Surface Grinder Manual

SURFACE GRINDERS
INSTRUCTION MANUAL AND PART LISTS
SHARP INDUSTRIES
3501 Challenger Street, Torrance, CA 90503
TEL: 310-370-5990 FAX: 310-542-6162 WEB: www.sharp-industries.com

PREFACE
1. This instruction manual is for SHARP PSGS 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.
3. Please follow the instruction manual for operation and
maintenance. Do not change any circuits, functions and parts of

machine without approvals from SHARP. Please note that SHARP
will not take any responsibilities for these faults.
4. Since SHARP subscribes to a process of continuous
improvement for our products, designs and specifications are

subject to change without notices.
5. Please check the machine and its accessories right away after
unpacking. If there are any problems, please do not hesitate to
contact us directly.
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SHARP INSTRUCTION MANUAL Page 2

SAFETY INSTRUCTIONS
1. Avoid using any improper work pieces.

2. The grinder can only be operated or maintained by eligible persons who have
trained for handling grinding machines.
3. On-site safety training is required for both operators and troubleshooters.
4. The buyer shall remind their operators to follow the safety instructions at all
times.
5. Please read the instruction thoroughly before using the machine. If there are
any queries about the machine, please contact our local representatives or us
directly. Do not attempt to overcome any machine problems by yourself.
6. Make sure the main power source of machine is properly shut down during
maintenance.
7. Do not measure, move or exchange work pieces when a working table is
moving or the wheel is rotating / approaching to the work pieces.
8. DONT remove grits or dirt from machine until the grinding process is fully
finished.
9. Before turning on the spindle, make sure the grinding wheel is fastened on the
spindle and the rotating direction of wheel is matching the direction on the
cover. Let the wheel run idly for at least 5 minutes before grinding any work
pieces.
10. Be familiar to all switches, especially the emergency stop button.
11. Goggles, masks and working boots are required while operating
machines.
12. Neckties, gloves, and unsuitable work suits like long sleeves and loose
garments are not allowed while operating the grinder.
13. Hair tie or hat is required for longhaired operators.
14. Keeping a clean and dry environment around machine can prolong the
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machine service life.
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.
17. DONT make any table adjustments while machine is still functioning.
18. Stabilize work pieces before grinding.
19. To avoid any accidents, once a wheel starts functioning, keeping a safety
distance between the work piece and the wheel is obligatory.
20. DONT leave the operating grinder unattended.
21. Only firmed work pieces are allowed to put on the machine during grinding.
22. DONT attempt to stop the running wheel by hands or other outer forces.
23. DONT use compressed air / fluid to clean the machine at any time, since it will
cause fallen grits and dusts uncontrolled.
24. DONT use compressed air / fluid to clean the drain ditch of machine in order to
prevent the dirt from entering the slideways.
25. DONT adjust the nozzle after the wheel starts up. Close down the coolant
before turning off the wheel.
26. DONT change any applications or machine capacity such as using overloaded
work pieces or oversize wheels, installing a vertical spindle head and so on
without confirming.
27. Before installing the wheel onto spindle, first to clean up the flange cone bore
and spindle taper. Never knock on the wheel or flange if it is difficult to
remove wheel. Please use the wheel spindle screw nut to remove wheel
instead.
28. Except for trained operators, others are not allowed to access the machine
during the grinding process. Leaning on the machine is prohibited.
29. ONLY professional electro-engineers are eligible to maintain the electrical
devices.
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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.
33. Avoid wearing metal adornments like eyeglasses frames, bracelets and
bangles while repairing or maintaining electrical parts.
34. Please do not approach to the sparking zones while grinding.
35. DONT grind flammable metals like aluminum, magnesium and unhealthful
substances which will easily generate dusts, gases, liquids or vapors during
grinding.
36. The interlock switches installed on wheel guard and control box are for the
purpose of power interruption.
37. Please calculate peripheral speed before adjusting the frequency of spindle
motor inverter (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.
39. After an 8-hour operation, please rest the machine for at least 1 hour.
40. Please don’t touch the directional control arm either by hand or by any outer
forces during table movement.
UNLOADING INSTRUCTIONS
(A) Using Fork-lift Trucks
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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.
(B) Using Cranes or Elevating Platforms
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Release the wooden case from the
fixative devices.
Unload the wooden case by the

crane or elevating plateform.
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.
NOTES
* ALL SHARP MACHINES HAVE BEEN UNDERTAKEN A 4-HOUR
RUNNING TEST FOR SMALL MACHINES AND AN 8-HOUR TEST

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FOR BIGGER MACHINES BEFORE DELIVERY, TO INSURE THEIR
EXCELLENT CONDITION. PLEASE CONTACT US IMMEDIATELY IF
THERE ARE ANY QUESTIONS RELATED TO OUR MACHINES.
* WE WOULD LIKE TO EMPHASIZE SHARP THREE PROMINENT
FEATURES AS:
1. SMOOTH TABLE TRAVERSE RUNNING
2. QUIET MACHINE OPERATIONS
3. SIMPLE AND MODERN MACHINE-DESIGN WITHOUT MUCH
MAINTENANCE REQUIRED
THANK YOU FOR USING SHARP SURFACE GRINDING
MACHINES AND SINCERELY HOPE SHARP MACHINES CAN
GRIND YOU A BRIGHT FUTURE. PLEASE ENJOY IT!
WARNING
1. Turn the wheel spindle CLOCKWISE.
2. The peripheral speed of the wheel should be 2300 m/min or up.
3. The spindle rotation speed should be 1800/1500 (60Hz/50Hz)
min¯¹.
4. Max wheel dimension:
(GS-25, 30) OD406mm x ID127mm x W25mm.
(GS-30B, 40) OD406mm x ID127mm x W38mm.
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(GC, GO) OD406mm x ID127mm x W50mm.
1. No cleaning or removing any workpieces or tools before the
wheel fully stops.
2. The wheel cover must remain close while the wheel is in
operation.
1. Avoid improper operations causing wheel cracked.
2. Machine should be operated by trained employees.
3. No compressed fluid or air cleaning the spindle anytime.
1. Keep a safe distance from the working table while the table is in
motion.
2. Avoid grinding unhealthful substance to reduce the causes of
dusts, gases, liquids or vapors.
3. Avoid grinding flammable or explosive metals like aluminum
and magnesium.
HYDRAULIC SYSTEM LUBRICATION OIL

1. Keep oil pressure around 10~25 bar. MOBIL : Vactra No. 2
2. Use MOBIL Vacuolinel oil 1409, SHELL Tonna
SHELL : Tonna S-68 (V-68)
oil S-68, BP Energol GHL-68, ARAL Vitam
GF-68, ESSO Nuto H-68. BP : Maccurat D-68
3. Always keep the oil above the minimum red
ARAL : Deganit BW-68 (B68)
warning line.
4. Change new oil and clean oil tank after CASTROL : Magna BD-68
3-month of the first usage, then repeat this
ESSO : Fibis K-68
cleaning process once a year.
DO NOT use COMPRESSED AIR to clean the coolant channel

