhard Express Dual 3000MC. If cared for and operated

correctly this machine will give you years of good service.
This manual will enable you to obtain the best results from your Express Dual so

please read it thoroughly before using your machine.
If you have any service or operational issues please contact your distributor or

phone our technical support hotline

Technical Helpline (USA only)

1-888 474 6348

Rest of World: UK Head Office, England

(+44) 1788 811600

Email:

[email protected]

Technical FAQs can be found on our web site:

www.bernhard.co.uk

When ordering spare parts please quote the machine type and serial number.

THE MANUFACTURERS ACCEPT NO RESPONSIBILITY FOR ANY SITUATION ARISING FROM THE
FITTING AND/OR USE OF NON-ORIGINAL SPARE PARTS.

Summary of Contents for EXPRESS DUAL 3000MC

Page 1: ...read this manual carefully before using the Express Dual This manual should be kept in a safe place so that it can be used for future reference Manual Control Spin Grinder User s Guide Instruction Ma...

Page 2: ...Bernhard and Company Limited 2 EXPRESS DUAL 3000MC NOTES...

Page 3: ...RB Welcome to the Bernhard Express Dual 3000MC If cared for and operated correctly this machine will give you years of good service This manual will enable you to obtain the best results from your Ex...

Page 4: ...f Pictograms MAXIMUM LIFT PLATFORM LOAD 250 KG 550 LBS BEWARE TRAPPING FEET OR OTHER OBJECTS WHEN LOWERING LIFT PLATFORM MAXIMUM GRINDSTONE DIAMETER 150mm MAXIMUM SPEED 2200 Rev Min BEWARE MOVING GRIN...

Page 5: ...G PROTECTION 1 Identification of Pictograms Continued POINTS FOR ATTACHING LIFTING EYES BEWARE MOVING COMPONENTS KEEP HANDS AND OTHER OBJECTS CLEAR GRINDSTONE START CONTROL REEL START CONTROL STOP CON...

Page 6: ...EXPRESS DUAL 3000MC Bernhard and Company Limited 6 Motor Stop E Stop Twist to release Traverse On Reel Spin Drive On Grindstone On Clamp Up Down...

Page 7: ...those supplied specifically for use on the EXPRESS DUAL Warranty will be invalidated 2 7 NEVER fit or use a grinding wheel which has been dropped or subjected to any other form of abuse NOTE Grinding...

Page 8: ...located in a well lit environment with adequate headroom For ideal operation the machine should be accessible from the front rear and at least one side with clearance around it as indicated in the ske...

Page 9: ...POSITE DIRECTIONS at the point of contact 3 5 Preparation If the machine has been received in a crate the handles on the control wheels should be removed from the underneath of the control wheels and...

Page 10: ...ndled Allen Key A2706 3 16 AF Tee handled Allen Key A2719 Grinding Wheel Nut Wrench A2720 1 2 AF Allen Key A2714 Adjustable Sprocket Driver A9182 Drive Rod Plain short A4134 Drive Rod Square short A40...

Page 11: ...lade will be perfectly STRAIGHT and flat whilst mounted on the bedbar During the reel grinding process it is advisable that the bedknife bedbar assembly is replaced in the unit after having been groun...

Page 12: ...unter clockwise to release it NOTE The machine must NOT be stopped when there is contact between the reel and grinding wheel except in cases of emergency 5 3 5 Reset Button see also Electrical Fault F...

Page 13: ...he mainshaft 6 2 Mounting Mower The mainshaft Grinding stone should be wound down to its lowest position and the unit placed on the table The unit should then be carefully moved towards the multifix b...

Page 14: ...act is in a suitable position see Figure 6 3 1 Rotate hand wheels anti clockwise to move grinding wheel away from reel It is important that the grinding wheel should clear the highest blade along the...

Page 15: ...the pin or adjustable type sprocket drivers fitted to the plain drive rod 6 4 2 When the cutting unit is in place and firmly fixed into the multifix brackets or front roller brackets and the rear clam...

Page 16: ...le drive shaft can be detached from its socket on the end of the machine by pulling sharply on the shaft to release it from a spring loaded ball detent Earlier units by first removing the spring retai...

Page 17: ...te direction This is critical where the grinding wheel cannot pass beyond the end plates if they protrude below the maximum diameter of the reel NOTE On the EXPRESS DUAL it is not necessary for the wh...

Page 18: ...way from the reel 6 6 3 Move the grinding wheel to the right hand end of the reel and using the right hand on the right control wheel and the left hand on the reel raise the shaft until the reel again...

Page 19: ...hand side of the reel raising the shaft with your right hand and moving the grinding wheel along with your left hand Repeat this process until the contact along the reel is even and parallel 6 7 6 Sc...

