Proth Psgs Manual PDF

PROTH INDUSTRIAL CO., LTD.
SURFACE
GRINDERS
PSGS INSTRUCTION MANUAL AND PART LISTS

No. 20, 9th Rd., Taichung Industrial District, Taichung 407, Taiwan
TEL: +886-4-2358-3131
FAX: +886-4-2350-3131
E-MAIL: [email protected]
WWW.PROTH.COM.TW
PSGS INSTRUCTION MANUAL

PREFACE
1. This instruction manual is for PROTH 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 PROTH
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 PROTH. Please
note that PROTH will not take any responsibilities for these
faults.
4. Since PROTH 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.
PSGS INSTRUCTION MANUAL P.2 OF 57

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
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.
30. Please read the warning signs carefully before checking the power source.
31. Any machine modifications should be approved by PROTH.
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. PROTH 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 PROTH 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
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
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.

NOTES
 All PROTH 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.
 We would like to emphasize PROTH 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 PRTOH surface grinding machines and sincerely
hope PROTH machines can grind you a bright future. Please enjoy it!

WARING
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.
(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
SHELL : Tonna S-68 (V-68)
Tonna 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
ARAL : Deganit BW-68 (B68)
red 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.
※ 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--
(A) INSTALLATION .......................................................................... P.12
(B) STARTING UP THE MACHINE .................................................. P.19
(C) WHEEL ...................................................................................... P.34
(D) GRINDING OPERATION............................................................ P.40
(E) THE HYDRAULIC SYSTEM ....................................................... P.47
(F) WET GRINDING......................................................................... P.50
(G) PERFECT SURFACE FINISH .................................................... P.51
(H) ELECTRO MAGENTIC CHUCK................................................. P.52
(I) FOR AD3 AUTO DOWN FEED OPERATION............................. P.54
(J) MAINTENANCE ......................................................................... P.56

(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.
Fig. 1-1 Lifting

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

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.


3. 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” 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.

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
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.
4.2.5 The 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 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
MODEL SLIDEWAYS & SLIDEWAYS &
SYSTEM SLIDEWAYS
LEADSCREW LEADSCREW
1. Oil 1. Automatic 1. Automatic 1. Automatic

exchanged recirculation non-recirculation non-recirculation
PSGS-2550AH every 1 year. oil lubed. oil lubed. oil lubed.
PSGS-3060AH
PSGS-3060BH 2. Change new 2. Clean and 2. Clean & check 2. Clean & check
PSGS-4080AHR oil filter every check the the slideways, the slideways,
PSGS-40100AHR 6 months. slideways leadscrews and leadscrew and
every 6 nut every 6 nut every 6
months. months. months.
MOBIL： VACUOLINE MOBIL： Vactra NO.2
OIL NO.1409 SHELL： Tonna S – 68 (V –
SHELL： TONNA OIL S68 68)
BP： ENERGOL BP： Maccurat D – 68
OIL REQUIRED
GHL-68 ARAL： Deganit BW – 68
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
MODEL SLIDEWAYS & SLIDEWAYS &
SYSTEM SLIDEWAYS
LEADSCREW LEADSCREW
None. 1. Do not need 1. Manual type one 1. Automatic

lubrication. shoot lubrication non-recirculation
pump and pull 5 oil lubed.
times a day.
PSGS-2550M
2. Clean the ball 2. Clean & check 2. Clean & check
rolling the slideways, the slideways,
slideways leadscrews and leadscrew and
every 6 nut every 6 nut every 6
months. months. months.
MOBIL： Vactra NO.2
SHELL： Tonna S – 68 (V –
68)
BP： Maccurat D – 68
OIL 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
(1) Cimtech 100

3 Cincinnati Milacron
(2) Cimtech 200
4 Fuchs (1) Ratak Synthan 47
(1) Kuhlschmierst off 166 or 193

5 Mobil
(2) Mobil cut 321
6 Oemeta (1) Unimet RD
7 Shell (1)Metalina Fluid GR
Note:
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.


