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555 Service Manual

1. 3707070 mt 8 Pin Socket SAO Gs C C Primary Ground Decal 9707164 au Primary Ground Lug TE cess TIEN Din Rail 14 Long 971474225 Power Line Filter 3707390 Control Board LU 3 07990 esse Magnetic Starter 1 HP M 9707558 uento Eu Voltage Sensor Relay rv amp 6 55 vbax dS Terminal Block End Stop J 3707020 um Terminal Block Jumper Terminal Block Plate WO 9707028 RCM 2 Conductor Geey Terminal Block EEE 571872572 2 Conductor Blue Terminal Block ec EN 3709920 Low Voltage Relay Warning Decal nee 6009270 2 2 Electrical Panel PEWNE anus na 90259 Circuit Breaker 20 Amp ON OT DX PNE Terminal Strip 2 Row 19 Pole 727 M 3707707 _ _ Terminal Strip Double Flat Spade 25 m VOII Terminal Strip Single 90 Spade Lo 3707708 m Terminal Strip Double 90 Spade STOFB2A Ground Terminal Block 3707328 Door Safety Switch Monitor Eton SUTE Power Supply 24 VDC 0 3 Amp 2 3707524 opin Contro
2. DS 55370 T Tooling Spacer ETE T Acme Shaft L H Tooling 20592 P Knob T 3 8 16 x 1 0 Lg a o 00202 weise Hanger V j c 5 Clamp Weldment Large L H ZEE TAE Pr Clamp Weldment Large R H ss 2 1 RAPA Tooling Post Assembly L H 2152 ZANO Tooling Post Assembly m Handwheel 3 50 Dia ee ee sss Conical Washer 382 Id x 75 OD x 035 Thick 67 EXPLODED VIEW 55454 CARTON ASSENBLY 68 PARTS LIST 55454 CARTON ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION p t E Spanner Wrench l m 190320 1110 24 x 3 16 Socket Head Setscrew c T u TIMES 1 4 x 1 2 Roll Pin 09394 1 4 20 2 prong Knob 30022 Dresser Support Block o 55461 Dresser Support Weldment 3708845 3 4 Wide x 1 4 Thick Diamond Dresser 6509588 T Knob Assembly l a crga oq Key 3 16 x 75 WO mag Retaining Ring 3709584
3. SEE EERE Se Lu ET TUNG os FE DU PFR TORA 1 HEF IW N 79 IIS up HEL BRL Ca U HE E zTDH ST ARI 0 Fit mae S Po LL bent ala KL 0 ad Hu 11 LI d Mili MAL r 2 ARR L9 3 C TE 5 5 BH Al RZ EJ e Gr ag LICHT I v o M SHS 27 8 5 5 wee o aa usu har C d s THE B 5 za ER C CECILO BREMER FTF REIJEF ey R EFEALER gt IRINE l SAFETY MICE SWITCH SAFETY WITH ROTATION SWITCH gt ESS EMEFEERC Y STOP SW ICH SSN RAFETY i ij SWITCH I Le x VOLTAGE RELAY H wer a Hur HAERETIC STAPTEP s15 3PITORDIE ST TCH ZELL IF TRAVERSE RITE Sa ICH SWITCH TP IRWERE FEED PX2 RIRHE PRIRINITF SUNICH TOC TRAERSE FIE FELAETNIT Wa RELAY 80
4. Flange Coupler 625 Bore O00909 Drive Adapter 1 2 sq 3 5 Lg ae 6009052 Adapter p 6009217 aan aaa Driver Coupler Adapter 10 320000 Sleeve Coupler 69 EXPLODED VIEW 55571 ALIGNMENT GAGE ASSEMBLY 70 PARTS LIST 55571 ALIGNMENT GAGE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION B120611 5 40 x 38 Socket Head Cap Screw H o B161011 esistenti 8 32 x 5 8 Socket Head Cap Screw B251016 1 4 20 x 5 8 Button Head Socket Cap Screw VY YMHCO A B251216 ettet 1 4 20 x 3 4 Button Head Socket Cap Screw B252001 1 4 20 x 1 1 4 Hex Head Cap Screw m EEEE 8 32 Hex nut NN K121501 een 5 Lockwasher Split o EE ee 8 Lockwasher Split O K251501 1 4 Lockwasher Split 1 P DUZO Front Clamp Plate eaa O 2029 Clamp Block HH 0 0 T Knob Assembly 3 8 16 x 75 Dog Point m OE 218151215 Gage Base Weldment 50597 Gage Bar Assembly Vertical TO oma a n 3529069 Spacer 25 ID x 375 OD x 69
5. ENGE Cog Belt m HE 505959 Thrust Washer 75 ID x 1 25 OD Lass SEIT Retaining Ring eee C250460 1 4 28 x 1 4 Socket Head Set Screw 80126 3 16 SQ x 1 00 Key 63 EXPLODED VIEW 55452 MOWER SUPPORT ASSEMBLY PARTS LIST 55452 MOWER SUPPORT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION n n 5251016 eine 1 4 20 X 5 8 Button Head Cap Screw B251216 1 4 20 x 3 4 Button Head Cap Screw 622472 1 4 20 x 1 4 Point Set Screw J377 000 3 8 16 Locknut Jam Nylon 215 8 72 0 0 0 ENIM ME 1 2 13 Hex Jam Nut c E K251501 1 4 Lockwasher Split TE 0S ee Knob 4 prong 1 2 13 F 17119 Threaded Stud 1 2 13 x 65 Lg 50242 Roller Clamp Weldment TO 50288 Tooling Block Adjustment 50290 Front Clamp Plate DOZO ne Clamp Block 55449 Tooling Base Plate 3570 Tooling Spacer 55374
