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6337951 Service Manual

1. ON O U W N P PART NO D160866 D161266 R000480 3706078 3706079 3707073 3707163 3707164 3707378 3707556 3707624 3707625 3707626 3707627 3707628 3707629 3707631 3707688 3707764 3707779 3707850 6009270 D131266 80259 3707859 3707602 3707632 3707634 3707695 3707707 3707708 3707709 3707798 3707857 3707907 3707913 3707914 3707918 3707919 3707941 3707942 3707778 6339552 CONTROL SUB PANEL DESCRIPTION 8 x 1 2 LONG PHILLIPS PAN HEAD 8 x 3 4 LONG PHILLIPS PAN HEAD 8 EXTERINAL LOCK WASHER 19 POLE DECAL TB1 19 POLE DECAL TB2 8 PIN SOCKET PRIMARY GROUND DECAL PRIMARY GROUND LUG DIN RAIL 14 0 LG STARTER MAGNETIC GROUND TERMINAL BL END STOP SCREWLESS JUMPER ADJACENT TERMINAL BLOCK TERMINAL BLOCK END PLATE TERMINAL BLOCK 2 CONDUCTOR GREY TERMINAL BLOCK 2 CONDUCTOR BLUE TERMINAL BLOCK TAG 1 10 LOW VOLTAGE RELAY RGI LINE FILTER 6 AMP CIRCUIT BREAKER TRAVERSE CONTROL BOARD ELECTRICAL SUB PANEL 6X3 4 LONG PHILLIPS PAN HEAD CIRCUIT BREAKER 20 AMP 24VDC POWER SUPPLY DIN RAIL 6 0 LONG TERMINAL BLOCK TAG 11 20 TERMINAL BLOCK TAG 21 30 2 POLE JUMPER WIDE SPADE DOUBLE FOR TERMINAL STRIP SPADE DOUBLE 90 SPADE SINGLE 90 RELAY TERM BLOCK 8 AMP 24VDC INFEED CONTROL DOOR SWITCH MONITOR TERMINAL BLOCK 4 POLE GRAY TERMINAL BLOCK 4 POLE BLUE TERMINAL BLOCK END PLATE 2 POLE TERMINAL BLOCK JUMPER CONTROL BOARD FOR POSITIONING LED SPIN CONTROL BOARD 19 POLE TERMINAL STR
2. SP WIRE 39 WIRE 38 e GROUND SCREW p WIRE CONNECTION TERM TO TERM CONNECTION WIRING SCHEMATIC O LINE FILTER 24 VDC POWER SUPPLY OPEN TURTLE CLOSED RABBIT GRINDING WHEEL INFEED DC MOTOR 1s 35 OHM BLUE TRAV PROX PXI LH me L BROWN TRAV PROX PX2 RH REVERSE FINGER PROX Ms Pa rev L GND SPIN MOTOR RELAY RTP 38 50K OHM TORQUE SSP 39 10K OHM VELOCIY 15 PRXI PRX2 9 MODE 9 REMOTE TORQUE REMOTE SPEED
3. 9 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 Wear respirator or filter mask where appropriate Wear protective gloves 10 ALWAYS USE SAFETY GLASSES 11 SECURE YOUR WORK Make certain that the cutting unit is securely fastened with the clamps provided before operating 12 DON T OVERREACH Keep proper footing and balance at all times 13 MAINTAIN GRINDER WITH CARE Follow instructions in Service Manual for lubrication and preventive maintenance 14 DISCONNECT POWER BEFORE SERVICING or when changing the grinding wheel 15 REDUCE THE RISK OF UNINTENTIONAL STARTING Make sure the switch is OFF before plugging in the Grinder 16 USE RECOMMENDED ACCESSORIES Consult the manual for recommended accessories Using improper accessories may cause risk of personal injury 17 CHECK DAMAGED PARTS A guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced 18 NEVER LEAVE GRINDER RUNNING UNATTENDED TURN POWER OFF Do not leave grinder until it comes to a complete stop 19 KNOW YOUR EQUIPMENT Read this manual carefully Learn its application and limitations as well as specific potential hazards 20 KEEP ALL SAFETY DECALS CLEAN AND LEGIBLE If safety decals become damaged or illegible for any reason repla
4. Loosen set screw and check See adjustment section Reason When bearing preload is too tight it causes excessive loading to drive the carriage When traverse belt is disengaged the proper traverse load is 2 to 3 lbs Use a tension scale to check A general guide only Have enough play so the crank turns snugly but during operation it is free PARTS LIST DIAGRAM NO PART NO B230611 B251011 B310813 B311013 B311213 B371216 B372811 B374811 J167000 J257100 J311000 J317100 J372000 J377000 K311501 3706039 3706186 3706215 3706217 3706218 3706226 3707908 3708209 3708820 3708889 3709027 3709304 4609063 6339039 6339050 6339051 6339056 6339057 6339189 6339190 6339201 6339521 6339522 6339524 ON O U R W N P MODEL 633 6339520 FRONT DOOR ASSEMBLY DESCRIPTION M6X10 SOCKET HEAD CAP SCREW 1 4 20x5 8 SOCKET HEAD CAP SCREW 5 16 18x1 2 BUTTON HEAD SOCKET SCREW CAP 5 16 18x5 8 BUTTON HEAD SOCKET SCREW CAP 5 16 18x 75 BUTTON HEAD SOCKET SCREW CAP 3 8 16x3 4 BUTTON HEAD SOCKET SCREW CAP 3 8 16x1 3 4 SOCKET HEAD CAP SCREW 3 8 16x3 SOCKET HEAD CAP SCREW 8 32 JAM LOCKNUT 1 4 20 LOCKNUT 5 16 18 HEX NUT 5 16 18 LOCKNUT 3 8 16 HEX JAM NUT 3 8 16 JAM LOCKNUT 5 16 LOCKWASHER SPLIT HOLE PLUG 687 DIA WINDOW GASKET LEDGE HANDLE SHOULDER BOLT 5 DIA X 2 5 LG SHOULDER BOLT 38 DIA X 2 5 LG COMPRESSION SPRING 72OD X 3 0 LG DOOR SWITCH WITH DISCONNECT 3 8 16x3
5. needs to be maintained between the carriage proximity flag bracket and the TRAVEL LIMIT See FIG 22 NOTE The light on the proximity switch activates when metal crosses in front of the switch ADJUSTABLE RELIEF TENSION If the relief angle appears to vary during relief grinding adjust the tension on the nylon plug and set screw See FIG 23 SAFETY SWITCH ALIGNMENT For the safety switches to work properly they must be adjusted so the sender and receiver are parallel to each other with a maximum gap of 19 inches bmm See FIG 24 Adjust by moving the doors or mounting brackets A special wrench is needed to adjust the safety screws used to hold the switch in place ORIGINAL INSTRUCTIONS PROXIMITY SWITCH yl 4 Mh 1 4 B CARRIAGE PROKJMI TY FLAG BRACKET NYLON PLUG SET SCREN TRAVERSE BELT TENSION To adjust the tension on the traverse belt tighten the screws and nuts located at the left side of the traverse belt Tighten nuts until the comprension springs measure 3 4 See FIG 25 If the springs are not tensioned equally uneven loading on the traverse system may cause parts to fail DO NOT OVERTIGHTEN OVERTIGHTENING COULD DAMAGE THE BELT OR TRAVERSE DRIVE SYSTEM TRAVERSE CLAMP FORCE If the traverse clamp is slipping during regula
6. 6332901 COMMON ASSEMBLY PARTS LIST PARTS LIST 6332901 COMMON ASSEMBLY e PART NO DESCRIPTION P PART NO DESCRIPTION 6339516 TRAVERSE BASE ASSEMBLY 41 6339187 VACUUM DOOR SPACER 6339537 CROSS SLIDE SUB ASSSEMBLY 42 6339191 CONTROL BOX RING 6339505 SPIN DRIVE ASSEMBLY 43 6339542 VACUUM DOOR WELDMENT 6339530 FRONT TOOLING ASSEMBLY 44 6339543 ALIGNMENT GAUGE HOUSING 6339534 REAR TOOLING ASSEMBLY 45 6339556 CONTROL BOX WELDMENT 6339538 POSITION GAUGE ASSEMBLY 46 6339557 CONTROL ARM 6339544 FRAME WELDMENT PAINT 47 6509020 TRAVERSE BASE END CAP B130412 6 32x1 4 PAN HEAD MACHINE SCREW 48 6509035 CROSS SLIDE MOUNT PLATE B190813 10 24x1 2 BUTTON HEAD SOCKET CAP SCREW 49 6509039 ACCESS PANEL RIGHT SIDE B250616 1 4 20x3 8 BUTTON HEAD SOCKET CAP SCREW 50 6509040 SMALL ACCESS PANEL B250816 1 4 20x1 2 BUTTON HEAD SOCKET CAP SCREW 51 6509212 CONTROL PANEL HINGE B250819 1 4 20x1 2 THUMBSCREW 52 6339188 ADESIVE BACK FOAM B251016 1 4 20x5 8 BUTTON HEAD SOCKET CAP SCREW B310813 5 16 18x1 2 BUTTON HEAD SOCKET CAP SCREW B311013 5 16 18x5 8 BUTTON HEAD SOCKET CAP SCREW B311213 5 16 18x 75 BUTTON HEAD SOCKET CAP SCREW B314811 5 16 18x3 SOCKET HEAD CAP SCREW FULL B371211 3 8 16x3 4 SOCKET HEAD CAP SCREW B502811 1 2 13x1 3 4 SOCKET HEAD CAP SCREW B503211 1 2 13x2 SOCKET HEAD CAP SCREW B504801 1 2 13x3 HEX HEAD CAP SCREW H371602 ROLL PIN 375Dx1 0 J13
7. 80380 GEARMOTOR 1 20 HP 3707225 CABLE TIE 6 5Lx 18 3707601 PROXIMITY SENSOR 3708195 RETAINING RING EXTERNAL 6539082 HEAD POSITION SENSOR CORD 3708419 WAVE SPRING 78 ID 6509237 GRINDING WHEEL KNOB 3708436 WAVE SPRING 6509216 HEAD SENSOR BRACKET 3708658 COMPRESSION SPRING 6509269 VACUUM HOSE BRACKET 3708884 SPACER 28IDx 620D 3708121 DOUBLE CORD CLAMP 3709044 BALL BEARING B251018 1 4 20x5 8 PAN HEAD MACHINE SCREW 3709072 COMPRESSION SPRING 480D B250618 1 4 20x3 8 PAN HEAD MACHINE SCREW PARTS LIST 6339531 CARRIAGE ASSEMBLY DIAGRAM NUMBER PART NO DESCRIPTION B130412 6 32x1 4 PAN HEAD MACHINE SCREW B190509 10 24x5 16 PAN HEAD MACHINE SCREW B191013 10 24x5 8 BUTTON HEAD SOCKET CAP SCREW B250616 1 4 20x3 8 BUTTON HEAD SOCKET CAP SCREW B252016 1 4 20x1 1 4 BUTTON HEAD SOCKET CAP SCREW B253216 1 4 20x2 BUTTON HEAD SOCKET CAP SCREW J137000 6 32 LOCKNUT JAM NUT J252000 1 4 20 HEX JAM NUT J887300 7 8 14 LOCKNUT K191501 10 LOCKWASHER SPLIT K251501 1 4 LOCKWASHER SPLIT 28187 BLOCK TRAVERSE CLAMP 28188 SPACER TRAVERSE CLAMP 28189 BLOCK CLAMP SUPPORT 50310 TIP BELT CLAMP 3706193 GRAB CATCH METAL 3708184 RETAINING RING INTERNAL 3708186 BALL BEARING DOUBLE ROW 5 6329040 TRAVERSE CLAMP MACHINED 6329058 CARRIAGE BASE BELT ON O U BP W N P 6339130 CATCH BRACKET 6339532 DUST DOOR WELDMENT 6339559 PIN PLATE WELDMENT 6509023 GRINDING HEAD PIVOT SHAFT PARTS LIST 6339510 FINGER AND BODY ASSEMBLY PARTS LIST
8. C next No Replace SSP Yes end of troubleshooting No replace SDC Original adjustment was not set properly Too much load on drive motor will cause motor to hunt and vary speed When connections are not tight the control board varies volt age to the DC motor which then varies speed OC IN PROBLEM Traverse Drive not working Assuming SSS Svstem Start Switch is on with 120 volts AC to control panel and all other functions are working Verifv all wires shown on the wiring diagram on pages 88 are correct and pull on wire terminals with approximately 3lbs 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 Traverse Motor Switch TMS is not on Traverse Speed Pot TSP set to zero Traverse is waiting for signal from Index Finger Proximity Sensor In Torque mode only Fuse on Traverse Drive Control TDC has failed Traverse Drive Control TDC is bad Bad Traverse Motor Switch TMS Checkout Procedure A Turn on TMS B Set TSP to 35 on the control panel C If the Spin Torque selector is in torque mode and the carriage is on the right proximity sensor the traverse board wats for the indexing finger to be activated before traveling to the right D Check fuse and replace if failed See Page 23 Too heavy a gr
9. CONTACT A QUALIFIED ELECTRICIAN R DAIZ ORIGINAL INSTRUCTIONS 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 this Spin Relief Grinder For those without the background service can be arranged through your local distributor This section 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 any panels or shields or attempt any internal troubleshooting adjustments or parts replacement If you have questions not answered in this manual please contact your distributor TORQUE REQUIREMENTS 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 3MARKS 6 MARKS Bolts Going Into a Nut or Into a Thread Hole in Steel HEAD on HEAD on HEAD Refer to the table at the right 6 ft Ibs 9 ft Ibs 13 ft Ibs thread 0 8 kg m 1 25 kg m 1 8 kg m Bolts Going Into a Thread Hole In Aluminum f 5 16 In 11 ft lbs 18 ft lbs 28 ft lbs Use the Grade 2 values in the table at the right thread 3 8 In 19 ft lbs 31 ftlbs 46 ft lbs Socket Head Scre
