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KENT USA KGS-2040SO1 Operation Manual

Precision surface grinder
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PRECISION SURFACE GRINDER
Operations Manual
KGS-2040SO1
(2025/4)

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Summary of Contents for KENT USA KGS-2040SO1

  • Page 1 PRECISION SURFACE GRINDER Operations Manual KGS-2040SO1 (2025/4)
  • Page 2 Guarantee affairs 1. This machine is guaranteed for one year in normal operation. (working 8 hours per day) 2.The machine and electric parts are offered free of charge, in case of damage in one year.( except the man-made and nature calamity) 3 .Before operating this machine, please read operation manual to protect the operator safety.

  • Page 3: Table Of Contents

    Contents Chapter Page Installation guidelines General safety rules Safety rules for this machinery 1 - 2 1 - 3 1 -4 Diagram for potential danger area 1. 4 Diagram for marking signs location 1 . 5 Safety device placement diagram Summary of the machine Basic description of the machine and noise 2 - 1...
  • Page 4 Contents Chapter Page Level adjustment of work table Hydraulic line layout Electrical connections and grounding 4- 9 Test operation 5- 1 Preparations before test operation Hydraulic system Safety inspection before operation Operation instructions Operation panel instructions 6.1.1 Operation panel (KGS-SD) 6.1.2 Operation panel layout 6.1.3...
  • Page 5 Chapter Contents Page Handwheel and work table speed control level operation 6-15 Precautions to be taken during operation 6-16 Proper use of grinding wheels 6-17 6.4.1 Selection of grinding wheel 6-27 6-18 6.4.2 Grinding wheel grading method 6.4.3 Wheel flange inspection 6-21 6.4.4 Balancing the grinding wheel...

  • Page 6: Chapter One Installation Guidelines

    Chapter One Installation Guidelines General safety rules ( 1 ) The employer must select trained, qualified personnel to operate and maintain the machine. ( 2 ) The employer must adhere to local national safety laws and regulations for teaching operators safety and hygiene education. ( 3 ) The employer must caution operators to watch for unsafe operation practices.

  • Page 7: Safety Rules For This Machinery

    ( 1 ) Persons wearing ties, gloves, loose fitting clothing and shirts with very long sleeves must not operate or maintain the machine. ( 2 ) Operation personnel within their work area must not lean on the machine. ( 3 ) When the machine is in operation, wheel guard, right and left stroke adjusters and nozzles must not be adjusted by hand or with tools.
  • Page 8 ( 12) Make sure the surface of the electric magnetic chuck is clean before mounting work pieces. If there is scarring on the surface, first regrind its surface. ( 13 ) Use the proper clamps when mounting non-magnetic material work pieces such as aluminum, graphite, etc., or work pieces that are difficult to be hold on the magnetic chuck.
  • Page 9 ( 11 ) Do not use very thin and short work pieces or work pieces which have complex shapes or unstable centers of gravity on the magnetic chuck for grinding. ( 12) When grinding, besides securely mounting the work piece, one should make sure no other object is placed on the machine.

  • Page 10: Diagram For Potential Danger Area

    Diagram for potential danger area Hazard districts Description In spindle shaft working district where the grinding wheel rotates swiftly, is easily susceptible to hand injury. In working table traveling district where the operator head is subjected to collision when extending out to look at the working object. In working table traveling district, it is risky for the operator or the third person walking into this district.
  • Page 11 Diagram for warnning signs location Nomen clature Electric Control Box Electric Power Box Lubrication Oil Tank H 1 droulic Tank Crossfeed Motor �indle Motor, Power Elevation Motor Coolant Motor � � � � i=-i- I_ -� 1...

  • Page 13: Chapter Two Summary Of The Machine

    Chapter Two Summary of the Machine Basic Description of the Machine and Noise Standards 2.1.1 Basic Description of the Machine The X axle movement of the machine (from left to right) can be driven hydraulically or manually. The front/rear (Z axle), auto crossfeed can be done by the cross feed motor. The following are types of work piece materials which can used on the machine: Steels (carbon steel, alloy steel), stainless steel, cast iron and non-ferrous metals (like copper, aluminum), porcelain, composites.

