Sharp SH-920 Instruction Manual

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SURFACE

GRINDERS

- INSTRUCTION MANUAL -

SH-920, 1224, 1632, 1640

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Summary of Contents for Sharp SH-920

Page 1 SURFACE GRINDERS - INSTRUCTION MANUAL - SH-920, 1224, 1632, 1640...
Page 2 PREFACE 1. This instruction manual is for Sharp SH series ONLY. Please keep this manual in a safe place where operators can easily access to when necessary. Please read this instruction manual carefully before operating Sharp machine. 2. Please check the serial No. of machine which should be the same as the number indicated on the accuracy table of this manual.
Page 3 15. Keep the chuck surface clean. If it is scratched, re-grind it immediately. 16. It is obligated to wear gloves while loading sharp work pieces. Please use cranes for loading bigger-sized work pieces, especially the ones are over 25 kg.
Page 4 30. Please read the warning signs carefully before checking the power source. 31. Any machine modifications should be approved by Sharp. 32. All electrical components must be properly grounded and comply with the related regulations for the safety concern. Failure to do so will void the warranty.
Page 5 (if installed this optional accessory). Please check page 50 for more details. 38. Sharp warranty of each machine is based on an 8-hour standard operation per day. If the machine is operating more than 8 hours per day, please note that Sharp has the right to shorten the warranty period to 6-month.
Page 6 UNLOADING INSTRUCTIONS (A) Using Fork-lift Trucks Release the wooden case from the fixative devices. Unload the wooden case by the fork lift. Uncrate the machine. Position the machine at the desirable position. Unpack and install the machine. Note: The capacity of fork-lift trucks depends on the gross weight of machines. P.6 OF 70...
Page 7 (B) Using Cranes or Elevating Platforms Release the wooden case from the fixative devices. Unload the wooden case by the crane or elevating platform. Uncrate the machine. Position the machine at the desirable position. Unpack and install the machine. Note: The capacity of cranes or elevating platforms depends on the gross weight of machines.
Page 8 N O T E S  All Sharp machines have been undertaken a 4-hour running test for small machines and an 8-hour test for bigger machines before delivery, to insure their excellent condition. Please contact us immediately if there are any questions related to our machines.
Page 9 W A R N I N G W A R N I N G 1. The wheel spindle turns clockwise. 2. The wheel should bear peripheral speed 2300 m/min or up. 3. The spindle rotation speed is 1800/1500 (60Hz/50Hz) min 4.
Page 10 DO NOT COMPRESSED AIR to clean the coolant channel and working table because the airborne grits and dusts will damage the slideways. ※ The chuck surface hasn’t been grinded before delivery. ※ Please grind it after proper installation of the machine. ※...
Page 11 -- TABLE OF CONTENTS-- (A) INSTALLATION ................P.12 (B) STARTING UP THE MACHINE ..........P.19 (C) WHEEL ..................P.32 (D) GRINDING OPERATION ............P.38 (E) THE HYDRAULIC SYSTEM ............P.45 (F) WET GRINDING................. P.48 (G) PERFECT SURFACE FINISH ............ P.49 (H) ELECTRO MAGENTIC CHUCK ..........
Page 12 (A) INSTALLATION LIFTING 1.1 The machine should be lifted by a fork-lift truck or crane. 1.2 There are clamps tightened on the spindle and table to stabilize during transition, DONT remove these clamps until the machine is completely installed. Fig. 1-1 Lifting P.12 OF 70...
Page 13 Fig. 1-2 Lifting P.13 OF 70...
Page 14 INSTALLATION 2.1 Location: It is very important to install the grinding machine at the proper site to obtain high accuracy. An ideal location is as followings: 2.1.1 The best location for the machine is where has the least temperature variations. 2.1.2 Avoid installing the machine in a place where the nearby machines may splash cutting chips.
Page 15 P.15 OF 70...
