Bernhard Express Dual 4000DX User Manual/Instruction Manual

Touch screen model

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Express Dual 4000DX

EXPRESS DUAL 4000DX

Touch Screen Model

User

s Guide &

Instruction Manual

Please read this manual carefully before using the Express Dual 4000DX.

This manual should be kept in a safe place so that it can be used for future reference.

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Page 1 EXPRESS DUAL 4000DX Touch Screen Model User s Guide & ’ Instruction Manual Please read this manual carefully before using the Express Dual 4000DX. This manual should be kept in a safe place so that it can be used for future reference.
Page 2 EXPRESS DUAL 4000DX NOTES ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................© Bernhard and Company Limited...
Page 3: Table Of Contents
EXPRESS DUAL ED4000DX Precison Reel/Cylinder Grinder Welcome to the Bernhard Express Dual 4000DX. 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.
Page 4: Identification Of Pictograms
WHEN LOWERING LIFT PLATFORM BEWARE! HIGH VOLTAGE MAXIMUM GRINDSTONE DIAMETER 150mm MAXIMUM SPEED 4000 Rev/Min RUNS AT 2200 Rev/Min BEWARE! MOVING GRINDSTONE AND SHAFT REEL ROTATING AT BETWEEN 147 AND 255 Rev/Min TOTAL WEIGHT OF MACHINE (KG) © Bernhard and Company Limited...
Page 5 LIFTING EYES BEWARE! MOVING COMPONENTS KEEP HANDS AND OTHER OBJECTS CLEAR WEAR EYE, EAR AND BREATHING PROTECTION TRAVERSE START CONTROL GRINDSTONE START CONTROL REEL START CONTROL STOP CONTROL ENGAGE / DISENGAGE (INCREASE / REDUCE) GRINDSTONE FEED © Bernhard and Company Limited...
Page 6: Safety
If a lift table is fitted NEVER attempt to lift in excess of the rated capacity, and always ensure that the area is clear before lowering the load. © Bernhard and Company Limited...
Page 7: Installation
NOTE Ensure that the packing under the feet is correct before tightening the bolts, otherwise twisting of the frame may occur. © Bernhard and Company Limited...
Page 8 The mainshaft should be washed down as instructed in the maintenance section of this manual. The feed control screws are normally coated with Molycote , and may be washed ® down with WD40 if required and recoated with Molycote (or similar anti friction coating) ® ® when dry. © Bernhard and Company Limited...
Page 9: Table Of Contents
................A4087 Multifix Channels ............... A2712 8mm Allen Key ................A8786 Pack of Spare Fuses ..............A2708 3mm Allen Key ................A3306 22mm 1/2 Drive Socket ............A6603 Guarantee Certificate .............. A6615 Operating Instructions ............. © Bernhard and Company Limited...
Page 10: Understanding The Machine
The rear of the unit will be held by the radiused pressure bar at the rear of the grinder. © Bernhard and Company Limited...
Page 11 Other motor, VSD inverter (reel spin speed control), and other electrical devices are protected by individual fuses located on the electrical control panel accessible via key entry to the enclosure on the right hand side of the guard. © Bernhard and Company Limited...
Page 12 Ensure traverse is not engaged To mount mower To engage clamp 6.1.3 Unscrew the traverse engagement screw until it is released from the traverse chain so that fork/grindstone can be traversed manually along the mainshaft. © Bernhard and Company Limited...
Page 13 A backing up plate is supplied to protect the rear of the units and to evenly disperse the force of the pressure bar across the width of the mower (see Fig. 6.3.1.). Fig: 6.3.1 © Bernhard and Company Limited...
Page 14 “set up guide” should be completed and filed for future reference so that the identical multifix brackets positions can be used for all subsequent applications on the same type of unit. © Bernhard and Company Limited...
Page 15 The drive head of the shaft can also be slid through it’s support for further adjustment or final connection/ disconnection of drive. 6.4.3 Tighten the drive rod via the allen screw in the flexible coupling onto the flat of the drive shaft. © Bernhard and Company Limited...
