Southbend Grinder SB1023 User Manual

Weight ..........................................................................................................................................................................540 lbs.

Length/Width/Height ................................................................................................................................ 50³⁄4" x 36¹⁄2" x 66"

Footprint (Length/Width)...........................................................................................................................................24" x 24"

Shipping Dimensions:

Type....................................................................................................................................................................Wooden Crate

Content........................................................................................................................................................................ Machine

Weight ...........................................................................................................................................................................690 lbs.

Length/Width/Height ....................................................................................................................................... 41" x 29" x 65"

Electrical:

Required Power Source.................................................................................................. 110V or 220V, Single Phase, 60 Hz

Switch............................................................................................ Allen/Bradley Magnetic Contactor w/Thermal Overload

Switch Voltage.................................................................................................................................................................. 110V

Cord Length......................................................................................................................................................................... 62"

Cord Gauge ................................................................................................................................................................14 Gauge

Recommended Circuit Size ..........................................................................................................................................15 Amp

Plug Included.......................................................................................................................................................................Yes

Plug Type ..................................................................................................................................................................110V 5-15

Motors:

Spindle Motor

Type ............................................................................................................................TEFC Capacitor Start Induction

Horsepower............................................................................................................................................................. ³⁄4 HP

Voltage............................................................................................................................................................110V/220V

Prewired .................................................................................................................................................................. 110V

Phase ..........................................................................................................................................................Single-Phase

Amps................................................................................................................................................................9.5/5 Amp

Speed............................................................................................................................................................... 3450 RPM

Cycle .......................................................................................................................................................................60 Hz

Number Of Speeds.........................................................................................................................................................1

Power Transfer..................................................................................................................................... Integral Spindle

Bearings...................................................................................................................Shielded and Permanently Sealed

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For Machines Mfg. Since 8/09

Model SB1023

I N T R O D U C T I O N

Main Specifications:

Operation Information

Maximum Distance Wheel To Table........................................................................................................................ 8¹⁄4

Maximum Distance Table To Spindle Center.......................................................................................................... 12"

Long Stroke................................................................................................................................................................ 14"

Maximum Grinding Width....................................................................................................................................... 8⁷⁄8

Spindle Taper............................................................................................................................................... 5¹⁄2 Degrees

Spindle Speed................................................................................................................................................. 3450 RPM

Hub Diameter............................................................................................................................................................ 1¹⁄4

Grinding Wheel Diameter........................................................................................................................................... 7"

Grinding Wheel Width................................................................................................................................................ ¹⁄2

Grinding Wheel Bore................................................................................................................................................ 1¹⁄4

Floor To Table Height................................................................................................................................................ 40"

Column Width........................................................................................................................................................... 5¹⁄8

Column Length ......................................................................................................................................................... 5¹⁄8

Vertical Handwheel Graduation........................................................................................................................ 0.0005"

Vertical Handwheel Revolution............................................................................................................................. 0.05"

Crossfeed Handwheel Graduation....................................................................................................................... 0.001"

Crossfeed Handwheel Revolution ............................................................................................................................ 0.1"

Longitudinal Travel................................................................................................................................................... 14"

Cross Travel .............................................................................................................................................................. 8⁷⁄8

Table

Table Length ........................................................................................................................................................... 12¹⁄8

Table Width.............................................................................................................................................................5¹⁵⁄16"

Table Thickness ........................................................................................................................................................ 2.2"

T-Slot Width................................................................................................................................................................ ¹⁄2

T-Slot Height............................................................................................................................................................... ³⁄4

Stud Size...................................................................................................................................................................... ¹⁄2

Construction

Base Construction Material ......................................................................................................... Meehanite Cast Iron

Body Construction Material......................................................................................................... Meehanite Cast Iron

Table Construction Material........................................................................................................ Meehanite Cast Iron

Paint .................................................................................................................................................................Urethane

Spindle Bearing Type ........................................................................................ Angular Contact, P5 Class (ABEC-5)

Other Specifications:

Country Of Origin ........................................................................................................................................................ Taiwan

Warranty.........................................................................................................................................................................1 Year

Serial Number Location................................................................................................. Machine Data Label, Cabinet Door

Assembly Time...............................................................................................................................................................1 Hour

Features:

Allen-Bradley Electrical Components

Storage Cabinet

Grinding Wheel Included

Swedish SKF Bearings

Steel Ball Bearing Slideways for Super Smooth and Precise Operation

Excellent South Bend Uncompromising Quality

Diamond Wheel Dressing Tool w/Base

Balancing Arbor and Hub

Hub Puller

Toolbox w/Tools Included

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Model SB1023

For Machines Mfg. Since 8/09

S A F E T Y

SaFeTY

Understanding risks of Machinery

Operating all machinery and machining equipment can be dangerous or relatively safe depending

on how it is installed and maintained, and the operator's experience, common sense, risk awareness,

working conditions, and use of personal protective equipment (safety glasses, respirators, etc.).

The owner of this machinery or equipment is ultimately responsible for its safe use. This

responsibility includes proper installation in a safe environment, personnel training and usage

authorization, regular inspection and maintenance, manual availability and comprehension,

application of safety devices, integrity of cutting tools or accessories, and the usage of approved

personal protective equipment by all operators and bystanders.

The manufacturer of this machinery or equipment will not be held liable for injury or property

damage from negligence, improper training, machine modiﬁcations, or misuse. Failure to read,

understand, and follow the manual and safety labels may result in serious personal injury, including

amputation, broken bones, electrocution, or death.

The signals used in this manual to identify hazard levels are deﬁned as follows:

Death or catastrophic

harm WILL occur.

Moderate injury or ﬁre

MAY occur.

Death or catastrophic

harm COULD occur.

Machine or property

damage may occur.

Basic Machine Safety

1. Owner’s Manual: All machinery and

machining equipment presents serious

injury hazards to untrained users. To

reduce the risk of injury, anyone who uses

THIS item MUST read and understand

this entire manual before starting.

3. Trained/Supervised Operators Only:

Untrained users can seriously injure

themselves or bystanders. Only allow

trained and properly supervised personnel

to operate this item. Make sure safe

operation instructions are clearly

understood. If electrically powered, use

padlocks and master switches, and remove

start switch keys to prevent unauthorized

use or accidental starting.

2. Personal Protective Equipment: Operating

or servicing this item may expose the user

to ﬂying debris, dust, smoke, dangerous

chemicals, or loud noises. These hazards

can result in eye injury, blindness, long-

term respiratory damage, poisoning,

4. Guards/Covers: Accidental contact with

moving parts during operation may cause

severe entanglement, impact, cutting,

or crushing injuries. Reduce this risk by

keeping any included guards/covers/doors

installed, fully functional, and positioned

for maximum protection.

cancer, reproductive harm or hearing loss.

Reduce your risks from these hazards

by wearing approved eye protection,

respirator, gloves, or hearing protection.

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Model SB1023

11. Chuck Keys or Adjusting Tools: Tools used

S A F E T Y

5. Entanglement: Loose clothing, gloves,

neckties, jewelry or long hair may

get caught in moving parts, causing

entanglement, amputation, crushing,

or strangulation. Reduce this risk by

removing/securing these items so they

cannot contact moving parts.

to adjust spindles, chucks, or any moving/

rotating parts will become dangerous

projectiles if left in place when the machine

is started. Reduce this risk by developing

the habit of always removing these tools

immediately after using them.

12. Work Area: Clutter and dark shadows

increase the risks of accidental injury.

Only operate this item in a clean, non-

glaring, and well-lighted work area.

6. Mental Alertness: Operating this item

with reduced mental alertness increases

the risk of accidental injury. Do not let a

temporary influence or distraction lead to a

permanent disability! Never operate when

under the influence of drugs/alcohol, when

tired, or otherwise distracted.

13. Properly Functioning Equipment: Poorly

maintained, damaged, or malfunctioning

equipment has higher risks of causing

serious personal injury compared to

those that are properly maintained.

To reduce this risk, always maintain

this item to the highest standards and

promptly repair/service a damaged or

malfunctioning component. Always follow

the maintenance instructions included in

this documentation.

7. Safe Environment: Operating electrically

powered equipment in a wet environment

may result in electrocution; operating near

highly ﬂammable materials may result in a

ﬁre or explosion. Only operate this item in

a dry location that is free from ﬂammable

materials.

8. Electrical Connection: With electically

powered equipment, improper connections

to the power source may result in

14. Unattended Operation: Electrically

powered equipment that is left unattended

while running cannot be controlled and is

dangerous to bystanders. Always turn the

power OFF before walking away.

electrocution or fire. Always adhere to all

electrical requirements and applicable

codes when connecting to the power source.

Have all work inspected by a qualified

electrician to minimize risk.

15. Health Hazards: Certain cutting fluids

and lubricants, or dust/smoke created

when cutting, may contain chemicals

known to the State of California to cause

cancer, respiratory problems, birth defects,

or other reproductive harm. Minimize

exposure to these chemicals by wearing

approved personal protective equipment

and operating in a well ventilated area.

9. Disconnect Power: Adjusting or servicing

electrically powered equipment while it

is connected to the power source greatly

increases the risk of injury from accidental

startup. Always disconnect power

BEFORE any service or adjustments,

including changing blades or other tooling.

