INSTRUCTION MANUAL

This manual contains

important safety instructions.
To prevent accidents, these
instructions must be followed. Year of construction: 2001

TIMESAVERS Inc.
5270, Hanson Court MINNEAPOLIS, Minn. 55429-3161, U.S.A.
Phone ++1.763.537.3611 FAX ++1.763.537.9247
Label langs de stippellijn uitknippen

2200-900-WB / 2287-03
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TIMESAVERS

WIDE BELT GRINDING MACHINE

INSTRUCTION MANUAL

We are pleased to present this manual to you.

Read this manual carefully, before you operate this machine.

PATENT NOTICE

The machine and attachments illustrated and described in this booklet are manufactured under,
and protected by issued and pending patents.

The design and specification of these machines are subject to change without notice.
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INDEX

1. GENERAL ..................................................................................................................................6

1.1 INTRODUCTION.................................................................................................................7

1.2 MACHINE SPECIFICATION ............................................................................................9

2. DESCRIPTION AND FUNCTION ........................................................................................10

2.1 DESCRIPTION OF THE MACHINE ..............................................................................11

2.2 FUNCTION OF THE MACHINE ....................................................................................11

3. SAFETY, RESPONSIBILITY ................................................................................................13

3.1 SAFETY SUMMARY ........................................................................................................14

3.2 SAFETY EQUIPMENT .....................................................................................................15

3.3 IMPORTANT INFORMATION REGARDING SAFETY ............................................16

3.4 MACHINE LOCKOUT .....................................................................................................18

3.5 SAFETY GUIDELINES TIMESAVERS MODEL GR-2200-900 WB ..........................19

4. DELIVERY, INSTALLATION, CONNECTION ................................................................22

4.1 ASSEMBLY DRAWING ...................................................................................................23

4.2 WEIGHT OF MACHINE PARTS ....................................................................................24

4.3 DELIVERY AND INTERNAL TRANSPORT ................................................................25

4.3.1 SUPPLY .......................................................................................................................25
4.3.2 DAMAGE DURING TRANSPORT............................................................................25
4.3.3 CONTEMPORARY STORAGE .................................................................................25
4.3.4 PROTECTION DURING TRANSPORT ....................................................................26
4.3.5 CENTRE OF GRAVITY .............................................................................................26
4.3.6 TRANSPORT WITHOUT PACKING ........................................................................27

4.4 COMMISSIONING - INSTALLATION AND START-UP ...........................................28

4.4.1 BY A TIMESAVERS OR DEALER TECHNICIAN ..................................................28
4.4.2 INSTALLATION WITHOUT FACTORY/DEALER START-UP .............................29
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4.5 SETTING THE MACHINE IN PLACE...........................................................................30

4.5.1 PLACING THE MACHINE ........................................................................................30
4.5.2 LEVELLING OF THE MACHINE .............................................................................30

4.6 ADJUSTMENT AND CONNECTION .............................................................................31

4.7 DUST EXTRACTION SYSTEM ......................................................................................32

4.8 COMPRESSED AIR ..........................................................................................................34

4.9 ELECTRICITY...................................................................................................................35
4.9.1 ELECTRIC CIRCUIT DIAGRAMS ............................................................................35
4.9.2 ELECTRICAL SUPPLY..............................................................................................35

5. OPERATION ...........................................................................................................................37

5.1 OPERATION SYMBOLS..................................................................................................38

5.2 ADJUSTMENT OF CONVEYOR SPEED ......................................................................39

5.3 AUTOMATIC THICKNESS SETTING ..........................................................................40

5.3.1 ADJUSTMENT ...........................................................................................................40

5.4 INSTALLATION OF ABRASIVE BELTS ......................................................................41

5.5 MACHINE ADJUSTMENT ..............................................................................................44

5.6 ADJUSTMENT OF THE CONTACT ROLLER ............................................................46

5.7 HOW TO ADJUST THE BRUSH HEAD ........................................................................48

5.8 GRINDING PROCESS ......................................................................................................50

5.8.1 DEBURRING...............................................................................................................50
5.8.2 FINISHING ..................................................................................................................51
5.8.3 ADJUSTMENTS OF FIXED/FLOATING PRESSURE ROLLER BAR ...................51
5.8.4 RECOMMENDATIONS REGARDING DEBURRING AND GRINDING...............52

5.9 CLEANING OF YOUR MACHINE .................................................................................53

6. PARALLEL ALIGNMENT AND ADJUSTMENTS............................................................55

6.1 INTRODUCTION...............................................................................................................56

6.2 ADJUSTMENT OF FIXED TABLE ................................................................................58

6.3 CONVEYOR .......................................................................................................................59

6.3.1 READJUSTMENT OF TENSION BALANCE BETWEEN RIGHT AND LEFT .....59
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6.3.2 DRESSING (GRINDING) OF THE CONVEYOR BELT ..........................................60

6.4 FINGER SAFETY BAR (NO-GO-BAR) ..........................................................................62

6.4.1 PARALLEL ALIGNMENT .........................................................................................62
6.4.2 ADJUSTMENT OF THE HEIGHT .............................................................................64

6.5 ELECTRONIC OSCILLATION ......................................................................................66

6.5.1 FUNCTION..................................................................................................................66
6.5.2 ADJUSTMENT OF ABRASIVE BELT OSCILLATION ..........................................67

6.6 SET OF FLOATING PRESSURE ROLLERS WITH OVERTHICKNESS SAFETY68

6.6.1 ADJUSTMENT AND PARALLEL ALIGNMENT ....................................................68
6.6.1.1 PRESSURE ROLLER SET .....................................................................................68
6.6.1.2 OVERTHICKNESS SAFETY.................................................................................69

HEAD 1 70

6.7 CONTACT ROLLER .........................................................................................................71

6.7.1 PARALLEL ALIGNMENT .........................................................................................71

6.8 FINE ADJUSTMENT ........................................................................................................72

6.8.1 RE-ADJUSTMENT .....................................................................................................72
6.8.1.1 WEAR AND TEAR OF ABRASIVE BELT ...........................................................72
6.8.1.2 ANOTHER MAKE OF ABRASIVE BELT ............................................................72

HEAD 2 73

6.9 BRUSH HEAD ....................................................................................................................74

6.9.1 PARALLEL ALIGNMENT .........................................................................................74
6.9.2 RE-ALIGNMENT ........................................................................................................74

OTHER ADJUSTMENTS 75

6.10 AUTOMATIC THICKNESS SETTING ..........................................................................76

6.10.1 ADJUSTMENT .......................................................................................................76
6.10.2 ADJUSTMENT OF TABLE HEIGHT READ-OUT ..............................................77

6.11 MECHANICAL BRAKES .................................................................................................78

6.11.1 DESCRIPTION AND FUNCTION .........................................................................78
6.11.2 MAINTENANCE OF THE BRAKE .......................................................................80
6.11.3 REPLACEMENT OF BRAKE DISK PADS ..........................................................81

6.12 ADJUSTMENT DATA .......................................................................................................82

6.12.1 GRINDING LINE ....................................................................................................82
6.12.2 MEASURING METHOD ........................................................................................83
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6.12.3 FINGER SAFETY BAR ..........................................................................................84

6.12.4 SPRING LOADED PRESSURE ROLLERS...........................................................84
6.12.5 CONTACT ROLLER ..............................................................................................84
6.12.6 FIXED PINCH ROLLERS ......................................................................................85
6.12.7 BRUSH HEAD ........................................................................................................85
6.12.8 FIXED PINCH ROLLERS ......................................................................................85

6.13 BRUSHES ............................................................................................................................86

6.13.1 TYPES OF BRUSHES ............................................................................................86
6.13.2 BRUSH DESIGN.....................................................................................................88
6.13.3 STORAGE OF BRUSHES ......................................................................................89
6.13.4 DRESSING AND CLEANING OF BRUSHES ......................................................89

6.14 BRUSH REPLACEMENT.................................................................................................92

6.14.1 REMOVAL OF COMPLETE BRUSH WITH SLIDE............................................93
6.14.2 RE-INSTALLATION OF THE BRUSH WITH SLIDE .........................................93
6.14.3 DISMANTLING OF THE BRUSH FROM THE SLIDE .......................................94

7. ABRASIVE BELTS .................................................................................................................96

7.1.1 WHICH ABRASIVE BELT TO BE USED.................................................................96
7.1.2 STORAGE AND MAINTENANCE............................................................................96
7.1.3 STORAGE OF ABRASIVE BELTS ...........................................................................96
7.1.4 HOW TO INCREASE ABRASIVE BELT LIFE ........................................................97
7.1.5 HANDLING OF ABRASIVE BELTS .........................................................................97

8. MAINTENANCE .....................................................................................................................98

8.1 RECOMMENDATIONS ....................................................................................................99

8.1.1 GENERAL RECOMMENDATIONS ..........................................................................99
8.1.2 COMPRESSED AIR CLEANER ..............................................................................100
8.1.3 SWARF (DUST) ........................................................................................................100
8.1.4 CONVEYOR BELT AND V-BELTS........................................................................100
8.1.5 (PRESSURE ROLLERS AND/OR PRESSURE BARS) ..........................................100
8.1.6 LIMIT SWITCH TIP (CERAMIC TIP) .....................................................................101
8.1.7 INFINITELY VARIABLE CONVEYOR FEED DRIVE (VARIATOR) .................101
8.1.8 TENSION OF ABRASIVE BELT .............................................................................101
8.1.9 OSCILLATION..........................................................................................................101
8.1.10 SAFETY EQUIPMENT ........................................................................................101
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8.2 LUBRICATION FREQUENCY......................................................................................102

9. TROUBLESHOOTING ........................................................................................................103

10. SPARE PARTS ......................................................................................................................107

10.1 WHERE AND HOW TO ORDER SPARE PARTS ......................................................108

10.2 SUGGESTED SPARE PARTS LIST:.............................................................................109

10.3 STORAGE OF SPARE CONTACT ROLLER..............................................................109

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1. GENERAL
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1.1 INTRODUCTION

1. The model GR-2200-900-WB is suitable for deburring.

2. For service or inquiry about this manual please contact your dealer or us:

TIMESAVERS Inc.
Hanson Court
MINNEAPOLIS, Minn. 55429-3161, U.S.A.
Phone ++1.763.537.3611 FAX ++1.763.537.9247

3. Please always mention the machine no. and model. They are to be found in this manual and
on the machine plate.
Your Machine No.: 2287-03

4. Owner’s manual.
This manual is for Timesavers GR-2200-900-WB.

5. All machine operators must read the manual before operating the machine.
Always keep this manual within the reach of the machine operators.

6. This manual is meant for machine operators and authorized technicians. Only the sections
“General”, “ Description and Function”, “Safety, Responsibility”, “Operation”,
“Troubleshooting” and “Abrasive belts” are meant for the machine operators, too. The
sections “Delivery, Installation, Connection”, “Parallel alignment and adjustments”,
“Maintenance” and “Spare parts” are meant for authorized technicians ONLY.

7. Problems.
Should you have problems please do not hesitate to contact your dealer or our service
department. They are always ready to help you.

8. Training.
Without the necessary training - within the company, by training centers or within the
Timesavers-training center - nobody is allowed to work with the machine (not even for a
short while).
If you are interested in training by our training staff, please make an appointment with our
dealer or with us.

9. SAFETY
The directions to minimize the hazard of personal injuries are optically highlighted.
Furthermore, all instructions to prevent personal injuries and directions for safe machine
operation are summarized in the section “Safety”. These instructions must be followed.
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10.Symbols used in this manual:

The following symbols refer to danger or detailed technical information.

The DANGER or WARNING symbol refers to danger of

personal injury or machine danger.
This symbol is shown in this manual
where you have to be informed of possible or specific
danger.

These symbols are to be found

in this manual where you have to be informed of
specific danger.

Next to the INFO-symbol please find detailed

information
regarding correct machine operation.

Good luck!
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1.2 MACHINE SPECIFICATION

Work width 900 mm (35.433 inches)

Abrasive belt size (L x W) 1900 x 930 mm (74.803 x 36.614 inches)
CE-standard
Electronic oscillation
Mechanical brakes on main motors
Main switch, hour counter
460 Volt, 60 Hz

1st head
Contact roller Ø 180 mm (7.0866 inches), 35º Shore (NO 25 45)
Rotation speed 18 m/s, with the feed
Main motor 13 kW
Fine adjustment
Dial indicator on contact roller

2nd head
Brush head
Stainless steel brush, ST RV 10 01
Grinding speed 22 m/s, two rotation directions
Main motor 13 kW
Brush oscillation

Pressure elements
Pressure roller front, spring loaded, with end switch
Pressure roller middle and rear, fixed

Table and feed

Fixed table
Conveyor belt super grip
Belly-brake
Digital read-out in inches
Automatic thickness setting
Jog switches reverse feed
Conveyor motor frequency-inverted 1.5 kW 4-16 m/min
Motorized table height adjustment with single point measuring and digital read-out
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2. DESCRIPTION AND FUNCTION

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2 8 1. CONTACT ROLLER
2. BRUSH HEAD
1 3. BOTTOM FRAME
6
4. CONVEYOR TABLE
7 5. CONVEYOR BELT
6. PRESSURE ROLLS
OUTFEED INFEED
7. WORK PIECE
8. DUST HOODS
4 9. ELECTRICALLY
5 DRIVEN MAIN
3 MOTORS
9

Assembly wide belt grinding machine

2.1 DESCRIPTION OF THE MACHINE

A wide belt grinding machine is a stationary machine tool which grinds or deburrs work
pieces by means of endless wide abrasive belts and/or brushes (refer to Assembly wide belt
grinding machine).
The purpose of grinding or deburring is:
• elimination of burrs or radiussing edges;
• a high-quality finish;
• or a combination of both

2.2 FUNCTION OF THE MACHINE

The work piece to be ground (7) is fed into the machine at the infeed side of the machine. The
conveyor belt (5) feeds the work piece through the machine. During the conveyance pressure
rolls (6) press the work piece to the conveyor belt. The roller head (1) and brush head (2) are
driven by electrical motors and V-belts (9).

