Precision Surface Grinder

PSG-DXB/ACC-DXB Series
PSG52DXB/PSG63DXB
ACC52DXB/ACC63DXB
ACC820DXB/ACC1224DXB

Machine Number
Date of Manufacture

February 2005, First Edition

i
Purpose of this manual
This manual intends to help you make full use of the capabilities of the machine, and to provide
information for safety of the machine and its periphery as well as maintenance. It is basically written for
those with general knowledge of machine tools and the related works, but some of the contents discuss
matters that require particular qualifications. Please understand these notices and handle the machine
properly.

Please understand the contents of this instruction manual before you transport, install,
relocate, maintain, operate, use, or otherwise handle this product. Especially, notices of
Danger, Warning and Caution for safety should be confirmed and referred to the
corresponding signs attached to the machine.

All or part of the product referred to in this manual may be subject to the export control
under the “Foreign Exchange and Foreign Trade Control Law.” In this case, you need to
obtain permission pursuant to the said law in order to bring out or export the product to
other countries.

Specifications and configurations of this machine are subject to change without notice for
product improvement or other reasons.

It is prohibited by law to copy or reprint all or any part of this manual without prior
consent.

ii
 Introduction
Thank you for introducing “PSG-DXB series,” our Saddle Type Precision Surface Grinder
(hereinafter called the “machine”).

Utilizing our unique LSI control and system software, this machine realizes fully automatic cycle
grinding as well as easy and free operation just like with conventional general-purpose
machines.

This instruction manual (hereinafter called the “manual”) provides precautions to be observed
for safe use of the machine, operating instructions, and the points of inspection to maintain its
performance. Using the machine without fully understanding the contents of this manual may
not only cause unexpected accidents but keep the machine from performing with its intrinsic
functionality and adversely affect the machine’s life and the resulting work quality. This
manual should be read not only by actual operators of the machine but also by every personnel
who works at its periphery to obtain general information of the machine and understand the
dangerous points and matters as well as workarounds for them.

The contents of this manual are based on the machine configured with the standard
specification, and some descriptions may be different from the particular specification of the
machine you have introduced. Should you have any question regarding specifications, any
request for inspection or maintenance, or need help, please contact one of the sales offices or
information desks listed at the end of this manual.

iii
Symbols used in this manual
Although this machine is designed with ultimate priority on the safety of operators, there remain
some risks inevitable in the nature of the machine. In this manual, the severity and
dangerousness of such risks are divided into 3 levels; Danger, Warning, and Caution, and
indicated with the symbols below. Please read the definition of the symbols carefully and
understand them before you perform operation or maintenance of the machine.

"DANGER” indicates there is such an emergent danger as may lead to death or acute
injury of persons during operation of the machine.

"WARNING” indicates there is such a risk as may lead to death or acute injury of
persons during operation of the machine.

"CAUTION” indicates there is such a risk as may lead to light injury of persons during
operation of the machine.

The following symbols are also used in this manual.

Item with this symbol describes a “prohibited act” that must not be performed during
operation or maintenance of the machine.

Item with this symbol describes an “enforced act” that must be performed during
operation or maintenance of the machine, or an “important matter” that must be known.

 Item with this symbol includes information useful for operation or maintenance of the
machine.

 This symbol refers to the pages with related information.

iv
 For your safe use
This chapter provides instructions that should be followed for safe use of the machine. This
machine has many units and components that could present a danger to human body or cause
damages to the machine or materials if handled improperly, such as movable part, feeding part,
and the unit to install grinding wheels. Therefore, not only the actual operator of the machine
but all the persons who work around it including those for maintenance should carefully read
the warning signs attached to the machine and the contents in this chapter to understand the
dangerous components, dangerous acts, and instructions to follow before using the machine.

1 Before using the machine

To ensure your safety, please follow the instructions below strictly.

・ Be sure to read this manual before using the machine. Operating, maintaining, or
otherwise handling the machine without fully understanding the contents herein
may cause serious accidents.

・ Observe the warnings and cautions on the signs attached to the main unit of the
machine as well as those in this manual.

・ When you need to adjust any movable part, be sure to stop the movable units before
adjustment.

・ Do not touch or weight on the movable parts.

・ Do not modify the grinding wheel guard and/or operate the machine without the
grinding wheel guard.

・ Replacement of the grinding wheel and test run after that should be implemented by
personnel(s) who have completed the special education established by Article 59.3
。
of the Industrial Safety and Health Law。

・ Do not modify the grinding wheel guard and/or operate the machine without the
grinding wheel guard.

・ Never touch the grinding wheel until it stops completely.

・ Never use inappropriate grinding wheels that do not comply with the wheel guard
specification

When you use a magnet chuck, please follow the instructions below strictly.

・ When you rotate the the grinding wheel or move the table, make sure the magnet
chuck is ON (vacuum-locked) and the work is fixed.

・ Do not place a work near the ends of the magnet chuck as there is not sufficient
magnetic force.

Instruction Manual
OKAMOTO MACHINE TOOL WORKS, LTD.
2 Scope of warranties and responsibilities
Please understand the following regarding the warranties and responsibilities for the use of this
machine.

2.1 Limitations of warranty

Damages and troubles are not covered by the warranties if:

1) they arose in accidents caused by Act of God.

2) any alternation was made to the machine without our consent.

3) the machine was operated or used improperly without compliance with the instructions
provided in this manual

4) the machine was used without providing safety education to all the personnel to be involved
with the machine.

5) the failure was caused by using any other oil than the ones recommended.

Please note you shall bear all the costs for consumables as well as those for spare parts, labor
and transportation needed to maintain the machine after the warranty period expires.

2.2 Damages and Responsibilities

1) This machine should be installed, used and its components should be disposed in a way
compliant with all applicable laws of the country or local government.

2) Please read the instruction manual delivered by us before using this machine, and strictly
observe the signs of danger, warning and caution.

3) We shall not be liable for damages caused by improper operation or maintenance of the
machine.

4) We shall not be liable for damages caused by any modification or change made by any party
other than us to the documentations for this machine such as instruction manuals.

5) We shall not be liable for damages caused by defects of equipments or parts, even if such
equipments or parts were procured from the party specified by us.

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3 Warning Signs
A warning sign means a plate expressly warning about the dangerous points of the machine’s
main unit or its periphery. This chapter shows what individual plates indicate and where on
the machine they are placed, which should be understood by not only the actual operators of
the machine but by all personnel to work around the machine.

Never remove the warning signs.

Also, you must not change the position of the signs. If a sign comes off or
deteriorates and needs to be reattached, it should be stuck to the same position as it
was.

3.1 Types of warning signs

(1) Signs related to grinding wheel rotation

・To prevent serious bodily injury.

・Wear eye (or face) protection shield during dressing work.
・Do not remove this sign from the machine.

・To prevent serious bodily injury.

・Do not touch the grinding wheel when it is rotating.
・Do not remove this sign from the machine.

・Wheels may break and fly into pieces.

・The broken pieces may hit you and cause severe injury.
・Use the safety cover and protective eyewear properly.
・Do not remove this sign from the machine.

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(2) Signs for danger during operations

・To prevent serious bodily injury.

・Close the door when the machine is running in automatic cycle.
・Do not remove this sign from the machine.

・To prevent serious bodily injury.

・Do not touch the machine(or any movable parts).
・When the machine is running.
・Do not remove this sign from the machine.

・To prevent serious bodily injury.

・Do not enter the machine working area when the machine is running.
・Do not remove this sign from the machine.

(3) Signs for general information / danger before operation

・Please read the manual carefully before operating the machine.

・Do not remove this sign from the machine.

(4) Signs related to the Feeding part

・There is a danger of electric shock.

・Severe injury is possible.
・When the power is on, do not:
- remove the cover or the connector.
- work with wet hands.
・Be sure to cut the power before working on the electrical system.
・Do not remove this sign from the machine.

The symbol on the left is also attached to the feeding part.

It warns that the failure in safety confirmation or improper handling may
result in electrical shock, burn injury or death.

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3.2 Positions of the warning signs
The positions of the warning signs on the machine are illustrated as follows:

Fig. S-1Positions of the warning signs (front view of the main unit)

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 Kommentar:
Fig. S-2 Positions of the warning signs (side view of the main unit)

Fig. S-3 Positions of the warning signs (top view of the main unit)

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4 Emergency Stop switch
This machine has an [EMERGENCY STOP] switch to bring the machine to a halt particularly in
the event of an urgent danger.

4.1 Position of the Emergency Stop switch

The [EMERGENCY STOP] switch is the red mushroom-shaped switch on the operation panel.
Press this switch in the event of a hazardous condition to human body or the machine.

Emergency Stop switch

Operation panel
Fig. S-4 Position of the Emergency Stop switch

4.2 Release of the emergency stop state

To recover from the emergency stop state, follow the procedures below.

- Before recoverying the machine from the emergency stop state, make sure there is
。
no personnel working on the machine.。
- Make sure there is no tools or objects inside the machine and everything is ready to
start operating normally as soon as the power distribution is resumed. Failure to
confirm this can cause broken pieces to hit someone and result in severe physical
damage.
- Machine recovery from the emergency stop state should be performed only by those
who have completed appropriate education. Users should create their own safe
work procedure for recovery from the emergency stop state and provide thorough
instruction to all those who work on and around the machine.

1) Make sure the cause of the problem has been resolved.

2) Turn the [EMERGENCY STOP] switch to the right and reset it to the original state.

3) Press the [HYD. PUMP] switch on the operation panel to start the hydraulic pump.
This switch also works to prepare the machine for operation.
If the main breaker has been turned off after the emergency stop, perform necessary
operations according to the normal start-up procedure.

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 To learn how to start the machine, see
Chapter 3.2.1 “Starting the
Machine.”CONTENTS
Introduction...............................................................................................................................iii
Symbols used in this manual................................................................................................... iv

For your safe use .............................................................................. v

1 Before using the machine............................................................................................ v
2 Scope of warranties and responsibilities ....................................................................vii
2.1 Limitations of warranty...........................................................................................vii
2.2 Damages and Responsibilities ..............................................................................vii
3 Warning Signs ...........................................................................................................viii
3.1 Types of warning signs .........................................................................................viii
3.2 Positions of the warning signs................................................................................ x
4 Emergency Stop switch ..............................................................................................xii
4.1 Position of the Emergency Stop switch .................................................................xii
4.2 Release of the emergency stop state....................................................................xii

Chapter 1 Overview
1.1 Overview...................................................................................................................1-2
1.2 Name of Each Component .......................................................................................1-3
1.3 Machine Specifications .............................................................................................1-5
1.4 Accessories ..............................................................................................................1-7
1.4.1 Standard Accessories and Devices .....................................................................1-7
1.5 External Views and Machining Range......................................................................1-8
1.5.1 External views .....................................................................................................1-8
1.5.2 Machining range drawing ....................................................................................1-9

Chapter 2 Transportation & Installation

2.1 Work Flow of Transporation and Installation ............................................................2-2
2.2 Transportation Approach ..........................................................................................2-3
2.3 Installatin Procedure.................................................................................................2-5
2.4 Levelness Adjustment...............................................................................................2-7
2.5 Power Wiring ............................................................................................................2-8
2.6 Lubrication ................................................................................................................2-9

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Chapter 3 Operation
3.1 Functions of Operating Unit ..................................................................................... 3-2
3.1.1 Table Longitudinal Feed Handle ......................................................................... 3-3
3.1.2 Table Cross Feed Handle.................................................................................... 3-4
3.1.3 Upper section of the operation panel .................................................................. 3-5
3.1.4 Lower section of the operation panel ................................................................ 3-13
3.2 Automatic Cycle Grinding....................................................................................... 3-15
3.2.1 Types of automatic cycle grinding..................................................................... 3-15
3.2.2 Setting and starting the traverse grinding ......................................................... 3-16
3.2.3 Setting and starting the plunge grinding ........................................................... 3-25
3.3 Teaching ................................................................................................................. 3-32
3.3.1 Setting for table front/back reverse position teaching....................................... 3-32
3.4 Test Run ................................................................................................................. 3-33
3.4.1 Preparation for starting...................................................................................... 3-34
3.4.2 Test run procedures .......................................................................................... 3-35

Chapter 4 Maintenance
4.1 Maintenance Items ................................................................................................... 4-2
4.1.1 General Maintenance.......................................................................................... 4-2
4.1.2 Daily Checkup Items ........................................................................................... 4-2
4.1.3 Periodic Checkup Items ...................................................................................... 4-3
4.2 Consumables List..................................................................................................... 4-4
4.3 Replacing and Adjusting the Wheel ......................................................................... 4-5
4.3.1 Selection of the Wheel ........................................................................................ 4-5
4.3.2 Maximum Wheel Surface Speed......................................................................... 4-5
4.3.3 Wheel Cover Specification .................................................................................. 4-6
4.3.4 Installation of the Wheel Flange.......................................................................... 4-6
4.3.5 Installing Wheel Flange to Wheel Spindle........................................................... 4-7
4.3.6 Removing the Wheel Flange from the Wheel Spindle ........................................ 4-8
4.3.7 Test Run After Installing the Wheel ................................................................... 4-10
4.3.8 Dressing ............................................................................................................ 4-11
4.3.9 Balancing the Grinding Wheel .......................................................................... 4-13
4.4 Hydraulic Pressure and Lubrication ....................................................................... 4-15
4.4.1 Oil Supply .......................................................................................................... 4-15
4.4.2 Checkup and Adjustment of Hydraulic Pressure............................................... 4-15
4.4.3 Exchanging the oil............................................................................................. 4-16
4.4.4 Cleaning the lubrication orifice.......................................................................... 4-16
4.4.5 Adjustment of Table Reverse Shock ................................................................. 4-17

