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ASSEMBLY and SERVICE MANUAL

1. No Replace relays A B C amp D in RT1 RT1 Term A to term D should read the same 12 Volts DC measured at step H but opposite polarity Yes Skip to Step O No Replace relays A B C amp D in RT1 50 Black wire of RTP H to Red wire of RTP W Pot full CCW Pot Red line 2 Volts DC Volts DC SDC White wire of RTP L to Red wire of RTP W Pot full CCW 1 Volts DC Yes Replace SDC No Replace SSP Pot Red line 2 Volts DC At RT1 Term A and B or C and D check approx 0 ohms across the black and white wires Yes Motor should work end troubleshooting No go to Step P next Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10mm mini mum length Yes replace motor brushes No replace Spin Drive motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Grinding motor not working in manual jog mode Assuming 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown in the drawing are correct and pull on wire terminals with approximately 3 165 force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system
2. PELAY d r2 LIME B 35 TOCIE N25 TRAYEFIE DRINE gt MHT 37 ELK FN 3B 3 AO Mi LIFT xp 42 O Punch 42 LICHT o KORK LIGN 23 B42 va 45 N25 SPIN DRIVE BOARD TE v4 45 45 CES 45 47 p FED WIRING SCHEMATIC E 1000 5 FON CINE Iu gt lau LOE 10 102 TOLCH SCREEN 103 190 COMMUNICATION CABLE AFC LSENO 3 LES N 107 LOU FFO PLC 108 108 1 FRON LINE Yg vF TD LINE 5 31 TO LINE ER vi 3 124 vs FEIS 100 CPIND DRIYE 112 Hm 9 POWER RELAY 25 LINE ZE 113 100 TO LINE LOL FFO 3 04 1 13 PLC INMPLITX 100 LINE LOL 115 3 04 l 13 PLC QLiTPLO X 499 LOL 117 B ge i gt d SID e 118 2 LI ind Ms At 118 ni A oot d nm ran 1 een 120 TO LINE E S10P INPUT 4 215 124 LDL T Ve INFEED STEPPEP 123 L2B KHT ELF SS 2 Kn ER STEPPER gg KHTZYEL ower 125 130 KHT FED 125 AIDIAIA EANLERA ATIA FROM LINE A 4 0 ao SS rz e Nue ee Lap BRN BE gt 208 708 212 20 101 1 213 213 214 FROM LINE 101 213 3 120 zin 100 217 218 210 CIUT BREAKER LOAD RELAY COI
3. PARTS LIST 6329526 GRINDING HEAD ASSEMBLY PARTS LIST 6329526 GRINDING HEAD ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Socket Head Cap Screw 1 4 20 x 7 8 Long Socket Head Cap Screw 3 8 16 x 1 Long Socket Set Screw Cup Pt 1 4 20 x 3 8 Long Lock Patch 1 4 Flat Washer SAE 1 4 Split Lockwasher 3 8 Split Lockwasher Square Key 1 8 x 3 4 Long 1 HP 120 VAC Motor Conical Washer 1 36 OD x 88 OD Internal Retaining Ring Double Row Ball Bearing Poly V Belt Bearing Sleeve Motor Mount Plate Pulley Poly V 1 80 Diameter Pulley Poly V 1 44 Diameter Grinding Head Housing 9 16 18 Locknut Nylon Insert Jam Grinding Head Spindle Assembly Grinding Wheel knob Grinding Wheel see page 93 Retaining Ring External 50 Shaft Heavy Duty 6329527 CARRIAGE ASSEMBLY PARTS LIST PARTS LIST 6329527 CARRIAGE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Button Head Cap Screw 1 4 20 x 3 8 Long Button Head Cap Screw 1 4 20 x 1 1 4 Long Button Head Cap Screw 1 4 20 x 2 Long 1 4 Split Lockwasher 1 4 20 Jam Nut 7 8 14 Nylon Jam Locknut 4 x 31 Drive Screw Traverse Clamp Block Traverse Clamp Spacer Plate Clamp Support Block Belt Clamp Tip Compression Spring Retaining Ring Ball Bearing Shoulder Bolt 250 Dia x 387 Long Decal RPM Symbol Traverse Clamp Carriage Base Grinder Head Pivot Shaft Swing Door Latch Swing Door Weldment PARTS LIST 6309573 FINGER AND BODY ASSEMBLY PAR
4. DIGITAL GAGE Important Do not mark the scale unit with and electric engraver scratch the scale Always use 5844 battery silver oxide cell If the scale will not be used for more than three months remove the battery and store it properly Otherwise leakage if any from the battery may damage the unit Description of Parts 1 Beam 2 Main Scale 3 Battery compartment 4 Output Connection 5 Display 6 ON OFF Power 7 ZERO ABS switch 8 Origin Switch 9 Inch mm Switch 10 Tapped hole 11 Slider Battery Installation and Origin Setting Set the origin of the scale after installing the battery Otherwise the error sign E at the least significant digit may appear resulting in incorrect measurements 1 To install the battery remove the compartment lid and install the SR44 battery with its positive side facing up After the battery is installed set the origin 2 To set the origin move the slider to an area you wish to set as your origin Turn the power on Hold the ORIGIN switch down for more than one second The 0 00 display appears indication Origin setting is complete The origin will be retained even if the power is turned off Incremental INC amp Absolute ABS mode The LCD will dispay measurements from the origin when turned on ABS mode To origin see above The display can be set to zero at any desired position by pressing the ZERO ABS switch INC indicator will apper in the
5. If problem persists test as listed below Possible Cause Grinding Motor Switch is not on Circuit Breaker CB28 15A is tripped Grinding Motor Relay is not working REL Relay REL coil or con tacts are not working Relay 5 RT1 is not working Checkout Procedure A Turn switch on from either SPIN MANUAL screen or RELIEF MANUAL screen B Reset circuit breaker switch tripped by current overload C Check for REL incoming 115 Volts AC D Check for REL output voltage of 115 Volts AC E Check for REL input of 24 Volts DC at the coil Reminder Grind Drive switch must be on and doors must be closed F RT1 check that the light is on for relay 5 make sure grind drive swich is on L Light is on for Relay 5 check continuity Grinding Motor works Yes end troubleshooting No go to Step B next Grinding Motor works Yes end troubleshooting No go to step C next REL Term L1 to 12 for 115 Volts AC Yes go to step D next No Verify wiring replace Circuit Breaker CB28 REL Term 11 to T2 for 115 Volts AC Yes Verify 115 VAC at TB1 1 amp TB1 2 Check terminals replace Grind motor No go to step E next REL Term A1 to Term A2 for 24 Volts DC Yes Replace REL No Skip to Step F Light is On Go to Step I next Off Contact Factory RT1 Term 5 to 5 measure DC voltage 0 Volts DC Check wiring Relay REL should work end troubleshooting 24 Volts DC
6. Lift Power Cord Diode Jumper Assembly P DTO i c nn7nn DEE I IET ASSEMBLY 1 1 PARTS LIST DIAGRAM NUMBER 6200720 REEL LIFT ASSEMBLY PART NUMBER DESCRIPTION Button Head Cap Screw 10 24 x 1 2 Long Socket Head Cap Screw 3 8 16 x 1 Long Socket Head Cap Screw 3 8 16 x 1 1 4 Long Socket Head Cap Screw 3 8 16 x 2 1 2 Long Socket Head Cap Screw 3 8 16 x 4 1 2 Long Flat Head Cap Screw 1 2 13 x 1 1 2 Long Socket Head Cap Screw 1 2 13 x 2 Long 3 8 16 Nylon Locknut 3 8 16 Nylon Jam Locknut 1 2 13 Nylon Locknut 3 8 Flat Washer 3 8 Split Lockwasher 1 2 Flat Washer 1 2 Split Lockwasher Button Head Cap Screw Flat Washer Electro Mechanical Actuator Motor Service Electro Mechanical Actuator Compression Spring External Snap Ring Thrust Washer Cam Follower Flanged Bronze Bushing Lift Long Arm Lift Swing Arm Lift Short Arm Bearing Plate Bearing Plate Arm Block Ramp Support Strap Anti Rollback Plate Pivot Pin Lift Cross Support Lift Bearing Assembly Lift Frame Weldment Load Carrier Weldment Actuator Top Block Assembly Ramp Weldment Capacity Warning Decal Not Shown Capacity Warning Decal Text Not Shown 5 16 18 x 5 8 Button Head Socket Cap Screw Flat Washer 315 ID x 50 OD x 035 Thick 6529532 CANOPY ASSEMBLY WINCH amp BOOM PARTS LIST 66 PARTS LIST DIAGRAM NUMBER 6529532 CANOPY ASSEMBLY WINCH amp BOOM PART NUMBER DESCRIPTION Button
7. Replace front and rear shields See FIG 15 FRONT DUST SHIELD LINEAR BEARING TENSION ADJUSTMENT SCREW POSITION FACING DUT FIG 14 REAR DUST SHIELD FIG 15 ADJUSTMENTS Continued REEL FINGER DOVETAIL GIB AND FT ADJUSTING KNOB ADJUSTMENTS SHIFT COLLAR RELIEF FINGER e ADJUSTING 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 The gib adjustment should be sufficient to maintain a rigid position of the reel finger See FIG 16 Check the knob assembly rotating tension by checking the GJE ADJUSTING tightness of the nylon plug to the knob assembly threads SET SCREWS The tightness has to be sufficient so the knob assembly does not rotate during the relief grinding cycle See FIG 17 NYLON PLUG SET SCREW FIR TENSION ON NOTE To adjust the nylon plug you must lock the index THE RELJEF FINGER AD USTING 144 finger assembly down and then adjust the reel finger positioner so the clearance holes line up with the nylon plug set screw Take up any free play between the tee knob assembly reel finger slide and 375 threaded split shaft collar Loosen the shaft
8. Replace relay 5 RT1 ELECTRICAL TROUBLESHOOTING Continued PROBLEM Dust Collector not working in manual jog mode Assuming 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown on that draw ing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found tighten and retest system If problems persists test as listed below Possible Cause Dust Collector Switch is not on Vacuum Dust Collector Switch Vacuum on touch screen is not on Vacuum not working RT1 relay E is not working Circuit Breaker CB32 is not working 3 amp Relay 34 RE34 is not working Checkout Procedure Turn on switch located on top of Vacuum in the back right of corner of the machine B Turn switch on from SPIN MANUAL or RELIEF MANUAL Screen C Check for 115 Volts AC at the receptacle plug by plugging in a hand drill or light D With Vacuum switch on Check for RT1 Relay E on E RT1 Relay E verify continuity F Check for power out of circuit breaker CB32 G Check for RE34 input of 115 Volts AC at coil Check for RE34 input of 115 Volts AC at
9. Rotate index finger assembly to spin position B Check PLC input from Finger Stored Down prox A Rotate grind head assmbly down B Check PLC input from Head in Relief Pos Position prox A Jog Grind head to right prox with touch screen controls B Check PLC input from Right Traverse prox switch A Rotate grind head assmbly up B Check PLC input from Head in Relief Pos prox Message Status Clears Proceed to next system error message you have or continue running Remains go to Step B next From Help Screen verify Finger Stored Down prox input is on Red Follow instructions on Screen Clears Proceed to next system error message you have or Continue running Remains go to Step B next From Help Screen verify Head in Relief Pos prox input is work ing Follow instructions on screen Clears Proceed to next system error message you have or Continue running Remains go to Step B next From Help Screen verify Right Traverse Prox input is working Follow instructions on screen Clears Proceed to next system error message you have or Continue running Remains go to Step B next From Help Screen verify Head in Relief Pos prox input is work ing Follow instructions on screen ELECTRICAL TROUBLESHOOTING Continued System Error Message RELEASE FINGER FOR RELIEF ENTER NUMBER OF BLADES LOW VOLTAGE DE TECTED DOOR MUST BE CLOSED TO OPERATE INCREASE TOR
10. SHOWN TOINSTALL THE WIRE INSERT SMALL SCREWDRIVER INTO THE CAVITY MARKED A TO OPEN THE WIRE HOLE AITAGH THE OTHER END THE GREEN W YELLUW STRIPE WIRE SUPPLIED TO THE SROUND STUD ON THE TRANSFORMER 8 IMPORTANT GROUNDING In case of a malfunction or electrical 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 CONTACT A QUALIFIED ELECTRICIAN 10 PERIODIC MAINTENANCE DAILY MAINTENANCE IS SPECIFIED ON PAGE 4 OF THE OPERATOR S MANUAL AND IS TO BE PERFORMED BY THE OPERATOR LISTED BELOW ARE PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY S MAINT