When the work piece is fed through the machine, it first passes the roller head (1). The roller
head consists of a contact roller and a tension roll around which the abrasive belt runs. The
tension roll is used to tension the abrasive belt and to track it by means of the oscillation
system. The abrasive belt is driven by the contact roll.
Then the work piece passes the brush head (2).
The brush head rotates at a lower speed and oscillates, i. e. the brush moves side-to-side with a
stroke of 10 mm (0.0408 inches). This function ensures that the work piece will be brushed
evenly.
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Then the work piece runs at the outfeed side out of the machine.
Selectively, a work piece can be processed by the first head, second head or with the two
heads in one pass.

The conveyor table (4) can be adjusted in height and is suitable for work pieces of different
thicknesses. Through the dust hood (8) the dust is extracted which occurs during grinding.
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3. SAFETY, RESPONSIBILITY
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3.1 SAFETY SUMMARY

REMEMBER TO PUT SAFETY FIRST - THINK!

The “Danger” sign refers to the danger of personal

injury or machine danger. The sign can be found in
this manual informing you of possible dangers.

READ this manual first before operating the machine.

2. ALWAYS disconnect electrical power before

carrying out maintenance, adjustment, cleaning and
lubrication of the machine.

3. The operator IS NOT ALLOWED to stand in line

with the work piece at the operation and rear side
of the machine. He MUST stand ASIDE during
operation.

4. Avoid explosion or fire:

- Clean the machine daily.
- Do not smoke or weld by the machine.

5. Do not remove safety covers and safety doors.

Keep your body and clothing away from rotating
parts.
NEVER perform cleaning when the machine is
running.
NEVER wear gloves.
Do not create pinch point between part and table
when feeding the machine.

6. NEVER clean the abrasive belt (and/or brush)

while they are IN the machine.
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3.2 SAFETY EQUIPMENT

1. EMERGENCY STOPS.
The emergency stops are at the front side (c) of the machine
on the operator’s panel and when the machine is executed
with 2 or more heads at the left hand side of the rear side (d)
of the machine. After activating the emergency stop the
machine will stop. After pushing the reset (a) button the
a emergency stop will be set free.
DO NOT RESET THE MACHINE, BEFORE YOU ARE
b SURE THAT THERE IS NO LONGER A REASON FOR
AN EMERGENCY STOP!!!
0 1

c
2. FINGER PROTECTION BAR (NO-GO BAR), BELLY BRAKE.
At the infeed end the machine is equipped with a finger
protection (e) bar. A belly brake bar (f) can be equipped to
the infeed table as an option. If one of these finger
protections is pressed, the conveyor belt stops.
d

3. DOOR SWITCHES.
On the belt loading side, the machine is equipped with an
interlock door switch (g). If one of these doors is opened the
machine will stop automatically (emergency stop). If any
general maintenance required has to be done, the door switch
can be by-passed (by an authorized person only) using the
set-up key (b) on the operator’s panel.
e

4. BRAKING OF MAIN MOTORS (ELECTRONIC)

The heads stop by electronic braking device, if
f • the emergency stop is pushed.
• the doors on the belt loading side are opened.
• the grinding belt erupts.
• the belt protection switches are activated.

5. STOPPING OF CONVEYOR BELT

The conveyor belt stops if
• the emergency stop is activated.
• the finger protection bar is pushed.
• the belly brake is pushed.
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g 6. STARTING OF HEADS
A head can be started if
• the abrasive belt is tensioned.
• the emergency stop is not activated.
• the doors are closed.

3.3 IMPORTANT INFORMATION REGARDING SAFETY

To proceed with caution is the best insurance against accidents!

Read the following information carefully and understand this manual before operating the
machine. Timesavers want you to have a safe and efficient machine operation. If you have any
questions, please contact your dealer or Timesavers.

1. As manufacturer of machines we point out that many countries have their own
safety rules for the operator and regarding the electrical connections.

2. We point out especially that in the majority of countries it is NOT allowed that
unqualified personnel carries out repairs to the electronic, etc.

3. The machine has to be grounded.

4. Do NOT operate the machine without supervision.

5. Do NOT work on the machine knowing that there is something wrong.

6. ALWAYS disconnect electrical power and switch off main switch before the
machine or parts of the machine will be adjusted, repaired or maintained.
Make sure that it may NOT be possible to start machine operation by a third person
during repair or maintenance work (key-snap lock, padlock etc.).

7. Do NOT work on the machine if safety devices are removed. The safety devices are
mounted to avoid accidents.

8. The adjustment of the pressure elements is necessary to firmly hold the parts to the
conveyor belt and to avoid a kick-out or sticking of work pieces.
Regarding proper adjustment of the pressure elements, see chapter Adjustment of
pressure elements.

9. The finger protection minimizes the hazard that hands or fingers will be clamped
under the pressure elements or abrasive heads
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IMPORTANT:
Is the opening of the table (conveyor bed) higher than 40 mm (1.5748 inches),
there is a danger that hands or arms of the operator could be pulled into the
machine. In this case the finger protection cannot be activated automatically. If
there is a danger that your fingers are clamped, stop the machine by pushing the
finger protection bar upwards or pushing the emergency stop on the operator’s
panel.

Make sure that you know where the emergency stops are before operating the
machine.

10. Safe operation:

Do NOT operate the machine when the door of the electrical cabinet is open.
The electrical cabinet complies with the IP-54 safety standard and is safe when the
door is closed and locked!

Furthermore, no dust can enter the electrical cabinet when the door is closed. (Dust
in the electrical cabinet can cause malfunction of the machine.)

See safety guidelines at the end of this section.

See MACHINE SPECIFICATION at the beginning of this manual.

The safety devices must be checked regularly for proper function.

Operation without safety devices is dangerous.
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3.4 MACHINE LOCKOUT

1. The personnel, authorized to lockout the machine, MUST have the proper tools
to carry out set-up, maintenance and repair work properly.

2. Before repair, maintenance or set-up the following items have to be observed:

- Shut off electrical power by means of the main switch.

- Disconnect pneumatics and hydraulics. Pressures have to be relieved.

- Physically block all machine members that could move from gravity or spring
pressure.

- Check whether the electrical power is disconnected by pushing the buttons on

the operator’s panel.

- Identify the Lockout Condition with a tag on the electrical disconnect and
pneumatic shut off valve.

- When the work is complete, restore the machine to its original state and remove
all tags.

NEVER clean abrasive belt and/or brush while they are IN the machine.
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3.5 SAFETY GUIDELINES TIMESAVERS MODEL GR-2200-900 WB

3
4

5
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Description Hazard Protection Design User Requirement

1. Infeed of the machine Hand and limb crushing - Finger safety bar - Check finger protection
points - Safety stop circuit on each shift.
main motor brake - Check safety circuit each
- Instructions regarding shift.
machine operation - Visually check main
and warnings in the motor brakes each week.
manual. - Read and fully understand
All operators must read operations & maintenance
review, and understand manual and all decals.
the operator’s manual .
for this machine.

2. Both sides of the con- Hand and limb crushing - Fixed guard plates - Check that each guard
veyor belt on the front point. on each end of the is in place and
and rear side of the infeed and outfeed securely fastened.
machine. conveyor rolls. - Read and fully under-
- Instructions regarding stand operations &
machine operation and maintenance manual
warnings in the manual and all decals.
All operators must read - Trained supervisor(s)
review, and understand ensure operators know
the operator’s manual how to feed part and
for this machine. stay clear of danger
zones.

3. Electrical cabinet Electrical shock and - Fixed guards - Maintain key security
and other electrical severe burn; maim or - Mechanically inter- to trained authorized
equipment death. locked doors. personnel only.
- Power disconnect with - Allow only trained
provision for key electricians to access
snaplock. any electrical panel
- Electrical danger decals - Ensure disconnect
on machine operates properly.
- Mechanical door lock - Read and fully under-
with possibility to stand operations &
additionally protect maintenance manual
by means of a padlock. and all decals.
- Safety sticker
- Instructions regarding
machine operation and
warnings in the manual.
All operators must read,
review, and understand
the operator’s manual
for this machine.
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4. Machine Interior; Hand, limb and body - Fixed safety guards on - Maintain key security
Different types and abrading and crushing the doors to trained authorized
multiple numbers of high on the operation side, personnel only.
speed heads with abrasives protected by switch. - Check safety circuit
and/or knives and moving Any other doors with a key to ensure interlock is
parts. - Instructions regarding operational.
machine operation and - Check all safety features
warnings. each week.
All operators must read - Clean dust and/or swarf
review, and understand accumulations (drifts)
the operator’s manual from machine on a
for this machine. regular schedule.
- Read and fully understand
operations & maintenance
manual and all decals.

5. Hoisting or lifting - Hand, limb and body - Instructions, safety - Use only adequate means
with shipping breams or crushing procedures and of transport with sufficient
pallet warnings in the manual. bearing-power. Never stand
Supply: All operators must read, under a lifted machine etc.
seaworthy crate or review, and understand - Proceed as per safety
transport beams or the operator’s manual instructions, safety guide-
wood pallets. for this machine. lines, national laws.
- Manual sent to customer - Only experienced machine
with the machine. riggers may uncrate and
place the machine.

6. Kickback at product Hand, limb and body - Pressure bars (shoes) - Ensure pressure bars (shoes)
infeed crushing and puncture.. and/or pinch rolls to and/or pinch rolls are
reduce occurrence. properly set.
Kickout at product outfeed - All operators must read, - Trained supervisor(s)
review, and understand ensure operators know
the operator’s manual how to feed parts and stay
for this machine. clear of danger zones.
- Engineered conveyor - Read and fully understand
belt with high operations & maintenance
coefficient of friction. manual and all decals.

7. Explosion Hand, limb, body - Non sparking ceramic - Hire professional dust
maiming, and/or severe tips on abrasive belt(s) collector designers and/or
Fire burns or death limit switches. engineers and installers for
- Engineered dust hood proper dust collector
to reduce dust build-up installation.
(sparks) - Instructions, safety - Maintain recommended
(fine dust and/or swarf) procedures and warnings air flow in dust collection
in manual. system.
- All operators must read - Consult the national and/or
review, and understand local dust and swarf
the operator’s manual collecting and disposal
for this machine. regulations.
- Clean dust and/or swarf
accumulations (drifts) from
machine regularly.
- Check all safety features
each week.
- Read and fully understand
operations & maintenance
manual and all decals.
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4. DELIVERY, INSTALLATION, CONNECTION

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4.1 ASSEMBLY DRAWING

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4.2 WEIGHT OF MACHINE PARTS

Machine : approx. 2000 kg

Conveyor table : ± 500 kg

Contact roller : ± 100 kg

Brush head : ± 100 kg

Tension roller : ± 80 kg
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4.3 DELIVERY AND INTERNAL TRANSPORT

The machine you have purchased has been designed to produce high quality products. To
meet these requirements, the machine has to be handled with care during installation.
Therefore, it is recommended that the unpacking, placing, and installation of the machine will
be carried out by qualified personnel. Upon receipt of the machine, check immediately
whether the machine has been damaged during transport.

Do not sign the Bill of Lading before you have checked whether the machine has been
damaged during transit.
In case of damage(s), this has to be recorded clearly on the Bill of Lading.

Timesavers is not liable for damage during transport.

4.3.1 Supply
The machine will be supplied in a crate or on transport beams or pallet, packed in plastic foil.
Tools and auxiliary equipment are included.

Please pay attention to the markings on the packing.

4.3.2 Damage during transport

Upon receipt of the machine check immediately whether the packing has been damaged
during transport. Any transport damage has to be claimed with the forwarding-agent within
the legally required period.
In case of damage, contact your dealer, TIMESAVERS or forwarding insurance company
immediately.

4.3.3 Contemporary Storage

The machine has to be protected against further damage (e.g. influence of weather).
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4.3.4 Protection during transport

Use proper, undamaged transport equipment with sufficient lifting capacity. Dimensions and
weights are to be considered (assembly drawing and Bill of Lading).

Never stand under the lifted machine.

The instructions regarding prevention against accidents must be observed.

The machine has to be handled carefully during transport.
NEVER lift or support on sensitive parts, e. g. electrical cabinet and guards or supports. Use
safe transport equipment.

4.3.5 Centre of gravity

If the machine has to be transported in a crate the crate has to be lifted by means of cables or a
forklift with the forks or cables as far as possible apart. The center of gravity is not always the
center of the packing.
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4.3.6 Transport without packing

Keep the Bill of Lading in case of further transport.

Transport (internal transport):

• Dismantle all tools of the machine

• Disconnect pneumatics
• Disconnect electrics

Transport by means of hoist-eyes:

Only for machines equipped with hoist-

eyes.
Hoist angle <90°.
When the machine has to be lifted on the
hoist-eyes a (wooden) beam has to be used
to prevent machine damage.

