Bernhard EXPRESS DUAL 4000 User Manual/Instruction Manual
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Bernhard EXPRESS DUAL 4000 User Manual/Instruction Manual

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EXPRESS DUAL 4000 MANUAL
EXPRESS DUAL 4000
ED4000 Automatic Spin Grinder
Machines SN:- 20343 - Onwards
User
s Guide &
'
Instruction Manual - Issue 01
Please 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.

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Questions and answers

Mohsin
June 1, 2025

How to replace grinder stone

0
1 comments:
Mr. Anderson
June 1, 2025

To replace the grinder stone on a Bernhard EXPRESS DUAL 4000:

1. Only trained personnel should perform the operation.
2. Remove the guard on the left-hand side of the grindstone.
3. Press the lock button on top of the grinding head to stop it from turning.
4. Use the supplied wrench to loosen and remove the locking nut.
5. While still on the mainshaft, loosen the nut on the stone carrier (sleeve and nut).
6. Do not hold the sleeve and nut in a vice to avoid distortion.
7. Inspect the new grindstone for cracks, chips, or water damage. Do not use if damaged.
8. Ensure all mounting surfaces are clean and grit-free.
9. Fit the new stone onto the mainshaft with the nut towards the left.
10. Hand-tighten the retaining nut, then fully tighten once installed.

This answer is automatically generated

0
wayne musteffe
February 17, 2025

i ground reels on friday then shut down grinder to go home came in monday to continue but grinding wheel will not start pushed overload relay in and i get my lights back on console but when i push button for grinding wheel i get a clik and light gos out on console

0
1 comments:
Mr. Anderson
February 17, 2025

The grinding wheel on the Bernhard EXPRESS DUAL 4000 may not start after pushing the overload relay due to several possible reasons:

1. Excessive Motor Load: If the current measured at the "MAIN" plug on the Control PCB exceeds the full load current indicated on the motor identification plate, the motor may be overloaded and require replacement.

2. Overload Relay Set Too Low: If the current is below the full load value, the overload relay may be set too low, causing it to trip prematurely.

3. Mechanical Resistance: The grinding wheel or other mechanical drive assemblies may have increased resistance due to dirt buildup or damage. Detach the motor drive and check if the mechanism moves freely.

4. Electrical Fault: If the above checks do not resolve the issue, an electrical fault in the system could be preventing the grinding wheel from starting.

Ensure that the machine is properly maintained, the guards are in place, and all safety precautions are followed before troubleshooting further.

This answer is automatically generated

0
larry tucceri
March 13, 2025

speed setting for 15 blade reels

0

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Summary of Contents for Bernhard EXPRESS DUAL 4000

  • Page 1 EXPRESS DUAL 4000 MANUAL EXPRESS DUAL 4000 ED4000 Automatic Spin Grinder Machines SN:- 20343 - Onwards User s Guide & ’ Instruction Manual - Issue 01 Please 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.
  • Page 2 EXPRESS DUAL 4000 NOTES ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................© Bernhard and Company Limited...

  • Page 3: Table Of Contents

    EXPRESS DUAL ED4000 Precision Reel/Cylinder Grinder You are now the owner/operator of a Bernhard’s Express Dual 4000 which, if cared for and operated correctly, 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

    TRAPPING FEET OR OTHER OBJECTS WHEN LOWERING LIFT PLATFORM BEWARE! HIGH VOLTAGE MAXIMUM GRINDSTONE DIAMETER 150mm MAXIMUM SPEED 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 EXPRESS DUAL 4000 Position Value Display Balance Indicator Reset Display Traverse On/Off Reel (Spin) Reel (Spin) Drive Drive On/Off Speed Control Grindstone Unclamp On/Off Clamp Service Switch Emergency Stop (Twist to release) © Bernhard and Company Limited...

  • Page 7: 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 8 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 9: Installation

    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 10: Identification Of Tools And Equipment

    4. Identification of Tools and Equipment The items below may not necessarily be included since the tools and equipment supplied will vary according to the machine specification. Express Dual 4000 and 4000DX (see illustrated parts list). A4066 Long 1/2” AF Ball handled Allen Key A2706 3/16” AF Tee handled Allen Key...