Page 16 90 degrees, the whole assembly can be lifted clear of the table, and moved to the other side of the mower unit if required. Fig. 6.4.4.2 Press “next” icon on operator display – display advances to next screen. © Bernhard and Company Limited...
Page 17: Bernhard And Company Limited
Press tick (“accept”) icon if OK. (Grind, Traverse and Reel drive motors start – display advances to the next screen). Press cross (“reject”) icon if you wish to make an alternative selection (display returns to size of mower question). © Bernhard and Company Limited...
Page 18 NOTE: The reversing bar will move approximately ½” (13mm) before the direction of travel is reversed and will allow the grinding wheel to move with it. It is therefore ESSENTIAL that this is taken into account when setting the maximum point of travel. © Bernhard and Company Limited...
Page 19: In Frame Grinding
Both handwheels will then rotate counter-clockwise, to back the stone away from the reel, and all motors will stop. (Programme will NOT let a reel “spark-out” with factory set programme parameters) © Bernhard and Company Limited...
Page 20 If the blades still need some grinding, the “resume” icon can be pressed, after closing the guard. After a pause the motors will re-start and the handwheels will return the grindstone to the position where the grind cycle was paused. The cycle will continue to it’s conclusion. © Bernhard and Company Limited...
Page 21 The clamp is still operated by the “lock” and “unlock” and the vacuum can be “toggled” on and off using its icon. For other screen information see QUICK START GUIDE at the back of this manual. © Bernhard and Company Limited...
Page 22: Electrical Fault Finding
This can best be done by detaching the motor drive and ensuring that the mechanism is moving freely. © Bernhard and Company Limited...
Page 23 ONLY WHEN FUSE HAS BLOWN TO ACCESS FUSE USE A SCREWDRIVER TO UNCLIP & PIVOT THE HOLDER UPWARDS SCREWDRIVER TO OPEN COVER & ACCESS FUSE TAKE CARE WHEN REMOVING FUSE NOT TO DISPLACE METAL CONTACTS © Bernhard and Company Limited...
Page 24: Maintenance
Place a wooden block under the mainshaft to the right hand side of the grinding wheel assembly, bridging the front bed and front channel to take the weight of the mainshaft when the side arm is removed (see Fig. 8.1.5). © Bernhard and Company Limited...
Page 25 8.1.17 Apply more feed as necessary to true the stone. NOTE Dressing in this way should be carried out periodically to keep the grindstone clean and true BUT remove only the minimum material off the stone to keep long service. © Bernhard and Company Limited...
Page 26 NEVER grip the sleeve and nut assembly in a vice. Fully tighten the nut when the assembly is fitted to the mainshaft. Sleeve Mainshaft Remove minimal material from sides and bottom of key 2nd Key © Bernhard and Company Limited...
Page 27 Shaft is wiped DRY before any grinding is carried out. Over a weekend, or longer periods where machine may not be used, spray main and other nearing shafts with Bernhard ‘Protective oil film’ but clean with WD40 / ‘Fine clean/lube’...
Page 28 These bearings run warm/hot, that is OK. Extra grease will not reduce the temperature, more likely the reverse, the seals and subsequently the bearings may fail prematurely. Replace the vacuum filter (if not already done following routine examination). © Bernhard and Company Limited...
Page 29 EXPRESS DUAL 4000DX Parts List Page MAIN FRAME FEED ADJUSTMENT MAINSHAFT MOUNTING AND MAIN MOTOR DRIVE TRAVERSE ASSEMBLY REEL DRIVE CLAMP ASSEMBLY MULTI-FIX BRACKET ASSEMBLY GUARD CONTROL BOX ELECTRICAL CABINET 9.10 LIFT TABLE 9.11 © Bernhard and Company Limited...
Page 30 Drawer Handle ................ 2 A6110 Dust Tray ................. 1 A6323 Dust Tray Handle ..............2 A6111 Drawer Runner (Pad) .............. 4 A6742 Drawer Runner (Drawer) ............4 A6741 M5 x 10 Button Socket Screw ..........8 A5129 © Bernhard and Company Limited...
Page 32 A8074 Encoder Layshaft Coupling ............. 2 Encoder Support Stud ............. 4 Cross Helical Gearbox 1:3 ............2 A6007 Feed Layshaft ................2 A9069 Electromagnetic Clutch 24v ............ 2 A8057 Feed Motor 24v ............... 2 A6018 © Bernhard and Company Limited...