and working table because the airborne grits and dusts will damage the slideways.
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※The chuck surface hasn’t been grinded before delivery.
Please grind it after proper installation of the machine.
※ ※ TO THE COMMISSIONED ENGINEER
1. Due to the improper operation, spindle vibrations would occur
because of the caused damage. Please kindly make sure to
provide the best quality of the spindle to the customer, with no
noises and good run out of the taper nose.
2. Clean rusty preventive around the housing channel and
throughout the spindle taper, in order to avoid the grit and dust
glued alongside. It can be the major cause of the spindle noise.
TABLE OF CONTENTS
PREFACE 2
SAFETY INSTRUCTION  3-5
UNLOADING INSTRUCTION  6-7
NOTES  8-10
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(A) INSTALLATION  12-18
(B) STARTING UP THE MACHINE  19-34
(C) WHEEL  35-39
(D) GRINDING OPERATION  40-49
(E) THE HYDRAULIC SYSTEM  50-52
(F) WET GRINDING  53-54
(G) PERFECT SURFACE FINISHED  55
(H) ELECTRO MAGNETIC CHUCK  56-57
(I) FOR AD3 AUTO DOWN FEED OPERATION  58-59
(J) MAINTENANCE  60-61
(K) SPARE PART LIST  62-87
(L) TROUBLE SHOOTING  88-104
(A) INSTALLATION
1. 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.
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Fig. 1-1 Lifting
LIFTING
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Fig. 1-2: Lifting
2. 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.
2.1.3 Install the machine at a vibration-free place, away from compressors, pressers,
planers and other machines which would cause vibrations.
2.1.4 If the ground is not solid enough or very close to the vibrating sources, please install
concrete foundation or setup a vibrant-free protection.
2.2 Foundation and Installation
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2.2.1 In case the machine is not installed properly, the result of stripe or chatter marks
can appear. To solve the problem, it is better to place the machine in a foundation as
shown in Fig. 2 with jack bolts.
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Fig. 2: Foundation
3. Mounting the table
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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” as shown in Fig. 2b, then tight and fix it
temporarily.
3.3.2 Put steel balls and retainers on the slideways (in Fig. 2a), with the longer one at
the rear and the shorter one in the front close to the operator.
3.3.3 Have 2 pieces of wood on both ends of the saddle slide as shown in the below
picture.
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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. 2c.
3.6 The wire rope will be loosen after long usage and may slip on the “drum”, and the result is
that the table cannot move smoothly. If this situation happens, please adjust the “adjust bolt” at
the right end of the table until it gets back to the tighten condition again.
4. 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
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longitudinal and transverse direction, adjust jack bolts until the level bulb indicates within
0.02/m.
4.2 To obtain good accuracy, it is recommended that the machine should be leveled
repeatedly.
4.2.1 The machine should stand still for 24 hours after final installation and it is better
to ensure that the machine temperature is similar to that of the ambient circumstances.
4.2.2 Start the machine with hydraulic system to let the table running reciprocally for at
least 2 hours, to ensure the machine gets used to the temperature of its normal
operation condition.
4.2.3 Re-check and adjust the leveling condition of the machine, then regrind the table
(or chuck) surface to make it flat.
4.2.4 Every time the machine level is checked, make sure the table (or chuck) surface
should be reground for accuracy.
4.2.5The machine will lose its level usually due to machine vibration and other causes,
so it is highly recommended that the machine needs to check leveling periodically.
4.2.6 Although the leveling operation is troublesome, it is essential for getting good
operation results. It is better to have the machine leveled at least once every month.
(B) STARTING UP THE MACHINE
1. 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.
2. Turn the table longitudinal control lever L1 to its valve closing position (Fig.3). Note: L1
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correspond to the handle for flow control valve 10a of Fig.20.
3. Turn the directional arm L2 to its neutral position (L2 in Fig.3), correspond to the arm
for pilot valve 10b of Fig.20.
4 Table dogs T1, T2 (Fig.3) must be well fixed at its proper position (not exceed its
maximum stroke) in table slot.
Fig. 3 Table Dogs
5. 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
HYDRAUIC TABLE SLIDEWAYS SLIDEWAYS
MODEL
SYSTEM SLIDEWAYS & &
LEADSCREW LEADSCREW
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1. Oil exchanged 1. Automatic 1. Automatic 1. Automatic
every 1 year. recirculation oil non-recirculation non-recirculation
PSGS-2550AH lubed. oil lubed. oil lubed.
PSGS-3060AH 2. Change new
PSGS-3060BH oil filter every 6 2. Clean and 2. Clean & check 2.Clean & check
PSGS-4080AHR months. check the the slideways, the slideways,
PSGS-40100AHR slideways every leadscrews and leadscrew and
6 months. nut every 6 nut every 6
months. months.
MOBIL： VACUOLINE OIL MOBIL： Vactra NO.2

NO.1409 SHELL： Tonna S – 68
SHELL： TONNA OIL S68 (V – 68)
BP： ENERGOL BP： Maccurat D – 68
OIL
GHL-68 ARAL： Deganit BW – 68
REQUIRED
ARAL： VITAM GF-68 (B68)
ESSO： NUTO H-68 CASTROL： Magna BD – 68
ESSO： Febis K 68
LUBRICATION AND MAINTENANCE II
VERTICAL CROSS
HYDRAUIC TABLE SLIDEWAYS SLIDEWAYS
MODEL
SYSTEM SLIDEWAYS & &
LEADSCREW LEADSCREW
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None. 1. Do not need 1. Manual type 1. Automatic
lubrication. one shoot non-recirculation
lubrication pump oil lubed.
2. Clean the ball and pull 5 times a
rolling slideways day. 2. Clean & check
every 6 months. the slideways,
PSGS-2550M
2. Clean & check leadscrew and
the slideways, nut every 6
leadscrews and months.
nut every 6
months.
MOBIL： Vactra NO.2

SHELL： Tonna S – 68
(V – 68)
OIL BP： Maccurat D – 68
REQUIRED ARAL： Deganit BW – 68
(B68)
CASTROL： Magna BD – 68
ESSO： Febis K 68
Soluble Cutting Oils
NO. BRAND SERIES
1 Aral (1) Multronl 400
2 Castrol (1) Syntilo DG 81
3 Cincinnati Milacron (1) Cimtech 100
(2) Cimtech 200
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4 Fuchs (1) Ratak Synthan 47
5 Mobil (1) Kuhlschmierst off 166 or 193
(2) Mobil cut 321
6 Oemeta (1) Unimet RD
7 Shell (1)Metalina Fluid GR
※
(1) THE MAIN REASON OF PEELING PAINT OF MACHINES IS BECAUSE OF THE
CONTAINED NITRITE AND GLYCOL WITHIN THE SOLUBLE CUTTING OIL.
(2) PLEASE USE THE BRANDS OF SOLUBLE CUTTING OIL AS
MENTIONED ABOVE ONLY!!!
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Fig.4 LUBRICANT INSTRUCTION CHART
6. The procedures for checking the electrical connection.
In case the machine wiring voltage is coordinate with that of power source.
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6.1 For safety reason, remove the grinding wheel from spindle.
6.2 Fix power source lead wire to the terminal board R.S.T
6.3 Press push button “SB1” for power source “on”
6.4 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.
6.5 Press push button “SA2” for pump motor “on”, it must be rotated in clockwise direction, if
not, please change any 2 wires on U2, V2, W2 terminals.
6.6 Turn the selector switch”SA31” to left, and turn the switch “SA3” to the left, the saddle must
be moved forward to the operator; if not, please change any 2 wires on U3, V3, W3
terminals.
In case the machine wiring voltage is different from that of power source.
6.7 Change the terminal on transformer Tr1, Tr2 to coordinate the machine wiring voltage with
the power source voltage.
6.8 Change wire connection of the following motors: spindle motor, pump motor, coolant motor.
6.9 Cross feed motor is of constant voltage 220V, so needn’t to change its wiring connection.
6.10 After changing the connections of the above mentioned transformer and motors, it
requires to test the directions of rotation of all motors following the same procedure as in
6.1 to 6.6.
7. Table longitudinal traverse (Fig. 7a, 7b, 7c)
7.1 Switch on power source “SB1”
7.2 Switch on hydraulic pump motor, “SA2”
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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.
7.5 If the table starts jerkily, there may be some air bubbles in the hydraulic system. The air
bubbles can be removed easily if you operated the table at slow speed with its full stroke
and stop a little while at both ends, repeat these processes several times.
7.6 If the table dogs T1, T2, fixed on the table T-slot, bump against table directional arm L2 due
to some causes, L2 will slip out an angle from direction control shaft L3 (see Fig. 5a) and
cause the table unable to travel automatically. In such case, the remedy is as followings:
7.6.1 Turn L1 to its valve closing position (pump is in operation) to stop table moving.
7.6.2 Take away table dogs T1, T2 or move it apart from L2, this is necessary for
avoiding fingers being clamped by table dogs and L2.
7.6.3 Take off arm L2 from its shaft L3 (Fig.5d) and turn L3 to a position with its marked
line in a perpendicular direction as shown in Fig.5b. then re-put L2 on L3 in its
correct position (as Fig.3)
7.6.4 Turn L1 by left hand about 60 degrees for low table speed.
7.6.5 Turn L2 right and left (about 15-20 degrees) by right hand, if still can’t make the
table move right and left, adjust L2 to other position on L3 and try turn L2 right and
left again. Time after time you can find the right position for L3.
7.6.6 Disassemble L2 from L3 (Fig.5d) and adjust L2 at its right position and then secure
it firmly on L3.
7.6.7 During this adjusting process, it needs that with left hand to control L1, and right
hand to turn L2 simultaneously.
7.6.8 This is a troublesome work, and requires lots of patience to try again and again.
7.6.9 Please don’t touch the directional control arm either by hand or by something else
during table movement.
8. 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
SA31 for automatic operation, the cross feed will soon be actuated and the wheelhead
will move forward to the operator.
8.3 Turn SA3 to right, wheelhead will automatically move backward to rear side.
8.4 Automatic cross feed traverse will reverse its direction when the limited switch LS3 or LS4
are actuated by trip dogs. (Fig.6)
8.5 The magnitude of cross feed is infinitely variable by the regulating knob ”RP32 ”.
8.6 By turning switch “SA31” to left, or pressing down the limit switch LS1, the automatic cross
feed traverse can be interrupted at once.
9. Automatic cross feed traverse (Continuous)
9.1 This function is available whenever the table longitudinal traverse is in actuation or not.
9.2 Turn selector switch SA31 to left position.
9.3 Turn SA3 to left, the wheelhead will move approach to the operator.
9.4 Turn SA3 to right, the wheelhead will move backward to the rear side.
9.5 This function will be stopped if limit switch LS1 or LS2 is pressed by stopper. But LS3 and
LS4 are not able to reverse the direction or stop this function.
10. For criss-cross grinding (Optional)
10.1 Turn the selection switch SA31 to right.

