ASSEMBLY AND SERVICE MANUAL
Contents
1. FUSE 2 AMP 115 VAC MAIN POWER BLACK HITE amw BLACK POT SETTINGS 8 30 4 3 h ACTUATIR 50 41 40 8 51 40 GREEN W YELLOW T3MABL2 S2HAGL WHITE 45RE2 2 COOLANT PUMP W41 S2MAGLL 115 WC IN 160 30M613 30 680 GREEN W YELLOW 75 GREEN W YELLOW 32 40 15 VAC FRIM SPS 151 iH 2 GRIND NR 145 2004 SEPRI MPRX GREEN W YELLOW GREEN W YELLOW GREEN V YELLUN GREEN W YELLOW PARTS LIST Continued 6709523 ELECTRICAL ASSEMBLY DIAGRAM PART NO NO DESCRIPTION 6009196 Cord Assembly Main Power W32 6109052 Receptacle Cor W41 3707525 Fuse 15AmP Slo Blo 6709084 Cord Assembly Grind Motor W45 6009198 Traverse Motor Assembly W34 3707526 Bridge Diode 25 AMP s 6109053 Wire Assembly 25F 25F W42 3707400 Traverse Control Board 6002. PARTS LIST Continued 6709520 TRAVERSE amp CARRIAGE ASSEMBLY PART NO DESCRIPTION B191233 Phillip s Head Machine Screw 10 32 x 3 4 B250801 Hex Head Cap Screw 1 4 20 x 1 2 B251017 Round Head Machine Screw 1 4 20 x 5 8 251611 Socket Head Screw 1 4 20 1 251811 Socket Head Cap Screw 1 4 20 x 1 1 8 B311201 Hex Head Cap Screw 5 16 18 x 3 4 B371201 Hex Head Cap Screw 3 8 16 x 3 4 J251000 Hex Nut 1 4 20 K190001 Flat Washer 10 K191501 Split Lockwasher 10 K250001 Flat Washer 1 4 K251501 Split Lockwasher 1 4 K310001 Flat Washer 5 16 K311501 Split Lockwasher 5 16 K370001 Flat Washer 3 8 K371501 Split Lockwasher 3 8 3589081 Spacer 191ID x 438OD x 43L 3619224 Compression Spring 3708046 Grommet 3708147 Shoulder Bolt 375D x 625L 3708454 Warning Decal Release Actuator 3708457 Warning Decal Hot Surface 3709183 Wiper Seal 3709583 Flexible Coupling 3709613 Star Knob 5 16 18 3709635 Pillow Block Brearing 3849239 Carriage Drive Shaft 3969032 Seal Mount 6009068 Proximity Support Rail 6009070 Proximity Bracket 6009071 Proximity Sensing Bracket 6009074 Rubber Pad 6009108 Left hand Traverse Proximity Switch 6009109 Right hand Traverse Proximity Switch 6009152 Shaft Collar 6009153 Rubber Washer 6009155 Modified Release Actuator 6009198 Traverse Motor Assembly 6009548 Actuator Bar Assembly 6009549 Release Arm Weldment 6009572 Proximity Rail Weldment Clamp B191011 Socket Head Cap
3. Recheck the bearing tension The tension is correct when you try to lift the carriage and can feel no free carriage movement up or down Check for excessive carriage traverse load by using a spring scale to pull on the carriage parallel to the drive shaft as in FIG 19 There should be only about a 3 to 5 Ib pulling force To double check manually slide the carriage assembly from one end of its travel to the other There should be uniform resistance through the full range of travel 13 Slide the linear actuator under the carriage and line up the hole in the carriage with the tapped hole in the top of the actuator block Insert the actuator mounting screw through the self aligning bearing and tighten it Be careful not to cross thread the screw 14 Reinstall the feed screw guide mounting screws and then the actuator release lever into the linear actuator 15 If being used reattach the two carriage bellows Refer to the assembly section of this manual ADJUSTMENT Continued TO ALIGN THE MOTOR SHAFT AND DRIVE SHAF There must be 0 12 to 0 50 in 3 0 to 12 7 mm en clearance between the traverse motor output shaft an the drive shaft inside the flexible coupling FIG 27 To prevent drive shaft whipping at higher travers speeds the two shafts must be aligned so they ar concentric within 010 in 0 25 mm To align 1 Loosen the two set screw in the coupling 2 Remove the cover on the outside of the right leg 3 Loose
4. e and could damage the rail Bearings which are too tight too loose will FIG 21 Actuator Mounting Screw under the rubber CD splash guard Drive Shaft Seal Plate Actuator Release Lever Tension Adjustment Screw Radial Rotation ADJUSTMENTS Continued TO REPLACE THE CARRIAGE LINEAR BEARINGS 7 Attach the three linear bearing pillow blocks loosely to the bottom of the carriage with their tension adjustment Rear Pillow Blocks screws FIG 23 facing outward 22 Clean the carriage rails NOTE The two rails are interchangeable and are also reversible end for end Insert a rail through the rear two pillow blocks and align the rear pillow blocks to each other with a straight edge TETTE laid along their sides See FIG 25 When aligned tighten Carriage the four socket head screws which hold each rear pillow block Slide the other carriage shaft through the front bearing but do not tighten the socket head screws Lift the complete carriage assembly back onto the Grinder main base and secure the rear carriage rail to its V groove bosses with the six bolts With the front rail resting in the V groove bosses and the carriage approximately centered on the machine tighten the two outside socket head screws which secure the front pillow block Lift the front of the carriage and tighten the two inside pillow block screws Secure the front carriage rail to its V groove bosses with the six bolts
5. Reinstall the wiper plate screw which held the right end of the strap Discard the leg screw and the shipping strap Nut on Base of Machine Hex Jam Nut Leveling Foot ASSEMBLY INSTRUCTIONS Continued LOCATE AND LEVEL THE GRINDER Set the Grinder on a level concrete floor on a single uncracked slab of concrete If the unit must be located near a wall allow adequate space for operating and servicing Refer to FIG 3 for recommended and alternate locations near a wall Place a level on the front carriage rail near the center of the machine and check the level from left to right See FIG 4A Adjust the leveling feet until the machine is level Place the level across the front and rear carriage rails near the left end of the machine See FIG 4B Adjust the two leveling feet on the left end until the rear rail the one closest to the coolant tray is slightly lower than the front rail so any coolant on the carriage main base or optional bellows will drain back into the coolant tray Place the level across the front and rear carriage rails near the right end of the carriage bed Level the right end in the same way as the left end For grinding accuracy the two ends must have the identical backward slant within 01 25 mm so the frame is not twisted Recheck the level in both directions When satisfactory tighten the hex jam nuts on the leveling feet securely against the nuts welded to the bottom
6. Remove the screw to disconnect the actuator from thecarriage Remove the bolts which secure the front and rear carriage rails to the Grinder base six screws for each rail accessible from beneath the machine The carriage assembly weighs about 50 Ibs 23 kg If necessary get help for the following steps Lift the complete assembly carriage carriage shafts and grinding head out onto the table in front of the Grinder Be careful you don t damage the motor cord Lift the carriage and slide the rails out of the bearings one at a time Remove the three linear bearing pillow blocks four screws each from the bottom of the carriage and discard them at a time slide the three new linear bearing pillow blocks onto a carriage rail Adjust the tension screw FIG 23 on the side of each bearing block so that when you radially rotate the pil low block around the carriage See FIG 24 rail there is no free play between the bearing and rail You should feel a strong drag Repeat this adjustment to all three pillow blocks and then remove the pillow blocks from the carriage rail NOTE The tension is too tight if you feel a cogging action when you rotate a pillow block around the rail This cogging is caused by the bearing skidding on the rail Rocking the bearing block back and forth should be a smooth uniform motion cause poor grinding quality Bearings which are too tight will also have a much shorter life
7. bedknife See Operators Manual Take off about 002 to 033 05 to 075 mm per pass during rough grind See Operators Manual Set the traversing speed to 12 FT MIN Visually check the outside diameter run out while slowly rotating the wheel Also check the motor without a wheel installed Replace the wheel if out of round REASON When the front face of the bedknife gets too hot the steel loses its temper softens Too much stock removal in one pass creates too much heat and softens the steel Wheel will glaze if not dressed often enough Also as a general rule use a higher traverse speed for the heavy grind Wheel will glaze if not dressed often enough If grinding wheel is not extended 1 2 12 mm over bedknife it will glaze more quickly because there is less dressing Too light a grinding cut doesn t permit enough dressing action on the wheel so it glazes Too slow a traverse speed can cause excessive heat buildup in the grinding wheel which glazes the wheel A grinding wheel which isn t properly trued up on outside or inside diameters can vibrate excessively and transfer that vibration to the motor ELECTRIC SCHEMATIC 67095233 34 This Page Left Intentionally Blank for Note Taking Purposes 6709528 MAIN BASE ASSEMBLY PARTS LIST PARTS LIST Continued 6709528 MAIN BASE ASSEMBLY PART NO DESCRIPTION
