ASSEMBLY and SERVICE MANUAL - irp-cdn.multiscreensite.com · 1 accu-pro 630 spin/relief grinder assembly and service manual 6307954 (3-03)

1

ACCU-Pro 630SPIN/RELIEF

GRINDER

ASSEMBLYand

SERVICEMANUAL

6307954 (3-03)

2

13. MAINTAIN GRINDER WITH CARE. Followinstructions in Service Manual for lubricationand preventive maintenance.

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

15. REDUCE THE RISK OF UNINTENTIONALSTARTING. Make sure the switch if OFF beforeplugging in the Grinder.

16. USE RECOMMENDED ACCESSORIES.Consult the manual for recommended accessoriesUsing improper accessories may cause risk ofpersonal injury.

17. CHECK DAMAGED PARTS. A guard or other partthat 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 as

well 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 illustration in ServiceManual for the proper location and part numbersof safety decals.

20. DO NOT OPERATE THE GRINDER WHEN UNDER THE INFLUENCE OF DRUGS, ALCOHOL OR MEDICATION.

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 area welllit.

5. KEEP ALL VISITORS AWAY. All visitorsshould be kept a safe distance from work area.

6. MAKE WORK AREA CHILD-PROOF withpadlocks or master switches.

7. DON'T FORCE THE GRINDER. It will do thejob better and safer if used as specifiedin this manual.

8. USE THE RIGHT TOOL. Don't force theGrinder or an attachment to do a job for whichit was not designed.

9. WEAR PROPER APPAREL. Wear no looseclothing, gloves, neckties, or jewelry whichmay get caught in moving parts. Nonslip footwear is recommended. Wear protective haircovering to contain long hair.

10. ALWAYS USE SAFETY GLASSES.

11. SECURE YOUR WORK. Make certain thatthe cutting unit is securely fastened with theclamps provided before operating.

12. DON'T OVERREACH. Keep proper footingand balance at all times.

Safety Awareness Symbols are inserted into thismanual to alert you to possible Safety Hazards .Whenever you see these symbols, follow theirinstructions.

The Warning Symbol identifies spe-cial instructions or procedures which, ifnot correctly followed, could result inpersonal injury.

The Caution Symbol identifies specialinstructions or procedures which, if notstrictly observed, could result in damageto or destruction of equipment.

3

IMPROPER USE OF GRINDING WHEEL MAYCAUSE BREAKAGE AND SERIOUS INJURY

Grinding is a safe operation if the few basic rules listed below are fol-lowed. These rules are based on materiel contained in the ANSI B7.1 SafetyCode for "Use, Care and Protection of Abrasive Wheels". For your safety,we suggest you benefit from the experience of others and carefully followthese rules.

DO DON'T

SAFETY INSTRUCTIONS

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. Pro-vide adequate ventilation to eliminate dust, or maintain dust level below theThreshold Limit Value for nuisance dust as classified by OSHA.

1. DO always HANDLE AND STOREwheels in a CAREFUL manner.

2. DO VISUALLY INSPECT all wheelsbefore mounting for possible damage.

3. DO CHECK MACHINE SPEED againstthe established maximum safe operating

speed.

4. DO CHECK MOUNTING FLANGES forequal and correct diameter.

5. DO USE MOUNTING BLOTTERS whensupplied with wheels.

6. DO be sure WORK REST is properlyadjusted.

7. DO always USE A SAFETY GUARDCOVERING at least one-half of thegrinding wheel.

8. DO allow NEWLY MOUNTED WHEELS to run at operating speed, with guardin place, for at least one minute beforegrinding.

9. DO always WEAR SAFETY GLASSESor some type of eye protection whengrinding.

1. DON'T use a cracked wheel or one thathas become damaged.

2. DON'T FORCE a wheel onto the machineOR ALTER the size of the mountinghole - if wheel 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 isstarted.

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

4

SPECIFICATIONS

Electrical Requirements .......................................................115V 50/60 Hz, 15 amp circuitNet Weight ...........................................................................1240 lbs (560 kg)Shipping Weight ...................................................................1400 lbs (636 kg)Maximum Grinding Length ....................................................34 inches (86cm)

Safety Warnings ................................................................................................... Page 2- 4Service Data ........................................................................................................ Page 5Assembly Instructions ........................................................................................... Page 6 -11Maintenance Instructions ...................................................................................... Page 12 -15Adjustments ......................................................................................................... Page 16 -23Machine Service .................................................................................................. Page 24 -27Electrical Troubleshooting Index ........................................................................... Page 28Electrical Troubleshooting .................................................................................... Page 29 -45Mechanical Troubleshooting ................................................................................. Page 46 -47Parts List ............................................................................................................. Page 48 -75Electrical Diagrams...................................... Page 76 -81

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 the warranty, you MUST use original equipment manufacturers replacement partsand 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. This dustcan cause personal injury as well as damage to the grinder. Machine is forindoor use only. Do not use a power washer to clean the machine.

CONTENTS

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

SERVICE DATA

SKILL AND TRAINING REQUIRED FOR SERVICING

This Service Manual is designed for technicians who have the necessary mechanical and electrical knowl-edge and skills to reliably test and repair the ACCU-PRO Spin/Relief Grinder. For those without the back-ground, 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 attempt anyinternal troubleshooting, adjustments, or parts replacement.

If you have questions not answered in this manual, please call your distributor. They will contact the manu-facturer if necessary.

Throughout this manual we refer to torquerequirements as "firmly tighten" or the like. For morespecific torque values, refer to the informationbelow.

Bolts Going Into a Nut, or Into a Thread Hole inSteel.Refer 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 (0.125kg - m)No. 8 screws: 20 in. - lbs (0.23 kg - m)No. 10 screws: 32 in. - lbs (0.37 kg - m)

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

Remove shipping straps from traversecarriage. Remove window protective sheets.

ASSEMBLY INSTRUCTIONS

Remove the sides, front, and back of the crate.Remove the plastic bag, shrink wrap and bubblewrap around boom assembly. Remove the metalclips that secure the grinder to the crate base.With a fork lift, raise the grinder from the woodbase and set it in its final position. See FIG. 1 and2.

THE UNIT WEIGHS1240 LBS. (560 kg). TOLIFT, USE POWEREQUIPMENT.

POSITION BASE

The ACCU-Pro Spin/Relief Grinder will require anoperating area of about 150" W x 108" D x 87" H (381x 274 x 221 cm). The mower reel will be lifted fromthe front of the machine. The machine operator willoperate the unit from this same position. Position thebase to allow sufficient operating room in front of themachine. See FIG. 1 and 2.

The base should be placed on a relatively level con-crete floor, with ample ceiling height to allow for theinstallation of the unit. Do not place the unit acrosstwo concrete slab seams or across a large crack.

FIG.1

FIG. 2

7

ASSEMBLY INSTRUCTIONS (Continued)

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

8


LEVEL BASE

Each leveling foot has been factory pre-adjusted soit protrudes from the base 1 3/4" (57 mm). See FIG.3. Place level on the top of the table and check thelevelness of the unit from side to side. Adjust theleveling feet as necessary to bring to level. See FIG.4.

Place a level across the table from front to rear.Adjust the leveling feet on the end of the machineas necessary to level. SeeFIG. 5

When both front to back and side to side levelingprocedures have been completed, thread the hexjam nuts up against the nut that is welded to thebottom until they lock into place. Be careful not tomove 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 firmlytightened.

FIG. 5

FIG. 4

FIG. 3

9

STORAGE PROCEDURE

It is important to follow the procedures below when placing your grinding in storage for an ex-tended 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 washer to clean thismachine!) See Maintenance section for instructions on cleaning polycarbonate.

-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 and drive shaft (see Lubrication section of manual) Remove grinding wheel and spray the movable parts of the finger system Cross 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 lubri-cant. (See Lubrication section for more details.)

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

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

-Check for damaged or missing parts.

10


FIG. 7

APPLY POWER

BEFORE YOU APPLY POWER TO THEGRINDER, REFER TO THE "IMPORTANTGROUNDING INSTRUCTIONS" ON PAGE 9.

115 Volt Model Only. Plug the control box power cord into astandard 115V AC 15-amp grounded receptacle. See FIG. 7.

220 Volt Model Only. For 220 Volt Applications order PartNo. 6300951, which includes a prewired 2 KVA 220 V stepdown to 115V 50-60 Hz transformer. See details on Page 11.

IT IS RECOMMENDED THAT THIS ACCU-PRO SPIN/RELIEF GRINDER HAS ITS OWNPERMANENT POWER CONNECTION FROMTHE POWER DISTRIBUTION PANEL, WITHNO OTHER MAJOR POWER DRAWEQUIPMENT ON THE SAME LINE.

IT IS REQUIRED THAT THE POWERDELIVERED TO THIS GRINDER IS 115 VAC -15 AMPS. THE TOLERANCE ON THISPOWER REQUIREMENT IS +/- 5%.THEREFORE THE MINIMUM VOLTAGEREQUIREMENT IS 109VAC WITH 15 AMPS.VOLTAGE MUST BE CHECKED WITH ALLEQUIPMENT UNDER LOAD (OPERATING)ON THE 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 correct before proceeding further withthe grinder.

PROPER GROUNDING OF THERECEPTACLE GROUND IN YOUR BUILD-ING MUST BE VERIFIED. IMPROPERGROUNDING IN YOUR BUILDING MAYCAUSE THE GRINDER TO MALFUNCTION.

FOR 15 AMP RATED LARGE MACHINESBelow is a list of required wire size in your building.

For 0 to 30 Feet from panel to receptacle = Use 14 Ga. Wire.For 30 to 50 Feet from panel to receptacle = Use 12 Ga. Wire.For 50 to 80 Feet from panel to receptacle = Use 10 Ga. Wire.For 80 to 140 Feet from panel to receptacle = Use 8 Ga. Wire.

For 0 to 9 Meters from panel to receptacle = Use 2.5mm Wire.For 9 to 15 Meters from panel to receptacle = Use 4.0mm Wire.For 15 to 24 Meters from panel to receptacle = Use 6.0mm Wire.For 24 to 42 Meters from panel to receptacle = Use 10.0mm Wire.

11

FOR 220 V 50 or 60Hz applications Product No.6300951 should be ordered.

6300951 includes a 2 KVA 220V, step down to115 V 50-60 Hz transformer should be ordered.

The wiring diagram is shown in FIG. 8.

The power cord has no connector. A connectorwhich is appropriate for your locality and 220 volt,8 amp application should be installed.


FIG. 8

IMPORTANT GROUNDING INSTRUCTIONS

In case of a malfunction of breakdown, grounding reduces the risk of electrical shock by providing a pathof least resistance for electrical current.

This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug. Theplug must be plugged into a matching outlet that is properly installed and grounded according to all localor other appropriate electrical codes and ordinances.

Before plugging in the Grinder, make sure it will be connected to a supply circuit protected by a properly-sized circuit breaker or fuse.

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 FORYOUR MACHINE. AN IMPROPER CONNECTION CAN CAUSE ADANGEROUS ELECTRICAL SHOCK. IF YOU ARE UNSURE OFTHE PROPER ELECTRICAL GROUNDING PROCEDURE,CONTACT A QUALIFIED ELECTRICIAN.

Use only a qualified electrician tocomplete the installation.

12

PERIODIC MAINTENANCE

DAILY MAINTENANCE IS SPECIFIED ONPAGE 4 OF THE OPERATOR'S MANUAL,AND IS TO BE PERFORMED BY THEOPERATOR. LISTED BELOW AREPERIODIC MAINTENANCE ITEMSTO BE PERFORMED BY YOURCOMPANY'S MAINTENANCE DEPARTMENT:

1. Clean the internal bag and cloth filter in the vacuumsystem weekly or more often depending on thenumber of reels ground. (Vacuum system is optionalequipment).

2. Use the grease fitting provided to grease the dovetail with high quality lithium grease monthly. Wipeoff excess grease. See FIG. 7.

3. Wipe and re-oil with spray lubricant, the grindingwheel diameter adjusting lead screw every threemonths. Wipe off all excess lubricant. See FIG. 7.

4 Check the gib adjustment on the Grinding wheeldiameter adjustment every 3 months. See FIG. 7.

5. Inspect the Poly-V belt for cracking and adjust thebelt tension per procedure called out in theadjustment section every three months.

6. Wipe and relube with never-seez, the vertical andhorizontal alignment shafts and lead screws, everysix months. See FIG. 8.

7. Lift the bellows and wipe off the traverse driveshaftand the bearing rails monthly. When a squeakingnoise is coming from the actuator bearings, followthe lubrication procedure for actuator and linearbearings. Generally, this will be every six months toa year.