6. The procedures for checking the electrical connection.

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”
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
8.3 SA31 for automatic operation, the cross feed will soon be actuated and the
wheelhead will move forward to the operator.
8.4 Turn SA3 to right, wheelhead will automatically move backward to rear side.
8.5 Automatic cross feed traverse will reverse its direction when the limited
switch LS3 or LS4 are actuated by trip dogs. (Fig.6)
8.6 The magnitude of cross feed is infinitely variable by the regulating
knob ”RP32 ”.
8.7 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.


Fig 6. Automatic cross feed

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
Grinding Size 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
Grinding Soft Hard
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
Material Diameter
To Under 205mm 205-355MM
Be
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

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
Speed High Low
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

4.6 Down Feed and Feed Chart:

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

Fine (0.005 – 0.015 mm)
(0.005 – 0.01 mm) 0.0002 – 0.006 inch wheel width
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
OIL TANK LUBRICANT

MODEL HYDRAULIC 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

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.)
1. FOR SURFACE GRINDING + AUTO DOWN FEED.

1.1 Turn selector switch SA111 to right for surface grinding.
1.2 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).
1.3 Set the number of spark-out passes required on PC112 counter.
1.4 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).
1.5 Switch “ON” the hydraulic pump switch SA2 (hydraulic table drive).

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.
2. FOR PLUNGE GRINDING + AUTO

2.1 Turn SA111 to left for plunge grinding.
2.2 Select the required down feed increments to the dial regulator C of auto
down feed unit AD3.
2.3 Set the number of down feed increments required on PC111 counter.
2.4 Set the number of spark-out passes on PC112 counter.
2.5 Switch “ON” the hydraulic pump switch SA2 (hydraulic table drive).
2.6 Turn lever L1 to left for table movement.
2.7 Turn SA31 to left.
2.8 Press “ON” the switch SB110 for auto down feed.
3. 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.
4. RAPID UP/DOWN
4.1 Turn the rapid up/down switch SA4 to right for up movement.
4.2 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
table. after working hours.
Each time
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.

Interval Maintaining points Remark
The machine level. The deviation must be within the range of 0.002
Every season
mm/m.
Hydraulic oil change. The hydraulic oil has to be changed and the oil
Every year deposit located on the bottom of oil tank has to be
cleaned.
Notes:
Do not use compressed fluid or air to clean up the spindle any time.

SURFACE
GRINDERS
- PSGS TROUBLE SHOOTING -

TEL: +886-4-2358-3131
FAX: +886-4-2350-3131
WWW.PROTH.COM.TW
PSGS TROUBLE SHOOTING

--TABLE OF CONTENTS--
【I】 Grinding defects, Causes and Remedy ................................ P.3
【II】 Electronic-related defects, Causes and Remedy ................. P.7
A. General (machines without CE) ......................................... P.7
B. General (machines with AD3) ........................................... P.10
C. Machines with AD1 or CE mark........................................ P.13
【III】 Hydraulic-related defects, Causes and Remedy................ P.16
PSGS TROUBLE SHOOTING P. 2 OF 18