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Chapter 5 Troubleshooting
5.1 Trouble Check List....................................................................................................5-2
5.1.1 Check List............................................................................................................5-2
5.2 Grinding Troublesshootings......................................................................................5-5
5.2.1 Causes and measures for roughness, chatter marks and patterns ....................5-5
5.2.2 Causes and measures for grinding burn and grinding crack ..............................5-6
5.2.3 Causes and measures for wheel clogging ..........................................................5-6
5.2.4 Causes and measures for wheel chipping-off .....................................................5-6
5.2.5 Causes and measures for wheel cracking ..........................................................5-7

Chapter 6 Operations of special accessories

6.1 Operations of special accessories............................................................................6-2
6.1.1 Automatic retraction ............................................................................................6-2
6.1.2 Manual retraction.................................................................................................6-3
6.1.3 Wheel spindle variable speed controller .............................................................6-4
6.1.4 Hydraulic overhead dresser ................................................................................6-5
6.1.5 Dress interval device (overhead dresser) .........................................................6-12

Attachments
1 External Views ..........................................................................................Attachment-2
2 Machining Range Drawing .......................................................................Attachment-6
3 Wheel Flange Drawing .............................................................................Attachment-8
4 Wheel Flange Washer Drawing..............................................................Attachment-10
5 Balance Arbor Drawing...........................................................................Attachment-11
6 Balance Piece Drawing ..........................................................................Attachment-13
7 Piece Holder Drawing.............................................................................Attachment-15
8 Wheel Flange Nut Drawing.....................................................................Attachment-16
9 Diamond Tool External Views .................................................................Attachment-17
10 Hydraulic Circuit Diagram.......................................................................Attachment-18
11 Lubrication Distribution Diagram ............................................................Attachment-19
12 Wheel Selection Criteria List for Common Metals..................................Attachment-20

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Chapter 1 Overview
This Chapter provides the outline of the machine, such as the configuration and name
and function of each component, and also discusses its specifications.

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5 Overview
This machine is designed to automatically grind with high precision and efficiency various
products from small precision parts and large components to molds such as metal stamping.
Its features include:

1) The dual-structured wide column is inherited from the DX series, enabling heavy grinding.

2) Wide frame and saddle minimize the table overhang.

3) Our unique LSI control and system software have realized fully automatic cycle grinding as well
as easy operation providing the same feel as with traditional general-purpose machines.

4) Push buttons and handles are assembled together on the operation panel to ensure easy
operation. Furthermore, the machine is equipped with the interlocking system, alarm display
functions, etc. to ensure safety.

5) Each slip guide surface is lubricated automatically. Also, roller bearings such as wheel
spindle bearing are provided with permanent grease, saving maintenance troubles.

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6 Name of Each Component
Components of the machine are shown below with their names.
For details of the operation panel, see Chapter 3 “Operation.”

6
5
7
4
8
3

9
2

Fig. 1-1 Front view of the machine

10

9
11

12

13

Fig. 1-2 Side view of the machine

1. Front cover 8. Table

2. Saddle cross feed handle 9. Operation panel
3. Table longitudinal feed handle 10. Wheel spindle
4. Table reverse dock 11. Column
5. Grinding wheel cover 12. Wheel spindle motor
6. Lubricant check window 13. Control panel
7. Injection cock

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 15

10

13

14

Fig. 1-3 Layout drawing (Plan view)

8. Table
10. Grinding wheel head
13. Control panel
14. Magnetic chuck
15. Hydraulic pump motor

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7 Machine Specifications
Specifications of the machine are listed as follows:

Table 1-1 PSG52DXB/ACC52DXB/ACC820DXB Machine Specifications

Values
Specification Item
PSG52DXB/ACC52DXB ACC820DXB
Table installation area (Length x Width) 550×200 mm 21.7×7.9″
Table maximum travel 650×230 mm 25.6×9.1″
Table top surface (φ205mm/8″) to wheel
bottom 47.5～397.5 mm 1.9×15.6″
Capacity
Size of standard chuck to install 500×200×70 mm 19.7×7.9×2.8″
Maximum weight of work (including chuck
200 kg 440 lbs
weight of 50 kg/110 lbs)
Width and number of T-grooves 17 mm×1 0.7″×1
Longitudinal feed speed (Ave) 300 - 25000 mm/min 11.8 - 984.3 in/min
Table
Feed per rotation of longitudinal feed
47 mm 1.9″
handle
Feed per handle rotation 0.1/1.0/5.0 mm 0.01/0.1/0.5″
(×1/×10/×50)
Manual feed
Saddle Feed per dial scale 0.001/0.01/0.05 mm 0.0001/0.001/0.005″
division (×1/×10/×50)
Intermittent feed 0.5 - 12.0 mm 0.02 - 0.47″
Automatic feed
Continuous feed 0 - 1000 mm/min 0 - 39.4 in/min
Rough 0.001 - 0.03 mm 0.00005 - 0.0015″
Automatic infeed grinding (12 levels) (12 levels)
(traverse and plunge cut) Fine 0.0001 - 0.01 mm 0.00005 - 0.0005″
grinding (11 levels) (11 levels)
Feed per handle rotation 0.01/0.1/1.0 mm -
(×0.1/×1/×10)
Grinding wheel Feed per handle rotation
head - 0.001/0.01/0.05″
(×0.1/×1/×5)
Manual infeed
Feed per dial scale
division (×0.1/×1/×10) 0.0001/0.001/0.01 mm -

Feed per dial scale - 0.00001/0.0001/0.0005″

division (×0.1/×1/×5)
Number of spark-outs 0 - 5 times 0 - 5 times
Vertical rapid feed speed 600 mm/min 23.6 in/min
Wheel size (outer diameter x thickness x hole φ205×19×φ50.8 mm φ8.1×0.7×φ2.0″
Grinding wheel diameter) 50Hz 3000 min－１ 3000 min－１
Number of revolutions
60Hz 3600 min－１ 3600 min－１
For grinding wheel spindle A.C 1.5 kW 2P A.C 2 HP 2P
For vertical feed /infeed 0.4 kW (A.C. servomotor)) 0.5 HP (A.C. servomotor)
Motors
For cross feed 0.75 kW(A.C. servomotor) 1 HP ((A.C. servomotor)
For hydraulic pump A.C 0.75 kW A.C 1 HP
50Hz 3-phase 200V±10% 3-phase 200V±10%
Main power
Power supply 60Hz 3-phase 220V±10% 3-phase 220V±10%
Power requirement 6 kVA 5 kVA
Weight Main unit Approx. 2200 kg Approx. 4840 lbs
Installation space Width x Depth x Height 2507×1774×1845 mm 98.7×69.8×72.6″

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 Table 1-2 PSG63DXB/ACC63DXB/ACC1224DXB Machine Specifications
Values
Specification Item
PSG63DXB/ACC63DXB ACC1224DXB
Table installation area (Length x Width) 605×300 mm 23.8×11.8″
Table maximum travel 750×340 mm 29.5×13.4 ″
335mm/13.2″ wheel
Table top surface for 50Hz 22.5 - 322.5 mm 0.9 - 12.7″
(φ205mm/8″) to
Capacity 305mm/12.0″ wheel
wheel bottom
for 60Hz 47.5 - 347.5 mm 1.9 - 13.7″
Size of standard chuck to install 600×300×80 mm 23.6×11.8×3.1″
Maximum weight of work (including chuck 420 kg 924 lbs
weight of 100 kg /.221 lbs
Width and number of T-grooves 17 mm×3 0.7″×3
Longitudinal feed speed (Ave) 300 - 25000 mm/min 11.8 – 984.3 in/min
Table
Feed per rotation of longitudinal feed
47 mm 1.9″
handle
Feed per handle rotation
0.1/1.0/5.0 mm 0.01/0.1/0.5″
(×1/×10/×50)
Manual feed
Feed per dial scale
Saddle division (×1/×10/×50) 0.001/0.01/0.05 mm 0.0001/0.001/0.005″
Intermittent feed 0.5 - 20.0 mm 0.02 - 0.79″
Automatic feed
Continuous feed 0 - 1000 mm/min 0 - 39.4 in/min
Rough 0.001 - 0.03 mm 0.00005 - 0.0015″
grinding (12 levels) (12 levels)
Automatic infeed
(traverse and plunge cut)
Fine 0.0001 - 0.01 mm 0.00005 - 0.0005″
grinding (11 levels) (11 levels)
Feed per handle rotation 0.01/0.1/1.0 mm -
Grinding wheel (×0.1/×1/×10)
head Feed per handle rotation - 0.001/0.01/0.05″
(×0.1/×1/×5)
Manual infeed Feed per dial scale
division (×0.1/×1/×10) 0.0001/0.001/0.01 mm -
Feed per dial scale - 0.00001/0.0001/0.0005″
division (×0.1/×1/×5)
Number of spark-outs 0 - 5 times 0 - 5 times
Vertical rapid feed speed 600 mm/min 23.6 in/min
Wheel size (outer diameter x 50Hz φ355×38×φ127 mm φ14×1.5×φ5.0″
thickness x hole diameter) 60Hz φ305×38×φ127 mm φ12×1.5×φ5.0″
Grinding wheel
50Hz 1500 min－１ 1500 min－１
Number of revolutions
60Hz 1800 min－１ 1800 min－１
For grinding wheel spindle A.C 3.7 kW 4P A.C 4.8 HP 4P
For vertical feed /infeed 0.4 kW (A.C. servomotor) 0.5 HP (A.C. servomotor)
Motors
For cross feed 0.75 kW(A.C. servomotor) 1 HP (A.C. servomotor)
For hydraulic pump A.C 1.5 kW A.C 2 HP
50Hz 3-phase 200V±10% 3-phase 200V±10%
Main power
Power supply 50Hz 3-phase 220V±10% 3-phase 220V±10%
Power requirement 10 kVA 10 kVA
Weight Main unit Approx. 2900 kg Approx. 6380 lbs
Installation space Width x Depth x Height 2827×1987×1845 mm 111.3×78.2×72.6″

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8 Accessories
The following accessories are provided with the machine.

8.1 Standard Accessories and Devices

(1) Grinding wheel (Sample) ············································································1 pce.

(2) Grinding wheel flange·················································································1 set

(3) Necessary work tools ·················································································1 set

(4) Splashguard cover······················································································1 set

(5) Magnetic chuck···························································································1 set

(6) Wheel dresser (Table dresser with a diamond tool1/2ct）·························1 set

(7) Jack bolts ··································································································1 set

(8) Sole plate ································································································1 set

(9) Clamps for transportation ···········································································1 set

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9 External Views and Machining Range

9.1 External views

Fig. 1-4 Front view

L
Fig. 1-5 Side view

W L H

PSG52DXB/ACC52DXB/ACC820DXB 2507 mm (98.7″) 1774 mm (69.8″) 1845 mm (72.6″)

PSG63DXB/ACC63DXB/ACC1224DXB 2827 mm (111.3″) 1929 mm (75.9″) 1845 mm (72.6″)

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9.2 Machining range drawing

PSG52DXB/ACC52DXB/ACC820DXB

PSG63DXB/ACC63DXB/ACC1224DXB

Fig. 1-6 Machining range drawing

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Chapter 2 Transportation & Installation
This chapter explains the necessary works from the time of machine introduction before
commencement of operation (foundation work, transportation, installation and
adjustment after installation).

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10 Work Flow of Transporation and Installation
The following are the necessary steps to install and start operating the machine.

1. Transportation  2.2 Transportation Approach

2. Installation  2.3 Installation Procedure

3. Levelness Adjustment  2.4 Levelness Adjustment

4. Power Wiring  2.5 Power Wiring

5. Lubrication  2.6 Lubrication

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11 Transportation Approach
The machine should be transported with care in the following procedure.

(1) Packing
This machine should be shipped with the table, saddle and grinding wheel head fixed so that they do
not move during transportation. Lifting this machine will require tools such as steel hanging bars,
wire ropes and chain blocks (none of which will be provided as standard accessories).

Assembly is to be performed by us or our designated personnel. Please refrain from

unpacking the shipment without our direction until the personnel checks the arrival
condition of all the packages.

(2) Lifting procedure

For transportation of the machine, use a crane and lift the load in the following manner.