10. DECAL FOLEY UNITED 6339551 CABINET ASSEMBLY DIA PART NO GRAM NO 39 3707601 6329075 6329076 6329159 6339025 6339050 6339172 6339173 6339174 6339197 3707968 3707967 3707966 3707969 3707233 3707234 3707351 3707358 3707360 3708378 3707224 3707255 3707225 6329079 6329080 6329081 6339182 6339183 6339185 6339186 6339203 DESCRIPTION 18mm PROXIMITY SENSOR LEFT TRAVERSE PROX CORD RIGHT TRAVERSE PROX CORD FINGER POSITION PROX CORD DECAL SHEET 633 653 ACCUPro 633 DECAL CONTROL PANEL DECAL POWER SWITCH DECAL LED DECAL FOR POSITION CONTROL PANEL TOP RED LED LIGHT GREEN LED LIGHT BLUE LED LIGHT SQUARE PUSH BUTTON BLUE TERMINAL 25 FEMALE 18 22 GA TERMINAL 25 MALE 18 22 GA TERMINAL 25 FEMALE 14 16 GA TERMINAL FORK 6 14 16 GA TERMINAL FORK 6 18 22 GA STRIP FOAM 25T MOUNT CABLE TIE CABLE TIE 4Lx 10Wx CABLE TIE 6 5Lx 18 INFEED MOTOR CORD LIGHT RECEPTACLE CORD VACUUM RECEPTACLE CORD CONTROL PANEL CORD POTENTIOMETER CABLE ASSEMBLY REAR DOOR SWITCH CORD FRONT DOOR SWITCH CORD SPIN MOTOR CORD WIRING DIAGRAM 6334551 REAR DOOR SWITCH W40 m Dci ISOCLU ABSDC A2 ATIDC GND MAK MD REV DB AICA PD ACC FOR 50 60 HZ 680 0 90 en 270 501 O ANTDC AUT S Noo
11. DIAGRAM NO ON O U W N e PART NO B190631 B190634 B251016 B251216 B254811 C160420 C190460 C190467 C250427 K191501 J191100 J197000 J377200 3579284 3706170 3706171 3706172 3706187 3706188 3708107 3708999 6339014 6339016 6339017 6339020 6339507 6339508 6339509 6339511 6339512 6339548 6339514 6339547 6509007 6509008 6509239 6509358 6509501 6509230 3707601 6539083 6339510 FINGER AND BODY ASSEMBLY DESCRIPTION 10 32x3 8 SOCKET HEAD CAP SCREW 10 32x3 8 BUTTON HEAD SOCKET CAP SCREW 1 4 20x5 8 BUTTON HEAD SOCKET CAP SCREW 1 4 20x3 4 BUTTON HEAD SOCKET CAP SCREW 1 4 20x3 SOCKET HEAD CAP SCREW 8 32x1 4 SOCKET SET SCREW CUP POINT SOCKET SET SCREW 10 32X1 4 10 32x1 4 SOCKET SET SCREW NYLON 1 4 20x1 4 NYLON 10 LOCKWASHER SPLIT 10 32 HEX NUT 10 24 LOCKNUT JAM 3 8 24 LOCKNUT JAM NYLON PLUG 1 8 DIA COMPRESSION SPRING 420D X 31 ID COMPRESSION SPRING 420D X 33 ID 1 4 20 X 3 8 SET SCREW WAVE SPRING 2 ID WAVE SPRING 24 ID COMPRESSION SPRING 24 OD WASHER FLAT 376x 563X 03 SPACER 5 OD x 33 ID FINGER STOP POSITION PIN BLOCK FINGER SLIDE BASE INDEX FINGER ASSEMBLY RELIEF ADJUSTER LOCK HANDLE RELIEF ANGLE POSISTIONER FINGER STOP PLATE ASSEMBLY FINGER STOP ADJUSTMENT KNOB FIXED FINGER ASSEMBLY RELIEF ROTATE HOUSING ASSSEMBLY CLAMP PLATE FOR RELIEF ASSEMBLY INDEX STOP PIN INDEX SENSOR BLOCK ANTI ROTATE PLATE STOP PLATE TEE KNOB ASSY 10 32X3 0 INDEX SENSOR GUARD PROXIM
12. be 3 16 to 1 4 4 6 mm Prox LED does not light when flag is under prox B Proximity switch is not working properly or wire connections are loose If incorrect adjust per adjustment section of manual Yes end troubleshooting No go to Step B next First check to see if proximity light comes on When the light is on it means that there is electric ity coming to proximity switch Actuate prox switches with steel tool to take measurements Left proximity PROX 1 check Traverse drive Control TDC be tween terminals 13 black wire and 15 brown wire Right proximity PROX check 14 black wire and 15 brown wire ORIGINAL INSTRUCTIONS The light coming on shows the proximity is getting electrical contact Proximity light on 0 Volts DC Proximity light off 12 Volts DC Proximity light on 0 Volts DC Proximity light off 12 Volts DC Replace proximity switch if the voltages do not read as above ELECTRICALTROUBLESHOOTING PROBLEM Traverse speed control goes at one speed only Possible Cause Defective speed control potentiometer Wiring hookup to poten tiometer is improper If components have been replaced Main circuit board dial pot settings not correct If board has not been replaced Checkout Procedure A Check potentiometer on control panel B Check potentiometer for 10 000 ohms Remove three wires from Traverse Drive Control red from term 8 whi
13. snugging 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 Ibs STEP 10 Test the Cross Slide the handwheel should turn freely STEP 11 Lower the jack and retest the Cross Slide Assembly through full range of motion If binding occurs follow the procedure under Cross Slide Assembly located on page 21 LOCK HANDLES NOTE It is also possible to remove the complete Cross Slide Assembly and do the repairs on a bench then reinstall NUT h DUTCHMAN SETSCREW HANDWHEEL ORIGINAL INSTRUCTIONS SLIDE SHAFTS MACHINE SERVICE ORIGINAL INSTRUCTIONS REPLACEMENT OF GRINDING HEAD SHAFT amp BEARINGS Remove grinding wheel and grinding wheel knob The Grinding Head Spindle Assembly consists of the grinding head spindle and a ball bearing press fit together The left side ball bearing is slip fit on the opposite end To replace the spindle assembly remove the left side grinding wheel grip knob square key and belt cover See FIG 32 Loosen the 4 socket head cap screws on the motor plate to remove the poly V belt Loosen the 2 set screws on the spindle pulley and remove the pulley square key and pulley spacer Push on the right hand side of the spindle assembly to compress conical washers so there is no pressure on the shaft retaining ring Using a retaining ring pliers remove the small external retaining ring from the spindle assembly You can now rem
14. to term 3 DISCONNECT POWER FROM MACHINE Worn Motor Brushes J Inspect Motor Brushes ORIGINAL INSTRUCTIONS STP on SDC board should be set as labled on pages 24 and 25 Adjust if incorrect and check Spin Drive Function Yes Go to Step I next No Replace SDC Check for 10 000 ohm Red wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Red wire to black wire Full CCW 10 000 ohms Full CW 0 ohms Yes replace SDC No replace SSP 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 Spin Drive Motor ELECTRICALTROUBLESHOOTING PROBLEM Spin Drive not working in relief mode Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram on pages 80 81 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 Relief Torque Pot RTP set to zero Spin Motor Switch SMS is not on Circuit Breaker is Tripped 4 AMP Spin Drive Control SDC is not working CB or Spin Motor Switch SMS is bad Spin Drive motor is bad Worn Motor Brushes Checkout Pr
15. 5 SOCKET HEAD CAP SCREW FULL THREAD 8 32x 50 BUTTON SAFETY HEAD SEAL FOAM 50 HIGH THRUST WASHER 507x 917 OD THRUST WASHER 375x 812 OD SPACER 385x 625x 25LG DOOR PIVOT BRACKET ACCUPro 633 DECAL DOOR PIVOT ARM MACHINED WINDOW 18 5 X 26 DOOR CENTER PLATE DOOR UPPER ARM BRACKET DOOR UPPER ARM REAR BUMPER 633 RIGHT DOOR WELDMENT 633 LEFT DOOR WELDMENT DOOR PIVOT ARM WELDMENT PARTS LIST PARTS LIST DIAGRAM NO PART NO ON O U W DN P B190411 B190613 B250816 B251016 B251216 B310813 B370801 B370816 B372001 B372016 B372401 B372416 H371202 J167000 J191000 J252000 J257000 J257100 J371000 J377000 J627100 K190001 K191501 K250001 K251501 K370001 K371501 09054 55492 80406 80418 80421 3249153 3706032 MODEL 633 6339545 REAR DOOR ASSEMBLY DESCRIPTION 10 24x1 4 SOCKET HEAD CAP SCREW 10 24x3 8 BUTTON HEAD SOCKET SCREW CAP 1 4 20x1 2 BUTTON HEAD SOCKET SCREW CAP 1 4 20x5 8 BUTTON HEAD SOCKET SCREW CAP 1 4 20x3 4 BUTTON HEAD SOCKET SCREW CAP 5 16 18x1 2 BUTTON HEAD SOCKET SCREW CAP 3 8 16x1 2 HEX HEAD CAP SCREW 3 8 16x1 2 BUTTON HEAD SOCKET SCREW CAP 3 8 16x1 1 4 HEX HEAD CAP SCREW 3 8 16x1 25 BUTTON HEAD SOCKET SCREW CAP 3 8 16x1 1 2 HEX HEAD CAP SCREW 3 8 16 X 1 1 2 BUTTON HEAD SOCKET SCREW CAP ROLL PIN 375Dx 75 8 32 LOCKNUT JAM 10 24 HEX NUT 1 4 20 HEX JAM NUT 1 4 20 LOCKNUT JAM 1 4 20 LOCKNUT 3 8 16 HEX NUT 3 8 16 LOCKNUT JAM 5 8 11 LOCKNUT FLAT
16. 7000 6 32 LOCKNUT JAM NUT J257100 1 4 20 LOCKNUT FULL J317100 5 16 18 LOCKNUT J507100 1 2 13 LOCKNUT FULL K191501 10 LOCKWASHER SPLIT K251501 1 4 LOCKWASHER SPLIT K310001 FLAT WASHER 5 16 SPLIT K311501 5 16 LOCKWASHER SPLIT K371501 3 8 LOCKWASHER SPLIT K501501 1 2 LOCKWASHER SPLIT 3706193 GRAB CATCH METAL 3706219 25 PLASTIC WASHER 3706220 WING HANDLE CAM LATCH 3708543 SHOULDER BOLT 313DIA X 32LG 3708908 ADJUSTABLE HANDLE 3 8 16x 78LG 6059030 HINGE FRONT END 6329070 HINGE PAINTED 6339083 ELECTRICAL PANEL ON O U W N e 6539516 TRAVERSE BASE PARTS LIST PARTS LIST 6539516 TRAVERSE BASE PART NO DESCRIPTION PART NO DESCRIPTION B190611 10 24x3 8 SOCKET HEAD CAP SCREW 3709331 RETAINING RING EXTERNAL B191211 10 24x3 4 SOCKET HEAD CAP SCREW 3709372 HOLE PLUG 50 DIA B250616 1 4 20x3 8 BUTTON HEAD CAP SCREW 6059062 TRAVERSE MOTOR ASSEMBLY B250811 1 4 20x1 2 SOCKET HEAD CAP SCREW 6339510 RELIEF ANGLE POSITIONER ASSEMBLY B250818 1 4 20x1 2 PAN HEAD MACHINE SCREW 6329034 COUPLER 625 DIA B250819 1 4 20x1 2 TRUSS HEAD MACHINE SCREW 6329036 PULLEY MOUNT BRACKET B251211 1 4 20x3 4 SOCKET HEAD CAP SCREW 6329141 MOTOR EXTENSION SHAFT B251411 1 4 20x7 8 SOCKET HEAD CAP SCREW 6339533 LIMIT SENSOR AND CLAMP B252011 1 4 20x1 1 4 SOCKET HEAD CAP SCREW 6329511 SHAFT SUPPORT BLOCK B253211 1 4 20x2 SOCKET HEAD CAP SCREW 6509021 BELLOWS CARRIAGE B
17. 9111 FRONT TOOLING RIGHT PLATE 6339112 FRONT TOOLING LEFT PLATE 6339113 LOCK PLATE 6339114 TOOLING LOCK BLOCK 6339115 BRAKE BLOCK 6339527 FORNT CLAMP WELDMENT 6339529 PINION SHAFT WELDMENT 6339526 FRONT TOOLING MOUNT ON O U BW N 6339534 REAR TOOLING PARTS LIST PARTS LIST DIAGRAM NO ON O U W DN P PART NO B250816 B251216 B251416 B311013 B311413 C190320 H180901 J311000 K121501 K251501 K311501 3706195 3706196 3706197 3706198 3706221 3708214 3708914 6339119 6339120 6339121 6339122 6339123 6339124 6339125 6339126 6339134 6339135 6339136 6339137 6339138 6339139 6339141 6509304 6339025 6339534 REAR TOOLING DESCRIPTION 1 4 20x1 2 FLAT HEAD SOCKET SCREW CAP 1 4 20x3 4 FLAT HEAD SOCKET SCREW CAP 1 4 20x7 8 FLAT HEAD SOCKET SCREW CAP 5 16 18x5 8 FLAT HEAD SOCKET SCREW CAP 5 16 18x7 8 BSHCS SKSS 10 24X3 16 CP PIN DOWEL 188Dx 5 16 18 HEX NUT FULL 5 LOCKWASHER SPLIT 1 4 LOCKWASHER SPLIT 5 16 LOCKWASHER SPLIT BEARING RAIL 15M LINEAR BEARING 15M M3 5 X 20MM SOCKET HEAD CAP SCREW M3 5 X 12MM SOCKET HEAD CAP SCREW COMP SPRING 25 OD CONICAL WASHER 38 PLUNGER SPRING BOTTOM PLATE REAR TOP PLATE REAR TOOL CLAMP PLATE REAR POSITION PIN BRACK PAWL RACK REAR TOOL BEARING SIDE PLATE SPARK PLATE REAR TOOLING SUPPORT POINTER KNOB PAWL TOP PLATE LOCATING PIN PLATE PAWL SPACER PLATE PAWL BOTTOM PLATE PAWL PI
18. ACCU Pro 633 AUTO INDEX SPIN RELIEF REEL MOWER GRINDER Patent No 6 010 394 6 290 581 amp 6 685 544 ORIGINAL INSTRUCTIONS SERVICE MANUAL YOU MUST THOROUGHLY READ AND UNDERSTAND ALL MANUALS BEFORE OPERATING THE EQUIPMENT PAYING PARTICULAR ATTENTION TO THE WARNING amp SAFETY INSTRUCTIONS IMPORTANT SAFETY MESSAGE ORIGINAL INSTRUCTIONS IMPORTANT SAFETY MESSAGE As manufacturers of sharpening equipment we want to confirm to you our customers our concern for safety We also want to remind you about the simple basic and common sense rules of safety when using this equipment Failure to follow these rules can result in severe injury or death to operators or bystanders It is essential that everyone involved in the assembly operation transport maintenance and storage of this equipment be aware concerned prudent and properly trained in safety Always use proper shielding and personal protective equipment as specified by the manufacturer Our current production machines include as standard equipment guards or shields for the grinding wheel safety signs and operators and service manuals Never bypass or operate the machine with any of the guards or safety devices removed or without the proper personal safety equipment Read and fully understand all the safety practices discussed in this manual and the Operators Manual All safety rules must be understood and followed by anyone who works with reel grinders Befor