8. Also check for any grinding grit buildup behind the gib Eliminate backlash in horizontal handwheel see Page 24 REASON When the rim doesn t extend over the top face it wears unevenly and causes grooves across the bed knife A loose gib backlash in infeed screw or grit buildup allows grinding head to move when grinding Traversing speed controls the grinding surface texture A slower traverse produces grind marks closer together A loose gib backlash in infeed screw or grit buildup allows grinding head to move when grinding TROUBLESHOOTING Continued PROBLEN The top face of the bedknife shows burn marks from being too hot Grinding wheel is glazing too quickly Grinding motor vibrates exces sively POSSIBLE CAUSE A Coolant not directed onto the bedknife and grinding wheel B Too heavy stock removal during grinding C Grinding wheel is glazing A Wheel needs dressing B Too light a cut when rough grinding C Grinding head is traversing too slow Grinding wheel is out of balance BEDKNIFE GRINDING REMEDY Direct coolant into the grinding wheel at the point of the grind See Operators Manual Take off about 002 to 003 05 to 075mm per pass during rough grind See Operators Manual Dress the wheel before the finish grinding pass on each bedknife See Operators Manual Dress the wheel before the finish grinding pass on each
9. B190613 Button Head Cap Screw 10 24 x 3 8 B190834 Button Head Cap Screw 10 32 x 1 2 B250816 Button Head Cap Screw 1 4 20 x 1 2 B251201 Hex Head Cap Screw 1 4 20 x 3 4 3708693 Button Head Cap Screw 5 16 18 x 1 2 B371201 Hex Head Cap Screw 3 8 16 x 3 4 B371211 Socket Head Cap Screw 3 8 16 x 3 4 B371601 Hex Head Cap Screw 3 8 16 x 1 D191067 Thread Cutting Screw AB 10 H371602 Roll Pin 375D x 1 00LG J197000 Insert Locknut Jam 10 24 J251000 Hex Nut 1 4 20 J257000 Thin Locknut 1 4 20 J317000 Nylon Locknut Jam 5 16 18 J317100 Nylon Locknut 5 16 18 4371000 Hex Nut 3 8 16 J501000 Hex Nut 1 2 13 K250001 Flat Washer 1 4 K251501 Split Lockwasher 1 4 K370001 Flat Washer 3 8 K371501 Split Lockwasher 3 8 3708388 Male Barb Connector 1 4509457 6709132 Plate Door Spring R H 3708604 Warning Decal Safety 3849294 Return Hose 1 3708569 Gas Spring 24 3708572 Stud Ball 10mm 3708577 D Handle 3709563 Adjustable Leveling Bolt 3709990 Large Foley United Decal 4509457 Grommet 6009008 Leg Brace 6009033 Right Hand Leg Frame Cover 6009510 Right Hand Leg Frame Weldment 6709022 Back Upper Tank Panel 6709026 Right Hand Upper Tank Panel 6709139 Left Hand Upper Tank Panel 6709130 Door Spring Bracket R H 6709119 Tank Cover Door 6709138 Left Hand Leg Cover 6709137 Left Hand Upper Cover 6709124 UPS Bracket 6709048 Machined Traverse Base 6709117 Hinge Cover 6709062 Upper Tank Side Bracket 6709063 Rubber Trim 36 6709071 Ferrule Handle 6709100 Guard Door Prox
10. Wire ASSEMBLY INSTRUCTIONS Continued FOR 220 V 50 or 60Hz applications Product No 6700951 should be ordered 6700951 includes a 2 KVA 220 Volt Step Down to 110 volt 50 60 Hz transformer which is prewired The wiring diagram is shown in FIG 8 The power cord has no connector A connector which is appropriate for your locality and 220 volt 8 amp application should be installed Use only a qualified electrician to complete the installation X 312 uM H2 We H B IMPORTANT GROUNDING INSTRUCTIONS In case of a malfunction of breakdown grounding reduces the risk of electrical shock by providing a path of least resistance for electrical current This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded according to all local or other appropriate electrical codes and ordinances Before plugging in the Grinder make sure it will be connected to a supply circuit protected by a properly sized circuit breaker or fuse Never modify the plug provided with the machine if it won 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 ASSEMBLY INSTRUC
11. critical for accuracy of grinding TROUBLESHOOTING Continued PROBLEN Top face of bedknife is ground ina convex shape high in the center POSSIBLE CAUSE A Grinding wheel loading up with grinding grit B Too heavy a grind on the final grinding pass C Gib screws loose or carriage infeed screw loose D Carriage has varying load in either direction because of grit buildup inside linear bearings E Rails not straight BEDKNIFE GRINDING REMEDY Dress the wheel prescribed in the Operators Manual Follow the procedures in the Operators Manual On the final pass crank down only about 001 025 mm Let the wheel spark out for 10 20 passes at about 5 ft min with no additional infeed Tighten gib screws to prevent movement See Page 23 Also check for any grinding grit buildup behind the gib Elimi nate backlash in horizontal handwheel See Page 24 With linear actuator released from the carriage check for a 5 Ib 2 25 kg maximum traversing load in both direc tions If load varies or car riage linear bearings are excessively noisy replace bearings See Page 19 Check straightness If not straight consult the factory through your distributor This is carefully checked at the factory so it is unlikely to be the cause REASON A loaded wheel creates undue pressure on the surface being ground Both ends of bedknife move because of this pressure allowi
12. from the ends of the machine and tighten their knobs Visually check that the grinding head will be able to traverse to both sides of the machine without contacting any components Turn all control panel switches OFF Set the TRAVERSE FT MIN knob to zero Close the guard door and press START Press CARRIAGE TRAVERSE to ON Set TRAVERSE FT MIN to a low speed and check that the grinding head runs through a complete traverse cycle Be prepared to press STOP if there is any interference Watch carefully for obstructions to the head travel and check that the grinding motor cord and proximity switch cords are not stretched NOTE If the unit doesn t begin a traverse cycle press the reset button on the motor contactor inside the control box See FIG 13 CHECK THE GRINDING MOTOR Turn all control panel switches OFF Close the guard door to connect the interlock Press START Press Grinding Motor Switch to ON Check that the grinding head runs properly Be prepared to press STOP if there is any problem NOTE If the grinding head doesn t begin properly press the reset button on the motor contactor inside the control box See FIG 13 CHARGING TO SUPPLEMENTARY POWER SUPPLY The Supplementary Power Supply SPS comes from the supplier with no charge When the machine is ready for operation plug it in and turn on the SPS The battery will charge in six hours For SPS functions refer to the separate manual supplied with the grinder MAK
13. not deliver 100 VAC power under EQUIPMENT ON THE SAME LINE load the relay will open and trip out the starter If this occurs your power supply line is inadequate IT IS REQUIRED THAT THE POWER and must be correct before proceeding further with DELIVERED TO THIS GRINDER IS 115 VAC the grinder 15 AMPS THE TOLERANCE ON THIS POWER REQUIREMENT IS 5 THEREFORE THE MINIMUM VOLTAGE WARNING REQUIREMENT IS 109VAC WITH 15 AMPS VOLTAGE MUST BE CHECKED WITH ALL FACTORY EQUIPMENT UNDER LOAD OPERATING ON PRESET THE CIRCUIT ADJUSTMENT WILL VOID DO NOT OPERATE THIS GRINDER WITH WARRANTY AN EXTENSION CORD PROPER GROUNDING OF THE RECEP ADJUSTMENT OF THE LOW TACLE GROUND IN YOUR BUILDING MUST VOLTAGE RELAY MAY CAUSE BE VERIFIED IMPROPER GROUNDING IN ELECTRICAL COMPONENT YOUR BUILDING MAY CAUSE THE GRINDER FAILURE ADJUSTMENT OF TO MALFUNCTION O THE LOW VOLTAGE RELAY WILL VOID ALL ELECTRICAL COMPONENT WARRANTY FOR 15 AMP RATED LARGE MACHINES For 0 to 30 Feet from panel to receptacle Use 14 Ga Wire For 30 to 50 Feet from panel to receptacle Use 12 Ga Wire For 50 to 80 Feet from panel to receptacle Use 10 Ga Wire For 80 to 140 Feet from panel to receptacle Use 8 Ga Wire For 0 to 9 Meters from panel to receptacle Use 2 5mm Wire For 9 to 15 Meters from panel to receptacle Use 4 0mm Wire For 15 to 24 Meters from panel to receptacle Use 6 0mm Wire For 24 to 42 Meters from panel to receptacle Use 10 0mm
