DéALL INSTRUCTION MANUAL MODEL: All D-6, D-8, and D-10 Series D624-8, D&24-10, D1024-12, D1024-14 SERIAL NO.: All Serial Numbers 220-63101 to 220-68148 221-63101 to 221-48286 227-64101 to 2927-68139 228-64101 to 2928-68121 SURFACE GRINDERDAMAGE CLAIM PROCEDURES VISIBLE DAMAGE AT THE TIME OF DELIVERY: 1 Note damage on carrier's deltvary reseiet. Accapt the shipment. It can be retumed later if rapains ‘are net possible in the fled Request a “damage inspection® from the dalivery carver: 8, Ths carrier will end his own people or contract an Independent ageney to meke the In- spection, B. The inspector will request a signature on the ropert and ieave @ copy. & The carrier “damage Inspection’ report is not final. 1f addilionat damage Js found when tepals are started, contact the esmer for another inepection: or at least give them the detalis of the damage, Do not move the equipment fram the recalvity area and keep all shipping matsriats until cartier “damage inepactien” report Is complete, 1 possible, take photographs of the damage and keep them for your fies. Photos could possibly PROVE a Claim at a lator time. Keep record of sll expanses and be sure they are documented. & —_Repale darmage in the fold whenever possible, Carlers encourage this to keep expansos down, 7. You have nine (8) months to fie a ctaim, CONCEALED DAMAGE: 4 a 8. ‘You have fourteen (14) days to report damage not noted at time of delivery Report damage as soon as possitie. This makes it easler to prove that it dd not happan at cosignea’s plant b. Inspect machine(s) carefully before moving from the racalving area. Again, it machina is ‘ot moved, itis emstar to prove your case, ‘Request a “damage inspaction’ from the delivery carrier 8, The carter wil send his cw people or contract an Independent agency to make the fy ‘spection. b. The ingpector will request a signalure on the report and leave @ copy. © The carer “damage inspection” rsport Is not final. Wf additional damage Is found when ‘repairs are started, contact the cater for ancther inspection; or at last gl them the delzils of the damage. De not move the equipment from the receiving area and Keep all shipping materials until carrier "damage inspection” report is complete. 'f possible, take photographs of the damage and keep them for your files. Photos could possibly prove a claim at a later time. ‘Keep a record of af! expenses and be sure they are documented. Repair damage in the fleld whenever possible. Carriers encourage this to keep expenses down, ‘You have nine (8) monihs to fie a claim.SURFACE GRINDERS =-SPECIFICATIONS-- Thia Information will be found stamped on your machine data plate. SERIAL NuMBER(__ J vowrace[ MODEL NUMBER] ]NORMAL AMPS. INSTANTANEOUS AMPS[ "] PHase[ eres] DRIVE BELT NO, STANDARD GRINDING WHEEL SIZE FOREWORD Read this manual carefully before operating your machine. The specifications contained herein were in effect at the tine this manual was approved for printing The DoaLl Company, whose policy is one of continugus imaravement, reserves the right, however to change specifications ar design at any time without notice and without ingutring obligations. You can avoid unnecessary delay and inconvenience by specifying correct model and serial number on all parts orders and corre- spondence The felliewing registered jrade tks of jhe OOALL Gampany are used in this handbook: DOALL, K een-Kool, SELECTRON, and COOL GRINDING" U.S. PAT.NC. 2,470,350 PRag1 (REV. 1-67) PRINTED IN U.S.AOPERATOR’S INSTRUCTION MANUAL Precision SURFACE GRINDERS BoALL COMPANY waa NORTH LAUREL AVENUE OFS PLAINES. ILLINOIS BoOTETABLE OF CONTENTS Chapter 1 Chapter 4 PAGE INSTALLATION PAGE PREPARATION FOR OPERATION Uncrating... ee ee 2 Daily Check-Up,..... 22 Lifting Instructions. . , . 3 Truing the Wheel , 23 Cleaning ......-.. 3 Dressing the Wheel... 25 Installation on Floor... 0 4 Balancing the Wheel, ,.. 26 Assembly... 05 5 Mounting the Wheel... - 28 Electrical Connections . . 6 “Grinding In" the Chuck’; 33 Check UP... eee ee 6 Coolant... 2... ee 34 Chapter 5 Chapter 2 OPERATION SELECTING GRINDING WHERTS ga worm... %8 Selecting Wheel Size . . 7 Coolant Application... . . 36 ‘ Safety Precautions... . 48 Grinding Wheel Insp... 8 Taal Geeaine % Table Speed... 2... 41 Wheel Dressing... . 41 Chapter 3 Non-Magnetic Materials. | 42 OPERATION OF CONTROLS Grinding Thin Parts... 4d Grinding Warped Stock... 44 Electrical Controls . . . 10 Surface Finish... ... 45 Table Speed Control... . 12 Manual Table Feed. ... 13 Chapter 6 Adjusting Trip Dogs ... 14 «= TROUBLESHOOTING... 49 Overtravel, 0.0... 18 Pilot Valve 2.2. 19 Chapter 7 Vertical Feed. 22... 19 LUBRICATION & Crossfeed Controls. ... 16 MAINTENANCE ...... 58 Manual Crossfeed. |. |. a7 Automatic Crossfeed |... 18 + Chapter 6 SELECTRON ....... 20 ACCESSORIES ....... 