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ASSEMBLY and SERVICE MANUAL

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2. PROXIMITY FLAG BRACKET ADJUSTABLE RELIEF TENSION NYLON PLUG amp SET SCREW If the relief angle appears to vary during relief grinding adjust the tension on the nylon plug and set screw See FIG 23 ADJUSTMENTS Continued SPIN GRINDING ATTACHMENT ADJUSTMENT If free play develops so the crank handle wants to rotate with free play when operating in the scissor action raising and low ering on the spin grinding attachment the free play can be elimi nated by tightening the set screw identified in FIG 24 If there is too much play in the spin drive pivot points torque down the hex nut tight so conical washer is compressed then back off 1 2 turn See FIG 24 TRAVERSE MOTOR COUPLING Traverse motor shaft must be concentric to traverse drive shaft within 010 The traverse shaft and motor shaft are to have at least 1 8 3 mm to 1 2 13 mm clearance so they do not contact each other The coupling is to be locked down tightly with the spiral grooves equally spaced for the full length See FIG 25 d tn nnt BETWEEN MOTOR 2 13MM SHAFT amp DRIVE SHAFT FIG 25 ADJUSTMENTS Continued ADJUSTING CROSS SLIDE ASSEMBLY If the cross slide becomes very difficult to turn it may become necessary to adjust the assembly To relieve the tension on the assembly follow the procedure listed below ST
3. 11 44LVR 7 54 S ll 1 43481 40 e El o N 21347 5 lg lt o He de D XWWALHY Da AY DEINEN Lee NI ZU reg CINWE LI CENWIE LT grand D Z113825 101 61 77 55 TST CDR TEIE 11 10201 62 8 cET3809 82 V CT3SES CIN Deng E A 26865 ORO SELELEQGLSLSLSLSLGLO 006060 0060006060 006 20808020302080303020 OSO SOLO SOS OSOLEROSOS OBOLOLOLOLORORSEOLO CEO 09 RCE O BORO EOS 14 BE 4 IIN did 0 at 9 NES HOMOL EAT 8 LA 15549 91 mme 7 zE 3814 ME IHIN IO T yn NS SN SK 9 07198
4. K Check output at SIC Have High Low Switch set on high speed rabbit MAQ term 13 to 14 Measure 0 volts DC Yes Replace wire 46 No Replace MAG Light comes on Yes go to step H next No Contact Factory Insure all wires are connected at the SIC to the connectors and that none have become loose Some connections have multiple wires in them be sure all are tight by gently tugging on them If all wires appear to be connected and correct proceed SIC Terminal phase Ato terminal phase A Measure 4 7 Volts DC 0 2 0 3 Volts while jog button is pressed SIC Terminal phase B to terminal phase B Measure 4 7 Volts DC 0 2 0 3 Volts while jog button is pressed Yes replace stepper motor No replace SIC ELECTRICAL TROUBLESHOOTING Continued PROBLEM No Manual jog cycle or Auto Cycle stops because of system error message on Touch Screen System Error Message STORE FINGER FOR SPIN GRIND ROTATE HEAD DOWN FOR SPIN GRIND HOME TRAVERSE TO RIGHT PROX TO START ROTATE HEAD UP FOR RELIEF GRIND Checkout Procedure A Rotate index finger assembly to spin position B Check PLG input from Finger Stored Down prox A Rotate grind head assmbly down B Check PLC input from Head Relief Pos Position prox A Jog Grind head to right prox with touch screen controls B Check PLC input from Right Traverse prox switch A Rotate grind head assmbly up B Check PL
5. is not working Relay RE112 is not working Relay RE112 Contacts bad Checkout Procedure A Turn switch on from either SPIN Grinding Motor works MANUAL screen or RELIEF MANUAL Yes end troubleshooting screen B Reset circuit breaker switch tripped by current overload C Check for GMC incoming 115 Volts AC D Check for GMc output voltage of 95 Volts DC E Check for RE112 input of 24 Volts DC at the coil Reminder Grind Drive switch must be on and doors must be closed F Check for RE112 input of 115 Volts AC G Check for RE112 output of 115 Volts AC No go to Step B next Grinding Motor works Yes end troubleshooting No go to step C next GMC Term L1 to 12 for 115 Volts AC Yes go to step D next No go to Step E next GMC Term A to A for 95 3 Volts DC Yes go to Step K No if 0 V replace GMC RE112 Term 0 to term 1 for 24 Volts DC Yes If 24 Volts DC go to Step F next No Skip to Step H RE112 Term 8 black wire No 40 to Term 4 white wire No 63 for 115 Volts AC Yes Go to step G next No Check continuity of wires 40 and 63 if bad replace bad wire RE112 Term 6 black wire No 102 to Term 2 white wire No 61 for 115 Volts AC Yes Check continuity of wires 102 and 61 if bad replace bad wire No replace RE112 ELECTRICAL TROUBLESHOOTING Continued Possible Cause Relay 5 RT1 is not work ing Grinding Head DC Mo
6. Cas NE amp 00 95 Kiem wr 6509462 RESISTOR LACK OLOJO Im H XN B ALIHA 816069 ASSY 308 DD ASSY 1819 IHS 994 MOTOR CABLE 18 TRAVERS N29 GIREL 12 2 309306 OE CI 13820162 2201 104 3788 SOLON ONIX 019195 ee ees Trad Far ar eor eae ca fr gt gt SISTER ASSY 6 R 00 THIS 9 Mk 18385 HONOL 3940 GROUND LUG 2 WORK LIGHT VACUUM N RE34 0D 2 1 NI VACUUM 1 1 TO LINE 2 27 4 EMERGENCY STOP N11 RELAY 1 13 1 24 3 118 24VDC CONTROL TO LINE 3 101 N11 POWER S
7. 6309532 6309536 6509545 6509304 6509576 3708579 3709613 6309022 6309544 6309538 MOWER SUPPORT ASSEMBLY DESCRIPTION Pan Head Machine Screw 10 24 x 3 8 Long No 10 Lockwasher Knob Assembly Quick Release Pin 31 Dia Shoulder Bolt 375 Dia x 50 Long 6 type B Lanyard Horizontal Scale Decal RH Vertical Scale Decal Bar Mounting Weldment Bracket L H Front Roller Horiz Weldment Bracket L H Roller Clamp Weldment Bracket Knob Assembly L H Front Roller Clamp Weldment Knob Assembly R H Front Roller Horiz Welment Bracket R H Roller Clamp Weldment Bracket Thrust Washer Hex Head Cap Screw 5 16 18 x 3 4 Long 5 16 18 Nylok Locknut 1 2 13 Hex Jam Nut 1 2 20 x 1 2 Flat Pt Socket Head Set Screw Toggle Clamp Pony Clamp Spring Pony Leaf R R Clamp Arm Weldment R R Clamp Base Welment R R Clamp Block Weldment Horizontal Scale Decal LH R H Front Roller Clamp Weldment Shoulder Bolt 375 x 3 25 Long Star Knob Slide Rear Roller Bracket Weldment PARTS LIST 6509465 SPIN DRIVE ASSEMBLY 86 DIAGRAM PARTS LIST Continued PART NUMBER 3708391 6509457 B251411 3709586 3709585 3709584 6009217 C250620 6009598 3709073 6009051 6009052 R000376 6009078 3707279 6009079 6009580 3708262 6009048 6009046 3709062 3709809 3709705 C310420 6009047 6009045 B375611 J377100 6509519 3708148 3709370 J252000 J257000 C310620 6009076 6009555 6509114 6009067 B25501
8. 6509010 6509565 CROSS SLIDE ASSEMBLY DESCRIPTION Socket Set Screw CPPT 5 16 18 x 3 4 Long 3 8 16 Hex Nut 3 8 16 Hex Jam Nylon Locknut 3 8 Split Lockwasher 3 16 Dia Nylon Plug Handwheel 4 5 Dia 38 Bore Bell V Washer 75 D x 035 T Thrust Washer Adjustable Handle 5 16 18 Female Orange Adjusting ACME Shaft Locking Stud Shaft Cross Slide Support Slide Shaft Cross Slide Cross Slide Horizontal support Socket Set Screw 5 16 18 x 5 8 Long Flat Washer Grey Decal Orange Decal 5 16 18 Locking Stud Adjustable Handle 5 16 18 Female Grey Spacer 406 ID x 75 OD x 1 0 Long Socket Head Cap Screw 3 8 16 x 1 1 4 Long Rollpin 3 8 Dia x 1 Long 3 8 Split Lockwasher Traverse Base Adjuster Bracket PARTS LIST 6509530 TRAVERSE amp CARRIAGE ASSEMBLY PARTS LIST Continued 6509530 TRAVERSE amp CARRIAGE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION B250811 1 4 20 Socket Head Cap Screw x 1 2 Long B250819 1 4 Truss Head Machine Screw x 1 2 Long B251011 1 4 20 Socket Head Cap Screw x 5 8 Long B371211 3 8 16 Socket Head Cap Screw x 3 4 Long B503211 1 2 13 Socket Head Cap Screw x 2 Long H371602 3 8 Dia Roll Pin x 1 Long J257100 1 4 20 Full Height Locknut K251501 1 4 Lockwasher K371501 3 8 Lockwasher K501501 1 2 Lockwasher 3707279 Strain Relief 3708419 Wave Spring 3708421 Flat Washer 3 4 ID x 1 OD x 075Thick 6509221 Fixed Traverse Base Bracket 6509553 Fixed End Cap We
9. Circuit Breaker 32 CB32 bad Checkout Procedure A Set TSP to 35 on the control panel B Insure release lever is in proper position C Too heavy a grind causes grinding head traverse motor to overload and trip the circuit breaker Reset CB32 D Check for 115 Volts AC incoming to insure traverse right or left has been pressed at least once E Check for relay 8 RT1 light on insure traverse right or left has been pressed at least once F Check relay 8 for continuity Insure relay 8 light is on G Check CB32 for voltage Traverse works Yes end troubleshooting No go to step B next Traverse works Yes end troublshooting No go to Step C next Traverse works Yes end troublshooting No go to Step D next On Term L1 to L2 for 115 Volts AC Yes Skip to Step H No go to Step E next Light is On go to Step F next Off Contact Factory RT1 Term 8 to 8 read 115 Volts AC Yes Replace Relay 8 RT1 No go to Step G next CB32 from Line neutral White wire at the line filter wire N11 34FTR8 FH to wire 32 36CB32 BL at CB32 measure 115 Volts AC No Replace CB32 Yes Verify continutiy of wire 25 Re place or repair bad wire s ELECTRICAL TROUBLESHOOTING Continued Possible Cause No DC Voltage from TDC Traverse Drive Control Traverse Motor is bad Check Relays 2 and 3 TSP 10K is bad Gap between flag and prox is incorrect P
10. For grinding motor belt adjustment loosen the four socket head cap screws that attach the motor Adjust the grinding motor for proper belt tension and tighten the four socket head cap screws The proper belt tension for the grinding head is to push down on the poly V belt half way between to two pulleys with 5 lbs 2 kg of force and belt movement dimensions to be 12 inches 3 mm See FIG 18 To verify belt tension mount the belt guard with two screws Turn the motor on Ifthe belt is tensioned correctly start up torque of the motor through the pulley to the belt should have zero slippage If there is belt slippage when turning on the motor there will be a slight squeal before the belt comes up to speed When you achieve correct tension reassemble all of the remaining parts that have been removed ADJUSTMENTS Continued INDEX FINGER PROXIMITY SETTING Set all motor switches to the off position Press the machine system start switch so the grinder is operational Push down on the index finger until the stop pin is within 06 inches 1 5 mm of bottoming out You can use 1 16 gage pin or rod stock between the stop pin and index finger Set the proximity switch to activate the light at this setting This assures the index finger to be close to its final stop position so the reel is completely indexed before the carriage starts to traverse See FIG 19 SENSUR LIGHT INDEX FINGER PROXIMITY SEN
11. Index Lock Handle Weldment Index Finger Positioner Weldment 1 8 Diameter x 1 4 Long Pin Roll Stop Plate Reel Positioner Adjuster PARTS LIST 6509574 STEPPER amp MOUNTING ASSEMBLY DIAGRAM PARTS LIST Continued PART NUMBER B190613 B252811 C250825 C251020 6509381 J377200 6509384 3708187 3708189 3708192 3709304 6509048 6509051 6509056 3708629 3708424 B190811 K191501 6509470 6509574 STEPPER amp MOUNTING ASSEMBLY DESCRIPTION Button Head Cap Screw 10 24 x 3 8 Long Socket Head Cap Screw 1 4 20 x 1 3 4 Long Socket Set Screw 1 4 20 x 1 2 1 4 20 x 5 8 Set Screw Base Cover Plate 3 8 24 Nylok Jam Locknut Infeed Stepper Assy Ball Bearing Retaining Ring Hose Clamp 2 25 Dia Thrust Washer Hex Pivot Pin Trunion Block Bellows 1 88 I D Flex Coupling Spiral Retaining Ring Socket Head Cap Screw 10 24 x 1 2 Long No 10 Lock Washer Stepper Infeed Motor 6509434 CONTROL PANEL ASSEMBLY PARTS LIST PARTS LIST Continued DIAGRAM PART NUMBER J627100 3708448 3708203 3708371 3708375 3708376 3708378 3708425 6509433 6509096 6509558 B190834 B250816 B191034 J197300 J257000 6509112 6509212 6509213 6509423 6509428 6509575 B250816 B190809 R000483 R000553 3708426 J161000 K161501 3708427 3708696 3709372 B190611 6509434 CONTROL PANEL ASSEMBLY DESCRIPTION Full Nylok Locknut 5 8 11 Long Warning D