  • Page 11: 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 12 NOTE The reset button and overload are both variable and should be adjusted, if required, as indicated in the appropriate service bulletins. The reel drive motor, traverse motor, and VSD inverter (reel spin speed control) are protected by individual fuses located in the electrical control box. © Bernhard and Company Limited...

  • Page 13: In Frame Grinding

    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. 6.2). © 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 Should the reversing bar be dragged by the traverse assembly in the direction of travel during the grinding processes, causing the stone traverse to reverse prematurely, it will be necessary to adjust the reversing bar damper as indicated in the service bulletin. © Bernhard and Company Limited...
  • Page 16 The drive head of the shaft can also be slid through it’s support for further adjustment or final connection/ disconnection of drive. 6.5.3 Tighten the drive rod via the allen screw in the flexible coupling onto the flat of the drive shaft. © Bernhard and Company Limited...
  • Page 17 Go back to the right hand end and repeat the process and again release the contact only slightly. NOTE It is important that the grinding wheel should clear the highest blade along the full length of the reel before grinding commences. © Bernhard and Company Limited...
  • Page 18 Repeat this process until the contact along the reel is even and parallel. 6.7.6 Screw in traverse knob to engage power traverse. NOTE Check auto traverse is changing direction at correct point at each end of its movement. © Bernhard and Company Limited...
  • Page 19 (PARALLEL) – no taper has been applied. NOTE It is important that the control wheels are moved equally. 6.7.8 Apply a good hard cut. Do not be afraid of the aggressive nature of the grinding process. © Bernhard and Company Limited...
  • Page 20 NOTE NEVER stop the machine while the grinding wheel and reel are in contact except in an emergency. Never allow the grinding wheel and reel to spark out. If this does happen put another cut on for a few more passes. © Bernhard and Company Limited...

  • Page 21: 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 22: 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 23 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 ‘stone clean and true BUT remove only the minimum material off the stone to keep long service. © Bernhard and Company Limited...
  • Page 24 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 25 NOTE Never apply nor leave any oil or grease on the mainshaft 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.
  • Page 26 CONTROL PANEL V2 - 21043-22387 ________________________ 53 CONTROL PANEL V3 - 22388-22529 _______________________ 54 CONTROL PANEL V4 - 22530 - ONWARDS __________________ 55 TOOLKIT UPTO SN:- 22560 _______________________________ 57 TOOLKIT SN:- 22561 - ONWARDS _________________________ 59 © Bernhard and Company Limited...

  • Page 27: Main Frame

    M5 X 8 CAP HEAD SOCKET SCREW 05318 M5 FORM B WASHERS 05127 M4 X 8 CSK SKT SCREW 06741 DRAWER RUNNER SET (L & R) 06321 DRAWER ED4 03619 TABLE TOP MAT ED4000 ED4000DX ED3000MC MAIN FRAME © Bernhard and Company Limited...

  • Page 28: Guard Hinge

    RIGHT HAND FRONT HINGE ED4/ED4DX GUARD 05520 M8 Nylock Nut 05731 M8 X 16 HEX SET SCREW 04925 Guard Switch Assy ED4000/ED4000DX 05412 M4 X 20 PAN HD POZI DRIVE MC SCREW 03551 GUARD LINK ARM ED4 GUARD GUARD HINGE © Bernhard and Company Limited...

  • Page 29: Guard

    EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 30 EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 31 05145 M6 X 12 BTN HEAD SOCKET SCREW 08408 CABLE FOR ED3/4 AM3/4 GUARD LIGHT ( 06740 DOOR MAGNET 04900 M4 X 12 BTN HEAD 03564 GUARD LIGHT BRACKET ED4 05145 M6 X 12 BTN HEAD SOCKET SCREW © Bernhard and Company Limited...

  • Page 32: Feed Assembly

    EXPRESS DUAL 4000 FEED ADJUSTMENT OLDER VERSION PRE OCTOBER 2012 © Bernhard and Company Limited...
  • Page 33 FEED CHNL-LH INC TOP & BTM CAP ONLY (Left Hand) 04042 FEED CHNL-RH INC TOP & BTM CAP ONLY (Right Hand) 06851 SADDLE BAND 283 2382 05129 M5 X 10 BTN HD SOCKET SCREW 05318 M5 FORM B WASHERS © Bernhard and Company Limited...