6. FIG 40 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 and screw the tip out Move the traverse belt out of the way and verify the clamped distance from the tip to the clamping block shoe Jam the nut against the clamp being careful BRALKET SCREWS BRAKET Ez The bracket that supports the clamp is also equpped with slots if further adjustments need to be JAN NUI NININLM DISTANCE 10 made To move the bracket loosen the two screws 2 5 mm that are holding it in place and slide forward or back Retighten the screws and make sure they are tight or the bracket will move during clamping Check the tip distance and make any necessary adjustments FIG 41 THE TIP HAS BEEN FACTORY SET SO THAT IT WILL SLIP IF THE GRINDING HEAD ASSEMBLY COMES IN CONTACT WITH SOMETHING CAUTION SHOULD BE USED AS ADJUSTING THE TIP WILL AFFECT THE SLIP LOAD AND COULD DAMAGE THE CLAMP TIP BELT OR TRAVERSE DRIVE SYSTEM 21 ADJUSTMENTS Continued SPIN GRINDING HEAD WEAR PADS The bronze wear pads used to move the spin wheel will wear and may need to be adjusted or replaced Replace or flip the pads when they wear to within a 1 16 1 5 mm of the screws To accomplish the best fit the holes in the pads are offset When installing GH new pads flip or rotate the pads until Gap 2 is as small as possible
7. E E am 1 4 20 x 3 4 Button Head Socket Screw s enden B259211 1 4 20 x 2 00 Socket Head Cap Screw 2506020 Roll Pin 250 50 19 EEE ER J252000 1 4 20 Hex Jam Nut jo 4627200 5 8 18 Locknut Jam L m K250001 Flat Washer 1 4 TT K251501 1 4 Lockwasher Split 1 OE J257000 1 4 20 Locknut Jam Nylon 057 2 Grinding Wheel 6 x 2 75B x 1 5W 460 j c OS ZOT ROA Grinding Wheel 6 x 2 75B x 38W 24G Type 1 CE 3708839 eis 3 8 16 x 1 2 Screw w locking Flange X gt Spin Flange Nut 1 A S003 MN ee opin Wheel Flange m CCA Wear Pad RECE CAC 55200 Relief Wheel Flange TM 5520 4 a e Relief Flange Nut 225 SAFE 2020 Spin Yoke 722 u 51 CN Bearing Support Bracket 21572210 Double Bearing Assembly o 80406 Spacer washer E s BUA Seo bereks Traverse Shoe usos eee ENT 00298 T Traverse Clamp Bracket 212 59290 X Single Bearing Ass
8. 55490 rarasati Arm Weldment Short 0 p P 9040 Arm Weldment Long Right Hand DA ee Arm Weldment Long Left Hand PL EE 55447 Neary 555 SRI Decal 2 ABER 90400 c Cabinet Weldment 1 o M 55465 SENSOREN REEL Polycarbonate Window Formed M sas 80416 Air Spring 20 a Enka 80418 Air Spring Stud 2 05 199 ee opirol Pin 25 Dia x 50 Long 10 37083 e RER Foam Strip 25 Thick Sold per Foot 2 3708458 Sharp Warning Decal 3708461 3600 RPM Warning Decal OP aen O ul ata Respirator Warning Decal ONY 3708606 Hearing Protection Warning Decal asia 3708703 Safety Symbol Warning Decal sss 3703372 ocio tS Patent Decal 4012 2 e Foam Seal 50 High Sold per Foot n RUNS Storage Hook STAZ 2582452 NEC Gage Mounting Pin OO M Up Down Decal o sa oS O Window Retaining Bracket Long _ 0509182 ee Window Retaining Bracket Medium RE
9. HAS A LEFT HUB HAS RIGHT HAND THREAD Place the ginding wheel hub assembly s back on the grinding shaft and make sure the spin hub is located between the drive yoke assembly and the relief hub is to the right of the drive assembly MAKE SURE THE WHEEL S IS PLACED ON THE SHAFT WITH THE SAME ORIENTATION AS SHOWN FAILURE TO INSTALL CORRECTLY WILL CAUSE THE WHEEL NUT TO LOOSEN THE NUT ON THE RELIEF HUB SHOULD BE BEARING RELIEF FLANGE RELIEF WHEEL SPIN NUT 8 SPIN WHEEL SPIN FLANGE FIG 33 Loosen bolts and tip back Press in indexing finger and the wheel should slide freely to the