FIG. 7

FIG. 8

13

LUBRICATION

STEP 1--Thoroughly clean all three shafts.

STEP 2--Flood spray all three shafts with a spray lubricant (do not use ateflon based lubricant) until the lubricant is dripping off the shafts. See FIG.10 Then run the carriage back and forth through its range of travel. This willcarry the lubricant into the actuator and bearings.NOTE: Because of the flood of lubricant you may find that the actuatorslips and traversing is erratic or stalls. This is not a problem as it will becorrected in the subsequent steps.

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

If the unit will be shut down for an extended period of time, more thanfour weeks, then the shafts and other appropriate parts of the unit shouldbe flooded with lubricant and that lubricant left in place until the unit isbrought back into service. When the unit is brought back into service the fulllubrication procedure as stated above should be repeated.

LUBRICATION OF ACTUATOR AND LINEAR BEARINGS

FIG. 10

14

MAINTENANCE (Continued)

CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE WINDOWSCleaning Instructions

DO NOT USE GASOLINEAdherence to regular and proper cleaningprocedures is recommended to preserveappearance and performance.

Washing to Minimize ScratchingWash polycarbonate windows with a mild, liquid dish washing detergent and lukewarm water, using a clean,soft sponge or a soft cloth. Rinse well with clean water. Dry thoroughly with a moist cellulose sponge to preventwater spots. Do not scrub or use brushes on these windows. Also do not use butyl cellosolve in direct sunlight.Fresh paint splashes and grease can be removed easily before drying by rubbing lightly with a food gradeVM&P naptha or isopropyl alcohol. Afterward, a warm final wash should be made, using mild, liquid dishwashing 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 such products thattend to polish and fill scratches are Johnson Paste Wax, Novus Plastic Polish #1 and #2, and Mirror Glazeplastic polish (M. G. M10). It is suggested that a test be made on a corner of the polycarbonate window with theproduct selected following the polish manufacturer's instructions.

Some Important " DON'TS"

tt DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows.

tt NEVER scrape polycarbonate windows with squeegees, razor blades or other sharp instruments.

t t Benzene, gasoline, acetone or carbon tetrachloride should NEVER be used on polycarbonate windows

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

Graffiti Removal

t t Butyl cellosolve, (for removal of paints, marking pen inks, lipstick, etc.)

t t The use of masking tape adhesive tape or lint removal tools works well for lifting off old weathered paints.

t t To remove labels, stickers, etc., the use of kerosene, VM&P naptha or petroleumspirits is generally effective. When the solvent will not penetrate sticker material, apply

heat (hair dryer) to soften the adhesive and promote removal.GASOLINE SHOULD NOT BE USED!

15

MAINTENANCE (Continued)

DIGITAL GAGE

Importantt t Do not mark the scale unit with and electric engraver or

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

remove the battery and store it properly. Otherwise, leak-age, if any, from the battery may damage the unit.

Description of Parts1. Beam 2. Main Scale3. Battery compartment 4. Outp 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, result-ing 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 and area you wish toset as your origin. Turn the power on. Hold the ORIGINswitch down for more than one second. The "0.00" dis-play 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 teh ZERO/ABSswitch. INC dindicator will apper in the display (INC mode), per-mitting measurements from this zero point. To return to the ABSmode hole the ZERO/ABS buttton form more than 2 seconds.

Error Symptoms & Remediest t ERRC and display flickering: Occurs when the scale

surface is stained. Clean the scale surface and coat athin film of low viscosity oil to keep out moisture.

t t E in the least significant digit: This occurs when theslider is moved too quickly, but it does not affect the mea-surement. If it stays on when the slider stops, the scalesurface is probably stained. If this is the case, take rem-edies as for ErrC.

t t B indication: Battery voltage is low. Replace the batteryas soon as possible.

16

ADJUSTMENTS

NOTE: It is not necessary to remove the linear actuatorfrom the drive shaft--Remove only the bearings.STEP 1--Remove the shoulder bolt from the top side ofcarriage. See FIG. 11.STEP 2--Turn the actuator release lever 1/2 turn clockwise torelease the actuator from the drive shaft. Slide the actuatorrelease lever out of actuator bar assembly by loosening theretainer shaft collar, which preloads the holding spring. SeeFIG. 12.STEP 3--Move the grinding head carriage to the left side. Liftthe bellows. Remove shoulder bolts fastening the sixbearings to the actuator body. See FIG. 13. Remove the oldbearings from the shoulder bolt, and discard, saving the insidewasher. Insert the shoulder bolts through the new bearingsand the saved inside washers. Then install these assembliesinto the actuator body and tighten the shoulder bolts.STEP 4--Slide the carriage over the actuator assembly to lineup the hole in the carriage with the tapped hole in the actuator.Insert the shoulder bolt through self aligning bearings andtighten.NOTE: Take extra caution not to cross thread the shoulderbolt.STEP 5--Slide actuator release lever with collar, spring washerand foam seal back into actuator bar assembly and lock inplace with retainer shaft collar. See FIG.12. Turn actuator release lever 1/2 turn counterclockwise to engage bearingsto drive shaft.STEP 6--Using a spring scale, connect the scale to thecarriage to pull on the carriage parallel to actuator drive shaft.Then while holding the drive shaft from rotating, pull oncarriage; the pull force should be 60 lbs. (See Step 7 for readjustment if necessary.)

LINEAR ACTUATOR BEARING REPLACEMENT

STEP 7--If readjustment is required to achieve pull force withinspecification, with actuator bearings engaged to drive shaft,readjust the two outboard screws with springs that hold theactuator together. See FIG. 13. To reach these screws, theactuator bar assembly must be removed. Turn each screwan equal amount when resetting for more or less tension,clockwise is more tension. Repeat Step 6 and verify pull force.Continue to adjust until within specification. The factorypreadjusted spring tension is .160 or 5/32" (4 mm) from un-der the washer holding the spring to the actuator block. SeeFIG. 12. This should give the 60 lbs. carriage pull force speci-fied.When adjustment is correct reinstall the actuator bar assem-bly. The bar assembly must be adjusted parallel to the actua-tor aluminum body and so it is just touching the outboardscrew heads. Then tighten the lock nut on the lower actuatorbar assembly mounting screw. See FIG. 12. Then reinstallthe release lever package as above.

FIG. 11

FIG. 12

FIG. 13

THE PULL FORCE IS TO BE CHECKED WHENSHAFT IS WIPED CLEAN AND DRY. IF CHECKEDWHEN OILY, TOO MUCH TENSION WILL BE SETAND AFFECT BEARING LIFE.

ACTUATORSHOULDER BOLT

17

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 bear-ing around 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 bea smooth uniform motion.

CARRIAGE LINEAR BEARING REPLACEMENT

SETTING THE BEARING TENSION CORRECTLY ISCRITICAL TO PROPER GRINDING. BEARINGSWHICH ARE TOO TIGHT OR TOO LOOSE WILLCAUSE POOR GRIND QUALITY. ALSO, BEARINGSWHICH ARE TOO TIGHT WILL HAVE SUBSTAN-TIALLY SHORTER LIVES AND MAY DAMAGE THESHAFT.

STEP 4--Slide linear bearing under carriage and attachwith the three screws.NOTE: Repeat Steps 2 thru 4 with the other three linearbearings.STEP 5--After all four linear bearings are reattached tothe carriage 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 traversing direc-tion, there should be only approximately a 3 lb force, withthe actuator disengaged, using a scale system similar toStep 6 of Linear Actuator Bearing Replacement Section inthis manual. To double check the assembly, slide the car-riage assembly from "end of travel" to "end of travel", itshould have very uniform resistance through the full rangeof travel.STEP 6--Replace the bellows carriage mounting bracketsonto the carriage. Replace front and rear shields. See FIG.15.

FIG. 14

FIG. 15

18


The reel finger slide to the reel finger positioner has adovetail with an adjustable gib for tensioning. Tighten thegib set screws on the side so there is no free play in thedovetail slide. Check for movement when pushing onthe relief finger side to side with 20 lbs. (44kg)force. Make sure the knob assembly for adjusting therelief finger to the grinding wheel is rotatable by hand.The gib adjustment should be sufficient to maintain arigid position of the reel finger. See FIG. 16.

Check the knob assembly rotating tension by checkingthe tightness of the nylon plug to the knob assemblythreads. The tightness has to be sufficient so the knobassembly does not 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 fingerpositioner so the clearance holes line up with the nylonplug set screw.

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

GRINDING HEAD BELT TENSIONADJUSTMENTThe grip grinding wheel knob need not be removed forbelt tensioning adjustment. Remove the six socket headcap screws holding, the two double tube clamps andthe belt cover. For grinding motor belt adjustment, loosenthe four socket head cap screws that attach the motor.Adjust the grinding motor for proper belt tension by push-ing back on the motor and tighten the four socket headcap screws. The proper belt tension for the grinding headis to push down on the poly V belt half way between thetwo pulleys with 5 lbs. (2KG) of force and belt move-ment dimensions to be .12 inches (3mm). See FIG. 18.To verify belt tension mount the belt guard with twoscrews. Turn the motor on. If the belt is tensioned cor-rectly, start-up torque of the motor through the pulley tothe belt should have zero slippage. If there is beltslippage when turning on the motor there will be a slightsqueal before the belt comes up to speed. When youachieve correct tension, reassemble all of the remain-ing parts that have been removed.

FIG. 18

REEL FINGER DOVETAIL GIB ANDADJUSTING KNOB ADJUSTMENTS

FIG. 17

FIG. 16

19


To align the Index Finger Locking Pin to the hole in theIndex Finger Assembly loosen the two socket headcap screws so the index sensor block is movable.Push down on the index finger assembly until thespring loaded index finger locks into hole with no bind-ing. Tighten the two socket head cap screws so theindex sensor block is secured, and the locking pinmoves freely. See FIG. 19.

LOCKING INDEX FINGER PIN

PROXIMITY SWITCH

For the proximity switch to perform properly and re-verse the direction of the carriage at each end of therails, a distance of 3/16" (4 mm) to 1/4" (6 mm) needsto be maintained between the carriage proximity flagbracket and the proximity switch. See FIG. 20.

NOTE: Light on proximity activates when metalcrosses over the switch.

FIG. 19

FIG. 20

20

ADJUSTABLE RELIEF TENSION


If the relief angle appears to vary during reliefgrinding, adjust the tension on the nylon plugand set screw. See FIG. 21.

The magnetic starter is factory set at a 12 AMPrating. See FIG. 22.

If your magnetic starter is frequently shuttingdown, contact your distributor.

The main control power source is for a 15 AMPsupply circuit. See machine setup section forexplanation.

NOTE: Manual/Auto Selector is factory set atmanual mode.

FREQUENT OVERLOADINGAND CIRCUIT TRIPPING

FIG. 21

FIG. 22

Manual/AutoSelector

ManualReset

OverloadSensor

21


SPIN GRINDING ATTACHMENT ADJUSTMENT

If play develops so crank handle wants to rotatein the scissor action on the spin grinding attach-ment, the play can be eliminated by tightening theset screw identified in FIG. 23.

If there is too much play in the spin drive pivotpoints, torque down the hex nut tight so conicalwasher is completely compressed, then back off1/2 turn. See FIG. 23.

TRAVERSE MOTOR COUPLING

Traverse motor shaft must be concentric totraverse drive shaft within .010. The traverse shaftand motor shaft are to have at least 1/8" (3 mm)to 1/2" (13 mm) clearance so they do not contacteach other. The coupling is to be locked downtightly with the spiral grooves equally spaced forthe full length. See FIG. 24.

REDUCER MOTOR ADAPTERTO ACTUATOR DRIVE SCREWCLAMPING COLLAR POSITIONING

The lower clamp collar, next to the reducermotor adapter, is to be positioned flush to the endof the actuator screw shaft and tighten down with6 ft. lbs (0.8 kg) of torque. See FIG. 25. The topclamp collar is factory adjusted and does not needany further adjustment. There is to be no slippagebetween the reducer motor adapter shaft andactuator screw when pushing down on grindinghead and stalling the reducer motor.

FIG. 24

FIG. 25

FIG. 23

22

ADJUSTING CROSS SLIDE ASSEMBLY

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

STEP 1--Using a hydraulic jack, raise the traversingcarriage base just enough to alleviate the wieght stresson the Cross Slide Assembly.STEP 2--Knock the pins on either side of the MountingFrame Adjuster and loosen the 4 bolts (B504801) thatconnect the Carriage Mounting Frame to the frame ofthe grinder.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 thevertical and horizontal handwheels for ease of move-ment through their full range of motion.STEP 6--If the Cross Slides tend to bind, repeat abovesteps jacking higher or lower (STEP 1) until thehandwheels move freely.STEP 7--When the Cross Slides move freely throughtheir full range of motion, drill new holes and repinassembly.


