How to Replace the Grinding Wheel

This procedure explains how to replace the Grinding Wheel.

Always Teach the Diamond Dresser to the Grinding Wheel and the Grinding Wheel to the Part after changing the Grinding Wheel! Failure to do this will cause a high speed collision between the Diamond Dresser and the Grinding Wheel or the Grinding Wheel and the Part which will severely damage the Grinder.

Tools Needed: 
Hammer
Hub Spanner Wrench
10mm Allen Wrench
12mm Allen Wrench
Guard Door Key
Grinding Wheel Lift Assist
Grinding Wheel ALO2-K8 (Plant Tool # 02056497)

PROCEDURE:
  1. Turn the Mode Select Knob, located on the Operator Control Panel, to the MDI MODE position.
  2. Turn the Axis Spindle Select Knob on the MPG (Hand Held Teach Pendant) to the "X" position to select the X Axis.

    The "X" Axis travels away from you (positive) and toward you (negative) when you are facing the Grinder Doors.
  3. Turn the Feed Increment Select Knob on the MPG (Hand Held Teach Pendant) to the 1000x (100 Micron per Rev.) speed position.
  4. While pressing the Dead-Man button on the side of the MPG, turn the MPG hand wheel to the left (positive direction) to move the Grinding Wheel back, to make room to work.

    Click here for view of Dead-Man button
  5. Push the Open Wheel Guard Push Button, located on the Operator Control Panel, to unlock the Wheel Guard Latch. The Push Button light will turn on.
  6. Power down the Grinder and install the proper Lockout/Tagout device.
  7. Remove the Guard Door from the side of the Grinder.
  8. Remove two hand screws from Grinding Wheel Cover.
  9. Swing open the Grinding Wheel Cover.
  10. Move the Coolant Nozzle out so that there is room for the new wheel to be installed.
  11. Place the Hub Spanner Wrench on the Grinding Wheel Hub Retainer.

    The Grinding Wheel Hub Retainer has reverse threads.
  12. While holding the Hub Spanner Wrench in place with one hand, tap on the Hub Spanner Wrench with a hammer to loosen the Grinding Wheel Hub Retainer.
  13. Remove the Grinding Wheel Hub Retainer and place it in a clean location.
  14. Loosen the Hand Nut on the Grinding Wheel Change Assist.
  15. Turn the Center Screw in the Grinding Wheel Change Assist a few times to the left to back it out a little using a 10mm Allen Wrench.
  16. Push the Grinding Wheel Change Assist into position against the Grinding Wheel.
  17. Turn the Grinding Wheel slowly by hand while pressing in on a hand screw until you feel a hole in the Grinding Wheel Hub with the screw.
  18. Tighten three Hand Screws to secure the Grinding Wheel Change Assist to the Grinding Wheel.
  19. Tighten the center screw on the Grinding Wheel Change Assist with a 10mm Allen Wrench to engage and pop the Grinding Wheel Hub off of the Grinding Wheel Spindle.
  20. Swing the Grinding Wheel out of the Grinder and move it to a lift assist to remove it from the area.

    A new Grinding Wheel weighs approximately 110lbs. This procedure must be performed in accordance with Plant Safety standards and specifications.
  21. Remove the 12mm mounting screws from the Hub.
  22. Remove the two Hub Rings.
  23. Assemble the new Grinding Wheel with a new cardboard ring on each side, the Hub Rings and the mounting screws.

    Verify that the new Grinding Wheel is not cracked by tapping on it with a small metal tool like an Allen Wrench to see if it makes a ringing sound like it should. Otherwise it may be cracked and should not be used or it could burst into pieces if it were.
  24. Tighten the mounting screws using a cross pattern to 35 Newton Meters.
  25. Clean the Grinding Wheel Spindle and the Grinding Wheel Guard with a clean rag and then move the new Grinding Wheel to the Grinding Wheel Change Assist.

    A new Grinding Wheel weighs approximately 110lbs. This procedure is to be performed only in accordance with Plant Safety standards and specifications.
  26. Tighten the three Grinding Wheel Change Assist Hand Screws into the Grinding Wheel Hub.

    A new Grinding Wheel weighs approximately 110lbs. This procedure is to be performed only in accordance with Plant Safety standards and specifications.
  27. Swing the Grinding Wheel in place in the Grinder.
  28. Push against the Grinding Wheel to snap it firmly onto the Grinding Wheel Spindle.
  29. Loosen the three Grinding Wheel Change Assist Hand Screws.
  30. Move the Grinding Wheel Change Assist from the Grinding Wheel to it's storage bracket.
  31. Hand tighten the reverse thread Grinding Wheel Hub Retainer onto the Grinding Wheel Hub.
  32. Place the Hub Spanner Wrench on the Grinding Wheel Hub Retainer.

    The Grinding Wheel Hub has reverse threads.
  33. While holding the Hub Spanner Wrench in place with one hand, tap on the Hub Spanner Wrench with a hammer to tighten the Grinding Wheel Hub Retainer.
  34. Swing the Grinding Wheel Cover closed.
  35. Hand tighten two Grinding Wheel Cover hand screws.
  36. Move the Coolant Nozzle so that it is located close to the Grinding Wheel surface.
  37. Replace the Guard Door to the side of the Grinder.
  38. Lock the Guard Door on the side of the Grinder and then power up the Grinder.
  39. Push the Open Wheel Guard pushbutton located on the Operator Control Panel, to lock the Wheel Guard Latch. The pushbutton light will turn off.
  40. Push the white RESET pushbutton.
  41. Teach or reference the new Grinding Wheel to the Diamond Dresser.

    Always Teach In the Diamond Dresser to the Grinding Wheel after changing the Diamond Dresser or the Grinding Wheel! Failure to do this will cause a collision between the Diamond Dresser and the Grinding Wheel which could severely damage the Machine.
  42. After teaching or referencing the Diamond Dresser to the Grinding Wheel you must do a DRY RUN Dressing to make sure nothing crashes.
  43. Dress the new Grinding Wheel.
  44. Balance the new Grinding Wheel.
  45. Teach or reference the new Grinding Wheel to the Part.