【I】 Grinding defects, Causes and Remedy

No. Defects Causes Remedy
1-1 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.
loosened.
3) Work table does not run Check slideways have
smoothly. enough 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 it vibration free or place
as 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 with new rubber couplings.
rubber 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 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.
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 building or streets.
Change the location/position.
surface.
1-3 Obvious ray 1) Bearings of grinding Please see item No. A-1 for
pattern parallel spindle are defected. more details.
lines that can be 2) Too much play on
seen by naked wheelhead guideways.
eyes. 3) Wheel is badly dressed. Dressing the wheel again.
1-4 Comma-shaped 1) Coolant gets too dirty. Clean coolant or use
lines appeared automatic 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 1) Grinding wheel gets too Use softer or coarser wheel.
and grinding hard or too thin. Increase table speed.
brunt caused by Reduce peripheral speed of
over-heating of the wheel.
the 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)
Rapid and auto 1) SA31 doesn’t switch on to Please switch it to the right
A-1 cross-feed are the right side. position.
not functioning. 2) SA3 and SA31 switches Fix wires well or replace
are defective or wires loose. new switch.
3) MCU (motor control unit) is Check the terminal block as
not working. following:
Or fuse of MCU is defective. 1. Short 75 and 76 by a wire.
(no power is delivered 2. Turn SA3 to either the
because fuse is broken). 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 Check LS1 and LS2
max stroke safety control is throughout or replace with
defective or being pressed. new switches.
5) PL-4P (PNP) Proximity Fix it well or replace a new
switch is too loose to engage one.
directional cam or LS5 is not
working.
6) The clamping plates for Please take off the clamping
saddle are not taken off. plates.
Automatic cross 1) Limit Switch LS3 and LS4 Fix trip dog or change to a
A-2 feed does not are not working or the trip dog new limit switch.
reverse and runs is too loose to control LS3
to one direction and LS4.


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.

A-3 doesn’t work burnt.
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
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. Otherwise, it
means the “insulation” is
bad; dry the coil and
improve its insulation.

B. General (machines with AD3)

B-1 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. switch.
(no power is delivered 2. Turn SB31 or SB32 to
because fuse is broken). either the right side or the
left one and stay in that
position.
out of order.
5) PL-4N (NPN) Proximity Fix it well or replace a new
working.
B-2 feed does not are not working or the trip dog new limit switch.


to a new switch.

B-3 doesn’t work burnt.
take off wires from
is broken.
“+”, “C2” and “-“, all of
switch is defect.


switch is defect.
switch

C. Machines with AD1 or CE mark

C-1 cross-feed are the right side. position.
not functioning. 2) SB31&SB32, SA31 Fix wires well or replace
switches are defective or new switch.
wires loose.
(no power is delivered 2. Turn SA3 to either the
because fuse is broken). right side or the left one
and stay in that position.
(not let it turn back)
out of order.
5) PL-4NP (NPN) Proximity Fix it well or replace a new
working.
C-2 feed does not are not working or the trip dog new limit switch.


to a new switch.

C-3 doesn’t work burnt.
take off wires from
is broken.
“+”, “C2” and “-“, all of
switch is defect.


switch is defect.
switch

【III】 Hydraulic-related defects, Causes and Remedy

No. Defects Checkup Remedy
3-1 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. 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 b. Add Mobil #2 or its
in 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

indicator ‘downward’ of 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 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
moving.
3) Inside hydraulic tank.
a. The color of hydraulic oil is a. Change the hydraulic oil.
creamy white.
b. Abnormal noise from the b. Change the pump.
pump.
c. Filter block up. c. Clean the oil tank and filter,
then change the hydraulic
oil.
d. d. Not enough oil. d. 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
table is vibrating with 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. No lubrication oil on the f. Examine it following the
slideways. above 3-2.


3-4 The table can not a. Directional control arm is a. Adjust directional control
reverse and runs loose. arm following inside
to one side manual.
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
inside the cylinder. body 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
3) Inferior oil. and clean the internal and
filter of the oil tank.
3-5 Workable can not 1) The electro magnetic Switch on the chuck or chuck
move chuck does not switch on, so control (auto demagnetizer)
that pump motor does not switch if it is used on the
work. machine.
2) Oil pump cannot deliver oil Fill in oil from the “P” port of
because air come into the oil the Relief Valve, and then
pump and piping (so start the hydraulic pump, the
called ”carition”) problem will be solved.