Page 16 Mounting the table 3.1 The following procedures are applicable to grinders with ball-rolling slideways. (Fig. 2a) 3.2 To protect the hardened and ground ball rolling slideways, the table is floated from steel balls when machine in transportation. 3.3 When the machine is placed in position, mounting the table as follows: 3.3.1 Wind the wire rope on the “drum”...
Page 17 3.4 Put the table on the wood. Lift one end of the table by two hands and take off the wood. Lay down this table slide on the steel balls carefully, and repeat the same process for the other end. 3.5 Fix the wire rope on the fixed stand as Fig.
Page 18 Leveling: Machines should be carefully leveled by a 0.02/m precision spirit level and equally load on the jack bolts. The adjusting procedure is as followings: 4.1 Put a spirit level in the middle of the table (or on its magnetic chuck if any) in longitudinal and transverse direction, adjust jack bolts until the level bulb indicates within 0.02/m.
Page 19 (B) STARTING UP THE MACHINE Take away the clamping plates 1.1 Take away the clamping plates which clamp: (A) the table with saddle, and (B) the saddle with machine bases. 1.2 Do not turn the hand wheel before the clamping plates are removed. Turn the table longitudinal control lever L1 to its valve closing position (Fig.3).
Page 20 Lubricants Lubricate every sliding surfaces with the recommended lubricants and the oil tank should be filled with oil to the center line of the level gauge, See the LUBRICATING INSTRUCATION CHART below: LUBRICATION AND MAINTENANCE I VERTICAL CROSS HYDRAULIC TABLE MODEL SLIDEWAYS &...
Page 21 Soluble Cutting Oils BRAND SERIES ARAL Multrol G100 CINCINNATI CIMCOOL Cimtech 100 FUCHS Ecocool S CO 5 OEMETA Unimet 280 or AS 192 Note: The main reason of peeling paint of machines is because of the contained nitrite and glycol within the soluble cutting oil. Please use the brands of soluble cutting oil as Mentioned above only.
Page 22 P.22 OF 70...
Page 23 The procedures for checking the electrical connection. For safety reason, remove the grinding wheel from spindle. Fix power source lead wire to the terminal board R.S.T Press push button “SB1” for power source “on” Press push button “SA1” for spindle “on” the spindle must be rotated in clockwise direction, if not, please change any 2 wires on R.S.T terminals.
Page 24 Table longitudinal traverse (Fig. 7a, 7b, 7c) 7.1 Switch on power source “SB1” 7.2 Switch on hydraulic pump motor, “SA2” 7.3 The table directional arm L2 should be able to turn for left of right an angle about 15 degrees from its neutral position. 7.4 Turn clockwise the table longitudinal control level L1 slowly until the table starts to move, the table will get its maximum speed when it turns to 90 degree.
Page 25 and again. 7.6.9 Please don’t touch the directional control arm either by hand or by something else during table movement. Automatic cross feed traverse (Intermittent) 8.1 With the following operations, it needs that the table longitudinal traverse must be in actuated condition. 8.2 Turn change-over switch SA3 to left and then release the switch 8.3 SA31 for automatic operation, the cross feed will soon be actuated and the wheelhead will move forward to the operator.
Page 26 P.26 OF 70...
Page 27 Fig 6. Automatic cross feed P.27 OF 70...
Page 28 CONTROL PANEL ( STANDARD / WITH AD1 ) P.28 OF 70...
Page 29 FUNCTIONS OF PANEL ( STANDARD / WITH AD1) SA0: Emergency stop. SB1: Main power “ON”. SB0: Main power “OFF”. SB01: Door unlock. SA100: Electro-magnetic chuck switch for magnetization and demagnetization. DL100: Chuck magnetization / demagnetization display. RP101: Demagnetization time. RP102: Adjustment for magnetic attraction. SB11: Grinding wheel “ON”.
Page 30 CONTROL PANEL ( WITH AD3 ) P.30 OF 70...