  • Page 34: Mainshaft Mounting And Main Motor Drive

    EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 35 ED3 MAIN MOTOR 50 / 60 HZ 06505 GRINDSTONE 6x1 1/2x2 3/4 ED 09506 SLEEVE AND NUT COMPLETE 09068 MAINSHAFT: EXPRESS DUAL 05318 M5 FORM B WASHERS 05759 M5 X 8 CAP HEAD SOCKET SCREW 06967 MAIN BELT GUARD FROM 10/04/03 © Bernhard and Company Limited...

  • Page 36: Traverse Assembly

    EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 37 M6 FORM B WASHER 06022 Traverse Motor 03741 TRAVERSE MOTOR LEAD FOR ED4 03311 CYLINDER DRIVE KEY 05320 M6 FORM B WASHER 05152 M6 X 25 SOCKET CAP SCREW 05517 M6 NYLOCK NUT 04460 MICROSWITCH ADAPTER PLATE 2011 © Bernhard and Company Limited...

  • Page 38: Reel Drive

    EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 39 SQUARE DRIVE ROD SHORT 05109 5/8 WHIT X 5 1/2 CAP HD SKT SCREW 04046 FLEX.DRIVE BRKT BASE/DIA.DRESS.HOLD 03170 CABLE FOR ED3/ED4 CYLINDER MOTOR 05129 M5 X 10 BTN HD SOCKET SCREW 07722 LAYSHAFT BEARINGS SFT 3/4 © Bernhard and Company Limited...

  • Page 40: Clamp Assembly

    EXPRESS DUAL 4000 CLAMP ASSEMBLY © Bernhard and Company Limited...
  • Page 41 LINEAR ACTUATOR WITH CABLE ED Plastic bush (included with linear actuator) 08833 TOP ENTRY COVERS 08121 HA-4 MALE INSERT SCREW TERMINAL 05524 M16 NYLOC NUT 05503 M10 HEX NUTS 05702 M10 X 20 HEX SET SCREW © Bernhard and Company Limited...

  • Page 42: Multi-Fix Bracket Assembly

    EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 43 M12 FORM B WASHER 03072 END CAP FOR SS TUBE 06601 ADJ. MOUNTING BRKT BASE SCALE 05125 M4 X 8 BTN HD SKT SCREW 03092 V BRACKET LINK BAR BUSH 03061 ADJUSTABLE BRACKET LINK BAR © Bernhard and Company Limited...

  • Page 44: Control Arm

    EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 45 03732 DISPLAY/INTERFACE PCB NEW ED/AM4 (Serial Number 20343 - Onwards) 03677 ED4000 CONTROL ARM FABRICATION 05183 M8 X 16 BUTTON HEAD SCREW 04888 M4 X 8 Pozi Polycarbonate screw 04898 ED4 Control Arm Cable Assy © Bernhard and Company Limited...

  • Page 46: Isolator Box Sn:- 20343 -21261

    EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 47 Traverse switch cable 04895 Encoder cable with sockets 05318 M5 FORM B WASHER 05512 M5 NUT Switch box - Obsolete - No replacement Switch housing - Obsolete - No replacement Screw - Obsolete - No replacement © Bernhard and Company Limited...

  • Page 48: Isolator Box Sn:- 21262 - Onwards

    EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 49 04891 M4 S/C Spring Washer 05406 M3 X 10 PAN HEAD SCREWS 05510 M3 HEX NUTS 05316 M3 STAR WASHER 05145 M6 X 12 BTN HEAD SOCKET SCREW 04893 Machine power cable 04894 Traverse switch cable © Bernhard and Company Limited...

  • Page 50: Vacuum System

    EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 51 06141 M6 X 20 X 40 OD MULTI LOBE KNOB 05321 M8 FORM B WASHER 05520 M8 Nylock Nut 06455 VACUUM MOUNT HOLDER 08833 TOP ENTRY COVERS 08121 HA-4 MALE INSERT SCREW TERMINAL 08835 IN LINE CONNECTOR (SET OF M&F) © Bernhard and Company Limited...

