ASSEMBLY and SERVICE MANUAL€¦ · 7 ASSEMBLY INSTRUCTIONS (Continued) Remove the carton and...

1 6327958 (6-07)

ACCU-ProAUTOMATIC

REEL MOWER GRINDERwith ACCU-Touch

ASSEMBLYand

SERVICEMANUAL

WARNINGYou must thoroughly read and understand thismanual before assembling or maintaining theequipment, paying particular attention to theWarning & Safety instructions.

2

The Warning Symbol identifies special instructionsor procedures which, if not correctly followed, couldresult in personal injury.

The Caution Symbol identifies special instructionsor procedures which, if not strictly observed, couldresult in damage to or destruction of equipment.

12. DON'T OVERREACH. Keep proper footing andbalance at all times.

13. MAINTAIN GRINDER WITH CARE. Followinstructions in Service Manual for lubrication andpreventive maintenance.

14. DISCONNECT POWER BEFORE SERVICING,or when changing the grinding wheel.

15. DO NOT USE SHARP OBJECTS ON THETOUCH SCREEN. Do not clean the touchscreen with solvents.

16. USE RECOMMENDED ACCESSORIES. Consultthe manual for recommended accessories. Usingimproper accessories may cause risk of personalinjury.

17. CHECK DAMAGED PARTS. A guard or otherpart that is damaged or will not perform its intendedfunction should be properly repaired or replaced.

18. KNOW YOUR EQUIPMENT. Read this manualcarefully. Learn its application and limitations aswell as specific potential hazards.

19. KEEP ALL SAFETY DECALS CLEAN ANDLEGIBLE. If safety decals become damaged orillegible for any reason, replace immediately. Referto replacement parts illustrations in Service Manualfor the proper location and part numbers of safetydecals.

20. DO NOT OPERATE THE GRINDER WHEN UNDERTHE INFLUENCE OF DRUGS, ALCOHOL, ORMEDICATION.

SAFETY INSTRUCTIONS

1. KEEP GUARDS IN PLACE and in working order.

2. REMOVE WRENCHES AND OTHER TOOLS.

3. KEEP WORK AREA CLEAN.

4. DON'T USE IN DANGEROUS ENVIRONMENT.Don't use Grinder in damp or wet locations.Machine is for indoor use only. Keep work areawell lit.

5. KEEP ALL VISITORS AWAY. All visitors shouldbe kept a safe distance from work area.

6. MAKE WORK AREA CHILD-PROOF with padlocks or master switches.

7. DON'T FORCE THE GRINDER. It will do thejob better and safer if used as specified in thismanual.

8. USE THE RIGHT TOOL. Don't force the Grinderor an attachment to do a job for which it was notdesigned.

9. WEAR PROPER APPAREL. Wear no looseclothing, gloves, neckties, or jewelry which mayget caught in moving parts. Nonslip footwear isrecommended. Wear protective hair covering tocontain long hair.

10. ALWAYS USE SAFETY GLASSES.

11. SECURE YOUR WORK. Make certain that thecutting unit is securely fastened with the clampsprovided before operating.

Safety Awareness Symbols are inserted into this manualto alert you to possible Safety Hazards. Whenever yousee these symbols, follow their instructions.

3

DO1. DO always HANDLE AND STORE wheels in a

CAREFUL manner.

2. DO VISUALLY INSPECT all wheels beforemounting for possible damage.

3. DO CHECK MACHINE SPEED against theestablished maximum safe operating speedmarked on wheel.

4. DO CHECK MOUNTING FLANGES for equaland correct diameter.

5. DO USE MOUNTING BLOTTERS whensupplied with wheels.

6. DO be sure WORK REST is properly adjusted.

7. DO always USE A SAFETY GUARDCOVERING at least one-half of the grindingwheel.

8. DO allow NEWLY MOUNTED WHEELS to runat operating speed, with guard in place, for atleast one minute before grinding.

9. DO always WEAR SAFETY GLASSES or sometype of eye protection when grinding.

IMPROPER USE OF GRINDING WHEEL MAY CAUSEBREAKAGE AND SERIOUS INJURY.

SAFETY INSTRUCTIONS

Grinding is a safe operation if the few basic rules listed below are followed. Theserules are based on material contained in the ANSI B7.1 Safety Code for "Use, Careand Protection of Abrasive Wheels". For your safety, we suggest you benefit fromthe experience of others and carefully follow these rules.

AVOID INHALATION OF DUST generated by grinding and cutting operations.Exposure to dust may cause respiratory ailments. Use approved NIOSH orMSHA respirators, safety glasses or face shields, and protective clothing.Provide adequate ventilation to eliminate dust, or to maintain dust level belowthe Threshold Limit Value for nuisance dust as classified by OSHA.

DON'T1. DON'T use a cracked wheel or one that HAS

BEEN DROPPED or has become damaged.

2. DON'T FORCE a wheel onto the machine ORALTER the size of the mounting hole - ifwheel won't fit the machine, get one that will.

3. DON'T ever EXCEED MAXIMUMOPERATING SPEED established for thewheel.

4. DON'T use mounting flanges on which thebearing surfaces ARE NOT CLEAN, FLATAND FREE OF BURRS.

5. DON'T TIGHTEN the mounting nutexcessively.

6. DON'T grind on the SIDE OF THE WHEEL(see Safety Code B7.2 for exception).

7. DON'T start the machine until the WHEELGUARD IS IN PLACE.

8. DON'T JAM work into the wheel.

9. DON'T STAND DIRECTLY IN FRONT of agrinding wheel whenever a grinder is started.

10. DON'T FORCE GRINDING so that motorslows noticeably or work gets hot.

4

This machine is intended for grinding the reel of reel type mower units ONLY.Any use other than this may cause personal injury and void the warranty.

To assure the quality and safety of your machine and to maintain thewarranty, you MUST use original equipment manufactures replacementparts and have any repair work done by a qualified professional.

ALL operators of this equipment must be thoroughly trained BEFOREoperating the equipment.

Do not use compressed air to clean grinding dust from the machine. Thisdust can cause personal injury as well as damage to the grinder. Machineis for indoor use only. Do not use a power washer to clean the machine.

CONTENTSSafety Warnings ............................................................................................................. Page 2-4Service Data .................................................................................................................. Page 5Assembly Instructions .................................................................................................... Page 6-10Maintenance Instructions ................................................................................................ Page 11-14Adjustments ................................................................................................................... Page 15-24Machine Service ............................................................................................................. Page 25-26Electrical Troubleshooting Index . .................................................................................... Page 28Electrical Troubleshooting ............................................................................................... Page 29-48Mechanical Troubleshooting ............................................................................................ Page 50-51Parts Lists ...................................................................................................................... Page 52-89Electrical Diagrams ........................................................................................................ Page 90-97

-Separate Drawings Included in the Product Packet

The grinder is equipped with a low voltage relay whichis factory preset at 100 VAC. If the power supply linedoes not deliver 100 VAC power under load, the relaywill open and trip out the starter. If this occurs, yourpower supply line is inadequate and must be correctbefore proceeding further with the grinder.

Low Voltage Relay

5

Throughout this manual we refer to torque requirementsas "firmly tighten" or the like. For more specifictorque values, refer to the information below.

Bolts Going Into a Nut, or Into a Thread Hole inSteelRefer to the table at the right.

Bolts Going Into a Thread Hole in AluminumUse the Grade 2 values in the table at the right.

Socket-Head Screws Going Into a Nut or SteelUse the Grade 8 values in the table at the right.

Machine ScrewsNo. 6 screws: 11 in.-lbs (0.125 kg-m)No. 8 screws: 20 in.-lbs (0.23 kg-m)No. 10 screws: 32 in.-lbs (0.37 kg-m)

SKILL AND TRAINING REQUIRED FOR SERVICING

This Service Manual is designed for technicians who have the necessary mechanical andelectrical knowledge and skills to reliably test and repair the ACCU-Pro or ACCU-Master Grinder.For those without that background, service can be arranged through your local distributor.

This Manual presumes that you are already familiar with the normal operation of the Grinder. Ifnot, you should read the Operators Manual, or do the servicing in conjunction with someonewho is familiar with its operation.

Persons without the necessary knowledge and skills should not remove the control box coveror attempt any internal troubleshooting, adjustments, or parts replacement.

If you have questions not answered in this manual, please call your distributor. They willcontact the manufacturer if necessary.

SERVICE DATA

TORQUE REQUIREMENTS GRADE 2 GRADE 5 GRADE 8

SMOOTH 3 MARKS 6 MARKS HEAD on HEAD on HEAD

1/4 In. 6 ft-lbs 9 ft-lbs 13 ft-lbs thread (0.8 kg-m) (1.25 kg-m) (1.8 kg-m)





6

ASSEMBLY INSTRUCTIONS

Remove shipping straps from traversecarriage. Remove window protective sheets.

Remove the sides, front, and back of the crate.Remove the plastic bag, shrink wrap and bubblewrap. Remove the metal clips that secure thegrinder to the crate base. With a fork lift, raise thegrinder from the wood base and set it in its finalposition. See FIG. 1 and 2.

POSITION BASE

The ACCU-Pro Spin/Relief Grinder will require anoperating area of about 120" W x 140" D x 90" H (305x 356 x 229 cm). The mower reel will be lifted fromthe front of the machine if using the optional winch &boom and from the rear with the optionalworkstation. The machine operator will operate theunit from the front of the machine. Position the baseto allow sufficient operating room in front of themachine (and behind if using the optionalworkstation). See FIG. 1 and 2.

The base should be placed on a relatively levelconcrete floor, with ample ceiling height to allow forthe installation of the unit. Do not place the unit acrosstwo concrete slab seams or across a large crack.

FIG.1

FIG. 2

THE UNIT WEIGHS 1490LBS. (676 kg). USEPOWER EQUIPMENT TOLIFT MACHINE.

70 "(178 cm)

85" (216 cm)with Optional

ManualWinch &Boom

88" (224 cm)with Optional

ElectricWinch &Boom

74"(188 cm)

20" (50 cm)

91" (230 cm)With OptionalWorkstation

50"(127 cm)

R36"(92 cm)

7

ASSEMBLY INSTRUCTIONS (Continued)

Remove the carton and remove the contents from the cartononto a workbench. The carton includes:

5" (127mm) DIA. X 3/8" (10mm)WIDE GRINDING WHEEL

3.5" (89mm) DIA. X 1" (25mm)WIDE GRINDING WHEEL

3.5" (897mm) DIA. X 3/8" (10mm)WIDE GRINDING WHEEL

SPIN DRIVEADAPTER

PRODUCTPACKET

ALIGNMENT GAGE

HORIZONTAL EXTENSION(ALIGNMENT GAGE)

ALLEN WRENCH

REEL POSITION GAGE

DRIP PAN

FLASHER BULB& LENS

8

ASSEMBLY INSTRUCTIONS (Continued)LEVEL BASE

Place a level on the top of the table and check the unit fromside to side for level. Adjust the leveling feet as necessary tobring to level. See FIG. 4.

Place a level across the table from front to rear. Adjust theleveling feet on the end of the machine as necessary to level.See FIG. 5.

When both front to back and side to side leveling procedureshave been completed, thread the hex jam nuts up againstthe nut that is welded to the bottom until they lock into place.Be careful not to move the leveling feet during this process.See FIG. 3. Make certain that all four leveling feet are firmlycontacting the floor.

Recheck with level after locking nuts are firmly tightened. FIG. 3

FIG. 5FIG. 4

2-1/4" [57 mm]

INSTALL THE FLASHER LIGHT

Locate flasher bulb and lense in carton. Install bulband lense to the flasher assembly socket. This islocated on top of the front right frame member onthe 632 ACCU-Pro. See Fig. 6.

FIG. 6

9


FIG. 7

APPLY POWER

BEFORE YOU APPLY POWER TO THEGRINDER, REFER TO THE "IMPORTANTGROUNDING INSTRUCTIONS" ON PAGE 10.

115 Volt Model Only. Plug the power cord into a standard 115VAC 20-amp grounded receptacle. See FIG. 7.

220 Volt Model Only. For 220 Volt Applications order Part No.6320935, 6320945, 6520915, or 6520925, which includes aprewired 3 KVA 220 V step down to 110 V 50-60 Hztransformer should be ordered.

IT IS RECOMMENDED THAT THISACCU-MASTER REEL MOWER GRINDER HASITS OWN PERMANENT POWER CONNECTIONFROM THE POWER DISTRIBUTION PANEL,WITH NO OTHER MAJOR POWER DRAWEQUIPMENT ON THE SAME LINE.

IT IS REQUIRED THAT THE POWERDELIVERED TO THIS GRINDER IS115 VAC - 20 AMPS. THE TOLERANCE ON THISPOWER REQUIREMENT IS +/- 5%.THEREFORE THE MINIMUM VOLTAGEREQUIREMENT IS 109VAC WITH 20 AMPS.VOLTAGE MUST BE CHECKED WITH ALLEQUIPMENT UNDER LOAD (OPERATING) ONTHE CIRCUIT.

DO NOT OPERATE THIS GRINDER WITHAN EXTENSION CORD.

The grinder is equipped with a low voltage relaywhich is factory preset at 100 VAC. If the powersupply line does not deliver 100 VAC power underload, the relay will open and trip out the starter. Ifthis occurs, your power supply line is inadequateand must be corrected before proceeding furtherwith the grinder.

PROPER GROUNDING OF THE RECEPTACLEGROUND IN YOUR BUILDING MUST BEVERIFIED. IMPROPER GROUNDING INYOUR BUILDING MAY CAUSE THE GRINDERTO MALFUNCTION.

FOR 20 AMP RATED LARGE MACHINESBelow is a list of required wire size in your building. (This is thewiring from the main panel to the grinder receptacle box.)

For 0 to 40 Feet from panel to receptacle = Use 12 Ga. Wire.For 40 to 60 Feet from panel to receptacle = Use 10 Ga. Wire.For 60 to 100 Feet from panel to receptacle = Use 8 Ga. Wire.For 100 to 160 Feet from panel to receptacle = Use 6 Ga. Wire.

For 0 to 12 Meters from panel to receptacle = Use 4.0mm Wire.For 12 to 18 Meters from panel to receptacle = Use 6.0mm Wire.For 18 to 30 Meters from panel to receptacle = Use 10.0mm Wire.For 30 to 48 Meters from panel to receptacle = Use 16.0mm Wire.

10

For 220 V 50 or 60Hzapplications Product No.6320935, 6320945, 6520915 or6520925 should be ordered.

These products includes a 3KVA 220 Volt Step Down to 110volt 50/60 Hz transformerwhich is prewired.

The wiring diagram is shown inFIG. 8.

The power cord has noconnector. A connector whichis appropriate for your localityand 220 volt, 10 ampapplication should be installed.


FIG. 8IMPORTANT GROUNDING INSTRUCTIONS

In case of a malfunction or electrical breakdown, grounding reduces the risk of electrical shock by providinga path of least resistance for electrical current.

