Irontite Products Van Norman 794-8688-06 Instruction Manual And Parts List Download Page 50

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FG5000/FG10000 Flywheel Grinder

800-553-5953

CONTROL BOX ASSEMBLY

MACHINE MODEL NUMBERS

/ VOLTS / HZ / PHASE

794-8688-06

FG10000 208-230/60/3 PAG

794-8688-50

FG5000 208-230/60/3 PAG

794-8688-38

FG10000 460/60/3 PAG

794-8688-53

FG5000 460/60/3 PAG

794-8688-06

794-8688-38

794-8688-50

794-8688-53

ITEM

PART #

DESCRIPTION

BX1

794-8687-77

Control Board

PN1

794-8687-78

Panel

DR1

794-8687-72

Din Rail

*GND

794-8142-14

Ground lug

FB1

794-8686-75

794-8180-16

794-8132-70

794-8180-16

Fuse Holder

794-8633-68

794-8688-72

794-8132-69

794-8659-98

Fuse

794-8633-68

794-8688-72

794-8132-69

794-8659-98

Fuse

794-8633-68

794-8688-72

794-8132-69

794-8659-98

Fuse

TF1

794-8676-78

794-8623-17

794-8676-78

794-8623-17

Transformer

FX1

794-1421-17

Fuse

BR1

794-8687-76

Bridge Rectifier

MR1

794-8691-47

794-8691-46

Motor Relay

MO1

794-8691-55

794-8691-63

794-8691-51

Motor Overload

MR2

794-8691-45

Motor Relay

MO2

794-8691-57

794-8691-59

794-8691-57

794-8691-59

Motor Overload

RS4

794-8687-73

Relay Socket

RS5

794-8687-73

Relay Socket

TB1

794-8626-01

Terminal Barrier

CR1

794-8625-15

Relay

CR2

794-8625-15

Relay

CR3

794-8625-15

Relay

CR4

794-8625-15

Relay

CR5

794-8625-15

Relay

CS1

794-8687-74

Current Sensor

SR1

794-8687-79

Strain Relief

SR2

794-8687-79

Strain Relief

SR3

794-8144-03

Strain Relief

SR4

800-8014-71

Strain Relief

SR5

800-8014-71

Strain Relief

SR6

800-8014-71

Strain Relief

SR7

800-8014-71

Strain Relief

SRN3

800-8667-93

Strain Relief Nut

SRN4

800-8667-93

Strain Relief Nut

SRN5

800-8667-93

Strain Relief Nut

SRN6

800-8667-93

Strain Relief Nut

SRN7

800-8667-93

Strain Relief Nut

PCTB

794-8016-71

Printed Circuit Board

*460v machines have the second GND near the terminal strip for CSA compliance

Summary of Contents for Van Norman 794-8688-06

Page 1: ...WAY BRAND PRODUCTS Irontite Products Inc PO Box 9877 Cedar Rapids IA 52409 USA 800 553 5953 319 377 9101 FAX Copyright 2018 by Irontite Products Inc All Rights Reserved Rev 181102 Equipment specifica...

Page 2: ...ntrol of IRONTITE 2 Damage malfunction or failure caused by or resulting from modification of the machine mechanical or electrical without written authorization by IRONTITE 3 Damage malfunction or fai...

Page 3: ...ot 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 THI...

Page 4: ...e 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 tripp...

Page 5: ...4 FG5000 WITH 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 43 460V 60 Hz 3 Ph 20 14 FG5000 WITH POWERHEAD AND AUTOGRIND 794 8688 50 208 230V 60 Hz 3 Ph...

Page 6: ...1mm 1 15 794 8011 28 Grinding Wheel 4 101 6 mm Flaring Cup FG5000 1 16 794 8011 12 Grinding Wheel 6 152 4 mm Flaring Cup FG5000 1 17 794 8011 30 Grinding Wheel 6 152 4 mm Flaring Cup FG5000 1 18 794 8...

Page 7: ...91 Wood Dowel Pins inserted into bottom back of board 2 794 8015 98 Mounting Screw 25 X 20 X 1 5 2 794 8688 03 Main Tool board base with dowel pegs small shelf sold separately below 1 794 8044 43 Tray...

Page 8: ...46 liter 1 794 8011 41 Coolant Additive 1 Gal 3 8 L 1 794 8011 42 Coolant Additive 5 Gal 18 9 L 1 794 8017 44 E Z Lock Inserts 1 794 8017 45 E Z Lock Inserts 5 pack 1 794 8011 55 Table Lubricant 1 qt...