10.2 Turn the selection switch SA3 to right (or left), with the hand released and the criss-cross
travel will be engaged.
10.3 Adjust the knob RP32 for the rate of feed movement.
_______________________________________________________________________________________

_______________________________________________________________________________________

CONTROL PANEL
_______________________________________________________________________________________

Fig. 7a
For PSGS-2550M/2550H/3060H Models
M: All manual operated.
H: Hydraulic longitudinal traverse.
CONTROL PANEL
MACHINE WITH AD3
_______________________________________________________________________________________

MACHINE WITHOUT AD3
SB1: Power “ON” button

SA0: Power “OFF” button
SA1: Grinding wheel “ON-OFF” switch
SA2: Hydraulic pump “on-off” switch
_______________________________________________________________________________________

SA5: Switch of dust suction
SA6: Switch of coolant system
SA3: Switch, cross feed backward or forward
SA31: Switch, cross feed auto/manual
: Criss cross grinding (option)
RP31: Cross feed engaged time
RP32: Cross feed rate adjusting knob
SA4: Switch rapid, up/down operation
SA100: Switch of electro-mag. Chuck
RP101: Demagnetizing time
RP102: Chucking power adjustment
HL100: Power display lamp
SB110: On-off switch for auto down feed
SA111: Selector switch for surface grinding or plunge grinding
SB120: Button switch for automatic parallel dressing attachment
PC111: Downfeed increments counter
PC112: Spark out passes counter
SA112: Wheel up traverse time, while auto cycle grinding is finished.
_______________________________________________________________________________________

Functions of Panel
SA0: Emergency stop.
SB0: Main power ON.

SB1: Main power OFF.
SA9: AD1 On/Off

SB11: Grinding wheel ON
SB10: Grinding wheel OFF .

SB21: Hydraulic motor ON.
SB20: Hydraulic motor OFF.

SA31: Auto/manual cross feed selections.
SB31: Criss-Cross grinding switch.

SB32: Cross feed forward button.
SB33: Cross feed backward button.

RP31: Cross feed stroke adjuster by electronic one touch system.
SB34: Criss-Cross speed adjuster.

SB39: Cross feed rate adjuster.
SA40: Button for grinding wheel downward movement (press SB40 & SB44 together).
SB43: Button for grinding wheel upward movement.
SB44: Button for grinding wheel downward movement (press SA40 & SB44 together).
SA5-6: Dust suction/ coolant system.
SB35: Auto dressing time adjuster

SB36: NC intermittent feed switch.
SA100: Electro magnetic chuck switch for magnetization, chuck power off, and
demagnetization.
SB26: Demagnetization time
SB28: Adjustment for magnetic attraction
HL100: Chuck magnetization/ demagnetization display.
_______________________________________________________________________________________

(C) WHEEL
1. 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.
1.2 Two pieces of paper washers should be placed on each side of wheel and serve as elastic
packing between wheel and flange.
1.3 The screws for fixing the flange should be tightened gradually and in diagonal sequence,
the wrench should be applied step by step to each screw in turn.
1.4 When the wheel runs under coolant for some time the paper packing washers may be
damaged, the fixing screws should be retightened in diagonal sequence again.
2. Check wheel mounting before operation. It is essential to check the following points
before start for grinding operations.
2.1 Wheel guard is in its right position.
2.2 Turn the wheel in no load condition for a few minutes.
3. Wheel Balancing
3.1 Efficient balancing is essential to eliminate the unnecessary and additional stress to be
build-up in the wheel. High-quality grinding results, such as grinding accuracy, surface finish as
well as the extended life of grinding wheel, wheel spindle and bearings, depend to a
considerable extent on careful balancing.
Usually the static balancing will be sufficient. The grinding wheel together with its mounting
_______________________________________________________________________________________

flange should be fitted to balancing arbor and then place it on the wheel balancer. And the
balancing operations proceed as following:
3.1.1 The wheel balancer must be leveled first (Fig.9), and check it by a spirit.
3.1.2 Lay the wheel to oscillate, in order to find out the center of gravity, then mark its
downward position S with chalk. (Fig.14)
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. If not, the
correction weight “K” must change place until no oscillation occur in every
position or the wheel is in balance. (Fig.17)
3.1.6 Dressing: Mount the wheel onto the spindle, dressing it (especially for new
wheel), make it concentric with rotation center.
3.1.7 Rebalance: after dressing, the wheel may lose its balance, so that the
rebalancing operation is necessary.
3.1.8 After balancing, the wheel must be given a test run of grinding operation at least
five minutes at full working speed before it is being used.
3.2 Mount the wheel flange assembly:
Prior to get the flange-mounted grinding wheel to the grinding spindle, operators must be
taken to ensure the flange cone bore and spindle taper are in absolutely clean condition.
After that the wheel is pushed by hand onto the spindle taper, and subsequently, tighten
wheel flange assembly securely with fixed bolt (Fig.12). Release wheel flange assembly
from spindle taper will be effected by using jack bolt (Fig.13).
3.3 How to check the wheel vibration:
If the spindle vibrates significantly please take off the wheel assembly first, and then switch
_______________________________________________________________________________________

on the spindle and proceed to check with the following precautions:
3.3.1 If no vibration occurred it means the wheel balance is no good, please rebalance
it.
3.3.2 If the spindle is still vibrate, please disassemble the motor and spindle cartridge,
and check the rubber coupling and coupling refer SD 50008A Index NO. 1, if the
rubber coupling is found broken, change a new one, if couplings found loosen
set it well.
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. Otherwise spindle vibration will be resulted and unable to get good
surface finish. A balanced wheel assembly will lose its balance during grinding
operation owing to its wear. It is advisable to rebalance the wheel assembly
periodically.
Grinding wheel is intended to absorb humidity and coolant, it is advisable not to
start coolant supply when the wheel is not running. Otherwise the wheel will
absorb liquid on its bottom side only and make it out of balance. If the wheel is
allowed to stand for any length of time coolant will be collected at its lowest
side. Unbalance will also be resulted, if the wheel is not allowed to idle running
some length of time after the completion of grinding operation. The purpose of
idle running is essential to throw-off coolant by centrifugal force.
3.4 The wheel dressing can be done either by diamond dresser mounted on the magnetic
chuck (Fig.18b) or on the parallel dressing attachment (Fig.18a) which mounted beside
spindle cartridge.
_______________________________________________________________________________________