16. Difﬁcult Operations: Attempting

difficult operations with which you are

unfamiliar increases the risk of injury.

If you experience difficulties performing

the intended operation, STOP! Seek an

alternative method to accomplish the

same task, ask a qualified expert how the

operation should be performed, or contact

our Technical Support for assistance.

10. Secure Workpiece/Tooling: Loose

workpieces, cutting tools, or rotating

spindles can become dangerous projectiles

if not secured or if they hit another object

during operation. Reduce the risk of this

hazard by verifying that all fastening

devices are properly secured and items

attached to spindles have enough clearance

to safely rotate.

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Model SB1023

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S A F E T Y

additional Surface Grinder Safety

7. Workpiece Contact: A heavy impact on a

1. eye Protection: Grinding causes small

particles to become airborne at a high

rate of speed. ALWAYS wear eye

grinding wheel can cause it to break or ﬂy

apart, causing serious personal injuries.

Avoid jamming the workpiece into the

wheel to reduce this risk.

protection when using this machine.

2. Wheel Speed rating: Wheels operated at

a faster speed than rated for may break

or ﬂy apart. Before mounting a new

wheel, be sure the wheel

8. Hand/Wheel Contact: Grinding wheels

have the capability of removing a lot

of skin fast. Make sure the workpiece

is securely clamped to the table, then

position your hands a safe distance away

when grinding. Avoid wearing gloves as

they may get caught in the grinding wheel

and cause even more serious entanglement

injuries.

RPM rating is equal or higher than the

speed of the grinder.

3. Wheel Flanges: Only use the ﬂanges

included with the grinder when

mounting wheels. Other ﬂanges may

not properly secure the wheel and could

cause the wheel to ﬂy off or break apart.

9. Cracked Wheel: Cracked wheels may break

and ﬂy apart during operation. Replace

cracked wheels immediately!

4. ring Test: Perform a "ring test" on

grinding wheels before installation to

ensure that they are safe to use. A wheel

that does not pass the ring test may

break or ﬂy apart during operation.

10. Fire Hazard: DO NOT connect a surface

grinder to a dust collection system that is

used with woodworking machines. Sparks

emitted from the grinding process may

ignite wood particles, resulting in ﬁre or

explosion. Only use a metal-speciﬁc dust

collection system with this machine.

5. Starting Grinder: If a wheel IS damaged,

it will usually ﬂy apart shortly after

start-up. To protect yourself, always

stand to the side of the grinder when

turning it ON and allow it to gain full

speed before standing in front of it.

6. Lung Protection: Grinding produces

hazardous dust, which may cause long-

term respiratory problems if breathed.

Always wear a NIOSH approved dust

mask or respirator when grinding.

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For Machines Mfg. Since 8/09

Model SB1023

P R E P A R A T I O N

^PP^rer^Pae^raTp^iOnaration Overview Things You'll need

The purpose of the preparation section is to help

you prepare your machine for operation.

During the setup process, operation, and

maintenance of your machine, you'll need the

following items:

The typical preparation process is as follows:

For Lifting

1. Unpack the machine and inventory the

•

A forklift or other power lifting device

rated for the weight of the machine.

Lifting Strap or Chain (rated for at least

1500 lbs.)

contents of the box/crate.

•

2. Clean the machine and its components.

3. Identify an acceptable location for the

For Power Connection

machine and move it to that location.

•

A machine power connection that meets

federal, state, and local electrical codes.

An electrician may be required.

4. Level the machine and either bolt it to the

floor or place it on mounts.

For assembly

5. Assemble the loose components and make

any necessary adjustments or inspections to

ensure the machine is ready for operation.

•

Assistant

Cotton Rags

Mineral Spirits

Safety Glasses

Wrench 14mm

Wrench 19mm

Oil Can with any General Machine Oil

6. Connect the machine to the power source.

7. Test run the machine to make sure it

functions properly and is ready for operation.

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Model SB1023

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P R E P A R A T I O N

Unpacking

This item was carefully packaged to prevent

damage during transport. If you discover any

damage, please immediately call Customer

Service at (360) 734-1540 for advice. You may

need to file a freight claim, so save the containers

and all packing materials for possible inspection

by the carrier or its agent.

inventory

Main Inventory: (Figure 2)

Qty

A. Machine w/Wheel Installed...........................1

Tool Box Inventory: (Figure 3) Qty

Figure 2. Main inventory.

B. Tool Box..........................................................1

C. Phillips Head Screwdriver #2........................1

D. Hub Puller......................................................1

E. Handles...........................................................2

F. Balancing Arbor.............................................1

G. Machine Foot Assemblies..............................5

H. Box-End Wrench 14 x 17mm.........................1

I. Open-End Wrench 12 x 14mm ......................1

J. Adjustable Spanner Wrench .........................1

K. Diamond Dresser ...........................................1

L. Diamond Dresser Base ..................................1

M. Chuck Mounting Hex Bolts ¹⁄2-12 x 2"

w/Nuts ............................................................2

N. Hex Wrench 4mm ..........................................1

O. Bottle for Oil...................................................1

Figure 3. Small parts inventory.

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Model SB1023

P R E P A R A T I O N

Cleaning & Protecting

The unpainted surfaces are coated at the factory

with a heavy-duty rust preventative that

prevents corrosion during shipment and storage.

The beneﬁt of this rust preventative is that it

works very well. The downside is that it can be

time-consuming to thoroughly remove.

Many cleaning solvents are

toxic if inhaled. Minimize

your risk by only using

these products in a well

ventilated area.

Be patient and do a careful job when cleaning

and removing the rust preventative. The time

you spend doing this will reward you with

smooth-sliding parts and a better appreciation

for the proper care of the unpainted surfaces.

Avoid chlorine-based solvents, such as

acetone or brake parts cleaner that may

damage painted surfaces. Always follow the

manufacturer’s instructions when using any

type of cleaning product.

Although there are many ways to successfully

remove the rust preventative, we have cleaned

thousands of machines and found the following

process to be the best balance between efﬁciency

and minimized exposure to toxic fumes or

chemicals.

Basic steps for removing rust preventative:

1. Put on safety glasses and disposable gloves.

2. Coat all surfaces that have rust preventative

with a liberal amount of your cleaner or

degreaser and let them soak for a few

minutes.

Before cleaning, gather the following:

•

Disposable rags

Cleaner/degreaser (certain citrus-based

degreasers work extremely well and they

have non-toxic fumes)

3. Wipe off the surfaces. If your cleaner or

degreaser is effective, the rust preventative

will wipe off easily.

•

Safety glasses & disposable gloves

Note: To clean off thick coats of rust preventative

on ﬂat surfaces, such as beds or tables, use

a PLASTIC paint scraper to scrape off the

majority of the coating before wiping it off

with your rag. (Do not use a metal scraper or

it may scratch the surface.)

Note: Automotive degreasers, mineral spirits, or

WD•40 can be used to remove rust preventative.

Before using these products, though, test them

on an inconspicuous area of a painted area to

make sure they will not damage it.

4. Repeat Steps 2–3 as necessary until clean,

then coat all unpainted surfaces with a

quality metal protectant or light oil to

prevent rust.

Gasoline and petroleum

products have low flash

points and can explode

GAS

or cause fire if used for

cleaning. Avoid using these

products to remove rust

preventative.

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Model SB1023

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P R E P A R A T I O N

Weight Load

Location

Refer to the Machine Speciﬁcations for the

weight of your machine. Make sure that the

surface upon which the machine is placed will

bear the weight of the machine, additional

equipment that may be installed on the machine,

and the heaviest workpiece that will be used.

Additionally, consider the weight of the operator

and any dynamic loading that may occur when

operating the machine.

Physical Environment

The physical environment where your machine

is operated is important for safe operation and

longevity of parts. For best results, operate this

machine in a dry environment that is free from

excessive moisture, hazardous or flammable

chemicals, airborne abrasives, or extreme

conditions. Extreme conditions for this type

of machinery are generally those where the

ambient temperature is outside the range of 41°–

104°F; the relative humidity is outside the range

of 20–95% (non-condensing); or the environment

is subject to vibration, shocks, or bumps.

Space Allocation

Consider the largest size of workpiece that will

be processed through this machine and provide

enough space around the machine for adequate

operator material handling or the installation

of auxiliary equipment. With permanent

installations, leave enough space around

the machine to open or remove doors/covers

as required by the maintenance and service

described in this manual.

Electrical Installation

Place this machine near an existing power

source. Make sure all power cords are protected

from traffic, material handling, moisture,

chemicals, or other hazards. Make sure to leave

access to a means of disconnecting the power

source or engaging a lockout/tagout device.

Children or untrained

people may be seriously

injured by this machine.

Only install in an access

restricted location.

Lighting

Lighting around the machine must be adequate

enough that operations can be performed

safely. Shadows, glare, or strobe effects that

may distract or impede the operator must be

eliminated.

Wall

Power

Connection

24"

14"

30"

17"

10"

68"

72"

Figure 4. Space required for full range of movement.