SURFACE
GRINDERS
- PSGS PART LISTS -

TEL: +886-4-2358-3131
FAX: +886-4-2350-3131
WWW.PROTH.COM.TW
PSGS PART LIST

NAME PLATE:
Please keep 'Model' & 'Serial No.' of this machine
for parts order.
Thank you for your cooperation!
PSGS PART LIST P.2 OF 31

--TABLE OF CONTENTS--
MACHINE ASSEMBLY ........................................................................ P.4
MACHINE BASE STRUCTURE........................................................... P.5
LONGITUDINAL STRUCTURE ........................................................... P.7
CROSS STRUCTURE ....................................................................... P.13
VERTICAL STRUCTURE ................................................................... P.20
SPINDLE ASSEMBLY ........................................................................ P.24
HYDRAULIC SYSTEM ....................................................................... P.27
PARALLEL DRESSING ATTACHMENT .............................................. P.29

MACHINE ASSEMBLY

MACHINE BASE STRUCTURE

PSGS SD10008A
序號件號品名數量
INDEX NO PART NO PART NAME QUANTITY
1 SD9114A* 大吊栓 FLYING RING 2
2 SD9115A* 小吊栓 FLYING RING 2
3 特氟龍 TURCITE B 2
4 SD9113A* 通風蓋板 COVER 2
5 螺絲 SCREW 4
6 SD1111A* 主機座 MACHINE BASE 1
7 SD9111A* 腳座螺絲 JACK BOLT 3
8 SD9112A* 腳墊盤 SETTING PLATE 3
9 SD9116A* 主機銘板 NAME PLATE 1

LONGITUDINAL STRUCTURE
(FOR PSGS-2550M BALL ROLLING WAYS)

PSGS SA20008A (FOR PSGS-2550M BALL ROLLING WAYS)

1 SCREW 14
CONVEX BALL
2 SA2435A* 1
SLIDEWAY
3 SA2311A* SPLASH GUARD 1
4 SA1113A* TABLE 1
5 SCREW 2
CONCAVE BALL
6 SA2434A* 1
SLIDEWAY
7 SA2113A* TRIP DOG 2
8 SA2112A* ADJUSTING NUT 4
9 SA2429A* CABLE 2
10 AA2437A* CABLE FIXED RING 1
11 SA2212A* CABLE FIXED BASE 2
12 NUT 4
13 BALL5/8” 45
CONCAVE BALL
14 SA2433A* 2
SLIDEWAYS
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

LONGITUDINAL STRUCTURE

PSGS SD20008A

1 螺絲 SCREW 3
2 SD2111A* 齒排 RACK 1
3 螺絲 SCREW 2
4 墊圈 WASHER 2
5 SD2555A* 把手輪 HANDWHEEL 1
6 SD2550A* 把手桿總成 HANDLE 1
7 SD2311A* 防濺槽 SPLASH GUARD 1
8 SD2116A* 墊套 WASHER 2
9 螺絲 SCREW 2
10 SD2410A* 手動傳動組 DRIVE 1
11 SD2114A* 左調距滑塊 SLIDER DOG 1
12 SD2112A* 調距螺母 SLIDER DOG NUT 4
13 SD2113A* 右調距滑塊 SLIDER DOG 1
14 螺絲 SCREW 4
15 橡皮墊 RUBBER WASHER 1
16 SD1112A* 滑動座 SLIDER 1
17 螺絲 SCREW 4
18 墊圈 WASHER 4
19 墊圈 WASHER 4
20 螺絲 SCREW 4
21 SD2115A* 驅動座 ROD HOLDER 2


22 墊圈 WASHER 2
23 螺母 NUT 4
24 SD1113A* 工作台 TABLE 1
25 SD2210A* 油壓缸 CYLINDER 1

CROSS STRUCTURE
(FOR PSGS-2550M BALL ROLLING WAYS)

PSGS SA30008A (FOR PSGS-2550M BALL ROLLING WAYS)


