Bernhard EXPRESS DUAL 4000 User Manual/Instruction Manual Download Page 52

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EXPRESS DUAL 4000

CONTROL PANEL V1 - SERIAL NUMBER 20343 - 21033

J7 INVERTER

Part

Part #

Description

Qty

08206 24V DC HOUR METER FOR PCB

08620 INPUT/OUTPUT PCB NEW ED4/AM4

08620 Programmed Omron JX Inveter 0-5v

08203 THERMAL OVERLOAD BASE FOR PCB

08117 THERMAL OVERLOAD 6-9A

Please contact Bernhard & Co

08148 3MF CAPACITOR

03301 NEW TRANSFORMER FOR ED5/ED3PCB

Please contact Bernhard & Co

08990 ED4000 SPARE FUSE KIT

08962 MACHINE CONTROL PCB FOR EX DUAL

Summary of Contents for EXPRESS DUAL 4000

Page 1: ...ase 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 ED4000 Automatic Spin Grinder User s Guide Instructi...

Page 2: ...EXPRESS DUAL 4000 Bernhard and Company Limited NOTES...

Page 3: ...it thoroughly before using your machine 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...

Page 4: ...13 14 15 16 17 20 18 19 21 21 20 23 24 25 25 24 22 22 26 26 30 MAXIMUM LIFT PLATFORM LOAD 250 KG 550 LBS BEWARE TRAPPING FEET OR OTHER OBJECTS WHEN LOWERING LIFT PLATFORM MAXIMUM GRINDSTONE DIAMETER...

Page 5: ...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 CONT...

Page 6: ...and Company Limited 6 Emergency Stop Twist to release Unclamp Clamp Reset Display Traverse On Off Reel Spin Drive On Off Grindstone On Off Position Value Display Balance Indicator Service Switch Reel...

Page 7: ...hose 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 w...

Page 8: ...ocated 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 sket...

Page 9: ...OSITE 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 r...

Page 10: ...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 A4063 2 Pin Drive large A4276...

Page 11: ...ade 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 ground...

Page 12: ...ttons toggle Press to turn on press again to turn off 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...

Page 13: ...nd down to its lowest position and the unit placed on the table The unit should then be carefully moved towards the multifix brackets or front roller brackets which can be adjusted in any direction to...

Page 14: ...g the mainshaft from one end of the machine as the stone is raised to check that the point of contact is in a suitable position see Figure 6 3 NOTE If the cutting unit has no front roller fitted so th...

Page 15: ...re 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 whole width of the grinding wheel t...

Page 16: ...ket drivers fitted to the plain drive rod 6 5 2 When the cutting unit is in place and firmly fixed into the multifix brackets or front roller brackets and the rear clamped with the radiused pressure b...

Page 17: ...unit if required 6 6 Applying the Cut Before starting any of the motors it is necessary to bring the grinding wheel into its approximate cutting position 6 6 1 With the stone positioned at the left h...

Page 18: ...t process with the left hand on the control wheel and the right hand on the traverse knob moving the grinding wheel along the reel by hand using the traverse engagement screw winding up the left hand...

Page 19: ...the entire length of the reel Press the red reset button to zero the display zero the grinder to the reel The central green LED illuminates and both counters zero Winding the right hand handwheel will...

Page 20: ...eens Hand Mowers 8 10 minutes 6 8 2 Now take off the cut by simultaneously moving both hand wheels anti clockwise when the stone is at one end of its traverse until the grinding wheel is clear of the...

Page 21: ...essed 7 7 Traverse If the contactor is functioning properly check the microswitch If this is found to be OK check capacitor if possible If neither of these is faulty then the motor is probably at faul...

Page 22: ...or position 8 1 3 Release the 2 allen screws in the bearing flange ring on the left hand end of the main shaft 8 1 4 Raise the mainshaft to its maximum height maintaining the shaft as horizontal as po...