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P R E P A R A T I O N

Lifting & Moving

Leveling & Mounting

Generally, you can either bolt your machine

to the ﬂoor or mount it on machine mounts.

Although not required, we recommend that you

secure the machine to the ﬂoor and level it while

doing so. Because this is an optional step and

ﬂoor materials may vary, hardware for securing

the machine to the ﬂoor is not included.

This machine and its

parts are heavy! Serious

personal injury may occur

if safe moving methods are

not used. To reduce the

risk of a lifting or dropping

injury, ask others for help

and use power equipment.

We strongly recommend securing your

machine to the floor if it is hardwired to the

power source. Consult with your electrician to

ensure compliance with local codes.

Unbolt the machine from the pallet and make

sure that the table is locked in place. Connect a

chain or lifting strap to the lifting hook on the

machine (Figure 5), use a hoist or forklift to lift

the machine off the pallet, and move it to the

suitable location. All hoisting equipment and

straps must be rated to lift at lease 1500 lbs.

Leveling

Leveling machinery helps precision components,

such as bed ways, remain straight and ﬂat

during the lifespan of the machine. Components

on an unleveled machine may slowly twist due to

the dynamic loads placed on the machine during

operation.

never attempt to move this machine without

first locking the table in place. if the machine

is slightly tilted, the table could uncontrollably

slide, fall off of the machine and cause

machine damage or severe injury.

For best results, use a precision level that

is at least 12" long and sensitive enough to

show a distinct movement when a 0.003" shim

(approximately the thickness of one sheet of

standard newspaper) is placed under one end of

the level.

See the ﬁgure below for an example of a high

precision level.

Figure 6. example of a precision level.

Figure 5. Lifting location.

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Model SB1023

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P R E P A R A T I O N

8. Use a 19mm wrench to tighten the jam nuts

inside of the cabinet and lock the feet studs

into place.

assembly

After the machine is placed in the final location,

and before the lifting apparatus is removed,

you should install the machine feet. Included

with your machine are four cushioned feet with

built-in adjustment studs (see Figure 7). These

feet are easily installed and provide for accurate

machine leveling.

Note: Over the course of the next six months,

periodically verify that the machine is still

level, and re-adjust the feet as required.

9. Rotate the top handwheel counterclockwise

to raise the headstock slightly. Then remove

the wood support block (see Figure 8).

To install the feet:

Top

Handwheel

1. Using lifting equipment and wooden blocks,

raise and support the machine base so there

is approximately 5" between the ﬂoor and

underside of the base.

Wood Support

Block

2. Remove the jam nuts from the foot studs.

3. Apply any general-purpose automotive

grease to the stud threads.

4. Thread the studs into the machine base

from the bottom up until the studs emerge

from the cabinet ﬂoor approximately 2" (see

Figure 7).

Foot Stud

Jam Nut

Figure 8. Support block.

Threaded

Hole

10. Using a 14mm wrench, install the two

handles into the handwheels (Figure 9).

Machine

Foot

Figure 7. Machine feet.

5. Thread the jam nuts onto the protruding

studs but do not tighten them at this time.

6. Place the machine onto the ﬂoor.

7. Using a precision level on the machine table,

adjust the feet studs, so the machine is level

from side-to-side and front-to-back.

Figure 9. Headstock height handwheel.

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Model SB1023

P R E P A R A T I O N

220v Conversion for SB1023

Power Connection

Wiring diagrams are provided in the back of

this manual (Page 36) showing the Model

SB1023 wired for both 110V and 220V.

Refer to these diagrams when following this

procedure. Additionally, you must purchase the

220V conversion kit in order to complete the

conversion. Call our parts department at

(417) 886-2954 and order part number

PSB1023180.

electrocution or fire

may occur if machine is

ungrounded, incorrectly

connected to power, or

connected to an undersized

circuit. Use a qualified

electrician to ensure a safe

power connection.

To convert the Model SB1023 to operate on

220v power:

Once your machine is set up and assembled as

previously described in this manual, it is ready to

be connected to the power source.

1. DISCONNECT MACHINE FROM POWER!

2. Rewire the motor for 220V, as shown in the

diagram on the inside of the motor junction

box. If there is not a diagram in the junction

box, use the diagram in this manual (Page

36).

Note About Extension Cords: Using an

incorrectly sized extension cord may decrease the

life of electrical components on your machine.

SB1023 110v (Prewired)

3. Replace the contactor on the machine with

the contactor from the 220V conversion kit.

Set the amp dial to 5.5A

Required Power Source........ 110V, 1-Phase, 60Hz

Full Load Amp Draw .............................. 9.5 Amps

Phase ..........................................................1-Phase

Frequency...................................................... 60 Hz

Minimum Circuit Size ............................. 15 Amps

Included Plug ...................................... NEMA 5-15

Minimum Extension Cord Size ................14 AWG

Maximum Extension Cord Length................ 50 ft.

4. Replace the power cord plug with a NEMA

6-15 plug.

SB1023 (220v Option)

Required Power Source........ 220V, 1-Phase, 60Hz

Full Load Amp Draw ................................. 5 Amps

Phase ..........................................................1-Phase

Frequency...................................................... 60 Hz

Minimum Circuit Size ............................. 15 Amps

Recommended Plug/Receptacle.......... NEMA 6-15

Minimum Extension Cord Size ................16 AWG

Maximum Extension Cord Length................ 50 ft.

-15-

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Model SB1023

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P R E P A R A T I O N

•

Investigate and correct strange or

unusual noises or vibrations before

operating the machine further. Always

stop the machine and disconnect it from

power before investigating or correcting

potential problems.

initial Lubrication

Your machine was lubricated at the factory,

but we strongly recommend that you inspect all

lubrication points yourself and provide additional

lubrication if necessary. Refer to Lubrication on

Page 30 for specific locations.

7. Press the STOP button.

8. WITHOUT resetting the switch, press the

START button. The machine should not

start.

Test run

After all preparation steps have been completed,

the machine and its safety features must be

tested to ensure correct operation. If you discover

a problem with the operation of the machine or

its safety components, do not operate it further

until you have resolved the problem.

•

If the machine does not start, the

STOP button safety feature is working

correctly.

•

If the machine does start (with the

stop button pushed in), immediately

disconnect power to the machine. The

STOP button safety feature is not

working correctly. This safety feature

must work properly before proceeding

with regular operations. Call Tech

Support for help.

Refer to Troubleshooting on Page 34 for

solutions to common problems that may occur

with surface grinders. If you need additional

help, contact our Technical Support at

(360) 734-1540.

To test run your machine:

1. Read and follow the safety instructions

at the beginning of the manual, take the

required safety precautions, and make sure

the machine is set up and adjusted properly.

inspections &

adjustments

The following list of adjustments were performed

at the factory before your machine was shipped:

2. Ring test the grinding wheel, and install the

wheel onto the spindle.

Refer to Ring Test on Page 25, and

Installing & Removing Grinding Wheels

on Page 20 for procedures.

•

Ring Test on Page 25

Wheel Dressing on Page 25

Wheel Balancing on Page 26

Lubrication on Page 30

3. Clear away all tools and objects used during

assembly and preparation.

4. Connect the machine to the power source.

5. Push the STOP button in, then twist it

clockwise so it pops out. When the STOP

button pops out, the switch is reset and

ready for operation.

Handwheel Backlash Adjustment on

Page 32

•

Column & Table Gib Adjustment on

Page 32

6. Verify that the machine is operating

correctly by pushing the START button.

•

When operating correctly, the machine

runs smoothly with little or no vibration

or rubbing noises.

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O P E R A T I O N

OPeraTiOn

To complete a typical operation, the operator

does the following:

Operation Overview

The purpose of the operation section is to

familiarize you with the basic controls,

terminology, capabilities, and adjustments that

are necessary to use this machine.

1. Examines the grinding wheel to make sure it

is suitable for use t

2. Examines the workpiece to make sure it is

properly prepared for grinding.

To better understand the remaining parts of

this section, please take a moment to read this

overview.

3. Uses the elevation handwheel to raise

the grinding wheel assembly to provide

clearance for mounting the workpiece.

4. Wipes the table surface clean to remove any

debris that may interfere with the clamping

process.

To reduce the risk of

serious injury when using

this machine, read and

understand this entire

manual before beginning

any operations.

5. Uses a magnetic chuck to hold the workpiece

to the table, then turns the elevation

handwheel to lower the grinding wheel to

just above the top surface of the workpiece.

6. Turns the grinder ON, then stands aside

while the wheel reaches full speed.

Loose hair, clothing, or

jewelry could get caught

in machinery and cause

serious personal injury.

Keep these items away

from moving parts at all

times to reduce this risk.

7. Performs the grinding operation.

Note: Because the method for performing

each grinding operation varies, specific

actions are not listed here.

8. When the grinding operation is complete,

turns the grinder OFF and allows the

grinding wheel to come to a complete stop.

During operation, small

metal chips may become

airborne, leading to serious

eye injury. Wear safety

glasses to reduce this risk.

9. Removes the workpiece from the table.

-17-

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G. Spindle On Button: Supplies power to the

Controls

grinding wheel motor.

Refer to Figures 10–11 and the following

descriptions to become familiar with the basic

controls of this machine.