1 SD2550A* HANDLE 1
2 SD2556A* NUT 1
3 SD3555A* HANDWHEEL 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

CROSS STRUCTURE

PSGS SD30008A

1 螺絲 SCREW 4
3 SD3119A* LEAD SCREW NUT 1

前後螺桿座
HOLDER
4 SD3122A* 保護管 PROTECTION TUBE 1
5 墊圈 WASHER 4
6 鍵 KEY 1
7 SD3110A* LEADSCREW ON 1
前後螺桿組
CROSS
8 螺絲 SCREW 2
9 SD3121A* 間隙調整座 ADJUST BASE 1
10 螺絲 SCREW 2
11 Ｃ型扣環 C-RING 1
12 SD3125A* 皮帶輪護片 PULLEY COVER 2
13 時規皮帶 TIMING BELT 1
14 SD3113A* 時規皮帶輪 PULLEY 1
15 鍵 KEY 1
16 SD3114A* 間隔環 SPACER 1
17 軸承 BEARING 1
18 SD3115A* 前後指示盤 DIAL HOLDER 1
19 螺絲 SCREW 3
20 SD3116A* 前後刻度盤 GRADUATED DIAL 1


21 SD3126A* 彈簧 SPRING 1
22 鍵 KEY 1
23 SD3117A* 離合器聯軸座 CLUTCH HOUSING 1
25 鋼珠 BALL 3
26 軸承 BEARING 1
27 太陽墊圈 WASHER 1
28 太陽螺母 SPACER 1
29 SD3555A* 把手輪 HAND WHEEL 1
30 SD2556A* 梅花螺帽 HAND WHEEL NUT 1
32 墊圈 WASHER 4
33 螺絲 SCREW 1
34 SD3123A* 前後馬達 MOTOR FOR CROSS 1
36 SD3124A* 時規皮帶輪 PULLEY 1
37 螺絲 SCREW 2
38 SD3129A* 極限滑塊 LIMIT DOG 2
39 SD3128A* SROKE ADJUSTED 1

調距導軌
RAIL
40 SD3132A* 固定螺絲 FIX SCREW 2
41 SD3131A* 調距滑塊 SLIDER DOG 2
42 螺絲 SCREW 2


43 SD3127A* 前後調距座 SPACER 2

VERTICAL STRUCTURE

PSGS SD40008A

1. SD4113A* 上機架側蓋板 WAY CPVER SUPPORT 1
2. SD4121A* 上下滑板 VERTICAL SLIDEWAY 1
3. 螺絲 SCREW 2
4. SD4111A* 上機架蓋板 CLOUMN COVER 1
5 SD4112A* 上機銘板 NAME PLATE 1
6 WAY COVER 1
SD4114A* 上機架側蓋板
SUPPORT
7 SD4115A* 防塵布 SLIDEWAY COVER 1
8 SD4122A* 上下滑板 VERTICAL SLIDEWAY 1
9 螺絲 SCREW 6
10 墊圈 WASHER 1
11 螺絲 SCREW 2
12 DUST PROTECTION 1
SD4118A* 下 4 號防塵片
OVER
SD4117A* 下 2,3 號防塵片
OVER
SD4116A* 下 1 號防塵片
OVER
16 SD2556A* 梅花螺帽 HAND WHEEL NUT 1
17 SD3555A* 把手輪 HANDWHEEL 1
18 太陽螺帽 NUT 1
19 太陽墊片 WASHER 1


20 軸承 BEARING 1
21 SD4313A* 指示盤螺絲 SCREW 1
22 SD4315A* 彈簧墊圈 SPRING WASHER 1
23 螺絲 SCREW 3
24 墊圈 WASHER 3
25 SD4324A* 螺母 NUT 2
26 SD4321A* 刻度盤 GRADUATE DIAL 1
27 SD4323A* 固鎖螺絲 LOCKING SCREW 1
28 SD4322A* 離合器 CLUTCH 1
29 SD4312A* 指示盤 INDICATER 1
31 SD4311A* 上下軸座 VERTICAL HOUSING 1
32 螺絲 SCREW 6
33 螺絲 SCREW 6
34 SD4124A* 通風後蓋板 COVER 1
35 SD1114A* 上機架 COLUMIN 1
36 螺絲 SCREW 6
37 螺絲 SCREW 4
38 墊圈 WASHER 4
40 SD4400A* 主軸座 SPINDLE HOUSING 1
41 扣環 RING 2