• Fix lifting device properly!

• Proceed with caution when lifting the machine!
• Make sure that the machine is hanging right-up!

Transport with forklift:

Only on mounted (wooden) bars

• Slide a lifting device under the beams and tilt the machine.
• Drive the forklift under the machine.
• Proceed with caution when lifting the machine.

Consider the weight of the machine (weight machine parts and Bill of Lading).
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4.4 COMMISSIONING - INSTALLATION AND START-UP

4.4.1 By a TIMESAVERS or dealer technician

Contact Timesavers or your dealer as soon as possible, preferably 20 days prior to the date you
will be ready to put the machine into operation, so that it can be guaranteed that a technician
will be at your disposal in time.
The technician assists during the starting procedure and explains the operation and
maintenance of the machine.

Before arrival of the technician, the following has to be performed:

1. The packing has to be removed. The machine has to be placed. All brackets, blocks and
beams, used during transport, have to be removed (see MOUNTING OF MACHINE).

2. Rust preventative has to be removed. The client has to offer a person to carry out cleaning
before starting the machine.

3. Adjust levelling bolts and place foundation plates. The machine has to be placed on a
stable cement floor and aligned horizontally. The levelling bolts have to be placed on the
foundation plates (see INSTALLATION OF THE MACHINE).

4. Electrical and pneumatic connections. Electrical connection: 3 phases + ground. The

electrical and pneumatic systems have to be connected by an electrician. The earthing
resistor has to be checked (see Machine Specification and INSTALLATION OF THE
MACHINE).

5. Suitable abrasive belts (and/or brushes) must be on hand!

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4.4.2 Installation without factory/dealer start-up

Proceed according to the instructions of this manual (INSTALLATION OF THE MACHINE)
and check the following items:

1. Running direction of the conveyor belt

2. Functioning of the finger protection at the operation side of the machine

3. Adjustment of the pressure elements

(See corresponding chapters)

In case of doubt do not hesitate to contact Timesavers or your dealer. Timesavers

and your dealer are not liable for problems caused by carelessness during the
starting-up procedure.
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4.5 SETTING THE MACHINE IN PLACE

Before setting the machine in place review the assembly drawings, supplied with the machine,
regarding dimensions and the exact location of the electrical and pneumatic connection points.

Fig. 4.6
Fig. 4.7

4.5.1 Placing the machine

• Remove all brackets, blocks and beams, etc., used for transport.
• Dismantle the wooden transport bars on both sides of the machine.
• Place the machine with the levelling points (Fig. 4.6) on the foundation plates (Fig. 4.7)
(supplied with the machine).

4.5.2 Levelling of the machine

The machine has to be levelled by adjusting the levelling bolts (Fig. 4.6) on the steel
foundation plates Level the machine as follows:

• Put a liquid level (Fig. 4.8a) on the measure bolts (Fig. 4.8b) at the left and right hand side
on the front side of the machine.
• Level the machine on the front side with the levelling bolts (Fig. 4.6).
• Do the same adjustment on the rear side of the machine.

Preferably use a liquid level with a precision of 1 mm/m min.

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Fig. 4.8

4.6 ADJUSTMENT AND CONNECTION

1. Check the parallel alignment and adjustments of the following machine parts. (This has
to be performed by authorized personnel only.)
• Table
• Conveyor
• Pressure elements (rolls and/or pressure rolls)
• Abrasive heads (roll and/or brush)
• Automatic thickness setting

2. Connect electrics.

3. Connect the machine to the dust extraction unit.

4. Connect pneumatics.

5. Check all safety devices.

For detailed descriptions please refer to the concerning sections in this manual.
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4.7 DUST EXTRACTION SYSTEM

The Timesavers dust extraction system complies with the CE-normative.

The dust hoods have to be connected to a dust extraction unit of sufficient capacity to exhaust
the dust efficiently.

An efficient dust extraction unit prevents an accumulation of dust and minimizes

the danger of fire or explosion.

It is recommended to keep the extraction pipe diameter as constant as possible. Changes in

diameter cause velocity changes of the dust-air mixture which can cause dust accumulation.

Prevent sparks in the extraction system as these can cause fire! Ensure that the
abrasive belt is not touching the metal parts of the machine and that there are no
metal parts (nails?) in work pieces.
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Connection of the Dust Extraction Duct

On a variable pass-line machine a rigid ducting from the machine to the dust collection system
has to be mounted.

On a machine with variable pass-line the sanding heads and the frame stay at a constant
height, while the conveyor bed moves up and down to adjust the thickness needed for the
work piece.

1. First check whether you have a machine with constant pass-line or not, before connecting a
fixed or flexible ducting to the dust collection system.

2. The dimension sketch of the machine indicates the diameters which have to be applied to
the dust extraction hood(s) on top of the machine.

3. Connect the dust collection ducting to the dust hood(s) on top of the machine.

Fixed ducting for

variable passline
‘variable pass’
Dusthood of the
machine
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4.8 COMPRESSED AIR

Your machine has to be connected to a pneumatic system which must be able to supply a
pressure of at least 6 bar.

Compressed air is essential for the function of a number of machine parts (e. g. oscillation,
tension of abrasive belt) and has to be dry, clean and oil-free.
In case of polluted air (with water, oil etc.) the compressed air has to be cleaned. Therefore,
the main reducing valve (Fig. 4.10) is equipped with a dust and water separator.

The dust and water separators have to be cleaned regularly and, if necessary, the water has to
be drained off for a correct functioning of the pneumatic parts of the machine.

Connection and operation

The operator’s panel for the air supply is on the left hand side of the machine. The main
connection behind the operator’s panel has to be connected as follows:

1. Open the lower panel on the left side of the machine.

2. Connect the main air hose to the main reducing valve (Fig. 4.10b).
3. The air pressure must be 6 bar.
4. Open air supply with lever (Fig. 4.10a).

Turn the air supply off when the machine is not in operation.

PRESSURE
a RELIEF VALVE
(8 BAR)

Fig. 4.10
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4.9 ELECTRICITY

The design and construction of your TIMESAVERS machine is based upon the USA standard
UL- and OSHA regulations.

You must ensure that employees shall not be permitted to work on electrical circuit parts or
equipment that have not been de-energized and locked out and/or tagged out unless they are
qualified, authorized and trained to use safe work practices. In certain countries and certain
places the connection to the electrical supply may only be carried out by an authorized
electrician. (Consult your electrical contractor.)

Always disconnect power before opening the electrical cabinet. Prevent water or
moisture from entering the electrical cabinet.

The machine has to be connected to an electrical cabinet. The voltage and frequency of the
machine must be in accordance with the main voltage and frequency. The correct voltage and
frequency are shown on the index sheet of the electrical diagrams and on the machine plate.

Make sure that no dust can enter the electrical cabinet. Dust in electric circuits may
cause malfunctions.

4.9.1 Electric circuit diagrams

A set of electric circuit diagrams with an index sheet is supplied with each machine. Please
find these diagrams enclosed. The electric diagrams inform you about connections. Regarding
the specific data, valid for your machine, please refer to the index sheet.

On the index sheet a number of groups with numbers are drawn. These groups represent the
different electrical groups of your machine, such as main connection, control current, first,
second head, etc. The power for each group is shown as well as current consumption, when
the machine is fully loaded, control current etc.

A diagram no. per group is also shown. When the diagrams are placed in the order of the
index sheet they join up and can be read as one single, long diagram.

4.9.2 Electrical supply

1. Check if the total amperage of the main cable complies with the total amperage shown on
the machine plate or on the index sheet of the electrical diagrams.

A cable which is too thin can be overloaded resulting in fire or explosion.

The supply cable must be thick enough to transport the total amperage, indicated on the
index sheet, and must comply with the local rules. Consult your electrical company.
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2. Connect a supply cable to the machine as follows:

a. Lead the supply cable through the hole at the upper side of the electrical cabinet at
the operation side of machine. (Fig. 4.11).

Use a cable gland fitting for the power cable. Consult your electrician.

b. Connect the three phases (L1, L2, and L3) and the earth (Fig. 4.11b) (green/yellow)
as shown in Fig. 4.11.

3. Check whether the wires are connected correctly by turning the main switch on “ON” and
turning the lever of the table switch upwards (Fig. 4.11a). The conveyor table must then
move upwards, too, and the conveyor opening must become smaller.
If this is not the case, the electrical supply must be disconnected immediately (main switch)
and one phase must be replaced by another (e. g. L1 by L2).

Fig. 4.11
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5. OPERATION

Attention!! The key select switch at the operator’s panel must be set at position
zero (to the left). The key must be removed and may only be in hands of
authorized personnel.

0 1
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5.1 OPERATION SYMBOLS

The operation symbols, indicated in this manual and on the machine, enable an easier
operation.

Below please find a list of the symbols:

Symbol Meaning Symbol Meaning

Start conveyor Reset

RESET

Stop conveyor Key Switch

Machine adjustment
0 1

Table upward Main motor

Rotation of motor
Table downward with the feed; ensure that
the motor is completely
stopped, then start again
Rotation of motor
m/min Conveyor, stepless
against feed; ensure that
variable
the motor is completely
stopped, then start again
Jog button reverse feed to
adjust heads Brush oscillation
on/ off

Jog button reverse feed to

adjust heads
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5.2 ADJUSTMENT OF CONVEYOR SPEED

The speed can be adjusted infinitely variable by turning the button on the
m/min operator’s panel to the desired position. The conveyor speed is shown on the
digital read-out on the operator‘s panel.

To start or to stop the conveyor belt move the lever on the operator’s panel to the left
respectively to the right. Then the switch can be released and will return to the center-position.
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5.3 AUTOMATIC THICKNESS SETTING

With the automatic thickness setting device the conveyor table can be adjusted automatically
to the requested thickness of the work pieces to be ground. The thickness of the work piece is
to be read out at the operator’s panel with an accuracy of 0.1 mm (0.003937).

Ca. 10 mm

Table stop
Table

1 Table stop 2 3

5.3.1 Adjustment
1. Lower the table, using the select switch at the operator’s panel.
2. Position the work piece on the conveyor belt under the feeler of the automatic thickness
setting device.
3. Raise the table, using the select switch. As soon as the work piece activates the switch
(feeler) of the thickness setting device, the table stops at the correct height
4. Release the select switch at the operator’s panel. The lever moves to its neutral position.
5. Now the height of the table is adjusted according to the thickness of the work piece.

00.0
F R S
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5.4 INSTALLATION OF ABRASIVE BELTS

Usually, abrasive belts are not made by manufacturers of wide belt sanding machines, but by
specialized manufacturers of abrasive belts. Therefore, please consult your supplier of
abrasive belts regarding selection of the correct abrasive belt for your application.

1. Switch off the machine and wait for it to come to a

complete stop.

2. Open conveyor table to at least 10 mm (0.3937 inches)

d so you can be sure that the abrasive belt cannot touch
the conveyor belt.

3. Lower the abrasive belt tension roller with the tension

switch mounted on the type plate (a) of the head.

4. Remove the filling block (b), by pulling the lever to the

center-position (c), and pulling the locking bolt
a upwards. Then remove the filling block (b).

5. Install the abrasive belt on the abrasive head by sliding

it onto the tension roller guiding (d) first and then
around the contact roll.

Ensure that the edges of the abrasive belt will not

be damaged.
c
The rotating direction of the abrasive belt is indicated
with an arrow at the inner side of the abrasive belt. The
b
rotating direction has to correspond with the rotating
direction indicated with the arrow on the type plate (a)
of the abrasive head.

6. Move the abrasive belt (f) until it enters the tracking

f bracket (g) of the oscillation system on the other side of
the machine and the tension roller bridge moves to the
right and to the left due to the oscillation system. Pull
the abrasive belt back slightly and find the oscillation
turning point.

P.S.: Before continuing installation ensure that the

g tension roll moves while sliding the abrasive belt into
the tracking bracket and pulling it out of the tracking
bracket. Every time you put a new abrasive belt on an
abrasive head, make it a habit to check whether the
oscillation is working.
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6. Place the filling (support) block, (color must match!)

and clamp it with the locking bolt.

i 7. Tension the abrasive belt by using the tension switch.

8. Check the abrasive belt tension pressure. The pressure

gauge (i) on the left side behind the lower panel
indicates the abrasive belt tension pressure.
h
The pressure must be:
Deburring belt tension 2 – 2.5 bar.
Grinding belt tension 3 - 4 bar.

If the pressure is not correct, readjust by turning the

black button (h).

10.Make sure that the tensioned abrasive belt does not

touch any of the two belt safety levers (j) on the two
j sides of the machine.

11.Turn the abrasive belt by hand to check whether the

tension roller is in line with the contact roller.

12.Start the abrasive head.

Keep away from rotating abrasive belt to avoid

serious personal injury.

If the edges of the abrasive belt are damaged, these damages MUST be corrected.
Slight damages can be repaired by cutting out the damaged area (in a radius),
using a Stanley knife or scissors). See pictures on the next page.
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The relation x: y ≈ 1 : 10

x y
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5.5 MACHINE ADJUSTMENT

For detailed description of the adjustment of machine components, mentioned

in this section, please refer to the concerning sections in this manual. The
section PARALLEL ALIGNMENT is NOT for the machine operators, BUT for
AUTHORIZED personnel only.