H. emergency Stop (Off) Button: Cuts power

to the grinding wheel motor.

A. Longitudinal Travel Handwheel: Moves the

table back and forth along the longitudinal

axis (X-axis).

B. Center Table Stop: Provides a barrier for

the table stops to limit table movement.

C. Table Stop: Adjusts along the length of the

table to limit longitudinal travel.

D. Cross axis Lock Knob: Locks the cross

table movement (Y-Axis).

Figure 11. Control panel.

E. elevation Handwheel: Controls vertical

movement of the grinding wheel assembly.

F. Cross Travel Handwheel: Moves the table

forward and backward along the cross axis

(Y-axis).

Figure 10. Basic controls.

-18-

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O P E R A T I O N

Grit Size

Wheel Selection

The ideal grit for an operation depends on a

number of considerations. Use the table below to

choose a grit suitable for your desired results.

Most grinding wheels from major manufacturers

are marked in a somewhat uniform manner.

Understanding these markings will help you

understand the capabilities of various wheels.

Always refer to the manufacturer’s grinding

recommendations when selecting a wheel for

your project.

results

Operation

Consideration

Coarse Grit

(10–46)

Fine Grit

(54–180)

Material

Removal

Increased Decreased

The grinding wheel you choose will depend on

several factors related to the operation you plan

to perform. The hardness of the material you

will be grinding and the surface finish you desire

are the two primary factors to consider when

selecting a grinding wheel.

Surface Finish

Rough

Soft

Smooth

Hard

Workpiece

Hardness

Width of Cut

Wide

Narrow

An example of the basic format for wheel

numbering is shown below. The wheel in this

example is a "36A60LV".

Grade

The grade of a wheel is an indicator of its

hardness based on an alphabetical scale in which

A is the softest and Z is the hardest.

Preﬁx abrasive Grit Grade Bond

Type

Size

Type

Wheel Hardness

Operation

Soft

Hard

Consideration

a–M

n–Z

The preﬁx is a manufacturer-speciﬁc designation

and will vary depending on the manufacturer.

Workpiece

Hardness

Hard

Soft

Width of Cut

Feed Rate

Wide

Slow

Fast

Narrow

Fast

Use the charts below as a basic wheel selection

outline for most grinding operations.

Wheel Speed

Slow

abrasive Type

abrasive

application

Type

Aluminum Oxide: For grinding

common steel.

White Aluminum Oxide: For

grinding harder metals (heat

treated steel, carbon steel, alloy

steel, etc.).

For grinding high speed steel.

Silicon Carbide: For grinding cast

iron and non-ferrous metals.

Ceramic Grain: For extremely hard

metals, such as tungsten carbide.

-19-

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4. Position the spanner wrench on the spanner

removing & installing

nut (Figure 14).

Grinding Wheels

Spacer

Washer

If you must conduct a ring test, the grinding

wheel must be removed and reinstalled onto the

hub. However, when doing this, remember that

overtightening or rotating the spanner nut in the

incorrect direction can damage threads, crack

the grinding wheel, and make grinding wheel

removal more difficult than necessary.

Spanner

nut

To remove and install a grinding wheel:

1. DISCONNECT MACHINE FROM POWER!

Figure 14. Wheel spanner nut.

2. Place a sheet of plywood on top of the table

to protect the table (Figure 12), and open

the grinding wheel cover.

5. Using the wrenches, loosen the spanner nut

in the direction shown in Figure 15.

Hold

Plywood

Figure 12. Protecting table.

Figure 15. removing spanner nut.

3. Position a 12mm wrench on the spindle shaft

that protrudes from the motor fan cover

(Figure 13).

6. Unthread the spanner nut (Figure 16).

Figure 13. Spindle shaft.

Figure 16. exposing wheel spacer washer.

-20-

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7. Remove the grinding wheel, as shown in

Figure 17.

Paper

Washer

Figure 19. important paper washer.

Note: If you need to replace or install new paper

washers, replacements can be cut out of

any thick construction paper or card stock.

Regular notebook paper or paper from a copy

machine is not acceptable, as it is too thin to

provide the required cushion. Don't forget to

record the wheel type and RPM rating on the

new paper washer.

Figure 17. removing wheel.

8. Wipe the grinding wheel seat shown in

Figure 18 so no paper is stuck to the seat.

The seat must be clean and free of debris.

Note: Wiping the threads, grinding wheel seat,

and hub with a lightly-oiled rag is acceptable

to prevent rust.

10. Ring test the grinding wheel, even if it is

new, then if the wheel is free of cracks, slide

the wheel onto the hub. Refer to Ring Test

on Page 25 for details.

Grinding Wheel

Seat

11. Complete the preceding steps in the reverse

order to install the grinding wheel.

•

After the grinding wheel is installed, you

will have to use the dressing tool to true-

up the wheel. Refer to Wheel Dressing

on Page 25 for details.

When the wheel runs true, the hub and

grinding wheel must then be removed

and balanced as an assembly since

grinding wheels can have different

densities at various points of the

Figure 18. Wheel mounting hub.

9. Inspect the paper washers for missing pieces

on both sides of the grinding wheel (Figure

19). The paper washers are cushions

wheel. The wheel will only deliver

superior results if it is properly trued-

up and balanced. Refer to Removing

& Installing Wheel & Hub on Page

22 to remove the assembly; and refer

to Wheel Balancing on Page 26 for

specific procedures on balancing.

between the spacer washer and the grinding

wheel seat. Without the washers, cracks can

spawn from the center of the wheel when the

spanner nut is tightened. Over time, these

cracks can radiate outward and the wheel

may explode possibly causing injury.

-21-

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To remove and reinstall the wheel and hub:

removing & installing

1. DISCONNECT MACHINE FROM POWER!

Wheel & Hub

2. Place a sheet of plywood or similar on top of

table to protect the table (Figure 20), and

open the grinding wheel cover.

When the wheel has been ring tested, and

dressed, the wheel and hub must be removed and

balanced as an assembly. However, remember

that overtightening or rotating the spindle bolt in

the incorrect direction can damage threads, crack

the grinding wheel, and make grinding wheel

removal more difficult than it needs to be.

When removing and installing the hub onto the

spindle or balancing arbor, keep in mind that the

mating surfaces between these components have

the single most important effect on your final

balancing results. Hubs, spindles, and balancing

arbors can be easily damaged during installation

and removal. Just one grain of sand, small burr,

or hidden ding in either mating surface will

undermine all balancing results. Make sure

that all mating surfaces are carefully stoned to

establish a perfect fit.

Figure 20. Protecting the table.

3. Position the spindle wrench on the spindle

NEVER pound on a hub or arbor for any reason.

This will permanently displace metal and change

high tolerance dimensions.

bolt (Figure 21).

NEVER use a hydraulic press to install the

balancing arbor or attempt to use a heat

differential between parts to establish a shrink-

fit. This will change high tolerance dimensions.

NEVER twist-fit the hub onto the spindle or

the balancing arbor. Doing this can gall the

tapered surfaces. Instead use a small arbor press

with light pressure to install and remove the

balancing arbor from the hub.

Spindle

Bolt

Figure 21. retaining fasteners.

ALWAYS make sure that all mating surfaces

are immaculately cleaned before hub or arbor

installation. Use a lint-free photography lens

cloth that is slightly oiled with a thin machine

oil. For the best fit, the mating surfaces must

be polished without having a wet layer of oil on

them. The oil should only be in the pores of the

metal.

-22-

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7. Oil the threads and thread the hub puller

O P E R A T I O N

4. Position a 12mm open end wrench on the

spindle shaft that protrudes from the motor

fan cover (Figure 22).

(Figure 25) into the hub until it stops.

Hub

Puller

Figure 25. Hub puller.

Figure 22. Spindle shaft.

8. While holding the wheel and hub from

sliding off of the spindle, tighten the hub

puller bolt until the wheel and hub assembly

are pulled off the spindle as shown in

Figure 26.

5. Using the wrenches, turn the spindle bolt

clockwise as shown in Figure 23.

Hold

Figure 23. Hub removal.

6. Remove the spindle bolt (Figure 24).

Figure 26. Pulling wheel hub.

Hub

Spindle bolt

Figure 24. Spindle bolt removal.

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O P E R A T I O N

9. Set the wrenches aside and carefully remove

the wheel and hub assembly with the hub

puller still installed (Figure 27).

Wheel inspection

Do not assume that a wheel is in sound condition

just because it is new—damage can often occur

during shipping, with age, with prolonged

exposure to moisture, or because of improper

storage.

To inspect a wheel for damage:

1. Remove the wheel and look for any cracks,

chips, nicks or dents in the surface of the

wheel. If you see any of these, DO NOT

attempt to use the wheel.

2. Do a ring test. This test will give you an

indication of any internal damage that may

not be obvious during a visual inspection.

Figure 27. Wheel and hub removal.

10. Unthread the hub puller and set it aside.

3. Inspect the paper washers on both sides

of the grinding wheel (Figure 29). These

washers are cushions between the spacer

washer and the grinding wheel seat. Without

the washers, cracks can be spawned from

the center of the wheel when the spanner

nut is tightened. Over time, these cracks can

radiate outward and the wheel may explode

during operation, possibly causing injury.