42 軸承 BEARING 1
43 SD4414A 傳動傘輪座 GEAR HOLDER 1
44 墊圈 WASHER 1
45 螺絲 SCREW 1
46 SD4422A* 傘齒輪 GEAR ASSEMBLY 1
47 軸承 BEARING 1
48 軸承 BEARING 1
49 鍵 KEY 1
50 SD4421A* 傘齒輪 GEAR ASSEMBLY 1
51 SK4423A* 間隔 SPACER 1
52 太陽螺帽 NUT 1
53 VERTICAL 1
上下螺桿
LEADSCREW
54 上下傳動軸 VERTICAL SHAFT 1

SPINDLE ASSEMBLY

PSGS SD50008A

1. SD5118A* 聯軸器墊 RUBBER COUPLING 1
2. SD5211A* 主軸 SPINDLE 1
3. 螺絲 SCREW 4
4. SPINDLE HOUSING 1
SD1116A* 主軸座背鎖板
HOLDER
5 SD1115A* 主軸座 SPINDLE HOUSING 1
6 SD5113A* 主軸壓柱 FIXED ELEMENT 2
7 螺絲 SCREW 2
8 SD5117A* 防塵塞 PLUG 4
9 SD5311A* 砂輪後蓋 COVER 1
10 SD5312A* 砂輪前蓋 COVER 1
11 砂輪蓋螺絲 SCREW 1
12 螺絲 SCREW 3
13 SD5216A* 鎖緊螺母 NUT 1
14 螺絲 SCREW 6
15 螺絲 SCREW 4
16 墊圈 WASHER 4
17 SD5111A* 主軸馬達 SPINDLE MOTOR 1
18 螺絲 SCREW 2
19 SD5315A* 防濺布 SPASH GUARD 1
20 螺絲 SCREW 1


21 TABLE SPLASH 1
SD5314A* 防濺板
GUARD
22 SPINDLE FIXING 2
SD5114A* 主軸壓柱
ELEMENT
23 螺絲 SCREW 3
24 SD5212A* 法蘭主體 WHELL FLFNGE 1
25 SD5215A* 砂輪 WHELL 1
26 鋼珠 STEEL BALL 3
27 SD5214A* 鎖緊面盤 LOCK NUT 1

HYDRAULIC SYSTEM

PSGS SD60008A

FLOW CONTROL 1
1. SD6152A* 流量閥把手
HANDLE BASE
2. SD6140A* 方向搖臂 DIRECTIONAL ARM 1
FLOW CONTROL 1
3. 流量閥把手桿
HANDLE
4. 螺絲 SCREW 1
5 SD6154A* 油壓銘板 NAME PLATE 1
7 螺絲 SCREW 2
8 SD6155A* 微動開關座 LIMIT SWITCT BASE 2
9 螺絲 SCREW 1
10 近接開關 PROXIMITY SWITCH 1
11 SD6156A* 方向凸輪 DIRECTIONAL CAM 1
12 螺絲 SCREW 1
13 墊圈 WASHER 1
14 SD6150A* 油壓閥 DIRECTIONAL VALVE 1
15 螺絲 SCREW 4
16 螺母 NUT 4

PARALLEL DRESSING ATTACHMENT

PSGS **9140HA

1 螺絲 SCREW 4
2 墊圈 WASHER 4
3 平行整輪座 MAIN BODY 1
4 螺絲 SCREW 3
5 螺母 NUT 3
6 固定片 WEDGE 1
7 下心軸固定片 LOWER COVER 1
8 調距滑塊 TRIP DOG 1
9 平行整輪護蓋 COVER 1
10 螺絲 SCREW 6
11 上心軸固定片 UPPER COVER 1
12 鑽石修刀 DIAMOND DRESSER 1
13 螺絲 SCREW 2
14 平行整輪心軸 SHAFT 1
15 扣環 LOCKING RING 1
16 油封 SEAL 1
17 心軸座 HOUSING 1
18 螺絲 SCREW 1
19 螺絲 SCREW 1
20 軸承 BEARING 1
21 刻度盤 GRADUATED DIAL 1