60This manual covers the following DeALL Surface Grinders... The D-6 Series Modals 0618-7 & DB24-8 and previous 0-6 models segs The D-6 Series > Models 0824-10 & De2d-12 and previaus 0-8 models J The B-10 Series ae Wodels 102412, 1030-12 a 402614 and 8103014 and previous 0-10 modelsCHAPTER 1 INSTALLATION UNCRATING Your DoALL Surface Grinder has been carefully crated for shipment to insure its accuracy when It reaches your plant. It is Amportant that the crate be removed carefully ao ag not to damage the machine. (2) Remove all crating, blocking, strapping, plastic bag, etc. Be sure to remove any slrappingused to hold hydraulic tank in place. The tank must be free from contact with the inside walls of the base. (2) Remove drive motor, cooiant tank, SELECTRON, electro— magnetic chuck and any other accessories which have been attached to skid. (3) Inspect ihe machine for broken or damaged parts. (4) Remove the bolts attaching the machine base to the skids. PS aus COPE yuan cae RILEY STE CXR se ee Always include the mode! and seriai numbers stamped oR this deta plete in garts orders or carrespondenze concerning your machineHoist should heve ample capacity for use Vifting the grinder. spreader 0-6 models weigh bar approximately 3400 pounds. D-8 models weigh up to 4800 pounds and 0-10 models weigh up to 5000 pounds. use padding if necessary to protect painted surfaces Lifting hooks a in access openings CAUTION DO NOT LIFT OR MOVE THE MACHINE BY THE SADDLE OR TABLE. This is the correct method of lifting the grinder. LIFTING INSTRUCTIONS If a hoist is available, the machine can be raised bodily from the floor and the skids removed. When using a hoist, a suitable sling or chain should be used to support the machine at the base, 28 shown above, Be sure to use a spreader bar so that the sling or chain does not press against the saddle. CAUTION: Do not at- tempt to lift or move machine by saddle or table. CLEANING Before shipment, all unpainted surfaces were coated with a rust preventive compound. This may be removed by wiping with ragssaturated with non-flammable solvent. Clean machine only by wiping and brushing, Do not use compressed air as this tends only to foree dirt and grit into the working parts After the cleaning compound has seen removed, wipe all finish- ed aurfaces withacloth moistened with lubricating oil. Do not move any of the controls or moving partsuntil the machine has been thor~ oughly cleaned and lubricated. A coating of of] or a rust-preventive spray shouldbe used to protect bare metal surfaces which are sub- Jeet to rusting, INSTALLATION ON FLOOR, (1) The machine should be iccated go as to provide good Light for the operator. dowever, it 1s important that the machine be placed where it will be subjected to a minimum of temperature variation and should, therefore, not be placed too close to outside windows, ventilating fans, or forced air blowers. (2) A special foundation is not necessary. Any floor is suitable provided it is strong enough to support the weight of the machine without vibration, (3) The grinder should be as free as possible from vibrations set up by other equipment. ‘These outside vibrations have a definite effect on the finish produced by the grinder. (4) The machine =qust be leveled by placing the supplied steel plates under the four mounting screws on the base of the machine. (The plates and leveling screws are usually packed with the tools for shipment.) Thread the four leveling screws down through the mounting holes and uge as jacks for adjustment. With a spirit level placed on the ground top surface of the table, level the machine in alidirections. When the machine is level tighten the leveling screw locknuts. The machine weight must bear evenly on alt four pads. ‘The leveling screws raust bear on the metal Sutface of the mount: ing pads - not on the vibration absorbing materia! which should contact the floor. Install the mount ing plates so that the | vibration atsording SRINOER material is contact- rin base ouNTING ing the floor:On beit-driven grinders, ‘the spindle drive belt tension is adjusted by raising or lowering the motor bracket (NO. 1 In ghota). To ta" this, first loosen the four screws (2). Then turn the adjusting screw (3), untib the belts are at ‘the proper tension. ASSEMBLY (1) Belt tensioning: If the grinder is a belt-driven model, the spindle drive motor, belts and bracket may have been removed for shipment. Install as shown in photo above. Adjust belt tension by turning the adjusting screw. NOTE: The best belt tension will produce the least vibration. To check for correct belt tension, place a tenth Indicator on the chuck, indicating on the tapered nose of the spindle. Start the spindle and adjust belt tension until vibra- tion hag been reduced to a minimum. (2) Install the SELECTRON bracket (if used) on the right-hand side of the bage. Mount the SELECTRON unit on the bracket. NOTE: BE SURE TO REMOVE PACKING AROUND TUBES. (3) Unerate the electromagnetic chuck (if used) and degrease. Install the chuck ag described under "Grinding in the Chuck" in the Chapter on Preparation for Operation. (4) Position the coolant tank (if used) so that the drain hose from the saddle can be inserted in the tank cover. The tank must not obstruct air intake through the base air filter. Remove any extra parts or toois which have been packed in the tank.ELECTRICAL CONNECTIONS The DOALL Serface Grinder is an entirely self-contained machine. The standard machine is completely wired and equipped with push button controls and magnetic etarvers with overload-reaet awit- ches. Other electrical control systems are available as special equipment. Depending on the grinder's electrical system, it may be necessary to connect a fused disconnect switch, See the wiring diagram furnished with the machine, Wire so that the spindle re- volves clockwise when {acing the shaft before mounting a grinding wheel. The coolant pump motor must rotate clockwise when view= ed from above. WARNING Check to be sure that the spindle (without grinding wheel) rotates clockwise, The spindle nose nut has a left- hand thread and clockwise rctation will