This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug. The plugmust be plugged into a matching outlet that is properly installed and grounded according to all local or otherappropriate electrical codes and ordinances.

Before plugging in the Grinder, make sure it will be connected to a supply circuit protected by a properlysized circuit breaker or fuse. SEE SERIAL NUMBER PLATE FOR FULL LOAD AMP RATING OF YOURMACHINE.

Never modify the plug provided with the machine--if it won't fit the outlet, have a proper outlet and circuitinstalled by a qualified electrician.

ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOURMACHINE. AN IMPROPER CONNECTION CAN CAUSE A DANGEROUSELECTRICAL SHOCK. IF YOU ARE UNSURE OF THE PROPERELECTRICAL GROUNDING PROCEDURE, CONTACT A QUALIFIEDELECTRICIAN.

USE ONLY A QUALIFIEDELECTRICIAN TOCOMPLETE THEINSTALLATION.

11

PERIODIC MAINTENANCE

FIG. 9

FIG. 10

LEADSCREW (2X)

ALIGNMENTSHAFT (2X)

DAILY MAINTENANCE IS SPECIFIED ON PAGE 4 OF THE OPERATOR'S MANUAL, AND IS TOBE PERFORMED BY THE OPERATOR.

LISTED BELOW ARE PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOURCOMPANY'S MAINTENANCE DEPARTMENT:

1. Clean the tank and filter of the vacuum system weeklyor more often depending on the number of reelsground. (VACUUM SYSTEM IS OPTIONAL

EQUIPMENT ALL 632 ACCU-PRO MODELS).

2. Use the grease fitting provided to grease the dovetail with high quality lithium grease monthly. Wipeoff excess grease. See FIG. 9.

3. Wipe and re-oil with spray lubricant, the grindingwheel diameter adjusting lead screw every threemonths. Wipe off all excess lubricant. See FIG. 9.

4 Check the gib adjustment on the Grinding wheeldiameter adjustment every 3 months. See FIG. 9.

5. Inspect the Grinding wheel Poly-V belt for crackingand adjust the belt tension per procedure called outin the adjustment section every six months.

6. Wipe and relube with never-seez, the vertical andhorizontal alignment shafts and lead screws, everysix months. See FIG. 10.

7. Lift the bellows and wipe off the bearing rails monthly.Lubricate linear bearing, follow the lubricationprocedure on the following pages. Generally, thiswill be every six months to a year.

12

STORAGE PROCEDURE

It is important to follow the procedures below when placing your grinding in storage for anextended period of time. Proper care will help maintain the working functions of the grinder anddecrease maintenance and problems that occur when storing the grinder.

BEFORE STORING THE GRINDER:

-Clean the machine thoroughly. (DO NOT USE COMPRESSED AIR OR A POWER WASHERTO CLEAN THIS MACHINE!) See Maintenance section for instructions on cleaningpolycarbonate.

-Lubricate the following parts by flooding the area with a spray lubricant and leaving it inplace: (Do not use a Teflon based lubricant)

Traverse Shafts & Linear bearings (see Lubrication section of manual)Remove grinding wheel and spray the movable parts of the finger systemCross slide shafts and adjustment screws (Right side of Traverse Base)Scratches in the paint or any other bare metal surfaces

-Work the lubricant in by moving parts through their full range of motion.

-Make sure all controls are in the off position and unplug the unit from the wall. Turn off the digitalalignment gage.

-Cover the unit if possible with a sheet or tarp.

BRINGING THE UNIT BACK INTO SERVICE:

-Remove the cover and reapply lubricant to the items stated above. Wipe off all excess lubricant.(See Lubrication section for more details.)

-Plug the unit into the wall and test all electrical functions.

-Check the belts for cracking and adjust the tension if necessary.

-Check for damaged or missing parts.

13

LUBRICATION

STEP 1--Thoroughly clean the shafts.

STEP 2--Flood spray the two shafts with a spray lubricant (do not use a teflon basedlubricant) until the lubricant is dripping off the shafts. See FIG. 11 Then run the carriage backand forth through its range of travel. This will carry the lubricant into the bearings.

STEP 3--With a clean rag, wipe off the excess amount of lubricant from the shafts. Run thecarriage back and forth through its range of travel and wipe the shafts after each traverse.Repeat until the shafts are dry to the feel. This completes the lubrication process.

If the unit will be shut down for an extended period of time, more than four weeks, then theshafts and other appropriate parts of the unit should be flooded with lubricant and thatlubricant left in place until the unit is brought back into service. When the unit is brought backinto service the full lubrication procedure as stated above should be repeated.

LUBRICATION OF LINEAR BEARINGS

TRAVERSE BASE ALONEWITHOUT DUST PROTECTIONCOMPONENTS

SHAFTS

FIG. 11

14

MAINTENANCE (Continued)CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE

WINDOWS

Cleaning Instructions

DO NOT USE GASOLINEAdherence to regular and propercleaning procedures is recommendedto preserve appearance and performance.

Washing to Minimize ScratchingWash polycarbonate windows with a mild dish washing liquid detergent and lukewarm water, using a cleansoft sponge or a soft cloth. Rinse well with clean water. Dry thoroughly with a moist cellulose sponge toprevent water spots. Do not scrub or use brushes on these windows. Also, do not use butyl cellosolve indirect sunlight.Fresh paint splashes and grease can be removed easily before drying by rubbing lightly with a goodgrade of VM&P naphtha or isopropyl alcohol. Afterward, a warm final wash should be made, using a milddish washing liquid detergent solution and ending with a thorough rinsing with clean water.

Minimizing Hairline ScratchesScratches and minor abrasions can be minimized by using a mild automobile polish. Three suchproducts that tend to polish and fill scratches are Johnson paste Wax, Novus Plastic Polish #1 and #2,and Mirror Glaze plastic polish (M.G. M10). It is suggested that a test be made on a corner of thepolycarbonate window with the product selected following the polish manufacturer's instructions.

Some Important "DON'TS"♦ DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows.♦ Never scrape polycarbonate windows with squeegees, razor blades or other sharp

instruments.♦ Benzene, gasoline, acetone or carbon tetrachloride should NEVER be used on polycarbonate

windows.♦ DO NOT clean polycarbonate windows in hot sun or at elevated temperatures.

Graffiti Removal• Butyl cellosolve, (for removal of paints, marking pen inks, lipstick, etc.)• The use of masking tape, adhesive tape or lint removal tools works well for lifting off old

weathered paints.• To remove labels, stickers, etc., the use of kerosene, VM&P naphtha or petroleum spirits is

generally effective. When the solvent will not penetrate sticker material, apply heat (hairdryer) to soften the adhesive and promote removal.

GASOLINE SHOULD NOT BE USED!

15

MAINTENANCE (Continued)

DIGITAL GAGE

Important ♦ Do not mark the scale unit with and electric engraver or

scratch the scale. ♦ Always use an SR44 battery (silver oxide cell) ♦ If the scale will not be used for more than three

months, remove the battery and store it properly.Otherwise, leakage, if any, from the battery maydamage the unit.

Description of Parts1. Beam 2. Main Scale3. Battery compartment 4. Output Connection5. Display 6. ON/OFF Power7. ZERO/ABS switch 8. Origin Switch9. Inch/mm Switch 10. Tapped hole11. Slider

Battery Installation and Origin SettingSet the origin of the scale after installing the battery. Otherwise,the error sign("E" at the least significant digit) may appear,resulting in incorrect measurements.1) To install the battery, remove the compartment lid and

install the SR44 battery with its positive side facing up.After the battery is installed, set the origin.

2) To set the origin, move the slider to an area you wish toset as your origin. Turn the power on. Hold the ORIGINswitch down for more than one second. The "0.00"display appears, indication Origin setting is complete. Theorigin will be retained even if the power is turned off.

Incremental (INC) & Absolute (ABS) modeThe LCD will dispay measurements from the origin when turnedon (ABS mode). To set the origin see above. The display can beset to zero at any desired position by pressing the ZERO/ABSswitch. INC indicator will apper in the display (INC mode),permitting measurements from this zero point. To return to theABS mode hole the ZERO/ABS buttton for more than 2 seconds.

Error Symptoms & RemediesERRC and display flickering: Occurs when the scalesurface is stained. Clean the scale surface and coat athin film of low viscosity oil to keep out moisture.E in the least significant digit: This occurs when theslider is moved too quickly, but it does not affect themeasurement. If it stays on when the slider stops, thescale surface is probably stained. If this is the case, takeremedies as for ErrC.B indication: Battery voltage is low. Replace the batteryas soon as possible.

16

ADJUSTMENTS (Continued)

STEP 1--Detach the bellows mounting brackets from thecarriage. Detach front and rear shields. See FIG. 15.STEP 2--Remove the three screws of one linear bearingand slide the linear bearing off the end of the carriage shaft.STEP 3--Insert a new linear bearing onto the end of thecarriage shaft with the tension adjustment screw pointingoutward. See FIG. 14. Adjust the tension screw of thelinear bearing so when you radially rotate the linear bearingaround the carriage shaft there should be no free playbetween the linear bearing and the carriage shaft.NOTE: Tension is too tight if you feel a cogging actionwhen you rotate the linear bearing around the shaft. Thiscogging is from the skidding of the bearing on the shaft andindicates tension screw is too tight.

Finally, sliding the bearing block back and forth should be asmooth uniform motion.

CARRIAGE LINEAR BEARING REPLACEMENT

SETTING THE BEARING TENSION CORRECTLYIS CRITICAL TO PROPER GRINDING. BEARINGSWHICH ARE TOO TIGHT OR TOO LOOSE WILLCAUSE POOR GRIND QUALITY. ALSO, BEARINGSWHICH ARE TOO TIGHT WILL HAVESUBSTANTIALLY SHORTER LIVES AND MAYDAMAGE THE SHAFT.

STEP 4--Slide linear bearing under carriage and attach withthe three screws.NOTE: Repeat Steps 2 thru 4 with the other threelinear bearings.STEP 5--After all four linear bearings are reattached to thecarriage check for correct bearing tension. The bearingtension is correct when you try to lift the carriage and canfeel no carriage movement, which is free play up and down.The most dependable method of checking free play is touse a magnetic base dial indicator attached to the traverseframe weldment and reading the vertical movement aboveeach bearing. This movement should be within .001" (.03mm) Also, when pulling the carriage in the traversingdirection, there should be only approximately a 3 lb force,with the belt disengaged. To check this attach a spring scaleto the carriage and pull parallel to the carriage shafts. Todouble check the assembly, slide the carriage assemblyfrom "end of travel" to "end of travel", it should have veryuniform resistance through the full range of travel.STEP 6--Replace the bellows carriage mounting bracketsonto the carriage. Replace front and rear shields.See FIG. 15.

REAR DUSTSHIELD

FRONT DUSTSHIELD

FIG. 14

FIG. 15

17

ADJUSTMENTS (Continued)REEL FINGER DOVETAIL GIB ANDADJUSTING KNOB ADJUSTMENTS

The reel finger slide to the reel finger positioner has a dovetail withan adjustable gib for tensioning. Tighten the gib set screwson the side so there is no free play in the dovetail slide. Checkfor movement when pushing on the relief finger side to sidewith a 20 lbs. (44 kg) force. Make sure the knob assembly foradjusting the relief finger to the grinding wheel is rotatable byhand. The gib adjustment should be sufficient to maintain arigid position of the reel finger. See FIG. 16.

Check the knob assembly rotating tension by checking thetightness of the nylon plug to the knob assembly threads.The tightness has to be sufficient so the knob assembly doesnot rotate during the relief grinding cycle. See FIG. 17.

NOTE: To adjust the nylon plug you must lock the indexfinger assembly down and then adjust the reel finger positionerso the clearance holes line up with the nylon plug set screw.

Take up any free play between the tee knob assembly, reelfinger slide and .375 threaded split shaft collar. Loosen theshaft collar locking cap screw and rotate the shaft collar untilthere is no end play. Retighten locking cap screw on thethreaded split shaft collar. See FIG. 16.

GRINDING HEAD BELT TENSION ADJUSTMENT

The left side grip grinding wheel knob must be removed forbelt tensioning adjustment. Remove the six screws holdingthe vacuum hose bracket, the two double tube clamps andthe belt cover. For grinding motor belt adjustment, loosenthe four socket head cap screws that attach the motormounting plate. Adjust the grinding motor for proper belttension and tighten the four socket head cap screws. Theproper belt tension for the grinding head is to push down onthe poly V belt half way between to two pulleys with5 lbs. [2 kg] of force and belt movement dimensions to be.12 inches [3 mm]. See FIG. 18.

To verify belt tension mount the belt guard with two screws.Turn the motor on. If the belt is tensioned correctly, start-uptorque of the motor through the pulley to the belt should havezero slippage. If there is belt slippage when turningon the motor there will be a slight squealbefore the belt comes up to speed.When you achieve correct tension,reassemble all of the remainingparts that have been removed.

FIG. 16

FIG. 17

FIG. 18

.12 [3 mm]

18


FIG. 19

FIG. 21

INDEX FINGER PROXIMITY SETTING

Set all motor switches to the off position.

Press the machine system start switch, so the grinder isoperational.

Push down on the index finger until the stop pin is within.06 inches (1.5 mm) of bottoming out. (You can use a1/16" gage pin or rod stock between the stop pin andindex finger). Set the proximity switch to activate the light atthis setting. This assures the index finger to be close toits final stop position so the reel is completely indexedbefore the carriage starts to traverse. See FIG. 19.

The spring load force pushing up on the index finger bringsit away from the proximity when released.

STEPPPER INFEED TRAVEL LIMITS

The infeed stepper maximum extension is 6.0" (152 mm)and minimum compression is 3.5" (89 mm). If youexperience a situation where the grind does not properlyfinish, check that you have not exceeded stepper travelby checking the values per FIG. 20.

LOCKING INDEX FINGER PIN

To align the Index Finger Locking Pin to the hole in theIndex Finger Assembly loosen the two socket head capscrews so the index sensor block is movable. Push downon the index finger assembly until the spring loaded indexfinger locks into hole with no binding. Tighten the twosocket head cap screws so the index sensor block issecured, and the locking pin moves freely. See FIG. 21.

FIG. 20

19

PROXIMITY SWITCHFor the proximity switch to perform properly and reverse thedirection of the carriage at each end of the rails, a distance of3/16" [4 mm] to 1/4" [6 mm] needs to be maintained betweenthe carriage proximity flag bracket and the proximity switch.See FIG. 22.

NOTE: The light on the proximity switch activates when metalcrosses over the switch.


ADJUSTABLE RELIEF TENSIONIf the relief angle appears to vary during relief grinding adjustthe tension on the nylon plug and set screw. See FIG. 23.

FIG. 22

FIG. 23

SAFETY SWITCH ALIGNMENT

For the safety switches to work properly they must beadjusted so the sender and receiver are parallel to each otherwith a maximum gap of .19 inches (5mm).See FIG. 24.(Adjust by moving the doors or brackers. If this does nothelp, a special wrench is needed to adjust the safety screwsused to hold the switch in place.)