right TO THE RIGHT amp THE NUT ON THE SPIN HUB SHOULD BE TO THE LEFT Reinstall the bearing on the left side of the shaft making sure to fit the pilot on the bearing into arm Tighten mounting screws and tighten the setscrews to the shaft Reinstall the left side cover panel Move bearing support back in place See relief hub bearing adjustment complete details WHEEL DRESSING If the grinding wheel becomes loaded with material it may be necessary to dress the wheel The 555 is supplied with a diamond dresser To use place the dresser on the spin drive horizontal arm in the area where the wheel is to be dressed Adjust the dresser to the appropriate position and angle Raise the grinding wheel so it is nearly touching the dresser FIG 34 spin grinding wheel into the dresser and then move the grinding
10. nedrv TECHNOLOGIES 555 AUTO INDEX SPIN RELIEF REEL GRINDER Patent No 5 321 912 6 010 394 amp 6 290 581 ASSEMBLY and SERVICE MANUAL i uw raras M TL FALI KO I LI O O w O a rur ur rr WARNING You must thoroughly read and understand this manual before operating the equipment paying particular attention to the Warning amp Safety instructions 55020 10 05 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 The Caution Symbolidentifies special special instructions or procedures Instructions or procedures which if not which if not correctly followed strictly observed could result in damage to could result in personal injury or destruction of equipment 1 KEEP GUARDS IN PLACE and in working 12 DON T OVERREACH Keep proper footing and order balance at all times 2 REMOVE WRENCHES AND OTHER 13 MAINTAIN GRINDER WITH CARE Follow TOOLS instructions in Service Manual for lubrication and preventive maintenance 3 KEEP WORK AREA CLEAN 14 DISCONNECT POWER BEFORE SERVICING 4 DON T USE IN DANGEROUS ENVIRONMENT or when changing the grinding wheel Don t use Grinder in damp or wet locations Machine is for indoor use only Keep work area 15 REDUCE THE RISK OF UNINTENTIONAL well lit STA
11. C 4 09 3708978 Foam Strip 25 Thick Sold by the foot 3 09675 u ua sa Blind Rivet 188 Dia 3708820 8 32 x 50 Button Head Safety Screw 6059040 Door Safety Switch Assembly Front SPEER 6059093 Light Receptacle Cord Not Shown i 6329065 Traverse Proximity Switch Left Hand Not Shown J 6329066 Traverse Proximity Switch Right Hand Not Shown 6329391 Main Power Cord Not Shown AG 6509391 Power Cord Warning Tag Not Shown AN 3708448 Electrical Warning Decal 2 45 ananassa s Door Switch Bracket 75 EXPLODED VIEW 55455 ELECTRIC PANEL SUB ASSENBLY PARTS LIST 55455 ELECTRIC PANEL SUB ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION n ns D160666 No 8x 3 8 Pan Head Self Tapping Screw D161266 No 8 x 3 4 Pan Head Self Tapping Screw n R000480 Lockwasher No 8 External Teeth s su Terminal Strip Decal
12. If it does not replace motor No go to Step P next ELECTRICAL TROUBLESHOOTING Continued Possible Cause Checkout Procedure Spin Speed Pot SSP L Check SSP 10K on Is not working control panel Spin Torque Pot STP M Check STP remote Is not set correctly torque on the top SDC board SSP is not working N SSP 10K Remove 3 Remote Speed wires Hed wire to term W White wire to term L Black wire to term H Worn Motor Brushes P Inspect Motor Brushes DISCONNECT POWER FROM MACHINE 33 On SDC Remote Speed check Black wire H terminal to Red wire W terminal for Pot Full CCW O volts DC Pot Full CW 4 4 Volts DC Check White wire L terminal to Red wire W terminal for Pot Full CCW 4 4 Volts DC Pot Full CW DC 0 Volts DC Yes Go to Step M No Go to Step N STP on SDC remote torque should be set at 2 00 o clock position See Pages 24 and 25 Adjust if incorrect and check Spin Drive Function Yes end of troubleshooting No Replace SDC Check for 10 000 ohms Hed wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Hed wire to black wire Full CCW 10 000 ohms Full CW 0 ohms Yes replace SDC No replace SSP Hemove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Spin Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Spin Drive not workin