Page 9: ...l lubricating oil This allows the table to be rotated without much force and eliminates deflection No need to replace table bearings and you can grind with closer tolerances and greater pressures Note...

Page 10: ...pieces from the Mitee Bite kit are not sold separately 794 8625 27 Radius Cutter Assembly PART DESCRIPTION QTY 794 8084 05 Boring Bar 1 5 38 1 mm Dia 1 794 8084 06 Boring Tool Carbide 1 794 8011 99 Sp...

Page 11: ...DESCRIPTION QTY REQ 000 1118 28 3 8 Metal Conduit Locknut 1 000 1241 41 30 072 72 B Wire Nut BL 2 000 1252 18 Flexible Task Lamp 1 000 2410 24 Elec Wire 16GA Black MTW 12 5 000 2410 75 Elec Wire 16GA...

Page 12: ...SY INDICATOR EXTENSION 1 5 794 8013 30 FOOT LEVELING 500 DIA 1 6 794 8020 53 FOOT ASSEMBLY 1 00 1 WARNING Always disconnect machine from its main power source before attaching anything to the grinding...

Page 13: ...9 SHCS 375 16 x 3 25 1 6 794 8010 86 Centering Cone 5 127 0 mm 1 13 000 0170 65 SHCS 375 16 x 3 00 1 7 794 8011 89 Wheel Spacer 1 25 4 mm 1 14 794 8677 99 Centering Cone Bolt 4 25 1 794 8011 90 Wheel...

Page 14: ...lide Rod 3 794 8688 46 Tightening Sleeve 4 794 8688 56 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 8...

Page 15: ...resurfaced by you using your FG5000 or FG10000 Item Part Description Item Part Description 1 794 8060 00 6 CBN Formula X Wheel 8 804 7803 01 Arbor Spacer 3 00 2 794 8628 23 Alignment Pin Assembly 9 80...

Page 16: ...mported flywheels Works well on cast iron and medium steel 794 8011 12 6 Diameter Flared Cup Black For use on some cast iron and ductile iron Special grit tends to be fast cutting and long wearing NOT...

Page 17: ...olant Pump Switch 5 PowerHead Up Down 6 AutoGrind On Off 7 AutoGrind Grinding Rate 8 Coolant Pump Reservoir Access 9 Table 10 Coolant Nozzle 11 Grinding Wheel 12 Grinding Motor 13 Column Lock Handle 1...

Page 18: ...or so it is centered over the table Relock the motor flange 2 A forklift is recommended for removing the machine from the skid and setting in place Lift only from the base cabinet from the rear Figure...

Page 19: ...ubricant P N 794 8011 55 to the reservoir through the filler hole Figure 8 and replace cap screw Make certain the small O ring is in place on the underside of cap screw 2 Remove the plastic oil contai...

Page 20: ...7 16 14 set screw This was installed during shipping of the machine to keep any debris out of the hole Remove set screw and discard FILL COOLANT TANK Open front access door and slide coolant tank out...

Page 21: ...On Single Phase Non Manual Machines the common wire must be connected to the bottom right of the main terminal block 3 After the electrical hookup is completed verify correct rotation of the table and...

Page 22: ...ome dull and or clogged with particles causing a decrease in cutting ability A clean grinding wheel will be evident and very little heat will be generated in the work piece Under ideal circumstances t...

Page 23: ...uld be done 3 Clean the table and lay the proper flange adapter on the table Use the largest possible flange adapter for maximum support Place your flywheel onto the table with the Crankshaft mounting...

Page 24: ...igure 24 c Select the down feed rate with the variable feed rate dial d Start to auto grind by depressing the on switch e Auto grind will stop feeding and turn off when the preset depth is reached fee...

Page 25: ...material removal The readings of this dial will be influenced by both stock removal and wheel wear RADIUS CUTTER OPERATION OPTIONAL Before grinding the flywheel or cutting a radius on a recessed flywh...

Page 26: ...t 4 COLUMN The main column is lubricated from the same plastic oil reservoir As long as oil is in this container both the table bearing surface and the column will be adequately lubricated You may nee...

Page 27: ...y worn out An E Z Lock insert extractor is supplied with the grinder 794 8637 45 Once a month remove the E Z Lock insert 794 8017 44 from the center of the table and coat the threads with an anti seiz...

Page 28: ...t to back and note the direction and amount of indicator travel SIDE TO SIDE HEAD TILT ADJUSTMENT The grinding head is also adjustable for side to side tilt This adjustment will affect the flatness an...