12. Maximum Speed The maximum speed potentiometer is preset to 10 30 posi tion for 50 Volts DC to the traverse motor Rev Torque The Reverse Torque setting determines the maximum cur rent limit for driving the motor in the reverse direction The potentiometer is preset to the 3 00 position It should not require adjustment Fwd Torque The Foward Torque setting determines the maximum current limit for driving the motor in the forward direction The poten tiometer is preset to the 3 00 position It should not require adjustment Accel Decel The potentiometer is factory preset to the minimum full counterclockwise 8 30 position This position turns the Acceleration Deceleration off for this application IR Compensation The IR Comp control is preset to 9 30 position Never adjust past the 11 00 position Regulation of the traverse motor 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 a point turn the IR COMP trim pot counterclockwise until the symptoms just disappear QOO 8 30 10 30 9 00 3 00 3 00 E 30 VIC MAX SPD FIG 29 MACHINE SERVICE Continued GRINDING HEAD ASSEMBLY Remove grinding wheel knob and grinding wheel The Grinding Head Spindle Assembly consists of the grinding head spindle and a ball bearing press fit
13. itis nonfunctional for this application Current Limit The current limit is preset at 3 00 at the factory Going above the current limit causes the motor to pulsate The current limit can be turned clockwise to increase the motor s maxi mum torque for grinding overloads The 10 amp circuit breaker on the control panel will trip if the overload persists for a prolonged period of time Use a lower grinding head traverse speed if nuisance tripping is experienced IR Compensation Regulation of the grinder motor 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 a point turn the IR COMP trim pot counterclockwise until the symptoms just disappear The control is preset to 9 00 position Never adjust past the 11 00 position when changing the setting to increase higher torque for heavy grinding Potentiometer ACCEL sa CALL CO e DCH amp VOC Clock Orientation Terminal ends Feet are always at the 6 00 position no matter potentiometer orientation on the board MACHINE SERVICE TRAVERSE DRIVE CONTROL BOARD TDC The Traverse Drive Control Board has five potentiometers as shown on drawing 6504434 which is included These poten tiometers have been set at the factory to the positions shown on the drawing Also see FIG 29
14. 5 16 18 Lock Nut Vac Bag Knob Foam Strip 25 Thick Heyco Bushing Vacuum Cloth Filter Button Head Cap Screw 5 16 18 x 7 8 Warning Decal Fuel Symbol Strain Relief Roll Pin 3 8 Dia x 1 25 Long 1 2 Flat Washer SAE 5 8 Hole Plug Up Down Decal PARTS LIST 6509440 CANOPY ASSEMBLY PARTS LIST Continued 6509440 CANOPY ASSEMBLY DIAGRAM PART NO 6509541 B190811 B310813 B371211 J197100 K310001 K371501 3708205 3708465 3708379 3708416 3709990 6509411 6509176 6509217 6509218 6509219 6509259 6509260 650926 1 6509437 6509439 6509441 6509435 3707224 3708703 3708820 K161501 K160001 J167000 R000558 R000480 DESCRIPTION Canopy Frame Weldment Socket Head Cap Screw 10 24 x 1 2 Socket Head cap Screw 5 16 18 Socket Head Cap Screw 3 8 16 x 3 4 10 24 Locknut 5 16 Flatwasher 3 8 Split Lockwasher Socket Holder Blind Rivet Foam Strip 50 Thick Soft Latch Decal Amber light 120 VAC Warning Decal Large Top Foam Pad Foam Pad Left Hand Large Back Foam Pad Foam Pad Right Hand Small Top Foam Pad Small Back Foam Pad Canopy Door Assembly Right Hand Canopy Door Assembly Left Hand Door Safety Switch Assembly Door Safety Switch Bracket Cable Tie Holder Typical used throughout machine Decal Warning Safety 48 32 x 50 Long Tamper Proof Screw 8 Loc
15. AC Yes replace Relay E RT1 No go to Step E next WB1 Wire Block 1 white wire 78 to CB2 black wire 58 for 115 Volts AC Yes replace CB2 and wire 70 No replace wire 58 RE34 Term 0 to term 1 for 115 Volts AC Yes go to Step G next relay cord 4 RE34 Term 8 to term 4 for 115 Volts AC Yes go to Step H next No go the step l next RE34 Term 6 to term 2 for 115 Volts AC Yes replace vacuum motor No replace RE34 WB2 Wire Block 1 white wire 48 to CB6 black wire 46 for 115 Volts AC Yes replace CB6 and wire 46 No replace wire 48 PROBLEM Winch does not work in either direction In your Product Packet Assembly there are series of prints Find the print titled Junction Box and Light Assembly before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause 7 amp circuit breaker on winch motor is tripped No voltage to motor Checkout Procedure A Reason Check for a lifting overload condition or wiring shorted to ground Reset breaker located at end of winch motor Check that motor coil cord from DC motor is plugged in Check for 115 Volt
16. ASSEMBLY DIAGRAM PART NUMBER B160607 B160613 B161014 R000483 B161211 B192013 B251201 J167000 J257100 K161501 K250101 R000553 R000558 3708448 3707180 3707273 3707275 3707294 6509340 3707412 3707413 3707447 3707439 3707444 6509480 6509481 3707046 3707164 3707163 3707279 DESCRIPTION Button Head Socket Cap Screw 8 32 x 1 4 Phillip Head Mach Screw 8 32x3 8 Phillip Head Mach Screw 8 32 x 5 8 10 Lock Washer Socket Head Cap Screw 8 32 x 3 4 Button Head Socket Cap Full Thread 10 24 x 1 25 Hex Head Cap Screw 1 4 20 x 3 4 8 32 Lock Nut 1 4 20 Nylok Lock Nut No 8 Lock Washer Flat Washer 10 24 Kep Nut 8 32 Kep Nut Warning Decal Liquid Tight Connector Strain Relief Wire 33 36 Strain Relief Wire 37 43 Strain Relief Wire 43 47 4 Stem Machine Light Electrical Box Cover with Switch Aluminum Electrical Box DPDT 120VDC Coil Relay 25 Spade Terminal Block 10 AMP Circuit Breaker Electric Junction Panel Junction Box Rough Service 100 Watt Primary Ground Lug Primary Ground Decal Strain Relief 30 PARTS LIST 6309538 MOWER SUPPORT ASSEMBLY ST mg I z e S gt DIAGRAM NUMBER PARTS LIST Continued PART NUMBER B190614 K191501 6009577 3708364 3708158 3708366 6509128 6509129 6509507 6509517 6509422 6509559 6509564 6509588 6509515 6509421 3709304 B311201 J317100 J507000 C500861 6309534 3709849 3709858
17. COLLAR FOAM SEAL ACTUATOR DRIVE SHAFT OUTBOARD SCREWS LOCK NUT ACTUATOR RELEASE LEVER RETAINER SHAFT COLLAR ACTUATOR BAR HOLDING SPRING ASSEMBLY SCREWS SHOULDER BOLT 6X BEARING 6X INSIDE WASHER 6X ADJUSTMENTS Continued CARRIAGE LINEAR BEARING REPLACEMENT STEP 1 Detach the bellows mounting brackets from the carriage Detach front and rear shields See FIG 15 STEP 2 Remove the three screws of one linear bearing and slide the linear bearing off the end of the carriage shaft STEP 3 Insert a new linear bearing onto the end of the carriage shaft with the tension adjustment screw pointing outward See LINEAR BEARING FIG 14 Adjust the tension screw of the linear bearing so when you radially rotate the linear bearing around the carriage shaft there should be no free play between the linear bearing and the carriage shaft NOTE Tension is too tight if you feel a cogging action when you rotate linear bearing around the shaft This cogging is from the skidding of the bearing on the shaft and indicates tension screw is too tight Finally sliding the bearing block back and forth should be smooth uniform motion SETTING THE BEARING TENSION CORRECTLY IS CRITICAL TO PROPER GRINDING BEARINGS WHICH ARE TOO TIGHT OR TOO LOOSE WILL CAUSE POOR GRIND QUALITY ALSO BEARINGS WHICH ARE TOO TIGHT ENSTON ADJUSTMENT SCREW __WILLHAVE SUBSTANTIALLY SHORTER LIVES POSITION FACING AND MAY DAMAGE THE SHAF
18. NUMBER PARTS LIST Continued PART NUMBER B190631 B190634 B251011 B254811 C190460 C190467 C190860 C190860 H122002 H250813 H254009 J191100 J377200 K191501 R000351 3579284 3709304 3708107 3708175 3708199 3709472 6509432 6509004 6509357 6509007 6509008 6509009 6509058 6509060 6509215 6509229 3579284 6509239 6509258 6509501 6509547 6509572 6509591 6509592 H120402 6509358 6509356 6309573 FINGER AND BODY ASSEMBLY DESCRIPTION Socket Head Cap Screw 10 32 x 3 8 Long Button Head Socket Cap Screw 10 32 x 3 8 Long Socket Head Cap Screw 1 4 20 x 5 8 Long Socket Head Cap Screw 1 4 20 x3 Long Socket Set Screw 10 24 x 1 4 Socket Set Screw Nylok Cup 10 32 x 25 Long Socket Set Screw CP PT 10 32 x 1 2 Long Socket Set Screw 10 32 x 1 2 Long Roll Pin 1 8 Dia x 1 1 4 Long Dowel Pin 1 4 Dia x 5 Long Drive Lock Pin 1 4 x 2 5 Long 10 32 Hex Nut 3 8 24 Jam Nylok Locknut No 10 Lock Washer Square Key 093 x 75 Long 1 8 Dia Nylon Plug Thrust Washer Compression Spring Compression Spring 3 8 16 Dia Split Shaft Collar Straight Grease Fitting Relief Finger Reel Finger Slide Reel Finger Positioner Index Stop Pin Index Sensor Block Slide Washer Eccentric Index Pin Gib Stop Plate Adjustable Index Lever Locking Index Finger Pin 1 8 Diameter Nylon Plug Anti Rotation Plate Dovetail Gib Tee Knob Assembly Knob Assembly Index Finger Assembly
19. below 100V Plug machine into a better source of power See Power requirements at front of manual A For safety reasons door must be closed to operate spin and or grind motors Close and latch door B Check PLC input from Door Saftey Switch A An excessive amount of time has passed between blade indexes or atthe start of a relief cycle Increase the Relief Torque Pot A An excessive amount of time has passed at the beginning of a Relief grind cycle before the finger down prox was detected Verify Torque pot setting and or spin direction Reminder Blade should push finger down Message Status Clears Proceed to next system error message you have or continue run ning Remains go to Step B next From Help Screen verify Finger Stored Down prox input is working Follow instructions on screen Clears Proceed to next system error message you have or continue run ning Clears Proceed to next system error message you have or continue run ning Clears Proceed to next system error message you have or continue run ning Remains go to Step B next From Help Screen verify Head in Relief Pos prox input is working Follow instructions on screen Clears Proceed to next system error message you have or continue run ning Clears Proceed to next system error message you have or continue run ning ELECTRICAL TROUBLESHOOTING Continued PROBLEM No Manual jog cycle or Auto Cycle st
20. ok Switch is Good Replace TDC Bad Replace switch Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Traverse Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Stepper Infeed not working in manual jog mode Assuming 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled 650 Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force all terminals to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Infeed Jog Switch is not held to on position Actuator is at physical limit Circuit Breaker 3 CB3 is tripped 2 amp High Low Switch is not on high speed Stepper motor drive coupling is loose No DC voltage to Stepper Infeed Control SIC No DC Voltage to OPTO terminal of SIC Checkout Procedure A Hold switch on in either direction B Move stepper in opposite direction C Reset circuit breaker switch tripped by current overload Grinding head stepper infeed mechanism jammed causing overl
21. pot SSP set at 400 L With 115 Volts AC at Term L1 and L2 check SDC output Have Relief Torque Pot RTP set to Red Line Spin Motor works Yes end troubleshooting No go to Step B next Spin Motor works Yes end troubleshooting No go to Step C next Spin Motor works Yes end troubleshooting No go to step D next Spin Motor works Yes end troubleshooting No go to step E next SDC Term L1 to 4L2 for 115 Volts AC Yes skip to step H next No go to Step F next Light is ON Yes go to Step G next No Contact factory RT1 Term 9 to term 9 for 115 Volts AC No go to Step H next Yes Replace relay 9 in RT1 SDC term A1 to term A2 measure approx 90 Volts DC Yes Skip to Step L No go to step I Next SDC term A1 to term A2 measure approx 12 Volts DC No Skip to step N Yes go to step J Next ELECTRICAL TROUBLESHOOTING Continued Possible Cause Relay 4 is bad Reversing relay s bad RT1 Spin Speed Pot SSP is not working Spin Drive motor is bad Worn motor brushes Checkout Procedure J Check RT1 for light 44 to be on Insure that Spin Drive switch has been pressed on from SPIN MANUAL screen at least once K With light 44 on verify continuity L Measure voltage at spin motor M Reverse direction of spin motor from SPIN MANUAL touch screen N SSP on Main Panel O With machine power off Check spin motor continuity P Inspect motor brushes