11. that connect the Carriage Mounting Frame to the frame of the grinder STEP 3 Jack the traversing carriage base up to put a preload on the Cross Slide Assembly STEP 4 Tighten the 4 bolts on the Carriage Mounting Frame to 75 ft Ibs STEP 5 Release the jack pressure and test the vertical and horizontal handwheels for ease of movement through their full range of motion STEP 6 If the Cross Slides tend to bind repeat above steps jacking higher or lower STEP 1 until the handwheels move freely STEP 7 When the Cross Slides move freely through their full range of motion drill new holes and repin the assembly CARRIAGE CROSS SLIDE ING ASSEMBLY PART OF FRAME ADJUSTMENTS Continued CROSS SLIDE SHAFT REPLACEMENT If the cross slide shafts become scarred or gnarled replace them by the following procedure STEP 1 Use 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 l
12. 155 force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Relief Torque Pot RTP set to zero Spin Motor Switch not on on Touch Screen Door is open Circuit breaker 42 is tripped 4A Relay 9 RT1 is not working Verify Light is on Verify Continutiy of relay 9 in RT1 Relay 4 RT1 is not working Checkout Procedure A Set SSP to 20 on the control panel B Turn spin drive switch on touch green area from RELIEF MANUAL screen C Alarm on screen should indicate that the door must be closed for the spin drive to operate Close door D Reset circuit breaker switch Tripped by current overload check that reel is free spinning E Check for SDC input of 115 Volts AC Check RT1 for light 9 to be on Door must be closed and spin drive switch on G With light 9 on Check RT1 relay 9 for continuity H With 115 Volts AC at Term L1 and L2 check 50 output Have Relief Torque Pot RTP set at Red Line l With 115 Volts AC at Term L1 and L2 check 50 output Have Spin Speed Pot SSP set to 400 Spin Motor works Yes end troubleshooting No go to Step B next Spin Motor works Yes end troubleshooting No go to Step C next Spin Motor works Yes end troubleshooting No go to step D next Spin Motor works Yes
13. ASSEMBLY PARTS LIST Continued 6509465 SPIN DRIVE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Reducer 10 1 Ratio Motor DC 20 HP TEFC Socket Head Cap Screw 1 4 20 x 7 8 Long Flange Coupler 50 Sleeve Coupler Flange Coupler 5 8 Drive Coupling Adapter Tee Knob Assembly Retaining Ring Drive Adapter 1 2 Square Square Key 1 8 x 75 Long Gearbox Slide Bracket Strain Relief Wire Gearbox Clamp Bracket Gearbox Slide Weldment Bracket T Knob 5 16 18 Linkage Spacer 2 29 Long Linkage Spacer R H Thread Belleville 75 Dia x 35 T Shoulder Bolt 375 Dia x 375 Long Nylon Ball 5 32 Dia Socket Set Screw 5 16 18 x 1 4 Linkage spacer L H Thread Linkage Spacer 2 5 Long Socket Head Cap Screw Nylok Hex Locknut 3 8 16 Support Bracket Weldment Handwheel 4 5 Dia Handle Hex Jam Nut 1 4 20 1 4 20 Nylok Locknut Socket Set Screw 5 16 18 x 3 8 Long Double Thread Rod Knob Assembly Spin Drive Plate Lock Geared Linkage Socket Head Cap Screw 1 4 20 x 3 1 8 Long Square Key 3 16 x 75 Long DC Motor Brush PARTS LIST 6329529 MISCELLANEOUS PARTS PARTS LIST Continued 6329529 MISCELLANEOUS PARTS DIAGRAM PART NUMBER NUMBER DESCRIPTION Grinding Wheel 3 5 Dia x 38 w Grinding Wheel 3 5 Dia x 1 Wide Grinding Wheel 5 Dia x 3 8 Side Grinding Wheel 5 Dia x 1 Wide 5 16 Allen Key 1 4 Lockwasher T Knob Assembly Alignment Extension Weldment Gage Bar Weldment Retaining Plate Pla
14. CANOPY ASSEMBLY REAR LIFT 77 7 ae 44 d PARTS LIST 6329538 CANOPY ASSEMBLY REAR LIFT DIAGRAM PART NUMBER NUMBER DESCRIPTION Door Slide Door Guide Bracket LH Rear Panel RH Lift Rear Panel LH Lift ACCUPro Decal Canopy Support Bracket Door Switch Mounting Plate Door Switch Mounting Bracket Latch Spacer Plate Guard Weldment RH Guard Weldment Lift LH Front Guard Door Assembly see page xx Door Safety Switch Assembly Rear Door Switch Cord Lift Control Decal Rocker Switch 6 Amp Circuit Breaker Lift Control Box Strain Relief 22 25 Wire Strain Relief 33 36 Wire Thrust Washer 94 OD x 50 ID Button Head Cap Screw 1 2 13 x 1 1 2 Long Lift Access Panel Flat Head Cap Screw 1 4 20 x 1 4 Long 8 Lock Washer 8 32 Kep Nut Flasher Base Assembly Lift Power Cord W139 Rear Door Switch Cord PARTS LIST 6200720 REEL LIFT ASSEMBLY PARTS LIST 6200720 REEL LIFT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Button Head Cap Screw 10 24 x 1 2 Long Button Head Cap Screw 10 24 x 3 4 Long Button Head Cap Screw 1 4 20 x 5 8 Long 10 24 Nylon Jam Locknut 1 4 20 Nylon Locknut 10 Lockwasher 10 24 Kep Nut Liquid Tight Strain Relief 27 47 Wire 6 Amp Circuit Breaker Rocker Switch Momentary on off on 25 Amp Bridge Diode Thermistor Assembly Electrical Warning Decal Lift Electrical Control Box Lift Control Decal Lift Actuator Cord Lift Controls Harness
15. PROBLEM Flasher light does not turn on at end of automatic cycle In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminals If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Bulb is burned out Flasher FLR is bad No 115 Volts AC to flasher Relay 7 RT1 is bad Circuit Breaker CB32 tripped Checkout Procedure A Remove bulb and test continuity B FLR Unplug flasher at terminal RT1 7 and touch lead to black wire at RT1 7 C After a cycle has completed measure voltage to Flasher D After a cycle has completed check RT1 for light 7 to be on E Check continuity of relay 7 F Reset CB32 Bulb Measure approx 300 Ohms Yes go to Step B next No Replace bulb Light works Yes go to step C next No Replace Flasher Assy RT1 Term 7 to Blue Term Block 17 Measure 115 Volts AC Yes Verify continuity in cord Replace flasher No go to step D next Light is on Yes go to step E next No Contact Factory RT1 Term 7 to 7 Measure 115 Volts AC Yes Replace Relay 7 RT1 No go to step F next Press in on Circuit breaker CB32 on front of control panel Works Yes En
16. Regulation of the traverse motor may be improved by slight ad justment 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 symp toms just disappear 8 30 2 30 8 320 3 00 3 00 RLL 9 Cw VIC FIG 29 12 00 9 00 Potentiometer Clock Orientation Terminal ends Feet are always atthe 6 00 position no matter how the potentiometer is orientated on the board 26 MACHINE SERVICE Continued 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 29 Loosen the 4 socket head cap screws on the motor plate to remove the poly V belt Loosen the 2 set screws on the spindle pulley and remove the pulley square key and pulley spacer Push 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 remove the spindle assembly out the right side by lightly tapping on the le
17. contacts L Check for RE34 output of 115 Volts AC at contacts Dust Collector works Yes end troubleshooting No go to Step B next Dust Collector works Yes end troubleshooting No go to Step C next Light works Yes Replace Vacuum No go to Step D next Light is on Yes go to step E next No Contact Factory RT1 Term E to E for 115 Volts AC Yes replace Relay E RT1 No go to Step F next Terminal Block 17 light blue wire 02 to CB32 brown 156 for 115 Volts AC Yes go to Step G next No replace CB2 RE34 Term 0 to term 1 for 115 Volts AC Yes go to Step H next No Check continuity of wires RE34 Term 8 to term 4 for 115 Volts AC Yes go to Step I next No Check continuity of wires RE34 Term 6 to term 2 for 115 Volts AC Yes Replace Plug No replace RE34 PROBLEM Winch does not work in either direction In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and Terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Checkout Procedure 7 amp circuit breaker on A Reason Check for a lifting Winch works winch motor i
18. display INC mode permitting measurements from this zero point To return to the ABS mode hole the ZERO ABS buttton for more than 2 seconds Error Symptoms amp Remedies 00 ERRC and display flickering Occurs when the scale surface is stained Clean the scale surface and coat a thin film of low viscosity oil to keep out moisture 00 E in the least significant digit This occurs when the slider is moved too quickly but it does not affect the measurement If it stays on when the slider stops the scale surface is probably stained If this is the case take remedies as for ErrC B indication Battery voltage is low Replace the battery as soon as possible ADJUSTMENTS Continued CARRIAGE LINEAR BEARING REPLACEMENT STEP 1 Detach the bellows mounting brackets from the carriage Detach front and rear shields See FIG 15 STEP 2 Remove the three screws of one linear bearing and slide the linear bearing off the end of the carriage shaft STEP 3 Insert a new linear bearing onto the end of the carriage shaft with the tension adjustment screw pointing outward See FIG 14 Adjust the tension screw of the linear bearing so when you radially rotate the linear bearing around the carriage shaft there should be no free play between the linear bearing and the carriage shaft NOTE Tension is too tight if you feel a cogging action when you rotate the linear bearing around the shaft This cogging is from the skidding of the bearing on the shaf
19. end troubleshooting No go to step E next SDC Term L1 to 12 for 115 Volts AC Yes skip to step H next No go to Step F next Light is On go to Step next No Bad PLC RT1 cables or Software RT1 Term 9 to term 9 for 115 Volts AC No Check CB42 4 Amp for 115 VAC check from CB to Blue Term Block 17 Yes Replace relay 9 in RT1 SDO term A1 to term A2 measure approx 12 Volts DC Yes Skip to Step L No go to step I Next 50 term A1 to term A2 measure approx 90 Volts DC No Skip to step N Yes go to step J Next ELECTRICAL TROUBLESHOOTING Continued Possible Cause Relay 4 is bad Reversing relay s bad RT1 Relief Torque Pot RTP is not working Spin Drive motor is bad Worn motor brushes Checkout Procedure J Check RT1 for light 4 to be off Insure that Spin Drive switch has been pressed on from RELIEF MANUAL screen at least once K With light 4 on verify continuity L Measure voltage at RT1 M Reverse direction of spin motor from SPIN MANUAL touch screen N RTP on Main Panel O With machine power off Check spin motor continuity P Inspect motor brushes Light is Off go to Step K next On Contact factory Remove one of the wires at Terminal 4 measure RT1 4 to 4 for 0 Ohms Yes Replace relay 4 RT1 No replace SDS RT1 Term A to term D should read the same 12 Volts DC measured at step H Note polarity Yes Skip to Step M
20. 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 SENSOR LIGHT INDEX FINGER PROXIMITY SENSOR The spring load force pushing up on the index finger brings SENSING FIN it away from the proximity when released FIG 19 STEPPPER INFEED TRAVEL LIMITS 6 2 GANG cy rigo ET 3 12223 35 88 WO M 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 INDEX FINGER ASSEMBLY INDEX FINGER LOCKING PIN LOCKING INDEX FINGER PIN To align the Index Finger Locking Pin to the hole in the Index Finger Assembly loosen the two socket head cap screws so the index sensor block is movable Push down on the index finger assembly until the spring loaded index finger locks into hole with no binding Tighten the two socket head cap screws so the index sensor block is secured and the locking pin moves freely See FIG 21 SOCKET HEAD CAP SCREWS INDEX SENSOR BLOCK FIG 21 ADJUSTMENTS Continued PROXIMITY SWITCH PRIKIMITY SWITCH For the proximity switch to perform pr
21. 3 3 va vg va B n E YF ve OPIVE LINE 2 30 SPIN PUER LIME 2 44 SPIN A LINE 2 45 SPIN DIFECIIUM B LINE 2 46 SPIN DIRECTION Er LINE 3 47 SPIN DIPECIION A LINE 2 48 VACUUN LINE 2 34 E S10P LOOP LINE 1 13
