BRODBECK IRONWORK 2X72 Mega Grinder Instruction Manual

BRODBECK IRONWORK 2X72 Mega Grinder Instruction Manual

WARNING:

THE OPERATION OF THIS MACHINE MAY RESULT IN INJURY, DISMEMBERMENT, OR DEATH.

Lockout and secure power source before performing any work on the

machine.

Make sure to use adequate personal protection equipment such as eye protection, respirator, etc. while operating this equipment.

Contact Brodbeck Ironworks LLC for any questions or concerns before operating this equipment
Ben Secrist 843-457-2755, [email protected] Vince Molina 301-221-9321, [email protected]
Ryan Brodbeck 513-485-8069, [email protected]

Main Chassis Assembly

Place 1 Teflon washer between Hinge Base where the Hinge will rotate (red arrow). Assemble the first Hinge to the Hinge Base with ½-13 x 1.25” long Carriage bolts, washers, and lock nuts.
Tighten enough to eliminate any wobble in the hinge. Over-tightening will result in difficulty transitioning between horizontal and vertical positions.

Place Teflon washer between Hinge Base where the Hinge will rotate. Assemble the second
Hinge to the Hinge Base on the opposite side as the first using ½-13 x 1.25” long Carriage
bolts, washers, and lock nut. Use the ½” internal threaded handle on the lower carriage bolt. This serves as a lock when in the horizontal or vertical position.

Insert the Hinge Lock Plate into the slots in the Hinges. Insert X-Brace into the Hinge Base. Slide 5/16-18 nylock nuts into the X-Brace. Secure with 5/16-18 x 3/4” long Button Head Screw by inserting it through the Hinge Base into the nylock nut. Do not completely tighten the 5/16-18 x 3/4” long Button Head Screw at this time.

Interlock the slots in the Base Lock Plates with the slots in the Hinge Base Plates. Slide the Hinge Bases into slots in the Grinder Base Plate.
Lock in place with two 3/8-16 x 5/8” lg hex head bolts (Apply thread locker to bolts before installing) per Base Lock Plate.

Install the 3/8-16 Threaded Handles into the Hinge-Side Side Plate. Do not tighten down all the way. Only tighten until the tip of the threads meet the inside face.

Lower the Hinge-Side Side Plate onto the Hinges. Make sure the tabs on the Hinges insert into the slots on the Hinge-Side Side Plate. Use two 3/8-16 x 5/8” lg hex head bolts (Apply thread locker to bolts before installing).
The 5/16-18 x 3/4” long Button Head Screws in the X-Brace can now be completely tightened.

Install the tabs of (in order from front to back) the Tool Arm Top Plate and Tool Arm Plates (3), into the slots of the Hinge-Side Side Plate. Place the Belt-Side Side Plate onto the Tool Arm and Motor Mount Plates.
Insert (4) 5/16-18 X 2-1/2” Carriage Bolts and secure with the 5/16 Nylock Nuts. If you overtighten the sides plates may bow outward.

Tracking and Tension Assembly Install the Tension Arm using the ½-13 X 1.75” Carriage Bolt , Spacer , Flat Washer(s) , and Nylock Nut. Tighten enough to eliminate side to side wobble. Overtightening can cause tracking issues. Additional washers are provided to fine tune the tracking.

Install the Gas Spring using 5/16-18 X 1.00” Hex Bolt , a Flat Washer on both sides of each eye , and Nylock Nut.

Do not overtighten the gas spring bolts. It will bind and cause tracking issues

Insert 3/8-16 Threaded Handle into the Tension Arm (apply Loctite).
Install the Tracking Wheel into the Tracking Arm using ½-13 X 3” Hex Bolt, Nylock Nut, and flat washer.
BE CAREFUL NOT TO OVERTIGHTEN BEARINGS. THE WHEEL SHOULD SPIN FREELY BUT THERE SHALL NOT BE EXTRA SPACE BETWEEN THE BEARINGS AND NUT OR BOLT HEAD.

Install 3/8-16 Threaded Knob into the Tension Arm. This will be used to adjust tracking in operation.

Motor Install

Install Motor into Belt Side Plate using 3/8-16 x 1 Hex Bolts and Split Lock Washers.

Install Drive wheel and secure with set screw. Align with other wheels to ensure proper tracking. The drive wheel should be approximately 7/16” off of the side plate

Notes:

• Make sure all wheel centerlines are aligned with each other to ensure proper
  There may be some variance due to tolerance stack ups.