Upon receipt of the machine and after completion of repair work, but before starting to
operate the machine, the following items have to be checked:

1. Parallel alignment and adjustment of the following machine components (by

authorized personnel only):
• Table
• Conveyor
• Pressure rollers
• Abrasive heads
• Oscillation
• Automatic thickness setting

Daily operations:

2. Ensure that the adjustment key switch is set at position “0” (to the left). The key must be
removed and may only be kept by authorized personnel.

3. Switch on main disconnection.

4. Check all safety devices. Refer to section SAFETY SUMMARY.

5. Raise the abrasive head to its highest position and slightly lower the conveyor table.

6. Install an abrasive belt. (Orienting the arrow printed on the inside surface of belt with the
direction of roll rotation.) Refer to section INSTALLATION OF ABRASIVE BELTS.

7. Adjust the conveyor table to the thickness of the work piece by means of the automatic
thickness setting.

8. Adjust the heads. (Please refer to the concerning chapters (or sections/items).

9. Start the dust extraction unit.

10. Start the vacuum pump (option) and the feed.

11. Start the heads.

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12. Feed a test work piece through the machine.

Make sure that during grinding of the test work piece nobody stands in front of
the machine, but aside. If an incorrect adjustment has been made by mistake, the
test work piece may be kicked out at the front/rear side of the machine.

The result can be evaluated by checking whether the edges of the work piece are deburred
or not. The work piece edges have to be radiussed evenly.

Now, the machine is adjusted for operational use.

13. If the machine has to be switched off, the abrasive heads have to be stopped first and then
the conveyor belt.

14. Close the main air supply, disconnect main switch, switch off the vacuum and dust
extraction unit. The abrasive heads have to be at a complete stop before closing main air
supply and switching off vacuum system.

15. Clean the machine.

If streaks (wavy type) are to be seen after grinding a test work

piece or if the machine stops due to sideways movement
(slipping) of the abrasive belt, the oscillation has to be
readjusted. This has to be done by authorized personnel only.
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5.6 ADJUSTMENT OF THE CONTACT ROLLER

The abrasive belt is driven by the contact roller. The tension Tension roll
roll is used to tension and to track the abrasive belt by means
of oscillating movements.
The rubberized contact roller has a diameter of 150 mm or Abrasive belt
180 mm (5.9055 or 7.0866 inches).
The hardness of the rubber is known as “Shore” and varies Contact roller
between 25° Shore and 90° Shore. 25° Shore is very soft and
flexible which allows the contact roller to follow the shape of the work piece and is therefore
best suited for deburring. 65° Shore is hard and best suited for finishing.

Whenever an abrasive belt with another thickness has to be installed, the contact roller head
has to be re-adjusted.

Adjustment of the contact roller head:

1. Put a new abrasive belt on the abrasive head. Please refer to section INSTALLATION OF
ABBRASIVE BELTS.

2. Raise the contact roller. Ensure that the work piece cannot touch the abrasive belt.

WORKPIECE

3. Take a flat work piece. Ensure that it is PRESSURE ROLL

pushed onto the conveyor belt by the two L CONTACT ROLLER

PRESSURE ROLL
pressure rollers in front and behind the
contact roller head.

4. Adjust the conveyor bed opening to the

thickness of the work piece. If the machine
is equipped with the single point thickness
setting device, please refer to the
corresponding section in this manual. Single point thickness setting

5. Use the jog buttons to feed the work piece

under the contact roller head which has to
be at a complete stop. Make sure that the
work piece is pushed on the conveyor belt by
the two pressure rolls in front and behind the
contact roller head. Jog buttons
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6. Lower the contact roller head until the

tensioned abrasive belt touches the work
piece slightly. This has to be checked.

7. Feed the work piece through the machine using the jog buttons. Take the work piece away on
the outfeed side.

8. Close all doors for your safety.

9. Reset the machine.

10. Start the machine.

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5.7 HOW TO ADJUST THE BRUSH HEAD

For detailed description see chapter BRUSHES.

Attention: To prevent premature wear of the conveyor belt, the brush may NOT
touch the conveyor!

Fig. 5.6

Fig. 5.7
The brush head has to be adjusted as follows:

1. Adjust the conveyor bed opening according to the thickness of the work piece. (If your
machine is equipped with an “automatic thickness setting (single point measuring device)”,
please refer to section AUTOMATIC THICKNESS SETTING.). This determines that the
work piece will be clamped correctly.

2. Start the conveyor belt and feed the work piece under the brush head, which has to be at a
complete stop, by means of the jog button (Fig. 5.7). Make sure the work piece is pushed to
the conveyor belt by the two pressure elements in front and behind the brush head.

3. Lower the brush head by turning the hand wheel (Fig. 5.7a) until the work piece is slightly
touched and moves the brush head. The displacement of the brush is indicated by the dial
indicator (Fig. 5.7b) (option).

4. Take the work piece away at the outfeed side of the machine.

5. Adjust the brush head 0.2 mm (0.007874 inches) lower.

6. Close all doors for your safety.

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7. Close the conveyor bed opening to the required final thickness of the work piece. The
correct value is indicated at the digital read-out on the operator’s panel.

8. Grind the work piece. The grinding pressure can be read-out on the ampere meter. The
grinding pressure can be adjusted depending on the required finish.
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5.8 GRINDING PROCESS

Usually, abrasive belts are not made by manufacturers of wide belt sanding machines, but by
specialized manufacturers of abrasive belts. Therefore, please consult your supplier of
abrasive belts regarding selection of the correct abrasive belt for your application.

5.8.1 Deburring
The purpose of deburring is to remove burrs and/or rounding off edges having a low impact
on the surface of the work piece. Put the conveyor table in the fixed and the front pressure bar
in the floating position. Depending on material, run the contact roller and the conveyor with
slow speed (e. g. stainless steel → slow speed and aluminium → faster).

Fig. 5.8
The brush removes the secondary burr, which the abrasive belt possibly left behind, and smooths
out the edges. The brush oscillates, which means it moves from side to side. This function
ensures an even wear on the brush.
Running with and against the feed allows a total deburring of all edges as well as the leading
edge and trailing edge of work piece.

During deburring the front pressure bar applies pressure to the work piece so that it will be
pressed to the conveyor belt. There remains sufficient friction between work piece and
conveyor belt to prevent kick-out of the work piece due to the much faster revolving abrasive
belt.

Abrasive belts of cloth are more wear-resistant and safer. Due to this, it is
recommended to use cloth abrasive belts for deburring (please refer to section
on abrasive belts further in this manual).
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5.8.2 Finishing

Fig. 5.9
Purpose of finishing (polishing) is to achieve a high-quality finish. The conveyor table has to
be put in the floating position and the front pressure bar has to be blocked (fixed). Run the
contact roller and conveyor belt at a high speed. The brush has to be moved upwards and may
not grind the work piece.

The machine can be executed with a fixed/floating table (see MACHINE

SPECIFICATION). The table has to be put to the floating position if warped
hot-rolled sheets have to be processed and differences in thickness of work
pieces have to be compensated.

5.8.3 Adjustments of fixed/floating pressure roller bar

1. Fixed position in combination with floating front pressure bar for deburring.
• Table fixed
Put lever upward (Fig. 5.10)
• Floating pressure roller
Put lever downward (Fig. 5.11)

2. Floating position in combination with fixed front pressure bar for fine grinding
(finishing).
• Table floating
Put lever downward (Fig. 5.10)
• Fixed pressure roller
Put lever upward (Fig. 5.11)
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Fig. 5.10 Fig. 5.11

Instruction regarding floating/fixed table

• When the table is in floating position, the pressure roller bar MUST be set at “fixed”.
• When the table is in fixed position the pressure roller bar MUST be set to “floating”
(processing of hot-rolled plates) The table may be in fixed position when cold-rolled plates
have to be processed.

5.8.4 Recommendations regarding deburring and grinding

Grinding
High speed of abrasive belt

High speed of conveyor belt

Deburring
Slow speed of abrasive belt

Slow speed of conveyor belt

If the abrasive head is executed with a two-speed drive, please read the following
recommendations:

Soft contact roller → Deburring at slow speed

(≤ 55 shore) → Grinding at high speed (new abrasive belt)

Hard contact roller → Grinding at high speed and slow feed speed for a
(≥ 55 shore) finish with a short scratch
→ Grinding at slow speed and high feed speed for a
finish with a long scratch
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5.9 CLEANING OF YOUR MACHINE

Your machine is designed to operate at a high performance level. To reach this expectation it
requires careful care and maintenance. The methods and care used to maintain this grinder
affect its grinding performance and ability to hold tolerances.

The frequency of cleaning will depend on the environment the grinder is placed in and how
often you use it. We recommend cleaning the machine whenever being used.

Cleaning the machine is considered normal maintenance and has to be carried

out according to the following instructions. If these instructions are NOT
observed this can be DANGEROUS.

1. Turn off all power to abrasive head or heads and feed drive(s).

2. Determine that abrasive belts are at a complete STOP.

3. Always disconnect power and lock out main disconnect switch of the machine before
performing maintenance etc. Lock the main switch!

4. Turn on your dust collection system.

• The dust collection system collects the dust you will stir up when cleaning the
machine.

5. Open the outboard door (s) (belt loading door).

6. Release tension of abrasive belt by using the appropriate select switch on the head.

7. Remove the abrasive belt(s).

NEVER use a household vacuum cleaner or standard industrial vacuum cleaner

to clean the machine. An explosion-proof vacuum cleaner must be used for
cleaning the machine.

8. Using a clean rag, wipe off all excess grease inside the machine.
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9. Remove all objects clogging dust hoods.

• Remove dust by using a hand brush and pan. Use the vacuum cleaner ONLY to
clean areas not accessible by brushing.

Take care using compressed air. Do not cause dust clouds. Dust clouds are
potentially explosive.

• Clean the following areas:

− Dust hoods,
− Inside and around the heads,
− Oscillation (transmitter and receiver): DO NOT use a brush, but a clean cloth,
− Under the conveyor bed,
− Inside the conveyor bed,
− Conveyor bed,
− Rollers of infeed and outfeed table
− Operator’s panel

10. Drain the compressed air filter bowel and clean it out (s. RECOMMENDATION AND
ADVICE further in this manual)

11. See RECOMMENDATION AND ADVICE further in this manual.

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6. PARALLEL ALIGNMENT AND ADJUSTMENTS

This section PARALLEL ALIGNMENT AND ADJUSTMENTS is for

authorized personnel only.
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6.1 INTRODUCTION

Your machine has been set and aligned in the factory. But you should check it before using.
Misalignment can occur due to transport.

With the key switch at the operator’s panel the safety doors can be by-passed by
setting the key switch at position 1 (to the right). Now the machine can be
operated with the doors open. After completion of parallel alignments and
adjustments the key switch has to be put to position 0 (to the left) and the key
has to be removed. The key may only be kept by authorized personnel.

The chapters parallel alignment and adjustment are meant for maintenance
personnel only.

The parallel alignment of the conveyor table, pressure elements and abrasive heads is
important to obtain a high-quality product. Parallel alignment is also important with regard to
safe machine operation (product sticking or kick-out).

Dial indicator on a T-stud

Use a dial indicator when checking and adjusting the parallel alignment of the machine. The
dial indicator is supplied with the machine.

Fig. 6.12

Fig. 6.13

The dial indicator (Fig. 6.12c) has to be mounted on the T-stud (Fig. 6.12a) by means of the
bolt (Fig. 6.12b) (supplied with the machine). The black cap (Fig. 6.12 c1) of the dial
indicator has to be removed. Mount the dial indicator upside down and in such a way that the
rear-end part of the feeler (Fig. 6.13a) can move through the hole (Fig. 6.13b) in the plate. The
dial indicator is fitted with 2 feeler heads (Fig. 6.12 c2 en c3).
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When measuring on a rubber roll or on a tensioned abrasive belt we recommend

using the finer feeler head (Fig. 6.12 c3). Measuring a larger surface area
ensures a better result.

While assembling the machine, the pressure elements (pressure roll) are parallel-aligned to
each other and to the frame. Always start with the fixed pressure bar and/or pressure rolls
when checking or adjusting the parallel alignment of the machine.

Pay attention to the following:

• Remember that a pressure roll is always lower than a contact roller (brush).
• Check the parallel alignment ALWAYS at the left and right hand side on the fixed
pressure rolls.
• ALWAYS measure the parallelism at the front and rear as far apart as possible.
• Usually, the machine is executed with a fixed/floating first pressure bar. Due to
this, this pressure bar cannot be used as reference point.

The table is mounted on the frame by means of four spindles. The table can be aligned by
adjusting the four spindles. Proceed as follows:
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6.2 ADJUSTMENT OF FIXED TABLE

Put the dial indicator on the edge of the table next to the conveyor belt. Make sure that the
edge of the table is clean. Adjust the table until the dial indicator can be moved between table
and pressure bar / rollers. Check if the needle of the dial indicator deflects and if there are
differences in height between left and right, front and rear side of the machine (see figures
previous page). If one of the measured values differs too much, readjust as follows:

1. Put the dial indicator at the point where the difference is greatest.

2. Put a spanner at the bottom-end of the spindle (b). Hold the spindle tight so it does not
turn, and loosen the locking nut (a) with an open-ended spanner.

3. Now turn the spindle while checking this on the dial indicator, until the needle of the dial
indicator is in the correct position.