14. of the base See FIG 2 Don t turn the leveling feet when tightening Again recheck the level after the nuts are firmly tightened DOES NOT HAVE TO BE PERFECTLY LEVEL HOWEVER IT IS CRITICAL THAT FRONT TO BACK LEVELING BE IDENTICAL BOTH ENDS OF THE MACHINE FOR GRINDING ACCURACY THE MACHINE INSTALL THE SPINNING HANDLES Install the spinning handle on the horizontal handwheels See FIG 5 Handle parts are packed in an envelope taped to the wheel 36 0 181 1 RECOMMENDED MINIMUM DISTANCES A Leveling Side to Side FIG 4 Regular Hex Nut Lock Nut FIG 5 ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT GROUNDING INSTRUCTIONS ON PAGE 9 03 115 Volt Model Only Plug the control box power cord into a standard 115V AC 15 amp grounded receptacle See FIG 7 220 Volt Model Only For 220 Volt Applications order Part No 6700951 which includes a 220 to 110 Volt Step Down Transformer See Details on page 9 IT IS RECOMMENDED THAT THIS ACCU PRO BEDKNIFE GRINDER HAS ITS OWN PERMANENT POWER CONNECTION FROM The grinder is equipped with a low voltage relay THE POWER DISTRIBUTION PANEL WITH which is factory preset at 100 VAC If the power NO OTHER MAJOR POWER DRAW supply line does
15. seal plates if applicable Be sure the seal plates are mounted concentric to the drive shaft Actuator Released FIG 18B ADJUSTMENTS Continued REPLACE THE LINEAR ACTUATOR BEARINGS Hold the drive shaft from rotating while you check 8 Slide the carriage over the actuator and line up the dick hole in the carriage with the tapped hole in the top of theactuator block Insert the actuator mounting screw through the self adjusting bearing and tighten the screw Install the two feed screw guide mounting screws Install the actuator release lever into the actuator bar assembly Turn the actuator release lever counterclockwise 1 2 turn to engage the actuator 10 Connect a spring scale so it pulls on the carriage parallel to the drive shaft Hold the drive shaft from rotating while you pull on the carriage See FIG 19 To overcome the actuator the pulling force should be 45 to 60 105 20 27 kg with 50 105 23 kg being ideal If not within those specifications the actuator tension must be adjusted See Adjusting the Pulling Force below Exceeding 60 Ibs force won t greatly improve drive performance and it will o shorten the bearing life Adjusting the Pulling Force If the pulling force is not within specification Step 10 above adjust it 1 With the actuator bearings engaged to the drive shaft readjust the two outboard screws with springs that hold the actuator together To reach these screws you m
16. 090 Wire Assembly 3Loop W58 6709089 Wire Assembly 3 Loop W59 6709078 Wire Assembly 25F 25F W60 6709081 Wire Assembly 25F 25F W61 6709079 Wire Assembly 25F 25F W62 6709080 Wire Assembly 25F 25F W63 6709097 Wire Assembly 25F 6FK W64 6709096 Wire Assembly 25F 6FK W65 6709082 Wire Assembly 25F 25F W66 6709083 Wire Assembly 25F 25F W67 6709095 Wire Assembly 25F 6FK W68 6709094 Wire Assembly 25F 6FK W69 3707428 Rocker Switch Mom On Off 3707515 Bridge Diode 10 AMPS 3707447 Relay DPST 120V Coil 3707518 Fuse 12AMP Slo Blo 3707367 On Off Switch 6709110 Wire Assembly STR FK W73 6709111 Wire Assembly STR FK W74 3707073 8 Pin Socket 3707539 Green Fluted Lens OOO NOU PARTS LIST Continued 17469909 COOLANT PUMP TANK ASSEMBLY PARTS LIST Continued 17469909 COOLANT PUMP TANK ASSEMBLY DIAGRAM PART NUMBER DESCRIPTION 3709642 Swivel Nozzle 3679116 Connector Shut Off Valve K190001 10 Flat Washer 10 24 x 1 Socket Head Cap Screw 10 Lockwasher Split Shut Off Valve Barbed Connector Pump 115V Connector Barbed Insert Tank Coolant Cover Coolant Tank Divider Coolant Tank 5 Divider Coolant Tank 6 5 Instruction Sheet Coolant Tank Coolant Hose
17. 18B Drive Shaft Remove the feed screw guide two mounting screws Seal Plate and slide the grinding head assembly back Lift the rubber splash guard to expose the actuator mounting screw FIG 17 on the top side of the carriage base Remove the mounting screw to disconnect the linear actuator from the carriage Slide the carriage assembly to one side Disconnect the shaft seal plate FIG 17 from each side of the linear actuator Slide the seals down the drive shaft until they are out of the way If the optional carriage bellows were installed the shaft seals may already have been removed Remove the shoulder bolts holding the six bearings three on each side to the actuator block Remove the old bearings and discard them but save the inside Actuator Release Lever S JW washers and shoulder bolts Inspect the hole from which the bearing and shoulder bolt were removea for foreign matter Clean thoroughly Wipe the drive shaft clean and dry Actuator Engaged force may have to be set too high in the following procedure This will shorten O the bearing life If is left on the drive shaft the pulling Insert the shoulder bolts through the new bearings and through the inside washers saved in Step 6 Then install the complete bearing assemblies into the actuator block and tighten the shoulder bolts Be very careful not to cross thread the bearing bolts Reinstall the shaft
18. 9180 Wire Assembly 25 6 W02 3707429 Rocker Switch On Off 3707523 Stop Pushbutton 3709509 Start Pushbutton B192013 Button Head Cap Screw 10 24 x 1 25 3707219 Fuse 2 AMP Slo Blo 3707087 Magnetic Starter 1 HP R000483 Internal Tooth Lock Washer 3707091 Fuse Block 6709112 Wire Assembly STR FK W75 3707092 Fuse 1 AMP Slo Blo 6709087 Wire Assembly 2 Loop W70 6009110 Wire Assembly 6FK 6FK W18 6009109 Right Hand Traverse Proximity Switch W38 6009108 Left Hand Traverse Proximitiy Switch W37 6009113 Wire Assembly 6 6 W16 6009202 Wire Assembly 6FK 6FK W23 6709099 Wire Assembly 2 Loop W72 R000553 Kep Nut 10 24 6009117 Wire Assembly 25F 6FK W28 6009118 Wire Assembly 6FK 10RG W30 6009204 Wire Assembly 6FK 6FK W15 6709113 Wire Assembly STR Fk W76 6709093 Wire Assembly 25 6 W53 6009181 Wire Assembly 25 6 W03 3707489 Lamp 24V 073 AMP 3707488 Amber Fluted Lens 6009199 Traverse Pot Assembly W35 3707219 Fuse 2 AMP Slo Blo 6009201 Wire Assembly 6 6 W39 6009104 Wire Assembly 25FK 6FK W29 6709072 Actuator Transformer Assembly W46 6709074 Magnet Assembly W47 3707487 Pilot Lamp Socket 6709077 Wire Assembly 25F 25F W49 6709085 Actuator Cord Assembly Switch W50 6709073 Magnetic Transformer Assemby W71 6709086 Transformer Cord Assembly W51 6709076 Battery Assembly W52 6709100 Proximity Door Assembly W54 6709092 Wire Assembly 25F 6FK W55 6709088 Wire Assembly 3 Loop W56 6709098 Wire Assembly 2 Loop W57 6709
19. ACCU Pro MODEL 670 SEMI AUTOMATIC BEDKNIFE GRINDER 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 Caution Symbol identifies special instructions or procedures which if not correctly followed could result in damage to or destruction of equipment The Warning Symbol identifies special instructions or procedures which if not strictly observed 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 or expose it to rain Keep work area well lighted 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 bedknife is securely fastened wi
20. AUSE A Traverse Motor Switch is not on Traverse motor does not work B Blown fuse C No voltage going to motor D Bad traverse motor REMEDY Turn on motor switch Replace the 2 amp slo blo fuse on the control board and decrease stock removal rate Replace actuator bearings if they are worn and do not rotate freely For more detail see actuator maintenance in the adjustment section of the manual Replace the lineal bearings in the main carriage Carriage should traverse freely with a 3 Ib maximum loading Also check for excessive bearing preload For more detail see carriage bearing replacement in the adjustment section of the manual Check for 90 volt DC at the circuit board leads going to the motor Across terminals A1 and A2 check reading with a voltage meter When there is voltage from the circuit board but DC motor does not run check wiring and connections The voltage reading varies with speed pot setting NOTE Make sure speed pot setting is towards the maxi mum dial reading for 90 volts Check for incoming voltage at L1 to L2 for atleast 105 Volts AC Red power light is on Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 9 5 mm minimum length and look at wear pattern on commuter for arcing Replace brushes if necessary Replace motor if brushes are good Remove wires from A1 to A2 from the spin motor Check wi