  • Page 14: Exterior And Part Names

    Exterior and Part Names · : ' · · -•-••• '° ·=•�C··o·.=;.::.::: :�.::.:--::::::-·� ... -•~---••• •--•- �- � • : ·: -1'! : ' : Fig. 2-2 Nomenclature Nomenclature Nomenclature Hydraulic tank Nozzle Machine base 2 Electric power box Column Hand wheel forward/backward 3 Coolant tank...

  • Page 15: Work Area

    Work Area �' iJ� MAX 500 J--------- - �, > ..Section A ( 1-2) � z-o � s1e s zc:· 11 �_, lf �l � . ll -=-- '_-===i I I 00 (2229) (2229) ( 44.:.5) Fig. 2 - 3 2.3.1 Work Area Specs ( 1)

  • Page 16: Chapter Three Preparations Before Installing The Machine

    Chapter Three Preparations Before Installing the Machine Site Requirements 3.1.l Selecting the Installation Location 3.1.l.l The site in which the machine is to be installed will deeply influence its function and grinding precision. The grinder may not be placed nearby milling, planing, drilling machine or even punching machines because the vibration produced by these machines will be transferred over to the grinder and cause patterns to form on the grinding surface.

  • Page 17: Power Requirements

    3.1.2 Space Required by the Machine �------, � Fig. 3 - 3 Power Requirements 3.2.1 Power Specifications Power Used by the Machine: 8.8 KW Recommended Power Cord: 6.0 mm x 4 (L 1, L2, L3, PE) Power Voltage: AC 415V +/- 10% Power Frequency: 50/60HZ +/- 2% Power Consumption: 8.8 KW Internal Control Voltage: AV 24V, DC 24...
  • Page 18 3.3.1 Forklifts Only forklifts of six tons or more can be used and the forklift operator must be qualified according to local government regulations. 3 .3 .2 Cranes Only cranes of six tons or more can be used and the crane operator must be qualified according to local government regulations.

  • Page 19: Chapter Four Transport And Installation

    Chapter Four Transport and Installation Before delivery, the machine has already been completely tested, adjusted and inspected for accurate calibration and operation. During transport and installation, make sure the machine does not become damaged by impact during movement or lowering. Transport before unpacking Please note: The machine's net weight: 5,000kg gross weight: 6,000kg (1) When using a forklift...

  • Page 20: Transport After Unpacking

    The machine has been tested, adjusted and inspected to an accepted level of precision before leaving the plant. It is very important that during transport and installation, proper care must be taken. Take extreme care not to let the machine become damaged or personnel be injured through impact.

  • Page 21: Machine Installation

    Machine installation 4.4.1 Use anchor bolts Machine weight: 5 000 kgs 77777777 Fig. 4-6 Fig. 4-7 4.4.1.1 Use the nuts to mount the anchor bolt to the machine, leaving at least 35 mm of thread for adjustment. 4.4.1.2 Slowly lower the machine so that the bolts are positioned opposite the anchor holes. 4.4.1.3 Use blocks to adjust the level.
  • Page 22 Remove the positioning blocks: The machine has already applied with a corrosion-resistant oil to ensure superior operation and efficient lubrication. 4.5.1 Removing the moisture proof covering: (see Fig. 4-11) i. electric control box h. Electric power box a. on the work table 4.5.2 To prevent movement or impact of the work table and saddle seat influencing the machine's precision during transport and moving, positioning devices have been...

  • Page 23: Level Adjustment Of Work Table

    Level adjustment of work table: level gauge specification 0.02mm/M. 4.6.1 Tum the right and left handwheels, moving the work table to the central position and right and left positions. Tum the front and rear handwheels to an up right position, moving a central position and right and left position.

  • Page 24: Hydraulic Line Layout

    ( oth e r ) F i g E R e ar F i g Hydraul line layou prevent misconnection of t hese that the can be referred to a when ma c ne . Hydraulic la yout gram ..., !::.