- Use a crane with sufficient withstand load.

- Treat the load with enough care not to cause a shock to the machine.
- To prevent making scratches, place cushioning materials such as cotton bedding or
wood chips between the ropes and the machine.

1) Remove the front cover and run steel bars through the two holes in the right and left of the frame.
2) Run a steel bar through the hole in the rear part of the frame side.
3) Entwine the steel bars with wire ropes, and place cushioning materials such as cotton bedding
or wood chips between the ropes and the machine.

Wire rope

Steel bar
Steel bar Φ50 (2.0″)
L=1500 (59.1″)
Φ50 (2.0″)
L=1500 (59.1″)

Fig. 2-1 Lifting procedure

- 22 -
4) When using a folk lift, palletize the machine before transporting it.

5) Set the front cover after setting the machine in place.

6) Open the door of the control panel and unscrew the bolts at the bottom. Lift the control panel
and remove the control panel stay from the main unit.

Bolts

7) Set the provided plastic covers to the lifting holes of the main unit to prevent the entrance of
dust into the machine.

- 23 -
12 Installatin Procedure
Follow the procedure below to install the machine.

1) This machine should be installed on a concrete base of 400mm (15.7″) in thickness, away from
vibration, abnormal moisture, heat and direct sunlight.
Especially at vibrational locations and reclaimed areas, vibration absorption measures should
be taken in the foundation work.

2) To check the foundation condition, place a bed at the installation site, set a level (with scale
division of about 0.02mm (0.0008″) per meter (39.4″)) on it, arrange people equivalent in
weight to the table and work, and have them move as you observe the variation on the scale.
If the variation is as small as a single scale division, the condition is presumed to be good.

Fig. 2-2 Levelness position

3) Determine the installation area with reference to the installation diagram, locate the sole plate
to fit the position of jack bolts of the main unit, and place the main unit on the sole plate.

4) Remove the electric box.

5) Make adjustment so that the gap between the floor and the bottom surface of the machine
becomes approximately 30-50mm (1.2 – 2.0″), roughly making it level.

6) Remove the vertical feed motor at the rear part of the machine and install the provided crank
handle.

Vertical feed motor Crank handle

- 24 -
7) Turn the handle counterclockwise about 10 times, raise the wheel head and remove the
protection pad. After removing the protection pad, remove the handle and reinstall the motor.

Protection pad

Clamp plates

Saddle clamp lever

8) Remove the right and left clamp plates at the front part of the table. As the removed clamp
plates will be necessary when transporting or relocating the machine, keep them in the tool box
or other place.

9) You can release the saddle clamp by turning its lever clockwise. The saddle clamp is also
used for plunge grinding and flute grinding.

10) Loose the 4 clamp bolts at the lower part of the operation box and adjust the direction of the
box so that the operator can handle it easily. Retighten the clamp bolts after adjustment.

11) Clean off the dirt, rust preventive oil and other oil contents on the machine.
If motes or dusts adhere to the slip surface during operation, rinse them away with the lubricant
used in this machine.

- Do not use flammable oil such as thinner.

- Do not scale off objects using tools like a scraper.

- 25 -
13 Levelness Adjustment
1) Place a precision level (with scale division of 0.02mm (0.0008″) per meter (39.4″)) on the
machine table and make adjustment with 5 jack bolts so that both longitudinal and lateral
inclinations stay within a single scale division (0.02mm (0.0008″) per meter (39.4″)).

Within a single scale division (0.02mm (0.0008″/1m (39.4″))

2) Tighten the lock nut when the levelness adjustment is completed.

3) Recheck the levelness with the level.

- Check and adjust the levelness on a weekly basis during the initial phases after
installation. When it becomes stable, recheck and adjust it on a monthly basis.

- 26 -
14 Power Wiring
Upon completion of the main unit installation, electric wiring and piping, arrange power wiring.

1) Connect the power wires to the primary terminals (L1, L2 and L3) of the breaker in the control
box through the hole. The ground wire should also be connected. (Ground terminal is E.)

Before turning on the breaker of the machine, make sure that the power is connected
correctly to the primary terminals using the “phase rotation indicator.”

2) After the wiring is completed, turn on the power switch to see the “Power” pilot lamp on the
operation panel light up.

3) If the rotation direction is opposite, exchange between two of the three wires connected to the
primary terminals (L1, L2 and L3) of the breaker (i.e. exchange between L1 and L3).

4) If the power indicator lamp does not light up or the motors do not start up, check out the fuse in
the control box and the reset lever of the overload relay.

- 27 -
15 Lubrication
Lubricate the machine with the oils prescribed below.

(1) Recommended oils

Please use the following oils for lubrication.
- Shell Tonna Oil S32 (Showa Shell Sekiyu)
- LUBWAY #150 (Sun Oil)
- GRIND-X hydraulic fluid NS-01A (Okamoto Machine Tool Works, Ltd)
- VACUOLINE １４０５ (MOBIL)
The oil quantity to be lubricated is 80L (21.1 gallons) with PS52DXB/ACC820DXB and 120L
(31.7 gallons) with PSG63DXB/ACC1224DXB.

(2) Lubrication procedure

1) Remove the filler cover at the rear part of the main unit.

2) Check the oil level through the oil window at the lower left part of the frame.

3) Start operating the machine to see the oil level viewable through the window drop as the oil is
fed to each part of the machine.

4) Check to see that the oil level rises up to the indicated line of the window at the upper part of
the column.

Recheck the oil level through the window in 10 minutes after stopping the machine, and supply
additional oil up to the proper level.

Failures resulting from the use of not recommended oils are not covered by the
warranty. Please be sure to use the recommended oils listed above.

(3) Lubricant Adjustment

1) In this machine, longitudinal, cross and vertical slip surfaces, vertical feed drive gears and
vertical feed screws are automatically lubricated by dropping oil from the oil cups at the top of
the column.

2) Wheel spindle bearing has grease hermetically included, and does not require lubrication.
Grease is applied to or hermetically closed in the cross feed screws, table racks and their
bearings at the time of assembly, saving troubles for lubrication

- 28 -
Chapter 3 Operation
This chapter explains actual operations of the machine.

- 29 -
16 Functions of Operating Unit
Basic functions of the operation panel are explained in this section.
Refer to the corresponding explanation pages to learn about each part of the panel.

25 27 29 30
1 2
3 33

7 26 28 30 32
5 35

6 38 39
34
8 9 10 11 12 13

37
14 15 16 17 18 19
36

20 21 22 23 24

41 44

40
42

43 45

Fig. 3-1 Operation Panel

surrounds the special accessories which are not equipped with the standard
specification machine. Names and layouts of the switches, buttons, meters, lighs and
other parts illustrated in this and the subsequent figures may be different from those of the
machine actually installed, depending on the delivered specification types, additional
devices, specification changes and other reasons including the state of technological
development.

- 30 -
16.1 Table Longitudinal Feed Handle

Table longitudinal feed handle

Fig. 3-2 Table longitudinal feed handle

Push and turn the handle, and release your hand to put it out of gear.
Feed the table to the right and left manually. Turn the handle clockwise to feed the table
rightwards and counterclockwise to feed it leftwards.

- 31 -
16.2 Table Cross Feed Handle

Dresser speed control knob (Option) Manual pulse feed speed selector
switch

Table cross feed handle

Fig. 3-3 Table cross feed handle

1) Table cross feed handle

This handle allows you to manually feed the table forward and backward. Turning the handle
counterclockwise feeds the table forward and turning it clockwise feeds it backward.

2) Dresser speed control knob

Dressing speed is controlled by the rotation amount of this knob.

3) Manual pulse feed speed selector switch

Select the axis to feed with the manual pulse handle as well as the feed amount per scale
division.
［x 1］ Feed amount is 0.001mm (0.0001″) per scale division and 0.1mm
(0.01″) per rotation.
［x 10］ Feed amount is 0.01mm (0.001″) per scale division and 1mm (0.1″)
per rotation.
［x 50］ Feed amount is 0.05mm (0.005″) per scale division and 5mm
(0.5″) per rotation.

Names and layouts of the switches, buttons, meters, lighs and other parts illustrated in this and
the subsequent figures may be different from those of the machine actually installed,
depending on the delivered specification types, additional devices, specification changes
and other reasons including the state of technological development.

- 32 -
 16.3 Upper section of the operation panel
You can control the position of the table and the wheel in the upper section of the operation
panel.

1 2

7 6

No Name Function
Vertical - The display is reset to 0 when the machine is powered on and when the RST key (3) is
position pressed.
display - Current position of the Y axis is shown here.
1
- The display shows [IOC**] in DGN (self-diagnostic) mode. The input/output status is
shown in (2). [**] indicates address number.
[Error] is shown when an alarm is activated.
Lateral - This display is not active and shows nothing normally.
position - In the self-diagnostic mode, the input/output status of IOC is shown with 8 digits of 1 and 0.
display (e.g. “1” indicates “ON” as input status while it indicates “Start” as output status, and “0”
indicates “OFF” or “Stop”.)
2
- Alarm number is displayed here when an alarm is activated.
- When installing a lateral scale (option), current lateral position is displayed here.
- In that case, the display is reset to 0 when the machine is powered on and when the RST
key (4) is pressed.
Reset (RST) - The vertical position display is reset to 0 with this key.
3 key - When an alarm is activated, you can reset it here.
- In IOC mode, the address number can be reset to 0 here.
Reset (RST) - You can reset the lateral position display to 0 with this key.
4
key
Data setting - When setting the grinding allowance, you can input data of the total grinding allowance for Y
keys axis in the setting mode.
5
- The number is incremented each time the setting key is pressed, repeating the sequence of
0 to 9 in each digit.
DGN - In DGN (self-diagnostic) mode, the display (1) shows [IOC**].
6 (self-diagnostic - When setting the address number, the number is incremented each time the setting key is
) key pressed, repeating the sequence of 0 to 9 in each digit.
Power - This indicator lights up when the main power is turned on.
7
indicator light

- 33 -
 8 9 10

Front/back reverse teaching

No Name Function
Back limit - Specify the back limit reverse position for front/back reverse. (This key does not function
reverse alone.)
8
positioning
key
Front/back - Press this key while pressing a reverse positioning key (8) or (10) to fix each reverse
reverse position.
9
position fix
key
Front limit - Specify the front limit reverse position for front/back reverse. (This key does not function
reverse alone.)
10
positioning
key

- 34 -
 11 12 13

Cross feed mode

No Name Function
Cross feed - The LED at the upper left corner of the key lights up and the cross feed manual handle
manual becomes active.
11
handle - The handle is active when the power is turned on.
select key - Cross rapid feed is disabled while this key is on.
Step feed - The LED at the upper left corner of the key lights up and the cross step feed becomes
12 key active.

Bias feed - The LED at the upper left corner of the key lights up and the cross continuous feed
13
key becomes active.

- 35 -
 14 15 16

Cross feed direction switching

No Name Function
Backward - The LED at the upper left corner of the key lights up, the table status becomes “feeding
key backward”, and the table travels to the back limit. (Reverse position is ignored.)
14
- THE table travels in the “table active” status (where the table cross feed speed control is
turned on and the key 34 or 35 is pressed).
Automatic - The LED at the upper left corner of the key lights up, and the table is automatically
feed key reversed at the preset teaching points in the table front/back reverse mode.
15
- The table travels in the “table active” status (where the table cross feed speed control is
turned on and the key 34 or 35 is pressed).
Forward - The LED at the upper left corner of the key lights up, the table status becomes “feeding
key forward”, and the table travels to the front limit. (Reverse position is ignored.)
16
- The table travels in the “table active” status (where the table cross feed speed control is
turned on and the key 34 or 35 is pressed).

- 36 -
 17 18 19

Cycle Selection

No Name Function
Plunge 1 - The table is automatically reversed within the longitudinal stroke and the cross feed is
key stopped.
17
- When the mode selector switch (20) is set to automatic sizing, the machine cuts the
specified amount of infeed (on the right side) each time the table reciprocates.
Plunge 2 - The table is automatically reversed within the longitudinal stroke and the cross feed is
key stopped.
18
- When the mode selector switch (20) is set to automatic sizing, the machine cuts the
specified amount of infeed (on both sides) each time the table is reversed.
Traverse - When the cross feed direction is set to automatic feed (15), the table is automatically
key reversed within the cross stroke.
19
- When the mode selector switch (20) is set to automatic sizing, the machine cuts the
specified amount of infeed each time the table is reversed.