  • Page 52: Control Panel V1 - 20343-21033

    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 Please contact Bernhard & Co...

  • Page 53: Control Panel V2 - 21043-22387

    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 Please contact Bernhard & Co...

  • Page 54: Control Panel V3 - 22388-22529

    3PDT plug-in relay,10A 24Vdc coil 08148 3MF CAPACITOR 08638 TRANSFORMER FOR ED 18 VOLT 03930 DPDT plug-in relay,12A 24Vdc coil 03929 3PDT plug-in relay,10A 24Vdc coil 08990 ED4000 SPARE FUSE KIT 08962 MACHINE CONTROL PCB FOR EX DUAL © Bernhard and Company Limited...

  • Page 55: Control Panel V4 - 22530 - Onwards

    3PDT plug-in relay,10A 24Vdc coil 08148 3MF CAPACITOR 08638 TRANSFORMER FOR ED 18 VOLT 03930 DPDT plug-in relay,12A 24Vdc coil 03929 3PDT plug-in relay,10A 24Vdc coil 08990 ED4000 SPARE FUSE KIT 08962 MACHINE CONTROL PCB FOR EX DUAL © Bernhard and Company Limited...
  • Page 56 If this runs from 6-9 then replace with part 08117 If this runs from 4-6 then replace with part 08116 Scale from 6 - 9 Part number 08117 Scale from 4 - 6 Part number 08116 © Bernhard and Company Limited...

  • Page 57: Toolkit Upto Sn:- 22560

    EXPRESS DUAL 4000 TOOLKIT UPTO SERIAL NUMBER:- 22560 © Bernhard and Company Limited...
  • Page 58 Keys - Only supplied with the lock, cannot order seperately 03492 SPRAY BOTTLE WITH ANTI RUST 1/2 LTR 03493 SPRAY BOTTLE WITH FINE CLEAN 1/2LTR 08902 3M MAINS LEAD 16AMP PLUG TO TAILS 06342 PRESSURE PLATE © Bernhard and Company Limited...

  • Page 59: Toolkit Sn:- 22561 - Onwards

    EXPRESS DUAL 4000 TOOLKIT SERIAL NUMBER:- 22561 - ONWARDS © Bernhard and Company Limited...
  • Page 60 SPRAY BOTTLE WITH FINE CLEAN 1/2LTR 08990 ED4000 SPARE FUSE KIT 02722 MOLYCOTE PASTE 06847 MOLYCOTE BRUSH 04133 SPLINE DRIVER (SET) 04095 PLAIN DRIVE ROD SHOR FOR MUT MODELS 08902 3M MAINS LEAD 16AMP PLUG TO TAILS 06342 PRESSURE PLATE © Bernhard and Company Limited...

  • Page 61: Wiring Diagrams

    EXPRESS DUAL 4000 10. Wiring Diagrams (Continued) © Bernhard and Company Limited...
  • Page 62 EXPRESS DUAL 4000 10. Wiring Diagrams (Continued) © Bernhard and Company Limited...
  • Page 63 EXPRESS DUAL 4000 10. Wiring Diagrams (Continued) © Bernhard and Company Limited...
  • Page 64 EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 65 EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 66 EXPRESS DUAL 4000 © Bernhard and Company Limited...
  • Page 67 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 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 Side © Bernhard and Company Limited...
  • Page 69 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 70: Safety

    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 71: 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 72: Operating Procedure

    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 73: Maintenance And Adjustments

    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 74: 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 75 EXPRESS DUAL LIFT TABLE © Bernhard and Company Limited...
  • Page 76 Tail Lift Ram (SN:- 18575 - 22351) (High) Seal Kit 04912 Seal kit for Lift Table Ram A03671 04910 Tail Lift Ram (SN:- 22352 - Onwards) Seal Kit 04911 Seal kit for Lift Table Ram A04910 © Bernhard and Company Limited...
  • Page 77 EXPRESS DUAL 4000 NOTES ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................© Bernhard and Company Limited...
  • Page 78 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...

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