BOLTS

PIN

PIN

BOLTS

CROSS SLIDEASSEMBLY

CARRIAGEMOUNTINGFRAME

PART OFFRAME

23

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 dutchman and tap with plastic hammerto loosen.STEP 3--Loosen the locking handles and tap thecenter stud with a plastic hammer.STEP 4--Loosen locknut and setscrew and removethe handlwheel.STEP 5--Remove the Slide Shaft.STEP 6--Remove all burrs and resurface the shaftto a clean, smooth, polished surface. (OR RE-PLACE WITH A NEW SHAFT.)STEP 7--Coat shaft with Never-Cease and re-installthe shaft through the Support, Cross Slide Block andthe three Dutchman. The shaft must move freelyinside the Cross Slide Block before reassembling.STEP 8--Retightening the nuts at the end of theDutchman to lock shaft in place.STEP 9--Reinstall the Handwheel by snuging thesetscrew to the flat located on the screw shaft, thentorque nut until tight and back off 1/2 turn. Torquethe setscrew to 70 in-lbs.STEP 10--Test the Cross Slide, the handwheelshould turn 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 22.

NOTE: It is also possible to remove the completeCross Slide Assembly and do the repairs on a benchthen reinstall.


LOCKNUT

CROSSSLIDE

LOCKHANDLES

SLIDESHAFTS

DUTCHMAN

NUT

LOCKNUT

HANDWHEEL

SETSCREW

24

CONTROL BOARD POTENTIOMETER ADJUSTMENTS

POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL (TDC)

Min. Speed--Factory set at full (CCW) 8:30. Do not change this setting.

(Right Traverse) Forward Torque--Factory set at full (CW) 4:30. Do not change this setting.(Left Traverse) Reverse Torque--Factory set at full (CW) 4:30. Do not change this setting.

IR COMP--Factory set to 9:00. IR COMP is current (I) resistance (R) compensation (COMP).IR COMP adjusts the output voltage of the drive which balances load to motor RPM. Regulation of a traversemotor may be improved by slight adjustment of the IR COMP trim pot clockwise from its factory-set position.Overcompensation causes the motor to oscillate or to increase speed when fully loaded. If you reach such apoint, turn the IR COMP trim pot counterclockwise until the symptoms disappear.

Max. Speed--Set at 3:30 for maximum voltage of 90 Volts DC to the traverse motor. When voltage is above 90volts DC, the traverse motor will start to pulsate and not run smoothly.

(Right Traverse) Forward Acceleration--Factory set at full (CCW) 8:30. Do not change this setting.(Left Traverse) Reverse Acceleration--Factory set at full (CCW) 8:30. Do not change this setting.

(DB) Dead Band is the potentiometer setting for the 50 or 60 Hz cycle control. Factory set to 9:00, works forboth 50 and 60 Hz. Do not change this setting.

Calibrating the DWELL TIME rotary DIP switch adjusts the amount of time the process remains in the stopposition after a limit switch is actuated. The DWELL TIME range is adjustable from 0 - 4 seconds. A DIPswitch setting of 0 sets the DWELL TIME to 0 seconds, while a setting of 8 sets the DWELL TIME to 4 sec-onds. Dwell time is preset to #4 setting for a 2 second dwell time when reversing at each end of stroke.

Diagnostic LED's indicate the function that is currently being performed:

* POWER indicates that ac power is being applied to the control.* FORWARD indicates that the process is running in the forward direction (traversing left).* REVERSE indicates that the process is running in the reverse direction (traversing right).* PROX 1 FWD LIMIT lights when the forward limit switch is actuated (left prox).* PROX 2 REV LIMIT lights when the reverse limit switch is actuated (right prox).* DWELL lights when the process remains stopped after a proximity switch is actuated.

3:00

12:0

0

6:00

9:00

PotentionmeterClock Orientation

25

SPIN DRIVE CONTROL BOARD (SDC)

The Spin Drive Control Board has three potentiometers on the lower board and two potentiom-eters on the upper board as shown on FIG. 26 and FIG. 27. These potentiometers have been setat the factory to the positions shown on FIG. 26 and FIG. 27.

In the Relief Grinding Mode--The Relief Speed Pot (RSP) and the Relief Torque Pot (RTP) interact with each other. The (RSP)is located on the upper spin board as a remote speed preset at 2:00 (20 Volts DC). See FIG. 26.The (RTP) is located on the control panel and is for relief torque adjustment.

Relief Speed Pot (RSP) when rotated clockwise will increase maximum spin drive speed. Thisspeed should never be above the 2:30 setting.

Relief Torque Pot (RTP) can vary the reel to finger holding torque for relief grinding. The recom-mended starting point is 30 in/lbs of torque setting. Never adjust the (RTP) potentiometer dialpast the red line marking. Setting the reel to finger torque to high could cause the traverse motorsystem to not operate smoothly.

In the Spin Grinding Mode--the Spin Torque Potentiometer (STP) and the Spin Speed Pot (SSP) interact with each other. The(STP) is located on the upper spin board as remote torque preset at 2:00 for torque setting. SeeFIG. 26. The (SSP) is located on the control panel and is for spin speed adjustment.

Spin Torque Pot (STP) controls maximum torque allowable in the spin grinding cycle only. Thisshould never be adjusted past the 2:30 position. If the reel does not turn check that the reel is freeturning by hand spinning.The Spin speed Pot (SSP) controls reel spin speed, adjust as required. This controls the spindrive speed for spinning the reel.

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

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 obtainablefor spin speed.

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 IRCOMP pot clockwise from its factory-set position. Overcompensation causes the motor to oscil-late or to increase speed when fully loaded. If you reach such a point, turn the IR COMP potcounterclockwise until symptoms just disappear.

CONTROL BOARD POTENTIOMETER ADJUSTMENTS (Continued)

26

CONTROL BOARD POTENTIOMETER ADJUSTMENTS (Continued)

GRINDING MOTOR CONTROL BOARD (GMC)

The Grinding Motor Control Board has four potenti-ometers on the board. These potentiometers havebeen set at the factory to the positions shown onthe drawing. See FIG. 28

Maximum Speed--The maximum speed potentiometer is preset to 1:00position for 90 Volts DC to the grinding motor for4300 RPM. The 4300 RPM is for optimum grindingwheel operating speed. DO NOT go above the 4300RPM.Check for 90 to 95 Volts DC on Grinding MotorControl (GMC) at Term A1 to Term A2.

Minimum Speed--the minimum speed is set full counterclockwise so itis nonfunctional for this application.

Current Limit--The current limit is preset at 3:00 at the factory. Thered light above current limit indicates when the grinding motor is above the preset current limit. Go-ing above the current limit causes the motor to pul-sate. The current limit can be turned clockwise to in-crease the motor's maximum torque for grinding over-loads. The overload in the control panel will trip if theoverload persists for a prolonged period of time. Usea lower grinding head traverse speed if nuisance trip-ping is experienced.

IR CompensationRegulation of the grinder motor may be improved byslight adjustment of the IR COMP pot clockwise fromits factory-set position. Over compensation causesthe motor to oscillate or increase speed when fullyloaded. If you reaches such a point, turn the IR COMPpot counterclockwise until thesymptoms disappear.

The control is preset to 9:00 position. Never adjustpast the 11:00 position when changing the setting toincrease higher torque for heavy grinding.

FIG. 26

UPPER SPIN BOARD

LOWER SPIN BOARD

FIG. 27

FIG. 28

NOTE: OVER VOLTAGE OPERATIONCAN BE DAMAGING TO THE MOTOR.DO NOT OPERATE THE MOTOR ATHIGHER THAN 95 VOLTS DC.

27

MACHINE SERVICE (Continued)

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 other ball bearing is slip fit on the opposite endduring assembly with loctite on the bearing bore. To replace the spindle assembly remove the grinding wheelgrip knob, square key and belt cover. See FIG. 30. Loosen the 4 socket head cap screws on the motor toremove the poly-V belt. Loosen the 2 set screws on the spindle pulley and remove the pulley, square key andpulley spacer. Push on the right hand side of the spindle assembly to compress conical washers so there isno pressure on the shaft retaining ring and to expose the retaining ring for removal. Using a retaining ringpliers remove the small retaining ring from the spindle assembly. You can now remove the spindle assemblyout the right side by lightly rapping on the left end with a rubber mallet. The second ball bearing can beremoved 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. 31. Slide this assembly into the Grinding HeadHousing and slip fit the new second ball bearing onto the spindle assembly and into grinding head housing(apply loctite #242 to the bore of the bearing before assembling). Using a C-clamp compress the conicalwashers so you can replace the retaining ring. The retaining ring is fragile and easily damaged when remov-ing. Always use a new retaining ring when reassembling and grinding head spindle. Only open the retainingring enough to install. Opening the ring excessively will damage the retaining ring, making it unusable.

Replace the pulley spacer and mount the square key positioned tight against the pulley spacer. Remount thepulley pushing against the pulley spacer and bottom out against the snap ring with no end play. Next tightenthe two pulley set screws. Then remount the poly-V belt. (See Grinding Head Belt Tension Adjustment in theadjusting section). Replace belt cover and square key and mount the grinding wheel grip knob and tightenthe two set screws.

THE BELT SIDE SHAFT RETAINING RING IS FRAGILE ANDEASILY DAMAGED WHEN REMOVING. ALWAYS USE A NEWRETAINING RING WHEN REASSEMBLING THE GRINDINGHEAD SPINDLE. ONLY OPEN THE RETAINING RINGENOUGH TO INSTALL. OPENING THE RING EXCESSIVELYWILL DAMAGE THE RETAINING RING, MAKING IT UNUSABLE.

FIG. 30

FIG. 31

28

ELECTRICAL TROUBLESHOOTING

SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICINGThis Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowl-edge and skills to reliably test and repair the ACCU-Pro electrical system. 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. If not, you shouldread the Operators Manual, or do the servicing in conjunction with someone who is familiar with its operation.

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

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

AC Main Power Controls ..................................................................................................... Page 29-31Spin Drive Controls in Spin Mode ........................................................................................ Page 32-33Spin Drive Controls in Relief Mode ...................................................................................... Page 34-36Grinding Motor Controls ....................................................................................................... Page 37-38

Traverse Drive Controls-w/prox .......................................................................................... Page 39-40Traverse--stopping and reversing........................................................................................ Page 41-43Infeed Controls .................................................................................................................... Page 44-45

ELECTRICAL TROUBLESHOOTING INDEX

All wires on the ACCU-Pro have a wire label at each end for troubleshooting. The wire label has a code whichtells you wiring information. The wire label has a seven position code. The first two digits are the wire number:01-99. The next three numbers or letters are the code for the component to which the wire attaches. Example:GMC for Grind Motor Control. The last two numbers or letters are the number of the terminal on the compo-nent to which the wire attaches.

WIRE LABELS

29

ELECTRICAL TROUBLESHOOTING (Continued)

(MAG) not working G. Push reset button on front of (MAG) Ref: Factory set for 12 amp

Bad contacts in contactor cause it notto hold in when turned on. If machineworks:Yes-- end troubleshootingNo--go to Step I. next

No 115 Volts AC power out F. Check for 115 V

H. Contactor coil chatters when (MAG) is powered up. Tighten terminals T1 , T2, & T3 that connect the overload and contactor together

Yes--check continuity of wires between T1 and T3 to switches

Volts AC (MAG) Term #T1 to T3 for 115

No--Replace the main power cord #32.

Yes-- Go to Step F next.

No 115 volts AC power to E. Check for incoming power (MAG) (MAG) Terminals L1 to L2 for 115(MAG) for 115 Volts. Volts AC

This may have tripped from either amotor overload condition or duringmachine shipment. Push (SSS). Ifmachine works--Yes--end troubleshootingNo--go to Step H. next

PROBLEM--AC Main Power Controls: no electrical power to control panel.Verify all wires shown on the wiring diagram on pages 72-75 are correct and pull on wire terminals withapproximately 3 lbs force to verify there are no loose terminal connections and/or no loose crimpsbetween wire and terminal. If problem persists, test as listedbelow.

Possible Cause Checkout Procedure

You must push the System A. Listen for the Magnetic Starter Machine worksStart Switch (SSS) to get (MAG) contacts to pull in with a Yes--end troubleshootingpower to control Panel clunk No--go to Step B. next

Main Power Cord is not B. Plug in main power cord Machine worksplugged in Yes--end troubleshooting

No--go to step C. next.