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).
3.4.2 The wheel dressing should begin from the middle of the width, as shown on
(Fig.18e), due to two edges are usually worn out. If dressing begins at the edges, there
may result in a danger of the higher pressure in the middle, so as overstress the diamond
tool and chattering it. As far as the life of the grinding wheel and diamond is concerned
the light dressing with more time is better than a heavy dressing.
3.4.3 Various degrees of roughness can be produced by varying the feeds and speeds
of the diamond dressing. For a 0.2mm or 0.3mm stock removal, it is advisable to roughen
the wheel, this is done by feeding the diamond in about 0.03mm and let the diamond
moves quickly over the wheel, this will makes the wheel bite well and the stock removal
good. If the workpiece is to be finish-ground to size with the same wheel, the wheel must
be redressed in different ways. In this time, the dressing operation should be proceed
slowly in two or three passes, with the diamond dressing feed limited to 0.01mm.
3.4.4 Experience has shown that, with highly accurate grinding or better surface finish is
required, the dressing operation with the diamond dresser mounted on the magnetic
chuck is better than which mounted on the spindle housing. The former is more stable
than the latter and the latter condition will causes light undulation in the surface of the
wheel.
3.4.5 Sufficient coolant supply spray to contact point of wheel and diamond is
necessary.
3.4.6 A 250mm/min to 1000mm/min wheel travel to pass through diamond is
recommended. For rough grinding higher travel speed is better.
_______________________________________________________________________________________

(D) GRINDING OPERATION
1. 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. The
wheel is dressed by passing over the diamond quickly, so that the surface of the wheel
is roughened and bites well.
1.2 Surface finish is required
If fine finish is to be produced, a finer grain wheel is required (40-80). In this case the
diamond is passed slowly over the wheel, so as to break up the grain.
1.3 Distortion of the workpiece
If the workpiece shows too much distortion as it is being ground, it announces that the
stock removal is too great and the longitudinal and cross movements of the table are
too slow, or the grinding wheel is blunt or “clogged”.
1.4 If the workpiece appears undesirable burns and grinding cracks, it announces that the
wheel is too hard, or the wheel is blunt or “clogged”.
_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

2. Selection of suitable grinding wheel:
Grinding wheel are usually characterized by the kind of abrasives, the grain size,
the grade of bond, the structure and the type of bond which they selected. The
different symbols of each item format the expression of a grinding wheel. We are in
need to familiar with them.
For instance, the expression WA 46K8V of a wheel which denotes:
WA: Kind of abrasive
46: Grain size
K: Grade
8: Structure
V: Bond type
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
Medium: 30, 36, 46, 54, 60
Fine: 70, 80, 90, 100, 120, 150, 180.
Grain
Size
Grinding Coarse Fine
condition
Stock removal much little
Surface roughness rough fine
Workpiece hardness soft hard
Surface contacted wide narrow
Dia. of the wheel big small
2.3 Grade: It indicates the strength of the bond which hold abrasive.
Soft: A-H
Medium: I-P
Hard: Q-Z
_______________________________________________________________________________________

Grade Soft Hard
Grinding
Condition
Workpiece hardness hard soft
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.
Close: 0, 1, 2, 3, 4, 5
Medium: 6, 7, 8, 9
Wide: 10,11,12
Structure
Grinding Wide Close
Condition
Surface roughness rough fine
Workpiece hardness soft hard
2.5 BOND TYPE

* The symbol of bonds Listed bellows:
V: Vitrified
S: Silicate
B: Resinoid
R: Rubber
_______________________________________________________________________________________

E: Shellac
3. Wheel to be recommended
Wheel Diameter
Material to be Under 205mm 205-355MM
ground
Carbon Under HRC25 WA 46K or A 46K WA 46J or A 46J
Steel Above HRC25 WA 46J WA 46I
Alloy Under HRC55 WA 46J WA 46I
Steel Above HRC55 WA 46I WA 46H
Tool Under HRC60 WA 46I WA 46H
Steel Above HRC60 WA 46H WA 46J
Stainless steel WA 46J WA 46H
Cast Iron C 46J C 46J

Brass C 30J C 30I
Aluminum Alloy C 30J C 30I
Tungsten Carbide GC 60-100 H, I GC 60-100 H, I
Glass C 60K C 60K
Marble C 36M or GC36M C 36M or GC36M
4. 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

Heat produced less much
Rough grinding: 100-500 mm/min, or under 1/2 of the wheel width.
Fine grinding: Under 50 mm/min, or under 1/4 of the wheel width.
4.3 Table Longitudinal Traverse:
Table traverse Quick Slow

Heat produced less much
Suitable speeds of the table traverse: m/min
Workpiece Soft steel Heat-Treated Tool steel Cast iron

Material steel
Speed 6-15 30-50 6-30 16-20
4.4 Suitable Peripheral speeds of wheel: 20-30m/sec.
_______________________________________________________________________________________

Wheel
Peripheral High Low
Speed
Condition
Grinding resistance small large
Heat produced much less

Surface finish fine rough
Wheel worn-out small great

Safety bad better
Material Peripheral Speed

Steel 20-30 m/sec
Cast Iron 20-18 m/sec
Tungsten Carbide 8-18 m/sec
Zinc alloy & Light Metal 25-30 m/sec
4.5 Down Feed and Feed Chart:
Workpiece Down Feed

Material
Cast Iron, Soft Cross Feed
Stainless & Heat
Grinding Steel & Tool Steel
Resistant Steel
Hardened Steel
0.0006 – 0.0012
0.0008 – 0.0012 0.0008 – 0.0016
inch Under 1/2 of
Rough inch inch
(0.015 – 0.03 wheel width
(0.02 – 0.03 mm) (0.02 – 0.04 mm)
mm)
0.0002 – 0.0004
------------
inch (0.005 – 0.015 Under 1/4 of
Fine 0.0002 – 0.006
(0.005 – 0.01 mm) wheel width
inch
mm)
_______________________________________________________________________________________

Note:
A) Before adjusting frequency of spindle motor inverter (option), please calculate
peripheral speed in accordant with a following formula.
V= πDN, D= wheel diameter (ψm), π=3.14, N= R.P.M. (spindle motor), V= peripherial speed
(m/min), N= (120xf)/np, f= frequency (Hz), np= polar number (spindle motor).
B) The calculated speed can not exceed maximum safe operating speed indicated on the
wheel.
_______________________________________________________________________________________

(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.
1. The hydraulic oil

For trouble free operation, the specified oil Mobil Vacouline 1409 or its equivalent one is
recommended.
2. Change of new oil

The oil is apt to oxidation contamination and ageing, it is recommended to have the
replacement of new oil after its first three months operation and every one year operation
of the machine.
The mix of new oil with highly aged oil is senseless. The addition of new oil can’t improve
the quality of the old oil, but cause the added new oil become useless rapidly.
3. How to test the hydraulic oil

A simple way to test the degree of oxidation contamination and ageing of the oil is:
Take a drop of hydraulic oil to the filter paper, if it appears light and yellow it means
the oil is clean and good. On the other hand, if it appears a dark spot, it means the oil
has been considerable aged, and has lost its quality.
4. Table shock
4.1 If the hydraulic system particularly in pipe line having contained some air in it, it will cause
the table shock.
4.1.1 If pipe connections do not be fastened well, air will be sucked in.

4.1.2 During the operation of connecting the hydraulic tank to
the machine, air will have chance to enter into the system.
4.1.3 In case the air have already been existed in the system the remedy process is to
run the table with low speed at full stroke, after a long period of operation the air will
be squeezed out.
4.2 A too high pressure will cause the table to shock also.
5. Oil capacity
MODEL HYDRAULIC OIL TANK LUBRICANT

MOTOR CAPACITY CAPACITY
PSGS-2045H 1HP 60L 3L
PSGS 1HP 60L 2L
PSGS 2HP 90L 2L
PSGC 5HP 120L 20L
PSGO 5HP/7.5HP 150L 20L
PSGP 10HP OR UNDER 550L 50L
PSGP ABOVE 10 HP 1300L 50L

(F) WET GRINDING

The wet grinding for most of the workpiece can provide the following advantages:
1. Reduced the possibility of distortion of the workpiece caused by heating.
2. Reduce the danger of burning.
3. Prevent wheel from clogging.
4. Shorten the grinding time.
5. Lengthen the wheel life.
6. Protect operator, machine and circumstances from grinding dust.
7. Clear transparent coolant is recommended to replace the milky one, because:
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.
8. 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.
9. The coolant will gradually lose its effectiveness, due to lost as spray and
evaporates during grinding, eventually it will become a thin mixture, so that new oil

must be added to correct the mixing ratio.
10. The coolant delivered from a water pump must be sprayed to the wheel through a
nozzle, to prevent the wheel from clogging.
11. An automatic paper strip filter is preferred instead of the simple coolant system in
order to obtain a sound surface finish.
(G)PERFECT SURFACE FINISH
Any one of the following items may prevent the machine operation to get a
perfect surface finish.