22. 5 127mm DIA X 3 8 10mm 6 WIDE GRINDING WHEEL e 3 5 89mm DIA X 1 25mm WIDE GRINDING WHEEL 3 5 897mm DIA X 3 8 10mm WIDE GRINDING WHEEL N ALLEN WRENCH REEL POSITION GAGE FLASHER BULB amp LENS HORIZONTAL EXTENSION DRIP PAN ALIGNMENT GAGE ASSEMBLY INSTRUCTIONS Continued LEVEL BASE Place a level on the top of the table and check the unit from side to side for level Adjust the leveling feet as necessary to bring to level See FIG 4 Place a level across the table from front to rear Adjust the leveling feet on the end of the machine as necessary to level See FIG 5 When both front to back and side to side leveling procedures have been completed thread the hex jam nuts up against the nut that is welded to the bottom until they lock into place Be careful not to move the leveling feet during this process See FIG 3 Make certain that all four leveling feet are firmly contacting the floor Recheck with level after locking nuts are firmly tightened INSTALL THE FLASHER LIGHT LENSE Locate flasher bulb and lense in carton Install bulb lense to the flasher assembly socket This is A BULB located ontop of the front right frame member on the 632 ACCU Pro and on the top of the right RIGHT CANOPY DIOR canopy door for the 652 ACCU Master See Fig 6 ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT GRO
23. 8 11 Locknut Canopy Frame Weldment Shoulder Bolt 75 Dia x 3 5 Long Trolley stop Bracket Winch Warning Decal Boom Weldment Button Head Socket Cap Screw 3 8 16 x 1 Long 3 8 16 Hex Jam Nylok Locknut 5 16 18 x 1 2 Nylon HHCS Decal Boom Cap 3 8 16 x 1 50 SHCS Trolley Wheel Assy Hook and Cable Assembly Electric Winch Trolley Base Decal Boom Capacity Symbol 5 16 Flat Washer Spacer Trolley Wheel 6529532 CANOPY DOORS ASSEMBLY PARTS LIST 70 PARTS LIST DIAGRAM NUMBER 6529532 CANOPY DOORS ASSEMBLY PART NUMBER DESCRIPTION Socket Head Cap Screw 10 24 x 1 2 Long Socket Head Cap Screw 10 24 x 5 8 Long 8 32 Nylon Jam Locknut 5 16 18 Hex Nut Button Head Cap Screw 1 4 20 x 1 2 Long 1 4 Split Lockwasher 8 Lockwasher 88 32 Nut Grab Handle Foam Strips Soft Latch Coded Door Switch Magnet Door Switch Assembly Button Head Safety Screw 48 32 x 1 2 Long Large Foley United Decal Canopy Door Front Window Canopy Door Side Window Window Retaining Bracket Long Window Retaining Bracket Short Window Retaining Bracket Medium Flasher Light Base Assembly Right Door Weldement Left Door Weldment 10 24 Nylon Locknut 6529534 CANOPY ASSEMBLY REAR LIFT PARTS LIST 72 PARTS LIST DIAGRAM NUMBER 6529534 CANOPY ASSEMBLY REAR LIFT PART NUMBER DESCRIPTION B190811 Socket Head Cap Screw 10 24 x 1 2 Long Button Head Cap Screw 1 4 20 x 1 2 Long Butt
24. 90811 191501 6509470 6509574 STEPPER 8 MOUNTING ASSEMBLY DESCRIPTION Button Head Cap Screw 10 24 x 3 8 Long Socket Head Cap Screw 1 4 20 x 1 1 4 Long Socket Set Screw 1 4 20 x 1 2 1 4 20 x 5 8 Set Screw Base Cover Plate 3 8 24 Nylok Jam Locknut Infeed Stepper Assy Ball Bearing Retaining Ring Hose Clamp 2 25 Dia Thrust Washer Hex Pivot Pin Trunion Block Bellows 1 88 D Flex Coupling Spiral Retaining Ring Socket Head Cap Screw 10 24 x 1 2 Long No 10 Lock Washer Stepper Infeed Motor PARTS LIST 6329535 MOWER SUPPORT ASSEMBLY PARTS LIST DIAGRAM PART NUMBER NUMBER Eeer 6509564 6329535 MOWER SUPPORT ASSEMBLY DESCRIPTION Pan Head Machine Screw 10 24 x 3 8 Long No 10 Lockwasher Knob Assembly Quick Release Pin 31 Dia Shoulder Bolt 375 Dia x 50 Long 6 type B Lanyard Horizontal Scale Decal RH Vertical Scale Decal Bar Mounting Weldment Bracket L H Front Roller Horiz Weldment Bracket L Roller Clamp Weldment Bracket Knob Assembly NS L H Front Roller Clamp Weldment Knob Assembly R H Front Roller Horiz Welment Bracket R H Roller Clamp Weldment Bracket Thrust Washer Socket Head Cap Screw 5 16 18 x 3 4 Long 5 16 Lockwasher Rear Roller Support Bracket Weldment 1 2 20 x 1 2 Flat Pt Socket Head Set Screw R H Front Roller Clamp Weldment Rear Clamp Rear Clamp Base Weldment Horizontal Scale Decal LH PARTSLIST 6509465 SPIN DRIVE
25. ACCU Master ACCU Pro AUTOMATIC REEL MOWER GRINDER with ACCU Touch ASSEMBLY and SERVICE MANUAL SAFETY INSTRUCTIONS Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards Whenever you see these symbols follow their instructions The Warning Symbol identifies special instructions or procedures which if not correctly followed could result in personal injury KEEP GUARDS IN PLACE and in working order REMOVE WRENCHES AND OTHER TOOLS KEEP WORK AREA CLEAN DON T USE IN DANGEROUS ENVIRONMENT Don t use Grinder in damp or wet locations Machine is for indoor use only Keep work area well lit KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area MAKE WORK AREA CHILD PROOF with padlocks or master switches DON T FORCE THE GRINDER It will do the job better and safer if used as specified in this manual USE THE RIGHT TOOL Don t force the Grinder or an attachment to do a job for which it was not designed WEAR PROPER APPAREL Wear no loose clothing gloves neckties or jewelry which may get caught in moving parts Nonslip footwear is recommended Wear protective hair covering to contain long hair ALWAYS USE SAFETY GLASSES SECURE YOUR WORK Make certain that the cutting unit is securely fastened with the clamps provided before operating The Caution Symbol identifies special instructions or procedures which if not strictly obse
26. C Stepper Infeed Control SIC Wiring bad Stepper Infeed Control SIC or Stepper motor is bad Checkout Procedure H Measure voltage at MAG insure power is on and green PSS has been pressed L Check light YO on PLC While pressing up or down it should light pressing down Y1 will also light J Check wiring at SIC K Check output at SIC Have High Low Switch set on high speed rabbit MAQ term 13 to 14 Measure 0 volts DC Yes Verify DC power to Mag term 13 No if 24 Volts DC Replace MAG Light comes on Yes go to step H next No Contact Factory Insure all wires are connected at the SIC to the connectors and that none have become loose Some connections have multiple wires in them be sure all are tight by gently tugging on them If all wires appear to be connected and correct proceed SIC Terminal phase Ato terminal phase A Measure 4 7 Volts DC 0 2 0 3 Volts while jog button is pressed SIC Terminal phase B to terminal phase B Measure 4 7 Volts DC 0 2 0 3 Volts while jog button is pressed Yes replace stepper motor No replace SIC ELECTRICAL TROUBLESHOOTING Continued PROBLEM No Manual jog cycle or Auto Cycle stops because of a system error message on Touch Screen System Error Message STORE FINGER FOR SPIN GRIND ROTATE HEAD DOWN FOR SPIN GRIND HOME TRAVERSE TO RIGHT PROX TO START ROTATE HEAD UP FOR RELIEF GRIND Checkout Procedure A
27. E TOUCH SCREEN D BERR ITN Et 14100 DEER EM 8 d SP pt Em Lm E d FUP META 3 TER T R MAO I 100 WIRING DIAGRAM 6524511 AC d Bun FLASHER 101 WIRING DIAGRAM BL RAR FN YE AIR Hf PADA 4 8 IB UIA ATI 102 6524511 DC LINPEX LEH SCREEN TEHLE 5 IT eese Lee Gas 11232 4 TED WIRING DIAGRAM 6524511 DC 103 CCHUERATIC BFN TOT ET BLU LLG BLU EIER 1D NELL T NLL 12 CEIS E1113 15113 woud T 12 v 15 1 17 NIL 13 u EMERGENCY SUP s D mp d PELAY en 13 1 24 31008 14 15 PYRIO CONTROL LB SLFFLY 00 17 10 LIME 3 101 IDI LB LI NIL 2D LOY VOLTAGE PEL 21 211 10 LINE 4 213 27 101 23 wi WAG L 25 TD LINE 2 26 N25 104 CAOC FRON LINE FROM LINE m GS 1 25 27 mer FELIZ og 28 FIND en e N23 eu al 832 v 25 22 72 N25 lt 31 44 Her far tl e 12 gt 32 34 oz VACULIN A
28. ENANCE DEPARTMENT Clean the tank and filter of the vacuum system weekly or more often depending on the number of reels ground VACUUM SYSTEM IS OPTIONAL EQUIPMENT ALL 632 ACCU PRO MODELS Use the grease fitting provided to grease the dove tail with high quality lithium grease monthly Wipe off excess grease See FIG 9 HAL Wipe and re oil with spray lubricant the grinding wheel diameter adjusting lead screw every three months Wipe off all excess lubricant See FIG 9 Check the gib adjustment on the Grinding wheel diameter adjustment every 3 months See FIG 9 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 Wipe and relube with never seez the vertical and horizontal alignment shafts and lead screws every six months See FIG 10 Liftthe bellows and wipe off the bearing rails monthly SHAFT 2X Lubricate linear bearing follow the lubrication procedure on the following pages Generally this will be every six months to a year 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 working 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 U
29. Head Cap Screw 1 4 20 x 1 2 Long Button Head Cap Screw 5 16 18 x 1 2 Long Socket Head Cap Screw 5 16 18 x 3 4 Long Button Head Cap Screw 3 8 16 x 3 4 Long Socket Head Cap Screw 3 8 16 1 Long 10 Machine Screw x 5 8 Long 3 8 16 Nylon Locknut 1 4 Split Lockwasher 5 16 Flat Washer SAE 5 16 Split Lockwasher 3 8 Flat Washer SAE 3 8 Split Lockwasher 2 Prong Knob Filter Bag Filter Cartridge Vacuum Hose End Adapter Vacuum Sizing Adapter Flat Washer 1 38 OD x 39 ID Liquid Tight Strain Relief 27 47 Wire Liquid Tight Strain Relief 19 30 Wire Strain Relief 22 25 Wire Liquid Tight Strain Relief 43 55 Wire Strain Relief 33 36 Wire 5 8 Hole Plug Socket Holder Foam Strip 3 16 Blind Rivet No Fuel Warning Decal Multiple Safety Symbols Decal Patent Decal Rear Top Filler Weldment Rear Canopy Panel Bottom Canopy Panel ACCUMaster Decal Canopy Support Panel Canopy Side Foam Pad Canopy Back Foam Pad Canopy Weldment 1 2 Hole Plug Fluorescent Machine Light Winch Cord Receptacle W139 Front Door Switch Cord Assembly Electrical Warning Decal PARTS LIST 6509526 WINCH AND BOOM ASSEMBLY PARTS LIST PART NO B251611 J257100 J627100 6509541 3708398 6509103 6509115 6509544 B371616 J377100 3708519 6509298 B372411 6509367 6509594 6509546 6509364 3708456 K310101 6509366 6509526 WINCH AND BOOM ASSEMBLY DESCRIPTION Socket Head Cap Screw 1 4 20 x 1 Long 1 4 20 Nylok Locknut 5
30. L NOOR T s o RIDE P I 1040 LIGHT 1 Ri CONTACT ES SIAM RESISIOR ale MRMILLY PLSHPULL SWITCH PONENTICNEIER a s DPEN PUSH SWITCH am 107 PLC INPUTS 1 BLOCES d 4 f 2 13 FILIO Las LINE 22 22 3 01 1 18 lt gt 10 LINE gt 108 203 COOP SAFETY SWITCH LEFT TRAVERSE RICHT TRAVERSE PRO FINGER ODkty S70PE0 HEAD IN FELIEF POL FAO 213 LUwv LO 5 FEN 190 10 NEY SPOT IN SCHEMATIC DI WITH CPROKIHI TY CLOSED POSITION IF SAFETY SWITCH INTERNAL CONTACTS C IN SWITCH WIDINA COUCM ATIA FROM LINE iaa TI S agua FROM LINE 301 3 11 HAT FT L DOLE 24 5 C 109 303 0 LOL 34 SEE 5 a De LIKE kx o 30b SEE SIEPPER nd W e LIE o 30E 309 v2 C TPAVEPLE FIGHT 209 LIME 7 38 310 C G TPAVEPSE LEFT O LIME 2 3B 312 313 Q SPEED ON TOFDLE OFF 313 LIKE 2 45 314 315 5 GRIND DRIVE POWER 315 LINE 3 112 31B 317 m 217 3LB 319 g FLASHING LICHT LIME 2 32 318 221 1 1 BUS 108 326 377 328 328 320 331 332 333 I 335 336 337 338 33 347 350 FROM LINE 5 325 332 334 336 338
31. OMP trim pot clockwise from its factory set position Overcompensation causes the motor to oscillate or to increase speed when fully loaded If you reach such a point turn the IR COMP trim pot counterclockwise until the symptoms just disappear 4 30 FULL Ct 9 00 SPD mE pr H a S FIG 27A See potentiometer orientation on page 24 FIG 27B MACHINE SERVICE TRAVERSE DRIVE CONTROL BOARD TDC The Traverse Drive Control Board has five potentiometers as shown on drawing 6524511 which is included These potentiometers have been set at the factory to the positions shown on the drawing Also see FIG 29 Maximum Speed The maximum speed potentiometer is preset to 2 30 position for 90 Volts DC to the traverse motor Rev Torque The Reverse Torque setting determines the maximum current limit for driving the motor in the reverse direction The potentiometer is preset to the 3 00 position It should not require adjustment Fwd Torque The Foward Torque setting determines the maximum current limit for driving the motor in the forward direction The potentiometer is preset to the 3 00 position It should not require adjustment Accel Decel The potentiometer is factory preset to the minimum full counterclockwise 8 30 position This position turns the Acceleration Deceleration off for this application IR Compensation The IR Comp control is preset to 9 30 position Never adjust past the 11 00 position