13. Does not work Check Wiring Verify Continuity Replace Switch Measure 120 Volts AC from ESS term 2 to Term Block 4 Blue Yes Go to Step N next No Check wire for continuity then verify switch continuity If bad replace ESS contactor NC Measure 120 Volts AC from SSS term 3 to Term Block 4 Blue Yes Go to Step O next No Check wire for continuity then verify switch continuity If bad replace SSS contactor NO Measure 120 Volts AC from LVR term 8 to Term Block 4 Blue Yes Go to Step P next No Check for 120 Volts AC from LVR term 6 to term 7 Yes Verify Continuity of term 1 to term 8 on LVR Replace LVR if bad No Verify Continuity of Wires Measure 120 Volts AC from MAG Term A1 to Term A2 Yes MAG Should pull in with clunck if not replace MAG No Verify Continuity of Wires PROBLEM Machine Shuts off when you turn on Grind motor switch or Spin Motor Switch Possible Cause Guard Doors are Open Door Safety owitches are not working properly No 24 Volts DC to Safety Monitor SSM No Power into 24 Volt DC Power Supply PWR No Power Out to Door Switches Rear Door Switch or Rear Ramp Switch is Bad Front Door Switch is Bad Checkout Procedure A Close the front doors and rear door and rear ramp lift model B Check Alignment of Door Safety Switches on front doors and rear door and rear ramp lift model C Check SSM for 24 Volts DC Turn switches off and press sta
14. S HERREN s sss P 3707648 6 Amp Circuit Breaker O 3 0 428 u asas Rocker Switch Momentary on off on m ZO POZO 25 Amp Bridge Diode 2 RE 3707644 Thermistor Assembly 1S M 3708448 Electrical Warning Decal 1G 6209 y a Lift Electrical Control Box 10 eo 6209102 Lift Control Decal m 6209110 Lift Actuator Cord i o snn nn BOT ee Lift Controls Harness ee 6329082 Lift Power Cord 6309134 Diode Jumper Assembly 55 EXPLODED VIEW 55583 GRINDING HEAD ASSENBLY e 2 a i p I I a I I 1 pe DE er pt E R 6 292 yk Ch dm u ae EC 96 PARTS LIST 55583 GRINDING HEAD ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION NENA B191011 10 24 X 5 8 Socket Head Cap Screw ZANA 3708848 1 4 28 x 1 2 Socket Head Cap Screw w patch B25 1 4 20 x 3 4 Socket Head Cap Screw B250816 1 4 20 x 1 2 Button Head Socket Cap Screw H 80407 1 4 20 x 1 00 Socket HeadCap Screw Low Head
15. Term T1 to Term T2 for 120 Grinding motor Relay Motor Relay Volts AC Yes Go to Step I next No Replace Gringing Motor Relay Bad Circuit Breaker Verify Power out of Circuit Check for 120 Volts AC from Breaker terminals TB2 6 to Terminal Block 4 Blue Yes Go to Step J next No Check circuit breaker for continuity Verify wiring and replace if needed Bad Grinding Motor J Verify Power to Grinding Verify wiring at terminals 1 2 amp 3 motor Cord on Terminal Strip 1 Check TB1 1 to TB1 2 for 120 Volts AC Yes Check terminals on motor cord If tight replace motor No Check wires from Grinding Motor Relay and Circuit Breaker to Terminal Strip 1 38 PROBLEM Traverse Drive not working ELECTRICAL TROUBLESHOOTING Continued Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram on page 76 are correct and pull on wire terminals with approximately 3lbs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause Traverse Motor Switch TMS is not on Traverse Speed Pot TSP set to zero Fuse on Traverse Drive Control TDC has failed Traverse Drive Control TDC is bad Bad Traverse Motor Switch TMS Checkout Procedure A Turnon