.19" (5mm)

FIG. 24

20

SPIN GRINDING ATTACHMENT ADJUSTMENT

If free play develops so the crank handle wants to rotate withfree play when operating in the scissor action (raising andlowering) on the spin grinding attachment, the free play can beeliminated by tightening the set screw identified in FIG. 24.

If there is too much play in the spin drive pivot points, torquedown the hex nut tight so conical washer is compressed, thenback off 1/2 turn. See FIG. 24.


FIG. 24TRAVERSE BELT TENSION

To adjust the tension on the traverse belt tighten the screws andnuts located at the left side of the traverse belt. Tighten nuts untilthe comprension springs measure 3/4". See FIG. 25. If the springsare not tensioned equally, uneven loading on the traversesystem may cause parts to fail.

DO NOT OVERTIGHTEN.OVERTIGHTENING COULDDAMAGE THE BELT OR TRAVERSEDRIVE SYSTEM.

TRAVERSE CLAMP FORCE

If the traverse clamp is slipping during regular operation it may benecessary to tighten the clamp. To tighten, loosen the jam nut onthe clamp tip. Screw the tip out so there is .10" gap between thetip and the Clamp Support Block. See FIG 26. Lock in place bytightening the jam nut against the clamp being careful not to movethe tip. Verify the distance between the clamp tip and block is still.10". The .10" setting allows slippage in a jam situation anddamage can occur if this adjustment is set to narrow.

CAUTION SHOULD BE USEDAS ADJUSTING THE TIP WILLAFFECT THE SLIP LOAD ANDCOULD DAMAGE THE CLAMPTIP, BELT OR TRAVERSEDRIVE SYSTEM.

FIG. 25

FIG. 26

21

ADJUSTING CROSS SLIDE ASSEMBLY

If the cross slide becomes very difficult to turn it maybecome necessary to adjust the assembly. To relieve thetension on the assembly follow the procedure listedbelow:

STEP 1--Using a hydraulic jack, raise the traversingcarriage base just enough to alleviate the weight stress onthe Cross Slide Assembly.STEP 2--Knock out the pins on either side of the MountingFrame Adjuster and loosen the 4 bolts (B504801) thatconnect the Carriage Mounting Frame to the frame of thegrinder.STEP 3--Jack the traversing carriage base up to put apreload on the Cross Slide Assembly.STEP 4--Tighten the 4 bolts on the Carriage MountingFrame to 75 ft-lbs.STEP 5--Release the jack pressure and test the verticaland horizontal handwheels for ease of movement throughtheir full range of motion.STEP 6--If the Cross Slides tend to bind, repeat abovesteps jacking higher or lower (STEP 1) until the handwheelsmove freely.STEP 7--When the Cross Slides move freely through theirfull range of motion, drill new holes and repin theassembly.


BOLTS

PIN

PIN

BOLTS

CROSS SLIDEASSEMBLY

CARRIAGEMOUNTINGFRAME

PART OFFRAME

22

ADJUSTMENTS (Continued)CROSS SLIDE SHAFT REPLACEMENT

If the cross slide shafts become scarred or gnarled,replace them by the following procedure:

STEP 1--Use a hydraulic jack to raise the weight offthe Cross Slide Assembly.STEP 2--Loosen the two nuts on the support castingthat hold the locking stud and tap with plastic or rubberhammer to loosen.STEP 3--Loosen the locking handles and tap thecenter stud with a plastic hammer.STEP 4--Loosen locknut and setscrew and removethe handwheel.STEP 5--Remove the Slide Shaft.STEP 6--Remove all burrs and resurface the shaft toa clean, smooth, polished surface. (OR REPLACEWITH A NEW SHAFT.)STEP 7--Coat shaft with Never-Cease and re-installthe shaft through the Support, Cross Slide Block andthe three locking studs. The shaft must move freelyinside the Cross Slide Block before reassembling.STEP 8--Retightening the nuts at the end of thelocking studs to lock shaft in place.STEP 9--Reinstall the Handwheel by snugging thesetscrew to the flat located on the screw shaft, thentorque nut until tight and back off 1/2 turn. Torque thesetscrew to 70 in-lbs.STEP 10--Test the Cross Slide, the handwheel shouldturn freely.STEP 11--Lower the jack and retest the Cross SlideAssembly through full range of motion. If bindingoccurs, follow the procedure under Cross SlideAssembly located on page 21.

NOTE: It is also possible to remove the complete CrossSlide Assembly and do the repairs on a bench thenreinstall.

LOCKNUT

CROSSSLIDE

LOCKHANDLES

SLIDESHAFTS

DUTCHMAN

NUT

LOCKNUT

HANDWHEELSETSCREW

23

CONTROL BOARD POTENTIOMETER ADJUSTMENTSSPIN DRIVE CONTROL BOARD (SDC)

The Spin Drive Control Board has three potentiometers on the lower board and two potentiometers on theupper board as shown on drawing 6524511 which is included. These potentiometers have been set at thefactory to the positions shown on the drawing. Also see FIG. 27A and 27B.

In the Relief Grinding Mode---The Remote Speed Pot and the Relief Torque Pot (RTP) interact with each other. The remote speed pot islocated on the upper board of the Spin Drive Control (SDC) preset at 9:30. The (RTP) is located on the controlpanel and is for relief torque adjustment. See FIG. 27B.

The Remote Speed Pot when rotated clockwise will increase maximum spin drive speed. The remote speedpot should never be above the 10:30 setting.

Relief Torque Pot (RTP) can vary the reel to finger holding torque for relief grinding. The recommended startingpoint is 15 in/lbs of torque setting. Never adjust the (RTP) potentiometer dial past the red line marking.Setting the reel to finger torque to high could cause the traverse motor system to not operating smoothly.

In the Spin Grinding Mode---The Remote Torque Potentiometer and the Spin Speed Pot (SSP) interact with each other. The remote torquepot is located on the upper board of the Spin Drive Control (SDC) preset at 2:00 for torque setting. The (SSP)is located on the control panel and is for spin speed adjustment. See FIG. 27B.

The Remote Torque Potentiometer controls maximum torque allowable in the spin grind cycle only. Thisshould never be adjusted past the 2:30 position.

The Spin Speed Pot (SSP) controls reel spin speed, adjust as required. This controls the spin drive speed forspinning the reel.

POTENTIOMETERS ON THE SPIN DRIVE CONTROL (SDC) LOWER BOARD See FIG. 27A.

Maximum Speed Pot---The maximum speed is factory preset to 4:30 (fully clockwise) to allow for maximum spin speed.

Minimum Speed Pot---The minimum speed is factory preset at 8:30 (full counterclockwise) so zero speed is obtainable for spinspeed.

IR Compensation Pot---The IR Compensation is factory set at 9:00.

Regulation of the spin or relief grind spin motor may be improved by a slight adjustment of the IR COMP trim potclockwise from its factory-set position. Overcompensation causes the motor to oscillate or to increase speed whenfully loaded. If you reach such a point, turn the IR COMP trim pot counterclockwise until the symptoms just disappear.

FIG. 27A

FIG. 27B

See potentiometerorientation on page 24

24

MACHINE SERVICE

FIG. 29

TRAVERSE DRIVE CONTROL BOARD (TDC)

The Traverse Drive Control Board has five potentiometers asshown on drawing 6524511 which is included. Thesepotentiometers have been set at the factory to the positionsshown on the drawing. Also see FIG. 29.

Maximum Speed---The maximum speed potentiometer is preset to 2:30 positionfor 90 Volts DC to the traverse motor.

Rev Torque---The Reverse Torque setting determines the maximum currentlimit for driving the motor in the reverse direction. Thepotentiometer is preset to the 3:00 position. It should notrequire adjustment.

Fwd Torque---The Foward Torque setting determines the maximum currentlimit for driving the motor in the forward direction. Thepotentiometer is preset to the 3:00 position. It should notrequire adjustment.

Accel - Decel---The potentiometer is factory preset to the minimum fullcounterclockwise 8:30 position. This position turns theAcceleration/Deceleration off for this application.

IR Compensation---The IR Comp control is preset to 9:30 position. Never adjustpast the 11:00 position.

Regulation of the traverse motor may be improved by slightadjustment of the IR COMP trim pot clockwise from its factory-set position. Overcompensation causes the motor to oscillateor to increase speed when fully loaded. If you reach such apoint, turn the IR COMP trim pot counterclockwise until thesymptoms just disappear.

50 HZ - 60 HZ SwitchThis motor control board has a switch which must be set for 50HZ or 60 HZ operation.

PotentiometerClock Orientation Terminal ends (Feet) are always at the 6:00 position,

no matter how the potentiometer is orientated on the board.

50 HZ - 60 HZSWITCH

25

Remove grinding wheel and grinding wheel knob. The Grinding Head Spindle Assembly consists of thegrinding head spindle and a ball bearing press fit together. The left side ball bearing is slip fit on the oppositeend. To replace the spindle assembly remove the left side grinding wheel grip knob, square key and beltcover. See FIG. 29. Loosen the 4 socket head cap screws on the motor plate to remove the poly-V belt.Loosen the 2 set screws on the spindle pulley and remove the pulley, square key and pulley spacer. Push onthe right hand side of the spindle assembly to compress conical washers so there is no pressure on theshaft retaining ring. Using a retaining ring pliers remove the small external retaining ring from the spindleassembly. You can now remove the spindle assembly out the right side by lightly tapping on the left end witha rubber mallet. The second ball bearing can be removed from the belt side of the Grinding Head Housing.

To reassemble place the 4 conical washers (2 Pair nested and then place the 2 pairs back to back) againstthe ball bearing on the new spindle assembly. See FIG. 30. Thoroughly clean the housing bore and theoutside diameter of both bearings. Apply blue Loctite #242 to the outside diameter of the two bearings. Slidethe spindle assembly into the right side of the Grinding Head Housing. Install the bearing sleeve against thebearing on the spindle assembly. Slip fit the new left side ball bearing onto the spindle assembly and intogrinding head housing. Install the 9/16-18 Locknut onto the spindle shaft and using a spanner wrench on theright side of the spindle and a 7/8 deepwell socket on the left side, torque the locknut to 20 Ft. Lbs.

Replace the square key and the pulley pushing the pulley against the locknut with no end play. Apply blueLoctite to the bore of the puley before instation. Next install blue Loctite #242 on the pulley setscrews andtighten the two pulley set screws. Then remount the poly-V belt. (See Grinding Head Belt Tension Adjustmentin the adjusting section). Replace belt cover and square key and mount the left side grinding wheel grip knoband tighten the two set screws.

MACHINE SERVICE (Continued)

FIG. 30

FIG. 31

REPLACEMENT OF GRINDING HEAD SHAFT & BEARINGS

26

ACCU-TOUCH CONTROL PANEL

Termial Strip #1(TB1)

Terminal Strip #2(TB2)

Touch Screen

Spin DriveControl Board

(SDC)

Traverse DriveControl Board

(TDC)

24 VDC PowerSupply (PWR)

Low Voltage Relay(LVR)

MagneticContactor

(MAG)

Main CircuitBreaker (MCB)

Grinding MotorRelay (REL)

Relay Board(RT1)

ProgrammableLogic Controller

(PLC)

Door SafetySwitch Monitor

(SSM)

Stepper InfeedController

(SIC)

Vacuum Relay(RE34)

AC Filter(FTR)

Main Ground Lug

Grey TerminalBlocks (TBG)

Blue TerminalBlocks (TBB)

27

ELECTRICAL TROUBLESHOOTINGSKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING

This Electrical Troubleshooting section is designed for technicians who have the necessary electricalknowledge and skills to reliably test and repair the ACCU-Touch electrical system. For those without thatbackground, service can be arranged through your local distributor.

This manual presumes that you are already familiar with the normal operation of the Grinder. If not, youshould read the Operators Manual, or do the servicing in conjunction with someone who is familiar with itsoperation.

Persons without the necessary knowledge and skills should not remove the control box cover or attemptany internal troubleshooting, adjustments, or parts replacement.

If you have any question not answered in this manual, please call your distributor. They will contact themanufacturer if necessary.

WIRE LABELS

All wires on the ACCU-Master have a wire label at each end for assembly and troubleshooting. The wirelabel has a code which tells you wiring information. The first set of digits are the schematic wire number:These identify the connection number. Look at the column numbers on the left side of the schematic rungto identify the wire(s) The next number(s) are the Foley wire number. The next group of numbers orletters are the code for the component to which the wire attaches. Example: RT1 for Relay Terminal 1.The last set of numbers or letters are the number of the terminal on the component to which the wireattaches.

ELECTRICAL TROUBLESHOOTING INDEX

AC Main Power Controls ................................................................................................. Page 28E-Stop ............................................................................................................................ Page 29Machine Light ................................................................................................................. Page 30Spin Drive Controls in Spin Mode .................................................................................... Page 31-32Spin Drive Controls in Relief Mode .................................................................................. Page 33-34Grinding Motor Controls .................................................................................................. Page 35Dust Collector Controls .................................................................................................. Page 36Winch Controls .............................................................................................................. Page 37Traverse Drive Controls--w/prox ..................................................................................... Page 38-39Stepper Infeed Controls-- ................................................................................................ Page 40-41System Error Messages ................................................................................................. Page 42-42Flashing Light ................................................................................................................. Page 46

28

ELECTRICAL TROUBLESHOOTING (Continued)PROBLEM--AC Main Power Controls: no electrical power to control panel.

In your Product Packet Assembly, there are a series of prints. Find the printtitled ACCU-Touch Wiring Diagram, before starting the troubleshooting below.Verify all wires shown on that drawing are correct and pull on wire terminals withapproximately 3 lbs force to verify there are no loose terminal connections and/orno loose crimps between wire and terminal. If loose terminals are found, retightenand retest system. If problem persists, test as listed below.

Possible Cause

You must turn ON theSwitch on the top ofthe control panel.

Main Power Cord is notplugged in

Main 20 amp outlet circuitbreaker has tripped inbuilding panel

Main 20 amp circuit breakerhas tripped in machinepanel

No 115 Volts AC to MainCircuit Breaker

No 115 Volts AC power from2-Amp Circuit Breaker

No 115 Volts AC power fromPower Switch (PSW)

No 24 Volts DC power fromPower Supply

Machine worksYes--end troubleshootingNo--go to Step B. next

Machine worksYes--end troubleshootingNo--go to Step C. next

Machine worksYes--end troubleshootingNo--but a light works in outlet--go to Step D. nextNo--but light does not work in outlet. You must solve your power delivery problem independent of machine.

Machine worksYes--end troubleshootingNo----go to Step E. next

Check 115 Volts AC from (MCB) 01MBC-brown wire to Blue Terminal BlockTBB17 light blue wire.Yes--go to Step F. nextNo--Verify Filter function, check wiring.