22. touch screen Next Page No go to Step E next No 115 Volts AC power to D Check for incoming power MAG MAG for 115 Volts AC E At rear junction box White box WB2 Across main power cord 02 in back of grinder beside vacuum white wire to 02 black wire for 115 Volts AC Wire Block 2 WB2 check for 115 Yes replace panel power cord 05 Volts AC No replace main power cord 02 No power from junction box ELECTRICAL TROUBLESHOOTING Continued PROBLEM Red E Stop screen displayed on Touch Screen In your Product Packet Assembly there are series of prints Find the print titled 650 Wiring Diagram and Junction Box Light Assembly before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause Checkout Procedure You must push the green A Listen for magnetic contactor Machine works Push to Start Switch PSS MAG to pull in with a clunk Yes end troubleshooting No go to Step B next Pull red e stop button out B Repeat push the green button Machine works PSS again Yes end troubleshooting No go to Step C next 115V power not delivered to C Check at Magnetic contactor coil MAG Term A1 to 2 for 115 Volts A
23. you have questions not answered in this manual please call your distributor They will contact the manufacturer if necessary TORQUE REQUIREMENTS GRADE2 GRADE5 GRADE 8 Throughout this manual we refer to torque requirements as firmly tighten or the like For more specific torque values refer to the information below SMOOTH HEAD Bolts Going Into a Nut or Into a Thread Hole in SEE are TUNE germs Steel thread 0 8 kg m 1 25 kg m 1 8 kg m Refer to the table at the right 5 161 1146 184466 28 ft lbs thread 1 5 kg m 2 5 kg m 3 9 kg m Bolts Going Into a Thread Hole in Aluminum Use the Grade 2 values in the table at the right thread 2 6 kg m 4 3 kg m 6 4 kg m Socket Head Screws Going Into a Nut or Steel e Midi uad Ricco M i i 1 2 In 45 ft lb 75 ft Ib 115 ft Ib Use the Grade 8 values in the table at the right ined re en WE e u KE Machine Screws No 6 screws 11 in Ibs 0 125 kg m No 8 screws 20 in lbs 0 23 kg m No 10 screws 32 in Ibs 0 37 kg m ASSEMBLY INSTRUCTIONS Remove the sides front and back of the crate Remove the plastic bag shrink wrap and bubble wrap around control panel Remove the metal clips that secure the grinder to the 4 x 6 wood base With a fork lift raise the grinder from the wood base and set it in its final position See FIG 1 and 2 THE UNIT WEIGHS 2300 LBS 1045 kg TO LIFT USE POWER EQUIPMENT The Control Panel has a shipping sc
24. 1 R000377 3707254 6509465 SPIN DRIVE ASSEMBLY DESCRIPTION Reducer 10 1 Ratio Motor DC 20 HP TEFC Self Tapping Screw 1 4 20 x 1 Long Flange Coupler 50 Sleeve Coupler Flange Coupler 5 8 Drive Coupling Adapter Socket Set Screw 1 4 20 x 3 8 Tee Knob Assembly 50 Long Retaining Ring Drive Adapter 1 2 Square Adapter Square Key 1 8 x 75 Long Gearbox Slide Bracket Strain Relief Wire Gearbox Clamp Bracket Gear Box Slide Weldment Bracket T Knob 5 16 18 Linkage Spacer 2 29 Long Linkage Spacer R H Thread Belleville Washer 75 Dia x 035 T Shoulder Bolt 375 Dia x 375 Long Nylon Ball 5 32 Dia Socket Set Screw 5 16 18 x 1 4 Linkage Spacer L H Thread Linkage Spacer 2 5 Long Socket Head Cap Screw Nylock Hex Locknut 3 8 16 Support Bracket Weldment Handwheel 4 5 Dia Handle Hex Jam Nut 1 4 20 1 4 20 Nylok Locknut Socket Set Screw 5 16 18 x 3 8 Long Double Thread Rod Knob Assembly Spin Drive Plate Lock Geared Linkage Socket Head Cap Screw 1 4 20 x 3 1 8 Long Square Key 3 16 x 75 Long DC Motor Brush PARTS LIST 6509549 MISCELLANEOUS PARTS PARTS LIST Continued PART NO 3700088 B371601 J377100 K370001 6009102 6509113 6509569 6509418 6509567 B252011 B120611 B161011 J161000 K121501 K161501 6509359 H060302 6509412 6509568 B190811 J197100 3708384 6509143 6509590 6509557 J317100 6509411 3700087 3700086 3709316 3707465 K251501 6
25. 2 43 System Error Messages Page 44 47 Flashing Light ELECTRICAL TROUBLESHOOTING Continued PROBLEM AC Main Power Controls no electrical power to control panel In your Product Packet Assembly there are series of prints Find the print titled 650 Wiring Diagram and Junction Box Light Assembly before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause You must turn ON the Switch on the front of the control panel Main Power Cord is not Checkout Procedure Look for Touch screen to come on B Plug in main power cord Machine works Yes end troubleshooting No go to Step B next Machine works plugged in Yes end troubleshooting No go to Step C next C Check circuit breaker and reset Machine works if necessary Check wall outlet Yes end troubleshooting with a light to make sure it works No but a light works in outlet go to Step D next No but light does not work in outlet You must solve your power delivery problem independent of machine Main 20 amp outlet circuit breaker has tripped MAG L1 black wire to L2 white wire 115 Volts AC Yes go to Problem Red E stop screen displayed on
26. 20 x 1 4 Long C250627 Socket Set Screw 1 4 20 x 3 8 Long Nylon Patch H184002 Roll Pin 3 16 x 2 5 Long J757300 3 4 16 Full Nylok Locknut K250001 1 4 Flat Washer 251501 1 4 Split Lockwasher K311501 5 16 Split Lockwasher R000376 Square Key 1 8 x 3 4 Long J257100 1 4 20 Locknut 3700089 Grinding Wheel 5 Dia x 1 Wide 3707023 DC Motor 1 HP 90V 3707294 Strain Relief 3707935 Tube Clamp 6309573 Finger Sub Assembly 3708193 Conical Washer 3708194 Internal Retaining Ring 5000 137 3708195 External Retaining Ring 5100 187 3708196 Internal Retaining Ring 5100 59 3708204 Ball Bearing 3708202 Poly V Belt 3708436 Wave Spring 3709072 Compression Spring 6509578 Grinding Head Spindle Assembly 6509018 Grinding Head Housing 6509052 Poly V Pulley 6509484 Plunger Pin 6509054 Plunger Pin Retainer 6509055 Belt Cover 6509210 Belt Cover Gasket B251016 Button Head Socket Cap Screw 1 4 20 x 5 16 Long 6509237 Grinding Wheel Knob 6509238 Grip Grinding Wheel Knob 6509247 Pulley Spacer 6509256 Motor Spacer 6509269 Vac Hose Bracket B250618 1 4 20 Pan Head Machine Screw x 3 8 Long 6509460 Proximity Switch Head Position 6509216 Proximity Switch Bracket 3707459 Proximity Switch Nut 6509461 Proximity Switch Finger Position 6509230 Proximity Switch Guard B190634 10 32 Button Head Socket Cap Screw x 3 8 Long K191501 10 Lockwasher 6309573 FINGER AND BODY ASSEMBLY PARTS LIST DIAGRAM
27. 52011 Socket Head Cap Screw 1 4 20 x 1 1 4 Long K501501 1 2 Split Lockwasher 3619224 Compression Spring 3708147 Shoulder Bolt 375 Dia x 625 Long 3709583 Flexible Coupling 3709635 Pillow Block Bearing 6009152 Shaft Collar 6009153 Rubber Washer 6509343 Actuator Assy 6509020 Traverse Base Adjustable End Cap 6509021 Bellows Carriage Mounting Bracket 6509024 Machined Traverse Base 6509025 Bellows End Mounting Bracket 650906 1 Motor Mount Bracket 6509063 Carriage Shaft 6509065 Carriage Drive Shaft 6509211 Carriage Proximity Flag Bracket 6509250 650 Way Cover Bellows 6509253 Carriage Dust Cover Bracket 6509566 Carriage Sub Assembly 6509585 Release Arm Weldment 3708454 Release Decal B250616 Button Head Cap Screw 1 4 20 x 3 8 6509565 Cross Slide Sub Assembly B190811 Socket Head Cap Screw 10 24 x 1 2 Long J197000 10 24 Locknut Jam B251211 Socket Head Cap Screw 1 4 20 x 3 4 Long 6009548 Actuator Bar Assembly 6309085 Traverse Motor Assy 3709668 Socket Head Screw 3709597 Sealed Bearing 3709596 Spacer 3709469 Compression spring K250001 1 4 Flat Washer 6509565 CROSS SLIDE ASSEMBLY PARTS LIST DIAGRAM NUMBER NUMBER C311220 J371000 J377000 K371501 3579109 3708148 3709062 3709304 3708705 6509390 6009035 6009082 6009095 6509011 6509015 C310820 3708665 6309115 6309114 6309113 3708706 3969065 B372011 H371602 K371501
28. 609501 3708813 6509349 3529069 3700089 6509549 MISCELLANEOUS PARTS DESCRIPTION Grinding Wheel 3 5 Dia x 38 W Hex Head Cap Screw 3 8 16 x 1 Long Nylok Locknut 3 8 Flat Washer Grab Hook Chain Gage Bar Assembly Vertical Pivot Plate Knob Assembly 1 4 20 x 1 25 Socket Head Cap Screw Socket Head Cap Screw 5 40 x 38 Long Socket Head Cap Screw 8 32 x 5 8 Long 8 32 Hex Nut No 5 split Lockwasher No 8Lockwasher Digital Gage 1 16 x 3 16 Roll Pin Base Weldment Indicator Alignment Extension Weldment Socket Head Cap Screw 10 24 x 1 2 10 24 Nylok Locknut Magnet Reel Positioner Gage Spreader Bar Weldment Drip Pan Weldment 5 16 18 Lock Nut Amber Light Assembly Lense Socket Flasher amp Bulb Grinding Wheel 5 Dia x 38 Wide Grinding Wheel 3 5 Dia x 1 Wide 5 16 18 x 3 U Bolt 1 1 2 25W Light Bulb 1 4 Lock Washer T Knob Assembly T Knob Assembly Retainer Plate Spacer 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 14 681429 21 WK LIN M GILJEG CIN DOE 1 828 2 Bi 24 SE 9912 es EE 8 4 2 14 28P54 3 FANT EE IA 100 53RT Y5 EES ZA 112 51RT1 15 ARTE zl SARTI
29. ACCU Master AUTOMATIC REEL MOWER GRINDER with ACCU Touch ASSEMBLY and SERVICE MANUAL SAFETY INSTRUCTIONS Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards Whenever you see these symbols follow their instructions The Warning Symbol identifies special instructions or procedures which if not correctly followed could result in personal injury KEEP GUARDS IN PLACE and in working order REMOVE WRENCHES AND OTHER TOOLS KEEP WORK AREA CLEAN DON T USE IN DANGEROUS ENVIRONMENT Don t use Grinder in damp or wet locations Machine is for indoor use only Keep work area well lit KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area MAKE WORK AREA CHILD PROOF with padlocks or master switches DON T FORCE THE GRINDER It will do the job better and safer if used as specified in this manual USE THE RIGHT TOOL Don t force the Grinder or an attachment to do a job for which it was not designed WEAR PROPER APPAREL Wear no loose clothing gloves neckties or jewelry which may get caught in moving parts Nonslip footwear is recommended Wear protective hair covering to contain long hair ALWAYS USE SAFETY GLASSES SECURE YOUR WORK Make certain that the cutting unit is securely fastened with the clamps provided before operating The Caution Symbol identifies special instructions or procedures which if not strictly observed coul
30. Abrasive Wheels For your safety we suggest you benefit from the experience of others and carefully follow these rules DO DO always HANDLE AND STORE wheels in a CAREFUL manner DO VISUALLY INSPECT all wheels before mounting for possible damage DO CHECK MACHINE SPEED against the established maximum safe operating speed marked on wheel DO CHECK MOUNTING FLANGES for equal and correct diameter DO USE MOUNTING BLOTTERS when supplied with wheels DO be sure WORK REST is properly adjusted DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding DO always WEAR SAFETY GLASSES or some type of eye protection when grinding DON T DON T use a cracked wheel or one that HAS BEEN DROPPED or has become damaged DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole if wheel won t fit the machine get one that will DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURRS DON T TIGHTEN the mounting nut excessively DON T grind on the SIDE OF THE WHEEL see Safety Code B7 2 for exception DON T start the machine until the WHEEL GUARD IS IN PLAGE DON T JAM work into the wheel DON T STAND DIRECTLY IN FRON
31. B indication Battery voltage is low Replace the battery gt as soon as possible ADJUSTMENTS LINEAR ACTUATOR BEARING REPLACEMENT NOTE It is not necessary to remove the linear actuator from the driveshaft Remove only the bearings STEP 1 Remove the shoulder bolt from the top side of carriage See FIG 11 STEP 2 Turn the actuator release lever 1 2 turn clockwise to release the actuator from the drive shaft Slide the actuator release lever out of actuator bar assembly by loosening the retainer shaft collar which preloads the holding spring See FIG 12 STEP 3 Move the grinding head carriage to the left side Lift the bellows Remove shoulder bolts fastening the six bearings to the actuator body See FIG 13 Remove the old bearings from the shoulder bolt and discard saving the inside washer Insert the shoulder bolts through the new bearings and the saved inside washers Then install these assemblies into the actuator body and tighten the shoulder bolts STEP 4 Slide the carriage over the actuator assembly to line up the hole in the carriage with the tapped hole in the actuator Insert the shoulder bolt through self aligning bearings and tighten NOTE Take extra caution not to cross the thread shoulder bolt STEP 5 Slide actuator release lever with collar spring washer and foam seal back into actuator bar assembly and lock in place with retainer shaft collar See FIG 12 Turn actuator release lever 1 2 turn counterclockwis