1. Too hard a wheel or wheel is not correctly chosen.
2. Workpiece is not clamped well.
3. A dirty mating surface between the spindle taper and wheel flange (adaptor) bore will
make the wheel to vibrate.
4. An unqualified wheel flange, such as poor concentricity and poor squareness.
5. Wheel and flange not matched well or there have somewhat slippage.
6. An unbalanced wheel or the wheel is not be balanced well.
7. Wheel won’t be well dressed.
8. The coupling between motor and spindle become loosen or broken.
9. A defect bearing is used in spindle or motor.
10. Coolant mixing ratio is improper, or too much oil.
< The correct ratio is oil : water=1 : 60-80. >
11. The coolant is dirty. For getting good surface finish the automatic paper strip filter
attachment is recommended.
(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.

The following practice must be followed to grind the mounting surface of magnetic chuck
before it has to be clamped in machine table.
1. The underside of the magnetic chuck must firstly be ground to perfect flat with great care.
The chuck is laid upside down on the table, not to be clamped, but stoppers at both right
and left sides are used to prevent chuck from moving.
Caution: the chuck should never be switched on. Wet grinding with max. Coolant volume
and minimum wheel infeed is recommended to avoid excessive heating and the consequent
surface inaccuracy to be resulted.
2. Both the ground area of the machine table and underside of the magnetic chuck are lightly
greased to prevent them from getting dust during their clamping operation. A very thin
grease film is preferred for keeping the mounting accuracy.
3. 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.
3.3 Spark out grinding with no infeed, 2 to 3 times passes of wheel over the chuck surface.
(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).
(The function of dial regulator D is replaced by the counters PC111 and PC112 in control
panel, it will not be in use here.)
A. FOR SURFACE GRINDING + AUTO DOWN FEED.
1. Turn selector switch SA111 to right for surface grinding.
2. Select the required down feed increment on the dial regulator C of auto down feed unit
AD3 and set the number of down feed increments on the lower portion of PC111
counter (the upper portion of counter shows the actual number of cross slide passes
actuated).
3. Set the number of spark-out passes required on PC112 counter.
4. Press the power button SB1 “ON” for power (usually press the power button for 2-3
seconds is required and then the hand can be released).
5. Switch “ON” the hydraulic pump switch SA2 (hydraulic table drive).
6. Turn lever L1 to left for table movement.
7. Turn SA31 to right for auto cross feed.
8. Turn SA3 to left or right as required (auto cross feed is engaged).

9. Push “ON” the switch SB110 FOR ARTO DOWN FEED.
B. FOR PLUNGE GRINDING + AUTO
1. Turn SA111 to left for plunge grinding.
2. Select the required down feed increments to the dial regulator C of auto down feed unit
AD3.
3. Set the number of down feed increments required on PC111 counter.
4. Set the number of spark-out passes on PC112 counter.
5. Switch “ON” the hydraulic pump switch SA2 (hydraulic table drive).
6. Turn lever L1 to left for table movement.
7. Turn SA31 to left.
8. Press “ON” the switch SB110 for auto down feed.
C. After the auto down feed grinding cycle is finished, should the hydraulic pump
switch SA2 turn to “OFF” position and the hydraulic system to be stopped as well as
the table control lever L1 run to closed position, so as the power button SB1 can be
engaged for next cycle.
D. RAPID UP/DOWN
1. Turn the rapid up/down switch SA4 to right for up movement.
2. Turn switch SA4 to left and press button switch SB1 simultaneously for down movement
(J) MAINTENANCE
Interval Maintaining points Remark
The surface of working To keep the clean and oiled surface is a necessity
Each time table. after working hours.
The grinding wheel. *Re-correct the wheel balance and re-clean up the
inner hole of wheel flange and the spindle.
Hydraulic oil tank. Check the oil level of it whether the oil need to be
re-filled.

Lubricating oil tank. Check the oil level of it whether the oil needs to be
re-filled.
Emergency stop. Check the function of switch whether it loses
efficacy or not.
Wheel cover locker. Check the function of switch whether it loses
efficacy or not.
Warm-up. Depending on working environment, we suggest to
warm up the machine when the room temperature
is below 25°C.
Daily routine Longitudinal slide-ways To check lubricating oil is even on slideways.
lubricating advice.
Cross slideways and To check lubricating oil is even on slideways and
ball screw lubricating the ball screw.
advice.
Upward/downward To check lubricating oil is even on slideways and
slideways and the the lead screw.
lead-screw lubricating
device.
Machine surface. Wipe it up.
The rear drain ditch. Clean up the dust and grit. Please do not use the
compressed fluid or air.
Weekly The automatic lub Check the automatic lub system and fill it up.
routine system.
Every month The electrical box. Keep the inner of electrical box dry and clean.
Every season The machine level. The deviation must be within the range of 0.002
mm/m.
Every year Hydraulic oil change. The hydraulic oil has to be changed and the oil
deposit located on the bottom of oil tank has to be
cleaned.

＊ Do not use compressed fluid or air to clean
up the spindle any time. ＊
(K) SPARE PARTS LIST
PSGS SD10008A MACHINE BASE ASSEMBLY
PSGS SA20008A LONGITUDINAL STRUCTURE
(ALL MANUAL OPERATED)
PSGS SD20008A LONGITUDINAL STRUCTRE
(HYDRAULIC LONGITUDINAL TRAVERSE)

PSGS SA30008A CROSS STRUCTURE
(ALL MANUAL OPERATED)
PSGS SD30008A CROSS STRUCTURE
(HYDRAULIC LONGITUDINAL TRAVERSE)
PSGS SD40008A VERTICAL STRUCTURE
PSGS SD50008A SPINDLE ASSEMBLY
PSGS SD60008A HYDRAULIC SYSTEM

PSGS SD10008A
INDEX NO PART NO PART NAME QUANTITY
1 SD9114A* FLYING RING 2
2 SD9115A* FLYING RING 2
3 TURCITE B 2
4 SD9113A* COVER 2
5 SCREW 4
6 SD1111A* MACHINE BASE 1
7 SD9111A* JACK BOLT 3
8 SD9112A* SETTING PLATE 3
9 SD9116A* NAME PLATE 1

PSGS SA20008A

1 SCREW 14
2 SA2435A* CONVEX BALL SLIDEWAY 1
3 SA2311A* SPLASH GUARD 1
4 SA1113A* TABLE 1
5 SCREW 2
6 SA2434A* CONCAVE BALL SLIDEWAY 1
7 SA2113A* TRIP DOG 2
8 SA2112A* ADJUSTING NUT 4
9 SA2429A* CABLE 1
10 AA2437A* CABLE FIXED RING 2
11 SA2212A* CABLE FIXED BASE 2
12 NUT 4
13 BALL5/8” 45
14 SA2433A* CONCAVE BALL SLIDEWAYS 2
15 SA2431A* SPACER 4
16 SCREW 14
17 SA2432A* BALL RETAINER 9
18 SA2561A* STOPPER 1
19 SA2565A* STOP CUSHION 2
20 SCREW 2
21 SA1112A* SADDLE 1
22 SA2423A* TUBE 1

23 SA2422A* DRUM 1
24 BEARING 2
25 SA2421A* DRUM BASE 1
26 SA2424A* DRUM SHAFT 1
27 SA2428A* DRIVE GEAR 1
28 KEY 1
29 BEARING 1
30 C-RING 1
31 SA2436A* SCREW 1
32 C-RING 1
33 BEARING 1
34 C-RING 1
35 SA2425A* NUT 1
36 SA2426A* HOUSING HOLDER 1
37 SA2427A* NUT 1
38 SD2555A* HANDWHEEL 1
39 SD2556A* NUT 1
40 SD2555A* HANDLE 1