19. D 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 Touch electrical system For those without that background service can be arranged through your local distributor This manual presumes that you are already familiar with the normal operation of the Grinder If not you 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 two or three numbers are the Foley wire number The next group of letters or numbers are the code for the component to which the wire attaches Example RT1 for Relay Terminal 1 The last set of numbers or letters is the name of the terminal on the component to which the wire attaches ELECTRICAL TROUBLESHOOTING ORIGINAL INSTRUCTIONS PROBLEM AC Main Power Controls no electrical power to control panel Verify all wires shown on the wiring diagr
20. EL Term L1 amp L2 REL Term T1 to Term T2 for 120 Volts AC Yes Go to Step I next No Replace Gringing Motor Relay Verify wiring at terminals 1 2 amp 3 on Terminal Strip 1 Check TB1 1 to TB1 2 for 120 Volts AC Yes Check motor cord terminals Replace motor No Check continuity of circuit breaker Replace ELECTRICALTROUBLESHOOTING PROBLEM SPIN DRIVE NOT WORKING IN SPIN MODE ORIGINAL INSTRUCTIONS Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram on page 80 81 are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or not loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem per sists test as listed below Possible Cause Spin Speed Pot SSP set to zero Spin Motor Switch SMS is not on Circuit Breaker is Tripped 4 AMP Spin Drive Control SDS is not working Spin Drive motor is bad Checkout Procedure A Set SSP to 200 on the control panel B Turn SMS switch on C Reset Circiut Breaker on front of Control Panel Push in if tripped D Check SDS L1 to L2 for 120 Volts AC E With the Selector switch in spin and the spin pot set to 400RPM Check SDC A1 and A2 for 90 120 Volts DC F Check spin motor continuity DISCONNECT POWER AN FROM MAC
21. Frame to 75 ft lbs 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 the assembly CARRIAGE CROSS SLIDE MOUNTING ASSEMBLY FRAME PART OF FRAME ADJUSTMENTS CROSS SLIDE SHAFT REPLACEMENT If the cross slide shafts become scarred or gnarled replace them by the following procedure STEP 1 Use a hydraulic jack to raise the weight off the Cross Slide Assembly STEP 2 Loosen the two nuts on the support casting that hold the locking stud and tap with plastic or rubber 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 handwheel STEP 5 Remove the Slide Shaft STEP 6 Remove all burrs and resurface the shaft to a clean smooth polished surface OR REPLACE 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 locking studs The shaft must move freely inside the Cross Slide Block before reassembling STEP 8 Retightening the nuts at the end of the locking studs to lock shaft in place STEP 9 Reinstall the Handwheel by
22. H FTR LINE FILTER FUS 1 FUSE1 FUS 2 FUSE2 FUS 3 FUSE3 GMS GRINDING MOTOR SWITCH ICB INFEED CONTROL BOARD IJS INFEED JOG SWITCH ISS INFEED SELECTOR SWITCH LVR LOW VOLTAGE RELAY PGC POSITION GAUGE CONTROL MAG MAGNETIC STARTER PSW POWER SWITCH PX1 LEFT PROXIMITY SWITCH PX2 RIGHT PROXIMITY SWITCH SMS SPIN MOTOR SWITCH TB1 TERMINAL STRIP 1 REL GRINDING MOTOR RELAY SRS SPIN ROTATION SWITCH TB2 TERMINAL STRIP 2 RSS REVERSE SELECTOR SWITCH SSP SPIN SPEED POTENTIOMETER TBG TERMINAL BLOCK GREY RTP RELIEF TORQUE POTENTIOMETER SSS SYSTEM START SWITCH TBW TERMINAL BLOCK BLUE SCB SECONDARY CIRCUIT BREAKER SSM SAFETY SWITCH MONITOR TSP TRAVERSE SPEED POT SCR SPIN CONTROL RELAY STR SPIN TORQUE RELAY TDC TRAVERSE DRIVE CONTROL SDC SPIN DRIVE CONTROL STS SPIN TORQUE SELCTOR SWITCH y MTBI 6 SSSRETURN 71 SSS ESS MAG 14018 12 spin torque power qut lo switches 1421B1 10 37181 10 165BPBNO 169LEDGN 161LEDGN 170LEDBU 163LEDBU 167BPB C Q 168LEDRD H62LEDRD RED GREEN BLUE PUSH BUTTO WIRING DIAGRAM ISOICBB 1331C8B ISIICBAI l mon 6334551
23. HER SPLIT B311211 5 16 18x3 4 SOCKET HEAD CAP SCREW H252807 PIN DRIV LOC 25 3706207 COMPR SPRING 841D 6339160 CLAMP BAR 6339161 CLAMP HOUSING 6339162 CAM LOCK 6339163 CLAMP RING 6339164 LEVER HANDLE 6339165 BASE HANDLE 6339540 REAR CLAMP WELDMENT J252100 1 4 28 HEX JAM NUT ON O U WN Be PARTS LIST 6509529 INFEED STEPPER PARTS LIST DIAGRAM NO CON O U A W N PART NO B190634 B250618 B251018 J377200 K191501 K251501 3700089 3707225 3707255 3708121 3709304 6509216 6509230 6509237 6509574 6509529 INFEED STEPPER DESCRIPTION 10 32x3 8 FLAT HEAD SOCKET SCREW CAP 1 4 20x3 8 PAN HEAD MACHINE SCREW 1 4 20x5 8 PAN HEAD MACHINE SCREW 3 8 24 LOCKNUT JAM H10 LOCKWASHER SPLIT 1 4 LOCKWASHER SPLIT GR WHEEL 50Dx1Wx 5 CABLE TIE CABLE TIE CORD CLAMP DOUBLE THRUST WASHER 375 BRKT PROXIMITY FINGER SENSOR GUARD INDEX SENSOR KNOB GR WHEEL STEPPER 6 MOUNTING ASSEMBLY 6339558 COMMON CARTON DIAGRAM NO PART NO 3706130 3708205 3700088 3700086 3700087 3700089 3707603 3707465 1 2 3 4 5 6 7 8 6339558 COMMON CARTON DESCRIPTION DRIVE ADAPTERS SOCKET HOLDER GRINDING WHEEL 3 50Dx 38Wx 502B 24G GRINDING WHEEL 3 5ODx1Wx 502B 24G GRINDING WHEEL 5 ODx 38Wx 502B 24G GRINDING WHEEL 5 OD X 1Wx 502B 24G BLUE LENS FLASHER BULB 6339552 CONTROL SUB PANEL DIAGRAM NO
24. HINE Spin drive control in Torque mode G Check continuity of mode selector switch 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 SDC Remove wires to Terminals L1and L2 and test betwen wires for 120V AC Yes reconnect wires to board then go to Step E next No Verify Power to Circuit Breaker and SMS and continuity of wires Replace CB or SMS if needed SDC Remove wires test Terminals A1 to A2 on the board for approx 90 120 V DC Yes reconnect wires and go to Step F next No go to Step G Remove wires at Terminal Strip 1 Term 4 amp 5 check 0 ohms across the black and white wires Yes end troubleshooting spin drive should run if not replace motor No go to Step J Light on SDC next to SP should be ON If not Remove wires 41SDCMOD and 44SDC COM from SDC control board Check con tinuity of wires should read 0 ohms Yes Check continuity of STS switch replace if bad Machine was in Torque mode No Light nest to SP is on but machine does not work Go to Step H next ELECTRICALTROUBLESHOOTING Possible Cause Checkout Procedure Spin Torque Pot STP H Check STP remote is not set correctly torque on the top SDC board SSP is not working I SSP 10K Remove 3 Remote Speed wires Red wire to term 2 White wire to term 1 Black wire
25. IP 2 ROW 6339551 CABINET ASSEMBLY PARTS LIST 76 PARTS LIST DIA GRAM PART NO NO ON O U RB W MN B190834 D250800 J197200 R000465 R000536 80419 3706039 3706105 3706133 3706134 3706135 3706136 3707009 3707029 3707090 3707093 3707219 3707342 3707367 3707446 3707525 3707564 3707565 3707566 3707567 3707568 3707595 3707597 3707658 3707713 3707826 3707927 3708462 3707908 3708419 3708421 3708872 3709990 DESCRIPTION 10 32x1 2 FLAT HEAD CAP SCREW 1 4 THREAD CUTTING SCREW 10 32 HEX LOCKNUT 10 EXTERNAL LOCK WASHER 1 4 INTERNAL LOCK WASHER POTENTIOMETER 10K HOLE PLUG 687 DIA DECAL SHEET REEL GRINDER CLEAR TUBE 3 5 OD END CAP 3 5 ID B VELCRO HOOK 1 WIDE VELCRO LOOP 1 WIDE LIQUID TIGHT STRAIN RELIEF 27 47 DIA LIQUID TIGHT STRAIN RELIEF 19 30 DIA FUSE 4 AMP SLO BLOW LIQUID TIGHT STRAIN RELIEF 43 55 DIA FUSE 2 AMP SLO BLOW RING YELLOW E STOP SWITCH ROCKER ON O POTENTIOMETER KNOB W POINTER FUSE 15 AMP SLO BLOW PUSH BUTTON GREEN BLOCK CONTACT NO SWITCH MOUTNING LATCH PUSH PULL RED BUTTON BLOCK CONTACT NC HOLE PLUG 875 DIA HOLE PLUG 625 DIA LIQUID TIGHT STRAIN RELIEF 54 71 DIA ROCKER SWITCH MOMENTARY SQUARE PUSH BUTTON GREEN FUSE HOLDER PANEL MOUNT DECAL WARNING 4500 RPM DOOR SWITCH W DISCONNECT WAVE SPRING 78 ID FLAT WASHER 75x1 0 X 075T DECAL PATENT
26. ITY SENSOR FINGER POSITION SENSOR CORD PARTS LIST 6339515 GRINDING HEAD DIAGRAM NO PART NO DESCRIPTION B251411 1 4 20x7 8 SOCKET HEAD CAP SCREW B371611 3 8 16x1 SOCKET HEAD CAP SCREW C250627 1 4 20x3 8 SOCKET SET SCREW 6509494 SPINDLE NUT K250001 FLAT WASHER 1 4 SAE K251501 1 4 LOCKWASHER SPLIT K371501 3 8 LOCKWASHER SPLIT R000376 SQ KEY 1 8 X 75 3707690 MOTOR 1HP 120VAC 3708193 CONICAL WASHER 88 3708194 RETAINING RING INT 3708202 BELT POLY V 320J4 3708204 BALL BRG DBL ROW 5 3708870 RETAINING RING 6329041 PLATE MOTOR MOUNT 6329042 PULLEY POLY V 1 80 6329100 PULLEY POLY V 1 44 6329089 SLEEVE BEARING DBL 6329523 GR HEAD SPINDLE ASSEMBLY 6339026 GRINDING HEAD HOUSING R000377 SQ KEY 3 16 X 75 ON O U BW N GRINDING WHEEL SEE CARTON ASSEMBLY 6509237 GRINDING WHEEL KNOB PARTS LIST 6339537 CROSS SLIDE DIAGRAM NO PART NO DESCRIPTION B160807 8 32x1 2 BUTTON HEAD SOCKET CAP SCREW B250816 1 4 20x1 2 BUTTON HEAD SOCKET CAP SCREW B252016 1 4 20x1 1 4 BUTTON HEAD SOCKET CAP SCREW B372011 3 8 16x1 1 4 SOCKET HEAD CAP SCREW H371602 ROLL PIN 375D x 1 0 C311220 5 16 1 8x 3 4 SOCKET SET SCREW CUP POINT J257000 1 4 20 LOCKNUT JAM J371000 3 8 16 HEX NUT J377000 3 8 16 LOCKNUT JAM K161501 8 LOCKWASHER SPLIT K251501 1 4 LOCKWASHER SPLIT K371501 3 8 LOCKWASHER SPLIT 3109027 SPACER 2811Dx 500 3579109 NYLON PLUG 3 16 DI 3708148 HANDWHEEL 4 5DIA 3708581 DIAL INDICATO
27. PERATING OR SERVICING THIS EQUIPMENT This is the electrical hazard symbol It indicates that there are DANGEROUS HIGH VOLTAGES PRESENT inside the enclosure of this product TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK do not attempt to open the enclosure or gain access to areas where you are not instructed to do so REFER SERVICING TO QUALIFIED SERVICE PERSONNEL ONLY IMPORTANT GROUNDING INSTRUCTIONS If electrical testing is required alway verify the machine has a proper ground before performing any tests 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 SEE SERIAL NUMBER PLATE FOR FULL LOAD AMP RATING OF YOUR MACHINE Never modify the plug provided with the machine if it won 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