21. E ELECTROMAGNETS DURING A POWER INTERUPTION HAS A BATTERY THIS BATTERY HAS A THREE YEAR LIFE AND MUST BE REPLACED AFTER THREE YEARS OF SERVICE LIFE SEE THE PARTS LIST FOR REPLACEMENT BATTERY PART NUMBER Carriage Bellows Foam Rail Wipers FIG 15 MAINTENANCE Continued LUBRICATION Actuator and Linear Bearings Do the following every six months or more often if the linear actuator seals are squeaking 1 Thoroughly clean the carriage rails drive shaft and shaft seals Wipe the shafts and seals thoroughly with a clean rag While cleaning traverse the carriage several times to clean the full length of the drive shaft and rails Flood spray all three shafts with WD 40 or an equivalent lubricant do not use a Teflon based lubricant until lubricant drips off the shafts Then run the carriage back and forth through its range of travel to carry lubricant onto the outer surface of the actuator bearings and the inner surface of the seals NOTE Because of the flood of lubricant you may find that the actuator slips and traversing is erratic or stalls This is not a problem as it will be corrected in Step 3 With a clean rag wipe the excess 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 feel dry IMPORTANT If the machine will be shut down for more than one month flood the shafts and other appropriate parts
22. E FINAL PREPARATIONS FOR OPERATION Carefully read the operating instructions in the Operators Manual First study the pages titled Getting to Know Your Grinder and General Operating Information for important background explanations about the machine and about bedknife grinding Then read the Operating Instructions pages for step by step procedures on mounting the bedknife and grinding its top and front faces MAINTENANCE DAILY MAINTENANCE IS SPECIFIED ON PAGE 4 OF THE OPERATOR S MANUAL AND IS TO BE PERFORMED BY THE OPERATOR LISTED BELOW ARE PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY S MAINTENANCE DEPARTMENT 1 Lift the bellows See FIG 14 if used and wipe off the traverse driveshaft and the bearing rails monthly When a squeaking noise is coming from the actuator bearings follow the lubrication procedure for actuator and linear bearings Generally this will be every 6 months to a year Check the gib plate adjustment in the carriage base every 3 months See Page 21 Replace the four foam rail wipers FIG 15 every 6 months of operation Note Wipers are removed if optional bellows are installed Clean the interior and the top cover of the Coolant Tank as necessary and at least every 6 months Check the brushes on the auto traverse drive motor once every 24 months Replace as necessary THE UNINTERUPTABLE POWER SUPPLY UPS WHICH IS USED AS A BACKUP TO HOLD THE BEDKNIFE TO TH
23. Head Cap Screw 1 4 20 x 7 8 Washer 25 x 62 OD x 12 Socket Head Cap Screw 3 8 16 x 3 4 Set Screw Cap Point 1 4 20 x 3 8 Socket Head Cap Screw 10 24 x 3 4 6709523 CONTROL PANEL ASSEMBLY PARTS LIST Continued PARTS LIST Continued DIAGRAM NO B130812 B161014 B190809 B192013 B192811 B371001 J317100 K371501 R000480 R000483 R000553 R000557 R000558 3707066 3707087 3707091 3707279 3707370 3707400 3707416 3707428 3707429 3707367 3707446 3707447 3707487 3707488 3707489 3707509 3707073 3707515 3707523 3708448 3709809 3709864 6009062 6009199 6709068 6709070 6709072 6709073 6709091 6709507 3707273 3709304 3707526 3707074 B161614 3707539 6709128 3707548 6109523 CONTROL PANEL ASSEMBLY DESCRIPTION Phillip s Head Machine Screw 6 32 x 1 2 Phillip s Head Machine Screw 8 32 x 5 8 Round Head Machine Screw 10 24 x 1 2 Button Head Cap Screw 10 24 x 1 25 Socket Head Cap Screw 10 24 x 2 00 Hex Head Cap Screw 3 8 16 x 5 8 Nylon Locknut 5 16 18 Split Lockwasher 3 8 External Teeth Lock Washer 8 Internal Teeth Lock Washer 10 Kep Nut 10 24 Kep Nut 6 32 Kep Nut 8 32 Strain Relief Wire 22 23 Magnetic Starter 1HP Fuse Block Strain Relief Wire 30 Diode Heat Sink Bridge Traverse Control Board Strain Relief Wire 33 36 On Off Switch Momentary On Off Switch On Off Switch Pot Knob with Pointe
24. IN PLACE DON T JAM work into the wheel DON T STAND DIRECTLY 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 bedknife from a reel mowing unit ONLY Any use other than this may cause personal injury and void the warranty This machine is intended for indoor use only To assure the quality and safety of your machine and to maintain the warranty you MUST use original equipment manufactures replacement O parts and have any repair work done by a qualified professional ALL operators of this equipment must be thoroughly trained BEFORE operating the equipment Do not use compressed air to clean grinding dust from the machine This dust can cause personal injury as well as damage to the grinder Do not use a power washer to clean the machine Low Voltage Relay WARNING The grinder is equipped with a low voltage relay which FACTORY is factory preset at 100 VAC If the power supply line PRESET does not deliver 100 VAC power under load the rela
25. O ELIMINATE CARRIAGE INFEED BACKLASH If there is backlash in the carriage infeed handwheel FIG 35 there are two adjusting points to check 1 Conical washers behind the shaft adjusting nut A Unscrew the shoulder bolt B Hold the horizontal handwheel and turn the shaft adjusting nut counterclockwise until the conical washers are touching each other Continue turning the nut counterclockwise until the next notch is centered over the shouder bolt hole Then turn the nut one notch 409 further Reinstall the shoulder bolt to lock the nut in position 2 Washers behind the handwheel A Remove the setscrew holding the calibration ring to the handwheel Go through the set screw hole and loosen the setscrew holding the handwheel to the shaft about one half turn Tighten the hex nut which secures the hand wheel to 100 in Ibs 1 15 kg m then back it off 1 2 turn Check for 015 in 0 4 mm gap between the wave washer and flat washer See the insert to FIG 35 Readjust the hex nut if necessary Tighten the set screw holding the handwheel to the shaft Reinstall and tighten the calibration ring setscrew Shoulder Bolt Horizontal Handwheel Hex Nut Wave and Flat Washers Conical Washers behind adjusting nut ADJUSTMENTS Continued POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL TDC Min Speed Factory set at full CCW 8 30 Do not change this setting Right Traverse Forward Torque Factor
26. PROX RH PX2 TRAVERSE PRIX LH REL RELAY RE2 RELAY 2 VIS VOLTAGE SENSOR SOCKET SSS SYSTEM STAR TOC TRAVERSE DR TRANSFORMER TF2 TRANSFORMER TMS TRAVERSE MJ TRAVERSE SPH SWITCH VE CONTROL MAGNETS ACTUATOR OR SWITCH ED POT SOAMS 4 6854 8116 5 S0AMS 6 L 6 TSP WIRE 35 SOEMS 5 BSTFZBL ATMGTL L15VAC 11111 88 BL TF 39114 9 B 9 0 3810C12 81 REV 50 60 KL Hz 30 3570 9 BK 3 101112131415 fr ACC 30 35TDC 8_ RED DIELL 5 MX SPO 33 TIME R COMP 9 0 7 WHT ED DELL 2 REV L PROX 1 FID LIMIT s GREEN 234567 99999600 REV 1d 4 30 N SP 7 57800 1 DR JISVAC 4RE2 8 EVERSE FORWARD PER EN 212 112 55223 rq
27. Screw 10 24 x 5 8 B250601 Hex Head Cap Screw 1 4 20 x 3 8 B252406 Socket Head Cap Screw 1 4 20 x 1 1 2 K251501 Split Lockwasher 1 4 3559117 Carrier Shaft 3709040 Spherical Bearing 3709044 Bushing Ball Bearing 3969004 Carriage Base 3969063 Sponge Wiper Holder 3969064 Sponge Wiper 3709668 Socket Head Screw 3709597 Sealed Bearing 3709596 Spacer 3709469 Compression Spring B253211 Socket Head Cap Screw 1 4 20 x 2 PARTS LIST Continued 6709524 BEDKNIFE SUPPORT ASSEMBLY PARTS LIST Continued PART NO B190411 B190605 B191011 B191611 B250611 B251211 B253611 B371611 C190420 C310420 6709518 H250802 H251202 H251406 H251802 K310101 H251602 J371000 J377000 J377100 4507000 K191501 K250001 K251501 K371501 3579109 6709127 6709519 3708245 3708393 3708554 3708563 3708564 3708330 3708702 3708694 6709135 3708701 3708581 3709016 3709062 3709304 6009035 6009036 6009095 6709004 6709526 6709107 6709008 6709011 6709012 6709013 6709015 6709016 6709021 6709134 6709058 6709108 6709136 6709061 6709501 6709506 3708593 6709510 B251411 3708691 B371211 C250627 B191211 6709524 BEDKNIFE SUPPORT ASSEMBLY DESCRIPTION Socket Head Cap Screw 10 24 x 1 4 Flat Head Socket Cap Screw 10 24 x 3 8 Socket Head Cap Screw10 24 x 3 8 Socket Head Cap Screw 10 24 x 1 Socket Head Cap Screw 1 4 20 x 3 8 Socket Head Cap Screw 1 4 20 x 3 4 Socket He