PSGS SD20008A

1 SCREW 3
2 SD2111A* RACK 1
3 SCREW 2
4 WASHER 2
6 SD2550A* HANDLE 1
7 SD2311A* SPLASH GUARD 1
8 SD2116A* WASH 2
9 SCREW 2
10 SD2410A* DRIVE 1
11 SD2114A* SLIDER DOG 1
12 SD2112A* SLIDER DOG NUT 4
14 SCREW 4
15 RUBBER WASHER 1
16 SD1112A* SLIDER 1
17 SCREW 4
18 WASHER 4
19 WASHER 4
20 SCREW 4
21 SD2115A* ROD HOLDER 2
22 WASHER 2
23 NUT 4
24 SD1113A* TABLE 1
25 SD2210A* CYLINDER 1

PSGS SA30008A

1 SD2550A* HANDLE 1
2 SD2556A* NUT 1
4 SA3116A* GRADUATE DIAL 1
5 SPACER 1
6 WASHER 1
7 BEARING 1
8 BERAING 1
9 SCREW 2
10 SD3115A* DIAL INDICATOR 3
11 SD3114A* SPACER 1
12 SA1112A* SADDLE 1
13 SA3431A* SUPPORTING BASE 1
14 SCREW 2
15 SA2432A* FIXED BASE 1
16 SCREW 4
17 SD3131A* ADJUSTING BASE 1
18 KEY 1
19 SA3110A* LEADSCREW ON 1
CROSS
20 KEY 1
21 SD3119A* LEADSCREW NUT 1
HOLDER
22 WASHER 4
23 SCREW 4
24 SD3122A* PROTECTION TUBE 1
25 TURCOTE B 4
26 SD1111A* MACINE BASE 1

27 SA2433A* HOLDER 1
28 SA3434A SHAFT 1

PSGS SD30008A

1 SCREW 4
3 SD3119A* LEAD SCREW NUT HOLDER 1
4 SD3122A* PROTECTION TUBE 1
5 WASHER 4
6 KEY 1
7 SD3110A* LEADSCREW ON CROSS 1
8 SCREW 2
9 SD3121A* ADJUST BASE 1
10 SCREW 2
11 C-RING 1
12 SD3125A* PULLEY COVER 2
13 TIMING BELT 1
14 SD3113A* PULLEY 1
15 KEY 1
17 BEARING 1
18 SD3115A* DIAL HOLDER 1
19 SCREW 3
20 SD3116A* GRADUATED DIAL 1
21 SD3126A* SPRING 1
22 KEY 1
23 SD3117A* CLUTCH HOUSING 1
25 BALL 3
26 BEARING 1
27 WASHER 1
28 SPACER 1

30 SD2556A* HAND WHEEL NUT 1
32 WASHER 4
33 SCREW 1
34 SD3123A* MOTOR FOR CROSS 1
35 SD1112A* SLIDER 1
36 SD3124A* PULLEY 1
37 SCREW 2
38 SD3129A* LIMIT DOG 2
39 SD3128A* SROKE ADJUSTED RAIL 1
40 SD3132A* FIX SCREW 2
42 SCREW 2

PSGS SD40008A

1. SD4113A* WAY CPVER SUPPORT 1
2. SD4121A* VERTICAL SLIDEWAY 1
3. SCREW 2
4. SD4111A* CLOUMN COVER 1
6 SD4114A* WAY COVER SUPPORT 1
7 SD4115A* SLIDEWAY COVER 1
8 SD4122A* VERTICAL SLIDEWAY 1
9 SCREW 6
10 WASHER 1
11 SCREW 2
12 SD4118A* DUST PROTECTION OVER 1
16 SD2556A* HAND WHEEL NUT 1
18 NUT 1
19 WASHER 1
20 BEARING 1
21 SD4313A* SCREW 1
22 SD4315A* SPRING WASHER 1
23 SCREW 3
24 WASHER 3
25 SD4324A* NUT 2
26 SD4321A* GRADUATE DIAL 1
27 SD4323A* LOCKING SCREW 1
28 SD4322A* CLUTCH 1
29 SD4312A* INDICATER 1

31 SD4311A* VERTICAL HOUSING 1
32 SCREW 6
33 SCREW 6
34 SD4124A* COVER 1
35 SD1114A* COLUMIN 1
36 SCREW 6
37 SCREW 4
38 WASHER 4
40 SD4400A* SPINDLE HOUSING 1
41 RING 2
42 BEARING 1
43 SD4414A GEAR HOLDER 1
44 WASHER 1
45 SCREW 1
46 SD4422A* GEAR ASSEMBLY 1
47 BEARING 1
48 BEARING 1
49 KEY 1
50 SD4421A* GEAR ASSEMBLY 1
51 SK4423A* SPACER 1
52 NUT 1
53 VERTICAL LEADSCREW 1
54 VERTICAL SHAFT 1

PSGS SD50008B

1. SCREW 1
2. SD5118A* RUBBER COUPLING 1
3. SA5116A* COUPLING FOR SPINDLE 1
4. KEY 1
5 SD5211A* SPINDLE 1
6 SCREW 4
7 SD1116A* SPINDLE HOUSING HOLEDR 1
8 SCREW 2
9 SD5117A* DUST COVER 4
10 SD5113A* SPINDLE FIXING ELEMENT 2
11 SD1115A* SPINDLE HOUSING 1
12 SD5114A* SPINDLE FIXING ELEMENT 2
13 SD5311A* WHEEL COVER(BACK) 1
14 SCREW 1
15 SD5212A* WHEEL FLANGE 1
16 SD5312A WHEEL COVER(FRONT) 1
17 GRINDING WHEEL 1
18 WHEEL COVER SCREW 1
19 SD5214A* WHEEL BALANCING WEIGHT 3
20 SD5213A* WHEEL FLANGE 1
21 SCREW 6
22 SD5216A* LOCK NUT 1
23 BALL 3
24 SCREW 3
25 SCREW 4
26 WASHER 4
27 SD5111A* MOTOR FOR SPINDLE 1
28 KEY 1
29 SD5112A* COUPLING FOR MOTOR 1

30 SCREW 1
31 SCREW 2
32 SD5315A* SPLASH COVER 1
33 SCREW 1
34 SD5314A* SPLASH COVER 1

PSGS SD60008A

1. SD6152A* FLOW CONTROL HANDLE BASE 1
2. SD6140A* DIRECTIONAL ARM 1
3. FLOW CONTROL HANDLE 1
4. SCREW 1
6 SD1112A* SLIDER 1
7 SCREW 2
8 SD6155A* LIMIT SWITCT BASE 2
9 SCREW 1
10 PROXIMITY SWITCH 1
11 SD6156A* DIRECTIONAL CAM 1
12 SCREW 1
13 WASHER 1
14 SD6150A* DIRECTIONAL VALVE 1
15 SCREW 4
16 NUT 4

PSGS **9140HA

1 SCREW 4
2 WASHER 4
3 MAIN BODY 1
4 SCREW 3
5 NUT 3
6 WEDGE 1
7 LOWERCOVER 1
8 TRIP DOG 1
9 COVER 1
10 SCREW 6
11 UPPER COVER 1
12 DIAMOND DRESSER 1
13 SCREW 2
14 SHAFT 1
15 LOCKING RING 1
16 SEAL 1
17 HOUSING 1
18 SCREW 1
19 SCREW 1
20 BEARING 1
21 GRADUATED DIAL 1
22 WEDGE 1
23 OIL INJECTOR 1
24 SCREW 1
25 CROSS SCREW 1
26 BEARING 1
27 BEARING 1
28 HANDLE 1
29 NUT 1
30 HANDLE 1
31 SCREW 1
32 FRONT COVER 1
33 SCREW 2
34 SCREW 1
35 SCREW 4
36 COVER 1

- (L) TROUBLE SHOOTING
【I】 Grinding defects, Causes and Remedy
No. Defects Causes Remedy