4. Hold the spindle tight so it does not turn, and tighten the locking nut. When locking check
whether the needle on the dial indicator deflects. Readjust, if necessary, by loosening the
locking nut, turning the spindle and retightening the locking nut.
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6.3 CONVEYOR

The conveyor belt is driven by the conveyor feed roller and tensioned by the conveyor
tensioning roller and feeds the work pieces through the machine.

6.3.1 Readjustment of tension balance between right and left

It is important that the face of the belt is parallel to the pressure elements and heads and that
the belt has the correct tension balance at the left and right hand side. The latter is important
for the correct running of the belt in the center of the conveyor table. When tension is too
high, the belt will be overloaded, when tension is too low, the conveyor feed roll will slip in
the conveyor belt.

Fig. 6.16

Fig. 6.17

1. Position both plastic guide wheels (Fig. 6.18a) free from the belt using the eccentric bolts
(Fig. 6.18b). The wheels are meant to avoid that the belt will move sideways during
grinding.

2. Start the conveyor belt by moving the lever (Fig. 6.16) to the left.

3. The belt should be able to run centrally without guide wheels when running idle. Find the
correct tension balance by tensioning or releasing the belt (Fig. 6.17a) at only one side
(with half a turn at the same time).
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4.
L

d = 1/100 L

5. Put the guide wheels back against the belt so that

they are revolving with the belt. Fig. 6.18

Parallel alignment

It is important that the table is exactly aligned to the pressure elements and/or
heads. This is to be checked first. Refer to the appropriate sections.

1. Put the dial indicator on a flat hard piece of wood or metal of 110 x 150 mm (4 x 6 inch)
min. on the conveyor belt and measure with regard to the pressure bar and/or pressure rolls
(preferably the fixed) from left to right at approx. 200 mm (approx. 7.874 inches) or more
often when irregularities are suspected.

2. Run the belt approx. 300 mm (11.811 inches) and repeat step 1. Carry on until the belt is
completely measured.

3. A tolerance of 0.1 mm (0.003937 inches) maximum between the values found is allowed.
If the tolerance is greater and if this causes problems to achieve the requested finish, the
conveyor belt has to be dressed (ground). This has to be done as follows:

6.3.2 Dressing (Grinding) of the conveyor belt

1. Put an abrasive belt with a grit of 60 or 80 (k60 or k80) on the abrasive head with the
hardest roller and adjust all heads away from the conveyor belt.

2. Reduce the opening of the table, do the final adjustment by rotating the hand wheel
(Fout! Verwijzingsbron niet gevonden.b), until a light pressure of the pressure rolls or
pressure bar on the conveyor belt occurs.

NEVER turn the hand wheel while the machine is switched off.

3. Start the conveyor belt and take a low speed.

Put talcum powder on the conveyor belt to prevent sticking of the rubber to the
abrasive belt.
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4. Start the abrasive head with an abrasive belt grit k60 or k80 and the dust extraction unit
and adjust the contact roller towards the belt until the belt is being touched slightly.

5. Let the belt run for 5 minutes and check where the belt is being touched. If the spots being
touched on the belt do not or hardly become larger, then the abrasive head can be slightly
adjusted towards the conveyor belt. Repeat this till the belt will be completely touched and
cleaned up.

6. Then check the parallel alignment again.

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6.4 FINGER SAFETY BAR (NO-GO-BAR)

The finger safety bar (Fig. 6.19) minimizes the hazard that hands or fingers will be clamped
under the pressure rolls or abrasive heads.

Fig. 6.19

If the bed opening is higher than 40 mm (1.5748 inches), the operator’s arm or
hand might be clamped under the pressure rolls or abrasive heads without
activating the finger safety bar. If you come in danger of becoming entangled in
moving parts, stop the machine by pushing the finger safety bar upwards or
activating the emergency stop on the operator’s panel.

Be certain you know where all emergency stops are, before you operate the machine.

If the machine is equipped with an adjustment-key-switch on the operator’s panel

on the front side of the machine, this key has to be set in the adjustment-position
first.

6.4.1 Parallel alignment

1. Lower the table until the dial indicator can just stand on the edge of the table next to the
conveyor belt under the finger protection bar.

2. Move the dial indicator forward and backward until the lowest point of the finger safety bar
has been found. Compare the left and the right hand side with each other. The difference
may not be greater than 0.1 mm (0.003937 inches). (S. ADJUSTMENT DATA). If the
difference is greater, re-adjust as described below:

3. Remove the guard by removing the bolts (Fout! Verwijzingsbron niet gevonden.a and b)
on the right and left.

4. Adjust the side which has to be readjusted to correct level, by loosening the bolts (Fout!
Verwijzingsbron niet gevonden.a) and tightening the finger safety bar. This has to be
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checked on the dial indicator.

5. Remount the protection cover.

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6.4.2 Adjustment of the height

The height of the finger safety bar with regard to the sanding path has to be adjusted as
follows:
• standard execution with fixed/floating table: ± 6 mm (0.23622 inches) higher than the
grinding path.

When the finger safety bar has been activated, the feed stops, before the work piece, fingers
or hands can become entangled in the first pressure element. Check the proper functioning of
the finger safety bar as follows:

Fig. 6.20
Fig. 6.21
1. Adjust the height of the table according to a work piece which is 20 mm (0.7874 inches)
thick. Close the conveyor bed opening to +/- 16 mm (0.62992 inches).

2. Start the feed and feed the work piece through the machine.

3. When activating the finger safety bar the conveyor belt will stop BEFORE the work piece
will be clamped under the first pressure element.

If the conveyor belt does not stop, the finger safety bar has to be readjusted as follows:

4. Remove the guard by removing the bolts (Fig. 6.19a and b) on the right and left.

5. Loosen the locking ring (Fig. 6.20a).

6. Adjust the finger safety bar to correct height by means of the dial indicator.

7. Retighten the locking ring.

8. Mount the guard!!!

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9. Check the functioning of the finger protection again (as described above). Repeat this
procedure until the finger protection bar is functioning properly.

10. Check the parallel alignment again.

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6.5 ELECTRONIC OSCILLATION

Fig. 6.22

An active tracking system is necessary to keep the fast revolving abrasive belt on the head,
known as oscillation system, that means the tension roll (Fig. 6.22a) pivots on the tension
cylinder by which simultaneously the abrasive belt oscillates.

6.5.1 Function
When the abrasive belt (Fig. 6.22c) is rotating on the head and the left hand side runs in front
of the photoelectric cell (Fig. 6.22d; consists out of a transmitter and a receiver), the abrasive
belt is detected. The photoelectric cell controls two magnetic valves which are pneumatically
connected to the oscillation cylinder (Fig. 6.22b). The magnetic valves switch the air stream
over the two sides of the oscillation cylinder. The light beam to the photoelectric receiver is
interrupted and one of the magnetic valves changes the high pressure side of the piston of the
oscillation cylinder causing the tension roller bridge to pull to the opposite direction and the
abrasive belt runs to the right, until the photoelectric receiver receives light beam and the
other magnetic valve is activated, causing the tension roller bridge to pull to the opposite
direction and the abrasive belt runs to the left etc. etc.
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6.5.2 Adjustment of abrasive belt oscillation

Fig. 6.23

Fig. 6.24

On the left hand side of the machine, on the abrasive head, below the guide hood of the
tension roll (Fig. 6.24a), a trim-lever (Fig. 6.24b) is fit to adjust the oscillation. Each abrasive
belt is different, if so, it has to be trimmed. Adjust as follows:

1. The air pressure can be adjusted by pulling the black button (Fig. 6.23) upwards and
turning it. Then push the button downwards again.

2. Start the head and check whether the abrasive belt oscillates regularly. (Visually check the
oscillation stroke. The stroke to the left hand side has to be the same as the stroke to the
right.)

3. If not, turn the lever to the left or to the right, while the machine is running, and check
whether the oscillation is regular and constant. Repeat these steps until the oscillation is
constant.

Keep away from rotating parts of the machine.

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6.6 SET OF FLOATING PRESSURE ROLLERS WITH OVERTHICKNESS

SAFETY

A pressure roller set contains of a steel bracket in which rubberized pressure rollers are
mounted.
Pressure rollers are used to push work pieces to the feed belt surface.
The over thickness safety activates an emergency stop when two work pieces are double fed
into the machine. In the event of double-feeding of work pieces, the left or right bracket (Fig.
6.25b) moves upwards and activates the safety switch (Fig. 6.25g). After removing the
double-fed parts push the RESET button at the operator’s panel and the emergency stop will
be set free.
g
h

e
f
d

Fig. 6.25

6.6.1 Adjustment and parallel alignment

6.6.1.1 Pressure roller set

1. Please refer to the ADJUSTMENT DATA further in this manual.

2. Put the dial indicator with T-stud on the edge of the conveyor table next to conveyor belt
under the pressure rollers and measure the parallel alignment of all pressure rollers at the
left and right hand side. Make a chart of the values found.

• Make sure that the machine is levelled (Please refer to SETTING THE
MACHINE IN PLACE).
• Ensure that the table is parallel-aligned (Please refer to PARALLEL
ALIGNMENT OF CONVEYOR TABLE).
• It is important that the surface of the conveyor belt is even and parallel- aligned
to the conveyor table (Please refer to ADJUSTMENT OF CONVEYOR BELT).
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The difference of the values found in one pressure roller set must not be more than 0.1 mm
(0.003997 inches). If the difference is greater, re-adjust as follows:

3. Loosen the locking nut (Fig. 6.25f). Readjust by turning the Allen key screw (Fig. 6.25e) in
or out. Due to this, the bracket (Fig. 6.25b) moves towards the machine frame Fig. 6.25a).
While doing this, check the dial indicator (when the screw is turned in, the pressure roller
moves down. When the screw is turned out, the pressure roller moves up).

4. Fasten the locking nut (Fig. 6.25f).

6.6.1.2 Over thickness safety

The limit switches at the left and right hand side have to be adjusted to 1 mm (0.03937 inches)
higher than the grinding line. Check the adjustment of the limit switches as follows:

1. Put a work piece under the single point measuring device (thickness setting device). Adjust
the height of the conveyor table according to the thickness of the work piece. (Please refer
to ADJUSTMENT OF LINDOMATIC.)

2. Start the feed and feed the work piece through the machine.

3. Raise the table just above 1 mm (0.03937 inches) with the lever at the operator’s panel.

4. Start the feed and feed a work piece through the machine. The over thickness safety will be
activated and the control current will be shut off.
Repeat steps 1 - 4 on the right hand side.

5. If the conveyor does not come to a stop (emergency stop is not activated), re-adjust the
height of the limit switches with the Allen key bolts as shown in Fig. 6.25h.
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HEAD 1
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6.7 CONTACT ROLLER

The abrasive belt is driven by a contact roller. The diameter of the contact roller is 180 mm
(7.0866 inches) (in special cases 150 mm / 5.9055 inches). In the most cases the contact
rollers are made of rubber. On special machines the contact roller can be made of steel only.
The abrasive belt runs around the contact roller and the tension roll which is used to tension
and to track the abrasive belt by means of the oscillation.
The hardness of the rubber can vary. The hardness is indicated in “shore" or "durometer" and
can be 25 shore up to 80 shore. 25 shore is soft and flexible which allows it to follow the
surface of the work piece and is therefore best suited for proper deburring. This is important to
achieve a good finish. 80 shore is hard and therefore best suited for grinding.

6.7.1 Parallel alignment

1. Put a new abrasive belt on the abrasive head (s. ABBRASIVE BELTS) and use the correct
filling (support) block (color!).

Ensure the filling (support) block is clean and undamaged.

2. Put the dial indicator on the left edge of the table next to the conveyor belt and raise the
table until the dial indicator touches the abrasive belt around the contact roller and deflects.

3. Release tension of the abrasive belt and move it slightly to the right until the dial indicator
touches the contact roller.

4. Retension abrasive belt.

5. Move the dial indicator forward and backward and find the lowest point.

6. Repeat steps 3 and 4 on the right hand side and compare the values with each other. The
tolerance may be 0.03 mm (0.00118 inches) max. (S. ADJUSTMENT DATA)

7. If the difference is greater, check whether the correct filling (support) block is used and
whether it is clean and undamaged.

8. If you used the correct filling block and if it is clean and undamaged, but the difference is
still too great, the abrasive head has to be readjusted. In that case, please contact your
dealer or Timesavers.
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6.8 FINE ADJUSTMENT

The distance between contact roller and grinding line can be adjusted with a precision of
0.01 mm (0.0003937 inches), using the fine adjustment. The fine adjustment is fit with an
adjustment knob (Fig. 6.26a) that is mounted on a spindle with rubber dust-cover (Fig. 6.26d).
By turning the adjustment knob (Fig. 6.26a) the spindle rotates in or out and the adjustment
shaft (Fig. 6.26e) moves up or down, and the distance between contact roller and grinding line
will be reduced or increased. The dial indicator (Fig. 6.26c) shows the movement of the
contact roller during fine adjustment.

6.8.1 Re-adjustment
The contact roller has to be adjusted as follows:

1. Loosen the locking knob (Fig. 6.26b).

2. Re-adjust the height of the contact roller by turning the

adjustment knob (Fig. 6.26a). Turning the knob counter-
clockwise reduces the distance between contact roller
and grinding line. Turning the knob clockwise increases
this distance.