- 37 -
 20 21 22 23 24

No Name Function
Mode - Rapid feed: The wheel ascends while the upward key (36) is pressed and descends while
selector the downward key (37) is pressed.
switch - 10 (5): The feed amount per scale division of the manual handle (40) is 0.01mm
(0.0005″).
- 1: The feed amount per scale division of the manual handle (40) is 0.001mm (0.0001″).
- 0.1: The feed amount per scale division of the manual handle (40) is 0.0001mm
20
(0.00001″).
- Automatic sizing grinding: The machine continues to grind the work until the preset
finished dimension is achieved, and stops automatically. The infeed method is specified
by the cycle selection (17), (18), or (19). The step infeed key (38) also becomes active.
- Grinding allowance setting: Data setting (5) and self-diagnostic function (6) become
available.
Rough - Set the infeed amount per cut for rough grinding in automatic infeed.
infeed - If the selected amount is [0], the infeed amount will be 0.
21
amount
switch
Fine - Set the infeed amount per cut for fine grinding in automatic infeed.
infeed - If the selected amount is [0], the infeed amount will be 0.
22
amount
switch
Fine - Set the amount to grind in fine grinding before the wheel reaches the specified position for
grinding the finished dimension (aggregate sum of the fine infeed amounts).
allowance - In automatic infeed, the machine performs “rough grinding” until it reaches the height of
switch the finished dimension + fine grinding allowance, then shifts automatically to “fine
23
grinding.”
- If the selected amount is 0, fine grinding is not performed and the machine continues to
grind the work until it reaches the specified position for the finished dimension at the
preset rough infeed amount.
Spark out - When the finished dimension is achieved, spark-out is performed as many times as
24 switch specified here.
- If the selected amount is [0], spark-out is not performed.

- 38 -
 25 27 29 31

26 28 30 32 33

No Name Function
Hydraulic - The LED at the upper left corner of the key lights up and the hydraulic pump is
25
pump on key activated, except during emergency stop.
Hydraulic - The hydraulic pump stops and the LED goes out.
26
pump off key
Wheel - The LED at the upper left corner of the key lights up and the grinding wheel spindle is
27 spindle start activated, except during emergency stop.
key
Wheel - The grinding wheel spindle stops and the LED goes out.
28 spindle stop
key
Coolant on - The LED at the upper left corner of the key lights up and the coolant injection pump is
29
key activated, except during emergency stop.
Coolant off - The coolant injection pump stops and the LED goes out.
30
key
Dust - The LED at the upper left corner of the key lights up and the dust collection system is
31 collection on activated, except during emergency stop.
key
Dust - The dust collection system stops and the LED goes out.
32 collection off
key
Emergency - Pressing this switch brings the machine to emergency stop state and locks the switch.
stop switch You can release the lock by turning the switch clockwise.
- When the switch is unlocked, the machine is in the open state and the motors can be
activated.
33
- When the switch is locked, the machine is in the emergency stop state and the
motors are stopped.
- If this switch is pressed while the vertical feed motor is traveling, the motor stops
traveling but the coordinates of the then-current vertical position are not guaranteed.

- 39 -
 36

34 35 39

37 38

No Name Function
Table feed - Pressing this key once switches the table feed direction to left. If the table is stopped at
left key the right limit, the key activates the table. If in a longitudinal stroke, the table performs
automatic reverse.
34
- Continuing to press this key brings the table to ““feeding leftward” status and forces the
table to travel leftward until it reaches the left limit. (Limit reverse setting is ignored.)

Table feed - Pressing this key once switches the table feed direction to right. If in a longitudinal
right key stroke, the table performs automatic reverse.
35
- Continuing to press this key brings the table to ““feeding rightward” status and forces the
table to travel rightward until it reaches the right limit. (Limit reverse setting is ignored.)

Rapid feed - The wheel continues to ascend while this key is pressed in the rapid feed mode, though it
36 upward stops at the upper limit.
key - When you release the key, the ascending motion slows down and stops.

Rapid feed
- The wheel continues to descend while this key is pressed in the rapid feed mode.
37 downward
- When you release the key, the descending motion slows down and stops.
key
Step - When you press this key in automatic sizing mode, the machine grinds the work until it
infeed key reaches the specified position for the finished dimension, at the infeed amount specified
with the [Rough infeed amount] switch (21) in rough grinding and at the infeed amount
38
specified with the [Fine infeed amount] switch (22) in fine grinding. (The machine stops
cutting infeed when the vertical position display shows it has reached the specified
position for the finished dimension.)
Table right - When this key is pressed, the LED at the upper left corner of the key flashes and the table
39 limit stop in automatic reverse mode travels to the right limit and stops. The LED goes out when
key the table stops.

- 40 -
 16.4 Lower section of the operation panel
You can control the vertical position of the wheel and switch on/off the chuck in the lower
section of the operation panel.

41 44

40
42

43 45

Fig. 3-4 Hydraulic operation panel

No Name Function
Vertical - 0.1: The feed amount per scale division of the handle is 0.0001mm (0.00001″), and the
feed handle position shown in display 1 changes as the wheel travels.
(manual (Turn to + side for ascending and to – side for descending.)
pulse) - 1: The feed amount per scale division of the handle is 0.001mm (0.0001″), and the
40 position shown in display 1 changes as the wheel travels.
(Turn to + side for ascending and to – side for descending.)
- 10: The feed amount per scale division of the handle is 0.01mm (0.0005″), and the
position shown in display 1 changes as the wheel travels.
(Turn to + side for ascending and to – side for descending.)
Magnetic - Turn this knob clockwise to increase the magnetic force (adsorptive power).
41 force control - Turn this knob counterclockwise to reduce the magnetic force (adsorptive power).
knob
Chuck - The indicator lights up when the chuck is excited and goes out when it is stopped. It
excitation flashes when the chuck is demagnetized.
42
indicator
light
Chuck - Turn this switch to the right to start exciting the chuck.
switch - The chuck is stopped when the switch is set to the center.
43
- Turn this switch to the left to start demagnetizing the chuck. (The switch automatically
returns to the center.)

- 41 -
No Name Function
Cross feed - You can control the cross feed speed of the table when setting the bias feed. Turn it
speed clockwise to increase the speed.
control - The table goes into the cross feed stop status when you fully turn the knob
knob counterclockwise and set it at the OFF position.
44
- You can control the cross step amount of the table when setting the step feed. Turn it
clockwise to increase the step amount.
- The table goes into the cross feed stop status when you fully turn the knob
counterclockwise and set it at the OFF position.
Table - You can control the longitudinal feed speed of the table here. Turn it clockwise to
longitudina increase the speed.
l feed - The table goes into the stop status when you fully turn the knob counterclockwise and set
45
speed it at the OFF position.
control
knob

Names and layouts of the switches, buttons, meters, lighs and other parts illustrated in this and
the subsequent figures may be different from those of the machine actually installed,
depending on the delivered specification types, additional devices, specification changes
and other reasons including the state of technological development.

- 42 -
17 Automatic Cycle Grinding
In automatic grinding cycle, the machine automatically performs the following operations until it
completes the preset total grinding allowance.

17.1 Types of automatic cycle grinding

In automatic grinding cycle, the machine automatically performs the following operations until it
completes the preset grinding allowance (or until it reaches the specified position for the
finished dimension).

- Rough grinding Rough grinding is performed in the early stage of the cycle. The
machine grinds the work in a short time, with bigger infeed amount set.
- Fine grinding The machine completes the work with high precision surfaces, with
smaller infeed amount set.
- Spark out Spark-out is performed automatically after grinding as many times as
specified.
- Retract Retract the wheel head after all the processes are completed.

(1) Automatic grinding cycle patterns

The following patterns of automatic grinding cycle can be set by combination of different infeed
positions and cross feed modes.

Cycle selection Cross feed

Grinding pattern
key mode

Plunge one side infeed

With this grinding pattern, the machine
17
cuts deeply at some sections without
[Plunge 1] -
cross-feeding the wheel.
Plunge grinding

The wheel spindle cuts in the work at

right limits of the table travel.

Plunge both sides infeed

With this grinding pattern, the machine 18
cuts deeply at some sections without
[Plunge 2] -
cross-feeding the wheel.
The wheel spindle cuts in the work each
time the table reciprocates.

Step feed
The machine cross-feeds the wheel
Traverse grinding

spindle at both limits of the table travel. Step mode

This pattern is appropriate for finishing a
work with a large grinding area. 19
[Traverse]
Bias feed
The machine continuously feeds the Bias mode
wheel spindle at a constant speed while
reciprocating the table.

- 43 -
17.2 Setting and starting the traverse grinding
In the traverse grinding, the machine grinds the entire surface of the work by combining
longitudinal and cross feed of the table. You can perform step grinding by cross-feeding the
table intermittently while bias grinding is available by cross-feeding it continuously.

(1) Setting the reverse positions

1) Press the [Hydraulic pump on] key.

2) Specify the right and left reverse positions of the table using the
knob at the front of the table.

Table reverse positioning knob

Fig. 3-5 Table reverse positioning knob

3) Switch the cycle selection to [Traverse].

Traverse

- 44 -
 4) Specify the front/back reverse positions of the table with the teaching keys.

(2) Setting the longitudinal and cross feed speeds (cross step amount).
1) If the hydraulic pump is off, press the [Hydraulic pump on] key.

2) Set the [Table longitudinal feed speed control] knob and [Table cross feed speed control] knob
at 0.

Table cross feed speed control

Table longitudinal feed speed control

knob
Fig. 3-6 Table feed speed control knobs

3) Turn the [table longitudinal feed speed control] knob slowly to start the table, and adjust the
feed speed for longitudinal direction.

4) Turn the [Table cross feed speed control] knob slowly to start the table, and adjust the feed
speed (or the step amount) for cross direction.

- 45 -
Table cross feed speed control knob
If the cross feed mode is set to [Bias feed], turning this
knob clockwise increases the cross feed speed.
If the cross feed mode is set to [Step feed], turning it
clockwise increases the cross feed amount per step.
Setting it at 0 stops the table.

- 46 -
(3) Setting the position for the finished dimension (total grinding allowance)
Set the amount to grind the work before the wheel reaches the preset finished dimension (total
grinding allowance) so that the machine automatically finishes grinding when the work
achieves the finished dimension.
As this machine regards the position where the [vertical position display] shows “0” as the
specified position for the finished dimension and finishes grinding automatically, the first
process you should perform is to grind the work until the wheel contacts the entire top surface
of the work. Then measure the total grinding allowance from there to the position for the
finished dimension, and set it on the [vertical position display].

Whee

Grinding starts Grinding based

Rough
grinding on the rough
Fine grinding starts here. infeed amount Total grinding
Fine grinding Fine grinding allowance
allowance
Specified position for the finished dimension
Work
Finished dimension

Chuck

1) Set the [Rough infeed amount] switch at an appropriate amount.

2) Also set the [Fine infeed amount] switch and [Fine grinding allowance] switch at appropriate
amounts upon necessity.

3) Place the work on the chuck and turn on the [Chuck] switch.

4) Descend the wheel and bring it closer to the work.

5) Press the [Table feed left] key to start the table.

Fig. 3-7 Table feed direction combination keys

- 47 -
6) Adjust the feed speed with the [Table longitudinal feed speed control] knob.

7) Adjust the cross feed speed (in bias feed mode) or cross step amount with the [Table cross
feed speed control] knob.

Table cross feed speed control knob

If the cross feed mode is set to [Bias feed], turning this
knob clockwise increases the cross feed speed.
If the cross feed mode is set to [Step feed], turning it
clockwise increases the cross feed amount per step.
Setting it at 0 stops the table.

- 48 -
8) Start the wheel spindle, bring the wheel closer to the work and start coolant injection.

Main
spindle
on

Injection amount can be controlled with the cock on the right of the wheel cover.

9) Lower the wheel spindle manually and grind the work until the wheel contacts the entire top
surface of the work.

10) Stop the table at the right limit.

T
a

11) Stop coolant injection and set the table feed speed at 0 to stop the table.

12) Measure the height of the work and calculate the “total grinding allowance” for the finished
dimension (to the specified position for the finished dimension).
Do not move the wheel spindle up and down while measuring the work.

Work Total grinding

allowance
Specified position for
the finished dimension Finished
dimension

Chuck

Total grinding allowance = Work thickness – Finished dimension

- 49 -
13) The next step is to set the total grinding allowance to the machine.

Shift the [Mode selector] switch to [Grinding allowance setting].

14) Press the [Vertical position display reset (RST)] key to show “0” on the [Vertical position
display], and enter the total grinding allowance value using the [data setting] keys.

Vertical position display

Vertical position display Vertical position display

reset (RST)] key

Lateral position display

Data setting keys

- 50 -
(4) Setting the grinding conditions and starting automatic grinding
Specify the conditions of rough grinding and fine grinding as well as the number of spark-outs
after grinding, and start automatic grinding.

1) Specify the [Rough infeed amount], [Fine grinding allowance], [Fine infeed amount] and [Spark
out].
In automatic grinding, the machine starts with rough grinding and later shifts to fine grinding at
the position higher than the specified position for the finished dimension by the amount of [fine
grinding allowance].

Whee

Rough Grinding based on

grinding the rough infeed
amount Fine grinding starts here.
Fine grinding Fine grinding
allowance
Specified position for the finished
Work dimension
Finished
dimension

Chuck

2) Set the [Rough infeed amount], [Fine grinding allowance], [Fine infeed amount] and [spark out]
with the respective switch.