Guard doors must be C. Close and latch guard doors. Machine worksclosed and latched for Yes--end troubleshootingcontactor to pull in. No--go to step D. next.

Main 15 amp outlet circuit D. Check circuit breaker in your Machine worksbreaker has tripped building and reset if necessary. Yes--end troubleshooting

(Check wall outlet with a light to No--but light works in make sure it works) outlet--go to Step E. next.

No--but light does not work in outlet. You must

solve your power delivery problem independent of machine.

of (MAG)

30

Checkout Procedure


115V power notdelivered to (MAG)coil.

No power to thecontrol circuit

Blown Fuse F1

Bad EmergencyStop Switch (ESS)

Door saftey switchnot operating

Relay (REL) notoperating

Bad Relay contact

Possible Causes

I. Check at Magnetic Starter coil for115 Volts AC with main electricalpower on and pushing (SSS) andGrinding Motor Switch (GMS) in theoff position.

J. Check voltage to Fuse F1

K. Check voltage after Fuse F1

L. Check voltage after the (ESS)

M. Check output of safety switchwith guards closed

N. Check voltage

O. Check voltage at relay (REL2)

P. Check relay contact

(MAG) Term #A1 to A2 for 115 voltsACYes--replace magnetic starterNo--go to Step J. next

Measure 115 volts AC from fuse wire#02 at the fuse end to (MAG) L2.Yes-- Go to Step K. nextNo--Check continuity of wire #02, ifbad replace

Measure 115 Volts AC from fusewire #03 at the fuse end to (MAG)L2.Yes--To Step L. nextNo--Replace fuse

Measure 115 Volts AC from (ESS)term 2 to (MAG) L2Yes--Go to Step M. nextNo--Check wire #03 for continuity,then verify switch continuity. If badreplace EES

Check light on end of the safetyswitch. Light should be off whenguard is closed, on when opened.Yes--Go to Step N. nextNo--Go to Step U. next.

Measure 24 Volts DC at the safteyswitch, between the Orange andGray wire.Yes--Go to Step O. nextNo--Replace Saftey Switch

Measure 24 Volts DC at (REL2)term 0 and 1.Yes--Go to Step P. next.No--Verify continuity of wiresbetweeen the saftey switch and(REL2)

With saftey switch on and (REL2)on, measure 115 Volts AC at relayterm 8 to 6Yes--Verify wiring, Replace relayNo--Check continuity of wires onrelay.

31


Possible Cause

System Start Switch(SSS) not function-ing.

(MAG) not operating

Bad power to SafteyCircuit

Bad Bridge Diode

Bad Fuse or Trans-former

Measure 115 Volts AC at MAG term13 to 14 with SSS not pushed.Yes--Replace contactorNo--Verify wiring to 13 and 14. Ifbad replace.

PROBLEM--(MAG) turns on only with System Start Switch held in.

Checkout Procedure

A. Check wiring to and from MAG holdingcontact in. Verify the magnetic starter hold-ing contact is working.

Possible Cause

(MAG) holdingcontact has failed

Measure 115 volts AC at switch term 3 to (MAG)L2Yes--Go to Step R. nextNo--Check continuity of wire #89 from SSS toGMS, 89 from GMS to REL, term 6.

Measure 115 Volts AC at switch term 4 to(MAG) L2 with button pressedYes-- Go to Step S. nextNo--Replace switch

Measure 115 Volts AC at A1 and A2 on con-tractor with (SSS) on.Yes--If MAG is not clicking on, replace contrac-torNo--Go to Step T. next.

Check Related wiring to (MAG) Check conti-nuity of wire 23 from SSS terminal 4 to (MAG)terminal 14. Check continuity wire 17 from(MAG) terminal 14 to (MAG) terminal A1.Check voltage at (MAG) With SSS on, mea-sure 115 Volts AC at (MAG) A1 to (MAG) L2.Yes--Check continuity of wire 15 from (MAG)term 96 to (MAG) term A2

Measure 24 Volts DC at Bridge diode (BD2)terminal 107BD2+ to term 107BD2 -Yes--Verify continuity of wires between BD2and door saftey switch / replace saftey switchNo--Go to Step V. next

Measure 24 Volts AC at input of (BD2).Terminal (~) to Terminal (~)Yes--Replace Bridge Diode (BD2)No-- Go to Step W. next

Measure 115VAC at primary of (TFR)The two black wires are the primary side.Yes--Replace Transformer (TFR)No-- Check Fuse FU3 and replace if needed.Verify wiring from FU3 to TFR.

Q. Check push button contactinput.

R. Check push button contactoutput.

S. Check contractor action.

T. Check related wiring.

U. Confirm 24 Volts DC tosaftey circuit.

V. Measure voltage

W. Measure voltage

Checkout Procedure

32


PROBLEM--SPIN DRIVE NOT WORKING IN SPIN MODE.

Assuming (SSS) System Start Switch is on with 115 volts AC to control panel and all other functionsare working.

Verify all wires shown on the wiring diagram on pages 72-75 are correct and pull on wire terminalswith approximately 3 lbs force to verify there are no loose terminal connections and/or not loosecrimps between wire and terminal. If loose terminals are found, retighten and retest system. If prob-lem persists, test as listed below.

Possible Cause Checkout ProcedureSpin Speed Pot(SSP) set to zero

Spin Rotation Switch(SRS) are not on

Fuse 2 (4 AMP) isblown

Spin Rotation Switch(SRS) is not working

Spin Drive Control(SDS) is not working

Spin Drive motor isbad

A. Set (SSP) to 200 on the con-trol panel.

B. Turn (SRS) switch to direc-tion of reel rotation required.NOTE: center position is off

C. Check fuse and replace ifbad. Check that reel is freespinning.

D. Check for (SRS) input of115 Volts AC

E. Check for (SRS) output of115 Volts AC NOTE: Checkspin rotation switch in both po-sitions.

F. Check (SDS) L1 to L2 for115 Volts AC

G. Check (SDC) A1 & A2 forapprox. 90 Volts DC (HaveSpin Speed Pot set to 400RPM)H. Check for approx 90 VoltsDC input to (SRS)

J. Check for approx 90 VoltsDC out put to (SRS).

K. Check spin motor continu-ity

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

(SRS) Term 5 to term 8 for 115 Volts ACYes--go to Step E. nextNo--after verification of 115 VAC power at(MAG) term's T1 and T3, replace wire 91 &92

(SRS) Term 1 to term 4 for 115 Volts ACYes--go to Step F. nextNo--replace (SRS) switch

(SDC) Term L1 to term L2 for 115 volts ACYes--go to Step G. nextNo--replace wires 82, 83 and 24

(SDC) Term A1 to A2 for approx 90 volts DCYes--go to Step H. nextNo--go to Step L. next

(SRS) Term 6 to 7 for approx 90 Volts DCYes--go to Step J. nextNo--replace wires 13 & 14(SRS) Term 2 to 3 for approx 90 Volts DCYes--go to Step K. nextNo--replace (SRS) switch

Remove wires at (SRS) Term 2 & 3 check0 ohms across the black and white wiresYes--end troubleshootingNo--got to Step P. nextDisconnect Power

from Machine!

33


Spin Speed Pot (SSP)is not working

Spin Torque Pot (STP)is not set correctly

(SSP) is not working

Worn Motor Brushes


L. (SSP) (10K) on controlpanel

M. Check (STP) remotetorque on the top (SDC)board

N. (SSP) (10K) Remove 3Remote Speed wires.Red wire to term WWhite wire to term LBlack wire to term H

P. Inspect Motor Brushes

Input/output Controller (IOC) Pin #36 to 41Pot Full CCW --O volts DCPot Full CW--4.21 Volts DC(IOC) Pin #36 to 43Pot Full CCW --4.12 Volts DCPot Full CW-- DC 0 Volts DC

(STP) OK (SDC) remote torque should beset at 2:00 o'clock position. See Fig. 26.Adjust if incorrect and check Spin DriveFunction.Yes--end of troubleshootingNo--Replace (SDC)

Check for 10,000 ohmsRed wire to white wire Full CCW--0 ohms Full CW-10,000 ohmsRed wire to black wire Full CCW--10,000 ohms Full CW--0 ohmsYes--replace (SDC)No--replace (SSP)

Remove the brushes one at a time andmaintain orientation for reinsertion. See ifbrush is worn short 3/8" (10 mm) minimumlength.Yes--replace motor brushesNo--replace Spin Drive Motor

DISCONNECT POWERFROM MACHINE !

34


PROBLEM--Spin Drive not working in relief mode.

Assuming (SSS) System Start Switch is on with 115 volts AC to control panel and all otherfunctions are working.

Verify all wires shown on the wiring diagram on pages 72-75 are correct and pull on wireterminals with approximately 3 lbs force to verify there are no loose terminal connectionsand/or no loose crimps between wire and terminal. If loose terminals are found, retightenand retest system. If problem persists, test as listed below.

Possible CauseSpin 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

(SRS) Term 5 to term 8 for 115 VoltsACYes--go to Step E. nextNo--After verification of 115 Volts ACpower at (MAG) term. T1 & T3, replacewire #77 & 79.

(SRS) Term 1 to term 4 for 115 VoltsACYes--go to Step F. nextNo--replace (SRS) switch

(SDC) Term L1 to term L2 for 115 VoltsACYes--go to Step G. nextNo--replace wires #82, 83 &24

(SDC) Term A1 to A2 for approx 20 VoltsDCYes--go to Step H. nextNo--go to Step L. next

(SRS) Term 6 to 7 for approx 20 VoltsDCYes--go to Step J. nextNo--replace wires 13 & 14

(SRS) Term 2 to 3 for approx 20 VoltsDCYes--go to Step K. nextNo--replace (SRS) switch

Remove wire at (SRS) Term #2 & 3 for0 ohms across the black and whitewiresYes--end troubleshooting motor shouldwork (if it does not, replace motor)No--go to Step P. next

Checkout ProcedureA. Set (RTP) to 20 on the con-trol panel

B. Turn (SRS) switch to direc-tion of reel rotation required.NOTE: center position is off.

C. Check fuse and replace ifbad. Check that reel is free spin-ning

D. Check for (SRS) input of 115Volts AC

E. Check for (SRS) output of 115Volts AC NOTE: Check spin ro-tation switch in both positions

F. Check (SDC) L1 to L2 for 115Volts AC

G. Check (SDC) A1 & A2 forapprox 20 Volts DC. Have Relieftorque Pot (RTP) set to red line.

H. Check (SRS) for approx 20volts DC output

J. Check (SRS) for approx 20Volts output

K. Check spin motor continuity

DISCONNECT POWERFROM THE MACHINE

Relief Torque Pot(RTP) set to zero

Spin Rotation Switch(SRS) are not on.

Fuse 2 (4 AMP) isblown

(SRS) is notworking

Spin Drive control(SDC) is not working.

Spin Drive Motor is bad

35



(RTP) Relief Torque Potis not working

Relief Speed Pot (RSP)is not set correctly.

(RTP) is not working

Worn Motor Brushes

L. Check (RTP) (50K) on con-trol panel (check voltage withpots at fully clockwise andcounterclockwise positions)

M. Check (RSP) remotespeed (10k) on (SDC) topboard (this is preset to 9:00)

N. (RTP) (50K) Remove3 Remote Torque Wiresred wire to term Wwhite wire to term L.black wire to term H.

P. Inspect Motor Brushes

(SDC) Term Remote Torque W to H PotCCW--) volts DCPot CW--.21 Volts DC(SDC) Term Remote Torque W to LPot CCW--.21 Volts DCPot CW-- DC 0 Volts DCYes--go to Step M. nextNo--go to Step N. next

(RSP) to the top (SDC) board shouldbe set at 2:00. See Fig. 26. Adjust ifincorrect and check Relief Torque func-tion.Yes--end of troubleshootingNo--replace (SDC)

Check for 50,000 ohmsRed wire to white wire Full CCW--0 ohms Full CW--50,000 ohmsRed wire to black wire Full CCW--50,0000 ohms Full CW--0 ohmsYes--Replace (SDC)No--replace (RTP)

Remove the brushes one at a time andmaintain orientation for reinsertion. Seeif brush is worn short 3/8" (10 mm)minimum lengthYes--replace motor brushesNo--replace Spin Drive Motor

DISCONNECT POWERFROM MACHINE !

36

Remedy

ELECTRICAL TROUBLESHOOTING (Continued) SPIN DRIVE

PROBLEM : Spin drive speed goes at one speed only.