32. C MAG coil for 115 Volts AC with main electrical Yes replace magnetic starter power on and pushing PSS No go to Step D next Controller E stop ouput D Check on relay board RT1 for Light is relay on light on for output F farthest light Off Controller software corrupt or to right missing contact factory On go to step E next Controller E stop relay no E With the machine power on RT1 terminals F to F for 115 Volts AC continuity Relay light on measure across Yes Replace output relay F in RT1 relay contacts No go to step F next PSS Is bad F With the machine power on PSS Term 3 to 4 for 115 Volts AC measure across normally open PSS not pushed 0 Volts AC PSS contacts of PSS pushed No Replace PSS Yes go to step G next ESS Is bad G With the machine power on ESS Term 1 to 2 for 0 Volts measure across normally closed ESS pulled out 115 Volts AC ESS contacts of ESS pressed in No Replace ESS Yes go to step H next Bad wires H With the machine power off Measure continuity of wires 16 29 31 verify continuity of wires and 32 35 37 43 49 and 27 from LVR term connections 6 to MAG L3 Replace any bad wires or repair loose connections ELECTRICAL TROUBLESHOOTING Continued PROBLEM Machine light is not working Assuming AC main power cord wire 2 has 115 Volts AC at WB2 Wire Block 2 In your Product Packet Assembly there are series o
33. C input from Head in Relief Pos prox Message Status Clears Proceed to next system error message you have or continue running Remains go to Step B next From Help Screen verify Finger Stored Down prox input is on Red Follow instructions on Screen Clears Proceed to next system error message you have or Continue running Remains go to Step B next From Help Screen verify Head in Relief Pos prox input is work ing Follow instructions on screen Clears Proceed to next system error message you have or Continue running Remains go to Step B next From Help Screen verify Right Traverse Prox input is working Follow instructions on screen Clears Proceed to next system error message you have or Continue running Remains go to Step B next From Help Screen verify Head in Relief Pos prox input is work ing Follow instructions on screen ELECTRICAL TROUBLESHOOTING Continued System Error Message RELEASE FINGER FOR RELIEF ENTER NUMBER OF BLADES LOW VOLTAGE DE DOOR MUST BE CLOSED TO OPERATE INCREASE TORQUE KNOB SETTING TORQUE KNOB LOW OR DIRECTION WRONG Checkout Procedure A Release finger Make sure that the finger is allowed to come foreward at least once B Check PLC input from Door Saftey Switch A Blade countis required to run Relief grind Count blades and enter the number under the Blade Field A Input line voltage has dropped
34. EP 1 Using a hydraulic jack raise the traversing carriage base just enough to alleviate the weight stress on the Cross Slide Assembly STEP 2 Knock out the pins on either side of the Mount ing Frame Adjuster and loosen the 4 bolts B504801 that connect the Carriage Mounting Frame to the frame of the grinder STEP 3 Jack the traversing carriage base up to put a preload on the Cross Slide Assembly STEP 4 Tighten the 4 bolts on the Carriage Mounting Frame to 75 ft Ibs STEP 5 Release the jack pressure and test the vertical and horizontal handwheels for ease of movement through their full range of motion STEP 6 If the Cross Slides tend to bind repeat above steps jacking higher or lower STEP 1 until the handwheels move freely STEP 7 When the Cross Slides move freely through their full range of motion drill new holes and repin as sembly CARRIAGE CROSS SLIDE ING ASSEMBLY PART OF FRAME ADJUSTMENTS Continued CROSS SLIDE SHAFT REPLACEMENT If the cross slide shafts become scarred or gnarled replace them by the following procedure STEP 1 Use hydraulic jack to raise the weight off the Cross Slide Assembly STEP 2 Loosen the two nuts on the support casting that hold the dutchman and tap with plastic hammer to loosen STEP 3 Loosen the locking handles and tap the center stud with a plastic hammer STEP 4 Loosen locknut and setscrew and remove the handlwheel STEP 5 Remove th
35. If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Bulb is burned out Flasher FLR is bad No 115 Volts AC to flasher Relay 7 RT1 is bad Wire is bad Checkout Procedure A Remove bulb and test continuity B FLR Unplug flasher at terminal RT1 7 and touch lead to black wire at RT1 7 C After a cycle has completed measure voltage to Flasher D After a cycle has completed check RT1 for light 7 to be on E Check continuity of relay 7 F Measure voltage at relay Bulb Measure approx 300 Ohms Yes go to Step B next No Replace bulb Light works Yes go to step C next No Replace Flasher Assy RT1 Term 7 to TB2 Measure 115 Volts AC Yes Replace Cord 06 No go to step D next Light is on Yes go to step E next No Contact Factory RT1 Term 7 to 7 Measure 115 Volts AC Yes Replace Relay 7 RT1 No go to step F next RT1 Term 7 to TB2 Measure 115 Volts Yes Replace Cord 06 No Replace wire 36 This page was left blank intentionally for note taking purposes MECHANICAL TROUBLESHOOTING PROBLEM Actuator drive shaft whipping excessively at high traverse speed Possible Cause Checkout Procedure Bearings were bolted down tightly with Loosen bearing blocks and check squareness of bearing bearings putting bow into the drive shaft collar face 90 degrees to carriage rods with a s
36. Light is On go to Step K next Off Contact factory RT 1 Term 4 to term 4 for 0 Ohms Yes Replace SDC No replace Relay 4 RT1 RT1 Term A to term D should read the same 90 Volts DC measured at step Note polarity Yes Skip to Step N No go to Step M next RT1 Term A to term D should read the same 90 Volts DC measured at step H but opposite polarity Yes Skip to Step No Replace relays A B C amp D in RT1 SDC Black wire of SSP H to Red wire of SSP W Pot full CCW Pot Full CW 4 4 Volts DC 0 Volts DC SDC White wire of SSP L to Red wire of SSP W Pot full CCW Pot Full CW 0 Volts DC 4 4 Volts DC Yes Replace SDC No Replace SSP At Term A and B or C and D check approx 0 ohms across the black and white wires Yes Replace SDC No go to Step P next Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10mm mini mum length Yes replace motor brushes No replace Spin Drive motor PROBLEM Spin Drive not working in manual jog mode and in RELIEF MODE Assuming 115 Volts AC to control panel and all other manual jog mode functions are work ing In your Product Packet Assembly there are a series of prints Find the print titled 650 Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approx
37. NT a squeaking noise is coming from the actuator SHAFT 2X bearings follow the lubrication procedure for actuator and linear bearings Generally this will be every six months to a year LUBRICATION LUBRICATION OF ACTUATOR AND LINEAR BEARINGS STEP 1 Thoroughly clean all three shafts See FIG 10 STEP 2 Flood spray all three shafts with a spray lubricant do not use a teflon based lubricant until the lubricant is dripping off the shafts Then run the carriage back and forth through its range of travel This will carry the lubricant into the actuator and bearings NOTE Because of the flood of lubricant you may find that the actuator slips and traversing is erratic or stalls This is not a problem as it will be corrected in the subsequent steps STEP 3 With a clean rag wipe off the excess amount of lubricant from the shafts Run the carriage back and forth through its range of travel and wipe the shafts after each traverse Repeat until the shafts are dry to the feel This completes the lubrication process TRAVERSE BASE STANDING ALONE WITHOUT DUST PROTECTION COMPONENTS If the unit will be shut down for an extended period of time more than four weeks then the shafts and other appropriate parts of the unit should be flooded with lubricant and that lubricant left in place until the unit is brought back into service When the unit is brought back into service the full lubrication procedure as stated above
38. PARTS LIST Continued DIAGRAM PART NO B251611 J257100 J627100 6509541 3708398 6509103 6509115 6509544 B371616 J377100 3708519 6509298 B372411 6509367 6509594 6509546 6509364 3708456 K310101 6509366 6509526 WINCH AND BOOM ASSEMBLY DESCRIPTION Socket Head Cap Screw 1 4 20 x 1 Long 1 4 20 Nylok Locknut 5 8 11 Locknut Canopy Frame Weldment Shoulder Bolt 75 Dia x 3 5 Long Trolley stop Bracket Winch Warning Decal Boom Weldment Button Head Socket Cap Screw 3 8 16 x 1 Long 3 8 16 Hex Jam Nylok Locknut 5 16 18 x 1 2 Nylon HHCS Decal Boom Cap 3 8 16 x 1 50 SHCS Trolley Wheel Assy Hook and Cable Assembly Electric Winch Trolley Base Decal Boom Capacity Symbol 5 16 Flat Washer Spacer Trolley Wheel 6309510 TRAVERSE AND CARRIAGE ASSEMBLY PARTS LIST PARTS LIST Bottom 6309510 TRAVERSE AND CARRIAGE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION B190611 Socket Head Cap Screw 10 24 x 3 8 Long B250819 Button Head Socket Cap Screw 1 4 20 x 1 2 Long B253211 Socket Head Cap Screw 1 4 20 x 2 Long B255211 Socket Head Cap Screw 1 4 20 x 3 25 Long B311201 Hex Head Cap Screw 5 16 18 x 3 4 Long B503211 Socket Head Cap Screw 1 2 13 x 2 Long J251000 1 4 20 Hexnut J257100 1 4 20 Nylok Locknut K191501 No 10 Washer K251501 1 4 Split Lockwasher 00 JO Om K310001 5 16 Flatwasher K311501 5 16 Split Lockwasher B2
39. SOR The spring load force pushing up on the index finger SENSING PIN brings it away from the proximity when released FIG 19 STEPPPER INFEED TRAVEL LIMITS The infeed stepper maximum extension is 6 0 152 mm and minimum compression is 3 5 89 mm If you experience a situation where the grind does not properly finish check that you have not exceeded stepper travel by checking the values per FIG 20 NDEX FINGER ASSEMBLY LOCKING INDEX FINGER PIN To align the Index Finger Locking Pin to the hole in the Index Finger Assembly loosen the two socket head cap screws so the index sensor block is movable Push down on the index finger assembly until the spring loaded index finger locks into hole with no binding Tighten the two socket head cap screws so the index sensor block is secured and the locking pin moves freely See FIG 21 SOCKET HEAD CAP SCREWS INDEX SENSOR BLICK FIG 21 ADJUSTMENTS Continued PROXIMITY SWITCH PROXIMITY SWITCH For the proximity switch to perform properly and reverse the direction of the carriage at each end of the rails distance of 3 16 4 mm to 1 4 6 mm needs to be maintained between the carriage proximity flag bracket and the proximity switch 3 16 4 M MM y See FIG 22 1 4 NOTE The light on the proximity switch activates when metal crosses over the switch
40. T STEP 4 Slide linear bearing under carriage and attach with the FIG 14 three screws NOTE Repeat Steps 2 thru 4 with the other three linear bearings STEP 5 After all four linear bearings are reattached to the carriage check for correct bearing tension The bearing tension is correct when you try to lift the carriage and can feel no carriage movement which is free play up and down The most dependable method of checking free play is to use a magnetic base dial indicator attached to the traverse frame weldment and reading the vertical movement above each bearing This movement should be within 001 03 mm Also when pulling the carriage in the traversing direction there should be only approximately a 3 Ib force with the actuator disengaged using a scale system similar to Step 6 of Linear Actuator Bearing Replacement Section in this manual To double check the assembly slide the carriage assembly from end of travel to end of travel it should have very uniform resistance through the full range of travel STEP 6 Replace the bellows carriage mounting brackets onto the FIG 15 carriage Replace front and rear shields See FIG 15 FRONT DUST SHIELD REAR DUST SHIELD ADJUSTMENTS Continued REEL FINGER DOVETAIL GIB AND ADJUSTING KNOB ADJUSTMENTS nl RELIEF FINGER E ADJUSTING T KNOB The reel finger slide to the reel finger positioner has dovetail with an adjustable gib for tensioning Tighten the gib set scre