28. TIONS Continued INSTALL THE OPTIONAL CARRIAGE BELLOWS if ordered Optional carriage bellows are available to keep excess grindings dirt etc out of the carriage assembly To install the two bellows 1 Remove the left and right outside leg panels 2 Remove the shaft seal on each side of the linear actuator See FIG 9 NOTE When the bellows are used the shafts don t get lubricated and the seals would run dry They would then become noisy and not operate properly To remove the seals Crank the carriage all the way toward the front that is toward the operator s position Remove the actuator mounting screw on top of the carriage See FIG 9 Then push the carriage toward the right end of the Grinder Loosen the two set screws in the bearing pillow block at each end of the drive shaft Loosen the two set screws in the drive coupling at the right end of the carriage Turn the actuator release lever clockwise 1 2 turn until the actuator is released from the shaft See FIG 9 Slide the drive shaft out the left end of the machine Remove the shaft seals from the actuator two screws each Reinstall the drive shaft The right end of the shaft inside the coupling should be 1 8 1 4 3 to 6 5 mm from the end of the motor shaft Retighten all set screws Push the carriage back to the left and reattach the actuator with the mounting screw See FIG 9 Turn the actuator release lever 1 2 turn Remove the two rail wiper bra
29. ad Cap Screw 1 4 20 x 2 1 4 Socket Head Cap Screw 3 8 16 x 1 Set Screw Cup Point 10 24 x 1 4 Set Screw Cup Point 5 16 18 x 1 4 Gage Spring Retainer Assembly Roll Pin 25D x 50LG Roll Pin 25D x 75LG Drive Lock Pin 25D x 875LG Roll Pin 25D x 1 125LG Flat Washer 5 16 Roll Pin 25D x 1 00LG Hex Nut 3 8 16 Nylon Locknut Jam 3 8 16 Nylon Hex Locknut 3 8 16 Nylon Locknut 1 2 13 thin Split Lockwasher 10 Flat Washer 1 4 Split Lockwasher 1 4 Split Lockwasher 3 8 Nylon Plug 3 16 Diameter Electromechanical Actuator Pivot Bearing Assembly T Knob 2 5 3 8 16F Handwheel 3 5 Diameter Compression Spring 6250D x 3 0L Retaining Extension Ring 5100 118 Oilite Thrust Bearing 1 251D Shoulder Bolt 50D x 4 0L Button Head Socket Cap Screw M3 5 x 30 Linear Bearing Wide Rail Bellows 25 70 Button Head Socket Cap Screw M3 5 x 16 Inch Dial Indicator Thrust Washer Conical Washer 382 x 75 x 035 Thrust Washer Locking Stud Shaft Acme Adjusting Shaft Slide Shaft Machined Tooling Bar Tooling Mounting Bracket Assembly Tooling Slide Mounting Left hand Pivot Plate Index Stop Bracket Right Hand Gage Base Left Hand Gage Base Retainer Block Gage Gage Shaft Gage Tip Bearing Block Lock Block Decal Upper Tooling Index Cross Slide Support Wide Machined Rail 25 70 Decal Lower Tooling Index Tee Knob Assembly Right hand Magnet and Block Assembly Key 5 16 SQ x 1 2 Left Hand Magnet and Block Assembly Socket
30. ckets from each side of the carriage two screws each See FIG 11 Attach the outer end of each bellows to the Grinder leg panel See FIG 10 Use six bolts and hex nuts at each end The bolt heads go on the bellows side of the brackets Attach the inner end of each bellows to the carriage See FIG 11 Use four L brackets two on each side of the last bellows fold six bolts and two hex nuts at each end Nuts are required only for the lower holes of the L brackets Press the bellows down until it snaps onto the carriage rails Reattach the left and right outside leg panels Actuator Mounting Screw under the rubber splash guard 27 Drive Shaft Seal Plate Actuator Release Lever ASSEMBLY INSTRUCTIONS Continued INSTALL THE COOLANT TANK Assemble the Coolant Tank as outlined in the instructions Part No 7467909 in the coolant tank carton Center the Tank under the Grinder Plastic Adapter Install the 1 I D drain tubing over the barbed end of the Tubing plastic adapter on the coolant tray drain Cut the tubing to i the proper length to reach about 1 1 2 40 mm into the j Prefilter Sock large opening on top of the Coolant Tank See FIG 12 A pre filter sock is shipped with the Tank Install it onto the tubing using the plastic tie provided Drop the other end of Coolant the sock into the opening on top of the Tank Tank Read the coolant mixing
31. directions and the electrical FIG 12 warnings in the Coolant Tank instructions USED TO HIGH A CONCENTRATION OR LOW CONCENTRATION WILL CAUSE CORROSION AND PERFORMANCE PROBLEMS THE COOLANT RATIO AS SPECIFIED MUST BE Be sure the COOLANT PUMP switch is OFF Mix Part No 3708620 coolant in the coolant tank at a ratio of 50 parts water to 1 part concentrate This will take about 6 gallons of water and 1 pint of concentrate 24 liters of water and 0 5 liter of concentrate Refer also to the label on the coolant container and the instructions packed with the Coolant Tank CHECK THE COOLANT PUMP Plug the pump motor cord from the top of the Tank to the female connector from the control box RISK OF ELECTRICAL SHOCK MAKE CERTAIN THAT THE ABOVE ELECTRICAL CONNECTION IS SECURED ABOVE AND AWAY FROM POSSIBLE CONTACT WITH THE COOLANT Reset Button Turn all control panel switches OFF Close the guard door and press START Press Coolant Pump Switch to ON Check that the Coolant System functions properly Be gt prepared to press STOP if there is any problem i Due oi NOTE If the unit doesn t begin to pump coolant press the reset button on the motor contactor inside the control box See FIG 13 Secure any excess electrical cord to a crossbar on the underside of the machine ASSEMBLY INSTRUCTIONS Continued CHECK THE CARRIAGE TRAVERSE Move the proximity switch assemblies to about 12 300 mm
32. e to the grinder is inadequate and must be corrected AC voltage power source required These wires control magnetic starter voltage for main power Overload may have been tripped when moving machine or machine grinding head motor overload or electrical power surge TROUBLESHOOTING Continued ELECTRICAL Insufficient hesitation at carriage stops prior to reversing traverse direction for relief grinding If the carriage traverses to one end of stroke or the other and it stops and does not reverse direction If the carriage traverses past the proximity switch and keeps on traversing in same direction Traverse changes directions erratically while running in traverse cycle POSSIBLE CAUSE The dwell time on the traverse drive control not set properly Proximity switch is not working properly or wire connections are loose The two proximity switches have been reversed on the slide bar Proximity switch has failed Loose wire to proximity switch REMEDY Reset dwell time on traverse control board as required one increment increases dwell time by 1 2 second See Page 50 First check to see if proximity light comes on when placing a steel piece over the prox switch When the lightis on it means that there is electricity coming to proximity switch Left proximity PROX 1 check Traverse Drive Control TDC between terminals 14 black wire and 15 bro
33. er s instruc tions Some Important DON TS li 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 e The use of masking tape adhesive tape or lint removal tools works well for lifting off old weathered paints Toremove 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 ADJUSTMENTS TO REPLACE THE LINEAR ACTUATOR BEARINGS Actuator Mounting NOTE Do not remove the linear actuator from the drive O 2 shaft Only remove the bearings from the actuator block 1 Crank the horizontal handwheel until the carriage is all the way forward toward the operator position 2 Turn the actuator release lever 1 2 turn clockwise to release the linear actuator bearings from the drive shaft Slide the actuator release lever out of actuator bar assembly by loosening the retainer shaft collar which preloads the holding spring See FIG 18A and
34. he Operators Manual Follow the procedures in the Operators Manual On the final pass crank down only about 001 025 mm Let the wheel spark out for 10 20 passes at about 5 ft min with no additional infeed Tighten gib screws to prevent movement See Page 23 Also check for any grinding grit buildup behind the gib Elimi nate backlash in horizontal handwheel See Page 24 With linear actuator released from the carriage check for a 5 lb 2 25 kg maximum traversing load in both direc tions If load varies or car riage linear bearings are excessively noisy replace bearings See Page 19 Check straightness If not straight consult the factory through your distributor This is carefully checked at the factory so it is unlikely to be the cause REASON A loaded wheel creates undue pressure on the surface being ground Both ends of bedknife move because of this pressure allowing bedknife to rock on the middle support For precise grinding sparking out process is critical It eliminates exces sive final grinding pressure on centers and middle support which helps maintain grinding straight ness A loose gib backlash in infeed screw or grit buildup allows grinding head to move when grinding Uneven loading because of grit buildup in bearings can affect the straightness of grinding When grit buildup is excessive bearings may be noisy and must be replaced Straightness of rails is