11. Wipe the spindle and hub taper (Figure 28),

so the tapers are perfectly clean. Wiping the

threads and tapers with a lightly-oiled rag is

acceptable to prevent rust and still to allow

for a tight ﬁt.

Hub

Taper

Paper

Washer

Spindle Taper

Figure 28. Spindle taper.

Figure 29. important paper washer.

12. To install the grinding wheel and hub,

complete the preceding steps in the reverse

order, but skipping the steps regarding hub

puller usage. After the grinding wheel and

hub are installed, many machinists still

choose to dress the grinding wheel. Refer to

Wheel Dressing on Page 25 for details.

Note: If you need to replace or install new paper

washers, replacements can be cut out of

any thick construction paper or card stock.

Regular notebook paper or paper from a copy

machine is not acceptable, as it is too thin

to provide the required cushion. Be sure to

transfer any RPM limitations and wheel type

information.

-24-

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ring Test

Wheel Dressing

This test will give you an indication of any

internal damage that may not be obvious during

a visual inspection.

Superior grinding results can only be achieved

with a properly balanced and dressed wheel. Do

not assume that a wheel will run true on the

spindle if it is new or has not been separated

from the hub.

To perform a ring test:

Dressing the wheel correctly will save you from

wasting grinding abrasive and shattering the

dressing tool diamond. Additionally, with a

properly balanced and dressed wheel you can

rest assured that if you have finish problems, the

grinding wheel is not the culprit.

1. Make sure the wheel that you test is clean

and dry; otherwise, you may get false

results.

2. Hang the wheel in the air with a piece of

cord or string looped through the hole in the

center, as shown in Figure 30.

Depending on the finish required, varying

degrees of roughness can be obtained. For

example: A fast dressing at a depth of 0.03mm

will prepare a wheel surface for rough cuts, and

slow dressing with multiple light passes of the

diamond at a depth of 0.01mm will prepare the

same wheel for finish cuts.

Positioning is critical for the dressing tool so

you will not shatter the diamond or have poor

dressing results. The dressing tool must be

positioned in the trailing zone of the wheel, as

shown in Figure 31, for best results and safe

use. If the tool is positioned on the leading side

of the wheel, the diamond will be shattered or

even grabbed by the wheel and drawn under the

grinding wheel, causing severe damage or injury.

Paper Washer

Grinding

Wheel

Figure 30. ring test setup and test locations.

3. At the locations shown in Figure 30, gently

tap the wheel with a light non-metallic

device such as the handle of a screwdriver or

a wooden mallet.

Dressing

Tool

An undamaged wheel will emit a clear

metallic ring or “ping” sound in each of these

spots. A damaged wheel will respond with

a dull thud that has no clear tone. If you

determine from the ring test that the wheel

is damaged, DO NOT use it!

Magnetic Chuck

Figure 31. Safe tool positioning for wheel dressing.

-25-

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O P E R A T I O N

To dress the grinding wheel:

Wheel Balancing

1. Insert the diamond tipped dressing tool into

its base (Figure 32), and use a 4mm hex

wrench to tighten the locking set screw.

Static wheel balancing can be difficult and very

time consuming without practice. For accurate

grinding results, wheel balancing is mandatory.

For this balancing procedure, you will need a

wheel balancing fixture. The wheel balancing

fixture shown in Figure 33 is one example of the

many varieties available on the market.

Before proceeding, the grinding wheel must be

ring tested (refer to Page ) and dressed (refer to

Page ).

Figure 32. Dressing tool setup.

2. Lower the headstock so the wheel is

approximately 5mm lower than the tip of the

dressing tool.

3. Position the tip of the dressing tool at the

trailing side of the wheel, as shown in

Figure 31, and move the table inward until

the diamond tip of the dressing tool slightly

touches the edge of the grinding wheel.

Verify by manually rotating the wheel and

listening for contact.

Figure 33. Wheel on balancing fixture.

If ﬂood coolant was used with the grinding

wheel, run the machine with the grinding wheel

installed for 5-minutes to sling off any residual

coolant that may have settled to the low side of

the wheel. If the paper washers are missing, wet,

or damaged, replace them before proceeding. If

during a period of machine operation, you find

that a finish is becoming poor, redress the wheel.

If that does not correct the problem rebalance

your grinding wheel.

4. Turn on the magnetic chuck, and move the

cross slide so the tip is free of the grinding

wheel.

5. Start the grinder, and use the cross slide

handwheel to progressively move the table,

so the diamond sweeps across the wheel at a

depth between 0.01 – 0.03mm.

To balance the grinding wheel:

1. DISCONNECT MACHINE FROM POWER!

2. Set up the wheel balancer as outlined in its

product user manual.

3. Remove the grinding wheel and hub as

a unit from the spindle as outlined in

Removing & Installing Grinding Wheel

Hub on Page 22.

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4. Without letting any of the dogs or the lock

balls they contain fall out of the hub, use

a 2.5mm hex wrench to loosen the dogs

and position them at the 0°, 120°, and 240°

degree locations as indicated by the degree

scale on the hub (Figure 34).

7. Spin the wheel so it rotates one full turn and

comes to rest with the heaviest side hanging

down at six o'clock. This may take a few

times to ﬁnd the exact location.

8. Using a pencil, draw a line at the six o'clock

position to mark the heaviest side of the

wheel.

Balance Dog

Lock Ball inside

Degree Scale

9. Line up the closest dog with the line you

just drew and lock it in place. This dog will

now be positioned at the heaviest side of the

wheel and will be called dog "A".

Dog Slot

10. Using the scale, position the other two "B"

dogs so they are both evenly spaced 120°

degrees apart from dog "A". At this point all

dogs will be 120° apart from one another.

The "B" dogs are the two dogs you will move

to balance the wheel.

Hub

Paper Washer

Figure 34. Grinding wheel hub.

11. Rotate the wheel 90° degrees, let go, and

observe the direction that it rotates out of

balance. Move each "B" dog in one degree

increments, toward each other and away

from dog "A" to balance the wheel. For

example, depending on the amount of

balance correction, the distance between

the two "B" dogs will decrease, and the

distance between the "B" dogs and "A" dog

will increase. This step must be repeated

as many times as required until the wheel

will not rock back and forth by itself in any

position.

Note: Pay special attention to keep the dogs

engaged in the hub slot when they are loose.

If you lose any of the 4mm lock balls, it will

be impossible to continue this procedure

until they are replaced.

5. Using a slightly-oiled lint free cloth, wipe the

mating surfaces of the balancing arbor and

the internal hub taper perfectly clean, and

push the hub and arbor together, as shown

in Figure 35.

12. When you are satisﬁed with the wheel

balance, install the grinding wheel on the

machine, and run it for ﬁve minutes to verify

the wheel is in balance.

13. If any balance problems are detected, repeat

the balancing procedure.

Note: Some machinists will re-dress the grinding

wheel one last time at this point to ensure

ultra-high grinding precision.

Figure 35. installing the balancing arbor.

6. Place the balancing arbor onto the wheel

balancing ﬁxture (Figure 33).

-27-

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O P E R A T I O N

Magnetic Chuck

Grinder Operation

The Model SB1023 is designed to be used with

a magnetic chuck. The table is equipped with a

T-slot for securing your magnetic chuck. Refer to

your magnetic chuck manufacturer's instruction

manual for proper chuck preparation and

mounting techniques.

Grinding with a surface grinder is a delicate

process that takes practice, skill, and knowledge.

In addition to this, the method used for any one

procedure will depend on a number of factors,

including, but not limited to the material being

ground, the grinding wheel being used, the

quality and calibration of measuring tools, and

A magnetic chuck secures workpieces to the table the finish that is desired.

without the use of clamps. With proper attention

to preparation of both the workpiece and the

magnetic chuck, a magnetic chuck will provide

ample clamping force on most magnetic metals.

Refer to your magnetic chuck manufacturer's

instruction manual for proper workpiece

mounting techniques.

For these reasons, specific techniques are not

outlined in this manual. We recommend that you

consult books, trade magazines, metalworking

experts, and other reliable resources for

techniques pertaining to the specific tasks you

wish to perform.

The information that follows serves as a general

outline to help familiarize you with the basic

grinding technique.

Setup for a Typical

Grinding Operation

Once you have chosen the proper wheel for the

operation and properly installed the magnetic

chuck on the table, use the following procedures

to prepare for a grinding operation.

To prepare for a grinding operation:

1. DISCONNECT MACHINE FROM POWER!

2. To ensure ﬂat mating surfaces on the

workpiece and the magnetic chuck, surface

grind and stone the top of the chuck and the

bottom of the workpiece.

3. Make sure the magnetic chuck is turned

OFF, then place the workpiece onto the

chuck. Once the workpiece is positioned as

needed, turn the magnetic chuck ON.

4. Make sure the grinding wheel is not

contacting the workpiece, connect the

grinder to power, then turn the motor ON.

-28-

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Using the Surface Grinder

Surfaced Portion

Grinding Wheel

Operation of the grinder is controlled through

the movement of the three handwheels. The

elevation handwheel controls the up and down

movement of the grinding head. It is this axis

that governs the amount of stock removal.