16. ne Socket Head Cap Screw 1 2 13 x 2 Long 3 CYZA M 3 8 16 Nylon Locknut 3 8 16 Nylon Jam Locknut TO J507009 1 2 13 Nylon Locknut nn nu m cn 3 8 Flat Washer ZNA 2 3 8 Split Lockwasher K500001_ 1 2 Flat Washer J IK501501 1 2 Split Lockwasher m nus ner 80048 Button Head Cap Screw E 3599020 soreness Flat Washer M IL Yo MP Electro Mechanical Actuator 3707668 Motor Service Electro Mechanical Actuator HS 3708868 Compression Spring 370887 0 a External Snap Ring POW 3709000 use Thrust Washer sss 3709700 Cam Follower STU yo zc Flanged Bronze Bushing 6209070 Lift Long Arm E 6209071 Lift Swing Arm 50 2 6209072 Lift Short Arm 2 e E 620907 9 uuu Bearing Plate H 74812 8722 Bearing Plate Arm Block 6209089 Ramp Support Strap 2o 4 4 i 6209095 A
17. Acme Shaft L H Tooling Qe DO DOS c P V Roller Weldment L H c 50570 MR ER T Knob Assembly 3 8 16 x 75 Dog Point ete 01065 M Knob Assembly 1 4 20 x 1 0 Lg 555086 V Roller Weldment R H a ns SA T Rear Roller Clamp Weldment Dll TOON J Roller Roller Bracket Weldment 285212 Bolt T Slot 3 8 16 x 2 0Lg 2o 3708245 Knob T 235 3 8 16 F 2 200095 Handwheel 3 50 Diameter 74 8 gt 19 gt gt eee Conical Washer 382 x 75 x 035 T HO 3889045 Spacer 406 ID x 88 OD x 38Long aon BOGAT cesta Quick Clamp Handle p 251002 Roll Pin 25 Dia x 5 8 Long 65 EXPLODED VIEW 55460 VERTICAL MOWER SUPPORT ASSEMBLY 66 PARTS LIST 55460 VERTICAL MOWER SUPPORT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Jasa s n nn eee B3971601 u nala 3 8 16 X 1 Hex Head Cap Screw ARE CE 200820 1 4 20 x 1 4 Cup Point Cap Screw 4377000 3 8 16 Locknut Jam or 190 T asus 3 8 Lockwasher Split EA 151 Knob T Assembly 1 2 13 x 6 5 OWC 30 2 51 MC Tooling Block Adjustment
18. DC from Terminal Strip 2 Terminal 3 to Terminal Strip 1 Terminals 14 and 15 Yes Go to Step G next No Check Alingment of Rear door switch If no Voltage to Term14 or 15 then replace rear switch If still not working replace cord Measure approximately 24 volts DC from Terminal Strip 1 Terminal 17 to Terminal Strip 2 Terminals 2 and 4 Yes Replace SSM No Check Alingment of Front door switch If no ae to Term2 or 4 then replace front switch Measure 120 Volts AC at MAG term L3 to Term Block 4 Blue after SSS is pushed Yes Verify Wiring to LVR No Measure 120 Volts AC at MAG term T3 to Term Block 4 Blue after SSS is pushed If 120 Volts AC Replace MAG If no 120 Volts AC verify wiring to T3 ELECTRICAL TROUBLESHOOTING Continued PROBLEM SPIN DRIVE NOT WORKING IN SPIN MODE Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram on page 76 are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or not loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below opin Speed Pot SSP set to zero opin Motor Switch SMS is not on opin Rotation Switch SRS is not on Circuit Breaker is Tripped 4 AMP Spin Drive Control SDS is not working Spin Drive motor
19. Pages 24 and 25 See Adjustment Section Spin Drive Control SDC Board Setting A See adjustment section for trim pot setting on Page 24 B Readjust bearing preload for the reel Maximum torque load 25 in Ib to rotate reel C When 250 female spade terminals are not tight remove and crimp slightly together When reinstalling push on pressure should have increased for good contact 36 If wiring is wrong correct and test Yes end of troubleshooting No Go to Step B next Check for 10 000 ohms Hed wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Hed wire to black wire Full CCW 10 000 ohms Full CW 0 ohms Yes Go to Step C next No Replace SSP Yes end of troubleshooting No replace SDC Original adjustment was not set properly Too much load on drive motor will cause motor to hunt and vary speed When connections are not tight the control board varies voltage to the DC motor which then varies speed ELECTRICAL TROUBLESHOOTING Continued PROBLEM Grinding motor not working Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram on page 76 are correct and pull on wire termi nals with approximately 3lbs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem
20. Symbol identifies special special instructions or procedures instructions or procedures which if not which if not correctly followed strictly observed could result in damage could result in personal injury to or destruction of equipment PLEASE TAKE SPECIAL NOTE OF THE FOLLOWING WARNING DECALS LOCATED ON THE FRONT AND SIDES OF THE GRINDER oymbol for hearing protection required when operating this machine Symbol that operator and people in close proximity must wear respirators or d have an adequate mz 5 ventilation system oymbol for Read operators manual wear safety glasses and disconnect power before servicing ymbol to keep visitors a safe listance away from the grinder X Symbol for sharp object which will W X cause serious injury symbol identifying a panel cover area as having live electrical Symbol for minimum safe rated omponents within RPM of grinding wheel Symbol to keep exposed gasoline or flammables away from the grinder because it operates with a large amount of sparks 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 555 Spin Relief Grinder For those without the background service can be arranged through your local distributor This section presumes that you are already familiar with the normal opera
21. TMS B Set TSP to 35 on the control panel C Check fuse and replace if failed See Page 23 Too heavy a grind causes grinding head traverse motor to overload and blow the fuse NOTE Fuse can not be checked visually Use Ohm test to check fuse If the fuse needs replacing you MUST use a 3 amp slo blo fuse Part Number 3707546 D Check for 120 Volts AC incoming to TDC E Check for 120 Volts AC at TMS Make certain TMS is on 39 Traverse works Yes end troubleshooting No got to Step B next Traverse works Yes end troubleshooting No go to Step C next Traverse works Yes end troubleshooting No go to Step D next On TDC Terminal L1 to L2 for 120 Volts AC Yes Go to Step F next No Go to Step E next Measure 120 volts AC from TMS Terminal 5 to Term Block 4 Blue Yes Go to Step L next No Flip Switch and check again Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch ELECTRICAL TROUBLESHOOTING Continued Possible Cause No DC Voltage from TDC Traverse Drive Control Traverse Motor is bad TSP is not working TSP 10K is bad Worn motor brushes Checkout Procedure F Check for 90 Volts DC across TDC terminals A1 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 G Check traverse motor continuity DISCONNECT POWER FROM MACHINE
22. burr on cutting edge of reel blades Possible Cause Traverse speed set too high causing a heavy burr on the reel blade when spin grinding PROBLEM Cone shaped reel after grinding Possible Cause Grinding head travel not parallel to the reel center shaft PROBLEM Relief grind on the reel blades do not go the full length of the reel Possible Cause Need to adjust the finger stop Need to dress the Wheel to the correct angle Checkout Procedure Clean shafts and bearings according to the lubrication of Grinding Shaft and Linear Bearings instructions in the Maintance Section of the manual If problem persists replace linear bearings according to the replacement of linear bearings instructions Clean the wheel flanges and shaft see Lubrication of Grinding Shaft Replace flanges or shaft if necessary Clean and lubricate the shaft and pulley Checkout Procedure Adjust the clamping tip as specified in the Traverse Clamp Force section of this manual Slow the traverse speed or back off on the amount that is being infed Checkout Procedure Traverse speed should be set lower approximately 12 ft min 4 meters min for a smaller burr on the cutting edge Checkout Procedure Grinding head travel was not setup parallel to the reel center shaft in vertical and horizontal planes See Align the Reel Section Checkout Procedure Adjust finger stop and check for contact full length Dress the wheel For more detail see