Possible Cause

A. Check potentiometer wiring forproper hookup. See that speedpot is wired per electrical diagram

B. (SSP) 10K Remove 3 remotespeed wires.red wire to term Wwhite wire to term Lblack wire to term H

C. Check all pot settings on bothboards as of the (SDC) shownon Page 22. (See AdjustmentSection Spin Drive Control [SDC]Board Setting).

A. See adjustment section fortrim pot setting on Page 24.

B. Readjust bearing preload forthe reel. Maximum torque load 25in./lb to rotate reel.

C. When .250 female spade ter-minals are not tight, remove andcrimp slightly together. When re-installing, push on pressureshould have increased for goodcontact.

PROBLEM: Spin drive motor speed varies

If wiring is wrong, correct andtest.Yes--end of troubleshootingNo--Go to Step B. next

Check for 10,000 ohmsRed wire to white wire Full CCW--0 ohms Full CW--10,000 ohmsRed wire to black wire Full CCW--10,000 ohms Full CW--0 ohmsYes-- Go to Step C. nextNo--Replace (SSP)

Yes-- end of troubleshootingNo--replace (SDC)

Original adjustment was not setproperly

Too much load on drive motor willcause motor to hunt and varyspeed.

When connections are not tightthe control board varies voltageto the DC motor which then var-ies speed.

Wiring hookup to potentiometeris improper. (If componentshave been replaced

Defective spin speedcontrol (SSP) potentiometer.

Main circuit board dial pot set-tings not correct. (If board hasbeen replaced

IR Comp trim pot not adjustedproperly.

Torque to rotate the reel toohigh.

Check all terminal connectionsfor tightness.

37


PROBLEM-- Grinding motor not working.

Assuming (SSS) System Start Switch is on with 115 volts AC to control panel and all othermanual (jog) mode functions are working.

Verify all wires shown on the wiring diagram on pages 72-75 are correct and pull on wireterminals with approximately 3lbs force to verify there are no loose terminal connectionsand/or no loose crimps between wire and terminal. If loose terminals are found, retighten andretest system. If problem persists, test as listed below.

Possible Cause

Grinding MotorSwitch (GMS) is noton

Guard doors are notclosed and latched

GMS not working

Relay (REL1) notworking

Relay contacts notworking

Filter (FTR) is notworking (Filter is lo-cated in the secondcontrol box at the in-side back of thegrinder

Checkout Procedure

A. Turn switch on

B. Close and latch guarddoors.

C. Check for power to GMS

D. Check for power fromGMS

E. Check for power to relaycoil

F. Check for power to relaycontacts

G. Check for power fromrelay contacts

I. Check line side of filter forinput of 115 volts AC

J. Check load side of filterfor output of 115 Volts AC

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

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

GMS term 5 (MAG) to T3 for 115 Volts ACYes--go to Step D. nextNo--With power off, check continuity of wire78 and replace if bad.

GMS Term 4 to (MAG) T3 for 115 Volts ACYes--Go to Step E. nextNo--replace GMS

(REL1) Term 0 to 1 for 24 Volts DC.Yes--go to Step F. nextNo--Doors not closed or door switch bad.Follow separate troubleshooting on power.

(REL1) Term 2 on (MAG) T3 for 115 VoltsACYes--Go to Step G. nextNo--Replace wire #81

(REL) Term 4. to T3 for 115 Volts ACYes--Go to Step J. nextNo--Replace (REL)

(FTR) wire #98BL to #98 WH for 115 VoltsACYes--go to Step J. nextNo--replace wire #98

(FTR) Wire 361 to #62 for 115 Volts ACYes--go to Step K. nextNo--replace (FTR)

38

Checkout Procedure

K. Check (GMC) for input voltage of115 Volts AC

L. Check (GMC) resistor assy wireconnections.

M. Check (GMC) output voltage of90 Volts DC to motor.

N. Check grinding motor cord #01.

O. Check grinding motor continuity

P. Inspect Motor Brushes.


Possible Cause

Grinding Motor Control(GMC) is not working(GMC) is located in thesecond control box at theinside back of the grinder.

Grinding Head DC Motorcord is bad (removeback cover to motor)

Grinding Motor is bad

Worn Motor Brushes

(GMC) Term L1 to L2 for 115 VoltsACYes--go to Step L. nextNo--replace wires #61 and #62

(GMC) Term #S1, 52 and S3 forloose wiresYes--repair or replace resistor as-semblyNo--go to Step M. next.

(GMC) Term #A1 for 90 +/- 5 voltsDCYes--go to Step N. next**No--if 0 V replace (GMC)

At DC motor check Term #A1 to#A2 for 90 Volts DCYes--go to Step O. nextNo--replace grinding motor cord#97

Remove wires at terminal A1 andA2 at motor. Check for 0 ohmsacross terminals A1 and A2Yes--end troubleshootingNo--go to Step P. next

Remove the brushes one at a timeand maintain orientation for reinser-tion. See if brush is worn short 9/16" (14mm) minimum length.Yes--replace motor brushes.No--replace Grinding Motor.

DISCONNECT POWERFROM MACHINE!

DISCONNECT POWERFROM MACHINE!

**NOTE: If voltage checks less than 90 VDC, butnot 0 VDC, then adjust MAX SPEED POT on the(GMC) until you read 90 VDC. If you cannot achieve90 VDC, replace the (GMC).

39


PROBLEM--Traverse Drive not working.

Assuming (SSS) System Switch is on with 115 Volts AC to control panel and all otherfunctions are working.

Checkout Procedure

A. Turn on (TMS)

B. Set (TSP) to 35 on the controlpanel

C. Check fuse and replace iffailed. See Page ? ? . Too heavya grind causes grinding headtraverse motor to overload andblow the fuse,

D. Check for 115 Volts AC incom-ing to (TDC)

E. Check for 115 Volts AC at(TMS). (Make certain (TMS) ison)

Traverse worksYes--end troubleshootingNo--got to Step B. next

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

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

On (TDC) Terminal L1 to L2 for 115 VoltsACYes--Go to Step F. nextNo--Go to Step E. next

Check for 115 Volts AC at Term 1 & 4 ofthe (TMS) Note: Switch must be on.Yes--With power off, check continuity ofwires 28 & 29, if bad replace wires.No--Check 115 Volt AC power deliveredto (TMS) Term 2 & 5 per separate ACpower troubleshooting section.

Possible Cause

Traverse Motor Switch(TMS) is not on

Traverse Speed Pot(TSP) set to zero

Fuse on Traverse DriveControl (TDC) hasfailed

Traverse Drive Control(TDC) is bad

Bad wires to (TDC)

40

Checkout Procedure

F. Check for 90 Volts DC across(TDC) terminals #A1 to #A2 thisvoltage drives the DC traverse mo-tor. NOTE: Traverse must be onand have (TSP) turned full CW tomaximum voltage of 90 VDC

G. Check grinding motor continuity

H. Check (TSP) (10K) on controlpanel

J. Check (TSP) for 10,000 ohms.Remove three wires from (TDC)red from term #8white from term #7black from term #9

K. Inspect Motor Brushes


Possible Cause

No DC Voltage from(TDC) Traverse DriveControl

Traverse Motor is bad

(TSP) is not working

(TSP) (10K) is bad

Worn motor brushes

Check (TDC) terminals #A1 to #A2 for 90Volts DCYes--go to Step G. nextNo--go to Step H. next

Remove motor wires from Jumper #J1terminals #A1 & #A2 0 ohms across theblack and white wiresYes-end troubleshootingNo--go to Step K. next

(TDC) Pin #8 to #7Pot Full CCW Pot Full CW 0VDC 9.75 VDCPin #8 to 9Pot Full CCW Pot Full CW 9.75 VDC 0 VDCYes--replace the (TDC)No--go to Step J. next

Check for 10,000 ohms red to white wiresFull CCW--0 ohmsFull CW--10,000 ohmsRed to black wiresFull CCW--10,000 ohmsFull CW--0 ohmsYes--replace the (TDC)No--replace (TSP)

Remove the brushes one at a time andmaintain orientation for reinsertion. See ifbrush is worn short, 3/8" (10 mm) minimumlength.Yes--replace motor brushesNo--replace Traverse Motor

DISCONNECT POWERFROM MACHINE

DISCONNECT POWERFROM MACHINE

41


PROBLEM--Traverse does not stop to reverse directions when flag goes under the proxim-ity switch on the left side or right side of machine.

Gap betweenflag and prox isincorrect.

P r o x i m i t ySwitch is bad.

A. Gap between flag andprox should be 3/16 to 1/4" (4-6 mm). Prox LEDdoes not light when flagis under prox.

B. Proximity switch isnot working properly orwire connections areloose.

Checkout ProcedurePossible Cause

The light coming onshows the proximity isgetting electricalcontact.

Proximity light on- 0 Volts DCProximity light off- 12 Volts DC

Proximity light on- 0 Volts DCProximity light off- 12 Volts DC

Replace proximityswitch if the voltagesdo not read as above.

If incorrect, adjust per adjustmentsection of manual.Yes--end troubleshootingNo--go to Step B. next

First check to see if proximity lightcomes on. When the light is on, itmeans that there is electricitycoming to proximity switch. Ac-tuate prox switches with steel toolto take measurements.

Left proximity (PROX 1) checkTraverse drive Control (TDC) be-tween terminals #13 (black wire)and #15 (brown wire).

Right proximity (PROX) check#13 (black wire) and #15 (brownwire).

42


PROBLEM--Traverse speed control goes at one speed only.

Traverse Drive Control Pin #8 to 7Pot full CCW Pot Full CW 0 VDC 9.75 VDCPin #8 to 9Pot full CCW Pot Full CW 9.75 VDC 0 VDCYes--Pot is OKNo--Go to Step B. next

Check for 10,000 ohmsRed to White wiresFull CCW - 0 ohmsFull CW - 10,000 ohmsRed to Black wiresFull CCW - 10,000 ohmsFull CW - 0 ohmsYes--Go to Step C. nextNo--replace potentiometer.Wiper inside of potentiometer controlsspeed. Wiper may be bad and not makingcontact.

Wrong wire hookup effects traverse control.Reversing red and orange wires to potenti-ometer to the D C motor will run at zerospeed but maximum will be too slow. Re-versing red and white wires does not affectspeed control.Check for Proper function.Yes--end troubleshootingNo--Go to Step D. next

Minimum and maximum pot settings effecttraverse speed.

Checkout Procedure

A. Check potentiometer on controlpanel.

B. Check potentiometer for 10,000ohms.Remove three wires fromTraverse Drive Controlred from term #8white from term #7black from term #9

C. Check potentiometer wiring forproper hookup. See that speed potis wired per electrical diagram

D. Check all pot settings on circuitboard as shown in wiring diagram.(See adjustment section TraverseMotor Control Board Settings.)

Possible Cause

Defective speed controlpotentiometer

Wiring hookup to poten-tiometer is improper. (Ifcomponents have beenreplaced.)

Main circuit board dialpot settings not correct.(If board has not beenreplaced.)

43


PROBLEM--If the carriage traverses to one end of stroke or theother and it stops and does not reverse direction.

Possible Cause

Proximity switch is notworking properly or wireconnections are loose

The dwell time on thetraverse drive control notset properly.

Loose wire to proximityswitch.

Remedy

First check to see of proximity lightcomes on. When the light is on, itmeans that there is electricity comingto proximity switch.Actuate prox switches with steel toolto take measurements.

Left proximity (PROX1) checkTraverse drive Control (TDC) betweenterminals #14 (black wire) and #15(brown wire).

Right proximity (PROX) check (TDC)between terminals #13 (black wire) and#15 (brown wire).

Reset dwell time as required. One in-crement increases Dwell time by 1/2second.

Check wire connections from the prox-imity switches and tighten downscrews.

Reason

The light coming on shows the prox-imity is getting electrical contact.

Proximity light on- 0 Volts DC Proximity light off- 12 Volts DC

Proximity light on- 0 Volts DC Proximity light off- 12 Volts DC

Replace proximity switch if the volt-ages do not read as above.

A loose wire connection will giveintermittent electrical contact.

PROBLEM--Insufficient hesitation at carriage stops prior to reversing traverse.

PROBLEM--Traverse changes directions erratically while running in traversecycle.

44


PROBLEM--Infeed motor not working.

Assuming (SSS) System Start Switch is on with 115 Volts AC to control panel andall other functions are working.

Possible Cause

Infeed Jog Switch (IJS)is not held to on position

Infeed Speed Switch(IJS) is not on highspeed

Infeed motor/reducerdrive coupling is loose

No DC voltage to Grind-ing Wheel Infeed Motor(GIM)

Infeed Motor/Reducerwill not function

Switch (IJS) is bad

No DC Voltage from theVoltage Regulator.