Page 23: ...ainshaft NOTE Be careful to guide the assembly into the fork when lowering the mainshaft Make sure that the left hand side arm is centered in the channel 8 1 12 Loosen the small allen key in the reel...

Page 24: ...he mainshaft 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 an...

Page 25: ...ring 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 equivalent...

Page 26: ...AMP ASSEMBLY_______________________________________ 40 MULTI FIX BRACKET ASSEMBLY__________________________ 42 CONTROL ARM__________________________________________ 44 ISOLATOR BOX SN 20343 21261_____...

Page 27: ...6421 DUST TRAY RUNNER RH 1 4 03120 DUST TRAY ED SN 16391 ONWARDS 1 5 05158 M6 X 40 CAP HEAD SOCKET SCREW 4 6 06110 DRAWER HANDLE 4 7 03231 FRONT SKIRT ED SN 16391 ONWARDS 1 8 07013 ED4000 MACHINE LABE...

Page 28: ...W 8 3 03101 Igus Bush 16 4 03548 RIGHT HAND HINGE BRACKET ED4 ED4DX GUARD 1 5 03547 LEFT HAND HINGE BRACKET ED4 ED4DX GUARD 1 6 03552 GUARD STAY LONG ED4 ED4DX GUARD 2 7 06825 GAS STRUT 2 8 03549 LEFT...

Page 29: ...EXPRESS DUAL 4000 Bernhard and Company Limited 29 14 4 4 3 2 3 2 15 8 X6 7 13 13 11 X2 12 X4 10 X2 1 5 9 X2 GUARD FRONT...

Page 30: ...EXPRESS DUAL 4000 Bernhard and Company Limited 30 13 6 18 27 21X4 33X7 32 31X4 6 19 21X4 29X8 X8 28 23X4 16 20 22 25 24 26 30 34 35 37X4 36X2 17 37 38X3 GUARD FRAME...

Page 31: ...17 03729 FLUORESCENT TUBE ONLY ED AM GUARD 1 18 03568 KEY FOR ELECTRICAL DOOR ED4000 1 19 03567 GUARD LH END DOOR FABRICATION ED4 1 20 03566 GUARD RH END DOOR FABRICATION ED4 1 21 04900 4 X 12 BTN HEA...

Page 32: ...EXPRESS DUAL 4000 Bernhard and Company Limited 32 FEED ADJUSTMENT 25 10 8 11 12 16 2 1 3 4 5 25 7 7 7 9 13 15 18 17 14 19 20 21 22 23 24 19 6 X2 X2 18A 26 27 28 X2 X2 X2 OLDER VERSION PRE OCTOBER 2012...

Page 33: ...ON SPRING 2 13 09210 ENCODER COUPLING ENCODER END 2 14 08108 M3 X 6 POSI DRIVE PAN HEAD 4 15 04690 ENCODER BRACKET FOR EXPRESS DUAL 2 16 05129 M5 X 10 BTN HD SOCKET SCREW 4 17 05318 M5 FORM B WASHERS...

Page 34: ...5 2 1 6 4 3 8 7 9 24 12 15 14 10 11 MAINSHAFT MAIN MOTOR DRIVE ASSEMBLY 22 25 27 50HZ VERSIONS UK EUROPE 60HZ VERSIONS USA 25 18B 2 3 4 6 8 7 7 7 9 13 21A 16 17 16 17 19B 18A 19A 20B 20A 23 21B 26 26...

Page 35: ...321 M8 FORM B WASHER 4 15 05219 M8 X 30 HEX HEAD SET SCREW 4 16 07202 71X1 SPZ T LOCK PULLEY 1 17 07301 1108 X 19MM T LOCK BUSH 1 18A 07201 112X1 SPZ T LOCK PULLEY MAINSHAFT 1 18B 07203 95X1 SPZ T LOC...