22 斜梢 WEDGE 1
23 油栓 OIL INJECTOR 1
24 螺絲 SCREW 1
25 螺絲 SCREW 1
26 軸承 BEARING 1
27 軸承 BEARING 1
28 把手桿座 HANDLE CAM 1
29 螺母 NUT 1
30 把手桿 HANDLE 1
31 螺絲 SCREW 1
32 前護蓋 FRONT COVER 1
33 螺絲 SCREW 2
34 螺絲 SCREW 1
35 螺絲 SCREW 4
36 護蓋 COVER 1

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PROTH INDUSTRIAL CO., LTD.

PROTH INDUSTRIAL CO., LTD.

PSGS INSTRUCTION MANUAL

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

2. Please check the serial No. of machine which should be the

3. Please follow the instruction manual for operation and

4. Since PROTH subscribes to a process of continuous

5. Please check the machine and its accessories right away

PSGS INSTRUCTION MANUAL P.2 OF 57

1. Avoid using any improper work pieces.

PSGS INSTRUCTION MANUAL P.3 OF 57

PSGS INSTRUCTION MANUAL P.4 OF 57

PSGS INSTRUCTION MANUAL P.5 OF 57

Release the wooden case from the

Unload the wooden case by the fork

Uncrate the machine.

Position the machine at the desirable

Unpack and install the machine.

PSGS INSTRUCTION MANUAL P.6 OF 57

(B) Using Cranes or Elevating Platforms

Release the wooden case from the

Unload the wooden case by the crane or

Uncrate the machine.

Position the machine at the desirable

Unpack and install the machine.

PSGS INSTRUCTION MANUAL P.7 OF 57

 We would like to emphasize PROTH three prominent features as:

PSGS INSTRUCTION MANUAL P.8 OF 57

HYDRAULIC SYSTEM LUBRICATION OIL

PSGS INSTRUCTION MANUAL P.9 OF 57

DO NOT use COMPRESSED AIR to clean the coolant

※ ※ TO THE COMMISSIONED ENGINEER

PSGS INSTRUCTION MANUAL P.10 OF 57

(A) INSTALLATION .......................................................................... P.12

(B) STARTING UP THE MACHINE .................................................. P.19

(C) WHEEL ...................................................................................... P.34

(D) GRINDING OPERATION............................................................ P.40

(E) THE HYDRAULIC SYSTEM ....................................................... P.47

(F) WET GRINDING......................................................................... P.50

(G) PERFECT SURFACE FINISH .................................................... P.51

(H) ELECTRO MAGENTIC CHUCK................................................. P.52

(I) FOR AD3 AUTO DOWN FEED OPERATION............................. P.54

(J) MAINTENANCE ......................................................................... P.56

PSGS INSTRUCTION MANUAL P.11 OF 57

Fig. 1-1 Lifting

PSGS INSTRUCTION MANUAL P.12 OF 57

Fig. 1-2 Lifting

PSGS INSTRUCTION MANUAL P.13 OF 57

2.2 Foundation and Installation

PSGS INSTRUCTION MANUAL P.14 OF 57

PSGS INSTRUCTION MANUAL P.15 OF 57

3. Mounting the table

PSGS INSTRUCTION MANUAL P.16 OF 57

PSGS INSTRUCTION MANUAL P.17 OF 57

PSGS INSTRUCTION MANUAL P.18 OF 57

(B) STARTING UP THE MACHINE

Fig. 3 Table Dogs

PSGS INSTRUCTION MANUAL P.19 OF 57

LUBRICATION AND MAINTENANCE I