41. T of a grinding wheel whenever a grinder is started DON T FORCE GRINDING so that motor slows noticeably or work gets hot AVOID INHALATION OF DUST generated by grinding and cutting operations Exposure to dust may cause respiratory ailments Use approved NIOSH or MSHA respirators safety glasses or face shields and protective clothing Provide adequate ventilation to eliminate dust or to maintain dust level below the Threshold Limit Value for nuisance dust as classified by OSHA 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 manufactures replacement parts and have any repair work done by a qualified professional ALL operators of this equipment must be thoroughly trained BEFORE operating the equipment e Do not use compressed air to clean grinding dust from the machine This dust can cause personal injury as well as damage to the grinder Machine is for indoor use only Do not use a power washer to clean the machine Low Voltage Relay 4 WARNING quu f FACTORY PRESET TRIP LIGHT 4 INDICATES LOW VOLTAGE DELIVERED TO GRINDER WW The grinder is equipped with a low voltage relay which is factory preset at 100 VAC If the power supply line does not deliver 100 VAC power under load the relay will
42. UPPLY TO LINE 4 213 TO LINE 2 25 A LOW VOLTAGE RELAY FROM LINE FROM LINE 1 25 1 25 25 FROM LINE FROM LINE 1 11 1 11 12 N12 RE112 1 GRIND DRIVE BOARD 1 10K OHM VACUUM RELAY LINE 6 MOV TRAVERSE DRIVE BOARD SPIN DRIVE BOARD 3 FROM LINE 1 17 1B TCH102 COMMUNICATION CABLE AFC 1 S0M03 4S9 M PLC106 101 AROMAT FPO PLE FROM LINE 4 201 TU LINE 5 301 TO LINE 3 124 GRIND DRIVE POWER RELAY LINE 28 DIODE AROMAT FPO PLC INPUTS LOL INFEED STEPPER 470 OHM 129 WHT BLK WHT ORG WHT YEL 130 MHT RED FROM LINE 3 114 1DIX TO LINE 201 3 008 DOOR SAFETY SWITCH LEFT TRAVERSE PROX RIGHT TRAVERSE PRUX FINGER DOMN STORED PROX HEAD IN RELIEF POS PRUX LOW VOLTAGE RELAY FROM LINE go 3 120 FROM LINE joxe 3718 101 gt FROM LINE 3 110 SEE STEPPER LINE XXX SEE STEPPER LINE XXX TRAVERSE RIGHT LINE 2 38 TRAVERSE LEFT LINE 2 38 SPEED ON TORQUE OFF LINE 2 45 GRIND ORIVE PONER LINE 3 112 FLASHING LIGHT LINE 2 32 TO LINE 8 326 TRAVERSE DRIVE POWER LINE 2 35 ORIVE POWER 2 44 DIRECTION 2 45 DIRECTION B 2 46 DIRECTION B 2 47 DIRECTION A 2 48
43. al presumes that you are already familiar with the normal operation of the Grinder If not you should read 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 any internal troubleshooting adjustments or parts replacement If you have any question not answered in this manual please call your distributor They will contact the manufacturer if necessary WIRE LABELS All wires on the ACCU Master have a wire label at each end for assembly and troubleshooting The wire label has a code which tells you wiring information The first set of digits are the schematic wire number These identify the connection number Look at the column numbers on the left side of the schematic rung to identify the wire s The next number s are the Foley wire number The next group of numbers or letters are the code for the component to which the wire attaches Example RT1 for Relay Terminal 1 The last set of numbers or letters are the number of the terminal on the component to which the wire attaches ELECTRICAL TROUBLESHOOTING INDEX AC Main Power Controls Machine Light Spin Drive Controls in Spin Mode Page 32 33 Spin Drive Controls in Relief Mode Page 34 35 Grinding Motor Controls Page 36 37 Dust Collector Controls Winch Controls Traverse Drive Controls w prox Page 40 41 Stepper Infeed Controls Page 4
44. am and Junction Box and Light Assembly before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found tighten and retest system If problems persists test as listed below Possible Cause Dust Collector Switch Vacuum is not on Circuit Breaker 6 CB6 is tripped 10 amp See rear junction box RT1 relay E is not working Circuit Breaker 2 CB2 is not working 4 amp Relay 34 RE34 is not working CB6 is not working 10 amp Checkout Procedure A Turn switch on from SPIN MANUAL or RELIEF MANUAL screen B Reset circuit breaker switch tripped by current overload C With Vacuum switch on Check for RT1 Relay E on D RT1 Relay E verify continuity E Check for CB2 normally closed contacts F Check for RE34 input of 115 Volts AC at coil This relay is located in rear junction box Check for RE34 input of 115 Volts AC at contacts Check for RE34 output of 115 Volts AC at contacts L Check for CB6 normally closed contacts Dust Collector works Yes end troubleshooting No go to Step B next Dust Collector works Yes end troubleshooting No go to step C next Light is on Yes go to step D next No Contact Factory RT1 Term E to E for 115 Volts
45. and in SPIN MODE Assuming 115 Volts AC to control panel and all other manual jog mode functions are work ing In your Product Packet Assembly there are a series of prints Find the print titled 650 Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Spin Speed Pot SSP set to zero Spin Motor Switch not on on Touch Screen Door is open Circuit breaker 42 is tripped 4A Relay 9 RT1 is not working Verify Light is on Verify Continutiy of relay 9 in RT1 Relay 4 RT1 is not working Checkout Procedure A Set SSP to 200 on the control panel B Turn spin drive switch on touch green area from SPIN MANUAL screen C Alarm on screen should indicate that the door must be closed for the spin drive to operate Close door D Reset circuit breaker switch Tripped by current overload check that reel is free spinning E Check for SDC input of 115 Volts AC F Check RT1 for light 49 to be on Door must be closed and spin drive switch on With light 49 on Check RT1 relay 9 for continuity H With 115 Volts AC at Term L1 and L2 check SDC output Have Spin speed
46. carriage linear bearing adjustments PROBLEM Carriage traversing varies speed while grinding Oil on carriage drive shaft Wipe oil completely from the traverse shaft Spray down with a spray lubricant do not use a teflon based lubricant and wipe off completely Lineal bearings in the carriage do not Check for grinding grit getting into the lineal bearings and rotate freely cause excessive driving torque of carriage Abrasive noise is detectable when excessive grit is in the lineal bearings Replace the four lineal bearings in the main carriage Check bellows for holes and replace if necessary Actuator bearings are not rotating freely Check bearings for free rotation or flat spots on the bearing outside diameter Replace the six bearings if necessary See adjustment section for bearing replacement MECHANICAL TROUBLESHOOTING Continued PROBLEM Too heavy burr on cutting edge of reel blades Possible Cause Traverse speed set to high causing heavy burr on the reel blade when spin grinding PROBLEM Cone shaped reel after grinding Grinding head travel not parallel to the reel center shaft Checkout Procedure Traverse speed should be set lower approximately 12 ft min 4 meters min for a smaller burr on cutting edge Grinding head travel was not setup parallel to the reel center shaft in vertical and horizontal planes See Align the Reel Section in Operator s Manual PROBLEM Relief grind on the reel blades d
47. ctions on screen Clears Proceed to next system error message you have or Continue running Clears Proceed to next system error message you have or Continue running Clears Proceed to next system error message you have or Continue running Clears Proceed to next system error message you have or Continue running Clears Proceed to next system error message you have or Continue running ELECTRICAL TROUBLESHOOTING Continued System Error Message ACCEPT VALUES BE FORE RUNNING OPEN DOOR TO RESET LIGHT Checkout Procedure Message Status A Before an auto cycle can be Clears Proceed to next system error started verify the values in the message you have or continue run displayed boxes and accept them ning by pressing the Accept Values button on the touch screen A Before an auto cycle can be Clears Proceed to next system error started the last cycle completed message you have or continue run must cleared Open the door or ning press the Cycle Complete button on the main screen to reset ELECTRICAL TROUBLESHOOTING Continued PROBLEM Flasher light does not turn on at end of automatic cycle In your Product Packet Assembly there are a series of prints Find the print titled 650 Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminals
48. d result in damage to or destruction of equipment DON T OVERREACH Keep proper footing and balance at all times MAINTAIN GRINDER WITH CARE Follow instructions in Service Manual for lubrication and preventive maintenance DISCONNECT POWER BEFORE SERVICING or when changing the grinding wheel DO NOT USE SHARP OBJECTS ON THE TOUCH SCREEN Do not clean the touch screen with solvents USE RECOMMENDED ACCESSORIES Consult the manual for recommended accessories Using improper accessories may cause risk of personal injury CHECK DAMAGED PARTS guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced KNOW YOUR EQUIPMENT Read this manual carefully Learn its application and limitations as well as specific potential hazards KEEP ALL SAFETY DECALS CLEAN AND LEGIBLE If safety decals become damaged or illegible for any reason replace immediately Refer to replacement parts illustrations in Service Manual for the proper location and part numbers of safety decals DO NOT OPERATE THE GRINDER WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS IMPROPER USE OF GRINDING WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY Grinding is safe operation if the few basic rules listed below are followed These rules are based on material contained in the ANSI B7 1 Safety Code for Use Care and Protection of
49. des prewired 3 KVA 220 V step down to 115 V 50 60 Hz transformer should be ordered IT IS RECOMMENDED THAT THIS ACCU MASTER REEL MOWER GRINDER HAS ITS OWN PERMANENT POWER CONNECTION The grinder is equipped with low voltage relay FROM THE POWER DISTRIBUTION PANEL which is factory preset at 100 VAC If the power WITH NO OTHER MAJOR POWER DRAW supply line does not deliver 100 VAC power under EQUIPMENT ON THE SAME LINE load the relay will open and trip out the starter If this occurs your power supply line is inadequate IT IS REQUIRED THAT THE POWER and must be correct before proceeding further with DELIVERED TO THIS GRINDER IS 115 Ne grinder 20 AMPS THE TOLERANCE ON THIS POWER REQUIREMENT IS 5 E THEREFORE THE MINIMUM VOLTAGE REQUIREMENT IS 109VAC WITH 20 AMPS VOLTAGE MUST BE CHECKED WITH ALL EQUIPMENT UNDER LOAD OPERATING ON THE CIRCUIT 4 TRIP LIGHT DO NOT OPERATE THIS GRINDER WITH p ESSEN AN EXTENSION CORD VOLTAGE DELIVERED PROPER GROUNDING OF THE TO GRINDER N ty T S TACLE GROUND IN YOUR BUILDING MUST See BE VERIFIED IMPROPER GROUNDING IN YOUR BUILDING MAY CAUSE THE GRINDER TO MALFUNCTION FOR 20 AMP RATED LARGE MACHINES Below is a list of required wire size in your building For 0 to 40 Feet from panel to receptacle Use 12 Ga Wire For 40 to 60 Feet from panel to receptacle Use 10 Ga Wire For 60 to 100 Feet from panel to rece
50. e Slide Shaft STEP 6 Remove all burrs and resurface the shaft to a clean smooth polished surface OR RE PLACE WITH A NEW SHAFT STEP 7 Coat shaft with Never Cease and re install the shaft through the Support Cross Slide Block and the three Dutchman The shaft must move freely inside the Cross Slide Block before reassembling STEP 8 Retightening the nuts at the end of the Dutchman to lock shaft in place STEP 9 Reinstall the Handwheel by snuging the setscrew to the flat located on the screw shaft then torque nut until tight and back off 1 2 turn Torque the setscrew to 70 in lbs STEP 10 Test the Cross Slide the handwheel should turn freely LOCK STEP 11 Lower the jack and retest the Cross Slide HANDLES Assembly through full range of motion If binding occurs follow the procedure under Cross Slide Assembly located on page 21 NOTE It is also possible to remove the complete Cross Slide Assembly and do the repairs on a bench then reinstall NUT DUTCHMAN SHAFTS SETSCREW HANDWHEEL CONTROL BOARD POTENTIOMETER ADJUSTMENTS SPIN DRIVE CONTROL BOARD SDC The Spin Drive Control Board has three potentiometers on the lower board and two potentiometers on the upper board as shown on drawing 6504434 which is included These potentiometers have been set at the factory to the positions shown on the drawing Also see FIG 27A and 27B In the Relief Grinding Mode The Remote Speed Pot and the Relief Torque Pot RTP int