32. QUE KNOB SETTING TORQUE KNOB LOW OR DIRECTION WRONG Checkout Procedure A Release finger Make sure that the finger is allowed to come foreward at least once B Check PLC input from Door Saftey Switch A Blade count is required to run Relief grind Count blades and enter the number under the Blade Field A Input line voltage has dropped below 100V Plug machine into a better source of power See Power requirements at front of manual A For safety reasons door must be closed to operate spin and or grind motors Close and latch door B Check PLC input from Door Saftey Switch A An excessive amount of time has passed between blade indexes or atthe start of a relief cycle Increase the Relief Torque Pot excessive amount of time has passed at the beginning of a Relief grind cycle before the finger down prox was detected Verify Torque pot setting and or spin direction Reminder Blade should push finger down Message Status Clears Proceed to next system error message you have or continue run ning Remains go to Step B next From Help Screen verify Finger Stored Down prox input is working Follow instructions on screen Clears Proceed to next system error message you have or continue run ning Clears Proceed to next system error message you have or continue run ning Clears Proceed to next system error message you have or continue run ning Remains go to Ste
33. RIPTION Compression Spring External Retaining Ring Traverse Motor Assembly Finger amp Body Assembly see page 74 Traverse Base 5 8 Shaft Coupler Motor Extension Shaft Pulley Mount Bracket Prox Flag Bracket Weldment Shaft Support Block Assembly Grinding Head Assembly see page 70 Carriage Assembly see page 72 Traverse Base Adjuster End Cap Bellows Bracket Carriage Mount Bellows Bracket End Mount Plunger Pin Retainer Belt Cover Carrier Shaft Belt Cover Gasket Traverse Base Fixed Bracket Grinding Wheel Grip Knob Bellows Way cover Carriage Dust Cover Bracket Plunger Pin Cross Slide Assembly see page 68 6509565 CROSS SLIDE ASSEMBLY PARTS LIST PARTS LIST 6509565 CROSS SLIDE ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER Socket Set Screw CPPT 5 16 18 x 3 4 Long 3 8 16 Hex Nut 3 8 16 Hex Jam Nylon Locknut 3 8 Split Lockwasher 3 16 Dia Nylon Plug Handwheel 4 5 Dia 38 Bore Bell V Washer 75 D x 035 T Thrust Washer Adjustable Handle 5 16 18 Female Orange Adjusting ACME Shaft Locking Stud Shaft Cross Slide Support Slide Shaft Cross Slide Cross Slide Horizontal support Socket Set Screw 5 16 18 x 5 8 Long Flat Washer Grey Decal Orange Decal 5 16 18 Locking Stud Adjustable Handle 5 16 18 Female Grey Spacer 406 ID x 75 OD x 1 0 Long Socket Head Cap Screw 3 8 16 x 1 1 4 Long Rollpin 3 8 Dia x 1 Long 3 8 Split Lockwasher Traverse Base Adjuster Bracket
34. SE COMPRESSED AIR OR A POWER WASHER TO CLEAN THIS MACHINE See Maintenance section for instructions on cleaning polycarbonate Lubricate the following parts by flooding the area with a spray lubricant and leaving it in place Do not use a Teflon based lubricant Traverse Shafts amp Linear bearings see Lubrication section of manual Remove grinding wheel and spray the movable parts of the finger system Cross slide shafts and adjustment screws Right side of Traverse Base Scratches in the paint or any other bare metal surfaces Work the lubricant in by moving parts through their full range of motion Make sure all controls are in the off position and unplug the unit from the wall Turn off the digital alignment gage Cover the unit if possible with a sheet or tarp BRINGING THE UNIT BACK INTO SERVICE Remove the cover and reapply lubricant to the items stated above Wipe off all excess lubricant See Lubrication section for more details Plug the unit into the wall and test all electrical functions Check the belts for cracking and adjust the tension if necessary Check for damaged or missing parts LUBRICATION 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 shafts See FIG 11 Then run the carriage back and forth through its range of travel This will carr
35. ST 74 PARTS LIST DIAGRAM NUMBER PART NUMBER B251001 B251011 B310813 B311213 K310001 K311501 6329530 MAIN CABINET ASSEMBLY DESCRIPTION Hex Head Cap Screw 1 4 20 x 5 8 Socket Head Cap Screw 1 4 20 x 5 8 Button Head Socket Cap Screw 5 16 18 x 1 2 Button Head Socket Cap Screw 5 16 18 x 3 4 Socket Head Cap Screw 3 8 16 x 3 4 Hex Head Cap Screw 1 2 13 x 1 3 4 Hex Head Cap Screw 1 2 13 x 3 Hex Head Cap Screw 1 2 13 x 4 25 Roll Pin 375 Dia x 1 Long Roll Pin 375 Dia x 1 1 4 Long 5 16 18 Locknut 1 2 13 Locknut 1 4 Split Lockwasher 5 16 Flat Washer SAE 5 16 Split Lockwasher 3 8 Split Lockwasher 1 2 Flat Washer SAE Flat Washer 88 OD x 31 ID x 104 T 7 8 Hole Plug Wave Spring Flat Washer 1 0 OD x 75 ID x 08T 5 8 Hole Plug Fuel Warning Decal Swell Latch 1 2 Hole Plug Decal Up Down Gage Pin Mounting Vac Door Proximity Switch Head LH Traverse Proximity Switch Cord RH Traverse Proximity Switch Cord Proximity Switch Nut Cabinet Weldment Front Panel Weldment Traverse Base Assembly see page 64 Mower Support Assembly see page 78 Cross slide Mount Tooling Bar Shim Spin Drive Assembly see page 80 Tooling Bar Weldment Proximity Switch Bracket Weldment RH Proximity Switch Bracket Weldment LH 1 8 Hex Jam Nut Adjustable Leveling Bolt Right Hand Access Panel Left Hand Access Panel Small Hole Plug 1 75 Diameter PARTS LIST 6329525 TRAVERSE BASE ASSEMBL
36. Short Window Support Front RH Window Frame Weldment Front LH Window Frame Weldment Door Bracket Front Inside Window Window Retainer Switch Mount Front RH Inside Window Frame Weldment Front LH Inside Window Frame Weldment PARTS LIST 6329538 CANOPY ASSEMBLY REAR LIFT PARTS LIST DIAGRAM NUMBER 6329538 CANOPY ASSEMBLY REAR LIFT PART NUMBER DESCRIPTION Button Head Cap Screw 10 24 x 3 4 Long Button Head Cap Screw 1 4 20 x 1 2 Long Hex Head Cap Screw 1 4 20 x 5 8 Long Hex Head Cap Screw 1 4 20 x 1 2 Long Button Head Cap Screw 3 8 16 x 3 4 Long Socket Head Cap Screw 3 8 16 1 Long Socket Set Screw Cup Pt 5 16 18 x 1 Long 8 32 Nylon Jam Locknut 10 24 Nylon Locknut 1 4 20 Nylon Jam Locknut 3 8 16 Nylon Jam Locknut 8 Flat Washer 10 Flat Washer 1 4 Flat Washer 1 4 Split Lockwasher 3 8 Flat Washer SAE 3 8 Split Lockwasher Flat Washer 1 OD x 44 ID 2 Prong Knob Flat Washer 1 38 OD x 39 ID Liquid Tight Strain Relief 27 47 Wire Liquid Tight Strain Relief 19 30 Wire Liquid Tight Strain Relief 43 55 Wire 7 8 Hole Plug 5 8 Hole Plug Electrical Warning Decal Sharp Warning Decal Plastic Rivet Respirator Warning Decal Hearing Protection Warning Decal No Fuel Warning Decal Multiple Safety Symbols Decal Button Head Safety Screw 8 32 x 1 2 Long Patent Decal Spring Latch Foley United Decal Gage Mounting Pin Side Frame Spacer Plate Door Guide Bracket RH PARTS LIST 6329538
37. TLY IN FRONT of a grinding wheel whenever a grinder is started DON T FORCE GRINDING so that motor slows noticeably or work gets hot AVOID INHALATION OF DUST generated by grinding and cutting operations Exposure to dust may cause respiratory ailments Use approved NIOSH or MSHA respirators safety glasses or face shields and protective clothing Provide adequate ventilation to eliminate dust or to maintain dust level below the Threshold Limit Value for nuisance dust as classified by OSHA This machine is intended for grinding the reel of reel type mower units ONLY Any use other than this may cause personal injury and void the warranty To assure the quality and safety of your machine and to maintain the warranty you MUST use original equipment manufactures replacement parts and have any repair work done by a qualified professional ALL operators of this equipment must be thoroughly trained BEFORE e 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 Machine is for indoor use only Do not use a power washer to clean the machine Low Voltage Relay The grinder is equipped with a low voltage relay which is factory preset at 100 VAC If the power supply line does not deliver 100 VAC power under load the relay will open and trip out the starter If this occurs your power supply line is inadequate and must be correct be
38. TS LIST 6309573 FINGER AND BODY ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Socket Head Cap Screw 10 32 x 3 8 Long Button Head Socket Cap Screw 10 32 x 3 8 Long Socket Head Cap Screw 1 4 20 x 5 8 Long Socket Head Cap Screw 1 4 20 x3 Long Socket Set Screw 10 24 x 1 4 Socket Set Screw Nylok Cup 10 32 x 25 Long Socket Set Screw CP PT 10 32 x 1 2 Long Socket Set Screw 10 32 x 1 2 Long Roll Pin 1 8 Dia x 1 1 4 Long Dowel Pin 1 4 Dia x 5 Long Drive Lock Pin 1 4 x 1 75 Long 10 32 Hex Nut 3 8 24 Jam Nylok Locknut No 10 Lock Washer Square Key 093 x 75 Long 1 8 Dia Nylon Plug Thrust Washer Compression Spring Compression Spring 3 8 16 Dia Split Shaft Collar Straight Grease Fitting Relief Finger Reel Finger Slide Reel Finger Positioner Index Stop Pin Index Sensor Block Slide Washer Eccentric Index Pin Gib Stop Plate Adjustable Index Lever Locking Index Finger Pin 1 8 Diameter Nylon Plug Anti Rotation Plate Dovetail Gib Tee Knob Assembly Knob Assembly Index Finger Assembly High Index Lock Handle Weldment Index Finger Positioner Weldment 1 8 Diameter x 1 4 Long Pin Roll 6509358 Stop Plate 6509356 Reel Positioner Adjuster 6509574 STEPPER amp MOUNTING ASSEMBLY PARTS LIST DIAGRAM PARTS LIST Continued PART NUMBER B190613 B252011 C250825 C251020 6509381 J377200 6509384 3708187 3708189 3708192 3709304 6509048 6509051 6509056 3708629 3708424 1
39. UNDING INSTRUCTIONS ON PAGE 10 115 Volt Model Only Plug the power cord into a standard 115V AC 20 amp grounded receptacle See FIG 7 220 Volt Model Only For 220 Volt Applications order Part No 6320935 6320945 6520915 or 6520925 which includes a prewired 3 KVA 220 V step down to 110 V 50 60 Hz transformer should be ordered IT IS RECOMMENDED THAT THIS ACCU MASTER REEL MOWER GRINDER HAS ITS OWN PERMANENT POWER CONNECTION FROM THE POWER DISTRIBUTION PANEL WITH NO OTHER MAJOR POWER DRAW EQUIPMENT ON THE SAME LINE The grinder is equipped with a low voltage relay which is factory preset at 100 VAC If the power supply line does not deliver 100 VAC power under load the relay will open and trip out the starter If this occurs your power supply line is inadequate and must be corrected before proceeding further IT IS REQUIRED THAT THE POWER with the grinder DELIVERED THIS GRINDER 15 115 VAC 20 AMPS THE TOLERANCE ON THIS POWER REQUIREMENT 15 5 THEREFORE THE MINIMUM VOLTAGE REQUIREMENT IS 109VAC WITH 20 AMPS VOLTAGE MUST BE CHECKED WITH ALL EQUIPMENT UNDER LOAD OPERATING ON THE CIRCUIT FACTORY PRESET TRIP LIGHT INDICATES LOW DO NOT OPERATE THIS GRINDER WITH VOLTAGE AN EXTENSION CORD DELIVERED PROPER GROUNDING OF THE RECEPTACLE TO GRINDER GROUND IN YOUR BUILDING MUST BE VERIFIED IMPROPER GROUNDING IN YOUR BUILDING MAY CAUSE THE GRINDER TO MALFUNCTION FOR 20 AMP RATED LARGE MACHINES B
40. Y PARTS LIST 6329525 TRAVERSE BASE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Socket Head Cap Screw 10 24 x 3 8 Long Socket Head Cap Screw 10 24 x 3 4 Long Button Head Socket Cap Screw 1 4 20 x 3 8 Long Socket Head Cap Screw 1 4 20 x 1 2 Long Pan Head Machine Screw 1 4 20 x 1 2 Long Button Head Socket Cap Screw 1 4 20 x 1 2 Long Socket Head Cap Screw 1 4 20 x 3 4 Long Socket Head Cap Screw 1 4 20 x 7 8 Long Socket Head Cap Screw 1 4 20 x 1 1 4 Long Socket Head Cap Screw 1 4 20 x 2 Long Socket Head Cap Screw 1 4 20 x 4 Long Button Head Socket Cap Screw 5 16 18 x 1 2 Long Socket Head Cap Screw 5 16 18 x 1 Long Socket Head Cap Screw 1 2 13 x 2 Long Socket Head Set Screw Cup Point 1 4 20 x 1 4 Long 3 8 Diameter Roll Pin x 2 1 2 Long 1 4 20 Nylon Locknut Thin 1 4 20 Nylon Locknut 5 8 18 Nylon Locknut Thin 3 4 16 Nylon Locknut No 10 Washer 1 4 Flat Washer SAE 1 4 Split Lockwasher 5 16 Split Lockwasher 1 2 Split Lockwasher Square Key 1 8 x 3 4 Long Square Key 3 16 x 3 4 Long Traverse Pulley Support Traverse Pulley Shaft Drive Pulley Cog Idler Pulley Assembly Destaco Clamp Cog Belt Thrust Washer 1 1 400 x 3 4 ID External Retaining Ring Wave Spring 78 ID Wave Spring Compression Spring Spacer 5 8 OD x 9 32 ID x 3 8 Long Linear Ball Bearing PARTS LIST Continued 6329525 TRAVERSE BASE ASSEMBLY PARTS LIST Continued 6329525 TRAVERSE BASE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESC
41. ammable Logic Controller PLC Relay Board RT1 Termial Strip 1 TB1 Grinding Motor Relay REL Main Ground Lug AC Filter FTR Touch Screen Vacuum Relay RE34 Spin Drive Control Board SDC Traverse Drive Control Board TDC 24 VDC Power Supply PWR Blue Terminal Blocks TBB Grey Terminal Blocks TBG Low Voltage Relay LVR Magnetic Contactor MAG Main Circuit Breaker MCB ELECTRICAL TROUBLESHOOTING SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING This Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowledge and skills to reliably test and repair the ACCU 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 tel
42. ar Top Filler Weldment Guard Weldment RH Guard Weldment Boom LH Rear Panel Weldment Front Guard Door Assembly see page 55 R000480 8 Lock Washer R000558 8 32 Kep Nut 6529019 Flasher Base Assembly 6059526 WINCH AND BOOM ASSEMBLY PARTS LIST PARTS LIST Cont 6059526 WINCH AND BOOM ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Hex Head Cap Screw 3 8 16 x 1Long Hex Head Cap Screw 3 8 16 x 1 3 4 Long 3 8 16 hex Nut 3 8 16 Nylon Locknut 3 8 Flat Washer 3 8 Split Lockwasher Warning Decal Boom Capacity 7 Winch Handle Hook and Cable Assembly Pulley Guard Bracket Boom Weldment Boom Capacity Decal Winch Warning Decal Hook amp Cable Assembly is packed in carton assembly Install as shown cable runs down middle of boom tube PARTS LIST 6329533 FRONT GUARD DOOR ASSEMBLY PARTS LIST 6329533 FRONT GUARD DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Button Head Cap Screw 1 4 20 x 1 2 Long Button Head Cap Screw 1 4 20 x 1 1 2 Long Pan Head Machine Screw 8 x 3 4 Long 8 32 Nylon Jam Locknut 1 4 20 Nylon Jam Locknut 1 4 Flat Washer Flat Washer Door Safety Switch Coded Magnet Sharp Warning Decal 3 16 Blind Rivet Button Head Safety Screw 8 32 x 1 2 Long Extension Spring Black Pull Handle Front Outside Window Front Center Hinge Front End Hinge Center Window Support Spring Cover Sleeve Door Safety Switch Front Bottom Window Support Top Window Support
43. 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 the six 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 The proper belt tension for the grinding head is to push down on the poly V belt half way between to two pulleys with 5 lbs 2 kg of force and belt movement dimensions to be 12 inches 3 mm See FIG 18 To verify belt tension mount the belt guard with two screws Turn the motor on If the belt is tensioned correctly start up torque of the motor through the pulley to the belt should have zero slippage If there is belt slippage when turning on the motor there will be a slight squeal before the belt comes up to speed When you achieve correct tension reassemble all of the remaining parts that have been removed ADJUSTMENTS Continued INDEX FINGER PROXIMITY SETTING Set all motor switches to the off position Press the machine system start switch so the grinder is operational Push down on the index finger until the stop pin is within 06
44. coupling is loose No DC voltage to Stepper Infeed Control SIC No DC Voltage to OPTO terminal of SIC Checkout Procedure A Hold switch on in either direction B Move stepper in opposite direction C Reset circuit breaker switch tripped by current overload Grinding head stepper infeed mechanism jammed causing overload D Put switch on high speed rabbit for ease of checkout of Stepper Infeed Control SIC E You can feel stepper pulses on motor when HLS is on high or low amp IJS switch is depressed in either up or down direction Open stepper infeed inspection plate to check for loose coupling Retighten coupling to drive actuator screw See adjustment section of manual F SIC Check for 24 Volts DC Power in G SIC Check voltage at OPTO terminal Stepper motor works Yes end troubleshooting No go to Step B next Stepper Motor works Yes end troubleshooting No go to step C next Stepper Motor works Yes end troubleshooting No go to step D next High speed works Yes end troubleshooting No go to Step E next Stepper works Yes end troubleshooting No go to Step F next SIC Term GND to V measure 24 Volts DC Yes go to step G next No Skip to step H SIC Term GND to OPTO mea sure 24 Volts DC Yes go to step I No Replace wire 60 with resistor ELECTRICAL TROUBLESHOOTING Continued Possible Cause Mag contact or wire bad No Step pulse from PL
45. ction of Abrasive Wheels For your safety we suggest you benefit from the experience of others and carefully follow these rules DO DO always HANDLE AND STORE wheels in a CAREFUL manner DO VISUALLY INSPECT all wheels before mounting for possible damage DO CHECK MACHINE SPEED against the established maximum safe operating speed marked on wheel DO CHECK MOUNTING FLANGES for equal and correct diameter DO USE MOUNTING BLOTTERS when supplied with wheels DO be sure WORK REST is properly adjusted DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding DO always WEAR SAFETY GLASSES or some type of eye protection when grinding DON T DON T use a cracked wheel or one that HAS BEEN DROPPED or has become damaged DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole if wheel won t fit the machine get one that will DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURRS DON T TIGHTEN the mounting nut excessively DON T grind on the SIDE OF THE WHEEL see Safety Code B7 2 for exception DON T start the machine until the WHEEL GUARD IS IN PLACE DON T JAM work into the wheel DON T STAND DIREC
46. d Troubleshooting No Replace CB32 THIS PAGE LEFT INTENTIONALLY BLANK FOR NOTE TAKING PURPOSES MECHANICAL TROUBLESHOOTING Possible Cause Checkout Procedure PROBLEM Reels ground have high low blades Traverse Speed set to fast Check roundness using a magnetic base dial indicator Traverse speed should be set approximately 12 ft min 4 meters min if roundness is varying Lineal bearings for the grinding head Relubricate and adjust linear bearings per adjustment carriage are out of adjustment loose section If problem persists replace lineal bearings on or have grit buildup causing uneven the carriage base Check for any holes in the bellows traversing load that would permit any grinding grit penitration See adjustment section for lineal bearing replacement PROBLEM Excessive grinding stock being removed when traversing to the right in the relief grinding mode Gib adjustment for the relief finger assembly Tighten the set screws for the gib adjustment See is loose so reel finger has movement procedure in the adjustment section in the manual When traversing to the right minimum grinding stock removal should be seen as compared with heavy stock removal when traversing to the left PROBLEM Grinding stock removal from reel is irregular during spin grinding Lineal bearings on the grinding head The lineal bearing must be preloaded to the traverse carriage are too loose shafts with no vertical movement See manual adj
47. d 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 C DRIVE SYSTEM TRAVERSE CLAMP FORCE If the traverse clamp is slipping during regular 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 ADJUSTMENTS Continued ADJUSTING CROSS SLIDE ASSEMBLY If the cross slide becomes very difficult to turn it may become necessary to adjust the assembly To relieve the tension on the assembly follow the procedure listed below 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
48. d troubleshooting No go to Step B next Spin Motor works Yes end troubleshooting No go to Step C next Spin Motor works Yes end troubleshooting No go to step D next Spin Motor works Yes end troubleshooting No go to step E next SDC Term L1 to 4L2 for 115 Volts AC Yes skip to step H next No go to Step F next Light is ON Yes go to Step G next PLC RT1 cables or Software RT1 Term 9 to term 9 for 115 Volts AC No Check CB42 4 Amp for 115 Volts AC check from CB to Blue Terminal Block 17 Yes Replace relay 9 in RT1 SDC term A1 to term A2 measure approx 90 Volts DC Yes Skip to Step L No go to step 1 Next 50 term A1 to term A2 measure approx 12 Volts DC No Skip to step N Yes go to step J Next ELECTRICAL TROUBLESHOOTING Continued Possible Cause Relay 4 is bad Reversing relay s bad RT1 Spin Speed Pot SSP is not working Spin Drive motor is bad Worn motor brushes Checkout Procedure J Check RT1 for light 4 to be on Insure that Spin Drive switch has been pressed on from SPIN MANUAL screen at least once K With light 4 on verify continuity L Measure voltage at spin motor M Reverse direction of spin motor from SPIN MANUAL touch screen N SSP on Main Panel O With machine power off Check spin motor continuity P Inspect motor brushes Light is On go to Step K next Off Contact factory Remove one of th
49. e wires at Terminal 4 measure RT1 4 to 4 for 0 Ohms Yes Replace SDC No replace Relay 4 RT1 RT1 Term to term should read the same 90 Volts DC measured at step H Note polarity Yes Skip to Step O No go to Step M next RT1 Term A to term D should read the same 90 Volts DC measured at step H but opposite polarity Yes Skip to Step O No Replace relays A B C amp D in RT1 SDC Black wire of SSP H to Red wire of SSP W Pot full CCW Pot Full CW 4 4 Volts DC 0 Volts DC SDC White wire of SSP L to Red wire of SSP W Pot full CCW Pot Full CW 0 Volts DC 4 4 Volts DC Yes Replace SDC No Replace SSP At RT1 Term A and B or C and D check approx 0 ohms across the black and white wires Yes Motor should work end trouble shooting No go to Step P next Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10mm mini mum length Yes replace motor brushes No replace Spin Drive motor PROBLEM Spin Drive not working in manual jog mode and in RELIEF MODE Assuming 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3
50. elow is a list of required wire size in your building This is the wiring from the main panel to the grinder receptacle box For 0 to 40 Feet from panel to receptacle Use 12 Ga Wire For 40 to 60 Feet from panel to receptacle Use 10 Ga Wire For 60 to 100 Feet from panel to receptacle Use 8 Ga Wire For 100 to 160 Feet from panel to receptacle Use 6 Ga Wire For 0 to 12 Meters from panel to receptacle Use 4 0mm Wire For 12 to 18 Meters from panel to receptacle Use 6 0mm Wire For 18 to 30 Meters from panel to receptacle Use 10 0mm Wire For 30 to 48 Meters from panel to receptacle Use 16 0mm Wire ASSEMBLY INSTRUCTION Pantinnad For 220 V 50 or 60Hz applications Product No qam 14 25 GREEN 6320935 6320945 6520915 or W YALDW STRIPE 6520925 should be ordered GROUND WIRE TO BE These products includes a 3 KVA 220 Volt Step Down to 110 volt 50 60 Hz transformer which is prewired WANELLOW STRIPE The wiring diagram is shown in FIG 8 UGHT BLUE The power cord has no NEUTRAL L GHTBLUE connector A connector which NEUTRAL is appropriate for your locality and 220 volt 10 amp application should be installed USE ONLY A QUALIFIED ELECTRICIAN TO COMPLETE THE INSTALLATION Xi X3 H5 H1 INDIVIDU ALLY WIRE NUT TRANSFORMER LEADS H H4 H7 HS AND INSTALL THE GREEN W YELLOW STRIPE MRE SUPPLIED INTO THE TERMINAL BLOCK IN THE HOLE OPPOSITE WIRE X3