3) Shift the [Mode selector] switch to [Automatic sizing].

- 51 -
4) Press the [Table feed right] key to start the table.

Fig. 3-8 Table feed direction combination keys

5) Adjust the feed speed with the [Table longitudinal feed speed control] knob.

6) After the above mentioned procedures, the machine starts automatic grinding, performs
spark-outs when grinding is finished, and stops the table at the right limit.

7) After stopping at the right limit, the table automatically travels to the front limit and stops.

- 52 -
17.3 Setting and starting the plunge grinding
In plunge grinding, the machine cuts deeply at some sections without cross-feeding the table.
There are two patterns of plunge grinding: “Plunge one side infeed” where the wheel spindle
cuts in the work at both limits of the table travel, and “Plunge both sides infeed” where the
wheel spindle cuts in the work each time the table reciprocates.

(1) Setting the reverse positions

1) Press the [Hydraulic pump on] key.

2) Specify the right and left reverse positions of the table using the knob at the front of the table.

Table reverse dock

Fig. 3-9 Table reverse dock

- 53 -
3) Switch the cycle selection to [Plunge].

Plunge 1 Plunge 2

4) Set the [Table longitudinal feed speed control] knob and [Table cross feed speed control] knob
at 0.

Table cross feed speed control knob

Table longitudinal feed speed control knob

Fig. 3-10 Table feed speed control knobs

As cross feed is not performed, set the table feed speed at 0.

- 54 -
(2) Setting the position for the finished dimension (total grinding allowance)
Set the amount to grind the work before the wheel reaches the preset finished dimension (total
grinding allowance) so that the machine automatically finishes grinding when the work
achieves the finished dimension.
As this machine regards the position where the [vertical position display] shows “0” as the
specified position for the finished dimension and finishes grinding automatically, the first
process you should perform is to grind the work until the wheel contacts the part to grind.
Then measure the total grinding allowance from there to the position for the finished dimension,
and set it on the [vertical position display].

Whee

Grinding starts here.

Rough Grinding based on
grinding the rough infeed Total grinding
Fine grinding starts amount allowance
Fine grinding Fine grinding
allowance
Specified position for the finished
Work Finished
dimension
dimension

Chuck

1) Set the [Rough infeed amount] switch at an appropriate amount.

2) Also set the [Fine infeed amount] switch and [Fine grinding allowance] switch at appropriate
amounts upon necessity.

3) Place the work on the chuck and turn on the [Chuck] switch.

4) Descend the wheel and bring it closer to the work.

5) Press the [Table feed left] key to start the table.

Fig. 3-11 Table feed direction combination keys

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6) Adjust the feed speed with the [Table longitudinal feed speed control] knob.

7) Start the wheel spindle, bring the wheel closer to the work and start coolant injection.

Main
spindle
on

Injection amount can be controlled with the cock on the right of the wheel cover.

8) Lower the wheel spindle manually and grind the work until the wheel contacts the work surface.

9) Stop the table at the right limit.

Table stop
at right limit

10) Stop coolant injection and set the table feed speed at 0 to stop the table.

11) Measure the height of the work and calculate the “total grinding allowance” for the finished
dimension (to the specified position for the finished dimension).
Do not move the wheel spindle up and down while measuring the work. Do not move the Z axis
either.

Work
Total
grinding
allowance
Specified position for
the finished dimension Finished
dimension

Chuck

Total grinding allowance = Work thickness – Finished dimension

- 56 -
12) The next step is to set the total grinding allowance to the machine.

Shift the [Mode selector] switch to [Grinding allowance setting].

13) Press the [Vertical position display reset (RST)] key to show “0” on the [Vertical position
display], and enter the total grinding allowance value using the [data setting] keys.

Vertical position display

Vertical position display Vertical position

display reset (RST)]
Lateral position display

Data setting keys

- 57 -
(3) Setting the grinding conditions and starting automatic grinding
Specify the conditions of rough grinding and fine grinding as well as the number of spark-outs
after grinding, and start automatic grinding.

1) Specify the [Rough infeed amount], [Fine grinding allowance], [Fine infeed amount] and [Spark
out].
In automatic grinding, the machine starts with rough grinding and later shifts to fine grinding at
the position higher than the specified position for the finished dimension by the amount of [fine
grinding allowance].

Whee

Rough Grinding based

grinding on the rough
Fine grinding starts here.
Fine grinding Fine grinding
allowance
Specified position for the finished dimension
Work Finished
dimension

Chuck

2) Set the [Rough infeed amount], [Fine grinding allowance], [Fine infeed amount] and [spark
out].with the respective switch.

3) ［Shift the [Mode selector] switch to [Automatic sizing].

Automatic sizing

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4) Press the [Table feed right] key to start the table.

Fig. 3-12 Table feed direction combination keys

5) Adjust the feed speed with the [Table feed speed control] knob.

6) After the above mentioned procedures, the machine starts automatic grinding, performs
spark-outs when grinding is finished, and stops the table at the right limit.

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18 Teaching

18.1 Setting for table front/back reverse position teaching

1) Move the saddle until the wheel reaches the front end of the work, and press the [Front/back
reverse position fix] key while pressing the [Front limit reverse positioning] key.

2) Confirm at this time that the LED of the [Front/back reverse position fix] key (9) lights up.

Front/back reverse position fix key Front limit reverse positioning key

3) Move the saddle until the wheel reaches the rear end of the work, and press the [Front/back
reverse position fix] key while pressing the [Back limit reverse positioning] key.

4) Confirm at this time that the LED of the [Front/back reverse position fix] key (9) lights up.

Back limit reverse positioning key Front/back reverse position fix key

5) Shift the cross feed direction switching to [Automatic feed].

Automatic feed

6) Turn the [Table cross feed speed control] knob to start cross feeding, and confirm that the table
reverses automatically at the set teaching points.

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19 Test Run
This section explains procedures from starting the machine to performing actual operations.

1. Check before starting  3.4.1 Preparation for starting

2. Test run procedures  3.4.2 Test run procedures

Machine operations

Operation completion

- 61 -
19.1 Preparation for starting
Check the following points before starting the machine.

1) The hydraulic tank has sufficient amount of oil.

2) The power is connected correctly.

3) The table clamps are removed and the saddle clamp is loosed.

4) There is no object on the table and the chuck.

5) The wheel is not installed to the wheel spindle.

6) The injection nozzle and the dust collection intake are properly set without interfering with the
chuck and other units.

7) The table longitudinal feed speed is set to 0.

8) The table cross feed speed is set to 0.

9) Mode selector switch is set to 0.1 or 1.

10) The LED of the [Cross feed manual handle select] key is lighted.

11) The LED of the [Coolant on] key is lighted.

12) The LED of the [Dust collection on] key is lighted.

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19.2 Test run procedures
1) Turn on the power of your site.

2) Turn on the power breaker switch on the control panel.

Power breaker

Fig. 3-13 Breaker switch

3) Make sure the power indicator light is on.

4) Turn on the [Wheel spindle start] key and check that the wheel is rotating clockwise.

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5) Press the [Hydraulic pump on] key.

6) Check to see that the oil level rises up to the indicated line of the window at the upper right part
of the column.

If the machine is used for the first time after installation or if it has been stoopped for
prolonged periods, wait for 3 to 5 munutes without starting the machine until the oil
level rises up in the window.

7) Make sure the LED of the [Cross feed manual handle select] key is lighted.

8) Make sure the LED of the [Table right limit stop] key is lighted.

9) Move the table a few times with the [Table longitudinal feed handle].

At this time, stop the table at a position where the table reverse dock is located near the
proximity switch for right/left reverse direction in the middle part of the saddle.

10) Set the table longitudinal feed speed at 2.

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11) Press the table feed direction combination keys.

12) Turn the [Table longitudinal feed speed control] knob clockwise slowly to see there is no
abnormality in the table travel conditions.

The table feed speed here should be set at 5-6m (196.9″″ – 236.2″)
″) /min or below.

13) Set the table longitudinal feed speed at 0 to stop the table.

14) Turn the [Table cross feed handle] to the left and right and check that the table repeats moving
forward and backward.

The feed amount per scale division for cross-feeding the table can be controlled with the
[Manual pulse feed speed selector] switch.

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15) Set the table cross feed speed at 0.

16) Perform teaching of front/back reverse positions.

Refer to the “Teaching” section for the teaching procedures.

17) Press [Traverse] in the cycle selection keys.

Traverse

18) Press [Bias feed] in the cross feed mode keys.

Bias feed

- 66 -
19) Press [Forward] or [Backward] key for cross feed direction switching.

Backward Forward

20) Increase the table cross feed speed gradually and make sure that the saddle moves forward
and backward without problems and it is reversed without fault when a direction switching key
is pressed.

21) Set the table cross feed speed at 0.

22) Set the rough infeed amount to Set the rough infeed amount to
10μm (0.01 mm). 4 (0.0004″).

23) Set the fine infeed amount to Set the fine infeed amount to
2μm (0.002 mm). 1 (0.0001″).

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24) Set the fine grinding allowance to Set the fine grinding allowance to 10
(0.001″).
20μm (0.02 mm).

25) Set the number of spark-outs to 3.

26) Set the [Mode selector] switch to [Grinding allowance setting] mode.

27) Press the [Reset (RST)] key of the vertical position display unit to show “0” on the display.

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28) Set the grinding allowance to 0.150mm (0.006″) on the vertical position display.

You can enter values by pressing the keys below the display.

29) Check that the LED is lighted on the [Traverse] in the cycle selection keys and [Bias feed] in the
cross feed mode keys as well as the middle key in the cross feed direction switching keys.

30) Press the [Automatic feed] key.

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31) Turn the [Table longitudinal feed speed] knob slowly and set it at 7.

32) Turn the [Table cross feed speed control] knob slowly and set it at 5.

33) Set the [Mode selector] switch to [Automatic sizing] mode.

34) Check if the machine operates the cycle described as follows.

(1) The machine performs automatic infeed each time the table is reversed at the front and
back limit.
(2) The value shown in the vertical position display declines by 0.010 (0.006) from 0.150
(0.006) down to 0.020 (0.001).
(3) Subsequently, the value declines by 0.002 from 0.020 until it reaches the specified position
for the finished dimension.
(4) When the machine reaches the specified position for the finished dimension, it reverses the
table 3 times at the front and back limit for spark-outs. The saddle stops at the front limit
of the stroke and the table stops at the right limit (cylinder end state). (If the saddle is at
the back limit at the end of the cycle, it moves forward after the table stops at the right limit,
and stops when it reaches the reverse limit, completing the cycle.)

Use the table feed direction combination keys to switch the right/left direction of the table during
hydraulic drive. If you continue to press the direction key after the table reverse dock
passes through the non-contact switch, the table travels to the cylinder end and stops.
To restart the table, press the opposite direction key.

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35) Return the table to the middle position of the longitudinal stroke using the [Table longitudinal
feed handle].

36) Set the manual pulse feed speed at “x 50”, and press the [Cross feed manual handle select]
key.

37) Turn the [Saddle feed handle] to return the saddle to the middle position of the stroke.

38) Press the [Emergency stop] switch and confirm the stoppage of wheel spindle motor and
hydraulic motor.

39) Set the table longitudinal feed speed at 0.

40) Set the table cross feed speed at 0.

If you do not find any abnormality through the operations listed above, the test run is complete.

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Chapter 4 Maintenance
This chapter explains the points and procedures of checkup conducted periodically and
when needed, as well as replacement and adjustment methods of the machine components
and parts.
To maintain the intrinsic performance of the machine and secure the safety, be sure to
perform the checkup, cleaning and maintenance instructed in this chapter.

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4.1 Maintenance Items
To maintain the intrinsic precision and features for long periods, check up the machine
components regularly and maintain them properly.

4.1.1 General Maintenance

The grinder constantly requires coolant water during process. Do not fail to care the machine
components because leaving them without proper care will cause rust development.

(1) At the end of the operation, wipe the machine components, especially on the shiny
surfaces, with a dry cloth.
(2) Wipe the surface of the jigs with a wax cloth at the end of the operation.
(3) Clear off the grinding debris left in the wheel cover as well as the drainage of the table
and frame.

- If you pour water in the wheel guard for cleaning while the wheel spindle is not
rotating, the water may enter detailed parts of the machine. Do not wet the wheel
guard when the spindle is stopped.
- Using air to clean the work on the table may cause coolant water or grinding debris
to enter detailed parts of the machine. Wipe the table surface with a cloth or a wiper,
and clean the work with air outside the machine if needed.

4.1.2 Daily Checkup Items

To give full play to the machine's capabilities, check for any abnormality in the checkup items
listed below before or after the work, and remove the cause if any abnormality is found.
It is important to grasp the regular operating status because you need to determine the
presence of abnormality based on the regular normal operating status, checking the
appearance, vibration, sound, temperature, etc.