Check 115 Volts AC from 2-Amp CB"157CB13-BL" to Blue Terminal BlockTBB17 light blue wire.Yes--go to Step H. nextNo--Check continuity of CB and replace.

Check 115 Volts AC from PSW terminal#3 to Blue Terminal Block TBB17.Yes--go to Step I. nextNo--Check continuity of Switch andreplace

Check 24 Volts DC from PWR V+ to V-Yes--Verify wiring to Touch ScreenNo--Verify power to PWR. Replacepower supply.

Checkout Procedure

A. Look for Touch screen to come on.

B. Plug in main power cord

C. Check circuit breaker and resetif necessary. (Check wall outletwith a light to make sure it works)

D. Check circuit breaker and resetif necessary.

E. Check for incoming power(MCB) for 115 Volts AC

F. Check for 115 Volts AC from2-Amp Circuit Breaker

H. Check for 115 Volts AC fromPower Switch

I. Check for 24 Volts DC fromPower Supply (PWR)

29

ELECTRICAL TROUBLESHOOTING (Continued)

Possible Cause

You must push the greenPush to Start Switch (PSS)

Pull red e-stop button out

115V power not delivered toMAG coil

Controller E-stop ouputrelay on

Controller E-stop relay nocontinuity

(SSS) Is bad

(ESS) Is bad

Bad wires

Machine worksYes--end troubleshootingNo--go to Step B. next

Machine worksYes--end troubleshootingNo--go to Step C. next

(MAG) Term #A1 to A2 for 115 Volts ACYes--replace magnetic starter if notpulling in with click.No--go to Step D. next

Light is:Off-- Controller software corrupt ormissing, or Relay Board not working.On-- go to step E. next

(RT1) terminals F+ to F- for 115 Volts ACYes-- Replace output relay F in (RT1)No-- go to step F. next

(SSS) Term #3 to #4 for 115 Volts AC(SSS) not pushed, "0" Volts AC (SSS)pushed.No-- Replace (PSS)Yes-- go to step G. next

(ESS) Term #1 to #2 for "0" Volts(ESS) pulled out, 115 Volts AC (ESS)pressed in.No-- Replace (ESS)Yes-- go to step H. next

Measure continuity of wires #11, 12, 15, 22,35, 37, 50, 59, 60, 146, 147, 148, 149, &150. Replace any bad wires or repairloose connections.

Checkout Procedure

A. Listen for magnetic contactor(MAG) to pull in with a clunk.

B. Repeat push the green button(SSS) again.

C. Check at Magnetic contactor coilfor 115 Volts AC with main electricalpower on and pushing (SSS)

D. Check on relay board (RT1) forlight on for output "F" (farthest lightto right)

E. With the machine power on,Relay light on, measure acrossrelay contacts.

F. With the machine power on,measure across normally opencontacts of (SSS)

G. With the machine power on,measure across normally closedcontacts of (ESS)

H. With the machine power off,verify continuity of wires andconnections.

PROBLEM--Red E-Stop screen displayed on Touch Screen


30


Light worksYes--end troubleshootingNo--go to Step B. next

Check for 115 Volts AC across termi-nals # 6 & 7 on Terminal Strip 2 (TB2)Yes--replace cord for lightNo--go to Step C. next

Check wiring and tighten or replaceany damaged or loose parts.

Possible Cause

Light switches arenot turned on or thereis a bad bulb

Wire cord is bad

Wiring is bad

Checkout Procedure

A. Turn on machine light toggleswitch on light. Check the light bulbin another light fixture or replace witha new bulb. Plug a different light thatis known to work into light plug.

B. Check for 115 Volts AC atTerminal Strip

C. Check continuity of wiring fromMAG to Terminal Block

*NOTE: The light may flickeron and off when the grindingmotor is turned on. This is dueto the high current draw on thesystem when starting the grindmotor.

PROBLEM--Machine light is not working


31


Possible Cause

Spin Speed Pot (SSP) setto zero

Spin Motor Switch not onon Touch Screen

Door is open

Circuit breaker 42 istripped (4A)

Relay 9 (RT1) is notworking

Verify Light is on

Verify Continutiy ofrelay 9 in RT1

Relay 4 (RT1) is notworking (Spin/Torqueselector relay)

Checkout Procedure

A. Set (SSP) to 200 on the controlpanel.

B. Turn spin drive switch on (touchgreen area) from SPIN MANUALscreen.

C. Alarm on screen should indicatethat the door must be closed for thespin drive to operate. Close door.

D. Reset circuit breaker switch(Tripped by current overload)check that reel is free spinning

E. Check for (SDC) input of115 Volts AC

F. Check (RT1) for light #9 to be on(Door must be closed and spin driveswitch on)

G. With light #9 on, Check (RT1)relay 9 for continuity.

H. With 115 Volts AC at Term L1and L2, check (SDC) output. HaveSpin speed pot (SSP) set at 400

I. With 115 Volts AC at Term L1and L2, check (SDC) output. HaveRelief Torque Pot (RTP) set to RedLine.

Spin Motor worksYes--end troubleshootingNo--go to Step B. next

Spin Motor worksYes--end troubleshootingNo--go to Step C. next

Spin Motor worksYes--end troubleshootingNo--go to step D. next

Spin Motor worksYes--end troubleshootingNo--go to step E. next

(SDC) Term #L1 to #L2 for 115 Volts ACYes--skip to step H. nextNo--go to Step F. next

Light is ON.Yes--go to Step G. nextNo--Bad PLC, RT1, cables, or Software.

(RT1) Term 9+ to term 9- for 115 Volts ACNo-Check CB42 (4-Amp) for 115 Volts AC-check from CB to Blue Terminal Block 17Yes--Replace relay #9 in (RT1)

(SDC) term A1 to term A2 measureapprox 90 Volts DCYes--Skip to Step L.No-- go to step I. Next

(SDC) term A1 to term A2 measureapprox 12 Volts DCNo-- Skip to step N.Yes-- go to step J. Next

PROBLEM--Spin Drive not working in (manual) jog mode and in SPIN MODE.

Assuming 115 Volts AC to control panel and all other manual (jog) mode functions are working.

In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-TouchWiring Diagram before starting the troubleshooting below. Verify all wires shown on thatdrawing are correct and pull on wire terminals with approximately 3 lbs force to verify there areno loose terminal connections and/or loose crimps between wire and terminal. If looseterminals are found, tighten and retest system. If problem persists, test as listed below.

32


Possible Cause

Relay #4 is bad

Reversing relay(s) bad(RT1)

Spin Speed Pot (SSP)is not working

Spin Drive motor is bad

Worn motor brushes

Checkout Procedure

J. Check (RT1) for light #4 to be onInsure that Spin Drive switch hasbeen pressed on from SPIN MANUALscreen at least once

K. With light #4 on, verify continuity

L. Measure voltage at spin motor

M. Reverse direction of spin motorfrom SPIN MANUAL touch screen

N. (SSP) on Main Panel

O. With machine power off,Check spin motor continuity

P. Inspect motor brushes

Light is:On-- go to Step K. nextOff-- Contact factory

Remove one of the wires at Terminal 4,measure (RT1) 4+ to 4- for "0" OhmsYes--Replace (SDC)No--replace Relay 4 (RT1)

(RT1) Term A+ to term D+ should read thesame 90 Volts DC measured at step H.Note polarityYes--Skip to Step O.No-- go to Step M. next

(RT1) Term A+ to term D+ should read thesame 90 Volts DC measured at step H.,but opposite polarityYes--Skip to Step O.No-- Replace relays A, B, C, & D in(RT1)

(SDC) Black wire of (SSP)- H to Red wireof (SSP)-WPot full CCW Pot Full CW4.4 Volts DC 0 Volts DC(SDC) White wire of (SSP)- L to Red wireof (SSP)-WPot full CCW Pot Full CW0 Volts DC 4.4 Volts DCYes-- Replace (SDC)No-- Replace (SSP)

At (RT1) Term A+ and B+ or C+ and D+check approx. 0 ohms across the blackand white wiresYes-- Motor should work, end trouble-shooting.No--go to Step P. next

Remove the brushes one at a time andmaintain orientation for reinsertion. Seeif brush is worn short 3/8" [10mm] mini-mum length.Yes-- replace motor brushesNo-- replace Spin Drive motor

33


Possible Cause

Relief Torque Pot (RTP) setto zero

Spin Motor Switch not onon Touch Screen

Door is open

Circuit breaker 42 istripped (4A)


Verify Light is on

Verify Continutiy ofrelay 9 in RT1


Checkout Procedure

A. Set (SSP) to 20 on the controlpanel.

B. Turn spin drive switch on (touchgreen area) from RELIEF MANUALscreen.

C. Alarm on screen should indicatethat the door must be closed for thespin drive to operate. Close door.

D. Reset circuit breaker switch(Tripped by current overload)check that reel is free spinning

E. Check for (SDC) input of115 Volts AC

F. Check (RT1) for light #9 to be on(Door must be closed and spin driveswitch on)

G. With light #9 on, Check (RT1)relay 9 for continuity.

H. With 115 Volts AC at Term L1and L2, check (SDC) output. HaveRelief Torque Pot (RTP) set at RedLine.

I. With 115 Volts AC at Term L1and L2, check (SDC) output. HaveSpin Speed Pot (SSP) set to 400

Spin Motor worksYes--end troubleshootingNo--go to Step B. next

Spin Motor worksYes--end troubleshootingNo--go to Step C. next

Spin Motor worksYes--end troubleshootingNo--go to step D. next

Spin Motor worksYes--end troubleshootingNo--go to step E. next

(SDC) Term #L1 to #L2 for 115 Volts ACYes--skip to step H. nextNo--go to Step F. next

Light isOn--go to Step G. nextNo--Bad PLC, RT1, cables, or Software.

(RT1) Term 9+ to term 9- for 115 Volts ACNo--Check CB42 (4-Amp) for 115 VAC-check from CB to Blue Term Block 17Yes--Replace relay #9 in (RT1)

(SDC) term A1 to term A2 measureapprox 12 Volts DCYes--Skip to Step L.No-- go to step I. Next

(SDC) term A1 to term A2 measureapprox 90 Volts DCNo-- Skip to step N.Yes-- go to step J. Next

PROBLEM--Spin Drive not working in (manual) jog mode and in RELIEF MODE.


In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-TouchWiring Diagram, before starting the troubleshooting below. Verify all wires shown on thatdrawing are correct and pull on wire terminals with approximately 3 lbs force to verify there areno loose terminal connections and/or loose crimps between wire and terminal. If looseterminals are found, tighten and retest system. If problem persists, test as listed below.

34


Possible Cause

Relay #4 is bad

Reversing relay(s) bad(RT1)

Relief Torque Pot (RTP)is not working

Spin Drive motor is bad

Worn motor brushes

Checkout Procedure

J. Check (RT1) for light #4 to be offInsure that Spin Drive switch hasbeen pressed on from RELIEFMANUAL screen at least once

K. With light #4 on, verify continuity

L. Measure voltage at (RT1)

M. Reverse direction of spin motorfrom SPIN MANUAL touch screen

N. (RTP) on Main Panel

O. With machine power off,Check spin motor continuity

P. Inspect motor brushes

Light is:Off-- go to Step K. nextOn-- Contact factory

Remove one of the wires at Terminal 4,measure (RT1) 4+ to 4- for "0" OhmsYes--Replace relay 4 (RT1)No--replace (SDS)

(RT1) Term A+ to term D+ should read thesame 12 Volts DC measured at step H.Note polarityYes--Skip to Step M.No-- Replace relays A, B, C, & D in(RT1)

(RT1) Term A+ to term D+ should read thesame 12 Volts DC measured at step H.,but opposite polarityYes--Skip to Step O.No-- Replace relays A, B, C, & D in(RT1)

(SDC) Black wire of (RTP)- H to Red wireof (RTP)-WPot full CCW Pot @ Red line.2 Volts DC .1 Volts DC(SDC) White wire of (RTP)- L to Red wireof (RTP)-WPot full CCW Pot @ Red line.1 Volts DC .2 Volts DCYes-- Replace (SDC)No-- Replace (SSP)

At (RT1) Term A+ and B+ or C+ and D+check approx. 0 ohms across the blackand white wiresYes-- Motor should work, endtroubleshooting.No--go to Step P. next

Remove the brushes one at a time andmaintain orientation for reinsertion. Seeif brush is worn short 3/8" [10mm] mini-mum length.Yes-- replace motor brushesNo-- replace Spin Drive motor

35


Possible Cause

Grinding Motor Switch isnot on

Circuit Breaker (CB28)15A is tripped

Grinding Motor Relay isnot working (REL)

Relay (REL) coil or con-tacts are not working


Checkout Procedure

A. Turn switch on from either SPINMANUAL screen or RELIEF MANUALscreen

B. Reset circuit breaker switch(tripped by current overload)

C. Check for (REL) incoming115 Volts AC

D. Check for (REL) output voltageof 115 Volts AC

E. Check for (REL) input of 24Volts DC at the coil. Reminder,Grind Drive switch must be on anddoors must be closed.

F. (RT1) check that the light is onfor relay 5, make sure grind driveswich is on

I. Light is on for Relay 5, checkcontinuity

Grinding Motor worksYes--end troubleshootingNo--go to Step B. next

Grinding Motor worksYes--end troubleshootingNo--go to step C. next

(REL) Term #L1 to #L2 for 115 Volts ACYes--go to step D. nextNo--Verify wiring, replace Circuit Breaker(CB28)

(REL) Term #T1 to #T2 for 115 Volts ACYes-- Verify 115 VAC at TB1-1 & TB1-2,Check terminals, replace Grind motor.No--go to step E. next

(REL) Term A1 to Term A2 for24 Volts DCYes--Replace (REL)No--Skip to Step F.

Light is:On-- Go to Step I. nextOff--Contact Factory

(RT1) Term 5+ to 5-, measure DCvoltage0 Volts DC-- Check wiring, Relay (REL)should work, end troubleshooting.24 Volts DC-- Replace relay 5 (RT1)

PROBLEM--Grinding motor not working in (manual) jog mode.


In your Product Packet Assembly there are a series of prints. Find the print titled ACCU-TouchWiring Diagram, before starting the troubleshooting below. Verify all wires shown in thedrawing are correct and pull on wire terminals with approximately 3 lbs force to verify there areno loose terminal connections and/or loose crimps between wire and terminal. If looseterminals are found, tighten and retest system. If problem persists, test as listed below.