Page 36: ...ed 36 3 1C 1B 6 2A 2B 2C 2C 7 10 11 14 15 25 26 8 9 TRAVERSE ASSEMBLY V2 1A 4 20A 20B 20C 20D 27 13 31 12 12 24 23 21 22 5 4 5 4 5 4 5 33 16 17 18 19 29 30 34 35 32 36 28 38 38 38 38 37 X2 X2 X2 X2 X2...

Page 37: ...KET SCREW 4 13 05760 M5 X 20 CSK SKT SCREWS 2 14 04892 ED4000 ED4000DX Trav Switch Assy 1 15 04906 M4 X 16 PAN HEAD 2 16 04459 MICROSWITCH GUARD 2011 1 17 05138 M5 X 6 BUTTONHEAD SOCKET SCREW 2 18 063...

Page 38: ...PRESS DUAL 4000 Bernhard and Company Limited 38 4 29 11 15 20 26 18 14 29 21 9 19 25 17 16 REEL DRIVE 23 24 1 1 5 6 X2 X2 X2 6X2 2X2 2X2 6X2 6X2 5X2 7X2 6X2 8 12 12 X2 X2 22 10 4 3 2 3 2 19 27 13X5 28...

Page 39: ...KEY 2 13 08164 P CLIP SIZE 3 5 14 06011 CYLINDER DRIVE MOTOR ED 1 15 04110 RETAINING NUT LEFT HAND T NUT 1 16 06737 DIAMOND DRESSER 1 17 05156 M6 X 25 SOCKET CAP SCREW 1 18 04001 L POST DRIVE HEAD SUP...

Page 40: ...EXPRESS DUAL 4000 Bernhard and Company Limited 40 CLAMP ASSEMBLY 5 13 10 12 1 2 3 8 X4 7 4 9 12 14 11 6 11 13A X2 X4 X4 15 16 13B 13C...

Page 41: ...X 30 CSK SKT SCREW 4 7 05310 M10 FORM B WASHER 4 8 05503 M10 HEX NUTS 4 9 04101 RADIUS PRESSURE ARM BRACKET ED 1 10 05749 M16 x 170mm HT Bolt 1 11 05505 M10 NYLOCK NUT 2 12 05706 M10 X 45 HEX BOLTS 2...

Page 42: ...SS DUAL 4000 Bernhard and Company Limited 42 1 2 3 4 5 6 7 8 9 10 11 11 12 14 15 17 18 MULTIFIX BRACKET ASSEMBLY 2 11 22 22 22 22 21 20 23 16 19 13 9 11 16 10 15 12 13 13 13 18 18 18 14 14 14 6 17 17...

Page 43: ...Bracket C Clamp R H 1 9 04899 Multifix C Clamp Screw Assy 2 10 04003 ADJ MNTG BRK V BRACKET FINGER 2 11 06118 M10 X 20 LOCKING LEVERS 4 12 05401 V BRACKET STUD M16 2 13 06121 M12 X 30 ZINC LOCKING LE...

Page 44: ...EXPRESS DUAL 4000 Bernhard and Company Limited 44 1 2 3 4 5 8 6 9 10 11 18 17 16 12 14 7 13 X2 X4 X4 X4 X4 X8 19 SERIAL 20343 ONWARDS 15 04907 CONTROL ARM...

Page 45: ...GUARD SERVICE KEY SWITCH 1 8 04897 ED4000 Reel Speed Dial Assy 1 9 03691 METAL CONTROL BOX BASE ED4000 1 10 08037 B3M CONNECTORS 1 11 08038 Normally Closed Contact Block 1 12 05512 M5 HEX NUTS 4 13 0...

Page 46: ...ited 46 1 2 1 6 7 3 X2 X4 5 8 9A 9B 10 X3 2 11 12 13 20 21 22 17 X2 18 X2 ENCODERS TRAVERSE SWITCH MACHINE POWER 16 X2 19 X4 4 X4 ISOLATOR BOX VERSION 1 25B 14 25A 25C X3 OLD STYLE TRAVERSE SWITCH MAC...