• To make sure the belt has enough tension, put the belt on all four wheels, pull and hold down the tension arm all the way, pull the platen arm out until the belt is tight, lock the platen arm in place, and release the tension arm.

• When adjusting tracking, start off rotating by hand or running the motor at a slow

• Always adjust the speed on your VFD to 0 when starting after an attachment change

PLACE ALL WARNING LABELS ONTO THE MACHINE IN A VISIBLE LOCATION.

Accessories
Work Rest Assembly

Install Work Rest Spacers and Work Rest Bracket using ½-13 x 2-1/2” Hex Bolts and split lock washers on the Longest Arm .
Assemble the Large Work Rest & 3/8-16 Threaded Handle with one or two Flat Washers and slide into slot onto Work Rest Bracket.

Contact Wheel Assembly

Place 1 Teflon washer between Arm and Contact Wheel Bracket where the Contact Wheel Bracket will rotate (red arrow). Install the Contact Wheel Bracket with ½-13 x 2-1/2 Lg Carriage Bolt , Flat Washers , and Nylock Nuts on the Short Arm. Insert ½-13 x 2-1/2 Lg Carriage Bolt into the slot and secure with Flat Washers and ½-13” Internal Thread Adjustable Handle.
Install wheel using ½-13 x 3” Hex Bolt and (2) Nylock Nuts.
BE CAREFUL NOT TO OVERTIGHTEN BEARINGS. THE WHEEL SHOULD SPIN FREELY BUT THERE SHALL NOT BE EXTRA SPACE BETWEEN THE BEARINGS AND NUT OR BOLT HEAD.

MAREKO DEEP PLATEN ASSEMBLY

Place one Teflon washer between Arm and D-Plate where the D-Plate will rotate (red arrow). Install the Platen D-Plate with ½-13 X 2-1/2 Carriage Bolt , Flat Washer , and Nylock Nut on the Short Arm.
Insert the ½”-13 X 2-1/2” Carriage Bolt into the slot and secure with ½-13 Internal Threaded Adjustable Handle.
Install the 2” Idler Wheel into the top (thinner section) of the Platen D-Plate using ½”-13 X 3” Hex Bolt, Spacer, and Nylock Nut.
Install the 4” Contact Wheel into the bottom (wider section) of the Platen D-Plate using ½”-13 X 3” Hex Bolt, Spacer, and Nylock Nut.

Install the Platen onto the Platen D-Plate using ¼”-20 Threaded knobs and ¼”-20 X 1” Carriage Bolts.

Install the Wear Plate to the Flat Platen using short 1/4” Hex Bolts. Align with belt on machine and tighten in place. Overtightening may strip the threads in the wear plat

10” Platen Assembly

Place one Teflon washer between Arm and D-Plate where the D-Plate will rotate (red arrow). Install the Platen D-Plate with ½-13 X 2-1/2 Carriage Bolt , Flat Washer , and Nylock Nut on the Short Arm.
Make sure the holes in the D-Plate are on the bottom. (green arrow)
Insert the ½”-13 X 2-1/2” Carriage Bolt into the slot and secure with ½-13 Internal Threaded Adjustable Handle.
Install the Idler Wheels into the Platen D-Plate using ½”-13 X 3” Hex Bolt, Spacer, and Nylock Nut.
BE CAREFUL NOT TO OVERTIGHTEN BEARINGS. THE WHEEL SHOULD SPIN FREELY BUT THERE SHALL NOT BE EXTRA SPACE BETWEEN THE BEARINGS AND NUT OR BOLT HEAD.
Install the Platen onto the Platen D-Plate using ¼”-20 Threaded Handles and ¼”-20 X 1” Carriage Bolts.

Install the Wear Plate to the Flat Platen using short 1/4” Hex Bolts. Align with belt on machine and tighten in place. Overtightening may strip the threads in the wear plate.

Small Wheel Attachment Assembly

Install the Quick Change Offset brackets to the base using ¼” screws.
Install the brace and side plate using the long 5/16” bolts, washers, and nuts. Be sure to install the fender washers on the front 5/16 bolt to keep wheels from moving side to side. Be sure to snug and not overtighten these bolts. This can potentially cause tracking issues.
Note: The parts may need a little filing to fit. They are designed to fit tightly.
Install the Idler Wheel into the Small Wheel Bracket using ½-13 X 2-3/4” Hex Bolt , Nylock Nuts and Flat washers.
BE CAREFUL NOT TO OVERTIGHTEN BEARINGS. THE WHEEL SHOULD SPIN FREELY BUT THERE SHALL NOT BE EXTRA SPACE BETWEEN THE BEARINGS AND NUT OR BOLT HEAD.