36


Possible Cause

Dust Collector Switch isnot on (Vacuum)

Dust Collector Switch(Vacuum) on touch screenis not on

Vacuum not working

(RT1) relay E is not working

Circuit Breaker (CB32) isnot working (3-amp)

Relay 34 (RE34) is notworking

Checkout Procedure

A. Turn on switch located on topof Vacuum in the back right ofcorner of the machine.

B. Turn switch on from SPINMANUAL or RELIEF MANUALscreen.

C. Check for 115 Volts AC at thereceptacle plug by plugging in ahand drill or light.

D. With Vacuum switch on,Check for (RT1) Relay E on

E. (RT1) Relay E, verifycontinuity

F. Check for power out of circuitbreaker (CB32)

G. Check for (RE34) input of115 Volts AC at coil.

H. Check for (RE34) input of115 Volts AC at contacts

I. Check for (RE34) output of115 Volts AC at contacts

Dust Collector works--Yes--end troubleshootingNo--go to Step B. next

Dust Collector works--Yes--end troubleshootingNo--go to Step C. next

Light worksYes--Replace VacuumNo--go to Step D. next

Light is on:Yes--go to step E. nextNo--Contact Factory

(RT1) Term #E+ to #E- for 115 Volts ACYes--replace Relay E (RT1)No--go to Step F. next

Terminal Block 17 (light blue wire) #02 to(CB32) (brown) #156 for 115 Volts ACYes--go to Step G. nextNo--replace (CB2)

(RE34) Term 0 to term 1 for 115 Volts ACYes-- go to Step H. nextNo--Check continuity of wires.

(RE34) Term 8 to term 4 for 115 Volts ACYes--go to Step I. nextNo--Check continuity of wires.

(RE34) Term 6 to term 2 for 115 Volts ACYes--Replace PlugNo--replace (RE34)

PROBLEM--Dust Collector not working in (manual) jog mode.


I n y o u r P r o d u c t P a c k e t A s s e m b l y , t h e r e a r e a s e r i e s o f p r i n t s . F i n d t h e p r i n t t i t l e d ACCU-TouchWiring Diagram, before starting the troubleshooting below. Verify all wires shown on that draw-ing are correct and pull on wire terminals with approximately 3 lbs force to verify there are noloose terminal connections and/or no loose crimps between wire and terminal. If looseterminals are found, tighten and retest system. If problems persists, test as listed below.

37


Possible Cause

7 amp circuit breaker onwinch motor is tripped

No voltage to motor

Checkout Procedure

A. Reason: Check for a lifting overload condition or wiring shorted to ground. Reset breaker located at end of winch motor.

B. Check that motor coil cord from DC motor is plugged in

C. Check for 115 Volts AC at the plug end winch cord wire #6 by plugging in a hand drill

D. Check for Machine is plugged in Start button is pressed. (Red E-Stop Screen must not be up)

E. Verify wiring from MAG to Terminal Strip 2.

Winch works--Yes--end troubleshootingNo--go to Step B. next

Winch works--Yes--end troubleshootingNo--go to Step C. next

Drill works--Yes--replace winchNo-- go to Step D. next

Winch works--Yes--end troubleshootingNo--go to Step E. next

Measure 115 Volts AC from TB2-6 toTB2-7.Yes--replace cord to winchNo--Verify power out of mag. Replace bad wiring.

PROBLEM--Winch does not work in either direction.

In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-TouchWiring Diagram, before starting the troubleshooting below. Verify all wires shown on thatdrawing are correct and pull on wire terminals with approximately 3 lbs force to verify there areno loose terminal connections and/or loose crimps between wire and Terminal. If looseterminals are found, tighten and retest system. If problem persists, test as listed below.

38


Traverse worksYes--end troubleshootingNo--go to step B. next

Traverse worksYes--end troublshootingNo--go to Step C. next

Traverse worksYes--end troublshootingNo--go to Step D. next

On (TDC) Term L1 toL2 for 115 Volts ACYes--Skip to Step H.No--go to Step E. next

Light is:On-- go to Step F. nextOff-- Contact Factory

(RT1) Term 8+ to 8- read115 Volts ACYes-- Replace Relay 8 (RT1)No-- go to Step G. next

(CB32) from Line neutral, Light Bluewire at the line filter wire # 02FTRBU,to wire #156CB32-BL at CB32measure 115 Volts AC:No-- Replace CB32Yes-- Verify continutiy of wires to RT1.Replace or repair bad wire(s)

Possible Cause

Traverse Speed Pot (TSP)set to zero

Traverse Belt Clamprelease lever released

Circuit Breaker 32 (CB32)(3 amp) tripped

Traverse Drive Control(TDC) do not have power

Relay 8 (RT1) is bad

Circuit Breaker 32 (CB32)bad

Checkout Procedure

A. Set (TSP) to 35 on the controlpanel

B. Insure release lever is in adjustedproperly. See Adjustments sectionof this manual.

C. Too heavy a grind causesgrinding head traverse motor tooverload and trip the circuit breaker.Reset (CB32)

D. Check for 115 Volts ACincoming to (TDC) (insuretraverse right or left has beenpressed at least once)

E. Check for relay 8 (RT1)light on (insure traverse rightor left has been pressed at leastonce)

F. Check relay 8 for continuity,Insure relay 8 light is on

G. Check CB32 for voltage

PROBLEM--Traverse Drive not working in (manual) jog mode


In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-TouchWiring Diagram, before starting the troubleshooting below. Verify all wires shown on thatdrawing are correct and pull on wire terminals with approximately 3 lbs force to verify there areno loose terminal connections and/or loose crimps between wire and terminal. If looseterminals are found, tighten and retest system. If problem persists, test as listed below.

39


Possible Cause

No DC Voltage from (TDC)Traverse Drive Control

Traverse Motor is bad

Check Relays 2 and 3

(TSP) (10K) is bad

Gap between flag and proxis incorrect.

Proximity switch is bad

Worn motor brushes

Checkout Procedure

H. Check for 90 Volts DC across(TDC) terminals A! to A2 this voltagedrives the DC traverse motor.NOTE: Traverse must be on andhave (TSP) turned full CW to maximumvoltage of 90 VDC

I. Check traverse motor continuity

J. (RT1) Verify that relay 2 lightcomes on when Traverse Right ispressed, and that relay 3 light comeson when Traverse Left is pressed

K. Check (TSP) for 10,000 ohmsRemove three wires from (TDC)red from term S2white from term S0black from inline connector (Wire 39)

L. Gap between flag and Proxshould be 3/16" to 1/4" [4-6mm].Prox light does not light when flag isunder prox.

M. From the Touch screen, Enter"HELP" screen from main menu.

N. Inspect Motor Brushes

Check (TDC) terminalsA1 to A2 for 90 Volts DCY e s - - g o t o s t e p I. nextNo--go to Step J. next

Note:If voltage is less than 90 VDCverify pots on TDC. See page 24

Remove wires from terminalsA1 & A2 0 ohms acrossthe black and white wiresYes--go to Step J. nextNo--go to Step N.

Lights come:On-- go to step K. nextOff-- Skip to step L.

Check for 10,000 ohms red to whitewiresFull CCW--0 ohmsFull CW--10,000 ohmsRed to black wiresFull CCW--10,000 ohmsFull CW--0 ohmsYes--go to Step L. nextNo--replace (TSP)

If incorrect, adjust per adjustmentsection of manual.Traverse works--Yes-- End troubleshootingNo-- go to step M. next

Follow instructions on screen to verifytraverse proximity switches are ok.Switch isGood-- Replace (TDC)Bad-- Replace switch

Remove the brushes one at a time andmaintain orientation for reinsertion.See if brush is worn short, 3/8" [10 mm]minimum length.Yes--replace motor brushesNo--replace Traverse Drive Motor

40


Possible Cause

Infeed Jog Switch is notheld to on position

Actuator is at physical limit

Circuit Breaker (CB13)is tripped (2 amp)

High Low Switch is not onhigh speed

Stepper motor drivecoupling is loose

No DC voltage to StepperInfeed Control (SIC)

No DC Voltage to OPTOterminal of (SIC)

Checkout Procedure

A. Hold switch on ineither direction

B. Move stepper in opposite direction

C. Reset circuit breaker switch(tripped by current overload)Grinding head stepper infeedmechanism jammed causing overload

D. Put switch on high speed(rabbit) for ease of checkout ofStepper Infeed Control (SIC)

E. You can feel stepper pulses onmotor when (HLS) is on high or low& (IJS) switch is depressed in eitherup or down direction. Open stepperinfeed inspection plate to check forloose coupling. Retighten couplingto drive actuator screw. Seeadjustment section of manual.

F. (SIC) Check for 24 Volts DCPower in

G. (SIC) Check voltage at OPTOterminal

Stepper motor worksYes--end troubleshootingNo--go to Step B. next

Stepper Motor worksYes--end troubleshootingNo--go to step C. next

Stepper Motor worksYes--end troubleshootingNo--go to step D. next

High speed worksYes--end troubleshootingNo--go to Step E. next

Stepper works--Yes--end troubleshootingNo--go to Step F. next

(SIC) Term GND to V+ measure24 Volts DCYes-- go to step G. nextNo-- Skip to step H.

(SIC) Term GND to OPTO mea-sure 24 Volts DCYes-- go to step I.No-- Replace wire #60 (withresistor)

PROBLEM--Stepper Infeed not working in (manual) jog mode.


In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-TouchWiring Diagram, before starting the troubleshooting below. Verify all wires shown on that drawingare correct and pull on wire terminals with approximately 3 lbs force all terminals to verify thereare no loose terminal connections and/or loose crimps between wire and terminal. If looseterminals are found, tighten and retest system. If problem persists, test as listed below.

41


Possible Cause

Mag contact or wire bad

No Step pulse from PLC

Stepper Infeed Control(SIC) Wiring bad

Stepper Infeed Control(SIC) or Steppermotor is bad

Checkout Procedure

H. Measure voltage at (MAG) insurepower is on, and green (PSS) hasbeen pressed.

I. Check light Y0 on PLC. Whilepressing up or down it should light(pressing down Y1 will also light)

J. Check wiring at (SIC).

K. Check output at (SIC). HaveHigh/Low Switch set on high speed(rabbit)

(MAG) term 13 to 14, Measure0 volts DCYes--Verify DC power to Mag term 13No-- if 24 Volts DC, Replace (MAG)

Light comes on:Yes-- go to step H. nextNo-- Contact Factory

Insure all wires are connected at the(SIC) to the connectors and that nonehave become loose. Some connectionshave multiple wires in them, be sure allare tight by gently "tugging" on them. If allwires appear to be connected andcorrect, proceed:

(SIC) Terminal phase A to terminal phase A'Measure 4.7 Volts DC, 0.2-0.3 Volts whilejog button is pressed.(SIC) Terminal phase B to terminal phase B'Measure 4.7 Volts DC, 0.2-0.3 Volts whilejog button is pressed.Yes--replace stepper motorNo--replace (SIC)

42


PROBLEM--No Manual (jog) cycle or Auto Cycle stops because of a system error messageon Touch Screen.

System Error Message

STORE FINGER FORSPIN GRIND

ROTATE HEAD DOWNFOR SPIN GRIND

HOME TRAVERSE (TORIGHT PROX) TO START

ROTATE HEAD UP FORRELIEF GRIND

Message Status

Clears--Proceed to next systemerror message you have orcontinue running.Remains--go to Step B. next

From "Help" Screen verify FingerStored/Down prox input is on(Red) Follow instructions onscreen.

Clears--Proceed to next systemerror message you have orContinue running.Remains--go to Step B. next

From "Help" Screen verify Headin Relief Pos. prox input is work-ing. Follow instructions onscreen.


From "Help" Screen verify RightTraverse Prox input is working.Follow instructions on screen.


From "Help" Screen verify Headin Relief Pos. prox input is work-ing. Follow instructions onscreen.

Checkout Procedure

A. Rotate index finger assembly tospin position

B. Check (PLC) input from FingerStored/Down prox

A. Rotate grind head assmbly down

B. Check (PLC) input from Head inRelief Pos. (Position) prox

A. Jog Grind head to right prox withtouch screen controls

B. Check (PLC) input from RightTraverse prox switch

A. Rotate grind head assmbly up

B. Check (PLC) input from Head inRelief Pos. prox

43


Checkout Procedure

A. Release finger. Make sure thatthe finger is allowed to comeforeward at least once.

B. Check (PLC) input from DoorSaftey Switch

A. Blade count is required to runRelief grind. Count blades andenter the number under theBlade # Field.

A. Input line voltage has droppedbelow 100V. Plug machine into abetter source of power. SeePower requirements at front ofmanual.

A. For safety reasons, door mustbe closed to operate spin and / orgrind motors. Close and latchdoor.

B. Check (PLC) input from DoorSaftey Switch


RELEASE FINGER FORRELIEF

ENTER NUMBER OFBLADES

LOW VOLTAGE DE-TECTED

DOOR MUST BECLOSED TO OPERATE

INCREASE TORQUEKNOB SETTING

TORQUE KNOB LOW ORDIRECTION WRONG

Message Status

Clears--Proceed to next system errormessage you have or continue run-ning.Remains--go to Step B. next

From "Help" Screen verify FingerStored / Down prox input is working.Follow instructions on screen.

Clears--Proceed to next system errormessage you have or continue run-ning.


Clears--Proceed to next system errormessage you have or continue run-ning.Remains--go to Step B. next

From "Help" Screen verify Head inRelief Pos. prox input is working.Follow instructions on screen.



A. An excessive amount of timehas passed between blade indexesor at the start of a relief cycle.Increase the Relief Torque Pot.

A. An excessive amount of timehas passed at the beginning of aRelief grind cycle before the fingerdown prox was detected. VerifyTorque pot setting and / or spindirection. Reminder: Blade shouldpush finger down.

44


PROBLEM--No Manual (jog) cycle or Auto Cycle stops because of a system error messageon Touch Screen (Continued)


FINGER NOTRELEASED, CHECKLH PROX POS(POSITION)

MOVE NOT POSSIBLE INPAUSE MODE

MACHINE IS IN PAUSEMODE, PRESS RESUME

DOOR OPENED WHILEGRIND AND / OR SPINON

INCREASE TRAVERSEKNOB SETTING

TRAVERSE TIMEOUT,CHECK POT OR SETUP

Message Status

Clears--Proceed to next systemerror message you have orcontinue running.Remains--go to Step B. next

From "Help" Screen verify FingerStored/Down prox input is Work-ing. Follow instructions onscreen.

Clears--Proceed to next systemerror message you have orContinue running.





Checkout Procedure

A. During a relief grind cycle, thePLC did not see the finger releasedat the left prox position. Verify that thesetting of the left traverse prox allowsthe finger to come off the blade.

B. Check (PLC) input from FingerStored/Down prox

A. Press "Resume" on touch screento finish current cycle.

A. Machine was left in pause modeafter last cycle. Press "resume" ontouch screen.

A. Door was opened while potentiallydangerous operations were still on.Turn off motors, pause, or finish cyclebefore opening doors.

A. An excessive amount of time haspassed at the beginning of an autocycle before the grind head assy. hasmoved. Increase Traverse Speed potor check that carriage is not released.

A. An excessive amount of time haspassed during a traverse cycle.Increase Traverse Speed pot or verifythat carriage assembly is not re-leased or hitting an obstruction.

45


Checkout Procedure

A. Before an auto cycle can bestarted, verify the values in thedisplayed boxes and accept themby pressing the "Accept Values"button on the touch screen.