51. eplace or repair bad wire s ELECTRICAL TROUBLESHOOTING Continued Possible Cause No DC Voltage from TDC Traverse Drive Control Traverse Motor is bad Check Relays 2 and 3 TSP 10K is bad Gap between flag and prox is incorrect Proximity switch is bad Worn motor brushes Checkout Procedure H Check for 90 Volts DC across TDC terminals A to A2 this voltage drives the DC traverse motor NOTE Traverse must be on and have TSP turned full CW to maximum voltage of 90 VDC L Check traverse motor continuity J RT1 Verify that relay 2 light comes on when Traverse Right is pressed and that relay 3 light comes on when Traverse Left is pressed K Check TSP for 10 000 ohms Remove three wires from TDC red from term S2 white from term SO black from inline connector Wire 39 L Gap between flag and Prox should be 3 16 to 1 4 4 6mm Prox light does not light when flag is under prox M From the Touch screen Enter HELP screen from main menu N Inspect Motor Brushes Check terminals A1 to A2 for 90 Volts DC Yes go to step I next No go to Step J next Note lf voltage is less than 90 VDC verify pots on TDC See page 24 Remove wires from terminals A1 amp A2 0 ohms across the black and white wires Yes go to Step J next No go to Step N Lights come On go to step K next Off Skip to step L Check for 10 000 ohms red to white wires Full CCW 0 ohms F
52. fore proceeding further with the grinder N TRIP LIGHT INDICATES LOW VOLTAGE DELIVERED TO GRINDER So CONTENTS Safety Warnings Service Data Assembly Instructions Page 6 10 Maintenance Instructions Page 11 14 Adjustments Page 15 24 Machine Service Page 25 26 Elscirical Troubleshooing mer er a an Page 28 Electrical Troubleshooting Page 29 48 Mechanical Troubleshooting Page 50 51 Parts Lists Page 52 89 Electrical Diagrams Page 90 97 Separate Drawings Included in the Product Packet SERVICE DATA SKILL AND TRAINING REQUIRED FOR SERVICING This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the ACCU Pro or ACCU Master Grinder For those without that background service can be arranged through your local distributor This Manual presumes that you are already familiar with the normal operation of the Grinder 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 questions not answered in this manual please call your distributor They will contact the manufacturer if necessary TORQUE REQUIREMENTS GRADE2 GRADE5 GRADE 8 Throughout this manual we refer to
53. ft 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 30 Thoroughly clean the housing bore and the outside diameter of both bearings Apply blue Loctite 2242 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 Install the 9 16 18 Locknut 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 30 Ft Lbs Replace the square key and the pulley pushing the pulley against the locknut with no end play Apply blue Loctite to the bore of the puley before instation Next install blue Loctite 4242 on the pulley setscrews and tighten the two pulley set screws Then remount the poly V belt See Grinding Head Belt Tension Adjustment in the adjusting section Replace belt cover and square key and mount the left side grinding wheel grip knob and tighten the two set screws FIG 31 ACCU TOUCH CONTROL PANEL Stepper Infeed Controller SIC Door Safety Switch Monitor SSM Terminal Strip 2 TB2 Progr
54. hould never be above the 10 30 setting Relief Torque Pot RTP can vary the reel to finger holding torque for relief grinding The recommended starting point is 15 in Ibs of torque setting Never adjust the RTP potentiometer dial past the red line marking Setting the reel to finger torque to high could cause the traverse motor system to not operating smoothly In the Spin Grinding Mode The Remote Torque Potentiometer and the Spin Speed Pot SSP interact with each other The remote torque pot is located on the upper board of the Spin Drive Control SDC preset at 2 00 for torque setting The SSP is located on the control panel and is for spin speed adjustment See FIG 27B The Remote Torque Potentiometer controls maximum torque allowable in the spin grind cycle only This should never be adjusted past the 2 30 position The Spin Speed Pot SSP controls reel spin speed adjust as required This controls the spin drive speed for spinning the reel POTENTIOMETERS ON THE SPIN DRIVE CONTROL 50 LOWER BOARD See FIG 27A Maximum Speed Pot The maximum speed is factory preset to 4 30 fully clockwise to allow for maximum spin speed Minimum Speed Pot The minimum speed is factory preset at 8 30 full counterclockwise so zero speed is obtainable for spin speed IR Compensation Pot The IR Compensation is factory set at 9 00 Regulation of the spin or relief grind spin motor may be improved by a slight adjustment of the IR C
55. k wrap and cable tie that holds the winch trolley to the beam Lift Models Remove and discard the bolt used to hold the ramp up for shipping before using rear lift POSITION BASE The base should be placed on a relatively level concrete floor with ample ceiling height to allow for the installation of the unit Do not place the unit across two concrete slab seams or across a large crack The 632 ACCU Pro Spin Relief Grinder will require an operating area of about 150 W x 108 D x 87 H 381 x 274 x 221 cm The mower reel will be lifted from the front of the machine if using the boom and the rear if a lift is installed The machine operator will operate the unit from the front of the machine Position the base to allow sufficient operating room in front of the machine and behind if using the rear lift See FIG 2 The 652 ACCU Master will require an operating area of about 150 W x 108 D x 87 H 381 x 274 x 221 cm The reel mower assembly will be lifted from the front of the machine if using the boom and the rear if a lift is installed The machine operator will operate the unit from this same position Position the base to allow sufficient operating room in front of the machine See FIG 1 ASSEMBLY INSTRUCTIONS Continued Remove the carton and remove the contents from the carton onto a workbench The carton includes SPREADER BAR ASSEMBLY ONLY ON MODELS WITH PRODUCT e PACKET I SPIN DRIVE ADAPTER
56. led ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 155 force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Spin Speed Pot SSP set to zero Spin Motor Switch not on on Touch Screen Door is open Circuit breaker 42 is tripped 4A Relay 9 RT1 is not working Verify Light is on Verify Continutiy of relay 9 in RT1 Relay 4 RT1 is not working Spin Torque selector relay Checkout Procedure A Set SSP to 200 on the control panel B Turn spin drive switch on touch green area from SPIN MANUAL screen C Alarm on screen should indicate that the door must be closed for the spin drive to operate Close door D Reset circuit breaker switch Tripped by current overload check that reel is free spinning E Check for SDC input of 115 Volts AC F Check RT1 for light 49 to be on Door must be closed and spin drive switch on G With light 49 on Check RT1 relay 9 for continuity H With 115 Volts AC at Term L1 and L2 check SDC output Have Spin speed pot SSP set at 400 L With 115 Volts AC at Term L1 and L2 check SDC output Have Relief Torque Pot RTP set to Red Line Spin Motor works Yes en
57. ls you wiring information The first set of digits are the schematic wire number These identify the connection number Look at the column numbers on the left side of the schematic rung to identify the wire s The next number s are the Foley wire number The next group of numbers or letters are the code for the component to which the wire attaches Example RT1 for Relay Terminal 1 The last set of numbers or letters are the number of the terminal on the component to which the wire attaches ELECTRICAL TROUBLESHOOTING INDEX AC Main Power Controls Machine Light Spin Drive Controls in Spin Mode Page 31 32 Spin Drive Controls in Relief Mode Page 33 34 Grinding Motor Controls Dust Collector Controls Winch Controls Traverse Drive Controls w prox Page 38 39 Stepper Infeed Controls Page 40 41 System Error Messages Page 42 42 Flashing Light ELECTRICAL TROUBLESHOOTING Continued PROBLEM AC Main Power Controls no electrical power to control panel In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause You
58. must turn ON the Switch on the top of the control panel Main Power Cord is not plugged in Main 20 amp outlet circuit breaker has tripped in building panel Main 20 amp circuit breaker has tripped in machine panel No 115 Volts AC to Main Circuit Breaker No 115 Volts AC power from 2 Amp Circuit Breaker No 115 Volts AC power from Power Switch PSW No 24 Volts DC power from Power Supply Checkout Procedure A Look for Touch screen to come on B Plug in main power cord C Check circuit breaker and reset if necessary Check wall outlet with a light to make sure it works D Check circuit breaker and reset if necessary E Check for incoming power MCB for 115 Volts AC F Check for 115 Volts AC from 2 Amp Circuit Breaker H Check for 115 Volts AC from Power Switch L Check for 24 Volts DC from Power Supply PWR Machine works Yes end troubleshooting No go to Step B next Machine works Yes end troubleshooting No go to Step C next Machine works Yes end troubleshooting No but a light works in outlet go to Step D next No but light does not work in outlet You must solve your power delivery problem independent of machine Machine works Yes end troubleshooting No go to Step E next Check 115 Volts AC from MCB 01MBC brown wire to Blue Terminal Block TBB17 light blue wire Yes go to Step F next No Verify Filter function check wiring Check 115 Volts AC from 2 Am
59. ocking 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 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 NOTE Itis also possible to remove the complete Cross Slide Assembly and do the repairs on a bench then reinstall LOCK HANDLES HANDWHEEL ADJUSTMENTS Continued REEL LIFT PIVOT BOLTS There are four pivot bolts on the reel lift that must be adjusted correctly for proper lift function Tighten the screws and locknuts and then loosen 1 8 to 1 4 turn until the screw turns freely with fingers when the screw is under no load See items marked SCREWS AND LOCKNUTS below SCREWS AND LOCKNUTS ADJUSTMENTS Continued REEL LIFT SIDE BEARING ASSEMBLIES There are four side bearing assemblies two on each side on the reel lift The two on the right side looking from the front of the grinder are fixed with screws and washers The two on the left side looking from the front of the grinder are spring loaded against the lift frame They m
60. on Head Cap Screw 5 16 18 x 1 2 Long Button Head Cap Screw 3 8 16 x 3 4 Long Socket Head Cap Screw 3 8 16 1 Long 88 32 Nylon Jam Locknut 3110 24 Nylon Locknut 1 4 20 Nylon Locknut 5 16 18 Nylon Locknut 1 4 Split Lockwasher 5 16 Flat Washer SAE 5 16 Split Lockwasher 3 8 Flat Washer SAE 3 8 Split Lockwasher 2 Prong Knob Vacuum Hose End Adapter Vacuum Sizing Adapter Flat Washer 1 38 OD x 39 ID Liquid Tight Strain Relief 27 47 Wire Liquid Tight Strain Relief 19 30 Wire Strain Relief 22 25 Wire Liquid Tight Strain Relief 43 55 Wire Strain Relief 33 36 Wire Door Safety Switch Coded Magnet Door Safety Switch Assembly Socket Holder 3708416 Soft Latch 3708465 3 16 Blind Rivet No Fuel Warning Decal Multiple Safety Symbols Decal Patent Decal Button Head Safety Screw 8 32 x 1 2 Long 1 2 Hole Plug Rear Door Hinge Rear Door Bottom Rear RH Panel Bottom Rear LH Panel Rear Door Rubber Flap Rear Door Flap Bracket ACCUMaster Decal Lift Control Plate Canopy Side Foam Pad Canopy Rear Door Foam Pad Canopy Weldment LIFT Parts See Pages xx xx Lift Control Decal Lift Access Panel Button Head Cap Screw 1 2 13 x 1 1 2 Long 3709019 Thrust Washer B250805 Flat Head Cap Screw 1 4 20 x 1 2 Long 3707609 Fluorescent Machine Light Front Door Switch Cord Assembly Lift Power Cord W139 6529044 Rear Door Switch Cord Assembly 3708448 Electrical Warning Decal 6329530 MAIN CABINET ASSEMBLY PARTS LI