Checkout Procedure

A. (IJS) Hold switch on in eitherdirection

B. Put (IJS) on high speed forease of checkout

C. Open infeed motor couplinginspection plate to check forloose coupling. Retighten cou-pling to drive actuator screw.See adjustment section ofmanual.

D. Check for 12+ Volts DCacross terminals labeled 2 and5 of the (IJS) with (IJS) held on.

E. Check for 12 Volts DC at the(GIM) terminals

F. Disconnect (GIM) from theinfeed actuator and check (GIM)function under no load.

G. Check for 12+ Volts to (IJS).

H. Check for 12 volts DC atBridge Diode output.

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

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

Infeed works--Yes--end troubleshootingNo--go to Step D. next

Check term 2 & 5 of (IJS) for 12+ VoltsDC.Yes--go to Step E. nextNo--go to Step G. next

Check for 17 Volts DC at Term marked 73GIMBL and 3 GIMRD. You will need jump-ers to check.Yes--Go to Step F. nextNo--Replace cord wire no. 94

Check (GIM) function when disengagedfrom Infeed Actuator.Yes--Replaced Infeed ActuatorNo--Replace (GIM)

Check for 12+ Volts DC at Term 6 & 4 and3 & 1 of (IJS).Yes--Replace (IJS)No--go to Step H. next.

Check for 12 Volts DC at term 105BD1+and 105BD1-Yes--Replace Voltage RegulatorNo--Go to Step I. next.

45


PROBLEM--Infeed motor not working.

Assuming (SSS) System Switch is on with 115 volts AC to control paneland all other functions are working

Possible Cause

Bad Bridge Diode

No AC Voltage to the inputside of transformer

Checkout Procedure

I. Check Voltage

J. Check for 115 Volts AC attransformer input black wires.

Check 12.6 Volts AC at input ofBridge Diode (BD1) Term (~) toTerm (~)Yes--Replace Bridge Diode BD1No--Go to Step W. next

Check for 115 Volts AC at Term.76 TFRBL and 76 TFRBL. Youwill need jumpers to check this.Yes-- Replace TransformerNo--Check fuse FU3 and re-place if needed. Follow sepa-rate trouble shooting procedureon AC main power.

46

MECHANICAL TROUBLESHOOTING (Continued)

Possible Cause

Bearing were bolted down tightly with bearingsputting a bow into the drive shaft.

Traverse Speed set too fast.

Lineal bearings for the grinding head carriage are outof adjustment (loose) or have grit buildup causing un-even traversing load.

Gib adjustment for the relief finger assembly is looseso reel finger has movement. When traversing to theright minimum grinding stock removal should be seenas compared with heavy stock removal when travers-ing to the left.

Lineal bearings on the grinding head carriage are tooloose .

Oil on carriage drive shaft.

Lineal bearings in the carriage do not rotate freely.

Actuator bearings are not rotating freely.

Checkout Procedure

Loosen bearing blocks and check squareness ofbearing collar face 90 degrees to carriage rods with asquare and tighten down. The drive shaft to carriagefront shaft is 2.875 +/- .010" (73 +/- .3mm) apart. Seeadjustment section for more information.

Check roundness using a magnetic base dial indica-tor. 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 penetration. 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 adjust-ment section for carriage linear bearing adjustments.

Wipe oil completely from the traverse shaft. Spraydown with a spray lubricant (do not use a teflon basedlubricant) and wipe off completely.

Check for grinding grit getting into the lineal bearingsand causing excessive driving torque of carriage. Abra-sive noise is detectable when excessive grit is in thelineal bearings. Replace the four lineal bearings in themain carriage. Check bellows for holes and replace ifnecessary.

Check bearing for free rotation or flat spots on the bear-ing outside diameter. Replace the six bearings if nec-essary. See adjustment section for bearing replace-ment.

PROBLEM--Reels ground have high/low blades

PROBLEM--Excessive grinding stock being removed whentraversing to the right in the relief grinding mode.

PROBLEM-- Grinding stock removal from reel is irregular duringspin grinding.

PROBLEM--Carriage traversing varies speed while grinding.

PROBLEM--Actuator drive shaft whipping excessively at high traverse speed.

47

MECHANICAL TROUBLESHOOTING (Continued)

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

Checkout Procedure

Traverse speed should be set lower approximately 12ft/min. (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 Operators Manual for NORMAL HELIX AND RE-VERSE HELIX for information of dressing the grindingwheel.

Possible Cause

Traverse speed set too high causing a heavy burron the reel blade when spin grinding.

PROBLEM--Cone shaped reel after grinding.

Grinding head travel not parallel to the reel centershaft.

The right side corner of the grinding wheel is al-ways to be in contact with the reel blade. This ishigh point of the relief finger.

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

PROBLEM-- Traverse speed is too slow.

Possible Cause

Lineal bearing in the car-riage are set too tight.

Actuator springs set tootight

The two top and two bot-tom pivot screws arecompressing the conicalwasher too tight.

Check screw adjust-ment tension on nylonplug riding against thescrew thread.

Remedy

A. Readjust bearings for proper ten-sion. (for more detail see lineal bear-ing replacement in the adjustmentsection of the manual.)

B. Check to see if actuator bearingshave been overloaded, causing thebearing to not rotate freely. (Formore detail, see actuator setting inthe adjustment section of themanual.

A. Tighten down the locknut until itbottoms out and back off 1/2 turn.Check to see if there is a coneshape to the washer. Four (4) pivotpoints.

B. Loosen set screw and check.(See adjustment section.)

Reason

When bearing preload is too tight, itcauses excessive loading to drive thecarriage.When lineal actuator is disengaged, theproper traverse load 2 to 3 lbs. Use a ten-sion scale to check. (A general guide only.)NOTE: Check with linear actuator release

When actuator spring tension is exces-sive, bearings will not rotate freely caus-ing carriage to not run freely. When theconical washers are too tight, it createstoo much friction on the pivot points.

Have enough play so the crank turnssnugly but during operation it is free.

PROBLEM--Spin Drive cranks up and down too hard.

48

PARTS LIST 6309522 MAIN BASE ASSEMBLY

49

PARTS LIST (Continued) 6309522 MAIN BASE ASSEMBLY

DIAGRAMNUMBER

PARTNUMBER

DESCRIPTION

1 .................................... B251001 ............... Hex Head Cap Screw 1/4-20 x 5/82 .................................... B310813 ............... Button Head Socket Cap Screw 5/16-18 x 1/23 .................................... B502801 ............... Hex Head Cap Screw 1/2-13 x 1 3/44 .................................... B504801 ............... Hex Head Cap Screw 1/2-13 x 35 .................................... B506801 ............... Hex Head Cap Screw 1/2-13 x 4.25

6 .................................... H371602 ............... Roll Pin .375 Dia. x 1.00 Long7 .................................... J992000 ............... 1-8 Hex Jam Nut8 .................................... J507100 ............... 1/2-13 Locknut9 .................................... K251501 ............... 1/4 Split Lockwasher10 .................................. 3708612 ............... Warning Decal - No Fuel

11 ................................... 3708542 ............... Black Hole Plug .625 Dia.12 .................................. A993201 ............... Adjustable Leveling Bolt13 .................................. 3709990 ............... Large Foley United Decal14 .................................. 6309039 ............... Gage Pin Mounting15 .................................. 6309523 ............... Main Gage Weldment

16 .................................. 6509035 ............... Frame Adjuster Mounting17 .................................. 6509039 ............... Right-Hand Access Panel18 .................................. 6509040 ............... Left-Hand Access Panel - Small19 .................................. 6509116................ Fuel Warning Decal20 .................................. 6509510 ............... Tooling Bar Weldment

21 .................................. 3708606 ............... Warning Decal - Hearing Protection22 .................................. 3708703 ............... Warning Decal - Safety Symbol23 .................................. 3708605 ............... Warning Decal - Respirator Symbol24 .................................. 6709101 ............... Decal - Accu Pro25 .................................. 6309111 ................ Decal - Up/Down

26 .................................. B370811 ............... Socket Head Cap Screw 3/8 - 16 x 1/227 .................................. 3708375 ............... Grommet28 .................................. 6309389 ............... Tooling Bar Shim29 .................................. H372002 ............... Roll Pin 3/8 Dia. x 1" Long30 .................................. K500001 ............... 1/2 Flat Washer

50

PARTS LIST 6309525 GUARD ASSEMBLY

51

PARTS LIST (Continued) 6309525 GUARD ASSEMBLY

DIAGRAMNUMBER

2 ................................. B191011 ........... Socket Head Cap Screw 10 - 24 x 5/83 ................................. B191211 ........... Socket Head Cap Screw 10 - 24 x 3/44 ................................. B250818 ........... Pan Head Machine Screw 1/4 - 20 x 1/25 ................................. B251018 ........... Pan Head Machine Screw 1/4 - 20 x 5/8

6 ................................. B251218 ........... Pan Head Machine Screw 1/4 - 20 x 3/47 ................................. J197100 ............ 10-24 Full Nylon Locknut8 ................................. J251000 ............ Hex Nut 1/4 - 209 ................................. J257000 ............ 1/4-20 Thin Locknut10 ............................... K190001 ........... #10 Flat Washer

11 ............................... K250001 ........... 1/4 Flat Washer12 ............................... K251501 ........... 1/4 Split Lockwasher13 ............................... 3708416............ Soft Latch14 ............................... 6309028............ Left-Hand Panel Guard15 ............................... 6309029............ Right-Hand Panel Guard

16 ............................... 6309194............ Right-Hand Door Guard17 ............................... 6309193............ Left-Hand Door Guard18 ............................... 6309033............ Door Bracket Rear19 ............................... 6309124............ Door Front Plate20 ............................... 6309038............ Door Bracket Front

21 ............................... 3708819............ #8-32 Button Head Safety Screw22 ............................... 3707585............ #8-32 Flat Head Safety Screw23 ............................... 6309527............ Guard Door Hinge Assembly24 ............................... 6309107............ Door Safety Switch Assembly25 ............................... J167000 ............ #8 Locknut Jam

PARTNUMBER

DESCRIPTION

52

PARTS LIST 6309526 WINCH AND BOOM ASSEMBLY

53

PARTS LIST (Continued) 6309526 WINCH AND BOOM ASSEMBLY

1 .............................B372801 ........ Hex Head Cap Screw 3/8-16 x 1-3/42 .............................B376401 ........ Hex Head Cap Screw 3/8-16 x 4.03 .............................J371000 ......... 3/8-16 hex Nut4 .............................K370001 ........ 3/8 Flat Washer5 .............................K371501 ........ 3/8 Split Lockwasher

6 .............................3708456 ......... Warning Decal - Boom Cap acity7 .............................3708578 ......... Winch8 .............................3709407 ......... Hook and Cable Assembly9 .............................3709795 ......... Pulley10 ...........................6309009 ......... Rotation Thrust W asher

11 ...........................6309036 ......... Boom Capacity Decal12 ...........................6309037 ......... Winch Warning Decal13 ...........................6309535 ......... Boom Weldement