3. When adjustment is completed, tighten the locking knob

(Fig. 6.26b).
a
6.8.1.1 Wear and tear of abrasive belt b
The abrasive belt wears during grinding and will become
thinner. This has to be compensated.
Turn the adjustment knob (Fig. 6.26b) counter-clockwise c
until the desired adjustment has been made.
d
6.8.1.2 Another make of abrasive belt
If you want to use an abrasive belt of a different make, the
thickness of the new abrasive belt may be different.
e
Measure the thickness of previously used and new abrasive
belt and compensate for the difference in thickness, by
turning the adjustment knob clockwise or counter-
clockwise. If the abrasive belt is thicker, set the contact Fig. 6.26
roller to a higher position by turning the adjustment knob
clockwise. If it is thinner, set the contact roller to a lower position by turning the adjustment
knob counter-clockwise.
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HEAD 2
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6.9 BRUSH HEAD

6.9.1 Parallel alignment

1. Place the dial indicator on the left edge of the table next to the conveyor belt and raise the
table until the dial indicator touches the brush and deflects.

2. Move the dial indicator backward and forward and find the lowest point.

3. Repeat steps 1 and 2 on the right hand side of the brush and compare the values with each
other. The difference may not be greater than 0.03 mm (0.00118 inches). (Please refer to
ADJUSTMENT DATA)

4. If the difference is greater, re-align the brush head. Please refer to section Re-alignment.

5. If the difference is not greater than 0.03 mm (0.00118 inches), grind a test work piece
with the brush head only (see ADJUSTMENT OF BRUSH HEAD and MACHINE
ADJUSTMENT).

6. Check the test work piece. If necessary, re-align as follows:

6.9.2 Re-alignment

1. Shut off the main disconnector.

2. Remove the clutch (Fig. 6.27b).
3. Re-align by turning the hand wheel (Fig. a
6.27a). b
Upwards
turn clockwise.
Downwards
turn counter-clockwise.
This can be checked on the dial indicator.
4. Retighten the clutch (Fig. 6.27b).
5. Check by grinding a test work piece.

Fig. 6.27

Please refer to section BRUSHES for replacement of the brush and further
information on brushes.
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OTHER ADJUSTMENTS
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6.10 AUTOMATIC THICKNESS SETTING

With the automatic thickness setting the conveyor table can be adjusted automatically to the
requested thickness of the work pieces to be sanded. The thickness of the work piece to be
ground is to be read out at the operator’s panel with an accuracy of 0.1 mm (0.003937 inches).

Ca. 10 mm

Table stop
Table

1 Table stop 2 3

6.10.1 Adjustment
1. Lower the table, using the select switch at the operator’s panel.
2. Position the work piece on the conveyor belt under the feeler of the automatic thickness
setting device.
3. Move the table upwards, using the select switch. As soon as the work piece activates the
switch (feeler) of the thickness setting device, the table stops at the correct height.
4. Release the select switch at the operator’s panel. The lever moves to its neutral position.
5. Now the height of the table is adjusted according to the thickness of the work piece.

00.0
F R S

Fig. 6.30
Fig. 6.29
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6.10.2 Adjustment of table height read-out

1. Adjust as per instructions of section “Adjustment”.
2. Measure the thickness of the work piece.
3. Enter the data to the digital read-out (Fig. 6.30) as follows:
4. Press F and Reset simultaneously. Now the digital read-out indicates “0.00”.
5. Press F and Set simultaneously, the digital read-out starts running, it moves up to the
correct thickness value.
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6.11 MECHANICAL BRAKES

6.11.1 DESCRIPTION AND FUNCTION

Each abrasive head is fitted with air operated caliper brakes. Brakes are activated under one of
the following conditions:

• Emergency stop button is pressed.

• Abrasive belt brakes and tension cylinder extends full length, tripping limit switch.
• Abrasive belt mistrack, tripping limit switch.
• No abrasive belt on machine and tension cylinder extends, tripping limit switch.
• Interior access door is opened when power is on.

The brakes will release when fault is corrected and the “RESET” of the operator’s panel is
activated.

The brake is intended to stop the abrasive belt in approximately 4 - 7 seconds after it is
activated. This is controlled by air pressure and can be adjusted, if required.

Use the emergency button for emergency stop only. You will save on brake shoe and disk
wear, and unnecessary down time for repair.

The air pressure MUST be left on the machine until it comes to a stop, whether using normal
stopping procedures or the emergency stop.
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Single and double puck design

BRAKE DISC

PULLEY SHEEVE

BRAKE CALIPER
BRAKE PUCK, ONE ON
EACH SIDE OF DISC

BRAKE MOUNTING
BRACKET

Fig. 6.1: Side view of a caliper brake

BRAKE DISC

BRAKE PUCK, BRAKE PUCK,

ONE ON EACH TWO ON EACH
SIDE OF DISK SIDE OF DISK

BRAKE CALIPER
Fig. 6.2: Double puck and quad puck brake calipers
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6.11.2 MAINTENANCE OF THE BRAKE

The brake on each main motor is an important part of the machine’s safety system. How you
perform maintenance will determine the effectiveness of the brake’s ability to stop the main
drive system.

We recommend that you do the maintenance check outlined here four times per year and
replace any worn or damaged parts. If you use the emergency stop more than once a week, do
this maintenance check at least once a month.

1. Check the caliper spring.

• Remove the spring using pliers.
• Look for obvious stress cracks. Replace spring if there are cracks.
• Look for a “set” in the spring. Does it return completely after being pulled on? If not,
replace spring.
• Remount the spring.

2. Remove the brake pad holders.

3. Inspect each pad for amount of wear.

• Each pad is mounted to the holder with a screw. The pad should not be allowed to
wear down so far as to allow the screw to come into contact with disc.
• When only 0.9 mm (0.0354 inches) pad is left above the screw head, replace the pad.
If the pad has to be replaced, please see below.

4. Check the brake pad holders and brake pads on all brake calipers on all heads (if
available).
5. Check the air bladder for wear or leakage.
• Replace the air bladder if there is a leakage.

6. Check the brake disk.

• Check for excessive wear and/or deep grooves.
Replace the brake disk if the grooves (Fig. 6.3c) on either side is greater than 0.8
mm (0.0315 inches).
• Check for warping or wavy look on disk (Fig. 6.3b).
Use a straight edge (Fig. 6.3a) and a feeler gauge to check for warp.
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Fig. 6.3

6.11.3 Replacement of brake disk pads

Replace the brake disk pads as follows:

1. Remove the brass screw from each brake disk pad.

CAUTION! Use the correct size screwdriver to remove the brass screw. If you
use a screwdriver which is too small or too large, you may damage the head of
the brass screw.

2. Knock loose the old pads.

3. Clean the brake pad holder.

• Scrape it and clean it with an emery
cloth.

4. Place the new pad on the brake pad holder.

• Make sure to place the counter sunk
(largest hole) facing out (pls. refer to
Fig. 6.4).
Fig. 6.4
WARNING! Do NOT use any
adhesive to mount the pad. Possible incompatibility of the adhesive with the
brake pad may cause premature wear of the pads or may cause brake failure.

5. Replace the brass screw using the correct size screwdriver.

6. Remount brake calipers with the new pad on to the brake mount.
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6.12 ADJUSTMENT DATA

6.12.1 Grinding line

Reference for the adjustment of the grinding heads and the pressure elements is the grinding
line, i. e. if the adjustment value for a pressure element is “0”, the pressure element is on the
grinding line. The grinding line is an imaginary line that runs parallel to the conveyor bed.
The adjustment data is indicated in millimeters from the grinding line. ‘-‘ means: below the
grinding line. ‘+’ means: above the grinding line.

Example
Usually, tolerance limits are indicated with the adjustment data. To simplify matters we do not
indicate tolerances in this example. Suppose, there are the following adjustment data for the
finger safety bar, the front pressure bar and the set of floating pressure rollers:

FINGER SAFETY BAR

FLOATING SET OF
PRESSURE ROLLERS FRONT PRESSURE BAR

Grinding line Grinding line Grinding line

+6 mm
-1 mm 0
-0,1
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The correct adjustment is shown in Fig. 6.5. The adjustment data are edged. These values
depend on the height of the conveyor table.

= GRINDING LINE

1 0,1 6

56

49 50 mm 49,9

Fig. 6.5

6.12.2 Measuring method

1. Clean the edges of the conveyor table (next to the conveyor belt).
2. Connect the machine to the electrics (main switch).
3. Move the conveyor table until the dial indicator can be moved between conveyor table and
pressure bar/pressure rollers forward and backward and the needle of the dial indicator
deflects.
4. Choose a pressure element that is on the grinding line (adjustment value: 0 mm) and find
the correct measuring point (= lowest point) by moving the dial indicator backward and
forward. Turn the outer ring of the dial indicator to “0”. The dial indicator is on the
Grinding line when it indicates “0”.

If it is not possible to reach the dial indicator when it is on the grinding line, then turn the
outer ring of the dial indicator to a round number. Do this by adjusting the conveyor bed
opening by means of the hand wheel for the fine adjustment. If the dial indicator shows a
round number on the grinding line, it is easier to check the parallel alignment.

If the machine is switched off, it is NOT allowed to adjust the conveyor table
by means of the hand wheel.

5. Switch off the machine (main switch).

6. Now, check the parallel alignment of the pressure elements and heads to the conveyor
table. Find the correct measuring point by moving the dial indicator forward and backward
and finding the lowest point of the pressure elements and heads.
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6.12.3 Finger safety bar

// 0.1 mm

+6/+6.5 mm Grinding path

6.12.4 Spring loaded pressure rollers

Grinding path

0±0.05 mm 0±0.05 mm

6.12.5 Contact roller

// 0.03

Grinding path

-0.1 / -0.15 mm
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6.12.6 Fixed pinch rollers

Grinding path

0 ±0.05 mm 0 ±0.05 mm

6.12.7 Brush head

Grinding path

-0.3/-0.45 mm

6.12.8 Fixed pinch rollers

Grinding path

0 ±0.05 mm 0 ±0.05 mm
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6.13 BRUSHES

For a quietly running machine brushes have to meet the following requirements:
• balanced as per class G6.3 of DIN-ISO 1940-1
• maximum concentricity (=out of roundness) is 0.1 mm (0.003937 inches)
It is recommended to mention these requirements if you do not order new brushes from
Timesavers.

6.13.1 Types of brushes

The machine you have purchased is designed according to your requirements and equipped
with a suitable brush system. Please refer to the machine specification at the beginning of this
manual. This section (1.1.1. Types of brushes) has to be considered as background
information.

Many types of brushes are on the market. We are limiting ourselves to the description of the
following 3 brushes, i. e. steel wire brushes, nylon web brushes and nylon filament brushes.

1. Steel wire brushes

These brushes consist of a drum on which steel wires are welded. The thicker these steel wires
are, the harder the brush is. The weight per volume or density is important. The density is
expressed as a percentage of weight per volume. A standard brush has a density of 50 % up to
100 %. On a brush with a higher density the steel wires are denser and the brush will become
harder.
Steel wire brushes are usually used to deburr steel metal sheet or stainless steel. These brushes
are often too aggressive to brush aluminium.

There are three brush qualities:

• Standard steel quality: for deburring of sheet metal

Tensile strength: Tt = 180-200 kg/mm² (1800-2000 N/mm²), density 125 %, 0.2 mm
(0.007874 inches) double wave wire

• American steel wire quality: for deburring of sheet metal

Tensile strength: Tt = 280-300 kg/mm² (2800-3000 N/mm²), density 125 %, 0.2 mm
(0.007874 inches) double wave wire.

• Stainless steel wire brush for deburring of stainless steel

Tensile strength: Tt = 220 kg/mm² (2200 N/mm²), density 125 %, 0.35 mm (0.013779
inches) double wave wire.

When sheet metal has to be deburred in wet working machines, brushes with stainless steel
wires must be used to prevent that the wires will rust.
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2. Non-woven nylon web brushes

With these brushes the abrasive grits are bonded to the nylon web. The abrasive material can
be aluminium oxide or silicium carbide. These brushes are available as flap and disc brushes
in different densities and from coarse to fine grit.

Note: Grit sizes of brushes do NOT correspond with grit sizes of abrasive belts
as far as the surface finish is concerned!

A ground surface finish will be deburred - resulting in a finer surface reading which will be
smoother than original.
Usually, these brushes are also used for deburring of aluminium and non-ferrous materials.

3. Nylon filament (wire) brushes

These brushes consist of a drum with nylon bonded to filaments on the drum. Abrasives are
glued on the wires of the filaments. These brushes are available in different wire thicknesses,
grit sizes and densities.

Note: Grit sizes of brushes do NOT correspond with grit sizes of abrasive belts
regarding surface finish!

These brushes are able to follow the shape of the work piece because of the flexible filaments.
This is also depending upon the density of the brush.

These brushes are recommended for special application, e. g. brushing work pieces with burrs.
Also spider (=long string) brushes of this Brushlon material can be applied for special-shaped
parts. Usually, these brushes are used to brush aluminium and non-ferrous materials.
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6.13.2 Brush design

Three types of brushes are usually used in the Timesavers machines. These brushes are
exchangeable.

Steel wire brushes

Usually, steel wire brushes hardly wear. Due to this

fact, steel wire brushes often consist of one part.
Please refer to Fout! Onbekende schakeloptie-
instructie..
The shaft ends (C), flanges (A), and the brush core
(B) are welded together. A brush strip is spiral wound
around the brush drum. Attention: The wires cannot
wear down completely to the brush core due to the
brush flanges at the sides.