Page 31 FUNCTIONS OF PANEL ( WITH AD3 ) SA0: Main power “OFF” and EMERGENCY STOP button. SB1: Main power “ON” button. SA100: Electro-magnetic chuck switch for magnetization and demagnetization. DL100: Chuck magnetization/ demagnetization display. RP101: Demagnetization time. RP102: Adjustment for magnetic attraction. SA1: Grinding wheel “ON”...
Page 32 (C) WHEEL Wheel Mounting 1.1 The grinding wheel should be checked carefully before mounted by tapping it with a wood hammer to ensure that a clear sound is detected. A wheel having a crack inside it may result a sonant sound. Be sure that no crack is detected.
Page 33 3.1.3 Move the first balance weight “G” opposite to point “S” and set it. (Fig.15) 3.1.4 Move two correction weights “K” anywhere round the periphery, but at equal distance “a” from weight “G”. (Fig.16) 3.1.5 Turn the wheel through 90 degree and to see whether it is in balance.
Page 34 3.3.3 The spindle cartridge assembly are designed to have a life of operation more than 10 years under normal operation, please should not disassemble it without our advice. 3.3.4 Because of the very high spindle running speed, the wheel must be well balanced.
Page 35 3.4.1 The diamond tool should be located at an angle to the center line of the wheel as shown on Fig.18a, so that when the diamond loses its keenness (Fig.18c) it can be turned an angle, and another sharp edge can be utilized (Fig.18d).
Page 36 P.36 OF 70...
Page 37 P.37 OF 70...
Page 38 (D) GRINDING OPERATION The grinding results obtained depend to a very large extent on the choice of the correct grinding wheel and suitable operation. 1.1 For stock removal efficiency For intensive stock removal a coarse grain (about 30-60) wheel should be used.
Page 39 2.1 Kinds of abrasive A: For grinding common annealed steels WA: For grinding steels with higher hardness, such as heat-treated carbon steel, alloy steel, etc. H: Suitable for higher hardness steel, particularly high-speed steel C: For grinding with cast iron and non-ferrous materials. GC: For super-hard metal grinding such as tungsten carbide 2.2 Grain size: Coarse: 10, 12, 14, 16, 20, 24...
Page 40 2.3 Grade: It indicates the strength of the bond which hold abrasive. Soft: A-H Medium: I-P Hard: Q-Z Grade Grinding Soft Hard Condition Workpiece hardness hard soft Surface contacted wide narrow Movement of workpiece slow quick Wheel speed high slow 2.4 Structure: The structure number of a wheel refers to the relative spacing of abrasive grains, the larger the number, the wider the grain spacing.
Page 41 2.5 BOND TYPE * The symbol of bonds Listed bellows: V: Vitrified S: Silicate B: Resinoid R: Rubber E: Shellac Wheel to be recommended Wheel Material Diameter Under 205mm 205-355MM Ground Carbon Under HRC25 WA 46K or A 46K WA 46J or A 46J Steel Above HRC25 WA 46J...
Page 42 Choice of the Grinding Conditions 4.1 Down feed of grinding wheel Down Feed Great Small Grinding resistance large small Heat produced much less Surface finish rough fine Wheel worn-out much little 4.2 Cross Feed Cross Feed Great Small Grinding resistance large small Heat produced...
Page 43 4.4 Suitable speeds of the table traverse: m/min Workpiece Heat-Treated Soft steel Tool steel Cast iron Material steel Speed 6-15 30-50 6-30 16-20 4.5 Suitable Peripheral speeds of wheel: 20-30m/sec. Wheel Peripheral High Speed Condition Grinding resistance small large Heat produced much less Surface finish...