28. R 3708665 FLAT WASHER 41x1 3708705 ADJUSTABLE HANDLE 5 16 18 3708706 ADJUSTABLE HANDLE 5 16 18 3709062 CONICAL WASHER 38 X 75 X 035T 3709304 THRUST WASHER 375 X 812X 032T 3969065 SPACER 4061Dx 750 6009035 SHAFT LOCKING STUD 6009082 SUPPORT CROSS SLIDE 6009095 SHAFT SLIDE 6309113 SHAFT LOCKING STUD 6309114 DECAL ORANGE 6309115 DECAL GREY 6339027 DIAL INDICATOR MOUNT 6339028 DIAL INDICATOR STORE 6509011 CROSS SLIDE 6509015 SUPPORT CROSS SLIDE 6509010 ADJUSTER TRAVEL BRACKET 6509390 ADJUSTING SHAFT ON O U W N P 6339505 SPIN DRIVE ASSEMBLY PARTS LIST PARTS LIST DIAGRAM NO ON O U BW N PART NO B190613 B253216 C190420 E253200 H182002 J257000 K191501 3109027 3706138 3706154 3706155 3706156 3706157 3706158 3706159 B200611 3706162 3706165 3706166 3708861 3709062 6339005 6339006 6339012 6339501 6339502 6339503 6339504 6339536 3707255 6339505 SPIN DRIVE ASSEMBLY DESCRIPTION 10 24x3 8 BUTTON HEAD SOCKET CAP SCREW 1 4 20x2 BUTTON HEAD SOCKET CAP SCREW 10 24x1 4 SOCKET SET SCREW CUP POINT CARRIAGE BOLT 1 4 20x2 ROLL PIN 188Dx1 25 LONG 1 4 20 LOCKNUT JAM 10 LOCKWASHER SPLIT SPACER 2811Dx 500D GAS SPRING 130 1 9 STROKE GAS SPRING 60 1 9 STROKE STEEL CLEVIS ROD END CLEVIS PIN 3 16 X 1 3 4 LONG CLEVIS PIN 3 16 X 1 1 2 LONG T KNOB 1 5 1 4 20 5 16 18 x 5 BUTTON HEAD SOCKET CAP SCREW WITH PATCH M5 8 x 10 SOCKET HEAD CAP SCREW RUBBER GROMME
29. RACKET B256411 1 4 20x4 SOCKET HEAD CAP SCREW 6509025 BELLOWS END BRACKET B310813 5 16 18x1 2 BUTTON HEAD CAP SCREW 6509054 RETAINER PLUNGER B311611 5 16 18x1 SOCKET HEAD CAP SCREW 6509055 BELT COVER B503211 1 2 13x2 SOCKET HEAD CAP SCREW 6509063 CARRIER SHAFT C250420 1 4 20x1 4 SOCKET SET SCREW 6509210 GASKET BELT COVER H184002 ROLLPIN 188D x 2 6509221 FIXED TRAV BASE END BRACKET J257000 1 4 20 LOCKNUT JAM 6509238 GRIP KNOB GRINDING WHEEL J257100 1 4 20 LOCKNUT FULL 6509250 BELLOWS WAY COVER J627200 5 8 18 LOCKNUT JAM 6509253 CARRIAGE DUST COVER BRACKET J757300 3 4 16 LOCKNUT FULL 6339023 PLUNGER PIN K191501 10 LOCKWASHER SPLIT 6339132 LIMIT SENSOR BRACKET K250001 FLAT WASHER 1 4 SAE 3709257 BALL BEARING K251501 1 4 LOCKWASHER SPLIT 3709304 THRUST WASHER 375 K311501 5 16 LOCKWASHER SPLIT B371216 3 8 16x3 4 BUTTON HEAD CAP SCREW K501501 1 2 LOCKWASHER SPLIT B371616 3 8 16x1 BUTTON HEAD CAP SCREW R000376 SQ KEY 1 8 X 75 J377000 3 8 16 LOCKNUT JAM R000377 SQ KEY 3 16 X 75 B160607 8 32x3 8 BUTTON HEAD CAP SCREW 28192 TRAVERSE PULLEY SUPPORT K161501 8 LOCKWASHER SPLIT 50309 TRAVERSE PULLEY SHAFT 6339127 RELIEF ANGLE POINTER 3706056 DRIVE COG PULLEY 3706194 COMPRESSION SPRING 6ODx 55553 IDLER PULLEY ASSEMBLY 6329032 TRAVERSE BASE MACHINED 80335 CLAMP DESTACO 602 6329511 SHAFT SUPPORT BLOCK ASSEMBLY 80354 COG BELT 6339515 GRINDING HEAD ASSEMBLY 80355 THRUST WASHER 75ID 6339531 CARRIAGE ASSEMBLY BELT TRAVERSE 3707224 CABLE TIE MOUNT
30. SMS Terminal 1 91SMS 1 to blue wire O2FTRBU out of FTR Yes Go to Step O next No Flip Switch and check again Works Switch is upside down Does not work Check Wire 90 replace Switch Measure 120 Volts AC from ESS term 2 77ESS 2 to blue wire O2FTRBU out of FTR Yes Go to Step P next No Check wire 80 for continuity then verify switch continuity If bad replace ESS contactor NC Measure 120 Volts AC out of SSS at Terminal 13 on Terminal Strip 2 76TB2 13 to blue wire O2FTRBU out of FTR hold in SSS when checking Yes Go to Step Q next No Verify switch continuity If bad replace SSS contacto NO if not switch check wires 76 140 amp 77 Measure 120 Volts AC from LVR terminal 8 to blue wire O2FTRBU out of FTR Yes Go to Step R next No Check for 120 Volts AC from LVR term 6 to term 7 Yes Replace LVR if bad No Check wires to LVR Measure 120 Volts AC from MAG Term A1 to Term A2 Yes MAG Should pull in with clunck if not replace MAG No Verify Continuity of Wires ELECTRICALTROUBLESHOOTING PROBLEM Machine Shuts off when you turn on Grind motor switch or Spin Motor Switch Possible Cause Guard Doors are Open Door Safety Switch es are not working properly No 24 Volts DC to Safety Monitor SSM No Power into 24 Volt DC Power Sup ply PWR No Power Out to Door Switches Rear Safety Switch on the slide up door or workstation ramp depending on option installed i
31. T 375 ID MOTOR DRIVE ADAPTER 8 32 BALL NOSE SPRING PLUNGER CONICAL WASHER 25 CONICAL WASHER 38 SPIN DRIVE UPPER ARM SPIN MOTOR PIVOT BLOCK SPACER 26ID x 5O SPIN DRIVE LOWER ARM MOTOR HOUSING WELDMENT MOTOR HOUSING END SPIN DRIVE BASE PIVOT BLOCK ASSEMBLY SPIN MOTOR ASSEMBLY CABLE TIE PARTS LIST 6339530 FRONT TOOLING DIAGRAM NO PART NO DESCRIPTION B251416 1 4 20x7 8 BUTTON HEAD SOCKET CAP SCREW B251631 1 4 28x1 SOCKET HEAD CAP SCREW B311013 5 16 18x5 8 BUTTON HEAD SOCKET CAP SCREW B371625 3 8 16x1 FLAT HEAD SOCKET CAP SCREW B371611 3 8 16x1 SOCKET HEAD CAP SCREW C250620 1 4 20x3 8 SOCKET SET SCREW CUP POINT H251202 ROLL PIN 25Dx 75 LONG K251501 1 4 LOCKWASHER SPLIT K310001 FLAT WASHER 5 16 SPLIT K311501 5 16 LOCKWASHER SPLIT K371501 3 8 LOCKWASHER SPLIT 09853 KNOB 4 PRONG 1 2 13 17119 STUD THD 1 2 13x6 5 LONG 3706189 BEARING 3706190 RATCHET WRENCH 62 HEX 3706191 OILITE FLANGE BEARING 3706192 1 2 OD X 8 LONG SHAFT 3706202 DIE SPRING 600 OD 3706203 COMPRESSION SPRING 72OD 3706204 EXTERNAL RETAINING RING 3708125 SHOULDER BOLT 312 3708908 ADJUSTABLE HANDLE 3 8 16 3708094 ADJUSTABLE HANDLE 5 16 18 6009031 SPACER 386IDx 50 OD 6339095 FRONT TOOLING TOP 6339099 SPRING GUIDE 6339100 SLIDE CLAMP BLOCK 6339103 SHAFT SUPPORT BLOCK 6339104 TOOLING SUPPORT PLATE LONG 6339105 TOOLING SUPPORT PLATE SHORT 6339109 FRONT TOOLING MOUNT 6339110 FRONT TOOLING OUTER PLATE 633
32. Terminals for 120 Volts AC Yes Go to Step G next No Replace Power Cord 6059054 No 120 Volts AC power to Filter FTR G Check for 120V out of FTR Check for 120 VAC at FTR Load Terminals between wires labeled Note The nuetral Blue wire con 02FTRBU to 01FTRBR nection O2FTRBU will be used in Yes Go to Step H next other voltage checks No Replace Filter No 120 Volts AC power out of Filter No 120 Volts AC power to Main Circuit Breaker MCB 20 Amp No 120 Volts AC power from Main Circuit Breaker MCB 20 Amp H Check for 120V in to MCB I Check for 120V from MCB Check for 120 VAC from MCB 01MCB to blue wire O2FTRBU Yes Go to Step I next No Check wire 01 replace if needed Check for 120 VAC from MCB O3MCB to blue wire O2FTRBU Yes Go to Step J next No Flip Switch on MCB to ON Ma chine works end trouble shooting Machine does not work Recheck voltage and replace MCB if no voltage ELECTRICALTROUBLESHOOTING Possible Causes No 120 Volts AC power to Second ary Circuit Breaker SCB 6 Amp No 120 Volts AC power from Secondary Circuit Breaker SCB 6 Amp 120 Volts AC power not delivered to Terminal Strip Grinding Motor Switch GMS not working Spin Motor Switch SMS not working Bad Emergency Stop Switch ESS Bad System Start Switch SSS Low Voltage Relay REL not operating Bad Main Contactor MAG Checkout Procedure J Check fo
33. VOT SHAFT BOTTOM PLATE FRONT DECAL SCALE HORIZONTAL DECAL SHEET DIAGRAM NO ON O U BW N PART NO B110406 B190302 B190613 B190813 C190320 J257000 K190101 K191501 3706173 3706174 3706175 3706176 3706177 3706180 3706209 3706210 3706225 3707998 3708175 3709526 6339142 6339143 6339148 6339152 6339154 6339155 6339156 6339199 6339200 6339539 6709035 6339025 DESCRIPTION 4 40X1 4 SOCKET HEAD CAP SCREW 10 24 x 3 16 ROUND HEAD MACHINE SCREW 10 24x3 8 BUTTON HEAD SOCKET CAP SCREW 10 24x1 2 BUTTON HEAD SOCKET CAP SCREW 10 24X3 16 SOCKET HEAD SET SCREW CUP POINT 1 4 20 LOCKNUT JAM FLAT WASHER 225ID X 75 OD 10 LOCKWASHER SPLIT CAM LOCK HANDLE 25 DIA X 9 LG SHAFT LANYARD 8 SLEAVE BEARING 1 4 ID CONSTANT FORCE SPRING LINEAR BEARING 10M LINEAR SENSOR MACHINED GAUGE CORD ASSEMBLY OILITE BEARING 38ID X 50 OD LINEAR SENSOR MAGNET COMPRESSION SPRING 360D 1 DIA BALL KNOB 1 4 20 THREAD GAUGE TOP CAP GAUGE BOTTOM CAP HEIGHT STOP BLOCK SPRING PLATE GAUGE LATCH PIN LOCK PLATE BEARING BLOCK GAUGE BASE PLATE BEARING SUPPORT BLOCK GAUGE HOUSING WELDMENT STUD 1 4 20X3 00 LONG DECAL SHEET 6339541 REAR CLAMP ASSEMBLY PARTS LIST PARTS LIST 6339541 REAR CLAMP ASSEMBLY DIAGRAM NO PART NO DESCRIPTION 09351 KNOB BALL 1 18OD B252431 1 4 28x1 5 SOCKET HEAD CAP SCREW FULL K311501 5 16 LOCKWAS
34. WASHER 10 SAE 10 LOCKWASHER SPLIT FLAT WASHER 1 4 SAE 1 4 LOCKWASHER SPLIT FLAT WASHER 3 8 SAE 3 8 LOCKWASHER SPLIT FLAT WASHER 387x 625X 065 DOOR SAFETY SWITCH PLATE FLAT WASHER 271Dx 50 x 06 STUD GAS SPRING RETAINING CLIP GAS FLAT WASHER 252x 375x 018 BALL BRG R10 W OIL PARTS LIST MODEL 633 6339545 REAR DOOR ASSEMBLY DIAGRAM PARTNO DESCRIPTION NO 35 3706097 PULLEY 1 750D X 37ID 36 3706098 PULLEY 1 5OD X 25ID 37 3706099 CLEVIS ROD END M8 38 3706100 GAS SPRING 202 3 9 STROKE 39 3706212 CABLE ASSY REAR DOOOR 40 3707029 STRAIN RELF LIQUID TIGHT 41 3707908 DOOR SWITCH WITH DISCONNECT 42 3708820 8 32 50 BUTTON HEAD SAFETY SCREW 43 3708869 SPRING HINGE 44 3708998 WAVE SPRING 35 ID 45 3709597 BALL BEARING 46 6329131 CATCH 47 6329133 CATCH PIN 48 6329136 REAR SLIDE SPACER 49 6329137 REAR SLIDING DOOR 50 6329163 REAR DOOR ARM 51 6329164 PULLEY BLOCK 52 6329165 DOOR SWITCH BRACKET 53 6329166 CABLE GUIDE 54 6329167 BEARING BLOCK 55 6329172 REAR DOOR INNER SLIDE 56 6329174 REAR DOOR LIFT HANDLE 57 6329175 REAR DOOR STIFFENER 58 6329179 REAR DOOR OUTER PLATE 59 6329180 DOOR STOP BLOCK 60 6329181 HINGED WALKER PANE 61 6329182 DOOR STOP SPACER PLATE 62 6329183 DOOR CATCH BRACKET 63 6339168 REAR DOOR SLIDE UP 64 6339169 REAR DOOR CABLE BRACKET 65 6339170 CABLE CLAMP BLOCK 66 6339171 DOOR STOP BLOCK 67 B190813 10 24X1 2 BUTTON HEAD SOCKET CAP SCREW
35. WIRE 35 12086 16 1286 17 13786 19 1406 0 13718821 LL 145 77 115188 23 134188 4 IB TC oooooooooooooo ooooooooooooojo TO d ad ES GRIND MTR W31 TIBSCRA 160PGCV 161PGCGN 162PGCRD 163PGCB 166PGCSI 167PGCPB 47 000 SPIN MTR W33 TRAVERSE MTR gt sl INFEED MIR W137 3 OPTIONAL Q VAC MAIN POWER W32 RH PROX SWITCH W37 gt LH PROX SWITCH W36 FINGER PROX SWITCH W142 FRONT DOOR gt SWITCHW207 um
36. ain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Spin Drive Motor Possible Cause Board is in spin mode Relief Speed Pot RSP is not set correctly RTP is not working Switches on SDC incorrect Checkout Procedure J Spin Torque Selector not working K Check RSP remote speed 10k on SDC board L RTP 10K Remove 3 Remote Torque Wires red wire to term 2 white wire to term 1 black wire to term 3 M Verify postion of all pots and switch on SDC Light next to TQ on board should be ON If not remove wires 44SDCMOD and 44SDCCOM from SDC control board Machine works Yes Machine was in spin mode Check continuity of STS switch Replace if bad No Light next to TQ is ON but machine does not work go to step K Verify SPEED pot setting on the SDC board Should be set as speci fied on pages 24 and 25 Adjust if incor rect and check Relief Torque function Works Yes end of troubleshooting No go to Step L next Check for 10 000 ohms Red wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Red wire to black wire Full CCW 10 0000 ohms Full CW 0 ohms Yes go to Step M nest No replace RTP Verify postion of 4 pots on board Should be set as specified on pages 24 and 25 Verify that the Troque reduction feature is in the OFF position pushed toward the pots on board Motor works Yes end