51. e to engage bearings to drive shaft STEP 6 Using a spring scale connect the scale to the carriage to pull on the carriage parallel to actuator drive shaft Then while holding the drive shaft from rotating pull on carriage the pull force should be 60 lbs See Step 7 for readjustment if necessary THE PULL FORCE IS TO BE CHECKED WHEN SHAFT IS WIPED CLEAN AND DRY IF CHECKED WHEN OILY TOO MUCH TENSION WILL BE SET AND e AFFECT BEARING LIFE STEP 7 If readjustment is required to achieve pull force within specification with actuator bearings engaged to drive shaft readjust the two outboard screws with springs that hold the actuator together See FIG 13 To reach these screws the actuator bar assembly must be removed Turn each screw an 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 factory preadjusted spring tension is 160 or 5 32 4 mm from under the washer holding the spring to the actuator block See FIG 12 This should give the 60 Ibs carriage pull force specified When adjustment is correct reinstall the actuator bar assembly The bar assembly must be adjusted parallel to the actuator aluminum body and so it is just touching the outboard screw heads Then tighten the lock nut on the lower actuator bar assembly mounting screw See FIG 12 Then reinstall the release lever package as above FOAM SHAFT
52. ecal Rubber Pad Shoulder Bolt 75 Dia x 2 25 Long Grommet 1 75 1 0 25 Groove Grommet 1 50 1 0 125 Groove Foam Strip Shoulder Bolt 312 Dia x 375 Long Control Panel Decal Rubber Trim Control Arm Weldment Button Head Cap Screw 10 32 x 1 2 Long Button Head Socket Cap Screw 1 4 20 x 1 2 Long Button Head Cap Screw 10 32 x 5 8 Long 10 32 Locknut 1 4 20 Nylok Inst Locknut Handle Control Panel Hinge Control Panel Hinge Spacer Top Swing Panel Weldment Control Box Weldment Front Swing Panel Weldment Button Head Socket Cap Screw 1 4 20 x 1 2 Long Phillip Head Cap Screw 10 24 x 1 2 10 Toothed Lock Washer 10 24 Lock Nut Chart Holder Hook 8 32 Nut 8 Lockwasher 3 Square Plug 650 Patent Decal 1 2 Hole Plug 10 32 Socket Head Cap Screw x 3 8 Long 6509434 CONTROL PANEL ASSEMBLY PARTS LIST DIAGRAM PARTS LIST Continued PART NUMBER B160607 D160600 D250800 R000536 R000558 3707163 3707164 3707367 3707403 3707442 3707443 3707444 3707446 3707564 3707565 3707566 3707567 3707568 2707572 3708683 6509444 6509445 6509446 6509447 6509468 6509472 3707399 6509434 CONTROL PANEL ASSEMBLY DESCRIPTION 86 32 Button Head Cap Screw x 3 8 Long 8 Pan Head Self Tapping Machine Screw 1 4 Self Tapping Machine Screw 1 4 Lock Washer With Teeth 48 32 Nut Primary Ground Decal Primary G
53. ed at step H but opposite polarity Yes Skip to Step O No Replace relays A B C amp D in RT1 SDO Black wire of RTP H to Red wire of RTP W Pot full CCW Pot Red line 2 Volts DC 1 Volts DC SDC White wire of RTP L to Red wire of RTP W Pot full CCW 1 Volts DC Yes Replace SDC No Replace SSP Pot Red line 2 Volts DC At RT1 Term A and B or C and D check approx 0 ohms across the black and white wires Yes Replace SDC No go to Step P next Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10mm mini mum length Yes replace motor brushes No replace Spin Drive motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Grinding motor not working in manual jog mode Assuming 115 Volts AC to control panel and all other manual jog mode functions are work ing In your Product Packet Assembly there are series of prints Find the print titled 650 Wiring Diagram before starting the troubleshooting below Verify all wires shown in the drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Grinding Motor Switch GMO is not on Circuit Breaker CB28 10A is tripped
54. eract with each other The remote speed pot is located on the upper board of the Spin Drive Control SDC preset at 2 00 20 Volts DC The RTP is located on the control panel and is for relief torque adjustment See FIG 27B The Remote Speed Pot when rotated clockwise will increase maximum spin drive speed This speed should never be above the 2 30 setting Relief Torque Pot RTP can vary the reel to finger holding torque for relief grinding The recommended starting point is 15 in Ibs of torque setting Never adjust the RTP potentiometer dial past the red line marking Setting the reel to finger torque to high could cause the traverse motor system to not operating smoothly In the Spin Grinding Mode The Remote Torque Potentiometer and the Spin Speed Pot SSP interact with each other The remote torque pot is located on the upper board of the Spin Drive Control SDC preset at 2 00 for torque setting The SSP is located on the control panel and is for spin speed adjustment See FIG 27B The Remote Torque Potentiometer controls maximum torque allowable in the spin grind cycle only This should never be adjusted past the 2 30 position The Spin Speed Pot SSP controls reel spin speed adjust as required This controls the spin drive speed for spinning the reel POTENTIOMETERS ON THE SPIN DRIVE CONTROL SDC LOWER BOARD See FIG 27A Maximum Speed Pot The maximum speed is factory preset to 4 30 fully clockwise to allow for max
55. f prints Find the print titled Junction Box and Light Assembly before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminals If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Light switches are not turned on or there is a bad bulb Wire cord is bad Switch or machine light is bad Checkout Procedure A Turn on machine light toggle switch on lamp holder Check the light bulb in another light fixture or replace with a new bulb Next turn on light switch electrical junction cover switch B Remove cover of light junction box check for 115 Volts AC C Check for 115 Volts AC across machine light assembly Light works Yes end troubleshooting No go to Step B next Check for 115 Volts AC across light cord white wire 403 to switch black wire 03 Yes go to Step C next No replace light cord wire 03 Check for 115 Volts AC across ma chine black wire 10 to white wire 10 Yes replace machine light assembly No replace switch assembly Again we want to remind that there is a switch at the back of the machine light assembly which must be turned on for the light to work ELECTRICAL TROUBLESHOOTING Continued PROBLEM Spin Drive not working in manual jog mode
56. imately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Relief Torque Pot RTP set to zero Spin Motor Switch not on on Touch Screen Door is open Circuit breaker 42 is tripped 4A Relay 9 RT1 is not working Verify Light is on Verify Continutiy of relay 9 in RT1 Relay 4 RT1 is not working Checkout Procedure A Set SSP to 20 on the control panel B Turn spin drive switch on touch green area from RELIEF MANUAL screen C Alarm on screen should indicate that the door must be closed for the spin drive to operate Close door D Reset circuit breaker switch Tripped by current overload check that reel is free spinning E Check for SDO input of 115 Volts AC F Check RT1 for light 49 to be on Door must be closed and spin drive switch on With light 9 on Check RT1 relay 9 for continuity H With 115 Volts AC at Term L1 and L2 check SDC output Have Relief Torque Pot RTP set at Red Line l With 115 Volts AC at Term L1 and L2 check SDC output Have Spin Speed Pot SSP set to 400 Spin Motor works Yes end troubleshooting No go to Step B next Spin Motor works Yes end troubleshooting No go to Step C next Spin Motor works Yes end troubleshooting No go to step D next Spin Motor
57. imum spin speed Minimum Speed Pot The minimum speed is factory preset at 8 30 full counterclockwise so zero speed is obtainable for 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 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 a point turn the IR COMP trim pot counterclockwise until the symptoms just disappear AU D MAX 9 00 Y SPO TORQUE IR COMP k MIN W yl SPD 8 30 FULL CCW FIG 27A See potentiometer IR orientation on page 24 ae OBEN FIG 27B CONTROL BOARD POTENTIOMETER ADJUSTMENTS Continued GRINDING MOTOR CONTROL BOARD GMC The Grinding Motor Control Board has four potentiometers on the board as shown on drawing 6504434 which is included These potentiometers have been set at the factory to the positions shown on the drawing See FIG 28 Maximum Speed The maximum speed potentiometer is preset to 1 00 position for 95 Volts DC to the grinding motor for 4300 RPM The 4300 RPM is for optimum grinding wheel operating speed DO NOT go above the 4300 RPM Check for 95 Volts DC on Grinding Motor Control GMC at Term A1 to Term A2 Accel Decel The accel decel potentiometer is set full counterclockwise so
58. kwasher 8 Flat washer 48 32 Jam Locknut 48 32 Nut 8 Lockwasher w teeth RIGHT HAND CANOPY DOOR 6509437 PARTS LIST PARTS LIST Continued PART NO 6509436 B250816 J257100 J311000 K250001 3708378 6509099 6509105 6509111 6509110 6509112 6509182 6509104 6509437 RIGHT HAND CANOPY DOOR DESCRIPTION Canopy Door Weldment Right Hand Button Head Socket Cap Screw 1 4 20 x 1 2 1 4 20 Locknut 5 16 18 Hex nut 1 4 Flatwasher Foam Strip 25 Thick Canopy Door Hinge Canopy Door Side Window Short Retaining Window Bracket Long Retaining Window Bracket Handle Medium Retaining Window Bracket Canopy Door Front Window 6509439 LEFT HAND DOOR PARTS LIST PARTS LIST Continued PART NO 6509438 B250816 J257100 J311000 K250001 3708378 6509099 6509105 6509111 6509110 6509112 6509182 6509104 6509439 CANOPY LEFT HAND DOOR DESCRIPTION Canopy Door Weldment Left Hand Button Head Socket Cap Screw 1 4 2 1 2 1 4 20 Locknut 5 16 18 Hex nut 1 4 Flatwasher Foam Strip 25 Thick Canopy Door Hinge Canopy Door Side Window Short Retaining Window Bracket Long Retaining Window Bracket Handle Medium Retaining Window Bracket Canopy Door Front Window PARTS LIST 6509526 WINCH AND BOOM ASSEMBLY
59. ldment 6509560 RH Proximity Switch Bracket Weldment 6509561 LH Proximity Switch Bracket Weldment 6509458 LH Traverse Proximity Switch 6509459 RH Traverse Proximity Switch 3707224 Cable Tie Mount Used Throughout Machine 3707459 Proximity Switch Nut 6509566 CARRIAGE SUB ASSEMBLY PARTS LIST 5 ul Fe 25 a EE Ez L De Ea 22 PARTS LIST Continued DIAGRAM PART NUMBER B191211 B250616 6509584 J887300 K191501 K251501 R602031 3708105 3708184 3709040 3709044 3708186 3708208 6509019 6509023 6509251 3708462 6509566 CARRIAGE SUB ASSEMBLY DESCRIPTION Socket Head Cap Screw 10 24 x 3 4 Long BS Head Cap Screw 1 4 20 x 38 Long Swind Door Weldment 7 8 14 Nylok Jam Locknut No 10 Lockwasher 1 4 Split Lockwasher 4 x 31 Drive Screw Compression Spring Retaining Ring Spherical Bearing Ball Bushing Bearing Ball Bearing Shoulder Bolt 250 Dia x 387 Long Carriage Base Grinder Head Pivot Shaft Swing Door Latch Decal RPM Symbol PARTS LIST 6309510 GRINDING HEAD ASSEMBLY TOP PARTS LIST Continued 6309510 GRINDING HEAD ASSEMBLY TOP DIAGRAM PART NUMBER NUMBER DESCRIPTION 3708448 Warning Electric Symbol B250811 Socket Head Cap Screw 1 4 20 x 1 2 Long B250818 Pan Head Machine Screw 1 4 20 x 1 2 Long B251611 Socket Head Cap Screw 1 4 20 x 1 Long B311611 Socket Head Cap Screw 5 16 18 x 1 Long C250420 Socket Set Screw 1 4
60. lycarbonate windows with squeegees razor blades or other sharp instruments Benzene gasoline acetone or carbon tetrachloride should NEVER be used on polycarbonate windows DO NOT clean polycarbonate windows in hot sun or at elevated temperatures Graffiti Removal e Butyl cellosolve for removal of paints marking pen inks lipstick etc e The use of masking tape adhesive tape or lint removal tools works well for lifting off old weathered paints To remove labels stickers etc the use of kerosene VM amp P naphtha or petroleum spirits 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 MAINTENANCE Continued DIGITAL GAGE Important Do not mark the scale unit with and electric engraver or scratch the scale Always use an SR44 battery silver oxide cell If the scale will not be used for more than three months remove the battery and store it properly Otherwise leak age if any from the battery may damage the unit Description of Parts 1 Beam 2 Main Scale 3 Battery compartment 4 Outp Connection 5 Display 6 ON OFF Power 7 ZERO ABS switch 8 Origin Switch 9 Inch mm Switch 10 Tapped hole 11 Slider Battery Installation and Origin Setting Set the origin of the scale after installing the battery Otherwise the error sign E at the least significant digit may appear result ing in inco