Table 4-1 Daily Checkup Item List

Checkup Item Description

Lubricant should be seen on each part below during
operation.
- Vertical feed guideway
Lubricant flow - Longitudinal feed guideway
- Cross feed guideway
- Level through the lubricant check window.
- Inside the pipes
No abnormality is found in vibration, sound and temperature
Oil pump
during operation.
Filter No abnormality is found in the intake sound.
Wheel spindle drive motor
No abnormality is found in vibration, sound and temperature
Motors Cross feed servo motor
during operation.
Vertical feed servo motor
Installation and behavior of Switches and lamps should not be damaged or loosely fixed,
Operation
switches and indicating and should behave smoothly.
panel
lamps Each indicating lamp should function normally.

- 73 -
4.1.3 Periodic Checkup Items
Apart from the daily maintenance, the following points should be inspected on a regular basis.
Although the maintenance cycle should be determined individually based on the actual
operation conditions and periodic checkup materials, the following table will provide a guide of
maintenance cycle most commonly adopted except for cases of substantial functional decline.

Table 4-2 Periodic Checkup Item List

Checkup Checkup
Description
Item cycle
Supply of
Check the oil level through the window at the rear part of the frame
hydraulic oil
Monthly while the machine is not operating, and supply additional oil upon
(also used as
necessity. For details, refer to the section 4-15 “Oil Supply”.
lubricant)
Every 1-2
years, or Life of hydraulic oil depends on the use conditions and environment.
Exchange of
every As using deteriorated oil becomes gelatinous material and interferes
hydraulic oil
approx. with the function of pump and valve, exchange it with new hydraulic
(also used as
3,000 oil.
lubricant)
operating For details, refer to the section 4-16 “Oil Exchange”.
hours
Every 6 Clean the filter once every 6 months or as needed. It should also be
Filter
months or as
replacement
needed cleaned or replaced when exchanging the lubricant.

Check to see if the filter is dirty and if the filling port, other air inflow
Cleaning of air Monthly or as
openings and the fans are blocked with dust, and clean them when
inflow opening needed
needed.
Weekly for
the initial 1
Check the levelness on the table because machine level may
Levelness month after
somewhat change due to hardening of concrete in the initial 1 month
check installation,
after installing the machine.
and yearly
after that.

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4.2 Consumables List
The scope of consumables varies depending on the aspects of expected lifetime and the use
conditions. Shown here is a list of the parts constantly consumed.

Table 4-3 Consumable Parts List

Replacement/supply
Item Model Location Amount used
cycle
PSG52DXB/
Shell Tonna Oil S32(Showa Shell ACC52DXB/
Sekiyu) ACC820DXB:
Hydraulic Supply as needed.
oil LUBWAY #150 (Sun Oil) 80L
Replace every 1-2
(also Inside of (21.1 gallons)
GRIND-X hydraulic fluid NS-01A years, or every
the frame PSG63DXB/
used as approx. 3,000
(Okamoto Machine Tool Works, ACC63DXB/
lubricant) operating hours
Ltd) ACC1224DXB:
VACUOLINE １４０５ (MOBIL) 120L
(31.7 gallons)
PSG52DXB/ACC52DXB/
ACC820DXB: NOT-901-B3 Inside of Depends on extent
Filter 1
PSG63DXB/ACC63DXB/ the frame of dirtiness.
ACC1224DXB: NOT-902-A3

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4.3 Replacing and Adjusting the Wheel
This section describes the procedure to replace the grinding wheel and adjust the balance.

・ As the grinder revolves the wheel at high speed, it should be handled with enough
care. Even a minor carelessness may cause destruction of the wheel and lead to a
major accident. Always make sure to handle the grinding wheel correctly.
・ Replacement of the grinding wheel and test run after that should be implemented by
personnel(s) who have completed the special education established by Article 59.3
of the Industrial Safety and Health Law.

4.3.1 Selection of the Wheel

(1) Select a wheel with appropriate abrasive coating, grain size, bonding grade and
structure bond for the material and finishing accuracy of the work. The attachment
“JIS standadrds for grinding wheel selection” will provide you with approximate criteria.
(2) Examine the apperance of the wheel to make sure there is no hazardous flaws or
cracks resulting from improper handling.
(3) Check that the grinding wheel has specification labels attached to its both sides.

4.3.2 Maximum Wheel Surface Speed

Shown below are the standard wheel surface speeds attained when the standard accessory
wheel is used with this machine.

PSG52DXB/ACC52DXB/ACC820DXB PSG63DXB/ACC63DXB/ACC1224DXB

Frequency 50Hz 60HZ 50Hz 60Hz

Standard wheel 205mm 205mm 355mm 305mm
outer diameter (8″) (8″) (14″) (12″)
Revolving speed 3000min-1 3600min-1 1500min-1 1800min-1
Standard wheel 1,933m 2,319m 1,673m 1,725m
surface speed (76.1″) /min (91.3″) /min (65.8″) /min (67.9″) /min

The maximum wheel surface speed attainable with your grinding wheel is indicated on the
wheel with a test chart. Ensure it is higher than the standard speeds shown above.

- 76 -
4.3.3 Wheel Cover Specification
A sign is put on the front of wheel cover, indicating the maximum wheel surface speed allowed.

PSG52DXB/ACC52DXB/ACC820DXB PSG63DXB/ACC63DXB/ACC1224DXB

Maximum wheel surface speed 2400 m (94.4″) /min 2000 m (78.7″) /min
Maximum wheel outer diameter x 205×25mm 355×50mm
thickness (8×1″) (14×2″)
Outer diameter x thickness x hole
diameter
〈50Hz〉 205×19×50.8 mm 355×38×127 mm
(8×0.7×2″) (14×0.7×2″)
〈60Hz〉 Same as above 305×38×127mm
(12×1.5×5″)

This sign indicates that the wheel cover has sufficient strength to endure the wheel breakage
that happens while a standard-sized wheel is rotating at the surface speed of 2,400m/min
(94488in/min), in case of PSG52DXB/ACC52DXB/ACC820DXB.

Use a grinding wheel with higher specfication than the standard wheel surface speed
shown earlier.
Be sure to specify the maximum wheel surface speed when you order a grinding wheel.

4.3.4 Installation of the Wheel Flange

Before installing the grinding wheel to the flange, hold the wheel
with your finger through the wheel’s central hole, and hit the wheel
gently with a wooden hammer to check the sound. The wheel is in
a good condition if the sound is a clear metallic clang. If you hear
an unclear sound, the wheel is presumed to be damaged for some
reason, and should not be used

1) Clean the grinding wheel and the wheel flange.

Check the wheel and the flange carefully, particularly for any dent or waste in the taper bore of
the flange and on the mounting surface of the wheel.

2) Make sure that the grinding wheel has specification labels attached to its both sides.

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 3) Assemble the wheel and the flange as shown below.
When you fasten the clamping bolts, be sure to tighten the diagonally-located bolts equally.
Do not set the balance pieces yet. They should be set when managing the balance of the
grinding wheel (4.3.7).

Balance piece
Balance piece

End of hexagon Steel

socket lock screw ball
End of hexagon Steel
socket lock screw ball

Nut

Wheel flange Clamping bolt

Piece holder Wheel flange
Labels Washer

Labels

PSG52DXB/ACC52DXB/ACC820DXB PSG63DXB/ACC63DXB/ACC1224DXB

4.3.5 Installing Wheel Flange to Wheel Spindle

1) Clean the taper parts of the wheel spindle and the wheel flange.

2) Install the wheel flange to the wheel spindle.

3) Screw in the clamping nut.

Fit a wrench to the clamping nut and hit the wrench handle counterclockwise a few times with a
wooden hammer to tighten the nut.

Clamping nut
Clamping nut

Wrench Wrench

PSG52DXB/ACC52DXB/ACC820DXB PSG63DXB/ACC63DXB/ACC1224DXB

- 78 -
 As a wheel flange is quite heavy, handle it with care when you remove it.
It can suddenly drop and cause injury or damage the machine.

When you use a new grinding wheel, be sure to perform the procedure in section 4.3.9
“Balancing the Wheel” before starting the grinding work. Using an unbalanced wheel
will produce a vibration in the machine and affect the precision of processed works as
well as the machine accuracy and its functions.

4.3.6 Removing the Wheel Flange from the Wheel Spindle

1) Open the wheel cover.

2) Remove the clamping nut.

Fit a wrench to the clamping nut, loose and remove the nut by hitting the wrench handle
clockwise with a wooden hammer while holding the wrench and the wheel with the other hand.

Clamping nut
Clamping nut

Wrench Wrench

PSG52DXB/ACC52DXB/ACC820DXB PSG63DXB/ACC63DXB/ACC1224DXB

- 79 -
Screw in an extractor nut.
Fit the extractor nut to the wheel flange and turn it clockwise until it reaches the screw part of
the wheel spindle to screw it in.

Extractor nut Extractor nut

PSG52DXB/ACC52DXB/ACC820DXB PSG63DXB/ACC63DXB/ACC1224DXB

4) Remove the wheel flange.

Fit a wrench to the extractor nut and hit the wrench handle clockwise with a wooden hammer
while holding the wrench and the wheel with the other hand. This will let the wheel flange
removed from the wheel spindle.

Extractor nut Extractor nut

Wrench Wrench

PSG52DXB/ACC52DXB/ACC820DXB PSG63DXB/ACC63DXB/ACC1224DXB

As a wheel flange is quite heavy, handle it with care when you remove it.
It can suddenly drop and cause injury or damage the machine.

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4.3.7 Test Run After Installing the Wheel
(1) When you start revolving the wheel spindle after installing a wheel, be sure to close the
wheel cover. When starting the wheel spindle, make sure there are no personnel in
the scattering direction in case the wheel breaks. Turn on and off the switches a few
times to increase the revolving speed.
(2) Continue idle running for over 3 minutes and make sure there is no abnormality such
as wheel surface runout and abnormal vibration sound at this time.

Duration of the test run shuold be over 3 minutes after installing a new wheel and over 1
minute after installing a used wheel.

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4.3.8 Dressing
(1) After installing a new grinding wheel, the wheel diameter is somewhat decentered.
The process to adjust the grinding wheel with a diamond tool to create correct
cylindrical surfaces is called reshaping (truing). The diamond tool is also used to
create a sharp edge of the wheel when it becomes blunt-edged due to cracking or
clogging for grinding. This process is called edge-fixing (dressing). In general, these
two processes are collectively called dressing.

1) Installing the Table Dresser

The table dresser is used with a diamond tool installed to the block. The block with the
diamond tool is adsorbed to the chuck while dressing.

5.9 (1/50 Taper) Grinding wheel

Diamond tool
Block

(1) Dressing Procedure

1) The diamond tool is inclined at about 5 degrees to the perpendicular line of the grinding wheel.

Grinding wheel

- 82 -
2) The diamond tool abrades away by repeating dressing process. When more than half of the
tool is worn away, request the diamond tool maker to renew it.

3) Dressing with a worn diamond tool causes cracking on the wheel surface and reduce the
grinding efficiency.

Grinding wheel

Sharp edge
Worn surface

4) Dressing Conditions
Infeed amount of the diamond tool should normally be about 0.01-0.02mm (0.0004-0.0008″).
The feed speed should be determined in consideration of the required grinding precision and
processing efficiency. Generally, the feed speed is to be set between 0.4mm (0.0015″) (for
rough grinding) and 0.1mm (0.004″) (for finish grinding) per wheel rotation.

5) Injection of grinding fluid

Perform dressing with grinding fluid injected. As diamonds burn at a relatively low
temperature, they abrade away rapidly if not cooled with grinding fluid. If you perform
dressing without injecting grinding fluid, grains can fly in all directions and enter the slip
surfaces and hydraulic circuit, which can cause wear and failure of the equipment.

- 83 -
4.3.9 Balancing the Grinding Wheel
When you use a new grinding wheel, be sure to achieve the balance before using it.
Using an unbalanced wheel will produce a vibration in the machine and affect the precision of
processed works as well as the machine accuracy and its functions.

1) Install the grinding wheel to the wheel flange. Do not set the balance pieces yet.

2) Install the wheel flange to the wheel spindle, and perform dressing until there is no edge runout.

3) Install a balance arbor to the wheel flange removed from the wheel spindle and fix it with a nut,
and place it on the balancing machine.
The balancing machine should be set horizontally on a sturdy bed, away from wind.

Balancing machine (BW-260: PSG52DXB/ACC52DXB/ACC820DXB)

(BW-360:PSG63DXB/ACC63DXB/ACC1224DXB) Balance arbor

- 84 -
4) Turn the wheel flange slowly on the balancing machine,
and find the angle where the machine pointer stabilizes at
the center of the scale. The point located at the bottom
then is the heaviest part (indicated with “W” in the figure).
Mark this point with a chalk.

5) Set a balance piece on the opposite side of the W point.

6) Incline the wheel flange at a 90 degree angle and see

which side is heavier between W side and the balance
piece side.

7) Set two balance pieces on the lighter side to make adjustment.

If the balance piece side is If the W side is still heavier,

heavier, set additional set additional balance
balance pieces on the W pieces on the balance piece
side. Adjust the angle “A” side. Adjust the angle “B”
to achieve a balance. to achieve a balance.