tend to tighten it. However, if the spindle motor rotates counterclockwise, the nose nut will rapidly loosen and the grinding wheel may be thrown from the spindle. INITIAL LUBRICATION AND CHECK-UP (1) Check the hydraulic oil level and fill if necessary. Use seven gallons of DOALL"ESL" Hydraulic Fluid (see hyd, oll specifications in Lubrication Chapter). Since acertain amountof oil ls used to (iM the hydraulic system, it wilibe necessary to refill the tank after starting the machine. (2) Check the automatic oiler for the saddle and table ways and fill if necessary with DoALL Way Lubricant. Adjust as described in Lubrication Chapter. Check to be sure that oil is actually being delivered to the ways. (3) NEW GRINDERS: It is important that all the base acceas panels be kept in place during operation. The air filter should be cleaned when necessary and kept in place. {4) Study the chapter on Operation of Controls carefully. Start the machine and operate each control. Run the saddle and table to the extremes of their travel in order to remove any air trapped in the eylinders. (5) Fill the coolant tank {if used) with Kleen-Kool coolant made by DoALL. Mix the coolant as instructed on the container label.CHAPTER 2 SELECTING GRINDING WHEELS SELECTION OF WHEEL SIZE Each model grinder is designed to use only one particular size of wheel, as listed below: HOLE GRINDER MODEL DIAMETER | WIDTH |DIAMETER Deis-7 4 12 1-1/4 (previous model 6-1) D624-8 8 3/4 1-1/4 (previous modela D8-3,D8-0) pez4-10 10 3/4 3 (previous model D8-0-10) DB 24-12,D1024-12,D1030-12 12 i 3 {previous models De-3,010-0 & D10-3) 1024-14, D1030-14 44 1 3 (previoug modele D10-1, D10-4) scarica — mu weston Shs) esiion : sya WHEEL hale cao. n fai omen Psy | an ZA] sosiTee wr neem Sol le ool eee HEEL Wheels thinner than 1/2 inch can be used, but the cool grind adapter most be used with the nut reversed as shown in the sketch.GRINDING WHEEL INSPECTION (1) VISUAL INSPECTION - Examine the wheel carefully im- mediately after {thas been unpacked. Look fer cracks or chips which would indicate damage during shipping. (2) "RING" TEST - Next give the wheel the “ring” test. This is done by suspending the wheel from its center hole on a small bar or finger. Tap the wheel gently with a nonmetallic implement such as a wooden screwdriver handle. The best spot to tap a Wheel is about 45° on either side of the vertical centerline and about 1 or 2 inches from the outside edge of the wheel. Rotate the wheel about 45° and repeat the test. A sound and undamaged wheel will give aclear metallic tone. If it is cracked, there will be a "dead" sound. IC the wowed 18 atovck aprectiy alnag the vere UUcal centerline the” clue D) ever a aDsd wneot ‘silacmetimes’ mafledand may xive the (alae Hepresuiue that the wheel fy cracked, Wheels banded withorganle maneeialdy net give the eae lear aietallic anand as do viteiied and elllcate Sheets Alea, wails mast be dep and fee from Tava whem appiplng the ring tev Sikora the wound will ar dead For the ving test, tag the yneel at the locations shown, Repeat the ring test immediately before mounting either a new or used wheel, especially if the wheel has been in storage or out of service for 2 long time. (3) "RUN-IN" TEST - The "ring" test will usually detect cracked wheel; but it is not a positive indication, especially if per- formed by an inexperienced operator. Therefore, an additional "run- in" teat is easential.Mount the new wheel that has passed the ring test on the cor- rect adapter as desczibed elgewhere in Chapter 4. Close wheel guard securely. Stand back from the machine and run the spindle for at least one minute Before starting grinding. (4) GRINDING WHEEL STORAGE - Grinding wheels must be stored in a dry area. Some bond types may be seriously affected by dampness and temperature changes, Wheela should be supported on edge in racks which provide two-point cradle support. The wheels must be protected from damage. STANDARD MARKING SYSTEM CHART Bequence 1 2 2 4 5 € Prefix Abrasive Gramm Grade Structurs ond Manufacturer's Tyre Bae Type Record 1 A ® Lb §& Y MANUFACTURER'S ‘svsol. JWDICATING BXACT P racstNOD ALUMINUM OXIDE-@ Vey Da weseas |Meatois [Fina Fine w | Pa 2 nla |e 3 wl | oo 4 ts | se | 200] 570 5 2 | 60 | 120] 00 8 as 4380] 500 1 30] 00 é (USE OPTIONAL) O_o ABCDEFGUIIKXLMNOPQRSTUVWXIZ GRADE SCALE Standard grinding whee! marking system chartCHAPTER 3 OPERATION OF CONTROLS ELECTRICAL CONTROLS Pushbutton controle (see photo) are provided for starting and stop- Ping the spindle drive motor, hydraulic pump and coolant pump motors and column raiging motor (standard on large grinders, op- tional on others), In addition, an emergency stop pushbutton is pro- vided on some models for the Immediate stopping of all motors. A red warning light on the control pane! lights up Just before the oll level is low in the automatic lubricator tank. A float switch in the tank will automatically stop the machine when the oil level is low. If the column raising motor is used, a limit switch, mounted on the back of the column, ts provided to stop the spindle at the upper lim- it of its vertical travel, oa Electrical eantral panel (typical 0-6 Series panel shown) provides controls far the ‘spindle, hydrautic and coolant motors, ater gency stop and a lok oil fevel warning {ight for the sutomati¢c lubricator, The arrangement and type of controls will vary according to grinder made! ane accessories usedDoALL a 4 1 Front view of typical