35. imity Assembly 6709101 ACCU Pro Decal 6709505 Water Tank Base Weldment 6709512 Left Hand Leg Frame Weldment 6709129 Door Plate 3708378 Foam Strip 25 Thick 6709131 Door Spring Bracket L H 6709133 Plate Door Spring L H B251616 Button Head Socket Screw 1 4 20 x 1 B311613 Button Head Socket Cap Screw 5 16 18 x 1 0 B311213 Button Head Socket Cap Screw 5 16 18 x 3 4 6709125 UPS Top Shield B251016 Button Head Socket Cap Screw 1 4 20 5 8 R000454 Flat Washer 437 x 1 0 x 08T O YN 0 a a 5 2 OOO YN OCCO QD N 32 O O 0101010101 03 01 01 03 gt 4 PHP C ON 00 44 0 5 ON 00 10 03 FW PARTS LIST Continued 6709529 GRINDING HEAD ASSEMBLY PARTS LIST Continued PART NO B190811 B191233 B251616 B255011 B371211 C190820 C250420 C252420 C310420 J197000 J251000 J252000 J257000 J377000 K190001 K191501 K251501 3709705 K371501 6709103 3589081 3589106 3700409 370041 1 3702086 6709513 3708121 6709509 6709552 3708553 3708561 3708691 3709062 3709204 3709370 3709526 3709620 3709809 3809047 6009024 6009025 6009034 6009044 6009136 6109013 6709000 6709030 6709035 6709037 6709038 6709039 6709501 6709502 6709503 6709529 GRINDING HEAD ASSEMBLY DESCRIPTION Socket Head Cap Scre
36. items before discarding Inspect all items for shipping damage as they are removed from the shipping containers If you find any damage notify the carrier s claims agent and do not proceed further until the damage has been inspected by the agent Refer also to the Shipping and Receiving Instructions packed with the unit Remove the Coolant Tank carton from under the machine Remove the control box from under the machine Be careful of the electrical wiring which was preconnected at the factory Install the Control Box Attach the control box to the right front end of the machine using the two 3 8 16 x 5 8 hex head bolts and two lock washers provided See FIG 1 The fasteners are shipped in an envelope inside the control box carton Remove the Grinder from the Pallet To remove the Grinder from the wood pallet 1 Unbolt the brackets that hold each end of the Grinder legs to the bottom of the pallet The Grinder s four leveling feet FIG 2 are seated in countersunk holes in the pallet Lift one end of the machine until both feet are out of their holes 3 Prop this first end up with sturdy boards or other supports so the feet remain out of their holes then lift the other end and remove the Grinder from the pallet THE GRINDER WEIGHS 780 LBS 354 KG TO LIFT USE POWER EQUIPMENT OR GET ADEQUATE HELP Remove the shipping strap that secures the grinding head and carriage to the left end of the machine during shipment
37. n the two bolts which secure the motor assembly to the leg 4 Visually align the two shafts then tighten the motor mounting bolts Reinstall the leg cover 5 Check that the spiral gaps in the flexible coupling are equally spaced with no compressio or extension load on the coupling then tighten th coupling screws Check that the bearing load block is at 90 to the drive shaft within 1 4 degree Use a precision square held against the bearing shoulder and the rear rail as in FIG 26 TO ALIGN THE REAR RAIL AND DRIVE SHAFT The rear carriage rail and the drive shaft must be precisely aligned 1 Loosen the two bolts holding the bearing suppor blocks at each end of the drive shaft FIG 28 2 Align the drive shaft and rear carriage rail FIG 29 so the distance between their facing surface is 3 375 010 85 75 mm 0 25 See FIG 29 Then tighten the support block bolts Check that the bearing support blocks are still a 90 to the drive shaft within 1 4 degree Use a precision square held against the bearing shoulder and the rear rail If you have difficulty obtaining the above alignmen check the straightness of the carriage rails see below NOTE The vertical and horizontal straightness of th rails is very accurately set at the factory so they ar unlikely to be incorrect Contact the factory if you sus pect a problem after making the following tests If the drive shaft is adjusted you may have to
38. ng bedknife to rock on the middle support For precise grinding spark ing out process is critical It eliminates excessive final grinding pressure on centers and middle support which helps maintain grinding straightness A loose gib backlash in infeed screw or grit buildup allows grinding head to move when grinding Uneven loading because of grit buildup in bearings can affect the straightness of grinding When grit buildup is excessive bearings may be noisy and must be replaced TROUBLESHOOTING Continued PROBLEN The top face of the bedknife is ground unevenly across the width Too coarse a grind on bed knife The amount of stock removed varies when traversing in opposite directions POSSIBLE CAUSE A Grinding wheel rim is not completely over the top face being ground B Gib screws loose or carriage infeed screw loose Grinding head is traversing too fast A Gib screws loose or carriage infeed screw loose BEDKNIFE GRINDING REMEDY The wheel rim must extend over the bedknife top face by 1 2 13 mm whenever possible See Operators Manual If not possible dress the wheel more often Tighten gib screws to prevent movement see Page 23 Also check for any grinding grit buildup behind the gib Eliminate backlash in horizontal handwheel see Page 24 Slow down the traversing speed to 12 FT MIN Tighten gib screws to prevent movement see Page 23
39. oltage not going to mag netic starter Solenoid in magnetic starter does not pull in Solenoid pulls in but no voltage out of magnetic starter G Voltage is not going through interlock relay ELECTRICAL MAIN POWER REMEDY Turn switch on Reset breaker turn switch on and plug machine in Press System Start Switch Close the guard door Check status of the low voltage relay inside the control box With the volt meter set on AC voltage check L1 black to L2 white for lines coming in of 115 volt Check power source fuse Check for loose connections on magnetic starter Check for 115 Volts AC across starter coil A1 to A2 NOTE Contactor clicks when engaging Check for 120 volt AC between terminals T1 black and T3 white T1 and T3 are main power out lines NOTE T2 is jumpered to 13 Check reset overload on starter by pushing down on blue button Check terminal connections between contactor and overload relay If no voltage on output replace magnetic starter Check for 115 VAC at incoming side of relay Terminals 4 amp 8 Check for 115 VAC at output side of relay terminals 2 amp 6 Checks must be done with guard door close Relay Coil engaged REASON Because the guard door is interlocked to the grinding motor the grinding motor will not operate if door is open If norm light is lit relay is satisfied and line voltage is acceptable If trip light is lit line voltag
40. r 120V Coil Pilot Lamp Socket Amber Fluted Dome Lens Lamp 24V 073AMP Start Pushbutton Assembly 8 Pin Socket Diode Bridge 10 AMP Stop Pushbutton Assembly Warning Decal Electrical Shoulder Bolt 375D x 375L Tinnerman Nut Electrical Box Cover Traverse Pot Assembly Painted Pivot Bracket Box Control Panel Decal Actuator Transformer Assembly Magnetic Transformer Assembly Warning Decal Control Box Weldment Strain Relief Thrust Washer Bridge Diode 25 AMP Voltage Sensor 100VAC Phillip s Head Machine Screw 8 32 x 1 Green Fluted Dome Lens Battery Assembly UPS Battery Replacement UPS 3115 PARTS LIST Continued 6709523 ELECTRICAL ASSEMBLY SGESS 2 D BRIDGE DIODE ACTUATOR 02 BRIDGE DIODE MAGNETS FUSE 3 12 AMP FUSE 4 12 AMP ESS EMERGENY STOP SWITCH 67045232 Bias 9 12 97 OES 1 7 CLE A CPS COOLANT PLMP SWITCH FUL FUSE 1 1 AP WRECNMCUN 1 FUSE 2 2 AMP i GMS GRIND MOTOR SWITCH T MAG MAGNETIC STARTER AMS ACTUATOR MOTOR SWITCH EMS ELECTRO MAGNET SWITCH 2884 IMA 9005 4 28705 1 721 5 S 7018 2 50042 6SGHS 5 TOCPS 2 1720PS 5 55095 34 A TERM TO TERM CONNEC PXI TRAVERSE
41. realign the motor shaf and drive shaft see above Looser m align Flexible Shaft Traverse 012 to Matar 0 50 in Loosen lo aign ADJUSTMENT Continued TO ADJUST THE PROXIMITY SWITCHES For the proximity switches to work properly and reverse the direction of the carriage at each end of a traverse a distance of 3 16 in 1 32 4 75 mm 0 75 must be maintained between the top of the switch and the actuator bracket on the bottom of the carriage See FIG 33 To adjust the clearance loosen one of the switch mounting nuts while tightening the other TO ADJUST THE GIB PLATE The gib plate must be readjusted occasionally to eliminate free play Otherwise the grinding head can move from side to side and the bedknife may be ground unevenly The gib must allow the carriage to be cranked freely forward and back without any side play See FIG 34 To adjust 1 Crank the carriage all the way forward toward the operator position Tighten the front gib screw until the carriage has no side play but the horizontal handwheel can still be cranked Crank the carrige gradually back away from theoperator position and adjust the remaining gib screws as you go Proximity Switch 3 16 31 32 4 75 mm 20 75 between sensing bracket and switch Proximity Sensing Bracket Carriage Front Gib Screw ADJUSTMENTS Continued T