Page 34 Motor Bolt Retaining Plate ............2 A4078 Hex. Set Screw M10 x 70 ............2 A5711 Locknut M10 ................2 A5503 Button Head Socket Screw M5 x 10 ........2 A5129 Limit Switch ................2 A8842 © Bernhard and Company Limited...
Page 36 Hex Head Screw M6 x 18 ............4 A5719 Washer M6 ................4 A5320 Capacitor 3uf for Traverse Motor ........... 1 A8148 Friction Spring for Reversing Bar ..........1 A6746 Socket Screw ¼”Whit x ¼” ............1 A5101 © Bernhard and Company Limited...
Page 38 Socket Screw M6 x 12 ............. 1 A5146 Diamond Dresser ..............1 A6737 Locknut M10 ................1 A5503 Flexible Coupling ..............1 A6744 Grub Screw 3/8” Whit x 3/8”............ 2 A5106 Short Square Drive Shaft ............1 A4134 © Bernhard and Company Limited...
Page 40 C’s’k Socket Screw M10 x 30 ..........4 A5117 Nut M10 ................... 4 A5503 Hex Head Bolt M10 x 45 ............2 A5706 Nyloc Nut M10 ................. 2 A5505 Washer M10 ................6 A5310 Pressure Plate (not shown) ............ 1 A6342 © Bernhard and Company Limited...
Page 42 Cap Head Skt Screw M10 x 25 ..........4 A5116 Washer M12 ................4 A5315 Washer M10 ................4 A5310 Base Scale ................2 A6601 Button Head Skt Screw M4 x 8 ..........4 A5125 Multifix Channel (not shown) ........... 2 A4087 © Bernhard and Company Limited...
Page 44 Guard Light Bracket Fabrication ..........1 A03564 Guard LH Door End Fabrication ..........1 A03567 Guard RH Door End Fabrication ..........4 A03566 Guard Polycarbonate .............. 2 A03560 Electrical Panel Chassis Plate Fabrication ......1 A03618 © Bernhard and Company Limited...
Page 46 Control Pendant 24v (not shown) ..........1 A8018 Mains Control Pendant (not shown) ........1 A8890 Label for Tail Lift Pendant (not shown) ........1 A6552 Mains Tail Lift Controller (not shown) ........1 A8904 © Bernhard and Company Limited...
Page 48 Emergency Stop Button ............1 A8073 B4T02 Contact Block (for the above) ........1 A8358 Omron Graphical Operator Panel (HMI) touch screen ..1 A8500 Label ..................1 A6549 VIEW WITH HINGED LID OPEN CONTROL BOX OMRON NS5 © Bernhard and Company Limited...
Page 49: Electrical Panel
Overload Relay Feed motor Relay Traverse Feed motor capacitor down Relay Clamp up (on) Relay Clamp Down (off) Regulated Inverter Reel speed 24V dc control output Rectifier Transformer Fuses (DC out) 24V (AC) output © Bernhard and Company Limited...
Page 50 Light ............1 A8085 Fuse F10 – 6.3A Lift table ............. 1 A8087 Regulated 24v DC Power Supply ..........1 A3456 Inverter – Reel Speed Control ..........1 A3542 Traverse Capacitor – 3uF ............1 A8148 © Bernhard and Company Limited...
Page 51 EXPRESS LIFT TABLE MANUAL EXPRESS LIFT TABLE for Express Dual Spin Grinders User s Guide & ’ Instruction Manual Please read this manual carefully. This manual should be kept in a safe place so that it can be used for future reference.
Page 52 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 Side © Bernhard and Company Limited...
Page 53 If you have any service or operational problems contact your distributor, or phone our Technical Helpline (USA only) – 1-888 474 6348 (+44) 1788 811600 Bernhard and Company Ltd, England – or email techsupport@bernhard.co.uk use the technical support feedback form on our web site www.expressdual.com or www.bernhard.co.uk...
Page 54 When not in use always latch the platform into the vertical position or leave it horizontal at ground level. 1.9. When lowering a load ensure that the floor space below the table is clear of all objects. © Bernhard and Company Limited...
Page 55: General Description
Then from March 1998 units utilised a 24v DC power pack and transformer. From March 2003 the lift power unit is now 220v AC. All are controlled by a hand held push button panel, which controls both the raising and lowering functions. © Bernhard and Company Limited...