Page 47: ...Gland 3 11 08099 KOPEX PMA 90 DEGREES FITTING 1 12 08264 CONDUIT 20MM FOR MOTORS MTR 0 6 13 08111 MICROSWITCH FOR TRAVERSE 1 14 08101 KOPEX PMA 90 STRAIGHT FITTING 1 15 05210 M5 X 45 COUNTERSUNK SCRE...

Page 48: ...d Company Limited 48 1 2 1 6 7 3 X2 X4 5 8 9A 9B 10 X3 2 11 12 13 14 X2 20 21 22 17 X2 18 X2 ENCODERS TRAVERSE SWITCH MACHINE POWER 16 X2 19 X4 15 X2 4 X4 04909 ISOLATOR BOX NEW STYLE TRAVERSE SWITCH...

Page 49: ...Nylock 4 8 03628 ISOLATER BOX PALLET FRAME ED4000 1 9A 9B 03303 ROTARY CAM SWITCH CS20A A2 1 10 08114 Cable Gland 3 11 08099 KOPEX PMA 90 DEGREES FITTING 1 12 08264 CONDUIT 20MM FOR MOTORS MTR 0 6 13...

Page 50: ...EXPRESS DUAL 4000 Bernhard and Company Limited 50 3 4 1 2 2 1 5 6 8 9 8 10 7 11 13 13 13 12 14 14 15 16 X3 X2 X4 X2 18 17 19...

Page 51: ...M6 x 16 Hex head 2 7 05320 M6 FORM B WASHER 2 8 02750 2A JUBILEE CLIP BOX 10 2 9 06975 VAC HOSE 1 LENGTH 1 10 06064 INDUSTRIAL VACUUM 1 11 06288 CARTRIDGE FILTER FOR PC220 VACUUM 1 12 05748 M8 X 60 HE...

Page 52: ...UT OUTPUT PCB NEW ED4 AM4 1 3 08620 Programmed Omron JX Inveter 0 5v 1 4 08203 THERMAL OVERLOAD BASE FOR PCB 1 5 08117 THERMAL OVERLOAD 6 9A 1 6 Please contact Bernhard Co 1 7 08148 3MF CAPACITOR 1 8...

Page 53: ...UT OUTPUT PCB NEW ED4 AM4 1 3 08620 Programmed Omron JX Inveter 0 5v 1 4 08203 THERMAL OVERLOAD BASE FOR PCB 1 5 08117 THERMAL OVERLOAD 6 9A 1 6 Please contact Bernhard Co 1 7 08148 3MF CAPACITOR 1 8...

Page 54: ...20 Programmed Omron JX Inveter 0 5v 1 3 08203 THERMAL OVERLOAD BASE FOR PCB 1 4 08117 THERMAL OVERLOAD 6 9A 1 5 03929 3PDT plug in relay 10A 24Vdc coil 1 6 08148 3MF CAPACITOR 1 7 08638 TRANSFORMER FO...

Page 55: ...med Omron JX Inverter 0 5v 1 3 08203 THERMAL OVERLOAD BASE FOR PCB 1 4a 08116 THERMAL OVERLOAD 4 6A 4b 08117 THERMAL OVERLOAD 6 9A 5 03929 3PDT plug in relay 10A 24Vdc coil 1 6 08148 3MF CAPACITOR 1 7...

Page 56: ...D OPTIONS When a replacement thermal overload is required check the scale of the side of the unit If this runs from 6 9 then replace with part 08117 If this runs from 4 6 then replace with part 08116...

Page 57: ...EXPRESS DUAL 4000 Bernhard and Company Limited 57 TOOLKIT UPTO SERIAL NUMBER 22560...