grinder (1) Base (13) Wheat guard (2) Hydraulic tank off level gage (14) chuck (3) Aydraulic oit filter (13) Table trip dogs (4) Electrical controls (18) Table feed handwnee! (5) Crossfeed trip dogs (17) Motorized wheal (8) Saddle elevation (accessory). (2) Table (48) Govlant tank (8) Splash guard (19) Ait filters aad fan enctosure (3) Wachine date plate (20) Crossteed handwhael (iD) Work Light (21) Saddle crossfeed controls (1) Contant flow contrals (22) Table speed contral (12) Vertical feed handwhael (23) Automatic Downfesd (accessory). NOTE: SELECTRON chuck contro! (accessory) not shown.Rear view of typical grinder, (1) Coolant motor and pump mounted on sortable coolant tank (2) Goolant filter (3) Table feed cylinder disconnect knob (4) Electrical caainet (5) Motorized spindle (8) Automatic way lubricator (7) Machine column (8) Removable drip pan for spent way oil TABLE SPEED CONTROL Table speed is regulated with the control shown on page 13. It hag an “off” position and is graduated with reference numbers so that the table speed setting can be noted and repeated. ALWAYS AD- VANCE THE TABLE SPEED CONTROL SLOWLY, ALLOWING THE TABLE TO MAKE SEVERAL REVERSALS BEFORE REACH- ING MAXIMUM SPEED. Thie will allow the relatively cold ofl in the combination valve to be replaced by warmer ol] front the tank, if the machine is cold, maximum table speed may not be obtained until the hydzautic oil has reached operating temperature. This may take about 30 minutes, unless a tank heater (accessory) is used. When the table speed control is ir the "stop" position, the table remains stationary.Table and saddle controls. ) Table speed contro! y Hanual table feed handensel } Knob for manual cable operation ) Table cylinder p ston rod disconnect a @ Q 4 MANUAL TABLE FEED HANDWHEEL H{ manual table travel is desired, it is first necessary to disconnect the table from the table feed cylinder. ‘This is done by moving the table (hydraulically) to the extreme left and pulling up the manual table release knob (see photo above). Then disconnect the table ¢ylinder piston rod from the table by unscrewing the knob located on top of the right-hand table apron. The table is then ready for manual operation by means of the manual handwheel. It ia not necessary to use manuai table control very often---usually only for set-up purposes. NOTE Operating the table manually with table cylinder connected may allow air to enter the table feed cylinder. This will cause a jerking table hydrau- He feed. To eliminate the air from the ovlinder, rurthe table slowly to its full extent of travel several times.ADJUSTING TABLE TRIP DOGS The table trip doga control the maximum table stroke. They are positioned ona slide and locked In place by a small lever. The table- reversing pilot valve ia contacted by rollers on the trip dogs. Stop screws are locatedin auch a position at each end of the trip dog track 80 ag to prevent accidental removal of the dogs, while still allowing grinding of the complete table pad. Yhe spacing of the trip dogs determines the length of table traygl, Adjust the position of each dag by Joosening the Jacking lever and silding the dog along its track. Locate the trip dogs so that the grirding wheel wil! contact ai} of the work surface. To Adjust Trip Dogs: Use the table speed control to slowly position the table at the end of each stroke, then lock trip dogs in place by clamping the hand lever. WARNING NEVER ADJUST TABLE TRIP DOGS WHILE TABLE IS MOVING, FINGERS CAN BE CAUGHT BETWEEN TRIP DOG AND PILOT VALVE. Adjust the dogs so that the wheel just clears the work, but do not allow excess table travel (see drawing). Loosen each trip dog lock- ing lever and move the trip dogs on the slide so that one Is to the left and the other is to the right cf the workpiece. Line up the trip dogs visually and tighten the locking levers. NOTE: Newer ma- ghines have nameplates which indicate correct trip dog spacing.MAKING ALLOWANCES FOR OVERTRAVEL “Overtrayel” is the distance the table travels at the end of its stroke AFTER the dog has tripped the pilot valve. Overtravel will be greatest on a coid machine when the hydraulic oil 1s about 68° F. Overtravel will also be great when the machine is operated at higher table speeds (up to 125 fpm) after it has been warmed up. ‘Therefore, remember these notes: (1) The table trip dogs on a "cold" grinder should be positioned closer together in order tc compensate for increased overtravel (see drawing below). (2) Tripdog spacing should also be reduced when table speed is between 76 and 125 fpm. tenle travel fverteanat ty wi st eee be — acing 1"F | i ‘Overtravel is distance rabie mavels after dog has wrinped pilot valve, Tabla overtravel will be greater at high table speeds (up {o |26 fom) and when machine is cold. tale tive high | table speed _| = petri ace ‘spazing. Reduce ilp deg spacing when operating at high table speeds anc when machine Is cold. This will compensate for the increased ovor-travel. AS the machine warns wp ba eure to eheek over travel and increate trip dog spac ng if necessary. Be sure to allow for overtrave! of the table. 