Slack Wheel Attachment Assembly

Remove Flat Platen by loosening the ¼-20 Threaded Handles. Slide the Slack Grinding Bracket onto the ¼-20 x 1” Carriage Bolts and tighten ¼-20 Threaded Handles.
Install the Idler Wheel into the Slack Grinding Bracket using ½-13 X 2-3/4” Hex Bolt, and Nylock Nuts.
BE CAREFUL NOT TO OVERTIGHTEN BEARINGS. THE WHEEL SHOULD SPIN FREELY BUT THERE SHALL NOT BE EXTRA SPACE BETWEEN THE BEARINGS AND NUT OR BOLT HEAD.

QUICK CHANGE ATTACHMENT ASSEMBLY

Insert ½-13 x 2.5” Carriage Bolts through the base plate into the arm.
Insert ½” Teflon washer between the plate and the arm on the front carriage bolt. Install the ½-13 lock nut onto the front bolt with a washer.
Install the large black handle with a washer to the back bolt.
Insert the ¼-20 x 1” carriage bolts through the base plate at the desired height. Install small black handles onto the ¼-20 carriage bolt.
NOTE: If ¼” washers are included, they are from an old revision and are no longer needed on the current design.

Integral Bolster attachment assembly
Bearing Sets

Insert ½-13 x 4.5” socket head bolt through the bearing holder into the spacer, bearings(7), spacer, and bearing holder. Install the ½-13 lock nut. Tighten by hand until there is no space between the bearings and the bearings still spin without resistance.
Insert 3/8-16 x 4.5” socket head bolt through the bearing holder into the spacer, bearings(8), spacer, and bearing holder. Install the 3/8-16 lock nut. Tighten by hand until there is no space between the bearings and the bearings still spin without resistance.
Insert ¼-20 x 4.5” socket head bolt through the bearing holder into the spacer, bearings(11), spacer, and bearing holder. Install the ¼-20 lock nut. Tighten by hand until there is no space between the bearings and the bearings still spin without resistance.

Integral Attachment

Install the ¼-20 Round Head Screws through the QC Offset Brackets into the IAT Base. Insert the IAT Brace into the IAT Base. Install the IAT Side Plate onto the IAT Brace.
Assemble the IAT Platen tabs into the slots of the IAT Side Plate and the IAT Base. Insert the 5/16-18 x 4.0 button head screws through the IAT Side Plate into the base. Install the 5/16 – 18 lock nut with washer to the bolts and hand tighten

Wiring Instructions

Below is a reference aid for the electrical wiring for your grinder. Please make sure your set up matches the manufacturers instruction supplied.

WARNING: HIGH VOLTAGE. DISCONNECT ALL POWER BEFORE ANY ELECTRICAL WORK

Variable Speed Motor Wiring
Open junction box and connect the 4 conductor cable as follows:

1. Green wire to ground screw

2. Connect T4, T5, and T6 together

3. Connect T1 and T7 to the 4 conductor cable black

4. Connect T3 and T9 to the 4 conductor cable white

5. Connect T2 and T8 to the 4 conductor cable red
   NOTE: There are two wires(P1 & P2) that smaller than the others. These are not used. They can be left alone

6. Close the motor junction box and tighten cord (junction box can be rotated to desired orientation, arrives with cord grip coming out of the bottom)

VFD Setup

1. Install cord grips and wire 4 conductor cable (coming from motor). Strip 4-6” of cable jacket and separate each wire. Strip and install supplied ferrules and y connector(ground). Install according to the diagram as shown in “A” below. If the motor runs backwards, switch the red and white

2. GREEN – GROUND SCREW

3. BLACK – U

4. WHITE – V

5. RED – W

6. Install cord grips and wire 3 conductor cable (coming from motor). Strip 4-6” of cable jacket and separate each wire. Strip and install supplied ferrules and y connector(ground). Install according to the diagram as shown in “B” below. Turn cord grips until tight after connections are

7. GREEN – GROUND SCREW

8. BLACK – L1

9. WHITE – L2
   

10. Set the input voltage jumper (J1) to the correct supply voltage (230V shown in photo). Standard Household voltage is 115

11. Close Install plug or directly wire into supply power junction box.

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