Never attempt to remove too much material in

one pass. The best results are be achieved with

multiple light passes.

Workpiece

The longitudinal travel handwheel rapidly moves

the table from left to right. This allows the

operator to move the workpiece back and forth

underneath the grinding wheel.

Surfaced Portion

The cross travel handwheel controls the front-

to-back movement of the table and is only to be

used between longitudinal passes to expose a

new area of the workpiece to the grinding wheel

New Portion

Exposed

*Movement exaggerated for clarity

Surfaced Portion

When grinding, sweep the table back and forth

under the wheel in the longitudinal direction

until no further sparks emerge from the

workpiece, move the table in the cross direction

to expose a new portion of the workpiece to

the wheel, then take another sweep in the

longitudinal direction. Repeat this process until

the entire surface is ground. See Figure 36 for

an illustration of this process.

Surfaced Portion

Grinding Tips

While every grinding operation is unique, there

are a few techniques that apply to most, if not all

grinding operations.

•

During longitudinal passes, tighten the cross

travel lock knob to prevent chatter that may

occur as a result of slight cross movement of

the table.

New Portion

Exposed

*Movement exaggerated for clarity

Surfaced Portion

•

Between longitudinal passes, use the

squeegee to remove any foreign material

from the workpiece.

Continue/repeat as necessary until desired

results are achieved.

Figure 36. Grinding process illustrated.

-29-

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M A I N T E N A N C E

Maintenance

Maintenance Schedule Lubrication

If this machine is used in a heavy industrial

setting, or in a dirty or damp environment,

increase the lubrication intervals.

always disconnect

machine from power before

performing maintenance or

serious personal injury may

result.

To lubricate your machine:

1. DISCONNECT MACHINE FROM POWER!

2. Clean the upper column leadscrew section

with mineral spirits, dry with a rag, and

relubricate with any standard machine or

multipurpose grade grease (Figure 37).

To keep this machine in the best operating

condition, make sure to complete the follow-

ing maintenance items within the minimum

intervals listed below.

Leadscrew

Daily:

•

Check for and correct loose mounting bolts.

Check for and correct damaged or cracked

grinding wheel.

•

Check for and correct worn or damaged

wires.

•

Clean and protect table.

Vacuum metal shavings from machine.

Correct any other unsafe condition.

Grease Fitting

Bi-weekly

•

Remove the table, clean and relubricate the

ways, ball bearings, and rack and pinion.

Lubricate the column grease fitting with two

pumps of grease.

Lubricate the table cross way grease fitting

with two pumps of grease.

Clean and grease all three leadscrews.

Figure 37. Upper column leadscrew and grease fitting.

3. Wipe the column grease ﬁtting clean (see

Figure 37) and pump the ﬁtting with two or

three pumps of grease. Wipe off any grease

that bleeds through the seams.

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4. Clean the lower column leadscrew section

with mineral spirits, dry with a rag, and

relubricate with any standard machine or

multipurpose grade grease (Figure 38).

Figure 38. Lower column leadscrew.

5. Wipe the table cross feed grease ﬁtting clean

(Figure 39), and put two or three pumps

of grease into it. Wipe off any grease that

bleeds through the seams.

Figure 40. Ball bearing ways.

Grease Fitting

Figure 41. Table ways and rack.

Figure 39. Cross way grease fitting.

7. Clean the pinion, rack, bearings, ways, and

leadscrew with mineral spirits. Dry all parts,

and re-lubricate with white lithium grease.

6. With the help of another person, lift the

table off the ways and set the table upside

down on a workbench (Figures 40-41).

8. With the help of your assistant,

CAREFULLY place the table back onto the

ways. DO NOT drop the table or you may

put a nick in a way and ruin it permanently.

-31-

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Handwheel Backlash Column & Table Gib

adjustment adjustment

Backlash is the amount of play found in a

The gib is a tapered piece of steel that is held in

leadscrew. Without moving the table, the amount position by a gib screw. When the screw is turned

of backlash can be determined by lightly turning

the handwheel with your fingertips in one

direction until the handwheel stops, noting the

location shown on the handwheel scale. Then the

handwheel is turned in the other direction until

it stops. The distance between both stopping

locations is the amount of backlash. If the

clockwise, the gib will be moved to fill the loose

void in the way, thus, removing the play. If more

play is needed, adjust the screws the opposite

direction.

When adjusting the table or column gib screw

(Figure 43), keep in mind that the goal is to

backlash exceeds 0.007", adjust it back into range remove sloppiness in the ways without causing

the of 0.003" to 0.006".

the dovetailed ways to bind or prematurely wear.

A loose gib can cause dimensional problems or a

poor finish on the workpiece.

The backlash adjustment is made by tightening

or loosening the cross-feed leadscrew halfnut

cap screws shown in Figure 42. These screws

draw two halves of the halfnut together against

the leadscrew placing pressure on the threads.

If this fit is too tight, loosen the cap screws, tap

the table a few times with a rubber or wooden

mallet, and turn the handle slowly back-and-

forth until the handle turns freely. To readjust

the backlash, rock the handle back-and-forth and

tighten the screws slowly until the backlash is

correct.

Note: Avoid the temptation to overtighten

the cap screws at the leadscrew halfnut.

Overtightening will cause excessive wear

to the halfnut and leadscrew. Reducing

backlash to less than 0.003" is impractical

and reduces the life of the gib and the ways.

Figure 43. Column gib and leadscrew.

Gib

Cap Screws

Leadscrew

and Halfnut

Gib Screw

Figure 42. Table gib and leadscrew.

-32-

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For Machines Mfg. Since 8/09

Model SB1023

M A I N T E N A N C E

Service

Long-term storage

Long-term storage (more than a

year)

Machine Storage

1. Empty and flush any cutting fluid pumps,

never attempt to move this machine without

first locking the table in place. if the machine

is slightly tilted, the table could uncontrollably

slide and fall off of the machine and cause

machine damage or severe injury.

lines, or tanks.

2. DISCONNECT MACHINE FROM POWER!

3. Thoroughly clean all unpainted, bare metal

surfaces, then coat them with a heavy grease

or rust preventative. Take care to ensure

these surfaces are completely covered but

that the grease or rust preventative is kept

off painted surfaces. Make sure that both

the upper and lower portions of the column

leadscrew are completely coated with white

lithium grease.

Machinery can develop serious rust problems and

corrosion damage if it is not properly prepared

for storage. If decommissioning this machine, use

the steps in this section to ensure that it remains

in good condition.

Short-term storage (less than

year)

4. Remove the table, and then clean and pack

the bearings with white lithium grease.

1. DISCONNECT MACHINE FROM POWER!

5. Using mineral spirits, clean and brush the

ways, rack, pinion gear, and the leadscrew

with any quality grease or wax that is

specifically formulated for protecting

machine parts during storage.

2. Thoroughly clean all unpainted, bare

metal surfaces, then coat them with a rust

preventative oil or wax specifically designed

to protect machinery while in storage. DO

NOT USE MOTOR OIL in storage situations

as it does not sufficiently protect against

rust.

6. Open the main electrical box on the machine

and place a few moisture absorbing desiccant

packs at the bottom of the electrical box.

3. Lubricate the machine as outlined in the

Lubrication section on Page 30.

7. Cover and place the machine in an area

that is out of direct sunlight and away

from where paints and thinners are stored,

or where gasses are present. Fumes and

sunlight can bleach or discolor paint and

clear plastic guards.

4. Cover and place the machine in an area

that is out of direct sunlight and away

from where paints and thinners are stored,

or where gasses are present. Fumes and

sunlight can bleach or discolor paint and

clear plastic guards.

Note: When the machine is being put back into

service from long-term storage, lubricate

the machine as outlined in the Lubrication

section on Page 30.

5. Once or twice a month, depending on

humidity, wipe down the machine as

outlined in Step 2.

6. Every two months, move all handwheels so

the headstock and column move at least once

in their full range of motion. This will keep

the bearings, bushings, gears, and shafts

well lubricated and protected from corrosion,

especially during the winter months.

-33-

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Model SB1023

For Machines Mfg. Since 8/09

T R O U B L E S H O O T I N G

^TI^rf ^Oy^Uo^Bu^Ln^eSe^He^Od^Or^Teⁱⁿp^Glacement parts, or if you are unsure how to do any of the solutions given here, feel free

to call us at (360) 734-1540.

Symptom

Possible Cause

Possible Solution

Machine does not

start.

1. Power supply switched off/has

1. Switch power supply on/verify voltage.

incorrect voltage.

2. Blown fuse/tripped circuit breaker

2. Correct the cause of overload, then reset/replace

at main panel.

fuse or breaker.

3. Thermal overload relay has tripped.

3. Allow motor to cool. If necessary, press reset button

inside switch.

4. Plug or receptacle is corroded or

4. Clean/retighten contacts; correct the wiring.

mis-wired.

5. Break or short in wiring; or loose

5. Trace/replace broken or corroded wires; ﬁx loose

connections.

6. Motor ON/OFF switch at fault.

6. Replace switch.

7. Motor connection wired incorrectly.

7. Wire motor correctly (refer to inside junction box

cover or manual).