A. Before an auto cycle can bestarted, the last cycle completedmust be cleared. Open the door orpress the "Cycle Complete" buttonon the main screen to reset.


ACCEPT VALUES BE-FORE RUNNING

OPEN DOOR TO RESETLIGHT

Message Status



46


Possible Cause

Bulb is burned out

Flasher (FLR) is bad

No 115 Volts AC to flasher

Relay 7 (RT1) is bad

Circuit Breaker (CB32)tripped

Checkout Procedure

A. Remove bulb and test continuity

B. (FLR) Unplug flasher at terminal(RT1) 7+ and touch lead to blackwire at (RT1) 7-

C. After a cycle has completed,measure voltage to Flasher.

D. After a cycle has completed,check (RT1) for light 7 to be on

E. Check continuity of relay 7

F. Reset CB32

Bulb- Measure approx 300 OhmsYes--go to Step B. nextNo--Replace bulb

Light works:Yes--go to step C. nextNo-- Replace Flasher Assy.

(RT1) Term. 7+ to Blue Term Block 17Measure 115 Volts ACYes-- Verify continuity in cord,Replace flasherNo-- go to step D. next

Light is on:Yes-- go to step E. nextNo-- Contact Factory

(RT1) Term 7+ to 7- Measure 115 VoltsACYes-- Replace Relay 7 (RT1)No-- go to step F. next

Press in on Circuit breaker CB32 onfront of control panel. WorksYes--End TroubleshootingNo-- Replace CB32

PROBLEM--Flasher light does not turn on at end of automatic cycle.

I n y o u r P r o d u c t P a c k e t A s s e m b l y , t h e r e a r e a s e r i e s o f p r i n t s . F i n d t h e p r i n t t i t l e d ACCU-TouchWiring Diagram, before starting the troubleshooting below. Verify all wires shown on thatdrawing are correct and pull on wire terminals with approximately 3 lbs force to verify there areno loose terminals. If loose terminals are found, tighten and retest system. If problem persists,test as listed below.

47

THIS PAGE LEFT INTENTIONALLY BLANK FOR NOTE TAKING PURPOSES.

48

MECHANICAL TROUBLESHOOTING

Possible Cause

Traverse Speed set to fast.

Lineal bearings for the grinding headcarriage are out of adjustment (loose)or have grit buildup causing uneventraversing load.

Gib adjustment for the relief finger assemblyis loose so reel finger has movement.When traversing to the right minimumgrinding stock removal should be seen ascompared with heavy stock removal whentraversing to the left.

Lineal bearings on the grinding headcarriage are too loose.

Lineal bearings in the carriage do not rotatefreely.

Traverse Belt is slipping.

PROBLEM--Carriage traversing varies speed while grinding.

PROBLEM--Grinding stock removal from reel is irregular during spin grinding.

PROBLEM--Excessive grinding stock being removedwhen traversing to the right in the relief grinding mode.

PROBLEM--Reels ground have high/low blades.Checkout Procedure

Check roundness using a magnetic base dial indicator.Traverse speed should be set approximately 12 ft/min[4 meters/min] if roundness is varying.

Relubricate and adjust linear bearings per adjustmentsection. If problem persists, replace lineal bearings onthe carriage base. Check for any holes in the bellowsthat would permit any grinding grit penitration. Seeadjustment section for lineal bearing replacement.

Tighten the set screws for the gib adjustment. Seeprocedure in the adjustment section in the manual.

The lineal bearing must be preloaded to the traverseshafts with no vertical movement. See manual adjustmentsection for carriage linear bearing adjustments.

Check for grinding grit getting into the lineal bearings andcause excessive driving torque of carriage. Abrasivenoise is detectable when excessive grit is in the linealbearings. Replace the four lineal bearings in the maincarriage. Check bellows for holes and replace if necessary.

Check the spacing of the clamp to the support block.Clamp tip may need to be adjusted if the belt is slipping.The belt may also be too loose. See Adjustments sectionfor proper measurements of clamp gap and belt tension.

49

MECHANICAL TROUBLESHOOTING (Continued)

Checkout Procedure

Traverse speed should be set lower approximately 12 ft/min.[4 meters/min.] for a smaller burr on cutting edge.

Grinding head travel was not setup parallel to the reelcenter shaft in vertical and horizontal planes. See Alignthe Reel Section in Operator's Manual.

The right hand side of the grinding wheel is not in fullcontact for relief grinding.See Operator's Manual for NORMAL HELIX AND REVERSEHELIX for information of dressing the grinding wheel.

Possible Cause

Traverse speed set to high causing a heavyburr on the reel blade when spin grinding.

Grinding head travel not parallel to the reelcenter shaft.

The right side corner of the grinding wheelis always to be in contact with the reelblade. This is high point of the relief finger.

PROBLEM--Cone shaped reel after grinding.

PROBLEM--Relief grind on the reel blades do not go the full length of the reel.

PROBLEM--Too heavy a burr on cutting edge of reel blades.

50

PARTS LIST 6329549 CANOPY ASSEMBLY

51

PARTS LIST 6329549 CANOPY ASSEMBLYDIAGRAMNUMBER

1 ..................................................B250816 ........................ Button Head Cap Screw 1/4-20 x 1/2 Long2 ..................................................B251001 ........................ Hex Head Cap Screw 1/4-20 x 5/8 Long3 ..................................................B250801 ........................ Hex Head Cap Screw 1/4-20 x 1/2 Long4 ..................................................B371216 ........................ Button Head Cap Screw 3/8-16 x 3/4 Long5 ..................................................B371611 ......................... Socket Head Cap Screw 3/8-16 1 Long6 ..................................................J257000 ......................... 1/4-20 Nylon Jam Locknut7 ..................................................J257100 ......................... 1/4-20 Nylon Locknut8 ..................................................J377000 ......................... 3/8-16 Nylon Jam Locknut9 ..................................................K250001 ........................ 1/4 Flat Washer10 ................................................K251501 ........................ 1/4 Split Lockwasher

11.................................................K370001 ........................ 3/8 Flat Washer SAE12 ................................................K371501 ........................ 3/8 Split Lockwasher13 ................................................R000454 ........................ Flat Washer (1 OD x .44 ID )14 ................................................09394 ............................. 2 Prong Knob15 ................................................3589106 ......................... Flat Washer (1.38 OD x .39 ID)16 ................................................3707009 ......................... Liquid Tight Strain Relief .27-.47 Wire17 ................................................3707029 ......................... Liquid Tight Strain Relief .19-.30 Wire18 ................................................3707093 ......................... Liquid Tight Strain Relief .43-.55 Wire19 ................................................3707595 ......................... 7/8 Hole Plug20 ................................................J167000 ......................... 8-32 Lock Nut - Jam

21 ................................................3708448 ......................... Electrical Warning Decal22 ................................................J197000 ......................... 10-24 Lock Nut - Jam23 ................................................3708521 ......................... Plastic Rivet24 ................................................3708605 ......................... Respirator Warning Decal25 ................................................3708606 ......................... Hearing Protection Warning Decal26 ................................................3708612 ......................... No Fuel Warning Decal27 ................................................3708703 ......................... Multiple Safety Symbols Decal28 ................................................3707273 ......................... Strain Relief29 ................................................3708872 ......................... Patent Decal30 ................................................3709990 ......................... Foley United Decal

31 ................................................6309039 ......................... Gage Mounting Pin32 ................................................6329022 ......................... Side Frame Spacer Plate33 ................................................6329024 ......................... Canopy Boom Support Bracket34 ................................................R000536 ........................ Internal Tooth Lock Washer 1/435 ................................................6329053 ......................... ACCUPro Decal36 ................................................6329047 ......................... Door Guide Bracket RH37 ................................................6329048 ......................... Door Slide38 ................................................6329049 ......................... Door Guide Bracket LH39 ................................................6329059 ......................... Canopy Support Bracket40 ................................................3707728 ......................... Safety Switch NC/NC

41 ................................................6329543 ......................... Guard Weldment RH42 ................................................6329542 ......................... Guard Weldment LH43 ................................................6329112 ......................... Boom Hole Cover Panel44 ................................................6329533 ......................... Front Guard Door Assembly (see page 55)45 ................................................R000480 ........................ #8 Lock Washer46 ................................................R000558 ........................ #8-32 Kep Nut47 ................................................6529019 ......................... Flasher Base Assembly48 ................................................3708865 ......................... Safety Screw 8-32 x 1.5 Long49 ................................................6329109 ......................... Rear Right Hand Guard Panel50 ................................................6329110 ......................... Rear Left Hand Guard Panel

51 ................................................3707563 ......................... Strain Relief52 ................................................B190613 ........................ 10-24 x 3/8 Long Button Head Socket Cap Screw

PARTNUMBER DESCRIPTION

52

PARTS LIST 6329533 FRONT GUARD DOOR ASSEMBLY

53

PARTS LIST 6329533 FRONT GUARD DOOR ASSEMBLY

1 ............................ B250816 .......................... Button Head Cap Screw 1/4-20 x 1/2 Long2 ............................ B252416 .......................... Button Head Cap Screw 1/4-20 x 1 1/2 Long3 ............................ D161266 .......................... Pan Head Machine Screw #8 x 3/4 Long4 ............................ J167000 ........................... 8-32 Nylon Jam Locknut5 ............................ J257000 ........................... 1/4-20 Nylon Jam Locknut6 ............................ K250001 .......................... 1/4 Flat Washer7 ............................ R000453 .......................... Flat Washer8 ............................ 3707647 ........................... Door Safety Switch Coded Magnet9 ............................ 3708458 ........................... Sharp Warning Decal10 .......................... 3708675 ........................... 3/16 Blind Rivet

11 .......................... 3708820 ........................... Button Head Safety Screw #8-32 x 1/2 Long12 .......................... 3708855 ........................... Extension Spring13 .......................... 3708857 ........................... Black Pull Handle14 .......................... 6059013 ........................... Front Outside Window15 .......................... 6059029 ........................... Front Center Hinge16 .......................... 6059030 ........................... Front End Hinge17 .......................... 6059036 ........................... Center Window Support18 .......................... 6059044 ........................... Spring Cover Sleeve19 .......................... 6059021 ........................... Door Safety Switch (Front)20 .......................... 6059066 ........................... Bottom Window Support

21 .......................... 6059067 ........................... Top Window Support22 .......................... 6059068 ........................... Short Window Support23 .......................... 6059069 ........................... Front RH Window Frame Weldment24 .......................... 6059072 ........................... Front LH Window Frame Weldment25 .......................... 6309038 ........................... Door Bracket26 .......................... 6329046 ........................... Front Inside Window27 .......................... 6329071 ........................... Window Retainer/ Switch Mount28 .......................... 6329512 ........................... Front RH Inside Window Frame Weldment29 .......................... 6329513 ........................... Front LH Inside Window Frame Weldment

PARTNUMBER

DIAGRAMNUMBER DESCRIPTION

54

PARTS LIST 6329544 REAR SLIDE UP GUARD DOOR ASSEMBLY

55

PARTS LIST 6329544 REAR SLIDE UP GUARD DOOR ASSEMBLY

1 ............................ B190613 .......................... Button Head Socket Cap Screw 10-24 x 3/8 Long2 ............................ B251016 .......................... Button Head Socket Cap Screw 1/4-20 x 5/8 Long3 ............................ B250816 .......................... Button Head Socket Cap Screw 1/4-20 x 1/2 Long4 ............................ B372016 .......................... Button Head Socket Cap Screw 3/8-16 x 1-1/4 Long5 ............................ B372416 .......................... Button Head Socket Cap Screw 3/8-16 x 1-1/2 Long6 ............................ J167000 ........................... 8-32 Lock Nut Jam7 ............................ J197000 ........................... 10-24 Lock Nut Jam8 ............................ J257100 ........................... 1/4-20 Lock Nut9 ............................ J377000 ........................... 3/8-16 Lock Nut Jam

10 .......................... K370001 .......................... 3/8 Flat Washer11 .......................... K371501 .......................... 3/8 Lock Washer12 .......................... K160001 .......................... No. 8 Flat Washer13 .......................... 6329135 ........................... Rear Door Slide14 .......................... 6329551 ........................... Slide Up Rear Door Weldment15 .......................... 6329136 ........................... Rear Slide Spacer Plate16 .......................... K251501 .......................... 1/4 Lock Washer17 .......................... 3708819 ........................... 8-32 x .75 Button Head Safety Screw18 .......................... 3708992 ........................... Folding Handle19 .......................... 3708997 ........................... Compression Spring .24 OD x 1.5 Long20 .......................... 3708998 ........................... Wave Spring .35 ID

21 .......................... 6209165 ........................... Lower Guide Bar22 .......................... 6329029 ........................... Hinged Walker Panel23 .......................... 3708869 ........................... Spring Hinge24 .......................... 6329127 ........................... Door Safety Switch Key25 .......................... 6329128 ........................... Door Key Housing26 .......................... 6329131 ........................... Catch27 .......................... 6329132 ........................... Catch Bracket28 .......................... 6329133 ........................... Catch Pin29 .......................... 6329134 ........................... Catch Spacer Plate

PARTNUMBER


56

PARTS LIST 6329545 MAIN CABINET ASSEMBLY

57

PARTS LIST 6329545 MAIN CABINET ASSEMBLY

DIAGRAMNUMBER

PARTNUMBER

DESCRIPTION

1 ................................................. B251001 ......................... Hex Head Cap Screw 1/4-20 x 5/82 ................................................. B251011 ......................... Socket Head Cap Screw 1/4-20 x 5/83 ................................................. B310813 ......................... Button Head Socket Cap Screw 5/16-18 x 1/24 ................................................. B311213 ......................... Button Head Socket Cap Screw 5/16-18 x 3/45 ................................................. B371211 ......................... Socket Head Cap Screw 3/8-16 x 3/46 ................................................. B502801 ......................... Hex Head Cap Screw 1/2-13 x 1 3/47 ................................................. B504801 ......................... Hex Head Cap Screw 1/2-13 x 38 ................................................. B506801 ......................... Hex Head Cap Screw 1/2-13 x 4.259 ................................................. H371602 ......................... Roll Pin .375 Dia. x 1 Long10 ............................................... H372002 ......................... Roll Pin .375 Dia. x 1 1/4 Long

11 ............................................... J317100 .......................... 5/16-18 Locknut12 ............................................... J507100 .......................... 1/2-13 Locknut13 ............................................... K251501 ......................... 1/4 Split Lockwasher14 ............................................... K310001 ......................... 5/16 Flat Washer SAE15 ............................................... K311501 ......................... 5/16 Split Lockwasher16 ............................................... K371501 ......................... 3/8 Split Lockwasher17 ............................................... K500001 ......................... 1/2 Flat Washer SAE18 ............................................... R000453 ......................... Flat Washer (.88 OD x .31 ID x .104 T)19 ............................................... 3707595 ......................... 7/8" Hole Plug20 ............................................... 3708419 ......................... Wave Spring