23. if necessary WIRE LABELS All wires on the 550 have a wire label at each end for troubleshooting The wire label has a code which tells you wiring information The wire label has a seven position code The first two digits are the wire number 01 99 The next three numbers or letters are the code for the component to which the wire attaches Example TDC for Traverse Drive Control The last two numbers or letters are the number of the terminal on the component to which the wire attaches ELECTRICAL TROUBLESHOOTING INDEX AC Main Power Controls Page 27 29 opin Drive Controls Page 30 34 Grinding Motor Controls Page 35 36 Traverse Drive Controls w prox Page 37 38 Traverse stopping and reversing Page 39 41 ELECTRICAL TROUBLESHOOTING Continued PROBLEM AC Main Power Controls no electrical power to control panel Verify all wires shown on the wiring diagram on page 76 are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If problem persists test as listed below Possible Cause Checkout Procedure Emergency Stop Botton ESS A Pull Up on ESS Button is Depressed You must push the System Start Switch SSS to get power to control Panel Main Power Cord is not plugged in Guard doors must be closed and ALL Switches MUST be turned OFF for contactor to pull in Main 20 amp outlet circuit breaker has tr
24. is bad A Set SSP to 200 on the control panel B Turn SMS switch on B Turn SRS switch to direction of reel rotation required NOTE CENTER POSITION IS OFF C Reset Circiut Breaker on the side of the machine above the electrical panel cover Push in if tripped D Check SDS L1 to L2 for 120 Volts AC E Check SDC A1 amp A2 for approx 90 Volts DC Have Spin Speed Pot set to 400 H PM F Check for approx 90 Volts DC input to SRS G Check for approx 90 Volts DC out put from SRS H Check spin motor continuity Disconnect Power from Machine 32 opin Motor works Yes end troubleshooting No go to Step B next opin Motor works Yes end troubleshooting No go to Step C next opin Motor works Yes end troubleshooting No go to Step C next opin Motor works Yes end troubleshooting No go to Step D next SDC Term L1 to term L2 for 120 volts AC Yes go to Step E next No Verify Power to Circuit Breaker and SMS and continuity of wires Replace CB or SMS If needed SDC Term A1 to A2 for approx 90 volts DC Yes go to Step F next No go to Step L next SRS Term 2 to 3 for approx 90 Volts DC Yes go to Step G next No replace wires 13 amp 14 SRS Term 6 to 7 for approx 90 Volts DC Yes go to Step H next No replace SRS switch Remove wires at Terminal Strip 1 Term 4 amp 5 check 0 ohms across the black and white wires Yes end troubleshooting motor should work
25. persists test as listed below Possible Cause Grinding Motor Switch GMS is not on Guard doors are not closed 15 Amp Circuit Breaker CB is tripped GMS not working Grinding Motor Relay not working No Power to Relay Contacts A Turn switch on B Close front and rear guard doors and rear ramp lift option C Check 15 amp CB on the side of the grinder above the control cover Press in if tripped D Check for power to GMS E Check for power from GMS F Check for power to relay Coil Relay should click when GMS is turned on G Verify Power to Relay Contacts 37 Grinding Motor works Yes end troubleshooting No go to Step B next Grinding Motor