Page 58: ...DELS 1 12 02735 Drive Bolt for Adj Sprocket Driver 3 13 09534 ADJUST SPROCKET DRIVER COMPLETE ED 1 14 05503 M10 HEX NUTS 3 15 02708 3MM AF HEX KEY 1 16 02712 8MM LONG ALLEN KEY 1 17 02720 SHORT ARM HE...

Page 59: ...EXPRESS DUAL 4000 Bernhard and Company Limited 59 TOOLKIT SERIAL NUMBER 22561 ONWARDS...

Page 60: ...9 04063 LARGE TWO PIN SPROCKET DRIVER 1 10 05209 3 8 WHIT X 5 8 KCP SOCKET SCREW 1 11 03476 GATOR GRIP FOR ED TOOL KIT 1 12 03306 22mm 6POINT 1 2 DRIVE SHORT SOCKET 1 13 02735 Drive Bolt for Adj Sproc...

Page 61: ...B ED4000 MAIN CHASSIS ED4000 CONTROL PANEL 1 3 4 5 Transformer 10 9 101 100 230 0 24 0 TRANSFORMER 100vA 101 100 Wires 0 99 High voltage AC Wires 100 199 Low voltage AC Wires 200 399 Unregulated low v...

Page 62: ...less stated All chassis earths to terminate at same earth stud Applicable Ser 3023025 ED4000 ISOLATOR BOX 0 Isolator 2 00 2 5mm 2 Power In 1 000 L1 E L2 2 5mm 2 4mm L2 L1 T2 T1 16A 16A 3 2 5mm 2 2 5mm...

Page 63: ...4000 MAIN CHASSIS ED4000 CONTROL PANEL 1 3 4 5 Transformer 10 9 101 100 230 0 24 0 TRANSFORMER 250vA 101 100 Wires 0 99 High voltage AC Wires 100 199 Low voltage AC Wires 200 399 Unregulated low volta...

Page 64: ...l chassis earths to terminate at same earth stud Applicable Ser 3023025 ED4000 ISOLATOR BOX 0 Isolator 2 00 2 5mm 2 Power In 1 000 L1 E L2 2 5mm 2 4mm L2 L1 T2 T1 16A 16A 3 2 5mm 2 2 5mm 2 Reversing S...

Page 65: ...101 100 230 0 18 0 TRANSFORMER 250vA 101 100 Wires 0 99 High voltage AC Wires 100 199 Low voltage AC Wires 200 399 Unregulated low voltage DC Wires 400 Regulated low voltage DC All wiring is 1 00mm 2...

Page 66: ...chassis earths to terminate at same earth stud Applicable Ser 3023025 ED4000 ISOLATOR BOX 0 Isolator 2 00 2 5mm 2 Power In 1 000 L1 E L2 2 5mm 2 4mm L2 L1 T2 T1 16A 16A 3 2 5mm 2 2 5mm 2 Reversing Sw...

Page 67: ...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 68: ...ard and Company Limited 68 EXPRESS DUAL LIFT TABLE 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 69: ...quired 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 ensure that...

Page 70: ...eft 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 instruct...

Page 71: ...h 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 72: ...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 73: ...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 74: ...s 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 Chec...

Page 75: ...Bernhard and Company Limited 75 EXPRESS DUAL LIFT TABLE 5 4 7 6 8 9 10 8 11 11 10 30 2 5 3 6 7 13 14 15 16 17 18 19 21 LIFT TABLE 28 28 27 21 20 29 22 12 1 23 24 25 26 X2...

Page 76: ...2 15 04098 PULLEY MOUNT 2 16 05722 M6 X 40 HEX BOLT 1 17 05517 M6 NYLOCK NUT 1 18 04099 PULLEY MOUNT 2 1 19 06319 COVER PLATE 1 20 03174 CABLE FOR TAIL LIFT MAIN MOTOR 1 21 03173 CABLE FOR TAIL LIFT...

Page 77: ...EXPRESS DUAL 4000 Bernhard and Company Limited NOTES...

Page 78: ...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 England 44 1788 811600 or...

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