21 ............................................... 3708421 ......................... Flat Washer (1.0 OD x .75 ID x .08T)22 ............................................... 3708542 ......................... 5/8" Hole Plug23 ............................................... 3708612 ......................... Fuel Warning Decal24 ............................................... 3708867 ......................... Swell Latch25 ............................................... 3709372 ......................... 1/2" Hole Plug26 ............................................... 6309111 .......................... Decal - Up/Down27 ............................................... 6309039 ......................... Gage Pin Mounting28 ............................................... 6329098 ......................... Vac Door29 ............................................... 3707601 ......................... Proximity Switch Head30 a ............................................ 6329075 ......................... LH Traverse Proximity Switch Cord30 b ............................................ 6329076 ......................... RH Traverse Proximity Switch Cord

31 ............................................... 3707459 ......................... Proximity Switch Nut32 ............................................... 6329501 ......................... Cabinet Weldment33 ............................................... 6329504 ......................... Front Panel Weldment34 ............................................... 6329525 ......................... Traverse Base Assembly (see page 64)35 ............................................... 6329535 ......................... Mower Support Assembly (see page 78)36 ............................................... 6509035 ......................... Cross slide Mount37 ............................................... 6509389 ......................... Tooling Bar Shim38 ............................................... 6509465 ......................... Spin Drive Assembly (see page 80)39 ............................................... 6509510 ......................... Tooling Bar Weldment40 ............................................... 6509560 ......................... Proximity Switch Bracket Weldment RH

41 ............................................... 6509561 ......................... Proximity Switch Bracket Weldment LH42 ............................................... J992000 .......................... 1-8 Hex Jam Nut43 ............................................... A993201 ......................... Adjustable Leveling Bolt44 ............................................... 6509039 ......................... Right-Hand Access Panel45 ............................................... 6509040 ......................... Left-Hand Access Panel - Small46 ............................................... B250816 ......................... 1/4-20 x 1/2 Button Head Socket Cap Screw47 ............................................... 50382 ............................. Hinge48 ............................................... 3659083 ......................... Bumper49 ............................................... 3708458 ......................... Warning Decal - Sharp50 ............................................... B370816 ......................... 3/8-16 x 1/2 Button Head Socket Cap Screw

58

PARTS LIST 6329525 TRAVERSE BASE ASSEMBLY

59

PARTS LIST 6329525 TRAVERSE BASE ASSEMBLY


1 ................. B190611 ................ Socket Head Cap Screw 10-24 x 3/8 Long2 ................. B191211 ................ Socket Head Cap Screw 10-24 x 3/4 Long3 ................. B250616 ................ Button Head Socket Cap Screw 1/4-20 x 3/8 Long4 ................. B250811 ................ Socket Head Cap Screw 1/4-20 x 1/2 Long5 ................. B250818 ................ Pan Head Machine Screw 1/4-20 x 1/2 Long6 ................. B250819 ................ Button Head Socket Cap Screw 1/4-20 x 1/2 Long7 ................. B251211 ................ Socket Head Cap Screw 1/4-20 x 3/4 Long8 ................. B251411 ................ Socket Head Cap Screw 1/4-20 x 7/8 Long9 ................. B252011 ................ Socket Head Cap Screw 1/4-20 x 1 1/4 Long10 ............... B253211 ................ Socket Head Cap Screw 1/4-20 x 2 Long

11 ............... B256411 ................ Socket Head Cap Screw 1/4-20 x 4 Long12 ............... B310813 ................ Button Head Socket Cap Screw 5/16-18 x 1/2 Long13 ............... B311611 ................ Socket Head Cap Screw 5/16-18 x 1 Long14 ............... B503211 ................ Socket Head Cap Screw 1/2-13 x 2 Long15 ............... C250420 ................ Socket Head Set Screw Cup Point 1/4-20 x 1/4 Long16 ............... H184002 ................ 3/8 Diameter Roll Pin x 2 1/2 Long17 ............... J257000................. 1/4-20 Nylon Locknut Thin18 ............... J257100................. 1/4-20 Nylon Locknut19 ............... J627200................. 5/8-18 Nylon Locknut Thin20 ............... J757300................. 3/4-16 Nylon Locknut

21 ............... K191501 ................ No. 10 Washer22 ............... K250001 ................ 1/4 Flat Washer SAE23 ............... K251501 ................ 1/4 Split Lockwasher24 ............... K311501 ................ 5/16 Split Lockwasher25 ............... K501501 ................ 1/2 Split Lockwasher26 ............... R000376 ................ Square Key 1/8 x 3/4 Long27 ............... R000377 ................ Square Key 3/16 x 3/4 Long28 ............... 28192 .................... Traverse Pulley Support29 ............... 50309 .................... Traverse Pulley Shaft30 ............... 50354 .................... Drive Pulley (Cog)

31 ............... 55553 .................... Idler Pulley Assembly32 ............... 80335 .................... Destaco Clamp33 ............... 80354 .................... Cog Belt34 ............... 80355 .................... Thrust Washer (1 1/4OD x 3/4 ID)35 ............... 3708195 ................ External Retaining Ring36 ............... 3708419 ................ Wave Spring (.78 ID)37 ............... 3708436 ................ Wave Spring38 ............... 3708658 ................ Compression Spring39 ............... 3708884 ................ Spacer 5/8 OD x 9/32 ID x 3/8 Long40 ............... 3709044 ................ Linear Ball Bearing

PARTNUMBER

60

PARTS LIST (Continued) 6329525 TRAVERSE BASE ASSEMBLY

61

PARTS LIST (Continued) 6329525 TRAVERSE BASE ASSEMBLY


PARTNUMBER

41 ..................... 3709072 ................Compression Spring42 ..................... 3709331 ................External Retaining Ring43 ..................... 6059062 ................Traverse Motor Assembly44 ..................... 6309573 ................Finger & Body Assembly (see page 74)45 ..................... 6329032 ................Traverse Base46 ..................... 6329034 ................ 5/8 Shaft Coupler47 ..................... 6329035 ................Motor Extension Shaft48 ..................... 6329036 ................Pulley Mount Bracket49 ..................... 6329507 ................Prox Flag Bracket Weldment

50 ..................... 6329511 .................Shaft Support Block Assembly51 ..................... 6329526 ................Grinding Head Assembly (see page 70)52 ..................... 6329527 ................Carriage Assembly (see page 72)53 ..................... 6509020 ................Traverse Base Adjuster End Cap54 ..................... 6509021 ................Bellows Bracket Carriage Mount55 ..................... 6509025 ................Bellows Bracket End Mount56 ..................... 6509054 ................Plunger Pin Retainer57 ..................... 6509055 ................Belt Cover58 ..................... 6509063 ................Carrier Shaft59 ..................... 6509210 ................Belt Cover Gasket

60 ..................... 6509221 ................Traverse Base Fixed Bracket61 ..................... 6509238 ................Grinding Wheel Grip Knob62 ..................... 6509250 ................Bellows - Way cover63 ..................... 6509253 ................Carriage Dust Cover Bracket64 ..................... 6509484 ................Plunger Pin65 ..................... 6509565 ................Cross Slide Assembly (see page 68)

62

PARTS LIST 6509565 CROSS SLIDE ASSEMBLY

63

PARTS LIST 6509565 CROSS SLIDE ASSEMBLY

1 ...................................... C311220 ................Socket Set Screw CPPT 5/16-18 x 3/4 Long2 ...................................... J371000.................3/8-16 Hex Nut3 ...................................... J377000.................3/8-16 Hex Jam Nylon Locknut4 ...................................... K371501 ................3/8 Split Lockwasher5 ...................................... 3579109 ................3/16 Dia. Nylon Plug6 ...................................... 3708148 ................Handwheel 4.5 Dia. .38 Bore7 ...................................... 3709062 ................Bell V Washer .75 O. D. x .035 T8 ...................................... 3709304 ................Thrust Washer9 ...................................... 3708705 ................Adjustable Handle 5/16-18 Female - Orange10 .................................... 6509390 ................Adjusting ACME Shaft

11 .................................... 6009035 ................Locking Stud Shaft12 .................................... 6009082 ................Cross Slide Support13 .................................... 6009095 ................Slide Shaft14 .................................... 6509011.................Cross Slide15 .................................... 6509015 ................Cross Slide Horizontal support16 .................................... C310820 ................Socket Set Screw 5/16-18 x 5/8 Long17 .................................... 3708665 ................Flat Washer18 .................................... 6309115.................Grey Decal19 .................................... 6309114.................Orange Decal20 .................................... 6309113.................5/16-18 Locking Stud

21 .................................... 3708706 ................Adjustable Handle 5/16-18 Female - Grey22 .................................... 3969065 ................Spacer .406 ID x .75 OD x 1.0 Long23 .................................... B372011 ................Socket Head Cap Screw 3/8-16 x 1 1/4 Long24 .................................... H371602 ................Rollpin 3/8 Dia. x 1 Long25 .................................... K371501 ................3/8 Split Lockwasher26 .................................... 6509010 ................Traverse Base Adjuster Bracket

DIAGRAMNUMBER

PARTNUMBER

DESCRIPTION

64

PARTS LIST 6329526 GRINDING HEAD ASSEMBLY

65

PARTS LIST 6329526 GRINDING HEAD ASSEMBLY

1 ....................... B251411 .................... Socket Head Cap Screw 1/4-20 x 7/8 Long2 ....................... B371611 .................... Socket Head Cap Screw 3/8-16 x 1 Long3 ....................... C250627 .................... Socket Set Screw Cup Pt 1/4-20 x 3/8 Long - Lock Patch4 ....................... K250001 .................... 1/4 Flat Washer SAE5 ....................... K251501 .................... 1/4 Split Lockwasher6 ....................... K371501 .................... 3/8 Split Lockwasher7 ....................... R000376 .................... Square Key 1/8 x 3/4 Long8 ....................... 3707690 .................... 1 HP 120 VAC Motor9 ....................... 3708193 .................... Conical Washer 1.36 OD x .88 OD10 ..................... 3708194 .................... Internal Retaining Ring

11 ..................... 3708204 .................... Double Row Ball Bearing12 ..................... 3708202 .................... Poly-V Belt13 ..................... 6329089 .................... Bearing Sleeve14 ..................... 6329041 .................... Motor Mount Plate15 ..................... 6329042 .................... Pulley - Poly V 1.80 Diameter16 ..................... 6329100 .................... Pulley - Poly V 1.44 Diameter17 ..................... 6509018 .................... Grinding Head Housing18 ..................... J567200 ..................... 9/16-18 Locknut Nylon Insert Jam19 ..................... 6329523 .................... Grinding Head Spindle Assembly20 ..................... 6509237 .................... Grinding Wheel knob

21 ......................................................... Grinding Wheel (see page 93)22 ..................... 3708870 .................... Retaining Ring - External .50 Shaft Heavy Duty

DIAGRAMNUMBER


66

6329527 CARRIAGE ASSEMBLYPARTS LIST

67

PARTS LIST 6329527 CARRIAGE ASSEMBLY

DESCRIPTION

1 ...................... B250616 ........................ Button Head Cap Screw 1/4-20 x 3/8 Long2 ...................... B252016 ........................ Button Head Cap Screw 1/4-20 x 1 1/4 Long3 ...................... B253216 ........................ Button Head Cap Screw 1/4-20 x 2 Long4 ...................... K251501 ........................ 1/4 Split Lockwasher5 ...................... J252000 ........................ 1/4-20 Jam Nut6 ...................... J887300 ........................ 7/8-14 Nylon Jam Locknut7 ...................... R602031 ........................ #4 x .31 Drive Screw8 ...................... 28187 ............................ Traverse Clamp Block9 ...................... 28188 ............................ Traverse Clamp Spacer Plate10 .................... 28189 ............................ Clamp Support Block

11 .................... 50310 ............................ Belt Clamp Tip12 .................... 3708105 ........................ Compression Spring13 .................... 3708184 ........................ Retaining Ring14 .................... 3708186 ........................ Ball Bearing15 .................... 3708208 ........................ Shoulder Bolt .250 Dia. x .387 Long16 .................... 3708462 ........................ Decal - RPM, Symbol17 .................... 6329040 ........................ Traverse Clamp18 .................... 6329058 ........................ Carriage Base19 .................... 6509023 ........................ Grinder Head Pivot Shaft20 .................... 6509251 ........................ Swing Door Latch

21 .................... 6509584 ........................ Swing Door Weldment

DIAGRAMNUMBER

PARTNUMBER

68

PARTS LIST 6309573 FINGER AND BODY ASSEMBLY

69

PARTS LIST 6309573 FINGER AND BODY ASSEMBLY


PARTNUMBER

1 ...................................... B190631 ................Socket Head Cap Screw 10-32 x 3/8 Long2 ...................................... B190634 ................Button Head Socket Cap Screw 10-32 x 3/8 Long3 ...................................... B251011 ................Socket Head Cap Screw 1/4-20 x 5/8 Long4 ...................................... B254811 ................Socket Head Cap Screw 1/4-20 x3 Long5 ...................................... C190460 ................Socket Set Screw 10-24 x 1/46 ...................................... C190467 ................Socket Set Screw - Nylok Cup 10-32 x .25 Long7 ...................................... C190860 ................Socket Set Screw - CP-PT 10-32 x 1/2 Long8 ...................................... C190860 ................Socket Set Screw - 10-32 x 1/2 Long9 ...................................... H122002 ................ Roll Pin 1/8 Dia. x 1 1/4 Long10 .................................... H250813 ................ Dowel Pin 1/4 Dia. x .5 Long

11 .................................... H253202 ................ Drive Lock Pin 1/4 x 1.75 Long12 .................................... J191100 ................. 10/32 Hex Nut13 .................................... J377200................. 3/8-24 Jam Nylok Locknut14 .................................... K191501 ................ No. 10 Lock Washer15 .................................... R000351 ................ Square Key .093 x .75 Long16 .................................... 3579284 ................ 1/8 Dia. Nylon Plug17 .................................... 3709304 ................ Thrust Washer18 .................................... 3708107 ................ Compression Spring19 .................................... 3708175 ................ Compression Spring20 .................................... 3708199 ................ 3/8-16 Dia. Split Shaft Collar

21 .................................... 3709472 ................ Straight Grease Fitting22 .................................... 6509432 ................ Relief Finger23 .................................... 6509004 ................ Reel Finger Slide24 .................................... 6509357 ................ Reel Finger Positioner25 .................................... 6509007 ................ Index Stop Pin26 .................................... 6509008 ................ Index Sensor Block27 .................................... 6509009 ................ Slide Washer28 .................................... 6509058 ................ Eccentric Index Pin29 .................................... 6509060 ................ Gib Stop Plate30 .................................... 6509215 ................ Adjustable Index Lever

31 .................................... 6509229 ................ Locking Index Finger Pin32 .................................... 3579284 ................ 1/8" Diameter Nylon Plug33 .................................... 6509239 ................ Anti Rotation Plate34 .................................... 6509258 ................ Dovetail Gib35 .................................... 6509501 ................ Tee Knob Assembly36 .................................... 6509547 ................ Knob Assembly37 .................................... 6329592 ................ Index Finger Assembly - High38 .................................... 6329593 ................ Index Lock Handle Weldment39 .................................... 6509592 ................ Index Finger Positioner Weldment40 .................................... H120402 ................ 1/8" Diameter x 1/4" Long Pin Roll

41 .................................... 6509358 ................ Stop Plate42 .................................... 6509356 ................ Reel Positioner Adjuster

70

PARTS LIST 6509574 STEPPER & MOUNTING ASSEMBLY

71

DESCRIPTION

Button Head Cap Screw #10-24 x 3/8 LongSocket Head Cap Screw 1/4-20 x 1 1/4 LongSocket Set Screw 1/4-20 x 1/21/4-20 x 5/8" Set ScrewBase Cover Plate

3/8-24 Nylok Jam LocknutInfeed Stepper Assy.Ball BearingRetaining RingHose Clamp 2.25 Dia.