1-1 Chatter marks 1) The foundation is not firm Please improve the foundation.
appeared on the enough for the machine.
grinding surface. 2) The leveling screws (jack Check the leveling first and
bolts) in machine base are lock them tight.
loosened.
3) Work table does not run Check slideways have enough
smoothly. lubricant oil. And cylinders
are smoothly running.
4) Table is not fully supported. Re-scrap the contacted
surfaces of table and bed
slideways.
5) Grinding wheel does not sit Replace the intermediate
firmly on the wheel flange. washer between wheel and
flange, make sure to tighten
them well.
6) Flange (with wheel) does Clean both taper contacted
not fit firmly on the grinding surfaces, make sure they are
spindle taper nose. well contacted and fitted firmly.
7) Wheel and flange are not Make sure the water-based
well balanced. fluid on the wheel is dried out
BEFORE re-balancing wheel
and flange.
8) Wheel is asymmetrical. If wheel and flange cannot be
balanced well, dress the wheel
on periphery and both sides
before rebalancing again. If it

still cannot reach the balance,
please replace a new wheel.
9) The usage of improper Please select the proper wheel
wheel. base on the material of the
workpiece.
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. qualified technician.
12) Too much play on the Clean and adjust the gibs.
wheel head guideways.
13) Vibrations transferred to Improve the foundation, make

machine from outside, such as it vibration free or place
rough-running machines, machine in a vibration-free
traveling cranes inside the location/position.
buildings, street vehicles etc
14) Couplings of motor and Fix couplings well or replace
spindle are loosened or rubber with new rubber couplings.
is broken.

15) Unsteady running of The voltage of 3-phase power
grinding wheel. source may be unstable,
please check and make it
stable.
16) Stock removal is too great. Reduce infeed amount.
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.
1-2 Small and uneven 1) Traveling cranes or hoists Improve the foundation.
flutter marks inside the building. Change the location/position.
appeared on the 2) Traveling vehicles in the Improve the foundation .
workpiece surface. building or streets.
Change the location/position.
1-3 Obvious ray pattern 1) Bearings of grinding spindle Please see item No. A-1 for
parallel lines that are defected. more details.
can be seen by 2) Too much play on
naked eyes. wheelhead guideways.
3) Wheel is badly dressed. Dressing the wheel again.
1-4 Comma-shaped 1) Coolant gets too dirty. Clean coolant or use automatic
lines appeared paper strip filter.
when grinding is 2) Grinding wheel chips off. Clean the interior grits of the
getting a high wheel cover.
surface finish. Choose proper wheel.
1-5 Burned marks and 1) Grinding wheel gets too Use softer or coarser wheel.
grinding brunt hard or too thin. Increase table speed.
caused by Reduce peripheral speed of
over-heating of the the wheel.

workpiece. 2) Grinding wheel gets dull or Dressing the wheel to make it
clogged. rougher and sharper.
3) Stock removal is too great. Reduce infeed amount.
Reduce cross feed 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.
1-6 Grinding spark Cannot be spark out. Using spirit level to align the
abnormally. machine by adjusting the jack
bolt.
【II】 Electronic-related defects, Causes and Remedy
A. General (machines without CE)

A-1 Rapid and auto 1) SA31 doesn’t switch on to the Please switch it to the right
cross-feed are right side. position.
not functioning. 2) SA3 and SA31 switches are Fix wires well or replace new
defective or wires loose. switch.
3) MCU (motor control unit) is Check the terminal block as
not working. following:
Or fuse of MCU is defective. (no 1. Short 75 and 76 by a wire.
power is delivered because fuse 2. Turn SA3 to either the right
is broken). side or the left one and stay
in that position. (not let it turn
back)
3. Check whether the voltage
of 73 and 74 is around
220V±10% or not ; if not, it
indicates that the MCU is out

of order.
4) Limit Switch LS1 or LS2 for Check LS1 and LS2 throughout
max stroke safety control is or replace with new switches.
defective or being pressed.
5) PL-4P (PNP) Proximity switch Fix it well or replace a new one.
is too loose to engage
directional cam or LS5 is not
working.
6) The clamping plates for Please take off the clamping
saddle are not taken off. plates.
A-2 Automatic cross 1) Limit Switch LS3 and LS4 are Fix trip dog or change to a new
feed does not not working or the trip dog is too limit switch.
reverse and runs loose to control LS3 and LS4.
to one direction 2) Magnetic contactor for cross Check contactor wires to make
ONLY. feed motor is not functioning. sure the switch is working; if
not, please change to a new
switch.
A-3 Magnetizing Fuse of chuck-control is burnt. Change a new fuse.

doesn’t work Fuse on TR1 is broken Replace with a new one.
Transformer TR1 is defect 1. Check TR1 primary coil:
take off wires from terminals
a.b. if resistance show ∞Ω, it
means the coil is broken.
2. Check TR1 secondary coil:
same as above, if resistance
between c.d. is ∞Ω, the coil
is broken.
3. Any coil broken, TR1 must
be replaced with new one.
Switch SA100 is defective 1. Turn SA100 to right
position(magnetizing), check
terminals “C1” with “+”, “C2”
and “-“, all of them must be
in short circuit(OΩ),

otherwise the switch is
defect.
2. Turn SA100 to left
position(demagnetizing),
check terminal “C1” and “-“,
“C2” and “DE”. all of them
must be in short circuit(OΩ),
defect.
3. Repair or replace with new
switch
The electro magnetic chuck is 1. Check 2 wires of the chuck,

defective. it must be in short circuit
“OΩ”. If not, it indicates the
chuck is broken. Please
repair it.
2. Check each wire with chuck
body (earth), it must be ∞ Ω.
Otherwise, it means the
“insulation” is bad; dry the
coil and improve its
insulation.
B. General (machines with AD3)

B-1 Rapid and auto 1) SA31 doesn’t switch on to the Please switch it to the right
not functioning. 2) SA3 and SA31 switches are Fix wires well or replace new
defective or wires loose. switch.

3) MCU (motor control unit) is Check the terminal block as
not working. following:
Or fuse of MCU is defective. (no 1. Short 75 and 76 by a wire.
power is delivered because fuse 2. Turn SB31 or SB32 to either
is broken). the right side or the left one
and stay in that position.
3. Check whether the voltage
of 73 and 74 is around
220V±10% or not ; if not, it
indicates that the MCU is out
of order.
4) Limit Switch LS1 or LS2 for Check LS1 and LS2 throughout
max stroke safety control is or replace with new switches.
defective or being pressed.
5) PL-4N (NPN) Proximity Fix it well or replace a new one.
switch is too loose to engage
directional cam or LS5 is not
working.
6) The clamping plates for Please take off the clamping
saddle are not taken off. plates.
B-2 Automatic cross 1) Limit Switch LS3 and LS4 are Fix trip dog or change to a new
feed does not not working or the trip dog is too limit switch.
to one direction
ONLY. 2) Magnetic contactor for cross Check contactor wires to make
feed motor is not functioning. sure the switch is working; if
not, please change to a new
switch.
B-3 Magnetizing Fuse of chuck-control is burnt. Change a new fuse.

take off wires from terminals

a.b. if resistance show ∞Ω, it
2. Check TR1 secondary coil:
same as above, if resistance
between c.d. is ∞Ω, the coil
is broken.
3. Any coil broken, TR1 must
be replaced with new one.
position(magnetizing), check
terminals “C1” with “+”, “C2”
and “-“, all of them must be
in short circuit(OΩ),
defect.
check terminal “C1” and “-“,
“C2” and “DE”. all of them
must be in short circuit(OΩ),
defect.
3. Repair or replace with new
switch
The electro magnetic chuck is 1. Check 2 wires of the chuck,
defective. it must be in short circuit
“OΩ”. If not, it indicates the
chuck is broken. Please
repair it.
2. Check each wire with chuck
body (earth), it must be ∞ Ω.
“insulation” is bad; dry the
coil and improve its
insulation.