42. s to not rotate freely For more detail see actuator setting in the adjustment section of the manual TRAVERSING REASON Driving torque is lost because the oil is decreasing friction for driving linear actuator bearings Grinding grit over a period of time does get into the lineal bearings and cause excessive drive torque of carriage Abrasive noise is detectable when excessive grit is in the lineal bearings When bearing preload is too tight it causes excessive loading to drive the carriage When lineal actuator is disengaged the proper traverse load 2 to 3 Ib Use a tension scale to check A general guide only NOTE Check with linear actuator released When actuator spring tension is excessive bear ings will not rotate freely causing carriage to not run freely TROUBLESHOOTING Continued PROBLEN POSSIBLE CAUSE Actuator drive shaft whipping excessively at high traverse speed A Bearing shaft support blocks are not perpendicular to carriage shaft B Drive shaft is bent C DC drive motor shaft not concentric to drive shaft REMEDY Loosen the screws that retain the shaft support blocks on each end of the actuator shaft Use a square to align bearing face 90 degrees to the front rail and holding the actuator shaft to the front rail to 3 375 dimension For more detail see align front rail and drive shaft in the adjustment section in the manual Turn the actua
43. th the electromagnets provided before operating 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 REDUCE THE RISK OF UNINTENTIONAL STARTING Make sure the switch is OFF before plugging in the Grinder 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 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 Protection of Abrasive Wheels For your safe
44. th the ohm meter for 0 ohms across the white and black wires TRAVERSING REASON Extremely heavy grinding cuts cause excessive loading of the motor Worn and binding actuators causes heavy loading to motor Grinding grit over a period of time does get into the lineal bearings and causes excessive drive torque of carriage This checks to see that voltage is getting to the control board A short brush does not make an adequate electrical connection to run the electrical motor NOTE Brushes are long lived and seldom need replacing TROUBLESHOOTING Continued Traverse speed control goes at one speed only POSSIBLE CAUSE A Wiring hookup to potenti ometer is improper If compo nents have been replaced B Defective speed control potentiometer C Main circuit board dial pot settings not correct If board has been replaced REMEDY TRAVERSING REASON Check potentiometer wiring for Wrong wire hookup effects proper hookup See that speed pot is wired per electri cal diagram Check Potentiometer on control panel Check Petentiometer for 10 000 ohms Remove three wires from Traverse Drive Control red from term 8 white from term 7 black from term 9 Check all pot settings on circuit board as shown in wiring diagram See adjust ment section Traverse Motor Control Board Settings traverse control Reversing red and orange wires to poten
45. this manual please call your distributor They will contact the manufacturer if necessary TORQUE REQUIREMENTS Throughout this manual we refer to torque requirements as GRADE 2 GRADE 5 firmly tighten or the like For more specific torque values refer to the information below Bolts Going into a Nut or Into a Thread Hole in Steel SMOOTH 3 MARKS 6 MARKS Refer to table at the right HEAD onHEAD on HEAD 1 4In 6 ft lbs 9 felbs 13 ft lbs Bolts Going into a Thread Hole in Aluminum thread 0 8 1 25 1 8 kg m Use the Grade 2 values in the table at the right 5 16 In 110408 18ftlbs 28 ft lbs thread 1 5 2 5 kg m 3 9 kg m e eee 3 8 In 1944 31 25 46 ft lbs Use the Grade 8 values in the table at the right thread 2 6 kg m 4 3 kg m Machine S 7 16 In 30ftlbs 50ftlbs 75 ft lbs acnine screw thread 4 1 kg m j 6 9 kg m 10 4 kg m No 6 Screws 11in Ibs 0 125 kg m 1 21 458408 75ftlbs 115 ft lbs No 10 Screws 32 in Ibs 0 37kg m ASSEMBLY INSTRUCTIONS NOTE For clarity the Grinder is shown on the following pages without the optional carriage bellows installed UNPACK THE CARTONS NOTE Before you install the machine read the following assembly procedure completely Then study Getting to Know Your Bedknife Grinder in the Operators Manual Use care when unpacking Double check the packing cartons for any miscellaneous
46. tiometer the DC motor will run at zero speed but maximum will be too slow Reversing red and white wires does not affect speed control Traverse Drive Control Pin 8 to 7 Pot Full CCW 0 VDC Pin 8 to 9 Pot Full CCW 9 75 VDC If Yes pot is O K If No go to step below Pot Full CW 9 75 VDC Pot Full CW 0 VDC Check for 10 000 ohms red to white wires Full CCW 10 000 ohms Full CW 0 ohms Red to black wires Full CCW 0 ohms Full CW 10 000 ohms If Yes pot is O K If No replace potentiometer Wiper inside of potentiometer controls speed Wiper may be bad and not making contact Minimum and maximum pot settings effect traverse speed TROUBLESHOOTING Continued PROBLEN POSSIBLE CAUSE MECHANICAL Carriage traversing varies speed while grinding A Oil on carriage drive shaft B Lineal bearings in carriage do not rotate freely Traverse speed is too slow A Lineal bearings in the carriage are set too tight B Actuator springs set too tight REMEDY Wipe oil completely from shaft Spray down with WD 40 and wipe off Replace the lineal bearings in the main carriage For more detail see lineal bearing replacement in the adjustment section of the manual Readjust bearings for proper tension For more detail see lineal bearing replacement in the adjustment section of the manual Check to see if actuator bearings have been over loaded causing the bearing
47. tor screw clockwise 1 4 to 1 2 turn to release actuator from the drive shaft Slide the carriage to one end of the machine Mount indicator in the middle of the two bearing support blocks Check for a maximum of 015 indicator reading when you rotate the shaft Replace shaft if required NOTE Item A above must be done proper to this step Loosen two bolts holding the motor Align the motor shaft concentric to the drive shaft See if coupling spiral gaps are equally spaced when re aligned For more detail see Traverse Motor Coupling in the adjustment section TRAVERSING REASON Misalignment of shaft support blocks to carriage traverse rod causes a bow in the rod This bow will cause an out of balance which in turn will cause it to whip at high traverse speeds Excessive bend in the shaft will cause the shaft to whip at high traverse speeds Side load at the shaft end will bend the shaft and cause it to whip at high speed traversing TROUBLESHOOTING PROBLEN Top face of bedknife is ground ina concave shape low in the center POSSIBLE CAUSE A Grinding wheel loading up with grinding grit B Too heavy a grind on the final grinding pass C Gib screws loose or carriage infeed screw loose D Carriage has varying load in either direction because of grit buildup inside linear bearings E Rails not straight BEDKNIFE GRINDING REMEDY Dress the wheel prescribed in t
48. ty 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 6 DO be sure WORK REST is properly adjusted 7 DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel DO allov 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 10 DO TURN OFF COOLANT before stopping to avoid creating an out of balance condition 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 BURNS 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