・ Even If you carefully make fine adjustment at this point, you willl need to recheck
the balance as the wheel’s outer diameter becomes reduced in size because
composition changes over time.
・ After using the wheel with grinding fluid, dry run the wheel for a few minutes to
throw off the fluid sufficiently before making adjustment.
・ As the balancing machine requires high sensitivity, check the sensitivity in regular
use and repair the machine if it decreases.

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4.4 Hydraulic Pressure and Lubrication

4.4.1 Oil Supply

Check the oil level once a month, and supply additional oil if there is not sufficient amount left.

4.4.2 Checkup and Adjustment of Hydraulic Pressure

Check the hydraulic pressure once a month in the following procedure.

 Also refer to the attached drawing when performing the procedures in this section.

1) Set the table stroke at around 500mm (20″) and feed the table back and forth at the rate of
about 1m (40″) per minute

2) Read the hydraulic pressure on the pressure gauge while turning the gauge cock
counterclockwise.

3) If the pressure varies from the preset value, loose the lock nut of the relief valve and turn the
cock to adjust the value.

Model Standard value

PSG52DXB/ACC52DXB/ACC820DXB 1.3～1.5 Mpa (188.5 – 217.6 lbs/in2)
PSG63DXB/ACC63DXB/ACC1224DXB 1.5～1.8 Mpa (217.6 – 261.1 lbs/in2)

- 86 -
 4) When the pressure adjustment is complete, retighten the lock nut of the relief valve.

5) Turn off the pressure and turn the gauge cock clockwise to close it when the pressure gauge
pointer is at 0.

・ When the table feed speed is set to "0”, the pump is in the unloaded condition. Do
not adjust the pressure in this condition.
・ Be sure to close the gauge cock after setting the pump pressure. Using the
machine with the cock opened for a long time may damage the pressure gauge.

4.4.3 Exchanging the oil

Though life of oil depends on the use conditions and environment of the machine, the oil should
be exchanged in about one year (2,500 operating hours). Deteriorated oil generates
gelatinous material and interferes with the function of pump and valve. You can discharge the
oil in the machine through the drain. After draining the oil, supply new oil from the oil inlet.
Refer to the specifications for information of the oil type and amount.

4.4.4 Cleaning the lubrication orifice

If the lubricant level seen through the gauge window at the top of the column does not rise even
though no abnormality is found in the lubrication circuit, remove the valve at the top of the pipe
joint and clean the orifice.

1) When removing the valve, use a tool like needle-nose plier to pull out the valve, turning
its head right and left.
2) Check for any clog in the small hole of the orifice and clean it out with a wire if any.
3) When installing the valve after cleaning, make sure to insert it with the hole side faced
up.

Valve

- 87 -
4.4.5 Adjustment of Table Reverse Shock
Open the front cover and turn the right and left tarry valves with a flat-tip screwdriver to make
adjustment.

To make adjustment, fit the screwdriver to the head of the tarry valve and turn the valve.

Inclination of the valve head Vertical Inclined to the right Horizontal

Table shock Big Small
Table stop
Table reverse time Short Long

- 88 -
Chapter 5 Troubleshooting
This chapter explains causes of common failures and troubles such as those for
incompatibility of grinding wheels, and presents possible measures for them.

- 89 -
20 Trouble Check List
If the machine fails to operate or operates abnormally, look for the corresponding trouble
description in the list below.

20.1 Check List

Trouble Cause Measure

Table does not speed up. a. Filter is clogged. Clean the hydraulic circuit and
1 Hydraulic pump makes a loud b. Oil quantity is not sufficient. filter.
noise. Supply additional hydraulic oil.
Lubricant level does not rise a. Lubricant orifice bore is Remove the valve and clean it
clogged. up.
2
b. Adjustment of lubricant valve
is insufficient.
Abnormal noise is heard from Bearing is at the end of its life Replace the bearing.
3
the wheel spindle.
Spindle is not stable. a. Bearing keep is loose. Fasten the bearing keep more
(Special care is needed after a tightly.
4
sudden shock is given to the
wheel during rotation.)
Breaker trips as the power is a. Motor has a defect. Remove the lines for each motor
turned on. from the terminal stand and
b. Magnetic switch has a defect. push respective start buttons to
see if the breaker trips. If it
does not trip, the motor has a
5
defect and needs repair.
If the breaker trips in the test
above for “a”, the magnetic
switch has a defect and needs
repair.
Automatic infeed can not be a. Mode selector switch has not Shift the switch.
performed. been shifted.
b. Mode selector switch is at Replace the switch.
fault.
6 c. Error in grinding allowance Set the correct data.
setting.
d. Down feed amount switch is Set the infeed amount.
set to “0.
e. Servo motor is at fault. Replace the servo motor.

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 Trouble Cause Measure
Manual pulse generator does a. Mode selector switch has not Shift the switch.

not work. been shifted.

7
b. Manual pulse generator is at Replace the manual pulse

fault. generator.

Display unit does not display. a. Connecter is not plugged. Plug in the connector.
8
b. Display unit is at fault. Replace the display unit.

Fuse blows out when the a. Limit switch has a defect. Repair or replace the limit

machine starts operating. switch.

Repair or replace the solenoid

valve.
9
Check and replace the magnetic

chuck.
Check and repair the working

light.

Magnetic chuck does not work. a. Receptacle or plug has a Check the soldering condition
defect. and replace the solder.

b. Magnetic chuck has a defect. Check and replace the magnetic

c. Magnetic chuck code has a chuck.
10
defect. Check and replace the code.
Fuse blew out. Replace fuse F2 (3A).

e. Demagnetization controller Check and replace MA-3A.

has a defect.

Motor does not rotate. a. Thermal relay is activated. Raise the lever.
11
b. Motor has a defect. Check and repair the motor.

Working light does not turn on. a. Ramp burnt out. Replace the ramp.
12
b. Fuse blew out. Replace fuse F1 (2A).

Table does not start. a. Table feed direction switch has Select right or left of the table

not been turned on. feed direction switch.

13 b. Switch is at fault. Replace the sheet panel.

c. Solenoid valve ［YV3・4］ is at Replace the solenoid valve.

fault.

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 Trouble Cause Measure
Table does not perform a. Solenoid valve ［YV3・4］ is at Replace the solenoid valve.
Right/Left reverse fault.

b. Proximity switch [SQ4・5] is at Replace the proximity switch.

fault.
14
c. Adjustment of tarry is not Adjust the tarry.
proper.

d. Table dock setting is not Adjust the table dock.

proper.

Saddle cross feed does not a. Cross feed mode is not set as Switch to the correct mode.

start. should be.

b. Cycle select switch is set to Select traverse of the cycle

plunge 1・2. select switch.

c. Cross feed control volume is Increase the volume.

set to OFF.
d. Table is stopped at the right Select left key of the table feed

15 end. direction switch.

e. Cross feed servo motor is at Replace the servo motor.

fault.
f. Cross feed servo amplifier is at Replace the servo amplifier.

fault.
g. Cross feed timing belt is Replace the timing belt.

damaged.

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21 Grinding Troublesshootings
In grinding operations, improper wheel selection or grinding conditions may lead to troubles
such as:
- Troubles on the grinding surface
- Clogging, chipping-off, or cracking of tools
- Failures of moving parts of the machine
These troubles correlate with each other and cause various phenomena. The following list will
help you identify the cause and take proper measures.

21.1 Causes and measures for roughness, chatter marks and patterns

No. Cause Measure

1. Unbalanced wheel Restore the balance of the wheel.
2. Loose wheel flange Tighten the clamping bolt of the flange and achieve a balance.
3. Improper wheel selection
a. Grain size is big. If narrow, deep and regularly patterned marks are made,
choose a smaller grain size.
b. Bonding grade is low. If independent deep scars are made, use a wheel with higher
bonding grade.
4. Improper grinding conditions
a. Too much Infeed amount or Reduce the infeed amount or feed amount.
feed amount
b. Wheel surface speed is low. If the wheel diameter has become small, replace the wheel with
a new and bigger one.
c. Grinding fluid is not sufficient. Pour more grinding fluid.
5. Improper grinding fluid
a. Grinding fluid is contaminated or Clean inside the grinding fluid tank and the wheel cover.
has some foreign material inside.
b. Grinding fluid is deteriorated. Install a separation device (e.g. magnet separator, paper filter).
c. Grinding fluid is not proper. - Replace it with new grinding fluid.
- Replace it with other type of grinding fluid.
6. Improper dressing
a. Dressing speed is fast. Decrease the dressing speed.
b. Dressing speed is uneven. Keep the dressing speed constant.
c. Overhead dresser is not Adjust the dresser or change to the table dresser.
properly adjusted.
d. Infeed amount of the dresser is Adjust the infeed amount of the dresser.
not proper.
e. Dresser is not proper. - Use a sharp diamond tool.
- Hold the diamond tool short to increase the rigidity
- Make sure the diamond tool is installed tightly in a stable
condition.
- Replace the diamond tool if the head becomes blunted.
- Change the installation angle of the dresser.
7. Improper grinding operation
a. Work is not mounted correctly. Eliminate the lift of work mounting surface.
b. Dust Clean and check the dust collector. Clean up the working space.
8. Failures of the machine
a. Machine is not installed stably. Adjust the jack bolts.
b. Wheel spindle run-out. Replace the bearing.
c. Table movement is uneven. Perform air-bleeding of the table cylinder.
d. Table vibration Check vibration inside the hydraulic pump.
e. Vibration is produced by other Take vibration control measures or relocate the machine.
machines.

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21.2 Causes and measures for grinding burn and grinding crack

No. Cause Measure

1. Improper wheel selection
a. Bonding grade is high. Use a wheel with lower bonding grade.
b. Grain size is small. Use a wheel with bigger grain size.
c. Structure density is high Use a wheel with lower structure density (coarse) or a porous
(dense). wheel.
2. Improper grinding conditions
a. Table speed is slow. Increase the table speed.
b. Too much Infeed amount Reduce the infeed amount.
c. Wheel surface speed is fast. Reduce the wheel’s outer diameter.
3. Improper grinding fluid
a. Grinding fluid is not sufficient. Pour more grinding fluid.
b. Grinding fluid is not suitable. Replace it with other type of grinding fluid.
4. Improper dressing
a. Dressing speed is slow. Increase the dressing speed.
b. Diamond tool has blunted. Use a sharp diamond tool.

21.3 Causes and measures for wheel clogging

No. Cause Measure

1. Improper wheel selection
a. Bonding grade is high. Use a wheel with lower bonding grade.
b. Grain size is small. Use a wheel with bigger grain size.
c. Structure density is high Use a wheel with lower structure density (coarse) or a porous
(dense). wheel.
2. Improper grinding fluid - Replace it with other type of grinding fluid.
- Pour more grinding fluid.

21.4 Causes and measures for wheel chipping-off

No. Cause Measure

1. Improper wheel selection
a. Bonding grade is low. Use a wheel with higher bonding grade.
2. Improper grinding conditions
a. Too much Infeed amount Reduce the infeed amount.
b. Wheel surface speed dropped If the wheel diameter has become small, replace the wheel with
due to consumption. a new and bigger one.

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21.5 Causes and measures for wheel cracking

No. Cause Measure

1. Improper dressing
a. Dressing speed is slow. Increase the dressing speed.
b. Diamond tool has blunted. Use a sharp diamond tool.

c. Infeed amount of the dresser is Set more infeed amount to the dresser.
small.
2. Improper grinding conditions
a. Infeed amount is small. Increase the infeed amount.
3. Improper wheel selection
a. Grain size is small. Use a wheel with bigger grain size.

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Chapter 6 Operations of special accessories
This chapter explains operations of the special accessories.

- 96 -
22 Operations of special accessories
This section provides explanation of operational switches and other details of the special
accessories.
Please note that names and layouts of the switches, buttons, meters, lights and other parts
may be different from those of the machine actually installed, depending on the combination of
special accessories, specification changes and other reasons including the state of
technological development.

22.1 Automatic retraction

[Retraction amount setting] switch [Retraction selector] switch

[Manual retraction]
push button

Wheel spindle revolution speed Wheel spindle revolution speed setting

knob
1) Set the retraction amount with the [Retraction amount setting] switch.

2) Set the [Retraction selector] switch to “Auto” mode.

3) Set the grinding conditions with reference to the section of automatic grinding cycle in the
standard instruction manual, and perform automatic grinding cycle.

4) The wheel rises by the set retraction amount after spark-outs, completing the automatic
grinding cycle.

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22.2 Manual retraction

1) Set the retraction amount with the [Retraction amount setting] switch.

2) Set the [Retraction selector] switch to “Manual” mode.

3) Set the grinding conditions with reference to the section of automatic grinding cycle in the
standard instruction manual, and perform automatic grinding cycle.

4) The grinding wheel stops at the specified position for the finished dimension and the table
stops at the right limit after spark-outs, completing the automatic grinding cycle.