If such a brush is worn out, it has to be removed from

the machine. Then it can be recovered and/or
rewound by the brush manufacturer.

Fig. 6.6:Steel wire brush design

Non-woven nylon web and nylon filament brushes

As nylon web and nylon filament brushes wear out more easily, these brushes are designed
with quick change clamping flanges.

A Nylon brush (E) is often bonded to a hard cover drum

(D).
The shaft and drum (D) are clamped together by quick
exchange clamping bushings (locking assembly). The
holes for the locking bolts have to be slightly smaller
than the locking bolts. (Drill a hole of 4 mm for a
locking bolt of 5 mm.) These locking bolts ensure that
the brush will rotate with the hub. De hubs (C) are
clamped on the shaft (A) by the locking assembly
RfN8006 (B).

Fig. 6.7: Design with RINGFEDER

locking assembly RfN8006
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6.13.3 Storage of brushes

• It is important to store brushes free from the floor by supporting the shaft ends in such a
way that they do NOT touch the floor.

• Brushes have to be covered during storage.

6.13.4 Dressing and cleaning of brushes

It may be necessary to dress the brush due to uneven wear. During dressing, the brush will be
evenly dressed to a cylindrical shape over the entire length of the brush. This ensures that the
surface of the work piece will be treated evenly.

Dressing of steel wire brushes

Dressing of all steel wire brushes has to be done with a grindstone on a center grinding
machine (or turning lathe with grinding head). It has to be considered that steel wire brushes
have to ground in two rotation directions of the grindstone. If this is NOT possible, the brush
has to be turned around between the centers.

Cleaning of steel wire brushes in the machine

When brushing steel sheets, iron particles will bond themselves to the tops of the steel wires
of the brush. When brushing stainless steel after steel work pieces have been brushed, iron
particles may attach to the surface of the stainless steel sheet. If these particles begin to rust,
brown rust spots occur on the surface of the work pieces. These ferrous particles on the top of
the steel wires have to be removed by dressing the brush to prevent that iron particles attach to
the surface. The brush has to be dressed with an abrasive belt with grit size 60 - 80, which is
glued to a dress board. While running, the tops of the brush have to touch this abrasive belt
slightly. Please refer to dressing of the nylon web brush.

Dressing of nylon web brushes

Read the safety instructions first, which are supplied with the brush!

It is necessary to dress the brush due to uneven wear. Furthermore, a new brush has to be
dressed prior to use.
Dressing has to be done as follows:
• Make a dress plate
• Adjust the brush
• Dressing
• Finishing
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Make a dress board as follows:

Please refer to Fig. 6.8.

First check the dimensions of the brush (A).
Then take a flat sheet (C), e. g. a cold-rolled
flat aluminium sheet of approx. 3 mm
(0.1181 inches) min or a poly carbonate
board of 3 mm (0.1181 inches) or a ply
wood (water-resistant) of approx. 12 - 15
mm (0.47244 - 0.59055 inches) thickness.
The length of the board has to be equal to
the width of the brush (Wmin) and 4 times
the diameter of the brush (4xD). Make sure
Fig. 6.8: Dimensions of a dress board that the board is long enough so that it can
be clamped properly between the pressure
bars.

Take an abrasive belt with grit size 24,

Brush 600 mm 36 or 40 and glue it with double sided
or shorter tape on the flat board over the full
Brush longer than 600 mm
or conveyor-
speed <4 m/s
and conveyor speed >4 m/s length of the board.
If the brush is 600 mm (23.622 inches)
Grinding- or shorter (and the conveyor speed less
belt than 4m/sec), the abrasive belt has to
band correct incorrect be glued over the full length on the
board as shown in Fig. 6.9. If a brush is
longer than 600 mm (23.622 inches)
(and the conveyor speed faster than 4
Conveyor speed Conveyor speed m/sec.), the abrasive belt has to be
direction direction
glued diagonally as shown in Fig. 6.9.
Fig. 6.9: Position of grinding belt on the board This board is called “the dress board”.
When feeding the dress board into the
machine, it has to be positioned in such
a way that the brush will be dressed
over the full length.
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Adjustment of the brush

Position the dress board under the brush which has to be at a complete stop and clamp the
board under the pressure rollers in front and behind the contact roller head.
Lower the brush head until the first part of the dress board that has no abrasive material, is
slightly touched and moves the brush head. The displacement of the brush is indicated by the
dial indicator. Remove the dress board from the machine by using the conveyor belt.

Dressing of the brush (cylindrical)

Check that the brush does not touch the conveyor belt. Start the
machine. Let the brush rotate with the normal work speed. Start
the oscillation, if the machine is provided with oscillation. The
recommended conveyor speed is 4-7 m/sec. It is essential that the
infeed speed is correct so that the dress plate will not be warped
Fig. 6.10: Dressing of the brush due to the friction heat. Run the dress plate through the machine.
This has to be done as often as necessary to achieve the same
(cylindrical) result on the entire surface of the brush. If the dress
board is fed in reverse feed, it will not influence the dressing
result.

Finishing

After dressing, an abrasive nylon web brush will have a fuzzy

surface. The fuzz is simply fiber stripped bare of abrasive
mineral. The bare fibers must be removed to bring the brush to
the proper operating condition. To remove the bare fibers, feed a
wooden board of at least 15 mm (0.59055 inches) thickness
repeatedly through the machine. This wooden board must have
the same dimensions as the dress board. The heat created by the
Fig. 6.11: Finishing of the brushing friction will remove the bare fibers and bring the brush
brush
to the proper operating conditions.

Dressing of nylon filament (wire) brushes

Abrasive nylon filament brushes can only be dressed on a turning lathe by using special
dressing equipment. Usually, this equipment can be obtained from the supplier of the brushes.
During dressing of filament brushes on a turning lathe, the worn tops of the wires will be cut
off. Afterwards the brush can be re-used.
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6.14 BRUSH REPLACEMENT

ONLY BRUSH
WITH SLIDE

Fig. 6.12: Brush assembly with nylon web brush, slide and oscillation

1 drive pulley 6 connection block

2 v-belts 7 slide-support block
3 oscillation bracket (option) 8 brush
4 slide 9 bearing block
5 cam adjustment (back lash of slide) 10 bearing lock ring
5a eccentric bushing 11 slide housing
5b locking screw eccentric bushing 12 height adjustment hand wheel
5c eccentric shaft (Allen key) 13 oscillation-motor (option)
5d locking nut cam shaft
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6.14.1 Removal of complete brush with slide

The weight of the brush with slide is indicated in the machine specifications.
Please check the weight prior to removal or installation of the brush with slide.

See Fig. 6.12.

Replace the brush as follows by using the slide:
1. Stop the machine. The machine has to be at a complete stop.
2. Turn off the main switch. The machine has to be at a complete stop.
3. Remove the V-belts (2) of the pulley (1). The tension of the V-belts has to be released first.
This can be done by lifting the motor at one side. Optionally, brushes can be equipped
with an air cylinder motor lift (the control switch is located under the oscillation motor).
On other brushes the tension of the V-belts has to be released manually. Do not remove the
pulley from the shaft.
4. Loosen the oscillation bracket (3). (If the machine is equipped with oscillation.) (option)
5. Loosen the safety nut of the eccentric adjustment (5). Turn the eccentric shaft (5) counter-
clockwise, using an Allen key, until the slide can be pulled out of the machine easily.
6. Pull the slide out for 2/3 of its length (11). The slide support block (7) will keep the slide
horizontally.
7. Pull the slide completely out of the machine, using a hoist. If you want to put the brush
down, turn the brush unit so that the brush unit will lie upside down on the slide. In case
that the brush has to be re-installed, do not put the brush on the floor.
Note: A removable change cart with slide housing is an option, in order to
remove and fit the brush assembly if the hoist facilities are not available

6.14.2 Re-installation of the brush with slide

The slide with the brush has to be re-installed as follows:
1. Check the brush assembly for damages.
2. Clean the slide. It is not necessary to lubricate the rails of the slide, however, a light touch
of grease will not harm.
3. Before assembling a new brush, the diameter of the new brush has to be compared with the
diameter of the brush which has to be replaced. If the diameter of the new brush is larger,
the height has to be adjusted as follows: Raise the brush slide over half of the difference in
diameter of the brushes, by using the height adjustment (12).
4. Stop the machine. The machine has to be at a complete stop.
5. Shut off the main switch.
6. Use a hoist (or the optional change cart) to put the brush with slide into the machine. Slide
the slide into the machine.
Attention: NEVER turn the eccentric bushing (5A) or its locking ring (5B):
This is a factory-adjustment!

7. Turn the eccentric shaft (5C) clockwise until the slide is fixed. Then turn the eccentric shaft
counter-clockwise (5C) until the slide is no longer fixed: It must be possible to barely slide
the slide. Secure the eccentric shaft (5C) with the locking nut (5D).
8. Fasten the oscillation bracket (3). (If the machine is equipped with oscillation.)
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9. Fit the pulley, if required. Install the V-belts and tension them.

After the brush with the slide has been installed, it is recommended to do a test
run. (The brush has to be adjusted to the correct height first.) If the brush does
NOT oscillate, the setting is too tight. If the oscillation is incorrect (rumbling or
rattling), the slide has too much back lash.
Adjust the back lash of the slide with the eccentric shaft (5C); please refer to
item 7.

6.14.3 DISMANTLING OF THE BRUSH FROM THE SLIDE

Put the brush with slide upside down on a bench. The brush is supported by the slide.
Due to the brush design there is a difference between steel wire brushes and nylon web or
nylon filament brushes. For brush design please refer to section: BRUSH DESIGN.

Steel wire brushes

Remove the brush from the slide as follows:
1. Loosen the bolts in the bearing blocks by a few turns.

DO NOT remove them!

2. Remove the locking ring of the bearing at ONE side. Remove the bolts from the bearing
block and slide the bearing block from the shaft end.

Put the bolts back again and fasten them with nuts.

The drive shaft end of the brush can be between these bolts. Remove the other bearing
block in the same way.
3. Remove the pulley. (Please mark first.)
4. Remove the complete brush (brush, flanges and shaft ends are of one part).

Nylon flap and nylon filament brushes

Remove the brush from the shaft as follows:
1. Loosen the bolts in the bearing by a few turns.

DO NOT remove them!

2. The pulley is on the shaft end. Remove the bearing locking ring on the other shaft end.
3. Remove the bolts of the bearing block on this shaft end, too, and slide the bearing block
from the shaft.

Put the bolts back again and fasten them with nuts.

The drive shaft end of the brush can be between these bolts.
4. Loosen both locking assemblies. It may be necessary to slide the bearing across the shaft
(bolts and locking ring have to be removed first).
5. Remove the brush from the shaft. Please refer to section: BRUSH DESIGN.
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When using nylon flap and nylon filament brushes, it is recommended not to change the
position of the pulley and bearing at the side where the pulley is located, in order to achieve an
easier brush assembly. After the pulley has been re-installed in the machine, the pulley has the
same position so that it won’t be necessary to re-align.

Note: Mark the position of the pulley and the bearing at the side of the pulley
before dismantling. This makes it easier to assemble the construction. Back in
the machine, the alignment of the pulleys on the brush-shaft and the drive
motor have to be checked.
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7. ABRASIVE BELTS

7.1.1 Which abrasive belt to be used

When grinding metal parts the choice of the grit size of abrasive belt depends on the required
surface finish. NEVER use abrasive belts with a grit size that is finer than strictly necessary.
The finer the grit size the faster the coating gets clogged up with dust and the abrasive belt life
time will be considerably shortened. Depending upon the material, we recommend grinding
with a coarse grit size, e. g. 40, 60, 80, 100 or 120, if a higher amount of removal is requested.

For fine grinding we recommend grit size 180, 220, 320, 400 and 500. For special applications
consult your abrasive belt supplier, dealer or TIMESAVERS first.

For deburring of sheets on a machine with a contact roller of 25 to 30 shore we recommend

flexible cloth abrasive belts (type J).
On wet machines cloth abrasive belts are also recommended, but they must be suitable for wet
operation.

For advice on application please contact your abrasive belt supplier.

7.1.2 Storage and maintenance

Abrasive belts can be damaged easily. To prevent damage as far as possible, they have to be
stored carefully and handled with care. Below please find recommendations regarding proper
storage and handling of abrasive belts.

7.1.3 Storage of abrasive belts

− The abrasive belts have to be stored in a separate room.
− The abrasive belts have to be protected against sunlight.
− Do NOT store the belts lying on a cement or steel floor.
− It is recommended to store the abrasive belts in an air-conditioned room.
− The best storage conditions for abrasive belts are:
Temperature: 15-20 °C (55-56 F).
Humidity: 50-60%
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− Abrasive belts are delivered in boxes. They have to be stored as long as possible in the
closed boxes. When the box has to be opened the remaining abrasive belts have to be
stored hanging. A good suitable system to store the abrasive belts are frames with racks
with a radius of ± 125 mm (5”) as shown below:

7.1.4 How to increase abrasive belt life

− Stagger the work pieces to be ground across the full width of the conveyor belt to
distribute wear and tear of the abrasive belts as far as possible.
− Plan to grind widest work pieces first, then the narrower, and the smallest work pieces
last. This reduces the possibility of streaks caused by the grinding belt on which
previously a smaller part has been ground.