Page 20: ...When Is The Job Done 6 8 1 You will hear the cut begin to run out a rough guide of cutting times will be Fairway Units 12 20 minutes Medium Triple Units 10 15 minutes Greens Hand Mowers 8 10 minutes...

Page 21: ...rs should audibly pull in This can be checked by someone looking in the junction box while the start buttons are pressed 7 7 Traverse If the contactor is functioning properly check the microswitch If...

Page 22: ...aintaining the shaft as horizontal as possible until the right hand side comes up against the stop in the feed column and the left hand side is at its maximum height At this point the fork will drop a...

Page 23: ...in the channel before tightening the screws that lock the bearing inner to the shaft 8 1 10 Loosen the small allen key in the reel drive support block pull the diamond dresser out a short way and re t...

Page 24: ...inshaft This may entail filing a small amount of material from both the depth of the key and the sides Remove only a very small amount of material at a time then check the fit until the sleeve and nut...

Page 25: ...ainshaft during use For extended periods of down time spray on bright areas with Bernhard s Protective oil clean off with Bernhard s Clean and Lube spray or WD40 before use 8 2 2 Weekly Spray WD40 or...

Page 26: ...Bernhard and Company Limited 26 EXPRESS DUAL 3000MC NOTES...

Page 27: ...DRIVE__________ 30 TRAVERSE ASSEMBLY___________________________________ 32 REEL DRIVE____________________________________________ 34 CLAMP ASSEMBLY_______________________________________ 36 MULTI FIX...

Page 28: ...pper Front Skirt 1 A6352 4 Rear Skirt 1 A6397 not required if Lift Table fitted 5 Front Skirt 1 A6328 6 Drawer 2 A6321 7 Drawer Handle 2 A6110 8 Dust Tray 1 A6323 9 Dust Tray Handle 2 A6111 10 Drawer...

Page 29: ...tom cap 1 A4041 Feed Channel R H c w top and bottom cap 1 A4042 2 Feedscrew Cap for LCD counter c w Bush 2 3 Feedscrew 2 4 Locknut 4 A5502 5 Handwheel 150mm dia 2 A6113 6 5 8 Double Coil Spring Washer...

Page 30: ...Bush 1610 x 1 1 A7303 10 SPZ Drive Belt 1 A7102 11 Drive Belt Guard 1 A6334 12 Mainshaft 1 A9068 13 Grinding Stone 1 A6505 14 Sleeve 1 A9116 15 Nut 1 A9095 Sleeve and Nut assembly 1 A9506 16 Mainshaft...

Page 31: ...EXPRESS DUAL 3000MC Bernhard and Company Limited 31 MAINSHAFT MOUNTING AND MAIN MOTOR DRIVE 14 13 1 2 4 11 6 7 3 5 9 8 16 17 18 19 20 21 10 12 15 24 22 23 25 26 27...

Page 32: ...ew M12 x 25 2 A5712 13 Washer M12 2 A5315 14 Engagement Screw 1 A6112 15 Lobed Knob M12 1 A6102 16 Reversing Bar 1 A4111 17 Reversing Bar Stop 2 A4113 18 Cross Knob M8 x 15 2 A6131 19 Microswitch 1 A8...

Page 33: ...EXPRESS DUAL 3000MC Bernhard and Company Limited 33 TRAVERSE ASSEMBLY 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 13 25 26 27 28 29 30 31 32 33 34 36 37 35...

Page 34: ...Drive 2 A9121 6 Flexible Drive Shaft 1 A7404 7 Flexible Drive Bracket Base 1 A4046 8 Retaining Nut 1 A4110 9 L Post Drive Hd Support Bar 1 A4001 10 Flexible Drive Bracket 1 A4045 11 Cylinder Drive Mot...

Page 35: ...EXPRESS DUAL 3000MC Bernhard and Company Limited 35 18 19 20 5 4 2 8 6 7 9 1 5 4 3 10 11 12 14 15 16 13 17 REEL DRIVE...

Page 36: ...us Pressure Arm Bracket 1 A4101 2 Radius Pressure Arm 1 A4100 3 Pressure Bar Rubber 2 A6761 4 Linear Actuator 1 A6013 5 Plug 4 Pin 1 A8121 6 Hex Head Bolt M16 x 170 1 A5749 7 Nyloc Nut M16 1 A5524 8 C...

Page 37: ...EXPRESS DUAL 3000MC Bernhard and Company Limited 37 1 2 3 4 5 6 7 8 9 10 11 12 CLAMP ASSEMBLY...

Page 38: ...zontal 2 A4016 7 Mounting Brkt C Clamp L H 1 A4006 8 Mounting Brkt C Clamp R H 1 A4007 9 C Clamp Screw 2 A4008 10 V Bracket Clamp Finger 2 A4003 11 Kip Lever M10 x 20 4 A6118 12 V Bracket Stud M16 2 A...