8. Contactor not energized/has poor

8. Test all legs for power, test ﬁeld coil and replace if

contacts.

at fault.

9. Motor at fault.

9. Test for shorted windings, bad bearings and repair

or replace.

Motor chatters

1. Extension cord (if used) is causing

1. Move machine closer to the power source, or use a

during startup or

during operation.

voltage drop.

larger gauge wire or shorter extension cord.

2. Low power supply voltage.

2. Have the power supply veriﬁed and corrected by an

electrician.

Machine has exces-

sive vibration or

noise.

1. Motor fan rubbing on fan cover.

2. Motor is loose.

1. Fix/replace fan cover; replace loose or damaged fan.

2. Tighten any loose fasteners.

3. Grinding wheel out of balance.

4. Motor bearings worn or damaged.

3. Dress and balance grinding wheel.

4. Replace motor bearings or replace motor.

Machine stalls or

slows when operat-

ing.

1. Motor is being overloaded.

1. Reduce depth of cut.

2. Motor at fault.

2. Test for shorted windings, bad bearings and repair

or replace.

Handwheel has

1. Leadscrew is dirty or lacks proper

1. Clean and lubricate the leadscrew and service oil

excessive backlash,

endplay, binds, or

is difficult to move.

lubrication.

system (Page 30).

2. Leadscrew or leadscrew nut worn.

2. Adjust or replace leadscrew or leadscrew nut.

3. Linkage bolts, pins, and holes are

3. Replace linkage bolts, pins, and re-bush any worn

loose or worn.

pin holes.

4. Longitudinal feed rack and pinion

4. Replace rack and pinion gears.

are worn.

-34-

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For Machines Mfg. Since 8/09

Model SB1023

T R O U B L E S H O O T I N G

Symptom

Possible Cause

Possible Solution

Vibration when

grinding, poor

surface finish,

or incorrect final

dimensions.

1. Grinding wheel is out-of-round or is

1. Dress grinding wheel to make concentric and to the

loaded up with material.

required grit level (Page 25).

2. Grinding wheel is out of balance or

2. Remove, and ring test, and balance the grinding

damaged.

wheel (Page 20 & 26).

3. Missing or torn grinding wheel

3. Remove and replace paper washers, dress and

paper washers.

rebalance grinding wheel.

4. Incorrect grinding wheel hardness

4. Match wheel grade and grit rating with workpiece

or grit rating.

hardness.

5. Improperly installed magnetic

5. Stone table and chuck surfaces, and remove all

burrs and foreign material from mating surfaces,

and reinstall the chuck.

chuck.

6. Workpiece is loose.

6. Replace or repair chuck for poor holding power.

7. Wheel hub not installed onto

7. Remove wheel and hub assembly, stone taper high

spots or dings, and reinstall wheel and hub (Page

22).

spindle shaft correctly.

8. Loose machine component.

8. Inspect all machine connections, and tighten any

loose fasteners.

9. Ways or leadscrews are out of

lubrication or contaminants have

loaded up on the ways.

9. Remove table, clean and relubricate the ways and

ball bearings (Page 30).

10. Headstock is loose.

10. Tighten column gib (Page 32).

11. Grinding wheel has varying

11. Replace grinding wheel with acceptable brand

densities, or is of poor quality.

(Page 20).

12. Table and handwheel have lash.

12. Adjust cross feed leadscrew halfnut (Page 32).

13. Adjust cross feed gib (Page 32).

13. Table is loose.

14. Grinding operation requires

14. Install aftermarket coolant kit.

coolant.

15. Coolant is incorrect or incorrectly

15. Refer to coolant manufacturer's workpiece verses

mixed.

coolant type recommendations and correct coolant.

16. Bad motor or spindle bearings.

16. Replace motor or replace bearings.

-35-

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Model SB1023

For Machines Mfg. Since 8/09

E L E C T R I C A L

eLeCTriCaL

electrical Safety instructions

These pages are accurate at the time of printing. In the constant effort to improve, however, we may

make changes to the electrical systems of future machines. Study this section carefully. If you see

differences between your machine and what is shown in this section, call Technical Support at (360)

734-1540 for assistance BEFORE making any changes to the wiring on your machine.

1. Shock Hazard: It is extremely dangerous to

perform electrical or wiring tasks while the

machine is connected to the power source.

Touching electriﬁed parts will result in

personal injury including but not limited to

severe burns, electrocution, or death. For

your own safety, disconnect machine from

the power source before servicing electrical

components or performing any wiring tasks!

5. Circuit Requirements: Connecting the

machine to an improperly sized circuit will

greatly increase the risk of ﬁre. To minimize

this risk, only connect the machine to a

power circuit that meets the minimum

requirements given in this manual.

6. Capacitors/Inverters: Some capacitors and

power inverters store an electrical charge for

up to 10 minutes after being disconnected

from the power source. To reduce the risk of

being shocked, wait at least this long before

working on capacitors.

2. Wire Connections: All connections must be

tight to prevent wires from loosening during

machine operation. Double-check all wires

disconnected or connected during any wiring

task to ensure tight connections.

7. Wire/Component Damage: Damaged wires

or components increase the risk of serious

personal injury, ﬁre, or machine damage. If

you notice that any wires or components are

damaged while performing a wiring task,

replace those wires or components before

completing the task.

3. Modiﬁcations: Using aftermarket parts or

modifying the wiring beyond what is shown

in the diagram may lead to unpredictable

results, including serious injury or ﬁre.

4. Motor Wiring: The motor wiring shown

in these diagrams is current at the time of

printing, but it may not match your machine.

Always use the wiring diagram inside the

motor junction box.

8. Experiencing Difﬁculties: If you are

experiencing difﬁculties understanding the

information included in this section, contact

our Technical Support at (360) 734-1540.

WIRING DIAGRAM COLOR KEY

BLUE

WHITE

BLACK

BLUE

PINK

RED

WHITE

YELLOW

GREEN

LIGHT

BLUE

GREEN

PURPLE

TUR-

QUIOSE

YELLOW

GRAY

ORANGE

BROWN

The photos and diagrams included in this section are best viewed in color. You can

see them in color at www.southbendlathe.com.

NOTICE:

-36-

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For Machines Mfg. Since 8/09

Model SB1023

E L E C T R I C A L

SB1023 Wiring Diagram 110v

electrical Box

Spindle

Motor

Control Panel

Figure 45. electrical box & control panel location.

Figure 44. Spindle motor & pump motor locations.

Control Panel

(Viewed From

Motor

Behind)

ON BUTTON

(Viewed From

Behind)

GND

OFF BUTTON

(Viewed From

Behind)

Run Capacitor

200MFD

125VAC

GND

Electrical Box

GND

Neutral

Hot

110 VAC

5-15 Plug

Ground

(As Recommended)

-37-

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Model SB1023

For Machines Mfg. Since 8/09

E L E C T R I C A L

SB1023 Wiring Diagram 220v

Control Panel

(Viewed From

Motor Wired for 220V

Behind)

ON BUTTON

(Viewed From

Behind)

GND

OFF BUTTON

(Viewed From

Behind)

Run Capacitor

200MFD

125VAC

GND

Electrical Box

GND

Hot

220 VAC

6-15 Plug

(As Recommended)

Ground

220V Contactor Kit Part No. PSB1023180 / Set to 5.5A

-38-

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For Machines Mfg. Since 8/09

Model SB1023

P A R T S

Motor & Spindle

1A *

11A

*Only available as a complete assembly

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

11A

PSB1023001A MOTOR & SPINDLE ASSEMBLY

PSB1023001A MOTOR 110/220V 3/4HP 1PH

PSB1023002A GRINDING WHEEL COVER ASSEMBLY

PSB1023001A FAN COVER

PSB1023001A MOTOR BODY

PSB1023001A MOTOR COIL

PSB1023001A MOTOR ROTOR

PSB1023011A

PSB1023012

PCAP02M

PCAP14M

PCAP111M

PN03M

WHEEL FLANGE ASSEMBLY

GRINDING WHEEL 7"D X 1/2"W X 1-1/4"B

CAP SCREW M6-1 X 20

CAP SCREW M8-1.25 X 20

CAP SCREW M12-1.75 X 35

HEX NUT M8-1.25

P7206

PC200F

P6202ZZ

ANGULAR CONTACT BALL BEARING 7206

S CAPACITOR 200M 125V 1-3/8 X 2-3/4

BALL BEARING 6202ZZ

PSB1023001A GROMMET

PSB1023001A CONTACT PLATE

PSB1023001A CENTRIFUGAL SWITCH

PSB1023001A MOTOR FAN

PSB1023001A JUNCTION BOX

PSB1023001A TERMINAL BLOCK

PLW05M

LOCK WASHER 12MM

PSB1023001A SPINDLE

PSB1023001A OUTER SPINDLE NUT

PSB1023001A INNER SPINDLE NUT

PSB1023001A OUTER SPINDLE SPACER

PSB1023001A INNER SPINDLE SPACER

PSB1023001A BEARING SEAT

PS22

PS06

PCAP15M

PHLP HD SCR 10-24 X 5/8

PHLP HD SCR 10-24 X 3/8

CAP SCREW M5-.8 X 20

PSB1023001A CAPACITOR COVER

-39-

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Model SB1023

For Machines Mfg. Since 8/09

P A R T S

Column

100

102

104

73A

104

105 75

103

108

101

106

108

63A

107

See Column Parts List on Page 42.