37. am on pages 80 81 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 problem persists test as listed below Possible Cause Checkout Procedure Emergency Stop Botton ESS A Pull Up on ESS Button is Depressed Machine works Yes end troubleshooting No go to Step B next Machine works Yes end troubleshooting No go to step C next B Listen for the Magnetic Starter MAG contacts to pull in with a cl You must push the System Start Switch SSS to get power to control Panel unk Machine works Yes end troubleshooting No go to step D next C Plug in main power cord Then Press SSS Main Power Cord is not plugged in D Close guard doors and turn off Machine works all switches Then press SSS Yes end troubleshooting No go to step E next Guard doors must be closed and ALL Switches MUST be turned OFF for contactor to pull in Machine works Yes end troubleshooting No but light works in outlet go to Step F next No but light does not work in outlet You must solve your power delivery problem independent of machine E Check circuit breaker in your building and reset if necessary Check wall outlet with a light to make sure it works Follow steps A D and test Main 20 amp outlet circuit breaker has tripped F Check for 120VAC at Cord into FTR Power Cord 32 FTR Line
38. ard has four potentiometers two switches and one dial as shown on FIG 26 These potentiometers swtiches and dial have been set at the factory to the positions shown on FIG 26 In the Relief Grinding Mode The Torque Shut Off mode selector allows you to turn on or off the Torque Shut Off feature When switch 1 is set to ON the board will decrease the spin motor torque once the shut time is achieved after leaving the right proximity sensor The amount of time it takes before the torque is decreased is set with the Torque Shut Off Delay dial The spin motor toque will be increased to the higher value once the right proximity switch is activated again If the Torque Shut Off selector is in the OFF position the torque will remain constant during relief grinding Torque Shut Off Delay dail is used to set the duration of time before the torque is decreased after leaving the right proximity sensor during relief grinding If the dial is turned clockwise higher number the higher torque value will stay on for a longer period of time The Relief Speed RSP and the Relief Torque Pot RTP interact with each other The RSP is located on the spin board as a remote speed preset at 12 00 20 Volts DC See FIG 26 The RTP is located on the control panel and is for relief torque adjustment Relief Speed Pot RSP when rotated clockwise will increase spin drive speed the speed at which the reel indexes to the next blade This speed should never be above t
39. averse Forward Acceleration Factory set at full CCW 8 30 DO NOT CHANGE THIS SETTING Left Traverse Reverse Acceleration Factory set at full CCW 8 30 DO NOT CHANGE THIS SETTING DB Dead Band is the potentiometer setting for the 50 or 60 Hz cycle control Factory set to 9 00 works for both 50 and 60 Hz Do not change this setting Calibrating the DWELL TIME rotary DIP switch adjusts the amount of time the process remains in the stop position after a limit switch is actuated The DWELL TIME range is adjustable from 0 4 seconds A DIP switc setting of 0 sets the DWELL TIME to 0 seconds while a setting of 8 sets the DWELL TIME to 4 seconds Dwell time is preset to 2 setting for a 1 second dwell time when reversing at each end of stroke Diagnostic LED s indicate the function that is currently being performed POWER indicates that ac power is being applied to the control FORWARD indicates that the process is running in the forward direction traversing left REVERSE indicates that the process is running in the reverse direction traversing right PROX 1 FWD LIMIT lights when the forward limit switch is actuated left prox PROX 2 REV LIMIT lights when the reverse limit switch is actuated right prox DWELL lights when the process remains stopped after a proximity switch is actuated e POTENTIONMETER CLOCK ORIENTATION MACHINE SERVICE ORIGINAL INSTRUCTIONS SPIN DRIVE CONTROL BOARD SDC The Spin Drive Control Bo
40. ble Cause Checkout Procedure Grinding Motor Switch A Turn switch on GMS is not on Guard doors are not closed 15 Amp Circuit Breaker CB is tripped GMS not working Grinding Motor Relay not working No Power to Relay Contacts Bad Contacts in Grinding motor Relay Bad Circuit Breaker Bad Grinding Motor B Close front and rear guard doors and rear ramp lift option C Check 15 amp CB on the side of the grinder above the control cover Press in if tripped D Check for power to GMS E Check for power from GMS F Check for power to relay Coil Relay should click when GMS is turned on G Verify Power to Relay Con tacts H Verify power out of Grinding Motor Relay I Verify Power to Grinding motor Cord Grinding Motor works Yes end troubleshooting No go to Step B next Grinding Motor works Yes end troubleshooting No go to Step C next Grinding Motor works Yes end troubleshooting No go to Step D next Terminal strip 2 terminal 15 to terminal block 4 Blue for 120VAC Yes go to Step E next No check continuity of wires to GMS Terminal strip 2 terminal 14 to terminal block 4 Blue for 120VAC Yes Go to Step F next No replace GMS Check for 120 Volts AC from A1 to A2 of Grinding motor Relay Yes Go to Step G next No check wires to Grinding motor Relay A1 amp A2 REL Term L1 to Term L2 for 120 Volts AC Yes Go to Step H next No Check wires to R
41. ce immediately Refer to replacement parts illustrations in Service Manual for the proper location and part numbers of safety decals 21 DO NOT OPERATE GRINDER WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS ORIGINAL INSTRUCTIONS IMPROPER USE OF GRINDING WHEEL MAY CAUSE WARNING BREAKAGE AND SERIOUS INJURY GRINDING IS A 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 ABRASIVE WHEELS FOR YOUR SAFETY WE SUGGEST YOU BENEFIT FROM THE EXPERIENCE OF OTHERS AND CAREFULLY FOLLOW THESE RULES DO 1 DO always HANDLE AND STORE wheels in a CAREFUL manner 2 DO VISUALLY INSPECT all wheels before mounting for possible damage 3 DO CHECK MACHINE SPEED against the established maximum safe operating speed marked on wheel 4 DO CHECK MOUNTING FLANGES for equal and correct diameter 5 DO USE MOUNTING BLOTTERS when supplied with wheels 6 DO be sure WORK REST is properly adjusted 7 DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel 8 DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding 9 DO always WEAR SAFETY GLASSES or some type of eye protection when grinding AVOID INHALATION OF DUST generated by grinding and cutting operations Exposure to dust may cause respira
42. dial indicator If the movement exceeds 003 the bearing needs to be adjusted Retest the bearing after adjusting the tension on the bearing If the bearing does not improve to below the 003 reading then the bearing needs to be replaced Repeat steps 1 4 for the other two bearings STEP 6 Reattach the bellows carriage mounting brackets onto the carriage Replace front and rear shields See FIG 15 Dial Indicator must be positioned over the bearing being tested and located within 1 of the side of the carriage base Press down on Bearing FIG 4 Tester Fork and Read Dial If dial reads more than 003 of movement adjust bearing tension using the tension screw See FIG 2 REAR DUST SHIELD FRONT DUST SHIELD FIG 15 AD VIET ORIGINAL INSTRUCTIONS REEL FINGER DOVETAIL GIB AND ADJUSTING KNOB ADJUSTMENTS SHAFT COLLAR r RELIEF FINGER ADJUSTING T KNUB The reel finger slide to the reel finger positioner has a dovetail with an adjustable gib for tensioning Tighten the gib set screws 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 See FIG 16 Check the knob assembly rotating tension by checking GIB ADJUSTING the tightness of the nylon plug to the knob assembly SET SCREWS t
43. e operating this grinder an operator must read and understand all of the information in the operators manual and understand all of the safety signs attached to the product A person who has not read or understood the operators manual and safety signs is not qualified to operate the unit Accidents occur often on machines that are used by someone who has not read the operators manual and is not familiar with the equipment If you do not have an operators manual or current production safety signs contact the manufacturer or your dealer immediately The equipment is designed for one man operation Never operate the equipement with anyone near or in contact with any part of the grinder Be sure no one else including bystanders are near you when you operate this product Following these simple basic safety rules as well as others Find and understand all safety signs in the operators manual and on the equipment This will help minimize the possibility of accidents and increase your productivity in using this product Be careful and make sure that everyone who operates the grinder knows and understands that it is a very powerful piece of machinery and if used improperly serious injury or death may result The final responsibility for safety rests with the operator of this machine Throughout this manual the following safety symbols will be used to indicate the degree of certain hazards This symbol is used throughout this manaul to call attenti
44. edy First check to see of proximity light comes on When the light is on it means that there is electricity coming to proximity switch Actuate prox switches with steel tool to take measurements Check to see that the finger Proxim ity sensor is lit when the moveable indexing finger is in the back position To test swiitch the torque selector to spin if the carriage travels back and forth then its the finger proximity sensor is the most likely the issue Left proximity PROX1 check Traverse drive Control TDC between terminals 14 black wire and 15 brown wire Right proximity PROX check TDC between terminals 13 black wire and 15 brown wire ORIGINAL INSTRUCTIONS Reason The light coming on shows the prox imity is getting electrical contract The moveable indexing proximity sensor is not adjusted correctly or is not working Test the proximity sen sor by pressing on the index finger and look for the light on the end of the proximity sensor Adjust the position of the proximity sensor if not adjusted correctly Proximity Light on 0 Volts DC Proximity Light off 12 Volts DC Proximity Light on 0 Volts DC Proximity Light off 12 Volts DC Replace proximity switch if the volt ages do not read as above PROBLEM Insufficient hesitation at carriage stops prior to reversing traverse The dwell time on the traverse drive control not set properly Reset dwell time as required One