  • Page 28: Chapter Five Test Operation

    Chapter Five Test Operation Preparations before test operation 5.1.1 Lubrication device To extend the lifespan of the machine and protect the machine's functions, it is necessary to select the proper lubrication oil for use in the lubrication system. 5.1.2 After the hydraulic pump motor is started on the automatic lubrication pump. 5.1.3 Lubrication oil ( below is a table of recommended lubrication oils) Brand...

  • Page 29: Hydraulic System

    (1) Oil supply switch Lubrication device (2) Oil tank lid (3) Oil filter (4) Motor (5) High fill mark (6) Low fill mark ······® (7) Oil absorption screen ..Q) Fig 5-1 5.1.5.8 Before running the machine, first start the hydraulic pump motor. Run for 20 minutes allowing the lubrication oil from the oil pump to spray on each if the rails.

  • Page 30: Safety Inspection Before Operation

    Safety inspection before operation Please closely adhere to the following instructions. Once these preparations are complete, the machine can be started. 5.3.1 The machine must installed in an area where it is free from outside vibrations. 5.3.2 Clean the corrosion resistant oil and grease off the machine. 5.3.3 Install and calibrate the machine level.

  • Page 31: Chapter Six Operation Instructions

    Chapter Six Operation Instructions Operati � n Panel Ins����i��l 6.1.1 Operation Panel (> �� :::; o �o [)@� :!J:) s � ® � ® � @ � �...

  • Page 32: Operation Panel Layout

    6.1.2 Operation Panel Layout SO 1 : Emergency stop push-button S02 & LO 1 : Power start push-button and power indicator light S03 & L02 : Grinding wheel spindle motor push button and indicator light S04&L03 : Hydraulic pump motor push-button and indicator light SOS &...

  • Page 33: Touch Screen(Sdl)

    6.1.3 Touch screen(SDl) Touch screen(SDl)
  • Page 34 Description of the touch screen (H08) For aoto grinding cycle, the gringing data are input with the touch screen (H08). The grinding wheel position is also shown on the screen. In the Home Page, 4 setting button are related to 5 setting pages: •...

  • Page 35: Machine Operation

    6.1.4 Machine operation: 6. I .4. I Before operation Closely adhere to the following instructions. Once these preparations are complete, the machine can be started. ( 1) Install and calibrate machine level (2) Lubricate the machine according to the lubrication procedures. (3) Check the rotation direction of the wheel spindle (grinding wheel), it should be rotating in a clockwise direction.
  • Page 36 SAFETY NOTE : BEFORE PRESSING S02 FOR POWER ON, PLEASE CHECK AND CONFIRM YOUR POWER SUPPLY IS SAME AS THAT PRE-WIRED OF THE MACHINE WHEN SHIPPING. : 3-position selector switch for wheel spindle motor control. S03/L02 : Push-button with indicator for starting wheel spindle motor.
  • Page 37 SAFETY NOTE : 1. PLEASE CONFIRM THE WHEEL SPINDLE ROTATION DIRECTION. IT SHOULD BE IN CLOCKWISE. PLEASE CHECK IT BEFORE THIS IS TO A VOID THE DANGER IF SPINDLE ROTA TES IN COUNTER­ CLOCKWISE. THE DIRECTION "CLOCKWISE" IS THAT FROM THE OPERATOR FACES THE MACHINE.
  • Page 38 SAFETY NOTE : 1. THE FLOW CONTROL LEVER FOR T ABLE MOVEMENT MUST BE AT ITS "OFF" POSITION BEFORE STARTING THE HYDRAULIC MOTOR. 2. ADJUST THE TABLE TRAVEL STROKE BY 2PCS OF DOG IN FRONT OF THE TABLE. AND MAKE SURE THERE IS NO PEOPLE NOR OBSTACLE INSIDE THE TABLE TRAVEL STROKE BEFORE YOU TURN THE FLOW CONTROL LEVER TO MOVE THE TABLE.
  • Page 39 3. For automatic stop of the coolant system after auto. Downfeed/spark-out completed, tum the S14 to LEFT before starting the coolant system. : DC voltage meter showing the voltage into to the chuck, ranging from Oto 100V. OPEN QL09 OVER u uo c!!! ♦tt...
  • Page 40 machine). L09 off indicates the magnetic holding force is too weak. ( potential danger of workpiece ejection) C. If the current applied to the chuck is too high, ( possibly short or grounding) , L 10 lights up and the wheel spindle stops automatically. 2.
  • Page 41 Tum S 16 to MIDDLE LEFT and push S09 ( or SOS) to start the saddle movement BACKWARD ( or FORWARD) and adjust the increment by R 1 ( for ROUGH downfeed) and R3 (for FINE downfeed) The automatic crossfeed can be interrupted by turning the S 16 to other positions or turning S 17 to RIGHT.
  • Page 42 Specify the auto. downfeed for SURF ACE or PLUNGE grinding by turning S 17 to LEFT or RIGHT. Then turn S15 to LEFT press RESET on touch screen to make corrent position 0.000 and depress S07 to start automatic downfeed. FOR AUTO MA TIC DOWNFEED DATA INPUT, please refer to the description for theTOUCH SCREEN.