-40-

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For Machines Mfg. Since 8/09

Model SB1023

P A R T S

Table

128

144

128

114

127

126

119

129

152

125A

147

143

113

118A

115A

141

121

151

155

153

142

131

157

148

120

150

160

112

133

156

162

130

116

131

149

144

124

145

134

146

132

111

159

158

122

123

154

156

See Table Parts List on Page 42.

-41-

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Model SB1023

For Machines Mfg. Since 8/09

P A R T S

Column Parts List

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

PSB1023061

PSB1023062

COLUMN BASE

COLUMN

PSB1023082

PK05M

UPPER VERTICAL TRAVEL STOP

KEY 4 X 4 X 10

63A PSB1023063A ELEVATION LEADSCREW W/NUT ASSY

PK134M

KEY 4 X 4 X 14

PSB1023064

PSB1023065

PSB1023067

PSB1023068

PSB1023069

PSB1023070

PSB1023071

PSB1023072

BEVEL GEAR

ELEVATION HANDWHEEL SHAFT

COLUMN GIB

HANDWHEEL MOUNTING BRACKET

PLATE FOR RUBBER COVER

RUBBER COVER

100

101

102

103

104

105

106

107

108

P6202ZZ

P51102

BALL BEARING 6202ZZ

THRUST BEARING 51102

HANDWHEEL HANDLE

STEEL BALL 8MM

PSB1023095

PSTB002M

PZERK005

PCAP02M

PCAP14M

PCAP01M

PCAP06M

PCAP37M

PCAP16M

PSB1023104

PCAP11M

ZERK FITTING 1/8" PT

CAP SCREW M6-1 X 20

CAP SCREW M8-1.25 X 20

CAP SCREW M6-1 X 16

CAP SCREW M6-1 X 25

CAP SCREW M6-1 X 50

CAP SCREW M4-.7 X 16

LEADSCREW SPACER

CAP SCREW M8-1.25 X 16

SET SCREW M8-1.25 X 16

TAPER PIN M8 X 40

TOP PLATE

GIB ADJUSTMENT SCREW

73A PSB1023073A HANDWHEEL INDEX COLLAR ASSEMBLY

PSB1023074

PSB1023075

PSB1023076

PSB1023077

PSB1023078

PSB1023079

PSB1023081

ELEVATION HANDWHEEL SPACER

HANDWHEEL COLLAR PLATE

ELEVATION HANDWHEEL

COMPRESSION SPRING

ELEVATION SCALE

ELEVATION INDICATOR

PSS06M

PSB1023107

PCAP38M

LOWER VERTICAL TRAVEL STOP

CAP SCREW M5-.8 X 25

Table Parts List

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

111

PSB1023111

CROSS TRAVEL BASE

TABLE BASE

LOWER BEARING RACE

TABLE

HANDWHEEL INDEX COLLAR ASSEMBLY

CROSS GIB

CROSS LEADSCREW W/NUT ASSEMBLY

RACK

CROSS FEED HELICAL GEAR

LONGITUDINAL TRAVEL STOP

LONGITUDINAL SHAFT

LONGITUDINAL HANDWHEEL

HANDWHEEL SPACER

BEARING CAGE ASSEMBLY

FRONT UPPER BEARING RACE

REAR UPPER BEARING RACE

SPARK STOP

134

141

PSB1023134

COMPRESSION SPRING

CAP SCREW M4-.7 X 10

CAP SCREW M4-.7 X 16

CAP SCREW M5-.8 X 12

CAP SCREW M5-.8 X 16

CAP SCREW M6-1 X 20

CAP SCREW M6-1 X 25

CAP SCREW M10-1.5 X 35

SET SCREW M5-.8 X 8

SET SCREW M8-1.25 X 16

FLAT HD SCR M4-.7 X 8

HEX NUT 3/8-16

HEX NUT 5/16-18

KEY 4 X 4 X 12

KEY 1/4 X 1/4 X 3/4

BALL BEARING 6202ZZ

CROSS HANDWHEEL HANDLE

ROLL PIN 5 X 20

ZERK FITTING 1/8" PT

STEEL BALL 8MM

112

113

114

PSB1023112

PSB1023113

PSB1023114

PCAP17M

PCAP16M

PCAP33M

PCAP24M

PCAP02M

PCAP06M

PCAP84M

PSS31M

PSS06M

PFH31M

PN11

PN02

PK69M

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

162

115A PSB1023115A

116 PSB1023116

118A PSB1023118A

119

120

121

122

123

124

PSB1023119

PSB1023120

PSB1023121

PSB1023122

PSB1023123

PSB1023124

125A PSB1023125A

126

127

128

129

130

131

PSB1023126

PSB1023127

PSB1023128

PSB1023129

PSB1023130

PSB1023131

PSB1023132

PSB1023133

PK09

P6202ZZ

PSB1023156

PRP03M

PSB1023097

PSB102396

PSB1023160

PSB1023162

TRAVEL STOP

GIB ADJUSTMENT SCREW

BEARING RETAINING PLATE

CROSS HANDWHEEL SPACER

CROSS FEED HANDWHEEL

132

133

TAPER PIN M4 X 40

KNOB BOLT M8-1.25 X 21

-42-

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For Machines Mfg. Since 8/09

Model SB1023

P A R T S

Stand

183

181

172

182

178

180

(For 220V Conversion)

171

179

173

176

177

177A

184

185

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

171

172

173

PSB1023171

PSB1023172

PSB1023173

GRINDER BASE

COLUMN CAP

ELECTRICAL BOX

STAND W/DOOR ASSEMBLY

ON BUTTON

179

180

181

182

183

184

185

PSB1023179

PSB1023180

PCAP31M

PCAP84M

PSB1023183

PN06

O/L RELAY AB 193TAC16 10–16A

220V CONVERSION KIT

CAP SCREW M8-1.25 X 25

CAP SCREW M10-1.5 X 35

LIFTING HOOK M12-1.75

HEX NUT 1/2-13

174A PSB1023174A

176

177

178

PSB1023176

PSB1023177

PSB1023178

OFF BUTTON

CONTACTOR AB C09-400 110V

PSB1023185

ADJUSTING FOOT

-43-

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Model SB1023

For Machines Mfg. Since 8/09

P A R T S

Machine Labels

302

303

301

304

305

306

307

315

314

308

313

312

311

310

309

REF PART #

DESCRIPTION

CONTROL PANEL LABEL

ROTATION LABEL

SOUTH BEND NAMEPLATE 1 36MM

SB GRAY TOUCH-UP PAINT

TABLE TIP LABEL

REF PART #

309 PSB1023309

DESCRIPTION

MACHINE ID LABEL

PSBLABEL02VL DISCONNECT POWER LABEL

301

PSB1023301

302 PSB1023302

303 SB1317

304 PSBPAINT01

305 PSB1023305

306 PSBLABEL01VS READ MANUAL LABEL

307 PSBLABEL09VS FACESHIELD RESPIRATOR LABEL

310

311

312

313

314

315

PSBPAINT02

SB1321

PSBPAINT03

PSB1023314

PSB1023315

SB LIGHT BLUE TOUCH-UP PAINT

SOUTH BEND NAMEPLATE 5 203MM

SB DARK BLUE TOUCH-UP PAINT

MODEL NUMBER LABEL

SOUTH BEND LOGO RECT

308 PSB1023308

110V 1-PH LABEL

The safety labels provided with your machine are used to make the operator aware of the

machine hazards and ways to prevent injury. The owner of this machine MUST maintain the

original location and readability of these safety labels. If any label is removed or becomes

unreadable, REPLACE that label before using the machine again. Contact South Bend Lathe Co. at

(360) 734-1540 or www.southbendlathe.com to order new labels.

-44-

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W A R R A N T Y

WarranTY & reTUrnS

This quality product is warranted by South Bend Lathe Company to the original buyer for one year

from the date of purchase. This warranty does not apply to consumable parts, or defects due to any

kind of misuse, abuse, negligence, accidents, repairs, alterations or lack of maintenance. We do not

reimburse for third party repairs. In no event shall we be liable for death, injuries to persons or

property, or for incidental, contingent, special or consequential damages arising from the use of our

products.

We do not warrant or represent that this machine complies with the provisions of any law, act, code,

regulation, or standard of any domestic or foreign government, industry, or authority. In no event

shall South Bend’s liability under this warranty exceed the original purchase price paid for this

machine. Any legal actions brought against South Bend Lathe Company shall be tried in the State of

Washington, County of Whatcom.

This is the sole written warranty for this machine. Any and all warranties that may be implied by

law, including any merchantability or fitness, for any purpose, are hereby limited to the duration of

this warranty. To take advantage of this warranty, contact us by mail or phone to give us the details

of the problem you are having.

Thank you for your business and continued support.

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Printed In Taiwan

#CRJB12368

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