45. erify voltage to grind infeed motor GIM With the infeed speed switch in turtle check the DC voltage at the terminal strip where the Grinding Wheel Infeed Motor GIM cord attaches B Disconnect GIM from the infeed actuator and check GIM function under no load C Remove wires from ISS terminals 2 and 3 Check continuity between terminals on Switch ISS Check 3 8Volts DC at terminal 137TBB 21 and 137TBG 22 Yes Go to Step B next No Go to Step C next Check GIM function when disengaged from Infeed Actuator Motor should step slowly Yes Replaced Infeed Actuator No Replace Grind Infeed Motor Switch has continuity when on and not when switch if off Yes Replace Resistors assembly on ICB No Replace switch ISS Possible Cause PROBLEM Reels ground have high low blades Traverse Speed set too fast Lineal bearings for the grinding head carriage are out of adjustment loose or have grit buildup causing uneven traversing load Checkout Procedure Check roundness using a magnetic base dial in dicator Traverse speed should be set approximately 12 ft min 4 meters min if roundness is varying Relubricate and adjust linear bearings per adjustment section If problem persists replace lineal bearings on the carriage base Check for any holes in the bellows that would permit any grinding grit penetration See adjustment section for lineal bearing replacement PROBLEM Excessive grind
46. ft 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 the 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 a 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 WILL HAVE SUBSTANTIALLY SHORTER LIVES AND MAY DAMAGE THE SHAFT STEP 4 Slide linear bearing under carriage and attach with the three screws NOTE Repeat Steps 2 thru 4 with the other three linear bearings STEP 5 Position Dial Indicator assembly on the machine grinding head assembly next to the bearing to be tested Remove the bellows if the machine has them installed The dial indicator should be within 1 of the side of the Grinding head carriage directly above the bearing being tested It is best to measure to the traverse shaft with a wide flat tip 2 Insert Bearing Testing Fork 3706055 until the fork contacts the wiper bracket or the bearing 3 With the tip of the Dial Indicator on the traverse shaft zero out the Dial Indicator 4 Use your hand and press on the end of the Bearing Tester Fork until it contacts the traverse rail See Fig 4 Read the movement on the
47. hafts See FIG 11 Then run the carriage back and forth through its full range of travel This will carry the lubricant into the bearings STEP 3 With a clean rag wipe off the excess amount of lubricant from the shafts Run the carriage back and forth through its full range of travel and wipe the shafts after each traverse Repeat until the shafts are dry to the feel This completes the lubrication process If the unit will be shut down for an extended period of time more than four weeks then 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 should be repeated LINEAR BEARING TRAVERSE BASE ALONE WITHOUT DUST PROTECTION COMPONENTS TENSION ADJUSTMENT SCREW POSITION FACING FIG 14 ADJUSTMENTS ORIGINAL INSTRUCTIONS 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 FIG 14 Adjust the tension screw of the linear bearing so when you radially rotate the linear bearing around the carriage sha
48. he 3 00 setting Relief Torque Pot RTP is used to vary the reel to finger holding torque for relief grinding The recommended starting point is 30 in lbs of torque setting Never adjust the RTP potentiometer dial past the red line marking Setting the reel to finger torque to high could cause the spin motor system to not operate smoothly Relief Idle Torque Pot ITP is used to vary the reel to finger holding torque once the shut time is achieved after leaving the right proximity sensor if the Torque Shut Off Selector is set to on In the Spin Grinding Mode The Spin Torque Potentiometer STP and the Spin Speed Pot SSP interact with each other The STP is located on the spin board as remote torque preset at 2 00 for torque setting See FIG 99 The SSP is located on the control panel and is for spin speed adjustment Spin Torque Pot STP controls maximum torque allowable in the spin grinding cycle only This should never be adjusted past the 3 00 position If the reel does not turn check that the reel is free turning by hand spinning with the power off and the spin drive disconected The Spin speed Pot SSP controls reel spin speed adjust as required This controls the spin drive speed for spinning the reel IR COMP 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 pot clockwise from its factory set position Overcompensatio
49. hreads The tightness has to be sufficient so the knob assembly does not rotate during the relief grinding cycle See FIG 17 FIG 16 NYLON PLUG SET SCREW FOR TENSION ON NOTE To adjust the nylon plug you must lock the JENNA g index finger assembly down and then adjust the reel finger positioner so the clearance holes line up with the nylon plug set screw Remove 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 left side grip grinding wheel knob must be removed for belt tensioning adjustment Remove FIG 17 the screws holding the vacuum hose bracket the two double tube clamps and the belt cover For grinding motor belt adjustment loosen the four socket head cap screws that attach the motor mounting plate Adjust the grinding motor for proper belt tension and tighten the four socket head cap screws Proper belt tension is achieved when 5 Ibs of force applied to the belt halfway between the two pulleys results in 12 3mm of deflection See FIG 18 To verify belt tension mount the belt guard with two screws Turn the motor on If the belt is tensioned correctly start up torque of the motor through the pulley to the belt should have zero slippage If
50. ignment Adjustments in the adjusting sectionof the manual Install the new belt cover gasket on the belt cover and install the belt cover and square key Mount the left side grinding wheel grip knob with a slight gap to the cover and tighten the two set screws GRINDING WHEEL BELT COVER SET SCREWS PULLEY BALL BEARING BEARING SLEEVE CONICAL WASHERS GRINDING WHEEL SPINDLE ASSEMBLY GRINDING WHEEL GRINDING WHEEL KNIB MACHINE SERVICE ORIGINAL INSTRUCTIONS POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL TDC Min Speed Factory set at full CCW 8 30 Do not change this setting Right Traverse Forward Torque Factory set at full CW 4 30 DO NOT CHANGE THIS SETTING Left Traverse Reverse Torque Factory set at full CW 4 30 DO NOT CHANGE THIS SETTING IR COMP Factory set to 9 00 IR COMP is current I resistance R compensation COMP IR COMP adjusts the output voltage of the drive which balances load to motor RPM Regulation of a 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 disappear Max Speed Set at 3 30 for maximum voltage of 90 Volts DC to the traverse motor When voltage is above 90 volts DC the traverse motor will start to pulsate and not run smoothly Right Tr
51. in EISISsI bb MIN FWD REV POT SETTINGS so mq m 83 43 4X TEUS BREA 3050512 PSW TR GREEN 63TB2 5 O 6278146 ESS EMERGENCY STOP SWITC
52. increment increases Dwell time by 1 2 second PROBLEM Traverse changes directions erratically while running in traverse cycle Loose wire to proximity switch Check wire connections from the proximity switches and tighten down screws A loose wire connection will give intermittent electrical contact ELECTRICALTROUBLESHOOTING PROBLEM Infeed motor not working ORIGINAL INSTRUCTIONS Assuming SSS System Start Switch is on with 115 Volts AC to control panel and all other functions are working Possible Cause Infeed Jog Switch IJS is not held to on position Infeed Speed Switch IJS is not on high speed Infeed motor reducer drive coupling is loose No DC voltage to Grinding Wheel Infeed Motor GIM Infeed Motor Reducer will not function Switch IJS is bad No DC Voltage to the Infeed Control Board ICB Checkout Procedure A IJS Hold switch on in either direction B Put IJS on high speed for ease of checkout C Open infeed motor cou pling inspection plate to check for loose coupling Retight en coupling to drive actuator screw See adjustment section of manual D With the Infeed Speed Switch in rabbit position check for 24 Volts DC across terminals labeled 2 and 5 ofthe IJS with IJS held on E With the Infeed Speed Switch in rabbit check for 24 Volts DC at the terminals 137TBB 21 and 137TBG 22 F Disconnect GIM from the infeed actuator and check GIM fu
53. ind causes grinding head traverse motor to overload and blow the fuse NOTE Fuse can notbe checked visually Use Ohm test to check fuse If needs replacing MUST use a 3 amp slo blo fuse Part Number 3707546 E Check for 120 Volts AC incoming to TDC F Check for 120 Volts AC at TMS Make certain TMS is on Traverse works Yes end troubleshooting No got to Step B next Traverse works Yes end troubleshooting No go to Step C next Press on the indexing finger until the Indexing Proximity sensor lights Traverse works Yes end troublshooting No Verify Poximity sensor works and go to Step D next Traverse works Yes end troubleshooting No go to Step E next On TDC Terminal L1 to L2 for 120 Volts AC Yes Go to Step F next No Go to Step G next Measure 120 volts AC from TMS minal 5 to Term Block 4 Blue Yes Go to Step K next No Flip Switch and check again Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch ELECTRICALTROUBLESHOOTING Possible Cause No DC Voltage from TDC Traverse Drive Control Traverse Motor is bad TSP is not working TSP 10K is bad Worn motor brushes Checkout Procedure G Check for 90 Volts DC across TDC terminals A1 to A2 this voltage drives the DC traverse mo tor NOTE Traverse must be on and have TSP turned full CW to maximum voltage of 90 VDC H Check traverse motor contin
54. ing stock being removed when traversing to the right in the relief grinding mode Gib adjustment for the relief finger assembly is loose so reel finger has movement When traversing to the right minimum grinding stock removal should be seen as compared with heavy stock removal when traversing to the left Tighten the set screws for the gib adjustment See procedure in the adjustment section in the manual PROBLEM Grinding stock removal from reel is irregular during spin grinding Lineal bearings on the grinding head carriage are too loose The lineal bearing must be preloaded to the tra verse shafts with no vertical movement See manual adjustment section for carriage bearing adjustments PROBLEM Carriage traversing varies speed while grinding Lineal bearings in the carriage do not rotate freely Belt is slipping Traverse Belt tension to loose Check for grinding grit getting into the lineal bearings and causing 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 Belt Clamp may have moved See manual adjustment section for Traverse Clamp Force Check the spring length on left side of travese belt See manual adjustment section for Traverse Belt Tension Possible Cause Checkout Procedure PROBLEM Too heavy a burr on cutting edge of reel blade