5CROSS FEEO DIRECTIONAL CONTROL CROSS FEED SELECTOR AUTOMATIC CROSS FEED ADJUSTMENT WHEEL DRESSING SPEED CONTROL Mlustrating functions of the table and saddJe contrals CROSSFEED DIRECTIONAL CONTROL LEVER and CROSSFEED TRIP DOGS Use the crossiced directional control to select "in" or "out" move- ment of the saddle as shown above. The vertical or center position of the control lever is a “neutra’” position which stops saddle erossfeed, Pull the lever out to bring the saddle toward you, push the lever in for crogsfeed travel away from you. This control is also activated by the trip arm under the left-hand end of the saddle. Adjust the crossfeed trip dogs (gee photo, next page) to provide an automatic stop at the end of elther in or out saddle travel.Set the crossfeed trip dogs for the desired total sedd/e travel in each direction The saddle wilt avtonaticaily stop when the trip lever contacts the trip dog. CROSSFEED SELECTOR LEVER WITH WHEEL DRESSING SPEED CONTROL, Use the crossfeed selector to select the type of croasféed opera~ tion desired: manual, automatic or whsel dressing. Push the lever forward for manual operation of the saddle by means of the handwheel. When the lever is in the vertical position, the saddle croasfeed will take place automatically ateach table travel reversal in the direction selected with the directional control. Pull the lever back for wheel dressing operations. During wheel dressing, the table must be sta- tlonary andthe saddle moves in or out ad aelected with the direction- al control. The rate of crossfeed travel during wheel dressing is adjusted with the mall knob in the center of the selector lever. MANUAL CROSSFEED HANDWHEEL The manual crossfeed handwheel is provided with a zeroing alip ring. Use the slip ring to establish a zero” reference point from which to make adjustments, Loosen the locking knob in order to ad- just the slip ring, The slip ring is calibrated in increments of .001 in. The reference plate is graduated in .0002 in. increments, Jurning the manuat saddle cross feed haniwhee! one graduation on the slip ring pravides an in or out saddle crassfeed of 001 in, The small reference plate divides each slip ring graduation into tive parts. provi ing crossteed incre ments of .0002 in.approximately .050 in. saddle approximately crossfesd between ring grooves 010 in. feed between lines one revolution equals -050 in. crossfeed This contro! is used to adjust the increment of saddle crossfeed desired during automatic operation of the grinder AUTOMATIC CROSSFEED ADJUSTMENT CONTROL Use the crossieed adjuatment control to select the amount of auto- matic saddle crossfeed which is desired at each table reversal. Each revolution of the control knob will produce .080 in. crossteed (see drawing). The controi shaft is calibrated with ring grooves (each groove represents .050 in. crossfeed) and numbered lines (each line represents .010 in. crossfeed),PILOT VALVE The plot valve is operated by the table trip doge during auto- matic operation. Itcontrola the direction of table travel and requires no adjustment. If it is desired for set-up purposes to run the table beyond the trip dogs, the pilot valve reversing lever can be turned far enough to allow the table to pass the lever. (CAUTION: Move the table very slowly). The manual vert ical feed (downteed) hand- steel. The zeroing stip ring is provided with locking knobs. The large handwhee | is used for coarse adjustment down to. the workpiece. Each slip ring graduation pro- vides avertical travel of .0005 in. Then the center tine feed knob is used for fine adjustments down to 0001 in. as indi- catad on the graduated reference plate, which divides each slip ring gradation into five parts, VERTICAL FEED (""downfeed") HANDWHEEL The manual vertical feed handwheel is graduated in .0006 in. incrementa for coarse adjustment, A fine feed handwheel is located inthe center of the handwheel for fine adjustments to .0001 in. ag in- dicated on the reference plate. A zeroing slip ring is provided on the large handwheel, ‘The advantage in using a zeroing slip ring is that it eliminates the need todo mental arithmetic, a potential source of grinding error, For example, suppose that you wiahed to grind a step in a workpiece sothat itis exactly 0126 inchbelow the top gurface af the workpiece. The slip ring is simply set go that the handwheel reading is at zero. ‘Then, to grind a step .0125 below the workpiece surface, the hand- wheel is turned to the .0125 reading. No mental caleulations are re- quired. NOTE: Motorized wheel elevation, controlled by pushbut- ton, ia standard on the D-8 and D-10 Grinders, and an accessory on the D-6 Models.ose THE SELECTRON (accessory control for electromagnetic chuck), Description - The SELECTRON made by DoALL combines a rectifier and demagnetizer into one compact unit, for operating elec~ tromagnetic chucks, and has the additional advantage of providing variable holding power. Thisis an important feature in the grinding of thin work pleces which may be warped by full power. The holding Power can be reduced by merely turning the control knob to a setting whieh will hold the work without distorting it. Work is demagnetized in about 15 seconds by flipping the toggle switch. ‘The operator is constantly informed as to the condition of the chuck by a neon light which shows when the magnetic power is on. It varies in intensity to Indicate the re‘ative holding power of the chuck. A flashing red light signals the demagnetizing cycle and stops when the cycle is completed. SELECTRON HOLDING POWER 190) 90 jf 80 70 60 50 40 30 HIGH RANGE 20 KLoW RANGES 10 ° lowl 2 3 4 5 & %%F @ 9 TOFULL CONTROL KNOB SETTING ON IIjustrating the holding power provided by each setting of the contro! kaob. PERCENT HOLDING POWER SELECTRON Holding Power - Starting from a