  • Page 43: Handwheel And Work Table Speed Control Level Operation

    16. fine dress feed : 10 µ m 1 7. dress spark out times : 1 time Total downfeed amount 0.06mm AUTOCYCLE Use MPG to move the wheelhead downward slowly to touch the workpiece slightly. This position is the start point of auto cycle.Press RESET ( on touch screen) to make the position 0.000, and then press S07 to start auto downfeed.
  • Page 44 6.1.6.2 Each graduation of the cross handwheel is 0.02mm and one complete tum is 5mm. 6.1. 7 Vertical handwheel: (refer to figure and part name No.16 in Chapter Two, Section 2.2) 6.1. 7 .1 By depressing and turning the vertical handwheel, the wheel head moves upwards and downwards.

  • Page 45: Crossfeed Handwheel

    Handwheel and work table speed control level operation: 6.2.1 Longitudinal handwheel: When the longitudinal handwheel is pushed in and turned, the table can be moved longitudinally. However when the work table is driven hydraulically, the handwheel will disengage. 6.2.2 Crossfeed handwheel: 6.2.2.1 By turning the crossfeed handwheel, the saddle can be moved forward or backward.

  • Page 46: Precautions To Be Taken During Operation

    Precautions to be taken during operation (KGS-2040SD1) 6.3.1 Turn off the power before mounting/dismounting the grinding wheel on/off the wheel spindle. 6.3.2 Do not operate a machine without wheel guards and do not open the wheel guards during operation. 6.3.3 Before the grinding wheel comes to a complete stop, do not place hands on the work table or attempt to remove the work piece.

  • Page 47: Proper Use Of Grinding Wheels

    Proper use of grinding wheels 6.4.1 Selection of grinding wheel 6.4.1.1 The structure and grinding function of the grinding wheel Grinding wheels are driven mechanically at high speeds continuously generate minute yet hard and sharp particles and abrasive shavings. So, grinding wheels are a extremely useful grinding tool for all kinds of materials.

  • Page 48: Grinding Wheel Grading Method

    6.4.2 Grinding wheel grading method 2400 Abrasive Grain Size Bond Struct Binding Material Max. Cycle Speed 1400 12 220 porcelain ??? 1500 1700 14 240 ( 38A ) 16 280 resin 2000 20 320 2400 adhesive 24 400 2700 ( S A) 30 500 foaming resin 3000...
  • Page 49 Grinding selection reference Material Being Ground Hardness Wheel Flange (Rockwell HRC) Specs Carbon Steel Plates HRC 25 and below WA46H Steel Carbon Steel WA46J Carbon Steel Tubing HRC 25 and WA 46J Carbon Steel above Tubing Carbon Steel Tubing Alloy Steel Nickel-Chromium Steel HRC 55 and below WA46J Nickel-Chromium A lloy Steel...
  • Page 50 6.4.2.6 Three factors to select for ideal wheel grinding ( 1) When doing grinding work, first one must select the right wheel for which there are three chief factors. (a) high grinding efficiency (b) low grinding wheel wear (long lifespan wheel) ( c) obtaining the desired precision and machining quality (2) Conditions to consider when selecting a wheel 1.