61. o not go the full length of the reel The right side corner of the grinding wheel is always to be in contact with the reel blade This is high point of the relief finger The right hand side of the grinding wheel is not in full contact for relief grinding See Operator s Manual for NORMAL HELIX AND REVERSE HELIX for information of dressing the grinding wheel PARTS LIST 6509522 MAIN BASE ASSEMBLY PARTS LIST Continued 6509522 MAIN BASE ASSEMBLY DIAGRAM PART NO A993201 B310813 B502801 B504801 B506801 H371602 J507100 J992000 6509035 6509038 6509039 6509040 6509116 6509505 6509510 6509069 3708379 6509337 J257100 K250101 6509163 6509074 6509300 J317000 3708428 3709756 3708378 3707294 3708437 B311413 3708612 3707273 H372002 K500001 3708542 6309111 DESCRIPTION Hex Head Cap Screw 1 8 x 2 Button Head Socket Cap Screw 5 16 18 x 1 2 Hex Head Cap Screw 1 2 13 x 1 3 4 Hex Head Cap Screw 1 2 13 x 3 Hex Head Cap Screw 1 2 13 x 4 1 4 Roll Pin 3 8 Dia x 1 00 Long 1 2 13 Locknut 1 8 Hex Jam Nut Mounting Frame Adjuster Large Access Panel Left Hand Access Panel Right Hand Small Access Panel Left Hand Fuel Warning Decal Main Frame Base Weldment Tooling Bar Weldment Removable Front Panel Foam Strip Vacuum Assembly 1 4 20 Locknut 1 4 Flatwasher Tube Rubber Vacuum Mounting ACCU Master Decal Hinge
62. oad D Put switch on high speed rabbit for ease of checkout of Stepper Infeed Control SIC E You can feel stepper pulses on motor when HLS is on high or low amp IJS switch is depressed in either up or down direction Open stepper infeed inspection plate to check for loose coupling Retighten coupling to drive actuator screw See adjustment section of manual F SIC Check for 24 Volts DC Power in G SIC Check voltage at OPTO terminal Stepper motor works Yes end troubleshooting No go to Step B next Stepper Motor works Yes end troubleshooting No go to step C next Stepper Motor works Yes end troubleshooting No go to step D next High speed works Yes end troubleshooting No go to Step E next Stepper works Yes end troubleshooting No go to Step F next SIC Term GND to V measure 24 Volts DC Yes go to step G next No Skip to step H SIC Term GND to OPTO mea sure 24 Volts DC Yes go to step I No Replace wire 50 with resistor ELECTRICAL TROUBLESHOOTING Continued Possible Cause Mag contact or wire bad No Step pulse from PLC Stepper Infeed Control SIC Wiring bad Stepper Infeed Control SIC or Stepper motor is bad Checkout Procedure H Measure voltage at MAG insure power is on and green PSS has been pressed L Check light YO on PLC While pressing up or down it should light pressing down Y1 will also light J Check wiring at SIC
63. open and trip out the starter If this occurs your power supply line is inadequate and must be correct before proceeding further with the grinder TT CONTENTS Safety Warnings Service Data Assembly Instructions Maintenance Instructions Page 11 14 Adjustments Page 15 24 Machine Service Page 25 26 Electrical Troubleshooting gt FR Page 28 Electrical Troubleshooting Page 29 48 Mechanical Troubleshooting Page 50 51 Parts Lists Page 52 89 Electrical Diagrams Page 90 97 Separate Drawings Included in the Product Packet SPECIFICATIONS Electrical Requirements 115V 50 60 Hz 20 amp circuit Net Weight 2300 Ibs 1045 kg Shipping Weight 2500 Ibs 1140 kg Maximum Grinding Length 34 in 86 cm SERVICE DATA SKILL AND TRAINING REQUIRED FOR SERVICING This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the ACCU Master Grinder For those without that background service can be arranged through your local distributor This Manual presumes that you are already familiar with the normal operation of the Grinder If not you should read 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 any internal troubleshooting adjustments or parts replacement If
64. ops because of a system error message on Touch Screen Continued System Error Message FINGER NOT RELEASED CHECK LH PROX POS POSITION MOVE NOT POSSIBLE IN PAUSE MODE MACHINE IS IN PAUSE MODE PRESS RESUME DOOR OPENED WHILE GRIND AND OR SPIN ON INCREASE TRAVERSE KNOB SETTING TRAVERSE TIMEOUT CHECK POT OR SETUP Checkout Procedure A During a relief grind cycle the PLC did not see the finger released at the left prox position Verify that the setting of the left traverse prox allows the finger to come off the blade B Check PLC input from Finger Stored Down prox A Press Resume on touch screen to finish current cycle A Machine was left in pause mode after last cycle Press resume on touch screen A Door was opened while potentially dangerous operations were still on Turn off motors pause or finish cycle before opening doors A An excessive amount of time has passed at the beginning of an auto cycle before the grind head assy has moved Increase Traverse Speed pot or check that carriage is not released A An excessive amount of time has passed during a traverse cycle Increase Traverse Speed pot or verify that carriage assembly is not re leased or hitting an obstruction Message Status Clears Proceed to next system error message you have or continue running Remains go to Step B next From Help Screen verify Finger Stored Down prox input is Work ing Follow instru
65. pen the retaining ring enough to install Opening the ring excessively will damage the retaining ring making is unusable Replace the pulley spacer and mount the square key positioned tight against the pulley spacer Remount the pulley pushing against the pulley spacer and bottom out against the snap ring with no end play Next tighten the two pulley set screws Then remount the poly V belt See Grinding Head Belt Tension Adjustment in the adjusting section Replace belt cover and square key and mount the grinding wheel grip knob and tighten the two set screws THE RETAINING RING IS FRAGILE AND EASILY DAMAGED WHEN REMOVING ALWAYS USE A NEW RETAINING RING WHEN REASSEMBLING THE GRINDING HEAD SPINDLE CRIP KNDB ES ONLY OPEN THE RETAINING RING ENOUGH THE INSTALL i BELT COVER OPENING THE RING EXCESSIVELY WILL DAMAGE THE O RETAINIG RING MAKING IT UNUSABLE PULLEY SPACER RETATNING RING BALL BEARTNG CONICAL WASHERS GRINDING WHEEL SPINDLE ASSEMBLY GRINDING WHEEL GRINDING WHEEL KNOB This page was left blank intentionally for note taking purposes ELECTRICAL TROUBLESHOOTING SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING This Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowledge and skills to reliably test and repair the ACCU Master electrical system For those without that background service can be arranged through your local distributor This manu
66. ptacle Use 8 Ga Wire For 100 to 160 Feet from panel to receptacle Use 6 Ga Wire For 0 to 12 Meters from panel to receptacle Use 4 0mm Wire For 12 to 18 Meters from panel to receptacle Use 6 0mm Wire For 18 to 30 Meters from panel to receptacle Use 10 0mm Wire For 30 to 48 Meters from panel to receptacle Use 16 0mm Wire ASSEMBLY INSTRUCTIONS Continued For 220 V 50 or 60Hz applications Product No 6500952 should be ordered 6500952 includes a 3 KVA 220 Volt Step Down to 115 volt 50 60 Hz transformer which is prewired The wiring diagram is shown in FIG 8 The power cord has no connector A connector which is appropriate for your locality and 220 volt 10 amp application should be installed Use only a qualified electrician to e complete the installation x a R H IMPORTANT GROUNDING INSTRUCTIONS In case of a malfunction or breakdown grounding reduces the risk of electrical shock by providing a path of least resistance for electrical current This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded according to all local or 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
67. quare and tighten down The drive shaft to carriage front shaft is 2 875 010 73 3 mm apart See adjustment section for more information PROBLEM Reels ground have high low blades Traverse Speed set to fast Check roundness using a magnetic base dial indicator Traverse speed should be set approximately 12 ft min 4 meters min if roundness is varying Lineal bearings for the grinding head Relubricate and adjust linear bearings per adjustment carriage are out of adjustment loose section If problem persists replace lineal bearings on or have grit buildup causing uneven the carriage base Check for any holes in the bellows traversing load that would permit any grinding grit penitration See adjustment section for lineal bearing replacement PROBLEM Excessive grinding stock being removed when traversing to the right in the relief grinding mode Gib adjustment for the relief finger assembly Tighten the set screws for the gib adjustment See is loose so reel finger has movement procedure in the adjustment section in the manual When traversing to the right minimum grinding stock removal should be seen as compared with heavy stock removal when traversing to the left PROBLEM Grinding stock removal from reel is irregular during spin grinding Lineal bearings on the grinding head The lineal bearing must be preloaded to the traverse carriage are too loose shafts with no vertical movement See manual adjustment section for
68. rew and nut installed in its pivot bracket to limit travel during shipping Remove and discard this screw and nut The winch boom is held in place during shipping with a steel brace Remove and discard this brace Remove the shrink wrap that holds the winch trolley to the beam Remove shipping straps from traverse carriage Remove window protective sheets POSITION BASE The ACCU Master will require an operating area of about 150 W x 108 Dx 87 H 381 x 274 x 221 cm The reel mower assembly will be lifted from the front of the ma chine The machine operator will operate the unit from this same position Position the base to allow sufficient operating room in front of the machine See FIG 1 and 2 The base should be placed on a relatively level concrete floor with ample ceiling height to allow for the installation of the unit Do not place the unit across two concrete slab seams or across a large crack ASSEMBLY INSTRUCTIONS Continued Remove the carton and remove the contents from the carton onto workbench The carton includes See Parts List in back of this manual for Part Numbers Spreader Bar Assembly Product Package Includes Operators Manual Assembly amp Service Manual Warranty Card Warning Instruction Sheet Vacuum Manual Wiring Diagrams Spin Drive Coupler Assembly Grinding Wheels 3 Bulb amp Lens for Flashing light Reel Position Gage D
69. rip Pan Assembly Alignment Gage Assembly ASSEMBLY INSTRUCTIONS Continued LEVEL BASE Each leveling foot has been factory pre adjusted so it protrudes from the base 2 1 4 57 mm See FIG 3 Place a level on the top of the table and check the levelness of the unit from side to side Adjust the leveling feet as necessary to bring to level See FIG 4 leveling feet on the end of the machine as necessary to level See FIG 5 Place a level across the table from front to rear Adjust the 2 1 4 57 mm When both front to back and side to side leveling procedures have been completed thread the hex jam nuts up against the nut that is welded to the bottom until they lock into place Be careful not to move the leveling feet during this process See FIG 3 Make certain that all four leveling feet are firmly contacting the floor Recheck with level after locking nuts are firmly tightened INSTALL THE FLASHER LIGHT Locate flasher bulb and lense in carton Install bulb and lense to the flasher assembly socket located on the top of the right canopy door See Fig 6 ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT GROUNDING INSTRUCTIONS ON PAGE 10 115 Volt Model Only Plug the power cord into standard 115V 20 amp grounded receptacle See FIG 7 220 Volt Model Only For 220 Volt Applications order Part No 6500952 which inclu
70. round Lug On Off Rocker Switch Power Line Filter 2 Amp Circuit Breaker 4 Amp Circuit Breaker 10 Amp Circuit Breaker Potentiometer Knob With Pointer Green Pushbotton Start Normaly Open Contact Block Mounting Switch for Pushbutton Red Push Pull Button Stop Normaly Closed Contact Block 5 7 Color Touch Screen Low Voltage Warning Decal Electrical Panel Sub Assembly Traverse Potentiometer Spin Speed Potentiometer Relief Torque Potentiometer Power Switch Decal Decal Mirror 3 Amp Circuit Breaker PARTS LIST 6509444 CONTROL PANEL SUB ASSEMBLY DIAGRAM PARTS LIST Continued PART NUMBER D130608 D160666 3707558 3707073 3707317 3707321 3707322 3707431 3707524 3707556 3707569 3707571 3707577 3707581 3707582 6509424 6509425 3707574 6509444 CONTROL PANEL SUB ASSEMBLY DESCRIPTION 6 Pan Head Thread Cutting Machine Screw 8 Pan Head Thread Cutting Machine Screw Low Voltage Sensor 8 Pin Socket Grind Motor Board Traverse Control Board DC Power Supply 24V DC Relay Spin Relief Control Board Magnetic Starter PLC PLC Output Block w Relays Stepper Motor Drive Terminal Block Assembly Rear Terminal Block Assembly Side Rear Electrical Panel Side Electrical Panel 5 Amp Relay for PLC Output Block 6509598 JUNCTION BOX AND LIGHT ASSEMBLY PARTS LIST PARTS LIST Continued 6509598 JUNCTION BOX AND LIGHT