Thrust WasherHex Pivot PinTrunion BlockBellows, 1.88 I. D.Flex Coupling

Spiral Retaining RingSocket Head Cap Screw 10-24 x 1/2 LongNo. 10 Lock WasherStepper Infeed Motor

PART NUMBER

B190613B252011C250825C2510206509381

J3772006509384370818737081893708192

37093046509048650905165090563708629

3708424B190811K1915016509470

DIAGRAMNO.

12345

6789

10

1112131415

16171819

PARTS LIST (Continued) 6509574 STEPPER & MOUNTING ASSEMBLY

72

6329535 MOWER SUPPORT ASSEMBLYPARTS LIST

73

PARTS LIST 6329535 MOWER SUPPORT ASSEMBLY

DESCRIPTIONDIAGRAMNUMBER

PARTNUMBER

1 .......................B190614 ..................... Pan Head Machine Screw 10-24 x 3/8 Long2 .......................K191501 ..................... No.10 Lockwasher3 .......................6009577 ..................... Knob Assembly4 .......................3708364 ..................... Quick Release Pin .31 Dia.5 .......................3708158 ..................... Shoulder Bolt .375 Dia. x .50 Long6 .......................3708366 ..................... 6" type B Lanyard7 .......................6509128 ..................... Horizontal Scale Decal RH8 .......................6329072 ..................... Vertical Scale Decal9 .......................6509507 ..................... Bar Mounting Weldment Bracket10 .....................6509517 ..................... L.H. Front Roller Horiz. Weldment Bracket

11 .....................6329587 ..................... L. H. Roller Clamp Weldment Bracket12 .....................6509559 ..................... Knob Assembly13 .....................6509564 ..................... L.H. Front Roller Clamp Weldment14 .....................6509588 ..................... Knob Assembly15 .....................6509515 ..................... R.H. Front Roller Horiz. Welment Bracket16 .....................6329586 ..................... R.H. Roller Clamp Weldment Bracket17 .....................3709304 ..................... Thrust Washer18 .....................B311211 ..................... Socket Head Cap Screw 5/16-18 x 3/4 Long19 .....................K311501 ..................... 5/16 Lockwasher20 .....................70512 ......................... Rear Roller Support Bracket Weldment

21 .....................C500861 .................... 1/2-20 x 1/2 Flat Pt Socket Head Set Screw22 .....................6509576 ..................... R.H. Front Roller Clamp Weldment23 .....................3708881 ..................... Rear Clamp24 .....................6329514 ..................... Rear Clamp Base Weldment25 .....................6509304 ..................... Horizontal Scale Decal LH

74

PARTS LIST 6509465 SPIN DRIVE ASSEMBLY

75

6509465 SPIN DRIVE ASSEMBLYPARTS LIST (Continued)

DIAGRAMNUMBER

1 ......................................... 3708391 .......................... Reducer: 10:1 Ratio2 ...................................... 6329039 .......................... Motor, DC .20 HP TEFC3 ...................................... B251411 .......................... Socket Head Cap Screw 1/4-20 x 7/8 Long4 ...................................... 3709586 .......................... Flange Coupler .505 ...................................... 3709585 ......................... Sleeve Coupler6 ...................................... 3709584 .......................... Flange Coupler 5/87 ...................................... 6009217 .......................... Drive Coupling Adapter9 ...................................... 09394 .............................. Tee Knob Assembly10 .................................... 3709073 .......................... Retaining Ring

11 .................................... 6009051 .......................... Drive Adapter 1/2 Square12 .................................... 6009052 .......................... Adapter13 .................................... R000376 .......................... Square Key 1/8 x .75 Long14 .................................... 6009078 .......................... Gearbox Slide Bracket15 .................................... 3707279 .......................... Strain Relief Wire16 .................................... 6009079 .......................... Gearbox Clamp Bracket17 .................................... 6009580 .......................... Gearbox Slide Weldment Bracket18 .................................... 3708262 .......................... T-Knob - 5/16-1819 .................................... 6009045 .......................... Linkage Spacer 2.29 Long20 .................................... 6009046 .......................... Linkage Spacer R.H. Thread

21 .................................... 3709062 .......................... Belleville .75 Dia. x .35 T22 .................................... 3709809 .......................... Shoulder Bolt .375 Dia. x .375 Long23 .................................... 3709705 .......................... Nylon Ball 5/32 Dia.24 .................................... C310420 .......................... Socket Set Screw 5/16-18 x 1/425 .................................... 6009047 .......................... Linkage spacer L. H. Thread26 .................................... 6009048 .......................... Linkage Spacer 2.5 Long27 .................................... B375611 .......................... Socket Head Cap Screw28 .................................... J377100........................... Nylok Hex Locknut 3/8-1629 .................................... 6509519 .......................... Support Bracket Weldment30 .................................... 3708148 .......................... Handwheel 4.5 Dia.

31 .................................... 3709370 .......................... Handle32 .................................... J252000........................... Hex Jam Nut 1/4-2033 .................................... J257000........................... 1/4-20 Nylok Locknut34 .................................... C310620 .......................... Socket Set Screw 5/16-18 x 3/8 Long35 .................................... 6009076 .......................... Double Thread Rod36 .................................... 6009555 .......................... Knob Assembly37 .................................... 6509114........................... Spin Drive Plate Lock38 .................................... 6009067 .......................... Geared Linkage39 .................................... B255011 .......................... Socket Head Cap Screw 1/4-20 x 3 1/8 Long40 .................................... R000377 .......................... Square Key 3/16 x .75 Long

41 .................................... 3707623 .......................... DC Motor Brush

DESCRIPTIONPARTNUMBER

76

PARTS LIST 6329529 MISCELLANEOUS PARTS

77

PARTS LIST (Continued) 6329529 MISCELLANEOUS PARTS

DESCRIPTIONPARTNUMBER

DIAGRAMNUMBER

1 ............................ 3700088 ........................... Grinding Wheel 3.5" Dia. x .38 w2 ............................ 3700086 ........................... Grinding Wheel 3.5" Dia. x 1" Wide3 ............................ 3700087 ........................... Grinding Wheel 5" Dia. x .3/8" Side4 ............................ 3700089*.......................... Grinding Wheel 5" Dia. x 1" Wide5 ............................ R000863 .......................... 5/16 Allen Key6 ............................ K251501 .......................... 1/4 Lockwasher7 ............................ 80396 ............................... T-Knob Assembly8 ............................ 3529069 ........................... Space9 ............................ 6329517 ........................... Alignment Extension Weldment10 .......................... 6329518 ........................... Gage Bar Weldment

11 .......................... 6509349 ........................... Retaining Plate12 .......................... 6509418 ........................... Plate-Pivot13 .......................... 6509567 ........................... Knob Assembly14 .......................... 3708894 ........................... T-Knob Assembly15 .......................... B120611 ........................... Socket Head Cap Screw 5-40 x .38 Long16 .......................... B161011 ........................... Socket Head Cap Screw 8-32 x 5/8 Long17 .......................... J161000 ........................... 8-32 Hex Nut18 .......................... K121501 .......................... No. 5 Split Lockwasher19 .......................... K161501 .......................... No. 8 Lockwasher20 .......................... 6509359 ........................... Digital Gage.............................. 3707712 ........................... Battery Cover - Digital Gage

21 .......................... 6509412 ........................... Base Weldment Indicator22 .......................... H060302 .......................... 1/16 x 3/16L Roll Pin23 .......................... B190811 ........................... Socket Head Cap Screw 10-24 x 1/224 .......................... J197100 ........................... 10-24 Nylok Locknut25 .......................... 3708384 ........................... Magnet26 .......................... 6509474 ........................... Reel Positioner Gage27 .......................... 6509557 ........................... Drip Pan Weldment28 .......................... 3707603 ........................... Blue Lens29 .......................... 3707465 ........................... Flasher bulb

* 3700089- Grinding wheel is installed on grinding head when shipped. The other wheels are located in the carton assembly.

78

PARTS LIST 6529510 CONTROL PANEL ASSEMBLY

79

PARTS LIST 6529510 CONTROL PANEL ASSEMBLY

DIAGRAMNUMBER


1 ...................................... B190834 ............... Button Head Cap Screw 10-32 x 1/2 Long2 ...................................... B250816 ............... Button Head Cap Screw 1/4-20 x 1/2 Long3 ...................................... D250800 ............... Thread Cutting Screw 1/4-20 x 1/2 Long4 ...................................... J257000................ 1/4-20 Nylon Jam Locknut5 ...................................... R000536 ............... 1/4 Lock Washer6 ...................................... 3707342 ............... Yellow Emergency Stop Ring7 ...................................... 3707367 ............... Rocker Switch DPST8 ...................................... 3707399 ............... 3-Amp Circuit Breaker9 ...................................... 3707442 ............... 2-Amp Circuit Breaker10 .................................... 3707443 ............... 4-Amp Circuit Breaker

11 .................................... 3707446 ............... Potentiometer Knob12 .................................... 3707547 ............... 15-Amp Circuit Breaker13 .................................... 3707564 ............... Green Start Pushbutton14 .................................... 3707565 ............... Normaly Open Contact Block15 .................................... 3707566 ............... Switch Mounting Latch16 .................................... 3707567 ............... Push/Pull Red Emergency Stop Button17 .................................... 3707568 ............... Normaly Closed Contact Block18 .................................... 3707725 ............... Touch Screen19 .................................... 6329070 ............... Hinge20 .................................... 6329509 ............... Control Box Weldment

21 .................................... 6529046 ............... Control Panel Decal22 .................................... 6529511................ Electrical Panel Sub-Assembly23 .................................... 6529545 ............... Control Panel Top Weldment24 .................................... 6509446 ............... Potentiometer Assembly - Spin Speed25 .................................... 6509447 ............... Potentiometer Assembly - Relief Torque26 .................................... 6059445 ............... Potentiometer Assembly - Traverse Speed27 .................................... 3707624 ............... 2 Conductor Terminal Block - Ground28 .................................... 3707626 ............... Terminal Block Jumper29 .................................... 3707628 ............... 2 Conductor Terminal Block - Grey

Cords Not Shown

........................................ 6329078 ............... Main Power Cord

........................................ 6529036 ............... Light Receptacle

........................................ 6529037 ............... Dust Collector Receptacle

........................................ 6529039 ............... Flasher Cord

........................................ 6329124 ............... Rear Sliding Door Safety Swich Cord

........................................ 3707224 ............... Cable Tie Mount

........................................ 3707225 ............... Cable Tie 6.5 Long x .18 Wide

........................................ 3707255 ............... Cable Tie 4.0 Long x .10 Wide

80

PARTS LIST 6529511 CONTROL PANEL SUB-ASSEMBLY

81

PARTS LIST 6529511 CONTROL PANEL SUB-ASSEMBLY

DIAGRAMNUMBER


1 ...................................... D130608 ................Pan Head Self-Tapping Screw #6 x 3/8 Long2 ...................................... D160666 ................Pan Head Self-Tapping Screw #8 x 3/8 Long3 ...................................... D161266 ................Pan Head Self-Tapping Screw #8 x 3/4 Long4 ...................................... R000480 ................#8 Lockwasher5 ...................................... 55223 ....................Terminal Strip Decal6 ...................................... 80259 ....................20-Amp Main Circuit Breaker7 ...................................... 3707073 ................8-Pin socket8 ...................................... 3707163 ................Primary Ground Decal9 ...................................... 3707164 ................Primary Ground Lug10 .................................... 3707186 ................24VDC Contactor

11 .................................... 3707321 ................Traverse Control Board12 .................................... 3707322 ................Power Supply 40 Watt - 24VDC13 .................................... 3707328 ................Door Safety Switch Monitor14 .................................... 3707378 ................14" Din Rail15 .................................... 3707654 ................Power Line Filter16 .................................... 3707447 ................Relay - DPDT 120VAC Coil17 .................................... 3707524 ................Spin/Relief Control Board18 .................................... 3707556 ................Magnetic Starter19 .................................... 3707688 ................High/Low Voltage Sensor Relay20 .................................... 3707569 ................Aromat PLC

21 .................................... 3707571 ................Output Block with Relays22 .................................... 3707577 ................Stepper Drive - 2-Amp23 .................................... 3707593 ................6Pin Terminal Strip (for Stepper Drive)24 .................................... 3707606 ................9" Din Rail25 .................................... 3707624 ................2-Conductor Terminal Block - Ground26 .................................... 3707625 ................Screwless Terminal Bock End Stop27 .................................... 3707626 ................Terminal Block Jumper28 .................................... 3707627 ................Terminal Block End Plate29 .................................... 3707628 ................2-Conductor Terminal Block - Grey30 .................................... 3707629 ................2-Conductor Terminal Block - Blue

31 .................................... 3708920 ................Low Voltage Warning Decal32 .................................... 6529031 ................Electrical Sub Panel33 .................................... 3707574 ................5-Amp Relay Block

........................................ 3707631 ................Terminal Block Marker - 1-10

........................................ 3707632 ................Terminal Block Marker - 11-20

........................................ 3707656 ................Ground Wire Assembly W99

........................................ 6509449 ................PLC to Output Block Cable

........................................ 6529047 ................PLC to Touchscreen Cable

........................................ 6529030 ................PLC to Inputs Cable

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WIRING DIAGRAM 6324548 - AC

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WIRING DIAGRAM 6324548 - AC

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WIRING DIAGRAM 6324548 - DC

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WIRING DIAGRAM 6324548 - DC

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WIRING SCHEMATIC

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WIRING SCHEMATIC

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WIRING SCHEMATIC

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WIRING SCHEMATIC

ASSEMBLY and SERVICE MANUAL€¦ · 7 ASSEMBLY INSTRUCTIONS (Continued) Remove the carton and...

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Transcript of ASSEMBLY and SERVICE MANUAL€¦ · 7 ASSEMBLY INSTRUCTIONS (Continued) Remove the carton and...