fully demagne- tized condition, the holding power of the SELECTRON increases as shown on the chart (above) from minimum of 10% at "low" dial setting to 100% at "Full On", There are two curves on the chart-- the first showing the low range and the second the high range show- ing the curve as the control knob is turned down from the * Full On" setting without demagnetizing to the "Low" dial setting. Note that the holding power follows 2 new and considerable higher curve This phenomenon 1s called magnetic hysteresi« and becomes more pronounced with the harder steels. it actually provides a dual range of holding power for the work piece. When grinding very hard wSELECTRON CONTINUED... steel work pieces, and if the holding power is insufficient at low range control knob settings, the holding power in some instances can be more than doubled by turning from the zero settingto the "Full On" position and then down again to the desired setting. CAUTION Keep unit dry---coolant or moisture will short circuit the SELECTRON, Operation - (1) Turn control knob to desired holding power, (2) Set toggle switch to "Magnetize” position, (3) Set circuit breaker at "On" position. $0 and 100 watt SEL- ECTRONS are not equipped with a etrcult breaker. (4) Turn power switch on. Ing few seconds the magnetic circuit will be in operation. (5) To demagnetize flip toggle switch to demagnetize position. Inabont 15 seconds the work canbe removed from the chuck (CAUTION Remove work very carefully to avoid scratches). The SELECTRON is equipped with elther a circuit breaker or fuse in the A.C. line. If the circuit trips to the "Off" position after a few seconds the circuit breaker will reset and can be turned to the "On" position. If it trips "Off" again check the tubes and the power terminal strip in the SELECTRON. If either one is shorted out, it will short circuit the unit, causing the circuit breaker to trip. If the unitis equipped with a fuse and the unit can not be energized the fuse is probably defective. There are several models of SELECTRONS used on the DoALL grinders. This Model is used on the O-g series of machines 2CHAPTER 4 PREPARATION FOR OPERATION Check these paints each cay before operation. (1) Models with air filter in hase - Check alr filter daily. Re- move filter for cleaning by first sliding up, then pulling out on bottom. Check to see if fan is operating by pressing hydraulic start button. Make sure that all base panels are in place---thls is very Import- ant for proper base ventilation. (2) Check oil level in automatic lubricator, tank (sight gage on side)and fill if necessary with DoALL Way Lubricant. Check to see if column, table and aaddle ways are being lubricated by looking or feeling for fresh cil on the ways. (3) Check hydraulic tank oil level (sight gage at left side of bage) and fill If necessary aulic fluid. Mix with one gallon of EP-90 Hypoid oil at each refill. Keep tank: full at all times. (4) Check coolant_tank {uid level and condition of coolant, Change coolant and filter or fill tank If necessary. Use Kleen Kool made by DOALL and mix per instructions on container labe}. GTRUING THE WHEEL FACE (1) The position of the diamcnd on the table with respect to the grinding wheel is important for proper truing. The diamond point should be located slightly to the left of the wheel centerline (about 1/4 in.) as shown below. This ig a safety precaution to prevent the diamond from digging into the wheel, SIAOND s¥OULD BE AL Lica namo sauLa or MECLTAVE ANGLE. TO WHEZL Aa0ut Can 10 LeFL ‘CU? AR LESS OF VERTICAL ceareRuine oa olor - MOUNTED 14 797 sit gs & fi ISiT(OW Ow ‘woLOER * ae SET SCRE goku AT AlGAEST POtnT sey gre q OLDER OW AHEEL Fate HOuOER FRONT VIER eNO YIEW This is the correct position of a chuck-mounted diamond dresser when used for truing and dressing the wheel. (DoALL Oresser shown). NOTE ‘Use coolant if at all possible during truing pro- cedures. This will prevent the diamond from overheating. The diamond should also be cantec at a negative rake angle of 15° to the direction of wheel travel. In this way the diamond will be worn at a bevel. Then, in order tc present a sharp cutting surface to the wheel, al) that is necessary is to turn the diamond in the hold- er (15° or 26°} so that the high, sharp edge of the bevel encounters the wheel. This should be done regularly. The DoALL, diamond holder (available as accessory) has an arrow that indicates the dir- ection in which the holder should te placed on the table with respect to wheel rotation. The arrow on the holder should point in the dir- ection of wheel rotation as observed at the bottom of the wheel. This holder locates the diamond at the desired 15° angle. B(2) Start the spindle motor. Position the grinder saddle and ad- Just the wheel height so that the cutting edge of the diamond will just contact the highest point on the wheel periphery (usually at the center). The precaution is necessary to prevent the diamond from taking too deep a cut in the wheel with gubsequent damage to the diamond and the wheel. (8) It {s vital that the diamond be sharp, particularly for truing. When the diamond has worn, turn it a few degrees so that a sharp face is always against the wheel, Use Coolant (especially the Cool Grinding method, if that is available.) TRUING THE WHEEL SIDES "Side" truing of the wheel may be necessary. Turnoff the spindle motor and observe the wheel from its edge as it slows down. If any wobble 1s visible (this will