Page 44 4.6 Down Feed and Feed Chart: Workpiece Down Feed Material Cast Iron, Stainless & Cross Feed Soft Steel & Heat Resistant Tool Steel Grinding Hardened Steel Steel Feed amount is 0.0006~0.0012" 0.0008~0.0012" 0.0008~0.0016" Rough smaller than the 1/2 0.015-0.03mm 0.02- 0.03mm 0.02-0.04mm of wheel width Feed amount is...
Page 45 (E) THE HYDRAULIC SYSTEM A special hydraulic system for driving the longitudinal traverse of the table is adapted. The table speed is variable and can be adjusted from 5 m/min to 25m/mn. The hydraulic oil For trouble free operation, the specified oil Mobil Vacouline 1409 or its equivalent one is recommended.
Page 46 Oil capacity OIL TANK LUBRICANT MODEL HYDRAULIC MOTOR CAPACITY CAPACITY 120L 5HP/7.5HP 150L 10HP OR UNDER 550L ABOVE 10 HP 1300L P.46 OF 70...
Page 47 P.47 OF 70...
Page 48 7.1 The surface of workpiece can be easily watched during g grinding operation. 7.2 The grinding wheel can be kept bite and sharp to a longer time than the milky one. The recommended oil base coolant having the prefer mixing ratio at oil : water =1 : 60-80, if it is reduced to less than 1 : 50, the excessive heat make the workpiece apt to distortion.
Page 49 (G) PERFECT SURFACE FINISH Too hard a wheel or wheel is not correctly chosen. Workpiece is not clamped well. A dirty mating surface between the spindle taper and wheel flange (adaptor) bore will make the wheel to vibrate. An unqualified wheel flange, such as poor concentricity and poor squareness.
Page 50 (H) ELECTRO MAGENTIC CHUCK The electro magnetic chuck is an indispensable attachment for surface grinding machine. It require a perfect flat mounting surface to be clamped to the machine table, otherwise table will be subjected to distortion due to the huge magnetic attracting force of chuck.
Page 51 Clamp the magnetic chuck to the machine table. 3.1 Rough grinding the chuck surface same as the grinding of the underside of the chuck, but with different clamping method. 3.2 Switch on the magnetic chuck and then fine grinding the surface with 0.005mm wheel infeed.
Page 52 (I) FOR AD3 AUTO DOWN FEED OPERATION The special arrangement for AD3 auto down feed includes an auto down feed unit mounted to the shaft of elevating mechanism and two counters (one for down feed, the other for spark out) to be built-in at the right side of control panel. There are six increments of feed values, namely 0.005,0.010,0.015, 0.020,0.025 and 0.030mm,which can be selected on the dial regulator C of the auto down feed unit at your will (see the picture below).
Page 53 1.6 Turn lever L1 to left for table movement. 1.7 Turn SA31 to right for auto cross feed. 1.8 Turn SA3 to left or right as required (auto cross feed is engaged). 1.9 Push “ON” the switch SB110 FOR ARTO DOWN FEED. FOR PLUNGE GRINDING + AUTO 2.1 Turn SA111 to left for plunge grinding.
Page 54 (J) MAINTENANCE Interval Maintaining points Remark The surface of working To keep the clean and oiled surface is a necessity table. after working hours. Each Time *Re-correct the wheel balance and re-clean up the The grinding wheel. inner hole of wheel flange and the spindle. Check the oil level of it whether the oil need to be Hydraulic oil tank.
Page 55 (K) TROUBLE SHOOTING Grinding defects, Causes and Remedy 【I】 Defects Causes Remedy Chatter marks 1) The foundation is not firm Please improve the appeared on the enough for the machine. foundation. grinding surface. 2) The leveling screws (jack Check the leveling first and bolts) in machine base are lock them tight.
Page 56 10) Wheel is not dressed The angles of the diamond correctly. dresser must be turned regularly in order to keep sharp. Replace with a new one when the diamond dresser gets dull. The diamond dresser is not firmly fixed. 11) Too much play on the Re-adjust the spindle by a grinding spindle.