Page 29: ...ar the motor begin to strain Stop raising the column and back off the hex key screw one quarter turn Your leadscrew nut is now properly adjusted Non Power Column For Manual Column Machines lower the c...

Page 30: ...ughly and flush the coolant system Recharge the coolant making sure the coolant ratio is 50 to 1 or 1 and 1 2 cups per 5 gallons of water One cup 8 fluid ounces Use KW coolant only PN 000 2115 05 2 Al...

Page 31: ...can call 800 553 5953 for assistance from Irontite during normal business hours Flywheel Grinder is all stop condition Symptom Grinder was working fine and now nothing works It s like someone unplugg...

Page 33: ...5 HP 208 230 460 1Ph 1 18 794 8687 57 Motor 10 HP 208 230 460 3ph 1 19 000 1035 19 Hex Nut 3 8 16 4 20 800 8030 61 Lock Washer 4 21 794 8649 38 SHCS 3 8 24 x 1 25 2 22 794 8011 79 Adjusting Plate 1 2...

Page 34: ...000 1 89 000 1155 50 Flat Washer 1 2 1 29 794 8688 28 Leadscrew FG5000 1 90 800 8030 16 Ball 1 30 794 8689 40 5mm x 16mm Key 1 N S 794 8680 63 Bearing 2 30 794 8689 48 3 16 SQ X 1 3 8 Key 1 N S 794 86...

Page 35: ...Lower 1 56 794 8680 64 Shaft Extension 1 69 794 8687 44 Fine Feed Hand Wheel 1 57 794 8687 39 Motor Coupling Plate 1 70 794 8688 25 Label FG10 000 1 58 000 1154 60 Washer 4 70 794 8688 24 Label FG500...

Page 36: ...1 46 000 0167 80 SHCS 5 16 18 x 75 3 46 000 0165 35 SHCS 1 4 20 x 75 3 48 794 8687 61 Bear hug Nut 1 51 794 8687 51 SHCS M6 x 14mm 4 52 794 8680 61 PC PAG FG5000 10000 Adapter Flange 1 53 794 8680 95...

Page 37: ...hat you remove the E Z Lock Insert once a month and coat it with Anti Seize lubricant This prevents the insert from becoming permanently lodged in place from rust and grit Should the Table Spindle Thr...

Page 38: ...rive Motor 1 3 HP 208 230V 50 60 Hz 3 Ph 3 phase machine uses this motor 1 794 8651 09 Table Drive Motor 1 3 HP 115 230V 60 Hz 1 Ph 1 phase machine uses this motor 1 139 794 8011 99 Concave Washer 2 1...

Page 39: ...Jiffy Clamp 1 2 FG5000 1 150 800 8030 61 Lock Washer 3 8 4 167 000 1020 08 Hex Nut 1 4 20 1 151 000 1035 19 Hex Nut 3 8 4 168 794 8687 89 Base Cabinet 1 152 794 8619 33 Coolant Hose 1 169 000 1180 10...

Page 40: ...or FG10000 with Serial No 794 and below 1 183 794 8012 32 Leadscrew Nut Clamp 2 182 000 0166 08 SHCS 1 4 20 x 1 00 3 184 000 1208 50 Limit Switch 1 185 Supplied with Switch Item 184 2 186 000 1180 10...

Page 41: ...794 8071 18 Hose 1 213 800 8031 25 Nut 62 11 1 214 794 8015 62 Star Washer 1 215 794 8012 40 Hand wheel 1 216 794 8012 44 Spacer 1 217 800 8663 77 Washer 2 218 794 8688 09 Dial Graduated 1 219 See No...

Page 42: ...622 82 Table Stop Red TA1 794 8622 81 Table Start Green GR2 794 8622 82 Grinder Stop Red GR1 794 8622 81 Grinder Start Green CT1 794 8622 83 Coolant Switch SWITCH PANEL ASSEMBLY MACHINE MODEL NUMBERS...

Page 43: ...IS THE MANUAL MACHINE SWITCH PANEL BELOW IS THE POWER COLUMN ONLY SWITCH PANEL POWER COLUMN SWITCH NOTE The power column switch is actually 2 switches in one The jumper wire connects one side of both...

Page 44: ...top Switch TA2 794 8622 82 794 8622 85 Table Stop Red TA1 794 8622 81 794 8622 84 Table Start Green GR2 794 8622 82 794 8622 85 Grinder Stop Red GR1 794 8622 81 794 8622 84 Grinder Start Green CN1 794...