  • Page 51: Wheel Flange Inspection

    (5) If you want higher rotation speed grinding wheels that deliver a relatively faster work pace, grinding wheel will tend to be soft. If you want to decrease the rotation speed, this will have the effect like a soft wheel. Glass binder wheel flange are used at speed under 6500 S.F.P.M.
  • Page 52 (3) Then take the first balancing piece 'G' and attach it opposite to the 'G' mark. Caution, the mark 'G' cannot be moved hereafter (see Fig. 6-9) ( 4) After this, take the other two balancing pieces 'K' and attach to any position of equivalent distance 'a' (see diagram 6-9).
  • Page 53 6.4.4.3 The grinding wheel must be finished to complete precision. This can be established by looking at the grinding surface. By using the above procedure to balance the grinding wheel, you must remove it from the wheel spindle and position the grinding wheel on the balance table and then carefully balance it.

  • Page 54: Grinding Wheel Dressing And Correct Use Of The Diamond Dresser

    6.4.5 Grinding wheel dressing and correct use of the diamond dresser 6.4.5.1 The complete grinding wheel can be used to grasp the wheel balance attached to the electric clamp plate (but first use your hand to see if it is firmly attached) or the flat finishing wheel mounted on the main axle seat.

  • Page 55: Grinding Wheel Storage

    6.4.6 Grinding wheel storage: 6.4.6.1 Grinding wheels must be stored in a dry grinding wheel shelf ( as shown in Fig. 6-17) that is protected from impacts and vibration. When moving the grinding wheel, take extra precautions. 6.4.6.2 The golden rule when storing grinding wheels is that they must be stored in an upright position.

  • Page 56: Chapter Seven Daily Maintenance For Operators

    Chapter Seven Daily Maintenance for Operators 7.1 Daily maintenance for operators 7 .1.1 Dai 1 y inspection Oil Su 1 , Water Su (I) lubrication tank (2) crossfeed leadscrew (3) down feed leadscrew (4) hydraulic tank (5) wheel spindle (6) coolant tank Fig.
  • Page 57 Hydralic Hydraulic Oil Every Month MOBILDTE26 Capacity KENT-T68 Tank ESSO Nuto H68 140 L SHELL Tellus T CPCR68 Wheel Temperature Permanent Except when the bearings are Spindle Resistant damaged, the grease does not Grease have to be changed or added. Only the company may do this, the user or distributor should not attempt to disassemble on their...

  • Page 58: Daily Inspection

    7 .1.2 Daily inspection (Pre-operation Checklist) Item Inspection Inspection Condition Inspection Inspection Inspection Standard Subject Before Start Method Interval After Start ✓ Lubrication Visual Daily Above LOW line Mechanism ✓ Work Table Visual Daily At 'OFF' position Speed Lever ✓ Visual Daily Wheel...
  • Page 59 7.1.3 Daily inspection (Post-operation Checklist Item Inspection Inspection Condition Inspection Inspection Inspection Subject Before Start After Start Method Interval Standard ✓ Lubrication Visual Daily Above LOW line Mechanism ✓ Wheel Spindle Visual Daily At least 5 cm Motor distant from work piece ✓...

  • Page 60: Positions Of The Lubrication And Filling Mechanisms

    Positions of the lubrication and filling mechanisms 7.2.1 Lubrication mechanism (self-lubricating) Lubrication method: auto cycle Lubrication device 7.2.2 Crossfeed leadscrew, manual lubrication lubrication method: Use grease gun, about 5cc one time per week Cross leadscrew Upward/downward (vertical) leadscrew (1) Grease nipple ( oil injection mouth) (1) Grease nipple ( oil injection mouth) Fig.

  • Page 61: Waste Oil Box

    7.3 Waste oil box Waste oil box Fig. 7-5 Note: We recommend that you clean out the waste oil inside the waste oil box daily. Out of consideration for the environment, do not empty the waste oil box into a river or stream.

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