71. roximity switch is bad Worn motor brushes Checkout Procedure H Check for 49 Volts DC across TDC terminals A to A2 this voltage drives the DC traverse motor NOTE Traverse must be on and have TSP turned full CW to maximum voltage of 49 VDC L Check traverse motor continuity J RT1 Verify that relay 2 light comes on when Traverse Right is pressed and that relay 3 light comes on when Traverse Left is pressed K Check TSP for 10 000 ohms Remove three wires from TDC red from term S2 white from term SO black from inline connector Wire 39 L Gap between flag and Prox should be 3 16 to 1 4 4 6mm Prox light does not light when flag is under prox M From the Touch screen Enter HELP screen from main menu N Inspect Motor Brushes Check terminals A1 to A2 for 49 Volts DC Yes go to step I next No go to Step J next Remove wires from terminals 1 amp A2 0 ohms across the black and white wires Yes go to Step J next No go to Step N Lights come On go to step K next Off Skip to step L Check for 10 000 ohms red to white wires Full CCW 0 ohms Full CW 10 000 ohms Red to black wires Full CCW 10 000 ohms Full CW 0 ohms Yes go to Step L next No replace TSP If incorrect adjust per adjustment section of manual Traverse works Yes End troubleshooting No go to step M next Follow instructions on screen to verify traverse proximity switches are
72. rrect measurements 1 To install the battery remove the compartment lid and install the SR44 battery with its positive side facing up After the battery is installed set the origin 2 To set the origin move the slider to an area you wish to set as your origin Turn the power on Hold the ORIGIN switch down for more than one second The 0 00 dis play appears indication Origin setting is complete The origin will be retained even if the power is turned off Incremental INC amp Absolute ABS mode The LCD will dispay measurements from the origin when turned EE on ABS mode To set the origin see above The display can be 5 ie 1454 set to zero at any desired position by pressing the ZERO ABS gt switch INC indicator will apper in the display INC mode per w mitting measurements from this zero point return to the ABS Tam mode hole the ZERO ABS buttton form more than 2 seconds Don Error Symptoms amp Remedies ERRC and display flickering Occurs when the scale surface is stained Clean the scale surface and coat a thin film of low viscosity oil to keep out moisture E E in the least significant digit This occurs when the ay ai P slider is moved too quickly but it does not affectthe mea Leef ic JE surement If it stays on when the slider stops the scale surface is probably stained If this is the case take rem edies as for 341 le REM
73. s AC at the plug end winch cord wire 6 by plugging in a hand drill Check for main power cord 2 is plugged in to outlet Check connections inside rear junction box on WB2 Wire Block 2 from main power cord Winch works Yes end troubleshooting No go to Step B next Winch works Yes end troubleshooting No go to Step C next Drill works Yes replace winch No go to Step D next Winch works Yes end troubleshooting No go to Step E next WB2 115 Volts AC check black side to white side wires Yes replace cord 6 No replace cord 2 ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse Drive not working in manual jog mode Assuming 115 Volts AC to control panel and all other manual jog mode functions are work ing In your Product Packet Assembly there are a series of prints Find the print titled 650 Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose termi nals are found tighten and retest system If problem persists test as listed below Possible Cause Traverse Speed Pot TSP set to zero Traverse Actuator release lever released Circuit Breaker 32 CB32 2 amp tripped out Traverse Drive Control do not have power Relay 8 RT1 is bad
74. should be repeated MAINTENANCE Continued CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE WINDOWS Cleaning Instructions DO NOT USE GASOLINE Adherence to regular and proper cleaning procedures is recommended to preserve appearance and performance Washing to Minimize Scratching Wash polycarbonate windows with a mild dish washing liquid 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 prevent water 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 good grade of VM amp P naphtha or isopropyl alcohol Afterward a warm final wash should be made using a mild dish washing liquid detergent solution and ending with a thorough rinsing with clean water Minimizing Hairline Scratches Scratches and minor abrasions can be minimized by using a mild automobile polish Three such products that tend to polish and fill scratches are Johnson paste Wax Novus Plastic Polish 1 and 2 and Mirror Glaze plastic polish M G M10 Itis suggested that a test be made on a corner of the polycarbonate window with the product selected following the polish manufacturer s instructions Some Important DON TS DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows Never scrape po
75. t fit the outlet have a proper outlet and circuit installed by a qualified electrician ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOUR MACHINE AN IMPROPER CONNECTION CAN CAUSE A DANGEROUS ELECTRICAL SHOCK IF YOU ARE UNSURE OF THE PROPER ELECTRICAL GROUNDING PROCEDURE CONTACT A QUALIFIED ELECTRICIAN PERIODIC MAINTENANCE DAILY MAINTENANCE IS SPECIFIED ON PAGE 4 OF THE OPERATOR S MANUAL AND IS TO BE PERFORMED BY THE OPERATOR LISTED BELOW ARE PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY S MAINTENANCE DEPARTMENT Clean the internal bag and cloth filter in the vacuum system weekly or more often depending on the number of reels ground Use the grease fitting provided to grease the 2 D ADJUSTING dovetail with high quality lithium grease monthly GE Wipe off excess grease See FIG 9 Wipe and re oil with spray lubricant the grinding GREASE wheel diameter adjusting lead screw every three FITTING months Wipe off all excess lubricant See FIG 8 Check the gib adjustment on the grinding wheel diameter adjustment every 3 months See FIG 8 Inspect the Poly V belt for cracking and adjust the belt tension per procedure called out in the adjustment section every six months Wipe and relub with never seez the vertical and horizontal alignment shafts and lead screws every six months See FIG 10 Liftthe bellows and wipe off the traverse driveshaft and the bearing rails monthly When ALIGNME
76. together The other ball bearing is slip fit on the opposite end during assembly with loctite on the bearing bore To replace the spindle assembly remove the grinding wheel grip knob square key and belt cover See FIG 30 Loosen the 4 socket head cap screws on the motor to remove the poly V belt Loosen the 2 set screws on the spindle pulley and remove the pulley square key and pulley spacer Push on the right hand side of the spindle assembly to compress conical washers so there is no pressure on the shaft retain ing ring and to expose the retaining ring for removal Using a retaining ring pliers remove the small retaining ring from the spindle assembly You can now remove the spindle assembly out the right side by lightly tapping on the left end with a rubber mallet The second ball bearing can be removed from the belt side of the Grinding Head Housing To reassemble place the 4 conical washers 2 pair nested and then place the 2 pairs back to back against the ball bearing on the new spindle assembly See FIG 31 Slide this assembly into the Grinding Head Housing 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 conical washers so you can replace the retaining ring The retaining ring is fragile and easily damaged when removing Always use a new retaining ring when reassembling the grinding head spindle Only o
77. tor cord is bad remove back cover to motor Grinding Motor Worn Motor Brushes NOTE Checkout Procedure swich is on L Light is on for Relay 5 check continuity is bad L Check grinding motor continuity M Inspect Motor Brushes If voltage checks less than 95 VDC but not 0 then adjust MAX SPEED POT on the GMC until you read 95 VDC If you cannot achieve 95 VDC replace the GMC H RT1 check that the light is on for relay 5 make sure grind drive K Check grinding motor cord 01 Light is On Go to Step I next Off Contact Factory RT1 Term 5 to 5 measure DC voltage 0 Volts DC Replace wires 51 and 52 24 Volts DC Replace relay 5 RT1 At DC motor check term A1 to A2 for 95 Volts DC Yes go to Step L next No replace grinding motor cord 1 Remove wires at terminal A1 and A2 at motor Check for 0 ohms across terminals A1 and A2 Yes end troubleshooting No go to Step M next Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 9 16 14 mm minimum length Yes replace motor brushes No replace Spin Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Dust Collector not working in manual jog mode Assuming 115 Volts AC to control panel and all other manual jog mode functions are work ing In your Product Packet Assembly there are a series of prints Find the print titled 650 Wiring Diagr
78. works Yes end troubleshooting No go to step E next SDC Term L1 to 12 for 115 Volts AC Yes skip to step H next No go to Step F next Light is On go to Step next No Contact factory RT1 Term 9 to term 9 for 115 Volts AC No go to Step H next Yes Replace relay 9 in RT1 SDO term A1 to term A2 measure approx 12 Volts DC Yes Skip to Step L No go to step I Next SDC term A1 to term A2 measure approx 90 Volts DC No Skip to step N Yes go to step J Next ELECTRICAL TROUBLESHOOTING Continued Possible Cause Relay 4 is bad Reversing relay s bad RT1 Relief Torque Pot RTP is not working Spin Drive motor is bad Worn motor brushes Checkout Procedure J Check RT1 for light 44 to be off Insure that Spin Drive switch has been pressed on from RELIEF MANUAL screen at least once With light 4 on verify continuity L Measure voltage at RT1 M Reverse direction of spin motor from SPIN MANUAL touch screen N RTP on Main Panel O With machine power off Check spin motor continuity P Inspect motor brushes Light is Off go to Step K next On Contact factory RT1 Term 4 to term 4 for 0 Ohms Yes Replace relay 4 RT1 No replace SDS RT1 Term A to term D should read the same 12 Volts DC measured at step H Note polarity Yes Skip to Step M No go to Step N next RT1 Term A to term D should read the same 12 Volts DC measur
79. ws on the side so there is no free play in the dovetail slide Check for movement when pushing on the relief finger side to side with a 20 Ibs 44 kg force Make sure the knob assembly for adjusting the relief finger to the grinding wheel is rotatable by hand The gib adjustment should be sufficient to maintain a rigid position of the reel finger See FIG 16 Check the knob assembly rotating tension by checking the tightness of the nylon plug to the knob assembly threads The tightness has to be sufficient so the knob assembly does not rotate during the relief grinding cycle See FIG 17 NYLON PLUG SET SCREW FOR TENSION ON NOTE To adjust the nylon plug you must lock the index THE RELIEF FINGER ADJUSTING T KNUB finger assembly down and then adjust the reel finger positioner so the clearance holes line up with the nylon plug 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 the shaft collar until there is no end play Retighten locking cap screw on the threaded split shaft collar See FIG 16 GRINDING HEAD BELT TENSION ADJUSTMENT The grip grinding wheel knob need not be removed for belt tensioning adjustment Remove the six socket head cap screws holding the vacuum hose bracket the two double tube clamps and the belt cover

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