PARTNUMBER

DIAGRAMNUMBER

DESCRIPTION

54

PARTS LIST 6309510-(Bottom) TRAVERSE AND CARRIAGE ASSEMBLY

55

PARTS LIST 6309510-(Bottom) TRAVERSE AND CARRIAGE ASSEMBLY

DIAGRAMNUMBER

DESCRIPTION

1 ........................................... B190611 ................... Socket Head Cap Screw 10-24 x 3/8 Long2 ........................................... B250819 ................... Button Head Socket Cap Screw 1/4-20 x 1/2 Long3 ........................................... B253211 ................... Socket Head Cap Screw 1/4-20 x 2 Long4 ........................................... B255211 ................... Socket Head Cap Screw 1/4-20 x 3.25 Long5 ........................................... B311201 ................... Hex Head Cap Screw 5/16-18 x 3/4 Long6 ........................................... B503211 ................... Socket Head Cap Screw 1/2-13 x 2 Long7 ........................................... J251000 ................... 1/4-20 Hexnut8 ........................................... J257100 ................... 1/4-20 Nylok Locknut9 ........................................... K191501 ................... No. 10 Washer10 ......................................... K251501 ................... 1/4 Split Lockwasher11 ......................................... K310001 .................. 5/16 Flatwasher12 ......................................... K311501 ................... 5/16 Split Lockwasher13 ......................................... B252011 ................... Socket Head Cap Screw 1/4-20 x 1 1/4 Long14 ......................................... K501501 .................. 1/2 Split Lockwasher15 ......................................... 3619224 ................... Compression Spring16 ......................................... 3708147 ................... Shoulder Bolt .375 Dia. x .625 Long17 ......................................... 3709583 ................... Flexible Coupling18 ......................................... 3709635 ................... Pillow Block Bearing19 ......................................... 6009152 ................... Shaft Collar20 ......................................... 6009153 ................... Rubber Washer21 ......................................... 6509343 ................... Actuator Assy.22 ......................................... 6509020 ................... Traverse Base Adjustable End Cap23 ......................................... 6509021 ................... Bellows Carriage Mounting Bracket24 ......................................... 6509024 ................... Machined Traverse Base25 ......................................... 6509025 ................... Bellows End Mounting Bracket26 ......................................... 6509061 ................... Motor Mount Bracket27 ......................................... 6509063 ................... Carriage Shaft28 ......................................... 6509065 ................... Carriage Drive Shaft29 ......................................... 6509211 ................... Carriage Proximity Flag Bracket30 ......................................... 6509250 ................... 650 Way Cover Bellows31 ......................................... 6509253 ................... Carriage Dust Cover Bracket32 ......................................... 6509566 ................... Carriage Sub Assembly33 ......................................... 6509585 ................... Release Arm Weldment34 ......................................... 3708454 ................... Release Decal35 ......................................... B250616 ................... Button Head Cap Screw 1/4-20 x 3/836 ......................................... 6509565 ................... Cross Slide Sub Assembly37 ......................................... B190811 ................... Socket Head Cap Screw 10-24 x 1/2 Long38 ......................................... J197000 ................... 10-24 Locknut - Jam39 ......................................... B251211 ................... Socket Head Cap Screw 1/4-20 x 3/4 Long40 ......................................... 6009548 ................... Actuator Bar Assembly41 ......................................... 6309085 ................... Traverse Motor Assy42 ......................................... 3709668 ................... Socket Head Screw43 ......................................... 3709597 ................... Sealed Bearing44 ......................................... 3709596 ................... Spacer45 ......................................... 3709469 ................... Compression spring46 ......................................... K250001 ................... 1/4"Flat Washer

PARTNUMBER

56

PARTS LIST 6509565 CROSS

57

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 Plug

6 ....................................... 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 support

16 ..................................... 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 Lockwasher

26 ..................................... 6509010 ................ Traverse Base Adjuster Bracket

DIAGRAMNUMBER

PARTNUMBER

DESCRIPTION

58

PARTS LIST 6309530 TRAVERSE AND CARRIAGE ASSEMBLY

59

PARTS LIST 6309530 TRAVERSE AND CARRIAGE ASSEMBLY

DIAGRAMNUMBER

DESCRIPTIONPARTNUMBER

1 B250811 1/4-20 Socket Head Cap Screw x 1/2" Long2 B250819 1/4" Truss Head Machine Screw x 1/2" Long3 B251011 1/4-20 Socket Head Cap Screw x 5/8" Long4 B371211 3/8-16 Socket Head Cap Screw x 3/4" Long5 B503211 1/2-13 Socket Head Cap Screw x 2" Long

6 H371602 3/8" Dia. Roll Pin x 1" Long7 J257100 1/4-20 Full Height Locknut8 K251501 1/4 Lockwasher9 K371501 3/8 Lockwasher10 K501501 1/2 Lockwasher

11 3707279 Strain Relief12 3708419 Wave Spring13 3708421 Flat Washer - 3/4 ID x 1 OD x .075Thick14 6509221 Fixed Traverse Base Bracket15 6509553 Fixed End Cap Weldment

16 6509560 RH Proximity Switch Bracket Weldment17 6509561 LH Proximity Switch Bracket Weldment18 6309056 LH Traverse Proximity Switch19 6309057 RH Traverse Proximity Switch20 3707224 Cable Tie Mount (Used Throughout Machine)

21 3707459 Proximity Switch Nut

60

6509566 CARRIAGE SUB ASSEMBLYPARTS LIST

61

PARTS LIST (Continued) 6509566 CARRIAGE SUB ASSEMBLY

DESCRIPTION

1 ................... B191211 .................. Socket Head Cap Screw 10-24 x 3/4 Long2 ................... B250616 .................. BS Head Cap Screw 1/4-20 x .38 Long3 ................... 6509584 .................. Swing Door Weldment4 ................... J887300 .................. 7/8-14 Nylok Jam Locknut5 ................... K191501 .................. No. 10 Lockwasher

6 ................... K251501 .................. 1/4 Split Lockwasher7 ................... R602031 .................. #4 x .31 Drive Screw8 ................... 3708105 .................. Compression Spring9 ................... 3708184 .................. Retaining Ring10 ................. 3709040 .................. Spherical Bearing

11 ................. 3709044 .................. Ball Bushing Bearing12 ................. 3708186 .................. Ball Bearing13 ................. 3708208 .................. Shoulder Bolt .250 Dia. x .387 Long14 ................. 6509019 .................. Carriage Base15 ................. 6509023 .................. Grinder Head Pivot Shaft

16 ................. 6509251 .................. Swing Door Latch17 ................. 3708462 .................. Decal - RPM, Symbol

DIAGRAMNUMBER

PARTNUMBER

62

PARTS LIST 6309510-(Top) TRAVERSE & CARRIAGE ASSEMBLY

63

PARTS LIST 6309510-(Top) TRAVERSE & CARRIAGE ASSEMBLY

1 ....................................... 3708448 ................ Warning Electric Symbol2 ....................................... B250811 ................ Socket Head Cap Screw 1/4-20 x 1/2 Long3 ....................................... B250818 ................ Pan Head Machine Screw 1/4-20 x 1/2 Long4 ....................................... B251611 ................ Socket Head Cap Screw 1/4-20 x 1 Long5 ....................................... B311611 ................ Socket Head Cap Screw 5/16-18 x 1 Long6 ....................................... C250420 ............... Socket Set Screw 1/4-20 x 1/4 Long7 ....................................... C250620 ............... Socket Set Screw 1/4-20 x 3/8 Long8 ....................................... H254009 ................ Drive Loc. Pin 1/4 x 2.5 Long9 ....................................... J757300 ................ 3/4-16 Full Nylok Locknut10 ..................................... K250001 ................ 1/4Flat washer

11 ..................................... K251501 ................ 1/4 Split Lockwasher12 ..................................... K311501 ................ 5/16 Split Lockwasher13 ..................................... R000376 ................ Square Key 1/8 x 3/4" Long14 ..................................... J257100 ................ 1/4-20 Locknut15 ..................................... 3700089 ................ Grinding Wheel 5" Dia. x 1" Wide16 ..................................... 3707023 ................ DC Motor 1 HP 90V17 ..................................... 3707294 ................ Strain Relief18 ..................................... 3707935 ................ Tube Clamp19 ..................................... 6309573 ................ Finger Sub Assembly20 ..................................... 3708193 ................ Conical Washer

21 ..................................... 3708194 ................ Internal Retaining Ring 5000-13722 ..................................... 3708195 ................ External Retaining Ring 5100-18723 ..................................... 3708196 ................ Internal Retaining Ring 5100-5924 ..................................... 3708204 ................ Ball Bearing25 ..................................... 3708202 ................ Poly V Belt26 ..................................... 3708436 ................ Wave Spring27 ..................................... 3709072 ................ Compression Spring28 ..................................... 6509578 ................ Grinding Head Spindle Assembly29 ..................................... 6509018 ................ Grinding Head Housing30 ..................................... 6509052 ................ Poly V Pulley

31 ..................................... 6509527 ................ Plunger Pin32 ..................................... 6509054 ................ Plunger Pin Retainer33 ..................................... 6509055 ................ Belt Cover34 ..................................... 6509210 ................ Belt Cover Gasket35 ..................................... B251018 ................ Pan Head Machine Screw 1/4-20 x 5/16 Long36 ..................................... 6509237 ................ Grinding Wheel Knob37 ..................................... 6509238 ................ Grip Grinding Wheel Knob38 ..................................... 6509247 ................ Pulley Spacer39 ..................................... 6509256 ................ Motor Spacer

DIAGRAMNUMBER

PARTNUMBER DESCRIPTION

64

PARTS LIST 6309573 FINGER AND BODY ASSEMBLY

65

PARTS LIST (Continued) 6309573 FINGER AND BODY ASSEMBLY

DIAGRAMNUMBER


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 ......................................... H254009 .................... Drive Lock Pin 1/4 x 2.5 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 ......................................... 6509572 .................... Index Finger Assembly38 ......................................... 6509591 .................... 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

66

PARTS LIST 6309574 STEPPER & MOUNTING ASSEMBLY

67

6309574 STEPPER & MOUNTING ASSEMBLYPARTS LIST (Continued)

1 ...................................B161811............. Socket Head Cap Screw 8-32 x 1 1/8 Long2 ...................................B252811............. Socket Head Cap Screw 1/4-20 x 1 3/4 Long3 ...................................C250825 ............ Socket Set Screw 1/4-20 x 1/24 ...................................C251020 ............ 1/4-20 x 5/8" Set Screw5 ...................................6309500 ............. DL Motor/Reducer Assembly

6 ...................................J377200 ............. 3/8-24 Nylok Jam Locknut7 ...................................K161501 ............ #8 Split Lockwasher8 ...................................3708187 ............. Ball Bearing9 ...................................3708189 ............. Retaining Ring10 .................................3708192 ............. Hose Clamp 2.25 Dia.

11 .................................3709304 ............. Thrust Washer12 .................................6509048 ............. Hex Pivot Pin13 .................................6509051 ............. Trunion Block14 .................................6509056 ............. Bellows, 1.88 I.D.15 .................................6309052 ............. Actuator Motor Mounting Bracket

16 .................................6309053 ............. Calibration ring17 .................................B191611............. Socket Head Cap Screw 10-24 x 1" Long18 .................................K191501 ............ #10 Lockwasher19 .................................B160407 ............ 8-32 x 1/4 Button Head Socket Cap Screw20 .................................3708424 ............. Retaining Ring Ext. 1.75

21 .................................6509384 ............. Infeed Stepper Assembly22 .................................3708629 ............. Split Shaft Collar .25 I.D.23 .................................6309055 ............. Window24 .................................C250420 ............ 1/4-20 x 1/4 Socket Set Screw25 .................................C160420 ............ 8-32 x 1/4 Socket Set Screw

26 .................................6309040 ............. Adapter27 .................................6509381 ............. Base Cover Plate28 .................................B190613 ............ Socket Head Cap Screw 10-24x 3/8 Long


DIAGRAMNUMBER

68

PARTS LIST 6309541 CONTROL PANEL ASSEMBLY

58

69

PARTS LIST 6309541 CONTROL PANEL ASSEMBLYDIAGRAM NUMBER PART NUMBER DESCRIPTION1 ................................................B130812 ....................... Pan Head Machine Screw 6-32 x 1/22 ................................................B161014 ....................... Pan Head Machine Screw 8-32 x 5/83 ................................................B190809 ....................... Round Head Machine Screw 10-24 x 1/24 ................................................B192013 ....................... Button Head Cap Screw 10-24 x 1.255 ................................................B250816 ....................... Button Head Cap Screw 1/4-20 x 1/26 ................................................B371201 ....................... Hex Head Cap Screw 3/8-16 x 3/47 ................................................ J317100 ........................ Locknut 5/6-188 ................................................K371501 ....................... 3/8 Split Lockwasher9 ................................................R000480 ....................... Lockwasher #810 ..............................................R000483 ....................... Lockwasher #1011 ...............................................R000553 ....................... Kep Nut 10-2412 ..............................................R000557 ....................... Kep Nut 6-3213 ..............................................R000558 ....................... Kep Nut 8-3214 .............................................. 3707066 ........................ Strain Relief .22/.23 Wire15a ............................................ 3707556 ........................ Magnetic Starter 1 HP15b ............................................ 3707557 ........................ Overload Relay for Starter16 .............................................. 3707091 ........................ Fuse Block17 .............................................. 3707273 ........................ Strain Relief .33/.36 Wire18 .............................................. 3707367 ........................ Rocker Switch On/Off19 .............................................. 3707550 ........................ Traverse Control Board20 .............................................. 3707275 ........................ Strain Relief .33/.36 Wire21 .............................................. 3707314 ........................ Control Board 1 HP22 .............................................. 3707428 ........................ Rocker Switch On/Off/On23 .............................................. 3707429 ........................ Rocker Switch On/Off24 .............................................. 3707446 ........................ Knob with Pointer25 .............................................. 3707431 ........................ Relay 24VDC Coil26 .............................................. J371000 ........................ Hex Nut 3/18-1627 .............................................. 3707075 ........................ Boot - Toggle Switch28 ..............................................R000552 ....................... Kep Nut 1/4-2029 .............................................. 3707567 ........................ Stop Push-Pull Button30 .............................................. 3707080 ........................ Switch - Toggle Hes/Rev31 .............................................. 3707526 ........................ Bridge Diode - 25AMP32 .............................................. 3707564 ........................ Start Pushbutton33 .............................................. 3708448 ........................ Electrical Warning Decal34 .............................................. 3709809 ........................ Shoulder Bolt .375D x .375L35 .............................................. 3709864 ........................ Tinnerman Nut36 .............................................. 6009062 ........................ Electrical Box Cover37 .............................................. 6009199 ........................ Traverse Pot Assembly38 .............................................. 6709068 ........................ Box Painted Pivot Bracket39 .............................................. 6309047 ........................ Control Panel Decal40 .............................................. 3707403 ........................ Power Line Filter41 .............................................. 6309511 ........................ Transformer Assembly42 .............................................. 6709091 ........................ Warning Decal43 .............................................. 6309502 ........................ Control Box Weldment44 .............................................. 3707524 ........................ Spin Drive Control Board45 .............................................. 3709304 ........................ Thrust Washer .375 x .81246 .............................................. 6309065 ........................ Spin Pot Assembly47 .............................................. 6309066 ........................ Torque Release Pot Assembly48 .............................................. 6309516 ........................ Control Board box Weldmen49 .............................................. 3707558 ........................ Voltage Sensor50 ..............................................B161614 ....................... #8-32 x 1" PHMS51 .............................................. 3707073 ........................ 8 Pin Socket52 .............................................. 3708697 ........................ Decal - Patent53 .............................................. 3708826 ........................ Decal - Low Voltage54 .............................................. 3707566 ........................ Contactor Mounting Latch55 .............................................. 3707568 ........................ Contactor - Stop Button56 .............................................. 3707565 ........................ Contactor - Start Button57 .............................................. 6309105 ........................ Voltage Regulator Assembly58 .............................................. 3707294 ........................ Strain Relief .43/.47 Wire