Page 45: ...8 230 60 3 PAG 794 8688 37 FG10000 380 50 3 PAG 794 8688 38 FG10000 460 60 3 PAG 794 8688 50 FG5000 208 230 60 3 PAG 794 8688 51 FG5000 208 230 60 1 PAG 794 8688 52 FG5000 380 50 3 PAG 794 8688 53 FG5...

Page 46: ...794 8691 63 Motor Overload SR3 800 8014 71 800 8014 71 Strain Relief MR2 794 8691 45 794 8691 45 Motor Relay SR4 800 8014 71 800 8014 71 Strain Relief MD2 794 8691 57 794 8691 57 Motor Overload SR5 80...

Page 47: ...ut SRN4 800 8667 93 Strain Relief Nut SRN5 800 8667 93 Strain Relief Nut SRN6 800 8667 93 Strain Relief Nut SRN7 800 8667 93 Strain Relief Nut 794 8690 03 FG5000 380 50 3 ITEM PART DESCRIPTION BX1 794...

Page 48: ...arrier CR1 794 8625 15 794 8625 15 794 8625 15 794 8625 15 Relay CR2 794 8625 15 794 8625 15 794 8625 15 794 8625 15 Relay CR3 794 8625 15 794 8625 15 794 8625 15 794 8625 15 Relay SR1 794 8687 79 794...

Page 49: ...380 50 3 794 8688 42 FG5000 380 50 3 PC ITEM PART PART DESCRIPTION 794 8688 35 794 8688 42 BX1 794 8687 77 794 8687 77 Control Box PN1 794 8687 78 794 8687 78 Panel DR1 794 8687 72 794 8687 72 Din Ra...

Page 50: ...oad RS4 794 8687 73 794 8687 73 794 8687 73 794 8687 73 Relay Socket RS5 794 8687 73 794 8687 73 794 8687 73 794 8687 73 Relay Socket TB1 794 8626 01 794 8626 01 794 8626 01 794 8626 01 Terminal Barri...

Page 51: ...8 52 FG5000 380 50 3 PAG ITEM PART PART DESCRIPTION 794 8688 37 794 8688 52 BX1 794 8687 77 794 8687 77 Control Box PN1 794 8687 78 794 8687 78 Panel DR1 794 8687 72 794 8687 72 Din Rail GND 794 8142...

Page 52: ...15 Relay for Power Column 3 D 794 8625 15 Relay for Auto Grind 2 E 794 8691 45 Table Motor Contactor F 794 8691 46 47 Grinding Motor Contactor 794 8691 46 FG5000 794 8691 47 FG10000 G 794 8691 57 Tabl...

Page 53: ...3 5953 All Rights Reserved Rev 181102 WIRING DIAGRAM MACHINE MODEL NUMBERS 794 8690 00 794 8690 02 794 8690 08 WIRING DIAGRAM MACHINE MODEL NUMBER 794 8690 01 On Power Column Auto Grind equipped Machi...

Page 54: ...FG5000 FG10000 Flywheel Grinder Copyright 2018 by Irontite Products Inc 45 800 553 5953 All Rights Reserved Rev 181102 MACHINE MODEL NUMBER 794 8690 03 MACHINE MODEL NUMBER 794 8688 41...

Page 56: ...5000 FG10000 Flywheel Grinder Copyright 2018 by Irontite Products Inc 47 800 553 5953 All Rights Reserved Rev 181102 WIRING DIAGRAM MACHINE MODEL NUMBERS 794 8688 40 794 8688 43 794 8688 22 794 8688 3...

Page 57: ...5000 FG10000 Flywheel Grinder Copyright 2018 by Irontite Products Inc 48 800 553 5953 All Rights Reserved Rev 181102 WIRING DIAGRAM MACHINE MODEL NUMBERS 794 8688 06 794 8688 38 794 8688 50 794 8688 5...

Page 59: ...FG5000 FG10000 Flywheel Grinder Copyright 2018 by Irontite Products Inc 50 800 553 5953 All Rights Reserved Rev 181102 CONTROL BOX ASSEMBLY MACHINE MODEL NUMBERS 794 8688 37 794 8688 52...

Page 60: ...t 2018 by Irontite Products Inc 51 800 553 5953 All Rights Reserved Rev 181102 Irontite Products Inc Van Norman Brand PO Box 9877 Cedar Rapids IA 52409 USA 800 553 5953 1 319 377 9421 319 377 9101 FAX...

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