C. Machines with AD1 or CE mark

C-1 Rapid and auto 1) SA31 doesn’t switch on to the Please switch it to the right
not functioning. 2) SB31&SB32, SA31 switches Fix wires well or replace
are defective or wires loose. new switch.
3) MCU (motor control unit) is not Check the terminal block as
working. following:
Or fuse of MCU is defective. (no 1. Short 75 and 76 by a
power is delivered because fuse is wire.
broken). 2. Turn SA3 to either the
right side or the left one
and stay in that position.
(not let it turn back)
3. Check whether the
voltage of 73 and 74 is
around 220V±10% or
not ; if not, it indicates
that the MCU is out of
order.
4) Limit Switch LS1 or LS2 for max Check LS1 and LS2
stroke safety control is defective throughout or replace with
or being pressed. new switches.
5) PL-4NP (NPN) Proximity switch Fix it well or replace a new
is too loose to engage directional one.
cam or LS5 is not working.
6) The clamping plates for saddle Please take off the clamping
are not taken off. plates.
C-2 Automatic cross 1) Limit Switch LS3 and LS4 are Fix trip dog or change to a
feed does not not working or the trip dog is too new limit switch.

to one direction 2) Magnetic contactor for cross Check contactor wires to
ONLY. feed motor is not functioning. make sure the switch is
working; if not, please
change to a new switch.
C-3 Magnetizing Fuse of chuck-control is burnt. Change a new fuse.

take off wires from
terminals a.b. if
resistance show ∞Ω, it
2. Check TR1 secondary
coil: same as above, if
resistance between c.d.
is ∞Ω, the coil is broken.
3. Any coil broken, TR1
must be replaced with
new one.
position(magnetizing),
check terminals “C1” with
“+”, “C2” and “-“, all of
them must be in short
circuit(OΩ), otherwise
the switch is defect.
check terminal “C1” and
“-“, “C2” and “DE”. all of
them must be in short
circuit(OΩ), otherwise
the 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. Please repair
it.
2. Check each wire with
chuck body (earth), it
must be ∞ Ω.
“insulation” is bad; dry
the coil and improve its
insulation.
【III】 Hydraulic-related defects, Causes and Remedy
No. Defects Checkup Remedy

3-1 Hydraulic motor is 1) Wire lose of hydraulic motor Check the wire or change the
not working switch motor switch.
2) Magnetic switch/overload Check the connecting wires or
relay of pump motor are not change the whole set of
working properly. magnetic switch.

3-2 Table longitudinal 1) Check lubrication oil on
movement is the slideways
slowing down. a. Lubricant outlet on the a. Clean up
slideways or lubrication
controlled switch is blocked.
b. Not enough lubrication oil in b. Add Mobil #2 or its
the oil tank. equivalent as recommended.
c. Lubrication pump is in c. Adjust to proper pressure
proper pressure of 3-4 bar
(3~5kgf/cm2).
d. Filter inside the lubrication d. Clean the oil tank and add
oil tank is blocked. new oil
2) Move the table to the
extremely end, turn on the
flow control lever at full
speed to see that the
pressure indicator should
stand still.
a. The pressure gauge a. Replace the O-ring/seals of

indicator ‘downward’ the cylinders.
movement which means the
leakage inside the cylinders.
b. Using a 5-mm hex key to b. Should it stand still without

adjust the pressure of the relief moving which means the relief
valve in clockwise direction to valve was broken. Please
see if the pressure gauge change the new one.
indicator can be upward
movement or it stands still
without moving.
3) Inside hydraulic tank.

a. The color of hydraulic oil is a. Change the hydraulic oil.

creamy white. b. Change the pump.
b. Abnormal noise from the
pump. c. Clean the oil tank and filter,
c. Filter block up. then change the hydraulic oil.
d. Not enough oil. d. Add the oil till the upper limit.
3-3 The transverse a. The loose or bent of the a. Re-adjust the parallelism of
movement of the cylinder. the cylinder. Or replace with
table is vibrating new one if it is bent.
or not stable. b. Not enough oil. b. Add the new oil till the upper
limit.
c. The color of hydraulic oil is c. Change the new hydraulic
creamy white. oil.
d. Abnormal rotation speed of d. Change a new motor.
the motor.
e. Abnormal noise from the e. Change a new pump.
pump. f. Examine it following the
f. No lubrication oil on the above 3-2.
slideways.
3-4 The table can not a. Directional control arm is a. Adjust directional control arm
reverse and runs loose. following inside manual.
to one side b. The trip dogs (T1, T2) are b. Tighten the trip dog at the
loose. proper position.
c. Unknown body blocks up c. Cleaning the unknown body
inside the cylinder. inside the cylinder tank.
d. Hydraulic oil:
1) Brands. - Use the recommended
brands.
2) Not enough oil. - Add the oil till the upper limit.
- Change new hydraulic oil and
3) Inferior oil. clean the internal and filter of
the oil tank.

3-5 Workable can not 1) The electro magnetic chuck Switch on the chuck or chuck
move does not switch on, so that control (auto demagnetizer)
pump motor does not work. switch if it is used on the
machine.
2) Oil pump cannot deliver oil Fill in oil from the “P” port of the
because air come into the oil Relief Valve, and then start the
pump and piping (so hydraulic pump, the problem
called ”carition”) will be solved.

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SURFACE GRINDERS

INSTRUCTION MANUAL AND PART LISTS

TEL: 310-370-5990 FAX: 310-542-6162 WEB: www.sharp-industries.com

1. This instruction manual is for SHARP PSGS series ONLY.

3. Please follow the instruction manual for operation and

maintenance. Do not change any circuits, functions and parts of

4. Since SHARP subscribes to a process of continuous

improvement for our products, designs and specifications are

SHARP INSTRUCTION MANUAL Page 2

1. Avoid using any improper work pieces.

SHARP INSTRUCTION MANUAL Page 3

SHARP INSTRUCTION MANUAL Page 4

SHARP INSTRUCTION MANUAL Page 5

Unload the wooden case by the fork

Uncrate the machine.

Position the machine at the

Unpack and install the machine.

(B) Using Cranes or Elevating Platforms

SHARP INSTRUCTION MANUAL Page 6

Unload the wooden case by the

Uncrate the machine.

Position the machine at the

Unpack and install the machine.

* ALL SHARP MACHINES HAVE BEEN UNDERTAKEN A 4-HOUR

RUNNING TEST FOR SMALL MACHINES AND AN 8-HOUR TEST

SHARP INSTRUCTION MANUAL Page 7

EXCELLENT CONDITION. PLEASE CONTACT US IMMEDIATELY IF

THERE ARE ANY QUESTIONS RELATED TO OUR MACHINES.

* WE WOULD LIKE TO EMPHASIZE SHARP THREE PROMINENT

1. SMOOTH TABLE TRAVERSE RUNNING

2. QUIET MACHINE OPERATIONS

3. SIMPLE AND MODERN MACHINE-DESIGN WITHOUT MUCH

THANK YOU FOR USING SHARP SURFACE GRINDING

MACHINES AND SINCERELY HOPE SHARP MACHINES CAN

GRIND YOU A BRIGHT FUTURE. PLEASE ENJOY IT!

SHARP INSTRUCTION MANUAL Page 8

HYDRAULIC SYSTEM LUBRICATION OIL

DO NOT use COMPRESSED AIR to clean the coolant channel

SHARP INSTRUCTION MANUAL Page 9

Please grind it after proper installation of the machine.

※ ※ TO THE COMMISSIONED ENGINEER

1. Due to the improper operation, spindle vibrations would occur

because of the caused damage. Please kindly make sure to

provide the best quality of the spindle to the customer, with no

noises and good run out of the taper nose.

2. Clean rusty preventive around the housing channel and

glued alongside. It can be the major cause of the spindle noise.

SAFETY INSTRUCTION  3-5

UNLOADING INSTRUCTION  6-7

NOTES  8-10

SHARP INSTRUCTION MANUAL Page 10

(B) STARTING UP THE MACHINE  19-34

(C) WHEEL  35-39

(D) GRINDING OPERATION  40-49

(E) THE HYDRAULIC SYSTEM  50-52

(F) WET GRINDING  53-54

(G) PERFECT SURFACE FINISHED  55

(H) ELECTRO MAGNETIC CHUCK  56-57

(I) FOR AD3 AUTO DOWN FEED OPERATION  58-59

(J) MAINTENANCE  60-61

(K) SPARE PART LIST  62-87

(L) TROUBLE SHOOTING  88-104

1.1 The machine should be lifted by a fork-lift truck or crane.