55. n causes the motor to oscillate or to increase speed when fully loaded If you reach such a point turn the IR COMP pot counterclockwise until symptoms just disappear MACHINE SERVICE ORIGINAL INSTRUCTIONS SPIN TORQUE POT RELIEF SPEED DELAY SET SWITCH 1 SET TO STP 2 00 POT RSP 12 00 TO 1 OFF 12 00 TQ SHUT OFF DEYAY 9 00 3 00 6 00 Potentiometer Clock Orientation TB SHUT OFF FIG 30 O O 53 52 5 12 TI 9 00 IDLE TORQUE ITP 10 00 ELECTRICALTROUBLESHOOTING ORIGINAL INSTRUCTIONS CONTROL BOX LOW VOLTAGE SAFETY SWITCH RELAY LVR MONITOR SSM BLUE TERMINAL GREY TERMINAL DC POWER BLOCKS TBW BLOCKS TBG SUPPLY PWR OR TBB TERMINAL STRIP 2 TB2 moms 13 AER HEN TRAVERSE BOARD ZZA 3 AMP SLOW BLO FUSE MAGNETIC CONTACTOR MAG SECONDARY CIRCUIT BREAKER SCB TRAVERSE DRIVE CONTROL BOARD TDC d di m le MAIN CIRCUIT BREAKER MCB GRINDING ms E 4 yt MOTOR lt N SPIN DRIVE RELAY REL m c r gt CONTROL TERMIAL STRIP 1 TB1 POSITION GAUGE CONTROL PGC BRIDGE DIODE 1 AC FILTER BD1 FTR SPIN TORQUE SPIN CONTROL RELAY STR RELAY SCR ELECTRICAL TROUBLESHOOTING ORIGINAL INSTRUCTIONS SKILL AND TRAINING REQUIRE
56. nction under no load G Check for 24 Volts DC to IJS H Check for 24 volts DC Input to ICB Infeed motor works Yes end troubleshooting No go to Step B next High speed works Yes end troubleshooting No go to Step C next Infeed works Yes end troubleshooting No go to Step D next Check term 2 8 5 of IJS for 24 Volts DC Yes go to Step E next No go to Step G next Check for 24 Volts DC at Term marked 137TBB 21 and 137TBG 22 Yes Go to Step F next No Replace wires 127 and 128 Check GIM function when disengaged from Infeed Actuator Yes Replaced Infeed Actuator No Replace GIM Check for 24 Volts DC at Terminal 6 and 4 then check Terminals 3 and 1 of IJS Yes Replace IJS No go to Step H next Remove the Red and Blue wires goint to the ICB and Check for 24 Volts DC between the wires 150ICBB to 133ICBB Yes Replace ICB No Replace 24 VDC power supply PWR ELECTRICALTROUBLESHOOTING PROBLEM Infeed motor has no low speed turtle function ORIGINAL INSTRUCTIONS Assuming SSS System Start Switch is on with 115 volts AC to control panel and all other functions are working and infeed motor works in high speed rabbit position Possible Cause Incorrect DC Voltage from the Voltage Regulator in low speed turtle position Infeed Actuator is bound and will not allow low speed turtle function Infeed Speed Selector not working ISS Checkout Procedure A V
57. ng functions of the grinder and decrease maintenance and problems that occur when storing the grinder BEFORE STORING THE GRINDER Clean the machine thoroughly DO NOT USE COMPRESSED AIR OR A POWER WASHER TO CLEAN THIS MACHINE Lubricate the following parts by flooding the area with a spray lubricant and leaving it in place Do not use a Teflon based lubricant 1 Traverse Shafts amp Linear bearings see Lubrication section of manual 2 Remove grinding wheel and spray the movable parts of the finger system 3 Cross slide shafts and adjustment screws Right side of Traverse Base 4 Scratches in the paint or any other bare metal surfaces Work the lubricant in by moving parts through their full range of motion Make sure all controls are in the off position and unplug the unit from the wall Cover the unit if possible with a sheet or tarp BRINGING THE UNIT BACK INTO SERVICE Remove the cover and reapply lubricant to the items stated above Wipe off all excess lubricant See Lubrication section for more details Plug the unit into the wall and test all electrical functions Check the belts for cracking and adjust the tension if necessary Check for damaged or missing parts LUBRICATION ORIGINAL INSTRUCTIONS LUBRICATION OF LINEAR BEARINGS STEP 1 Thoroughly clean the shafts STEP 2 Flood spray the two shafts with a spray lubricant do not use a teflon based lubricant until the lubricant is dripping off the s
58. ntinuity from PWR to terminal blocks Measure approximately 24 volts DC from Terminal Strip 1 Terminal 17 to Terminal Strip 2 Terminal 3 Yes Go to Step F next No Verify Continuity of Wires to Terminal strip Replace SSM if wires check OK Measure approximately 24 volts DC from Terminal Strip 2 Terminal 3 to Terminal Strip 1 Terminals 14 and 15 Yes Go to Step G next No Check Alingment of Rear switches If no Voltage to Term14 or 15 then replace rear switch Measure approximately 24 volts DC from Terminal Strip 1 Terminal 17 to Terminal Strip 2 Terminals 2 and 4 Yes Replace SSM No Check Alingment of Front door switch If no Voltage to Terminal 2 or 4 then replace front switch Measure 120 Volts AC at MAG term L3 to Term Block 4 Blue after SSS is pushed Yes Verify Wiring to LVR No Check voltage at T3 If 120 Volts AC Replace MAG If no 120 Volts AC verify wiring to T3 ELECTRICALTROUBLESHOOTING PROBLEM Grinding motor not working ORIGINAL INSTRUCTIONS Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram on page 80 81 are correct and pull on wire ter minals with approximately 3lbs 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 Possi
59. o assure the quality and safety of your machine and to maintain the warranty you MUST use original equipment manufacturer s 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 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 INSTALLATION DAILY MAINTENANCE AND BASIC UPKEEP IS DISCUSSED IN THE OPERATORS MANUAL THIS MANUAL SHOULD BE USED IN CONJUNCTION WITH THE OPERATOR S MANUAL FOR PERFORMING SERVICE ON THIS EQUIPMENT SAFETY INSTRUCTIONS ORIGINALINSTRUCTIONS TO AVOID INJURY READ AND UNDERSTAND THE SAFETY ITEMS LISTED BELOW IF YOU DO NOT UNDERSTAND ANY PART OF THIS MANUAL AND NEED ASSISTANCE CONTACT YOUR LOCAL DEALER KEEP GUARDS IN PLACE and in working order REMOVE WRENCHES AND OTHER TOOLS KEEP WORK AREA CLEAN 4 DON T USE IN DANGEROUS ENVIRONMENT Don t use grinder in damp or wet locations Machine is for indoor use only Keep work area well lit 5 KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area 6 MAKE WORK AREA CHILD PROOF with padlocks or master switches 7 DON T FORCE THE GRINDER It will do the job better and safer if used as specified in this manual 8 USE THE RIGHT TOOL Don t force the Grinder or an attachment to do a job for which it was not designed
60. ocedure A Set RTP to 20 on the control panel B Turn SMS switch on C Reset Circiut Breaker on the right side of the machine Push in if tripped D Check SDC L1 to L2 for 120 Volts AC E Check power into SMS terminal 6 for 120 Volts AC F Check SDC A1 amp A2 for approx 20 Volts DC Have Relief Torque set to maximum torque full clockwise G Check spin motor continuity DISCONNECT POWER FROM THE MACHINE H Inspect Motor Brushes DISCONNECT POWER N FROM MACHINE l 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 SDC Remove wires to Terminals L1and L2 and test betwen wires for 120V AC Yes reconnect wires go to Step F No Go to Step E next Remove Wire to SMS Terminal 6 89sms 6 and check between the wire and Terminal Block 4 Blue for 120 VAC Yes Check switch continuity replace No Check CB continuity replace Check for approx 20 VDC from Terminal Strip 1 Terminal 4 48TB1 4 to Terminal 5 49TB1 5 Yes go to Step G next No Go to Step J Remove motor wires at Terminal Strip 1 left side lower strip Term 4 amp 5 and check 0 ohms across the black and white motor wires Yes end troubleshooting motor should work if it does not replace motor No go to Step H next Remove the brushes one at a time and maint
61. of troubleshooting No replace SDC 100 N PROBLEM Spin drive speed goes at one speed only Possible Cause Wiring hookup to potentiometer is improper If components have been replaced Defective spin speed control SSP potentiometer Main circuit board dial pot set tings not correct If board has been replaced Remedy A Check potentiometer wiring for proper hookup See that speed pot is wired per electrical diagram B SSP 10K Remove 3 remote speed wires red wire to term 2 white wire to term 1 black wire to term 3 C Check all pot settings on both boards as of the SDC shown on Pages 24 and 25 See Adjust ment Section Spin Drive Control SDC Board Setting PROBLEM Spin drive motor speed varies IR Comp trim pot not adjusted properly Torque to rotate the reel too high Check all terminal connections for tightness A See adjustment section for trim pot setting on Page 24 B Readjust bearing preload for the reel Maximum torque load 25 in Ib to rotate reel C When 250 female spade terminals are not tight remove and crimp slightly together When reinstalling push on pressure should have increased for good contact If wiring is wrong correct and test Yes end of troubleshooting No Go to Step B next Check for 10 000 ohms Red wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Red wire to black wire Full CCW 10 000 ohms Full CW 0 ohms Yes Go to Step
62. on to the safety procedures The word DANGER indicates an immediate hazardous situation which if not avoided will result in death or serious injury The word WARNING indicates a potential hazardous situation which if not avoided could result in death or serious injury The word CAUTION preceeded with a safety alert symbol indicates a potential hazardous situation which if not avoided may result in minor or moderate injury A N R ON ORIGINAL INSTRUCTIONS Safety Message Safety Instructions Service Data and Adjustments Trouble Shooting Parts Diagram Wiring Diagram PLC LED Read the operators manual before operating this equipment Keep this manual handy for ready reference Require all operators to read this manual carefully and become acquainted with all adjustments and operating procedures before attempting to operate the equipment Replacement manuals can be obtained from your selling dealer or the manufacturer The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactory use Like all mechanical products it will require cleaning and upkeep Lubricate and clean the unit as specified in the Operators manual Please observe all safety information in this manual the operators manua l and the safety decals on the equipment This machine is designed for sharpening reel type mower blades ONLY Any use other than this may cause personal injury and void the warranty T
63. ove 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 33 Thoroughly clean the housing bore and the outside diameter of both bearings APPLY BLUE LOCTITE 243 TO THE OUTSIDE DIAMETER OF THE TWO BEARINGS Slide the spindle assembly into the right side of the Grinding Head Housing Install the bearing sleeve against the bearing on the spindle assembly Slip fit the new left side ball bearing onto the spindle assembly and into grinding head housing APPLY BLUE LOCTITE 243 TO THE INSIDE THREAD OF THE 9 16 18 NUT and install onto the spindle shaft with the grooved side toward the bearing onto the spindle shaft and using a spanner wrench on the right side of the spindle and a 7 8 deepwell socket on the left side torque the locknut to 15 Ft Lbs APPLY BLUE LOCTITE 243 TO THE BORE OF THE PULLEY BEFORE INSTALLATION Replace the square key and install the new pulley pushing the counterbore side of the pulley against the spindle nut with no end play NEXT INSTALL BLUE LOCTITE 243 ON THE PULLEY SETSCREWS AND TIGHTEN THE TWO PULLEY SET SCREWS Then install the new external retaining ring on the spindle shaft Mount the new poly V belt See Grinding Head Belt Tension and Al