70

6309538 MOWER SUPPORT ASSEMBLYPARTS LIST

71

PARTS LIST (Continued) 6309538 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 Long

6 ....................................... 3708366 ................ 6" type B Lanyard7 ....................................... 6509128 ................ Horizontal Scale Decal RH8 ....................................... 6509129 ................ Vertical Scale Decal9 ....................................... 6509507 ................ Bar Mounting Weldment Bracket10 ..................................... 6509517 ................ L.H. Front Roller Horiz. Weldment Bracket

11 ..................................... 6509422 ................ 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 Bracket

16 ..................................... 6509421 ................ R.H. Roller Clamp Weldment Bracket17 ..................................... 3709304 ................ Thrust Washer18 ..................................... B311201 ................ Hex Head Cap Screw 5/16-18 x 3/4 Long19 ..................................... J317100 ................ 5/16-18 Nylok Locknut20 ..................................... J507000 ................ 1/2-13 Hex Jam Nut

21 ..................................... C500861 ............... 1/2-20 x 1/2 Flat Pt Socket Head Set Screw23 ..................................... 6309534 ................ Toggle Clamp24 ..................................... 3709849 ................ Pony Clamp Spring25 ..................................... 3709858 ................ Pony Leaf

26 ..................................... 6309532 ................ R.R. Clamp Arm Weldment27 ..................................... 6309536 ................ R.R. Clamp Base Welment28 ..................................... 6509545 ................ R.R. Clamp Block Weldment29 ..................................... 6509304 ................ Horizontal Scale Decal LH30 ..................................... 6509576 ................ R.H. Front Roller Clamp Weldment

31 ..................................... 3708579 ................ Shoulder Bolt .375 x 3.25 Long32 ..................................... 3709613 ................ Star Knob33 ..................................... 6309022 ................ Slide34 ..................................... 6309544 ................ Rear Roller Bracket Weldment

72

PARTS LIST 6509523 SPIN DRIVE ASSEMBLY

73

6509523 SPIN DRIVE ASSEMBLYPARTS LIST (Continued)

DIAGRAMNUMBER

1 ......................................... 3708391 .............................. Reducer: 10:1 Ratio2 ......................................... 6509336 .............................. Motor, DC .20 HP TEFC3 ......................................... B251411 .............................. Socket Head Cap Screw 1/4-20 x 7/8 Long4 ......................................... 3709586 .............................. Flange Coupler .505 ......................................... 3709585 ............................. Sleeve Coupler

6 ......................................... 3709584 .............................. Flange Coupler 5/87 ......................................... 6009217 .............................. Drive Coupling Adapter8 ......................................... C250620 ............................. Socket Set Screw 1/4-20 x 3/89 ......................................... 6009598 .............................. Tee Knob Assembly .50 Long10 ....................................... 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 Wire

16 ....................................... 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. Thread

26 ....................................... 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 Rod

36 ....................................... 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 Long41 ....................................... 3707623 .............................. DC Motor Brush


74

PARTS LIST 6309549 MISCELLANEOUS PARTS

75

PARTS LIST (Continued) 6309549 MISCELLANEOUS PARTS


DIAGRAMNUMBER

1 .............................................. 3700088 .................................. Grinding Wheel 3.5" Dia. x .38 w2 .............................................. B371601 ................................. Hex Head Cap Screw 3/8-16 x 1 Long3 .............................................. J377100 .................................. Nylok Locknut4 .............................................. K370001 ................................. 3/8 Flat Washer5 .............................................. 6009102 .................................. Grab Hook6 .............................................. 6509113 ................................. Chain7 .............................................. 6509569 ................................. Gage Bar Assembly-Vertical8 .............................................. 6509418 ................................. Plate-Pivot9 .............................................. 6509567 .................................. Knob Assembly10 ............................................ B252011 ................................. Socket Head Cap Screw 1/4-20 x 1-1/4 Long11 ............................................. B120611 .................................. Socket Head Cap Screw 5-40 x .38 Long12 ............................................ B161011 .................................. Socket Head Cap Screw 8-32 x 5/8 Long13 ............................................ J161000.................................. 8-32 Hex Nut14 ............................................ K121501 .................................. No. 5 Split Lockwasher15 ............................................ K161501 .................................. No. 8 Lockwasher16 ............................................ 6509359 ................................. Digital Gage17 ............................................ H060302 ................................. 1/16 x 3/16L Roll Pin18 ............................................ 6509412 ................................. Base Weldment Indicator19 ............................................ 6509568 ................................. Alignment Extension Weldment20 ............................................ B190811 .................................. Socket Head Cap Screw 10-24 x 1/221 ............................................ J197100 .................................. 10-24 Nylok Locknut22 ............................................ 3708384 .................................. Magnet23 ............................................ 6509143 .................................. Reel Positioner Gage25 ............................................ 6509590 ................................. Spreader Bar Weldment26 ............................................ 6509557 .................................. Drip Pan Weldment43 ............................................ J317100.................................. 5/16-18 Lock Nut45 ............................................ 3700087 ................................. Grinding Wheel 5" Dia. x .3/8" Side46 ............................................ 3700086 .................................. Grinding Wheel 3.5" Dia. x 1" Wide47 ............................................ 3709316 .................................. 5/16-18 x 3" U-Bolt 1 1/2"48 ............................................ 6509349 .................................. Retaining Plate49 ............................................ 3529069 .................................. Spacer50 ............................................ K251501 .................................. 1/4 Lockwasher51 ............................................ 6609501 ................................. T-Knob Assembly52 ............................................ 3708813 ................................. T-Knob Assembly53 ............................................ 3700089* ................................ Grinding Wheel 5" Dia. x 1" Wide

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

76

PARTS LIST 6309541 WIRING DIAGRAM

77

PARTS LIST (Continued)

DESCRIPTIONDIAGRAMNUMBER

1 ................................. B192013 ........... Button Head Cap Screw 10-24 x 1.252 ................................. R000553 ........... Kep 10-243 ................................. 3707080............ Toggle Switch Hes/Rev4a ............................... 3707556............ Magnetic Starter 1 HP4b ............................... 3707557............ Overload Relay for Starter5 ................................. 3707090............ Slo-Blo Fuse 4 AMP6 ................................. 3707091............ Fuse Block7 ................................. 3707092............ Slo-Blo Fuse 1 AMP8 ................................. 3707224............ Cable Mount Tie9 ................................. 3707225............ Cable Tie 6.5L x .18W x .052T10 ............................... 3707550............ Traverse Control Board11 ............................... 3707403............ Power Line Filter12 ............................... 3707425............ Control Board Power Motor 1 HP13 ............................... 3707428............ Rocker Switch MOM On/Off/On14 ............................... 3707429............ Rocker Switch On/Off15 ............................... 3707431............ DPST Relay 24VDC Coil16 ............................... See page 69 ..... Pushbutton Start Assembly17 ............................... 3707526............ Bridge Diode 25 AMP18 ............................... See page 69 ..... Pushbutton Stop Assembly19 ............................... 3707524............ Spin with Relay Control Board20 ............................... 6009104............ Wire Assembly .25F/#5FK21 ............................... 6009110 ............ Wire Assembly FER/FER22 ............................... 6009111 ............ Wire Assembly .25F/.25F23 ............................... 6009112 ............ Wire Assembly .25F/.25F24 ............................... 6009113 ............ Wire Assembly #6FK/#6FK25 ............................... 6009117 ............ Wire Assembly .25F/#6FK26 ............................... 6009118 ............ Wire Assembly #6FK/#10RG27 ............................... 6009180............ Wire Assembly .25F/#6FK28 ............................... 6009181............ Wire Assembly .25F/#6FK29 ............................... 6709112 ............ Wire Assembly STR/FK W7530 ............................... 6009196............ Main Power Cord31 ............................... 6009199............ Traverse Pot Assembly32 ............................... 6009201............ Wire Assembly #6FK/#6FK33 ............................... 6009202............ Wire Assembly #6FK/#6FK34 ............................... 6009203............ Wire Assembly .25F/.25F35 ............................... 6009204............ Wire Assembly #6FK/#6FK36 ............................... 6309106............ Wire Assembly 2-Loop

PARTNUMBER

78

PARTS LIST 6309541 WIRING DIAGRAM

79

PARTS LIST (Continued)

DIAGRAMNUMBER

37 ............................... 6309108............ Wire Assembly 2-Loop38 ............................... 6309060............Wire Assembly .25F/.25F39 ............................... 6309061............Wire Assembly .25F/.25FK40 ............................... 6309104............Wire Assembly .25F/.25F41 ............................... 6309063............Wire Assembly .25F/.25F42 ............................... 6309109............ Wire Assembly .25F/.25F43 ............................... 6309065............Spin (SSP) Pot Assembly44 ............................... 6309066............Relay Torque Pot Assembly45 ............................... 6309105............Voltage Regulator Assembly46 ............................... 6309107............Door Safety Switch Assembly47 ............................... 6309069............Wire Assembly 2-Loop48 ............................... 6309121............Wire Assembly .25F/Fer49 ............................... 6309071............Wire Assembly 2-Loop50 ............................... 6309072............Wire Assembly 2-Loop51 ............................... 6309122............Wire Assembly .25M/.25F52 ............................... 6309074............ Infeed Motor Cord53 ............................... 6309075............Wire Assembly .25M/#6FK54 ............................... 6309103............Wire Assembly .25F/.25F55 ............................... 6309077............Grinding Motor Cord56 ............................... 6309123............Motor BRD Power Cord57 ............................... 6309079............Wire Assembly .25F/RG58 ............................... 6309511 ............Transformer Assembly59 ............................... 6509301............Wire Assembly .25F x 260 ............................... 6509302............Wire Assembly .25F x 261 ............................... 6504596............Resistor/Jumper Assembly62 ............................... 6709113 ............Wire Assembly .25F x 263 ............................... 6709110 ............ Wire Assembly Str/FK W7364 ............................... 6509336............Spin Motor Assembly65 ............................... 6309056............Left-Hand T raverse Proximity66 ............................... 6309057............Right-Hand Traverse Proximity67 ............................... 3707586............Slow-Blo Fuse 1/4 Amp69 ............................... 6709111 ............Wire Assembly Str/FK W7470 ............................... 3707073............8 Pin Socket71 ............................... 3707367............Rocker Switch On/Off72 ............................... 3707546............Slo-Blo Fuse 3 AMP73 ............................... 6309084............Traverse Motor Cord74 ............................... 6309134............Diode Jumper Assembly


80

WIRING SCHEMATIC

81

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ASSEMBLY and SERVICE MANUAL - irp-cdn.multiscreensite.com · 1 accu-pro 630 spin/relief grinder assembly and service manual 6307954 (3-03)