produce lines in the work plece), the sides of the wheel must be trued. {2} Loosen the set screw holding the diamond in place and po- sition the diatnond in the side position on the holder. (2) Position the holder as shown in drawing below. Once a= gain, the rule applies of placing the diamond slightly to the left of the wheel centerline and at a negative rake angle of 15°. Make sure that the wheel guard will clear the diamond during table traverse. (3) Feed the diamond across the side of the wheel (using man- ual table control) at a very slow table speed and a cut of about .002 in, Then adjust the crossfeed handwheel for another cut and make another pass in the opposite direction. Duaexe sama aE A [ee auteur necaTi¥E sata aad Dea Ee ue oP Vig EN View Side truing the grinding wheel, using the DUAL Diamond Dresser. Pe]DRESSING THE WHEEL * After a wheel has been properly "flat trued" it may or may not have the desired “dress”. If the wheel is to be dressed for removal of material at a moderate rate and a fine finish is also deaired, its face should be as even and flat as possible. This may have been ac- complished in the truing process, but in general, a wheel should be Burposely dressed for the finish desired. Sometimes, however, the wheel will be heavily "loaded", i.e., glutted with chips from a pre- Vious grinding operation It insafflelent wheel material was removed inthe truing operation, some of this loading may remain in the trued wheel. Additional wheel material must then be removed to obtain a clean, sharp wheel, Consistent cleancolor of the wheel can be a guide to this. If rapid removalof material is paramount and finish secondary omit the finish cut when trulng the wheel or take one more cut (.001") ata fairly rapid crossfeed. This leaves a spiral groove and accomp- anying spiral ridge inthe wheel face, thereby providing a, more effec- tive cutting surface. For good dressing it is eegential that diamond be sharp so ab~ rasive grains will be completely fractured and project from wheel bond, Turn the diamond in its holder 15° or 20° when necessary. A dull diamond tends te crush grains into bond and crack them without producing a clean break, Gzainé mashed into wheel give effect of wheel loading while cracked grains come out while grinding and produce scratch ngs tn work. For fine finishes on flat grinding jobs, wheel edges should be rounded off with a band stone or precision tool after dressing. This will prevent chipped wheel edges and will keep feed lines on the work at a minimum. Shoulder grinding will necessitate a true 90° wheel edge. CAUTION Care should be taken to avold burning the diamond. Coolant applied to a hot diamond may cause it to crack, "Instructions for the use of the “Over-the-Whecl" Dresser Acces- sory are given in the Accessorics Chapter. 3BALANCING THE GRINDING WHEEL. For accurate grinding, it s essential that a grinding wheel be in good balance. All advantagea of well conditioned equipment, skill~ ful aet-up and operation are sacrificed if the grinding wheel 1s out of balance. The pounding or vibration of an unbalanced wheel, no matter how alight, will result in poor grinding. The DoAl! Balancing Arbor and Stand. ‘The balancing arbor and stand consist of an arbor shaft which sup- ports the wheel and adapter upon two V's formed by overlapping disks. To avoid false indication, the arbor and stand must be kept clean, in good condition and level. Before balancing, the wheel should be run several minutes without coolant to sling out excess water. Foliow this procedure to balance a wheel: (1) Mount the wheel on the griader and true the wheel. Mount the assembled wheel adapter on the tapered nose of the arbor shaft. Then place on the stand disks. (2) When the wheel tg placed on the stand, it will oscillate for a moment before coming to rest. Mark the exact bottom of the wheel withchatk, rotate it90* andallow itte come to rest again. If the chalk markis againat the bottom, the whee) is out of balance and the chalk mart: indicates the heavy side,MOUNTING THE GRINDING WHEEL (A) USING STANDARD (DRY or FLOOD GRIND) ADAPTERS Standard wheel adapters supplied with all models are of the dry or flood grind type (shown in photos and drawings), This type consists of an adapter designed to fit over the spindle tapered nose,and a spanner nut, The grinding wheel is clamped between the adapter and nut. The adapter is attached to the spindle by the spindle nose nut. To install: (1) Select correct adapter for the wheel size. (2) Degrease and clean the adapter, Inspect adapter carefully for scratches or burrs. The1.D. bore of the adapter is not a hardened surface and can be easily scratched if it is carelessly placed over the hardened spindle nose threads. (3) Place the adapter on the spindle nose. Lightly tighten spindle nose nut (do not tighten nut excessively). An opening is provided at the rear of the spindle onbelt-driven grinders sa that a socket wrench san be used to hold the spindle stationary while removing the nose mut. (4) Place wheel on adapter (do not remove wheel blotters, DOALL perforated wheel blotters must be used with "Cool grind- ing" adapters), Install spanner nut using spanner wrench furnished with machine, Do not tighten excessively or wheel may crack. (5) Dress face of grinding wheel, then dresg wheel sides as described under "wheel dressing”. (6) Remove wheel and adapter a4 unit. Use wheel puller furnish- ed with machine; remove spind:e nose nut, screw puller