Page 39: ...EXPRESS DUAL 3000MC Bernhard and Company Limited 39 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 MULTI FIX BRACKET ASSEMBLY 9 Parts List Continued...

Page 40: ...______________________________________ 1 Control Box 1 2 Control Box Lid 1 3 Control Box Arm 1 A4028 4 Pushbutton 3 A8040 5 B3T10 Contact Block 3 A8039 6 Emergency Stop Button 1 A8073 7 B4T02 Contact...

Page 41: ...use Holder 3 A8081 6 Fuse 2 amp Traverse reel drive 2 A8085 Fuse 5 amp Clamp 1 A8086 7 Contactor K209A10 1 A8063 8 Thermal Overload 1 A8116 9 Reversing Contactor K209A01 1 A8062 10 Cylinder Reel Drive...

Page 42: ...x Head Bolt M6 x 45 1 A5722 17 Nyloc Nut M6 1 A5517 18 R H Pulley Mounting Plate 1 A4099 19 Cover Plate 1 A6319 19 Full Width Cover Plate for High Lift Table not shown 1 20 Washer M6 2 A5320 21 Hex He...

Page 43: ...EXPRESS DUAL 3000MC Bernhard and Company Limited 43 1 5 4 7 6 8 9 10 8 11 11 10 12 2 5 3 6 7 13 14 15 16 17 20 18 19 21 21 20 23 24 25 25 24 22 22 26 26 30 LIFT TABLE 9 Parts List Continued...

Page 44: ...3 4 X1 X2 3 4 X1 X2 3 4 X1 X2 1 2 ISOLATOR PANEL CONTROL PANEL FS3 5AT FS2 5AT FS1 5AT 5 4 6 1 2 3 FS4 6 3AT Clamp Clamp 3 F 1 000 2 00 3 0 0 0 0 0 0 0 8 4 4 4 4 11 11 11 11 11 11 11 5 6 7 8 12 13 14...

Page 45: ...ABLE MANUAL EXPRESS LIFT TABLE Please read this manual carefully This manual should be kept in a safe place so that it can be used for future reference for Express Dual Spin Grinders User s Guide Inst...

Page 46: ...SS DUAL LIFT TABLE Bernhard and Company Limited 46 FIG 1 OVERALL VIEW WITH COVER REMOVED FIG 2 TABLE HEIGHT ADJUSTING DETAIL ADJUSTER A Raises Lowers Left Hand Side ADJUSTER B Raises Lowers Right Hand...

Page 47: ...is required safe operation can be assured only by constant attention to the operating and maintenance instructions contained in this manual It is therefore essential that the responsible person ensur...

Page 48: ...ft lift 1 4 Never attempt to lift an unstable load 1 5 Never use the table to try to assist another lifting device to lift a large load 1 6 Always carry out routine checks and maintenance as instructe...

Page 49: ...ease of handling Power is supplied by an electro hydraulic pack with the single hydraulic ram exerting the lift force through a pair of adjustable lifting chains Early units used a power pack with a...

Page 50: ...the platform to the floor and place the mower unit onto the platform Ensure that the unit is as central as possible and stable before pressing the UP button to bring the platform to the height of the...

Page 51: ...is from the grinding process is allowed to enter the Lift table mechanism The following checks should be carried out at approximately the intervals stated MONTHLY Visually check the complete unit conf...

Page 52: ...of voltage usually a loose or dirty connection is the cause on DC units finally check the condition of the motor brushes and their freedom to move If the lift fails to lower 1 Check the fuses 2 Check...

Page 53: ...EXPRESS DUAL LIFT TABLE Bernhard and Company Limited 53 NOTES...

Page 54: ...8 16 Hex Head Bolt M6 x 45 1 A5722 17 Nyloc Nut M6 1 A5517 18 R H Pulley Mounting Plate 1 A4099 19 Cover Plate 1 A6319 19 Full Width Cover Plate for High Lift Table not shown 1 20 Washer M6 2 A5320 21...

Page 55: ...EXPRESS DUAL 3000MC Bernhard and Company Limited 55 1 5 4 7 6 8 9 10 8 11 11 10 12 2 5 3 6 7 13 14 15 16 17 20 18 19 21 21 20 23 24 25 25 24 22 22 26 26 30 LIFT TABLE 9 Parts List Continued...

Page 56: ...e motors will shut down if the safety enclosure is opened The control panel for all Express Dual and Anglemaster models 3000 3000DX and 5000 will also be fitted with a key operated service switch This...

Page 57: ...USER MANUAL ADDENDUM NOTES...

Page 58: ...Toll Free 1 888 GRIND IT 1 888 474 6348 If you have any service or operational problems contact your distributor or phone our Technical Helpline USA only 1 888 474 6348 or Bernhard and Company Ltd En...

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