61. operly 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 needs to be maintained between the carriage proximity flag bracket and the proximity switch VIE 4 Wi See FIG 22 145 NOTE The light the proximity switch activates when metal crosses over the switch CARRJAGE PROX H 14 FLAG BRACKET 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 5mm See FIG 24 Adjust by moving the doors or brackers If this does not help a special wrench is needed to adjust the safety screws used to hold the switch in place ADJUSTMENTS Continued SPIN GRINDING ATTACHMENT ADJUSTMENT If free play develops so the crank handle wants to rotate with free play when operating in the scissor action raising and lowering on the spin grinding attachment the free play can be eliminated by tightening the set screw identified in FIG 24 If there is too much play in the spin drive pivot points torque down the hex nut tight so conical washer is compressed then back off 1 2 turn See FIG 24 TRAVERSE BELT TENSION To adjust the tension on the traverse belt tighten the screws and nuts locate
62. p B next From Help Screen verify Head in Relief Pos prox input is working Follow instructions on screen Clears Proceed to next system error message you have or continue run ning Clears Proceed to next system error message you have or continue run ning ELECTRICAL TROUBLESHOOTING Continued PROBLEM No Manual jog cycle or Auto Cycle stops because of a system error message on Touch Screen Continued System Error Message FINGER NOT RELEASED CHECK LH PROX POS POSITION MOVE NOT POSSIBLE IN PAUSE MODE MACHINE IS IN PAUSE MODE PRESS RESUME DOOR OPENED WHILE GRIND AND OR SPIN ON INCREASE TRAVERSE KNOB SETTING TRAVERSE TIMEOUT CHECK POT OR SETUP Checkout Procedure A During a relief grind cycle the PLC did not see the finger released at the left prox position Verify that the setting of the left traverse prox allows the finger to come off the blade B Check PLC input from Finger Stored Down prox A Press Resume on touch screen to finish current cycle A Machine was left in pause mode after last cycle Press resume on touch screen A Door was opened while potentially dangerous operations were still on Turn off motors pause or finish cycle before opening doors A An excessive amount of time has passed at the beginning of an auto cycle before the grind head assy has moved Increase Traverse Speed pot or check that carriage is not released A An excessive amo
63. p CB 157CB13 BL to Blue Terminal Block TBB17 light blue wire Yes go to Step H next No Check continuity of CB and replace Check 115 Volts AC from PSW terminal 3 to Blue Terminal Block TBB17 Yes go to Step I next No Check continuity of Switch and replace Check 24 Volts DC from PWR to V Yes Verify wiring to Touch Screen No Verify power to PWR Replace power supply ELECTRICAL TROUBLESHOOTING Continued PROBLEM Red E Stop screen displayed on Touch Screen In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause Checkout Procedure You must push the green A Listen for magnetic contactor Machine works Push to Start Switch PSS MAG to pull in with a clunk Yes end troubleshooting No go to Step B next Pull red e stop button out B Repeat push the green button Machine works SSS again Yes end troubleshooting No go to Step C next 115V power not delivered to C Check at Magnetic contactor coil MAG Term A1 to A2 for 115 Volts AC MAG coil for 115 Volts AC with main electrical Yes re
64. place magnetic starter if not power on and pushing SSS pulling in with click No go to Step D next Controller E stop ouput D Check on relay board RT1 for Light is relay on light on for output farthest light Off Controller software corrupt or to right missing or Relay Board not working On go to step E next Controller E stop relay no E With the machine power on RT1 terminals F to F for 115 Volts AC continuity Relay light on measure across Yes Replace output relay F in RT1 relay contacts No go to step F next SSS Is bad F With the machine power on SSS Term 3 to 4 for 115 Volts AC measure across normally open SSS not pushed 0 Volts AC SSS contacts of SSS pushed No Replace PSS Yes go to step G next ESS Is bad G With the machine power on ESS Term 1 to 2 for 0 Volts measure across normally closed ESS pulled out 115 Volts AC ESS contacts of ESS pressed in No Replace ESS Yes go to step H next Bad wires H With the machine power off Measure continuity of wires 1 12 15 22 verify continuity of wires and 35 37 50 59 60 146 147 148 149 amp connections 150 Replace any bad wires or repair loose connections ELECTRICAL TROUBLESHOOTING Continued PROBLEM Machine light is not working In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting belo
65. pyl alcohol Afterward a warm final wash should be made using a mild dish washing liquid detergent solution and ending with a thorough rinsing with clean water Minimizing Hairline Scratches Scratches and minor abrasions can be minimized by using a mild automobile polish Three such products that tend to polish and fill scratches are Johnson paste Wax Novus Plastic Polish 1 and 2 and Mirror Glaze plastic polish M G M10 is suggested that a test be made on a corner of the polycarbonate window with the product selected following the polish manufacturer s instructions Some Important DON TS DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows Never scrape polycarbonate windows with squeegees razor blades or other sharp instruments Benzene gasoline acetone or carbon tetrachloride should NEVER be used on polycarbonate windows DO NOT clean polycarbonate windows in hot sun or at elevated temperatures Graffiti Removal Butyl cellosolve for removal of paints marking pen inks lipstick etc The use of masking tape adhesive tape or lint removal tools works well for lifting off old weathered paints To remove labels stickers etc the use of kerosene VM amp P naphtha or petroleum spirits is generally effective When the solvent will not penetrate sticker material apply heat hair dryer to soften the adhesive and promote removal GASOLINE SHOULD NOT BE USED MAINTENANCE Continued
66. rved could result in damage to or destruction of equipment DON T OVERREACH Keep proper footing and balance at all times MAINTAIN GRINDER WITH CARE Follow instructions in Service Manual for lubrication and preventive maintenance DISCONNECT POWER BEFORE SERVICING or when changing the grinding wheel DO NOT USE SHARP OBJECTS ON THE TOUCH SCREEN Do not clean the touch screen with solvents USE RECOMMENDED ACCESSORIES Consult the manual for recommended accessories Using improper accessories may cause risk of personal injury CHECK DAMAGED PARTS guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced KNOW YOUR EQUIPMENT Read this manual carefully Learn its application and limitations as well as specific potential hazards KEEP ALL SAFETY DECALS CLEAN AND LEGIBLE If safety decals become damaged or illegible for any reason replace immediately Refer to replacement parts illustrations in Service Manual for the proper location and part numbers of safety decals DO NOT OPERATE THE GRINDER WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS IMPROPER USE OF GRINDING WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY Grinding is 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 Prote
67. s tripped No voltage to motor overload condition or wiring shorted to ground Reset breaker located at end of winch motor Check that motor coil cord from DC motor is plugged in Check for 115 Volts AC at the plug end winch cord wire 6 by plugging in a hand drill Check for Machine is plugged in Start button is pressed Red E Stop Screen must not be up Verify wiring from MAG to Terminal Strip 2 Yes end troubleshooting No go to Step B next Winch works Yes end troubleshooting No go to Step C next Drill works Yes replace winch No go to Step D next Winch works Yes end troubleshooting No go to Step E next Measure 115 Volts AC from TB2 6 to TB2 7 Yes replace cord to winch No Verify power out of mag Replace bad wiring ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse Drive not working in manual jog mode Assuming 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Po
68. ssible Cause Traverse Speed Pot TSP set to zero Traverse Belt Clamp release lever released Circuit Breaker 32 CB32 8 amp tripped Traverse Drive Control TDC do not have power Relay 8 RT1 is bad Circuit Breaker 32 CB32 bad Checkout Procedure A Set TSP to 35 on the control panel B Insure release lever is in adjusted properly See Adjustments section of this manual C Too heavy a grind causes grinding head traverse motor to overload and trip the circuit breaker Reset CB32 D Check for 115 Volts AC incoming to insure traverse right or left has been pressed at least once E Check for relay 8 RT1 light on insure traverse right or left has been pressed at least once F Check relay 8 for continuity Insure relay 8 light is on G Check CB32 for voltage Traverse works Yes end troubleshooting No go to step B next Traverse works Yes end troublshooting No go to Step C next Traverse works Yes end troublshooting No go to Step D next On Term L1 to L2 for 115 Volts AC Yes Skip to Step H No go to Step E next Light is On go to Step F next Off Contact Factory RT1 Term 8 to 8 read 115 Volts AC Yes Replace Relay 8 RT1 No go to Step G next CB32 from Line neutral Light Blue wire at the line filter wire O2FTRBU to wire 156CB32 BL at CB32 measure 115 Volts AC No Replace CB32 Yes Verify continutiy of wires to RT1 R
69. t 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 After all four linear bearings are reattached to the carriage check for correct bearing tension The bearing tension is correct when you try to lift the carriage and can feel no carriage movement which is free play up and down The most dependable method of checking free play is to use a magnetic base dial indicator attached to the traverse frame weldment and reading the vertical movement above each bearing This movement should be within 001 03 mm Also when pulling the carriage in the traversing direction there should be only approximately a 3 Ib force with the belt disengaged To check this attach a spring scale to the carriage and pull parallel to the carriage shafts To double check the assembly slide the carriage assembly from end of travel to end of travel it should have very uniform resistance through the full range of travel STEP 6 Replace the bellows carriage mounting brackets onto the carriage
70. te Pivot Knob Assembly T Knob Assembly Socket Head Cap Screw 5 40 x 38 Long Socket Head Cap Screw 8 32 x 5 8 Long 8 32 Hex Nut No 5 Split Lockwasher No 8Lockwasher Digital Gage Base Weldment Indicator 1 16 x 3 16L Roll Pin Socket Head Cap Screw 10 24 x 1 2 10 24 Nylok Locknut Reel Positioner Gage Drip Pan Weldment Amber lens Flasher bulb Socker Head Cap Screw 3 8 16 x 1 1 4 Long 5 16 18 Lock Nut 3 8 16 Nylok Locknut Flat Washer 1 00 OD x 375 ID x 188 T Warning Capacity Decal Spreader Bar Decal 5 16 18 x 3 U Bolt 1 1 2 Grab Hook Spreader Bar Weldment 3700089 Grinding wheel is installed on grinding head when shipped The other wheels are located in the carton assembly PARTS LIST 6529510 CONTROL PANEL ASSEMBLY 96 PARTS LIST 6529510 CONTROL PANEL ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Button Head Cap Screw 10 32 x 1 2 Long Button Head Cap Screw 1 4 20 x 1 2 Long Thread Cutting Screw 1 4 20 x 1 2 Long 1 4 20 Nylon Jam Locknut 1 4 Lock Washer Yellow Emergency Stop Ring Rocker Switch DPST 3 Amp Circuit Breaker 2 Amp Circuit Breaker 4 Amp Circuit Breaker Potentiometer Knob 15 Amp Circuit Breaker Green Start Pushbutton Normaly Open Contact Block Switch Mounting Latch Push Pull Red Emergency Stop Button Normaly Closed Contact Block Touch Screen Control Box Weldment Control Panel Decal Electrical Panel Sub Assembly Control Panel Top Weldment Potentiome