Page 57 Defects Causes Remedy 16) Stock removal is too Reduce infeed amount. great. Reduce cross feed movement. 17) Grinding wheel gets too Use softer or coarser wheel. hard, dull or clogged. Increase table speed. Reduce infeed amount. Roughen the wheel. Check the sharpness of the diamond dresser.
Page 58 Defects Causes Remedy movement. 4) Table speed is too low. Increase table speed. 5) Inefficient cooling. Increase coolant water. Use stronger mixture coolant (filled up with fresh oil) Fill up new coolant. Grinding spark Cannot be spark out. Using spirit level to align the abnormally.
Page 59 Electronic-related defects, Causes and Remedy 【II】 General (machines without CE) Defects Causes Remedy Rapid and auto 1) SA31 doesn’t switch on to Please switch it to the right cross-feed are the right side. position. not functioning. 2) SA3 and SA31 switches Fix wires well or replace are defective or wires loose.
Page 60 Defects Causes Remedy ONLY. 2) Magnetic contactor for Check contactor wires to cross feed motor is not make sure the switch is functioning. working; if not, please change to a new switch. Magnetizing Fuse of chuck-control is Change a new fuse. doesn’t work burnt.
Page 61 Defects Causes Remedy 3. Repair or replace with new switch The electro magnetic chuck is 1. Check 2 wires of the defective. chuck, it must be in short circuit “OΩ”. If not, it indicates the chuck is broken. Please repair it. 2.
Page 62 General (machines with AD3) Defects Causes Remedy Rapid and auto 1) SA31 doesn’t switch on to Please switch it to the right cross-feed are the right side. position. not functioning. 2) SA3 and SA31 switches Fix wires well or replace new are defective or wires loose.
Page 63 Defects Causes Remedy ONLY. 2) Magnetic contactor for Check contactor wires to cross feed motor is not make sure the switch is functioning. working; if not, please change to a new switch. Magnetizing Fuse of chuck-control is Change a new fuse. doesn’t work burnt.
Page 64 Defects Causes Remedy switch is defect. 3. Repair or replace with new switch The electro magnetic chuck is 1. Check 2 wires of the defective. chuck, it must be in short circuit “OΩ”. If not, it indicates the chuck is broken.
Page 65 C. Machines with AD1 or CE mark Defects Causes Remedy Rapid and auto 1) SA31 doesn’t switch on to Please switch it to the right cross-feed are the right side. position. not functioning. 2) SB31&SB32, SA31 Fix wires well or replace switches are defective or new switch.
Page 66 Defects Causes Remedy ONLY. 2) Magnetic contactor for Check contactor wires to cross feed motor is not make sure the switch is functioning. working; if not, please change to a new switch. Magnetizing Fuse of chuck-control is Change a new fuse. doesn’t work burnt.
Page 67 Defects Causes Remedy switch is defect. 3. Repair or replace with new switch The electro magnetic chuck is 1. Check 2 wires of the defective. chuck, it must be in short circuit “OΩ”. If not, it indicates the chuck is broken.
Page 68 Hydraulic-related defects, Causes and Remedy 【III】 Defects Checkup Remedy Hydraulic motor 1) Wire lose of hydraulic Check the wire or change the is not working motor switch motor switch. 2) Magnetic switch/overload Check the connecting wires relay of pump motor are not or change the whole set of working properly.
Page 69 Defects Checkup Remedy b. Using a 5-mm hex key to b. Should it stand still without adjust the pressure of the moving which means the relief valve in clockwise relief valve was broken. direction to see if the Please change the new one. pressure gauge indicator can be upward movement or it stands still without...
Page 70 Defects Checkup Remedy The table can not a. Directional control arm is a. Adjust directional control reverse and loose. arm following inside runs to one side manual. b. The trip dogs (T1, T2) are b. Tighten the trip dog at the loose.

This manual is also suitable for:

Sh-1224 Sh-1632 Sh-1640