49. ust FIG 20 remove the actuator bar assembly See FIG 17 Turn each outboard screw an equal amount when resetting Turn clockwise for more tension If the actuator release lever is Check the force again repeat Step 10 above tightened too much it will Continue adjusting and rechecking until within contact the outboard screw specification heads and override their adjustment which could cause a traverse malfunction Make certain that you have full engagement when you reengage the actuator NOTE The factory adjusted position to reach tension specifications is to compress the spring until there is 22 in 5 5 mm clearance between the underside of the washer and the actuator block See FIG 20 Use this as a starting point unless you are already close to the specified tension When the tension adjustment is correct reinstall the actuator bar assembly and actuator release lever ADJUSTMENT Continued TO REPLACE THE CARRIAGE LINEAR BEARINGS NOTE Set a small bench or table near the center front of the machine for use in the following procedure Remove the optional carriage bellows if used from the carriage Remove the actuator release lever from thelinear actuator Remove the complete carriage assembly from the machine A Remove the two feed screw guide mounting screws and pull the grinding head assembly back Lift the rubber flap and expose the actuator mounting screw FIG 22 on the top side of the carriage base
50. w 10 24 x 1 2 Phillip s Head Machine Screw 10 32 x 3 4 Button Head Cap Screw 1 4 20 x 1 Socket Head Cap Screw 1 4 20 x 3 1 8 Socket Head Cap Screw 3 8 16 x 3 4 Set Screw 10 24 x 1 2 Set Screw Cup Point 1 4 20 x 1 4 Set Screw Cup Point 1 4 20 x 1 1 2 Set Screw Cup Point 5 16 18 x 1 4 Locknut Insert Jam 10 24 Hex Nut 1 4 20 Jam Nut Hex 1 4 20 Locknut Thin 1 4 20 Locknut Jam Nylon 3 8 16 Flat Washer 10 Lockwasher Split 10 Lockwasher Split 1 4 Nylon Plug Lockwasher Split 3 8 Outer Flange 3 0 OD 5 8 1 Spacer 19110 x 4380D x 43L Flat Washer 39 x 1 38 x 125 Bushing Reducer 1 25 62 Straight Grinding Wheel Cup 6 x 2 x 1 252 Diamond Dresser Motor 1HP C Face Mount Double Tube Clamp Dresser Arm Weldment Grinding Wheel Guard Weldment Compression Spring 7810 7 0L Lock Handle Flat Washer Conical Washer 382 x 75 x 035 Thrust Wahser 375 x 812 Handle Ball Knob 1 4 20 Conical Washer 512 x 1 0 x 035 Shoulder Bolt 375D x 375L Clear Indicator Backlash Nut Gib Plate Calibrated Ring Handwheel 4 50 Diameter Model Feed Screw Guide Acme Adjusting Shaft Slide Carriage Base Rubber Cover Handle Stud Dresser Lock Bracket Adjuster Collar Rubber Cover Bracket Tee Knob Assembly Motor Pivot Assembly Eccentric Pin Assembly 6709520 TRAVERSE 8 CARRIAGE ASSEMBLY inued PARTS LIST Cont 99 9 e 7 5 7 gt NX Vi gt J y N 7 fe Be 7N
51. well time at 2 seconds etc Diagnostic LED s indicate the function that is currently being performed POWER indicates that ac power is being applied to the control FORWARD indicates that the process is running in the forward direction traversing left REVERSE indicates that the process is running in the reverse direction traversing right PROX 1 FWD LIMIT lights when the forward limit switch is actuated left prox PROX 2 REV LIMIT lights when the reverse limit switch is actuated right prox DWELL lights when the process remains stopped after a proximity switch is actuated FULL FULL FOR 50 OR 60 HZ CN CY 15 08 12 13 14 CO E212 2 2C REV ACC FWD ACC IR COMP SPD REV TR CN FWD TR N 8 30 4 30 4 30 9 00 3 30 8 30 8 30 9 00 FULL FUL FULL 2345587283910 MIN SPD O OOOO OOOO ONO Potentiometer Clock Orientation POT SETTINGS TROUBLESHOOTING ELECTRICAL PROBLEN POSSIBLE CAUSE Grinding motor do not function no apparent power to ma chine A Grinding Motor Switch GMS is not on B Main power source breaker is tripped power source switch is off or grinder is not plugged in C System Start Switch SSS is not on D Guard door is not closed E Insufficient Line Voltage to power the low voltage relay F V
52. with lubricant as outlined above and leave the lubricant in place until the unit will be used again Then repeat the above lubrication procedure before operating MAINTENANCE Continued CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE WINDOWS Cleaning Instructions DO NOT USE GASOLINE Adherence to regular and proper cleaning procedures is recommended to preserve appearance and performance Washing to Minimize Scratching Wash polycarbonate windows with a mild dish washing liquid detergent and lukewarm water using a clean soft sponge or a soft cloth Rinse well with clean water Dry thoroughly with a moist cellulose sponge to prevent water spots Do not scrub or use brushes on these windows Also do not use butyl cellosolve in direct sunlight Fresh paint splashes and grease can be removed easily before drying by rubbing lightly with a good grade of VM amp P naphtha or isopropyl alcohol Afterward a warm final wash should be made using a mild dish washing liquid detergent solution and ending with a thorough rinsing with clean water Minimizing Hairline Scratches Scratches and minor abrasions can be minimized by using a mild automobile polish Three such products that tend to polish and fill scratches are Johnson paste Wax Novus Plastic Polish 1 and 2 and Mirror Glaze plastic polish M G M10 It is suggested that a test be made on a corner of the polycarbonate window with the product selected following the polish manufactur
53. wn wire Right proximity PROX 2 check TDC between termi nals 13 black wire and 15 brown wire Replace proximity switch if the voltages do not read as above Reverse the switch assembly on the slide bar Make sure the proximity light is coming on when placing a steel piece over the prox switch Check proximity spacing to the sensor If no light first check adjustment section for proximity setting If there is a light it means that there is electricity coming to the proximity switch Left proximity PROX 1 check TDC between terminals 14 black wire and 15 brown wire Right proximity PROX 2 check TDC between terminals 13 black wire and 15 brown wire Replace proximity switch if the voltages do not read as above Check wire connections from the proximity switches and tighten down screws TRAVERSING REASON The light coming on shows the proximity is getting electrical contact Proximity light on 0 Volts DC Proximity light off 12 Volts DC Proximity light on 0 Volts DC Proximity light off 12 Volts DC This will only happen if the main reversing board has been replaced and not rewired to electrical dia gram Proximity light on 0 Volts DO Proximity light off 12 Volts DC Proximity light on 0 Volts DO Proximity light off 12 Volts DC A loose wire connection will give intermittent electrical contact TROUBLESHOOTING Continued PROBLEM POSSIBLE C
54. y ADJUSTMENT will open and trip out the starter If this occurs your WILL VOID power supply line is inadequate and must be correct WARRANTY before proceeding further with the grinder LAY MAY CAUSE ELECTRICAL COMPONENT FAILURE ADJUSTMENT OF THE LOW VOLTAGE RELAY WILL VOID ALL ELECTRICAL COMPONENT WARRANTY i ADJUSTMENT OF THE LOW VOLTAGE RE CONTENTS Assembly Page 6 12 Maintenance Page 13 15 Adjustments Page 16 23 Troubleshooting Page 24 33 Electrical Schematic POS LIS D Ter Page 35 48 SPECIFICATIONS Electrical Requirements 115V 50 60 Hz 15 amp circuit Net Weight 780 lbs 354 kg Shipping Weight 920 Ibs 417 kg Maximum Grinding Length 34 in 863 mm Sound Level Less than 75 Dba SKILL AND TRAINING REQUIRED FOR SERVICING This Service Manual is designed for technicians who have the neces sary mechanical and electrical knowledge and skills to reliably test and repair the ACCU Pro Bedknife Grinder For those without that background service can be arranged through a 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
55. y set at full CW 4 30 Do not change this setting Left Traverse Reverse Torque Factory set at full CW 4 30 Do not change this setting IR COMP Factory set to 9 00 Regulation of a traverse motor may be improved by slight adjustment of the IR COMP trim pot clockwise from its factory set position Overcompensation causes the motor to oscillate or to increase speed when fully loaded If you reach such a point turn the IR COMP trim pot counterclockwise until the symptoms disappear Max Speed Set at 3 30 for maximum voltage of 90 Volts DC to the traverse motor When voltage is above 90 volts DC the traverse motor will start to pulsate and not run smoothly Right Traverse Forward Acceleration Factory set at full CCW 8 30 Do not change this setting Left Traverse Reverse Acceleration Factory set at full CCW 8 30 Do not change this setting DB Dead Band is the potentiometer setting for the 50 or 60 Hz cycle control Factory set to 9 00 works for both 50 and 60 Hz Do not change this setting Calibrating the DWELL TIME rotary DIP switch adjusts the amount of time the process remains in the stop position after a limit switch is actuated The DWELL TIME range is adjustable from O 4 seconds A switch setting of O sets the DWELL TIME to 0 seconds while a setting of 9 sets the DWELL TIME to 4 seconds Dwell time is preset to 2 setting for a 1 second dwell time when reversing at each end of stroke A setting of 4 sets the d
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