71. ter Assembly Spin Speed Potentiometer Assembly Relief Torque Potentiometer Assembly Traverse Speed Main Power Cord Light Receptacle Dust Collector Receptacle Flasher Cord Cable Tie Mount Cable Tie 6 5 Long x 18 Wide Cable Tie 4 0 Long x 10 Wide 6529511 CONTROL PANEL SUB ASSEMBLY PARTS LIST PARTS LIST 6529511 CONTROL PANEL SUB ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Pan Head Self Tapping Screw 6 x 3 8 Long Pan Head Self Tapping Screw 8 x 3 8 Long Pan Head Self Tapping Screw 8 x 3 4 Long 8 Lockwasher Terminal Strip Decal 20 Amp Main Circuit Breaker 8 Pin socket Primary Ground Decal Primary Ground Lug 24VDC Contactor Traverse Control Board Power Supply 40 Watt 24VDC Door Safety Switch Monitor 14 Din Rail Power Line Filter Relay DPDT 120VAC Coil Spin Relief Control Board Magnetic Starter Low Voltage Sensor Relay Aromat PLC Output Block with Relays Stepper Drive 2 Amp 6Pin Terminal Strip for Stepper Drive 9 Din Rail 2 Conductor Terminal Block Ground Screwless Terminal Bock End Stop Terminal Block Jumper Terminal Block End Plate 2 Conductor Terminal Block Grey 2 Conductor Terminal Block Blue Low Voltage Warning Decal Electrical Sub Panel 5 Amp Relay Block Terminal Block Marker 1 10 Terminal Block Marker 11 20 Ground Wire Assembly W99 PLC to Output Block Cable PLC to Touchscreen Cable PLC to Inputs Cable WIRING DIAGRAM 6524511 AC CIR
72. th the reel blade This is high point of the relief finger The right hand side of the grinding wheel is not in full contact for relief grinding See Operator s Manual for NORMAL HELIX AND REVERSE HELIX for information of dressing the grinding wheel PARTS LIST 6329537 CANOPY ASSEMBLY WINCH amp BOOM PARTS LIST 6329537 CANOPY ASSEMBLY WINCH amp BOOM DIAGRAM PART NUMBER NUMBER DESCRIPTION B250816 Button Head Cap Screw 1 4 20 x 1 2 Long Hex Head Cap Screw 1 4 20 x 5 8 Long Hex Head Cap Screw 1 4 20 x 1 2 Long Button Head Cap Screw 3 8 16 x 3 4 Long Socket Head Cap Screw 3 8 16 1 Long 1 4 20 Nylon Jam Locknut 1 4 20 Nylon Locknut 3 8 16 Nylon Jam Locknut 1 4 Flat Washer 1 4 Split Lockwasher 3 8 Flat Washer SAE 3 8 Split Lockwasher Flat Washer 1 OD x 44 ID 2 Prong Knob 3589106 Flat Washer 1 38 OD x 39 ID 3707009 Liquid Tight Strain Relief 27 47 Wire 3707029 Liquid Tight Strain Relief 19 30 Wire 3707093 Liquid Tight Strain Relief 43 55 Wire 3707595 7 8 Hole Plug 3707597 5 8 Hole Plug Electrical Warning Decal Sharp Warning Decal Plastic Rivet Respirator Warning Decal Hearing Protection Warning Decal No Fuel Warning Decal Multiple Safety Symbols Decal Spring Hinge Patent Decal Foley United Decal Gage Mounting Pin Side Frame Spacer Plate Canopy Boom Support Bracket Hinged Walker Panel ACCUPro Decal Door Guide Bracket RH Door Slide Door Guide Bracket LH Canopy Support Bracket Re
73. torque requirements as firmly tighten or the like For more specific torque values refer to the information below SMOOTH HEAD Bolts Going Into a Nut or Into a Thread Hole in SEE are TUNE germs Steel thread 0 8 kg m 1 25 1 8 kg m Refer to the table at the right 516 In 11 ft lbs 180408 28 ft lbs thread 1 5 kg m 2 5 kg m 3 9 kg m Bolts Going Into a Thread Hole in Aluminum Use the Grade 2 values in the table at the right thread 2 6 kg m 4 3 kg m 6 4 kg m Socket Head Screws Going Into a Nut or Steel Midi EL BE i i 1 2 In 45 ft lb 75 ft Ib 115 ft Ib Use the Grade 8 values in the table at the right ined re en u Machine Screws No 6 screws 11 in Ibs 0 125 kg m No 8 screws 20 in Ibs 0 23 kg m No 10 screws 32 in Ibs 0 37 kg m ASSEMBLY INSTRUCTIONS Remove the sides front and back of the crate Remove the plastic bag shrink wrap and bubble wrap around control panel Remove the metal clips that secure the grinder to the wood base With a fork lift raise the grinder from the wood base and set it in its final position See FIG 1 and 2 THE UNIT WEIGHS 1500 2000 LBS 680 907 kg TO LIFT USE POWER EQUIPMENT Remove shipping straps from traverse carriage Remove window protective sheets 652 ACCU Master Boom Model The winch boom is held in place during shipping with a steel brace Remove and discard this brace Remove the shrin
74. ull CW 10 000 ohms Red to black wires Full CCW 10 000 ohms Full CW 0 ohms Yes go to Step L next No replace TSP If incorrect adjust per adjustment section of manual Traverse works Yes End troubleshooting No go to step M next Follow instructions on screen to verify traverse proximity switches are ok Switch is Good Replace TDC Bad Replace switch Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Traverse Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Stepper Infeed not working in manual jog mode Assuming 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled ACCU Touch Wiring Diagram before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force all terminals to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Infeed Jog Switch is not held to on position Actuator is at physical limit Circuit Breaker CB13 is tripped 2 amp High Low Switch is not on high speed Stepper motor drive
75. unt of time has passed during a traverse cycle Increase Traverse Speed pot or verify that carriage assembly is not re leased or hitting an obstruction Message Status Clears Proceed to next system error message you have or continue running Remains go to Step B next From Help Screen verify Finger Stored Down prox input is Work ing Follow instructions on screen Clears Proceed to next system error message you have or Continue running Clears Proceed to next system error message you have or Continue running Clears Proceed to next system error message you have or Continue running Clears Proceed to next system error message you have or Continue running Clears Proceed to next system error message you have or Continue running ELECTRICAL TROUBLESHOOTING Continued System Error Message ACCEPT VALUES BE FORE RUNNING OPEN DOOR TO RESET LIGHT Checkout Procedure Message Status A Before an auto cycle can be Clears Proceed to next system error started verify the values in the message you have or continue run displayed boxes and accept them ning by pressing the Accept Values button on the touch screen A Before an auto cycle can be Clears Proceed to next system error started the last cycle completed message you have or continue run must be cleared Open the dooror ning press the Cycle Complete button on the main screen to reset ELECTRICAL TROUBLESHOOTING Continued
76. ust be adjusted correctly for proper lift function These left side screws can be accessed through two holes on the inside of the vacuum chamber Remove the vacuum cover and take out the vacuum There are two plastic plugs on the back wall of the vacuum chamber Remove these plugs and raise or lower the lift until the spring retainer screws line up with the holes Tighten the screws until tight springs solid with blue loctite no 242 then back the scres out ONE full turn See items marke B311613 below When complete reinstall plugs vacuum and cover LEFT SIDE LOOKING FROM FRONT OF GRINDER 3289109 BETWEEN SIDE PLATE AND BEARING SHAFT 8311013 RIGHT SIDE LOOKING FROM FRONT OF GRINDER CONTROL BOARD POTENTIOMETER ADJUSTMENTS SPIN DRIVE CONTROL BOARD SDC The Spin Drive Control Board has three potentiometers on the lower board and two potentiometers on the upper board as shown on drawing 6524511 which is included These potentiometers have been set at the factory to the positions shown on the drawing Also see FIG 27A and 27B In the Relief Grinding Mode The Remote Speed Pot and the Relief Torque Pot RTP interact with each other The remote speed pot is located on the upper board of the Spin Drive Control SDC preset at 9 30 The RTP is located on the control panel and is for relief torque adjustment See FIG 27B The Remote Speed Pot when rotated clockwise will increase maximum spin drive speed The remote speed pot s
77. ustment section for carriage linear bearing adjustments PROBLEM Carriage traversing varies speed while grinding Lineal bearings in the carriage do not rotate Check for grinding grit getting into the lineal bearings and freely cause excessive driving torque of carriage Abrasive noise is detectable when excessive grit is in the lineal bearings Replace the four lineal bearings in the main carriage Check bellows for holes and replace if necessary Traverse Belt is slipping Check the spacing of the clamp to the support block Clamp tip may need to be adjusted if the belt is slipping The belt may also be too loose See Adjustments section for proper measurements of clamp gap and belt tension MECHANICAL TROUBLESHOOTING Continued PROBLEM Too heavy a burr on cutting edge of reel blades Possible Cause Traverse speed set to 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 Checkout Procedure Traverse speed should be set lower approximately 12 ft min 4 meters min for a smaller burr on cutting edge Grinding head travel was not setup parallel to the reel center shaft in vertical and horizontal planes See Align the Reel Section in Operator s Manual PROBLEM Relief grind on the reel blades do not go the full length of the reel The right side corner of the grinding wheel is always to be in contact wi
78. w Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there 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 Light switches are not turned on or there is a bad bulb Wire cord is bad Wiring is bad Checkout Procedure A Turn on machine light toggle switch on light Check the light bulb in another light fixture or replace with a new bulb Plug a different light that is known to work into light plug B Check for 115 Volts AC at Terminal Strip C Check continuity of wiring from MAG to Terminal Block Light works Yes end troubleshooting No go to Step B next Check for 115 Volts AC across termi nals 6 amp 7 on Terminal Strip 2 TB2 Yes replace cord for light No go to Step C next Check wiring and tighten or replace any damaged or loose parts NOTE The light may flicker on and off when the grinding motor is turned on This is due to the high current draw on the system when starting the grind motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Spin Drive not working in manual jog mode and in SPIN MODE Assuming 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print tit
79. y 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 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 TRAVERSE BASE ALONE WITHOUT DUST PROTECTION COMPONENTS MAINTENANCE Continued CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE WINDOWS Cleaning Instructions DO NOT USE GASOLINE Adherence to regular and proper cleaning procedures is recommended to preserve appearance and performance Washing to Minimize Scratching Wash polycarbonate windows with a mild dish washing liquid detergent and lukewarm water using a clean soft sponge or a soft cloth Rinse well with clean water Dry thoroughly with a moist cellulose sponge to prevent water spots Do not scrub or use brushes on these windows Also do not use butyl cellosolve in direct sunlight Fresh paint splashes and grease can be removed easily before drying by rubbing lightly with a good grade of VM amp P naphtha or isopro

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