64. r operation it may be necessary to tighten the clamp To tighten loosen the jam nut on the clamp tip Screw the tip out so there is 10 gap between the tip and the Clamp Support Block See FIG 26 Lock in place by tightening the jam nut against the clamp being careful not to move the tip Verify the distance between the clamp tip and block is still 10 The 10 setting allows slippage in a jam situation and damage can occur if this adjustment is set to narrow CAUTION SHOULD BE USED AS ADJUSTING THE TIP WILL AFFECT THE SLIP LOAD AND COULD DAMAGE THE CLAMP TIP BELT OR TRAVERSE DRIVE SYSTEM ORIGINAL INSTRUCTIONS ADJUSTMENTS ORIGINAL INSTRUCTIONS 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 STEP 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 Mounting 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
65. r 120VAC in to SCB K Check for 120VAC from SCB L Check for 120 VAC at terminal strip M Verify that GMS is off and Check for 120 Volts AC out of GMS at Terminals 1 N Verify that SMS is off and Check for 120 VAC out of SMS Terminals 1 O Check voltage after the ESS MAKE SURE SWITCH IS PULLED UP P Hold in SSS and Check voltage out of the SSS Q Hold in SSS and Check voltage at LVR LVR must be installed in 8 pin socket Note light on top of LVR should be on and steady RED if not Press the Reset button P Hold in SSS and Check voltage at MAG A1 amp 2 ORIGINAL INSTRUCTIONS Check for 120 VAC from SCB 03SCB to blue wire O2FTRBU out of FTR Yes Go to Step K next No Check wire 03 from MCB to SCB replace if needed Check for 120 VAC from SCB 67SCB to blue wire 02FTRBU out of FTR Yes Go to Step L next No Flip Switch on SCB to ON Machine works end o troubleshooting Machine does not work replace SCB Check for 120 VAC from Terminal 11 on Terminal Strip 2 07TB2 11 to blue wire O2FTRBU out of FTR Yes Go to Step M next No Check wires 7 07TBBG 2 and wire 67 67TBG 3 Check Jumper on Grey Terminal Blocks 1 3 Measure 120 volts AC from GMS Terminal 1 90GMS 1 to blue wire O2FTRBU out of FTR Yes Go to Step N next No Flip Switch and check again Works Switch is upside down Does not work Check wire to GMS Replace GMS Measure 120 volts AC from
66. s Traverse speed set too high causing a 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 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 Traverse speed should be set lower approximately 12 ft min 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 do not go the full length of the reel The right hand side of the grinding wheel is not in full contact for relief grinding See Operators Manual for NORMAL HELIXAND RE VERSE HELIX PROBLEM Traverse speed is too slow Possible Cause Lineal bearing in the Carriage are set too tight Remedy A Readjust bearings for proper tension for more detail see lineal bearing replacement in the ad justment section of the manual PROBLEM Spin Drive cranks up and down too hard The two top and two bottom pivot screws are compressing the conical washer too tight Check screw adjustment tension on nylon plug riding against the screw thread A Tighten down the locknut until it bottoms out and back off 1 2 turn Check to see if there is a cone shape to the washer Four 4 pivot points B
67. s Bad Front Door Switch is Bad Checkout Procedure A Close the front doors and rear slide up door or workstation ramp depending on option installed B Check Alignment of Door Safety Switches on Front doors and rear slide up door C Check SSM for 24 Volts DC Turn switches off and press start switch to pull in MAG before testing voltages D Check PWR for 120 Volts AC Turn switches off and press start switch to pull in MAG before testing voltages E Verify 24Volts DC out to Door Switches F With Rear slide up door closed Verify 24Volts DC back form rear Safety Switches G With Front doors Cloded Verify 24Volts DC back form Front Door Switch PROBLEM MAG turns on only with System Start Switch held in Possible Cause MAG holding contact has failed Checkout Procedure A Check wiring to and from MAG holding contact in Verify the magnetic starter holding contact is working ORIGINAL INSTRUCTIONS Machine works Yes end troubleshooting No go to Step B next See Alignment section of this Manual Machine works Yes end troubleshooting No go to Step C next Measure 24 volts DC from SSM Terminal A1 to Terminal A2 Yes Go to Step E No Go to Step D next Measure 120 volts AC from PWR Terminal L to Terminal N Yes Verify 24 VDC out of PWR V to V Replace if no Voltage out or Check Wiring amp Verify Continuity to SSM if there is 24 VDC No Verify Wiring and Co
68. te from term 7 black from term 9 C Check potentiometer wiring for proper hookup See that speed pot is wired per electrical diagram D Check all pot settings on circuit board as shown in wiring diagram See adjustment section Traverse Motor Control Board Settings ORIGINAL INSTRUCTIONS Traverse Drive Control Pin 8 to 7 Pot full CCW Pot Full CW 0 VDC 9 75 VDC Pin 8 to 9 Pot full CCW 9 75 VDC Yes Pot is OK No Go to Step B next Pot Full CW 0 VDC 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 C next No replace potentiometer Wiper inside of potentiometer controls speed Wiper may be bad and not making contact Wrong wire hookup effects traverse con trol Reversing red and orange wires to potentiometer to the D C motor will run at zero speed but maximum will be too slow Reversing red and white wires does not affect speed control Check for Proper function Yes end troubleshooting No Go to Step D next Minimum and maximum pot settings effect traverse speed ELECTRICALTROUBLESHOOTING PROBLEM If the carriage traverses to one end of stroke or the other and it stops and does not reverse direction Possible Cause Proximity switch is not working properly or wire connections are loose Machine is in Torque mode and the index ing finger is not being activated Rem
69. there is belt slippage 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 12 3 mm 12 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 a 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 The spring load force pushing up on the index finger brings it away from the proximity when released STEPPPER INFEED TRAVEL LIMITS The infeed stepper maximum extension is 6 0 152 mm and minimum compression is 3 5 89 mm If 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 ORIGINAL INSTRUCTIONS SENSOR LIGHT INDEX FINGER PROXIMITY SENSO SENSING PIN A 6 0 152MM MAX 3 5 88 MM MIN ADJUSTMENTS TRAVEL LMITS For the TRAVEL LIMITS to perform properly and reverse the direction of the carriage at each end of the rails a distance of 3 16 4 mm to 1 4 6 mm
70. tory 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 local safety codes DON T 1 DON T use a cracked wheel or one that HAS BEEN DROPPED or has become damaged 2 DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole if wheel won t fit the machine get one that will 3 DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel 4 DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURRS 5 DON T TIGHTEN the mounting nut excessively 6 DON T grind on the SIDE OF THE WHEEL see Safety Code B7 2 for exception 7 DON T start the machine until the WHEEL GUARD IS IN PLACE 8 DON T JAM work into the wheel 9 DON T STAND DIRECTLY IN FRONT of a grinding wheel whenever a grinder is started 10 DON T FORCE GRINDING so that motor slows noticeably or work gets hot UNPLUG THE EQUIPMENT PRIOR TO DOING ANY SERVICE ON THIS EQUIPMENT FAILURE TO REMOVE POWER TO THIS EQUIPMENT BEFORE SERVICING MAY RESULT IN INJURY OR DEATH IF POWER IS REQUIRED FOR TESTING OR TROUBLESHOOTING THIS SHOULD BE PERFORMED BY A TRAINED PROFESSIONAL OR LICENSED ELECTRICIAN REVIEW THE SYMBOLS AND DESCRIPTIONS ON PAGES 10 AND 11 OF THE OPERATOR S MANUAL UNDERSTAND ALL SYMBOLS BEFORE O
71. uity DISCONNECT POWER FROM MACHINE I Check TSP 10K on control panel J Check TSP for 10 000 ohms Remove three wires from TDC red from term 8 white from term 7 black from term 9 K Inspect Motor Brushes DISCONNECT POWER FROM MACHINE ORIGINALINSTRUCTIONS Check TDC terminals A1 to A2 for 90 Volts DC Yes go to Step H next No go to Step I next Remove motor wires from Terminal Strip 1 terminals 7 amp 8 check for 0 ohms across the black and white wires Yes end troubleshooting motor should work if it does not replace motor No go to Step K next TDC Pin 8 to 7 Pot Full CCW Pot Full CW OVDC 9 75 VDC Pin 8 to 9 Pot Full CCW Pot Full CW 9 75 VDC 0 VDC Yes go to setp K No go to Step J next 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 replace the TDC No Replace TSP 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 Motor ELECTRICALTROUBLESHOOTING PROBLEM Traverse does not stop to reverse directions when flag goes under the proximity switch on the left side or right side of machine Possible Cause Checkout Procedure Gap between flag and prox is incorrect Proximity Switch is bad A Gap between flag and prox should
72. ws Going Into a Nut or Steel thread Use the Grade 8 values in the table at the right 7 16 In 30 ft lbs 50 ftlbs 75 ft lbs Machine Screws No 6 screws 11 in Ibs 0 125kg m ta cae OS cd ee thread 6 2 kg m 10 4 kg m 15 9 kg m No 8 screws 20 in Ibs 0 23 kg m No 10 screws 32 in lbs 0 37 kg m PERIODIC MAINTENANCE ORIGINAL INSTRUCTIONS DAILY MAINTENANCE IS SPECIFIED ON PAGE 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 1 Clean the tank and filter of the vacuum system 7 weekly or more often depending on the number of j reels ground 4 2 Inspect the Grinding wheel Poly V belt for cracking and adjust the belt tension per procedure called out in the adjustment section every six months RENE 2 Wipe and relube with never seez the vertical and HN horizontal alignment shafts and lead screws every six months FIG 10 2 Lift the bellows and wipe off the bearing rails monthly Lubricate linear bearing follow the lubrication procedure on the following pages Generally this will be every six months to a year ALIGNMENT SHAFT 2X PERIODIC MAINTENANCE ORIGINAL INSTRUCTIONS STORAGE PROCEDURE It is important to follow the procedures below when placing your grinding in storage for an extended period of time Proper care will help maintain the worki

6337951 Service Manual

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