Page 56 When the unit has been moved onto the Dual table return the platform to its normal storage position to allow better access to the Dual table and avoid the risk of personal injury on the projecting corners of the platform. Unload the Dual table in the reverse order. © Bernhard and Company Limited...
Page 57 On DC powered units visually check the motor brushes for wear. NOTE: When any moving parts have been replaced or cleaned with a degreasing agent, ensure that they are re-assembled with an adequate quantity of medium grease. © Bernhard and Company Limited...
Page 58: Fault Finding
Check dump valve solenoid – could be debris under the seating or a valve failure. TECHNICAL SPECIFICATIONS Hydraulic Oil I.S.O.32 (eg catrol hysol XH) Capacity 0.9litre (2 pints USA) Max Hydraulic Pressure 140 Bar (Full Load) © Bernhard and Company Limited...
Page 59 Control Pendant 24v (not shown) ..........1 A8018 Mains Control Pendant (not shown) ........1 A8890 Label for Tail Lift Pendant (not shown) ........1 A6552 Mains Tail Lift Controller (not shown) ........1 A8904 © Bernhard and Company Limited...
Page 61 Press the on-off/reset switch on the operator control (HMI) box, to reset control system (HMI screen goes blank). • Wait 20 seconds before turning switch back on again. • Select alternative mode of operation when system re-loads. © Bernhard and Company Limited...
Page 62 Touch-up grind, quickest, to restore sharpness on a well maintained but “dulled” unit. • Maintain grind, more work required to restore the edge. • Rectification grind, restoration of a damaged blade. Selection proceeds to next screen © Bernhard and Company Limited...
Page 63 Press forward arrow (“next”) to proceed to next screen. • Note: the back arrow button (to stop all motors and return to the ‘confirm selection screen will not appear until all motors are up to speed. © Bernhard and Company Limited...
Page 64 NOTE: If guard is not closed warning screen will appear. Closing guard will return to “paused” screen. Restart machine. • Press “finished” button to “End” cycle. Screen 9 appears. © Bernhard and Company Limited...
Page 65 7 and 9 will appear accordingly. Screen 10 — “Grinding completed” • Press button to undo clamp and remove mower from machine. • Press “next” to return to “mount mower” screen 2, ready for next mower End of “Automatic” Section. © Bernhard and Company Limited...
Page 66: Quick Start Guide
(Also see Notes – “Other screens”). For general operation notes see main user manual. NOTES: • Engage clamp – lock down mower • Disengage / undo clamp End of “Manual” Section. © Bernhard and Company Limited...
Page 67 • Could be low voltage (increased Amperage) or a motor/drive problem. • Check machine before pressing blue rest button on main electrical control box and re-setting machine by pressing this button. © Bernhard and Company Limited...
Page 68 Could crash program or damage feed drive train. • Display advises manual raising of shaft by two revolutions of the handwheel on each side. • Press the mainshaft button to re-set the machine. © Bernhard and Company Limited...
Page 69 Terminal parameters – access to adjust operator panel settings Change password (currently disabled) Adjust grind parameters- access to grind cycle parameter table Default parameters- access to restore default settings Engineering menu – access to engineering menu (not user accessible) © Bernhard and Company Limited...
Page 70 Terminal parameters – access to adjust operator panel settings Change password (currently disabled) Adjust grind parameters- access to grind cycle parameter table Default parameters- access to restore default settings Engineering menu – access to engineering menu (not user accessible) © Bernhard and Company Limited...
Page 71 EXPRESS DUAL 4000DX NOTES ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................© Bernhard and Company Limited...
Page 72 Rest of World: UK Head Office, England (+44) 1788 811600 Email: techsupport@bernhard.co.uk 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.

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