5) Check the dimensions of the finished work, perform correction grinding if needed. After
finishing the process, press the [Manual retraction] push button to raise the wheel by the set
retraction amount.

For correction grinding, set the [Mode selector] switch to manual handle mode (see (20), page
3-10) and perform infeed cut using the manual handle.

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22.3 Wheel spindle variable speed controller
This controller allows stepless adjustment of the wheel revolution speed.

Wheel spindle revolution speed setting

Set the number of revolution of the wheel spindle.

Wheel spindle revolution speed

Number of revolution of the wheel spindle is displayed.

Set the wheel surface speed within the range of the wheel guard specification and the
wheel’s maximum wheel surface speed.

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22.4 Hydraulic overhead dresser
If a magnet chuck is equipped, the switches related to the magnet chuck are located on the left
part of the electric operation panel.

(1) Dressing operations

1) Press the [Hydraulic pump on] key.

2) Set the table longitudinal feed speed at 2.

3) Press a table feed direction key. (This will activate the hydraulic pressure.)

- 100 -
4) Press the [Forward] dressing direction selector key and adjust the speed with the speed control
knob.

Forward

Fig. Dressing direction selector key “Forward”

Listen to the dressing sound, and press the [Backward] dressing direction selector key when
the forward dressing is finished.

Backward

Fig. Dressing direction selector key “Backward”

5) The machine starts automatic infeed, taking up the feed near the end of the backward stroke.

6) Dressing is performed only by switching the dressing direction selector keys between [Forward]
and [Backward].

- 101 -
(2) Setting the infeed amount

1) Press the [Forward] dressing direction selector key to move the dresser fully forward, and
remove the infeed claw from the ratchet.

Forward

Fig. Dressing direction selector key “Forward”

Handle

Ratchet dial
Nuts
Infeed claw

Bracket
Overhead dresser

Rod

Fig. Overhead dresser

Loose the nuts and turn them to adjust the position of the infeed claw.
The front and rear nuts should be tightened after adjustment so that the infeed claw does not
move.

- 102 -
 2) Press the [Backward] dressing direction selector key to move the dresser backward.

Backward

Fig. Dressing direction selector key “Backward”

Handle

Ratchet dial
Nuts
Infeed claw

Bracket
Overhead dresser

Rod

Fig. Overhead dresser

As the automatic infeed is performed with the feed amount of this backward travel, you should
check the infeed amount and adjust the feed to achieve the desired infeed amount, trying a few
strokes.

3) Moving the infeed claw in the machine’s front direction reduces the infeed amount while moving
it in the machine’s rear direction increases the infeed amount.

4) When you finish setting the infeed amount, tighten the front and rear nuts to fix the claw.

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(3) How to place the diamond tool on the wheel’s outer diameter
(when replacing the wheel or installing a new wheel)

1) Make sure the wheel is stopped and open the wheel guard cover.

2) Press the [Forward] dressing direction selector key to move the dresser forward, remove the
infeed claw from the ratchet and turn the dial with your hand.
From the viewpoint of the operator, turning the dial counterclockwise descends the diamond
tool and moves it closer to the wheel while turning the dial clockwise ascends the tool and
moves it away from the wheel.

3) When the dial comes the center of the wheel width, press the stop key to stop the dresser .

Stop

Fig. Dressing direction selector key “Stop”

4) Turn the dial to adjust the diamond tool until it contacts the wheel a little.

5) When the diamond tool contacts the wheel, close the wheel guard cover.

6) Set back the dial a little to rotate the wheel.

7) Perform dressing, switching the dressing direction selector keys between “Forward” and
“Backward.”

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(4) Dressing speed adjustment
Dressing speed can be controlled with the [Dressing speed control] knob

Dressing speed control knob

Fig. Dressing seed control knob

Turning this knob clockwise slows down dressing while turning it counterclockwise speeds up
dressing.

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(5) Dresser levelness adjustment
If the dresser is not level, you may find the following conditions.
- Feeding makes (striped) pattern on the grinding surface.
- The grinding surface is rough.
In these cases, check the levelness of the dresser and make adjustment with the adjuster if it is
not level.

D
i
Adjuster

Dresser
levelness
Wheel

1) Perform dressing.

2) Grind the top surface of an appropriate test piece (wider than the wheel width).

3) Apply red lead primer or marker ink on the grinding surface of the test piece.

4) Stop coolant injection.

5) Make the wheel contact the test piece around its center and move the table for 4-5 strokes
without performing infeed. (Do not cross feed the table at this time.)

If the red lead primer disappears evenly from the test piece surface as a result of this operation,
the dresser levelness is good. If the red lead primer on the front or back side of the wheel
disappears, adjust the levelness of the dresser by the following operations.

6) Loose the 3 nuts which fix the overhead dresser (to the extent they are fastened loosely).

7) Drive in the adjuster to the left or right to adjust the levelness.

8) Retighten the nuts.

9) Try grinding the test piece again and repeat adjustment until you achieve levelness.

- 106 -
 (6) Replacement of the diamond tool
Lower the diamond holder, pick out the diamond tool and install a new one by turning it.

As the dresser uses hydraulic pressure of the main unit, it does not operate if the main
unit’s table feed speed control knob is set to the unload position because the circuit
pressure is 0. Turning the table speed control knob clockwise a little closes the circuit
and activates the pressure. Note that you should stop turning the knob before the
table starts moving.
If the dial (ratchet wheel) returns to the original position after infeed, the brake is
presumed to be loose, and you need to adjust the brake adjust bolt (to the extent the
dial does not return).

(7) Lubrication
There are 3 oil cups in the upper part of the dresser.
Supply additional lubricant (machine oil) as needed.

22.5 Dress interval device (overhead dresser)

Number of dressing Dress interval Manual dress start/stop

setting switch setting switch switch

Wheel wear correction Manual/Auto dress

setting switch selector switch

(1) Automatic cycle of dress interval

1) Specify the number of dressing with the [Number of dressing setting] switch, and set the
[Manual/Auto dress selector] switch to auto mode (right side).

2) Configure the settings with the [Wheel wear correction setting] switch and [Dress interval
setting] switch.

3) Define the grinding conditions with the automatic grinding cycle setting of the main unit and
perform automatic grinding.

4) The overhead dresser reciprocates according to the amount set with the [Dress interval setting]
switch as many times as specified with the [Number of dressing setting] switch. As the dress
correction and the wheel wear correction amounts are taken into accounts at this time, the
system will maintain the coordinates of the wheel bottom position after dressing. (See the
“Grinding Cycle Drawing”)

- 107 -
 The wheel wear correction is performed after each dressing only in auto mode (on the
condition that the dress correction amount is not smaller than the wheel wear correction
amount).

(2) Manual dressing function (with dress correction)

1) This function is used when adjusting the wheel and the diamond tool manually in the wheel
replacement process.

2) Set the dress selector switch to manual mode (left side).

3) Turn the [Manual dress] switch to the right and press it. Pressing it once reciprocates the
dresser once.

4) To stop the dresser within the wheel width or during reciprocation, turn the [Manual dress]
switch to the left. Repeat the procedures 3) to restart.

When you press the [Manual dress] switch, the dresser reciprocates once and performs
wheel wear correction.

- 108 -
- 109 -
Attachments
This attachment includes drawings required for machine installation, operation and
maintenance.

Attached drawings and lists

1 External Views Attachment-2
2 Machining Range Drawing Attachment-6
3 Wheel Flange Drawing Attachment-8
4 Wheel Flange Washer Drawing Attachment-10
5 Balance Arbor Drawing Attachment-11
6 Balance Piece Drawing Attachment-13
7 Piece Holder Drawing Attachment-15
8 Wheel Flange Nut Drawing Attachment-16
9 Diamond Tool External Views Attachment-17
10 Hydraulic Circuit Diagram Attachment-18
11 Lubrication Distribution Diagram Attachment-19
12 Wheel Selection Criteria List for Common Metals Attachment-20

- 110 -
23 External Views (PSG52DXB /ACC820DXB)

- 111 -
External Views (ACC52DXB)

- 112 -
External Views (PSG63DXB/ACC1224DXB)

- 113 -
External Views (ACC63DXB)

- 114 -
24 Machining Range Drawing (PSG52DXB/ACC52DXB/ACC820DXB)

- 115 -
Machining Range Drawing (PSG63DXB/ACC63DXB/ACC1224DXB)

- 116 -
25 Wheel Flange Drawing (PSG52DXB/ACC52DXB/ACC820DXB)

- 117 -
Wheel Flange Drawing (PSG63DXB/ACC63DXB/ACC1224DXB)

- 118 -
26 Wheel Flange Washer Drawing (PSG63DXB/ACC63DXB/ACC1224DXB)

- 119 -
27 Balance Arbor Drawing (PSG52DXB/ACC52DXB/ACC820DXB)

- 120 -
Balance Arbor Drawing (PSG63DXB/ACC63DXB/ACC1224DXB)

- 121 -
28 Balance Piece Drawing (PSG52DXB/ACC52DXB/ACC820DXB)

- 122 -
Balance piece Drawing (PSG63DXB/ACC63DXB/ACC1224DXB)

- 123 -
29 Piece Holder Drawing (PSG52DXB/ACC52DXB/ACC820DXB)

- 124 -
30 Wheel Flange Nut Drawing (PSG52DXB/ACC52DXB/ACC820DXB)

- 125 -
31 Diamond Tool External Views

- 126 -
32 Hydraulic Circuit Diagram

- 127 -
33 Lubrication distribution diagram

- 128 -
34 Wheel Selection Criteria List for Common Metals
Grinding method - surface grinding

Wheel outer diameter (mm)

Material
Material to be machined Over 205,
hardness 205 and below
not over 355
Rolled steel for general structure (SS) WA46K WA46J
205 and below
Plain carbon

Carbon steel for machine structure (S-C, S-CK) A46K A46

steel

Carbon steel tubes for structure (STK)

Carbon steel forgings (SF) Over HRC25 WA46J WA46J
Carbon steel castings (SC)
Nickel chrome steel (SNC)
Nckel-chromium-molybdenum steel (SNCM) HRC55 and
WA46J WA46I
Chrome steel (SCr) below
Alloy steel

Chromium-molybdenum steel (SCM)

Steel

Aluminium-chromium-molybdenum steel
(SACM)
Over HRC55 WA46I WA46H
High Carbon Chromium Bearing Steel (SUJ)
Alloy copper steel castings for structure (SCA)
HRC60 and
Toll steel

High-speed steel (SKH) WA46I WA46H

below
Alloy tool steels (SKS, SKD, SKT)
Over HRC60 WA46H WA46G
Stainless steel 1-4 (SUS 1-4)
steel
Stainless

WA46I WA46H
Heat-resisting steel 1-3 (SEH 1-3)
Stainless steel 5-16 (SUS 5-16)
WA36J WA30J
Heat-resisting steel 4-5 (SEH 4-5)
cast iron
Plain

Gray cast iron 1-5 (FC1-5) C46J C46I

Cast iron

Special cast iron GC46I GC46H

Chilled iron - -
cast iron
Malleable

Blackheart malleable iron (FCMB) WA46J WA46J

Whiteheart malleable iron (FCMW) A46J A46J

Brass (Bs) C30J C30I

Bronze (BC) A46K A46J
Non-ferrous metal

A1
Aluminum alloy A2 C30J C30I
A3
S
GC60-100 H, I
Cemented carbide G
D100-220
D
Material for permanent magnet (cast magnet) MC WA46J WA46I

- 129 -
 Okamoto Machine Tool Works, Ltd. ：http://www.okamoto.co.jp
URL：

Head office
Ohta Kosan Building Shin-Yokohama 8th Floor, 2-4-15 Shin-Yokohama,
Kohoku-ku, Yokohama, 222-0033 Japan
TEL. (81) 45-477-5231 FAX. (81) 45-477-5235
Overseas Department
Uchida Building 2nd Floor, 4444 Ikonobe-cho, Tsuzuki-ku,
Kohoku-ku, Yokohama, 224-0053 Japan
TEL. (81) 45-929-0312 FAX. (81) 45-932-6870

Okamoto Machine Tool Works, Ltd. Singapore Blanch (OJS)

10 Riverside Road, Singapore 739082 Republic of Singapore
TEL. (65) 6362-3818 FAX. (65) 6362-3368
Okamoto Machine Tool (Shanghai) Office
Room 2303, 23 Building B, Far East International Plaza No.317 XianXia Road,
Shanghai 200051, China
TEL. (86) 21-62350666 FAX. (86) 21-62088930
Okamoto Corporation
Founded November 1972
1342 Barclay Boulevard, Buffalo Grove, IL 60089, U.S.A.
TEL. (1) 847-520-7700 FAX. (1) 847-520-7980
Okamoto Machine Tool Europe GmbH
Founded January 1992
Paul-Ehrlichstr 9 D-63225 Langen Federal Repubulic of Germany
TEL (49) 6103-201100 FAX (49) 6103-2011020

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