7.1.5 Handling of abrasive belts

− A nick or tear along the edge will cause premature belt breakage.
− Install the abrasive belt with care. Before starting the motor, turn the abrasive belt by
hand to check correct alignment between tension roll and contact roller.
− Release tension of abrasive belt when not in use.
− In case the abrasive belts are not used for a while, remove and store them in a separate
room.

Never clean an abrasive belt while it is in the machine.

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8. MAINTENANCE

This section is only for qualified technicians authorized to carry out

maintenance.

Malfunction of the machine or machine damage can be avoided by checking the standard
functions and adjustments regularly. Besides these checks, a dust collection system with
sufficient capacity as well as clean, dry compressed air are important.

Regarding function, adjustment, readjustment and parallel alignment of the different machine
parts please refer to the corresponding chapters.
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8.1 RECOMMENDATIONS

8.1.1 General recommendations

Always disconnect electrics before performing maintenance work etc. Lock the main switch!!!

Locking the main switch has to prevent that the electrical supply can be switched on
accidentally.

After maintenance is performed and before current is turned on the personnel

has to be warned to stop all work on the machine and to stay away from the
machine.

DO NOT operate the machine while safety devices and guards are removed.

Recommended regular checks as follows:

Daily

- cleaning of the pressure rollers using a hard brush and a rag.

- cleaning of the conveyor belt using an industrial vacuum cleaner (explosion-proof).

Weekly

- additional cleaning of the conveyor belt using an

industrial, explosion-proof vacuum cleaner (extraction)
and/or brush.
- lubrication of tension roller bearings.
- Dust filter of the electrical cabinet to be cleaned (Fig.
8.1).

Monthly
Fig. 8.1
- cleaning of the chains of the table height adjustment
system and table spindles from swarf.

Machine stop

If the machine has not been operated for a week or longer, additional measures have to be
taken.
Perform maintenance (daily, weekly, monthly) as mentioned above.
- Remove the abrasive belt when machine is not in use and install a new abrasive belt when
putting the machine in operation again.
- Check all safety devices (emergency stops, finger protections etc.)
- Check the brakes.
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8.1.2 Compressed air cleaner

1. Check daily and drain water accumulation by

loosening knob Fig. 8.2b.

2. Check monthly (if necessary)

• Loosen and remove the ring.
• Clean the plastic cover (a) with a clean rag.
• Remove the air cleaner by loosening the nut. a
Clean it with acetone and an air pistol.
b
Ensure that no rubberized parts come in
contact with the detergent
All lubrication oils and greases must be
disposed - harmless for the environment. Fig. 8.2

8.1.3 Swarf (dust)

Remove daily. Accumulation of dust can cause fire or explosion.

8.1.4 Conveyor belt and V-belts

Check conveyor belt and V-belts once a week and, if necessary, tension.
After each adjustment/replacement it is necessary to check during operation whether the
conveyor belt is still running properly.
The conveyor belt must be tensioned properly. When tension is too high, the belt will be
overloaded. When tension is too low the belt will slip on the feed roller. (Please refer to
ADJUSTMENT OF CONVEYOR).
Incorrect machine operation may result in damage of the conveyor belt.
Processing thin work pieces can cause a premature wear of conveyor belt.
A conveyor belt which has not been tested may not run without supervision. When conveyor
belt has not been adjusted properly, it could be damaged badly!

8.1.5 (Pressure rollers and/or pressure bars)

Check pressure elements once a week and always when they have been overloaded. Pressure
roller adjustment is important to guarantee an even feed through the machine and to reduce
the hazard of kicking out of work pieces.
The high velocity of a kick out part presents a hazard of severe personal injury or death.
(Please refer to ADJUSTMENT OF PRESSURE ELEMENTS).
Examine the pressure elements for dirt. Dirt on contact rollers will be transmitted to work
piece and can ruin the surface finish.
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The process of recovering a rubber covered roll is time consuming and will cause a loss of
production time. We recommend you to have spare pressure rolls in your spare parts inventory
to reduce down-time.

8.1.6 Limit Switch Tip (Ceramic Tip)

Check abrasive belt mistrack limit switches to ensure that the ceramic tips are adjusted
properly, so that a mistrack of the belt will be detected.

The machine operator should inspect the mistrack limit switches every time when a new
abrasive belt is installed. If a ceramic tip is missing, it must be replaced immediately.

8.1.7 Infinitely variable conveyor feed drive (variator)

Machines with a mechanically, infinitely variable conveyor feed drive (variator) have to be
tested over the full speed range once in a week. If a machine has not been adjusted for a long
time, the v-belt wears a groove into the adjustable pulley discs.

The speed may only be adjusted when conveyor motor is running.

8.1.8 Tension of abrasive belt

Check regularly - at least once in a week. If necessary, adjust the pressure by means of the
pressure gauge on the pneumatic operator’s panel.

8.1.9 Oscillation
Check and remove dirt weekly.

8.1.10 Safety Equipment

Inspect and test safety equipment weekly. Check the brakes WEEKLY.
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8.2 LUBRICATION FREQUENCY

Part Location Frequency Castrol Shell Esso

Chains Bottom-right once a year Spherol AP2, Retinax Beacon 2

next to the Rustilo 553 Grease EP2
main drive
Spindles Bottom-right once a year Rustilo 553 Retinax Beacon Q2
next to the Grease EP2
main drive
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9. TROUBLESHOOTING

Please also refer to the chapters/sections ADJUSTMENTS and

MAINTENANCE.

PROBLEM CAUSE REMEDY

1. Motor does not • Safety device activated − Check whether it is switched off. Reset
start the machine AFTER the problem has
been solved
• Emergency stop still pressed − Pull out emergency stop
− Check finger safety / belly brake
• Door(s) open − Close door(s)

• Thermal protection switched off − Press switch

1. Machine stops • Overloaded abrasive head; − Remove work piece to be

regularly • Conveyor table too high, too much ground/deburrred and lower conveyor
pressure on the work pieces table
• Thermal safety equipment − Re-adjust
improperly adjusted

1. The abrasive head • Does the oscillation work − See chapter ,,ADJUSTMENT OF
stops and does not properly? OSCILLATION”
start again • Has the brake been activated?
• Did the conveyor belt stop? − Reset the machine with the ,,RESET”
• Emergency stop activated? button on the operators panel
• Belt safety switch activated? − Replace the abrasive belt and reset the
machine
• Malfunction of finger safety bar or − Check the adjustment, please refer to
belly-brake corresponding chapters
• Door(s) on belt loading side is − Close the door(s)
(are) open
• Air pressure too low − Increase air pressure
• of the machine − of the main valve. See section
,,COMPRESSED AIR”
• of the tension roller − of the abrasive belt tension. See
section ,,INSTALLATION OF
ABRASIVE BELT”
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PROBLEM CAUSE REMEDY

4. Abrasive belt does • Defect in oscillation bracket − See chapter ,,ADJUSTMENT OF

not oscillate any OSCILLATION”
more − Clean transmitter and receiver
• Problem with air pressure − Check whether transmitter and receiver
are adjusted properly
− Check the pressure valve of the tension
roller
− Move - WHILE THE MACHINE IS AT
A COMPLETE STOP - your hand
between transmitter and receiver and
make sure that the air pressure valve is
activated and the oscillation cylinder of
the tension roller moves
− Check whether the cylinder receives air
− Check whether there are loose
connections between transmitter and
receiver and air valve
− Check whether the oscillation cylinder
has a leak
− Check whether the oscillation cylinder is
adjusted correctly. Does the oscillation
cylinder move without moving the tension
roller?
− Check the spring in the oscillation
cylinder.
4. Irregular • Oscillation too fast − Reduce oscillation pressure
oscillation • Oscillation too slow − Increase oscillation pressure
− See chapter ,,ADJUSTMENT OF
OSCILLATION”
4. Rupture of • Wrong abrasive belt − Insert proper abrasive belt
abrasive belt • Is the abrasive belt been torn on the
joint?
• Fabrication fault − Contact your abrasive belt supplier
• Abrasive belt tension pressure − Lower the abrasive belt tension pressure
too high
• Incorrect belt rotation direction − Insert a new abrasive belt and check
whether the rotation direction indicated
inside the belt matches with the rotation
direction of the contact roller head.

• Is the abrasive belt been torn in the − See chapter ,,INSTALLATION OF

middle? ABRASIVE BELT” and ,,ABRASIVE
• Feed speed is too fast for the BELTS”
adjusted stock removal
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PROBLEM CAUSE REMEDY

7. Irregular • Abrasive belt clogs up: too much − Use an abrasive belt with a coarser grain,
deburring removal, grit size too fine, too much clean work piece prior to deburring
dirt on the work piece.
• Edges rounded off too much − Lower pressure
• Work piece slips on conveyor belt
- Pressure of head onto work piece − Apply more pressure by readjusting the
too low abrasive head
- Vacuum compressor switched off − Switch on vacuum compressor(option)
- Conveyor belt too slippery − Clean conveyor belt with water without
coolant
- Rear pressure rollers too low, this − Adjust the pressure rollers properly.
causes the work piece to stop on the
conveyor belt
8. Work pieces • Vacuum or magnet table required − Switch on vacuum or magnet track.
kicked out of • Too much grinding pressure − Apply less grinding pressure
machine • Pressure rollers too high − Adjust pressure rollers
• Work pieces too small and/or − Clean conveyor belt with water
conveyor belt greasy or slippery.
• Work pieces are not flat − Take flat work pieces
• Side guide strips are not used. − Use side guide strips
(Option)
• Check ‘0’ on the table height read- − Re-adjust.
out.

8. Irregular finish • Glossy spots: abrasive belt is worn − Place new abrasive belt
• Burrs not removed − Increase abrasive head speed
- Abrasive head speed too slow − Decrease conveyor speed
- Conveyor speed too high − Increase pressure
- Pressure too low − Use abrasive belt with coarser grit
- Excessive burrs
• Damage of abrasive head − Dress the contact roller/brush
(rubber of the contact roller, brush
slightly damaged)
− Coolant polluted / machine dirty − Clean machine
− Too much grinding pressure − Reduce grinding pressure
- Excessive burrs − Use abrasive belt with coarser grit size
• Marks − Replace abrasive belt

10. Chatter marks • Belt splice. − Insert new abrasive belt

• Worn contact drum bearings − Insert new bearings. Contact our service
• Worn main motor bearings department
• Worn conveyor motor bearings
• Loose or worn V-belts − Insert new V-belts.
• Flat spots on drum − Contact roller has to be dressed. Contact
• Out of balance drum or tension our service department
roller
• Irregular feed − See problem ,,Conveyor belt runs
irregularly”
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PROBLEM CAUSE REMEDY

11. Streaks - Wavy • Dirty or damaged abrasive belt. − Replace abrasive belt.
Type − Check air jet belt cleaner (if your
machine is equipped with an air jet belt
cleaner).

10. Streaks straight • Mark on contact roller − Replace contact roller or in case of slight
type damage redress the rubber roller.
Note: Always replace bearings, too, in
case contact roller has to be replaced.
• Mark on pressure rollers − Clean pressure elements

13. Vacuum table • Motor rotation incorrect − Check the electrical wires. See chapter
operates ,,VACUUM TABLE”
improperly
(Option)
13. Conveyor belt • Drive roller slips − Tension conveyor belt
runs irregularly • Tension balance of conveyor belt is − Adjust feed speed. See chapter
not correct ,,CONVEYOR BELT”
• Full size large parts increasing
vacuum − Adjust vacuum
• Vacuum too high when conveyor − Reduce vacuum
belt running without work pieces
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10. SPARE PARTS

We recommend having spare parts in stock:

Save time and money!
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10.1 WHERE AND HOW TO ORDER SPARE PARTS

Order-/Contact Address:

Your dealer
or
TIMESAVERS Inc.
5270, Hanson Court MINNEAPOLIS
Minn. 55429-3161
Phone 001-6125373611 FAX 001-6125379247

To handle your inquiry/order correctly, please provide the following information:

1. Your company name

2. Shipping address
3. Contact person
4. Telephone and fax number
5. Model, machine type
6. Machine serial number, (indicated on the ID plate)
7. The exact method of delivery you want:
a) Motor freight
b) Air freight
c) Mail
d) Airmail
e) (DHL - TNT etc.)

Please provide the following information, too:

1. Part no. and item no.

2. Quantity needed (pieces, dimensions, sizes)
3. Description of the part
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10.2 SUGGESTED SPARE PARTS LIST:

• Oscillation set, complete

• Control cylinder of belt oscillation
• Contact roller bearing
• Pressure roller bearing
• Tension roller bearing
• Bearing for conveyor belt
• Conveyor belt
• Variator drive belt
• V-belts for main motor
• Contact roller, complete
• Electric brake

10.3 STORAGE OF SPARE CONTACT ROLLER

If a spare contact roller (optional) is supplied with the machine, it has to be stored carefully.

Day- and sunlight have a negative effect on the rubber of contact rollers. Due to this contact
rollers have to be protected against day- and sunlight. If it is not possible to store abrasive
belts in a dark room, they should be stored in closed boxes.

The contact roller may never be stored on the rubber itself. The metal core of the contact roller
has to rest on (wood) beams at the right and left hand side of the rubberized part. They may
never be supported on the rubberized parts.

To prevent a possible imbalance in the rubber the spare contact roller has to be turned 90°
every month.
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