into adapter and turn puller screw in until it contacts spindle and forces adapter off. (B)_ USING "COOL GRIND" ADAPTERS (WITH OR WITHOUT BAL- ANCING LUGS), “Cool grind” adapters are identical to dry or flood grind adapters except for the addition of coolant collector flanges (see photos), Note that the adapters for the small wheels (7 and & in. dig.) have separate flanges, adapters and nuts while the large wheel (10, 12 & 14 In. dia.) adapters are two-piece units with rear flange combined with the adapter and front flange attached by screws. Assemble the adapters and wheels in the same manner as the dry or flood type, Balance the adapters with balancing lugs as described in “Wheel Balancing”, 28» Use wrench handle to tighten spindle nose nut (NOTE: spindle has ieft- hand threads). Using spanner wrench to tighten adapter fut Use whee! puller to remove wheel and adapter (cool grind adanter Shown),balancing weights Dry or flogd type with balancing weights for 7&8 in. diameter wheels. rear Flange mounts on spindle shaft Adapter without balancing weights for 726 in. diameter wheo!s Ory ar flood type without dalancing werghts for 1, 12 £14 in. diameter wheels,(for balanced type, use coo! grind adapter), Ory ar Flood grinding edapters. adrear flange adapter weights SH “ Cool grind type with balancing weights for 7&8 in. diameter wheels, Coal grind type without balancing weights for 7&4 in, diameter wheels. front flange si} ie a GSS spindle spindle nose nut _ talancing weignts 0, 12 £14 in. wheels. Three types of Wheel adapters used for coo! grinding. 31This is the type of wheel adapter used for dvy or flood gcinding with 19, 12 arta inch dia, sheels “*Caol Grinding’ * type af whee! adapters have perforated flanges tar Coolant flaw through tha wheel. This is the ‘aoapter for 7 or g in. dia. wheels. For larger, 19,12. 034 in. dia wheels, 4 tHo- piece coal grinding adapter is used"GRINDING IN" THE CHUCK ‘The surfaces of the chuck bave been ground at the factory, but, to ingure accuracy, it 1s necessary to “grind in" the chuck on the grinder with which it is to be used. The following procedure is ré¢. Stumended for a new chuck: Fach time the chuck lo removed Irom the machine, the top surface should again be ground, to insure par- alleliom between Hig surface and the saddle and table ways (1) Carefully clean and degreage the new chuck and the machine table pad. A"46 -I" or "J" wheel is recommended. (2) Use a tile or deburring tool to break the outside edges of the bottom side. Check the bottom surface for burrs. Apply a light film of ofl to table pad. (3) Grind the top (holding) surface of the chuck first. Place the chuck on the table and block in place Do not clamp the chuck down (Wig will provide a true, undistorted surface for grinding). Use a coarse dresged grinding wheel. (4) Take .0005 in. deep cuts, using .030 in, crossfeed and 75 ipm table speed, Use coolant. Do not turnchuck power on. Grinding should start with the high side of the cick. This is located by finding the high point at ack Hide Gf Shuck, setting downfeed slip ring to 0, rais~ ing wheel and locating highest poin: of front side of chuck. Then com- pare the two sides and start grinding at highest side. Grind in both directions, reducing downfeed alitile on second grind. Start with 1/8th wheel contact (if coolant is notused {for first pass, sparks can be more easily seen). (8) Dregs the wheel (using SELECTRON power to hold the dia- mond dresser). (6) Remove chuck, deburr, break corners and clean chuck and table pad. Place a light film of ofl on table pad and place chuck on pad with holding surface down. Block chuck in place. Do not usé SELECTRON power. Grind bottom of chuck until it is flat. Note: If it is necessary to dreas wheel again, use machinists’ clamp to hold wheel dresser on chuck. (1) Remove chuck, deburr, break corners and clean chuck and table pad very thoroughly (remove all oil), Apply alight film of DoALL, “Chuck-Lock" (furnished with machine) to table pad. (8) Place chuck in normal position with holding surface up. Use table clamps this time, tighten both clamps finger tae Tiret. Adjust chuck ao that it is parallel to table travel, use a .001 in. indicator. BGRINDING IN THE CHUCK CONTINUED ‘Tighten lefthandelamp. Tighten right-hand clamp tight, then back off slightly. Waen chuck is correctly oositioned, tighten right-hand clamp nut slightly more than finger tight. This will allow the chuck to expand in a horizontal plane without buckling. Dress wheel. (9) Grind top surface (with full SELECTRON power on) until it isflat. The final cut shouldbe at .0002 in. downfeed and .030 in. cross- feed with 75 fpm table speed. This type of heavy-duty chuck clanp must be wsed on all high-speed (125 fam) grinders. SELECTING and MIXING COOLANT DoALL Kleen-Kool 1s a nontoxic, chemical type coolant devel- oped specifically ior precision "Cool Grinding". When mixed with water it instantly forms a true chemical solution without the danger of inverting or separating in the machine. The solution is transparent, allowing the operator a clear view of the workpiece. Kleen-Xool hag the distinet advantage of not attacking aluminum er copper ag do seme of the cheaper synthetics. This allows its use over a wide range of materials. Any evaporative product of Kleen-Kool is readily redissolvable in water, resulting in a clean wheel. Soivent type cleaners are not recommended. Their use muy create afilm whichis extremely messy to remove, 4