works Yes end troubleshooting No go to Step C next Grinding Motor works Yes end troubleshooting No go to Step D next GMS term 5 to Terminal Block 9 Blue for 120 Volts AC Yes go to Step E next No With power off check continuity of wires to GMS GMS Term 6 to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step F next No replace GMS Check for 120 Volts AC from A1 to A2 of Grinding motor Relay Yes Go to Step G next No check continuity of wires to Grinding motor Relay REL Term L1 to Term L2 for 120 Volts AC Yes Go to Step H next No Check wires to REL Term L1 amp L2 ELECTRICAL TROUBLESHOOTING Continued Possible Cause Checkout Procedure Bad Contacts in H Verify power out of Grinding REL
26. relief grinding section in operating instructions of the manual 45 EXPLODED VIEW 55453 CABINET AND DOOR ASSEMBLY PARTS LIST 55453 CABINET AND DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION m 10 24 5 8 Button Head Socket Screw REECE 5251001 nase 1 4 20 x 5 8 Hex Head Cap Screw EA BOZIOJO 3 8 16 x 1 0 Button Head Socket Cap Screw kusasta 3 8 16 x 2 Button Head Socket Cap Screw O ERE D280808 1 4 20 x 1 2 Thread Cutting Screw F J197000 m 10 24 Locknut Jam Nylon Insert ra 5 16 18 Full Nut c MT 5 16 Locknut Jam Nylon Insert O T roo u uuu 3 8 16 Locknut Full Nylon Insert J507000 1 2 13 Locknut Jam Nylon Insert 1 4 Lockwasher Split J OE 3 8 Flatwasher Heavy J ns R000453 5 16 ID x 7 8 OD x 1 8 Thick Washer SE 222 Mere RS Grab Handle Enclosure Sor Tooling Bar Machined TO 242 2 asas Side Cover Panel Right Hand i O H 90598 PEWNE Side Cover Panel Left Hand 227205 Door Weldment nn E
27. seisaeaee ll Finger Slide 55117 Fixed Finger B190634 10 32 x 3 8 Button Head Socket Cap Screw D O 55118 p Stop Pin F E S da EE H SEID nen Index Finger Stop Block 1181202 reitera 3 16 x 3 4 long Roll Pin n 5957 Q Locking Plate Weldment 3 SO S7 USO S oes Spacer 252 ID x 50 OD x 125 Long 25 190467 10 32 x 1 4 Socket Head Set screw 20 H OD 12 7 3 16 Diameter Index Stop Pin OPE 5550 RO Indexing Finger Assembly ID 9 08107 Compression Spring 57 PARTS LIST 55451 PIVOT ARM AND GRINDING SHAFTASSY 1 of 2 PARTS LIST 55451 PIVOT ARM AND GRINDING SHAFT ASSY 1 of 2 DIAGRAM PART NUMBER NUMBER DESCRIPTION een BO1ODOJ 5 16 18 x 2 1 4 Hex Head Cap Screw H B371611 een 3 8 16 x 1 Socket Head Cap Screw e 372411 3 8 16 x 1 1 2 Socket Head Cap Screw H 3739601 een 3 8 16 x 2 1 4 Hex Head Cap Screw OCENA 5752001 3 4 10 1 25 Head Screw T 250820 1 4 20 x 1 2 Cup Point Set Screw u n JIST700 sanieren 5 16 18 Locknut Nylon Jam JOT OO DA 3 8 16 Lo
28. wheel side to side against the dresser which will dress the full face of the wheel For dressing the relief wheel put the dresser at the correct angle for normal helix reel or reverse helix reel See pages 24 and 25 of the Operators Manual For dressing the spin grinding wheel put the dresser in the straight position Close the doors and infeed the Close the doors and infeed the relief grinding wheel into the dresser Do Not move the grinding wheel from side to side 15 MAINTENANCE Continued GRINDING MOTOR BELT REPLACEMENT ALIGNMENT To replace or inspect the grinding motor belt remove the right side cover panel To remove the belt pull down on the tensioner pulley For the belt to function properly the grinding shaft pulley and the grinding motor pulley must be in line with the tensioner pulley To adjust the pulley position loosen the setscrews on the pulley Locate the belt in the center of the idler pulley Measure from the arm to the edge of the belt at the idler pulley Adjust the two other pulley s until the same measurement is achieved and tighten the pulley setscrews Before reinstalling the right side cover panel run the grind motor to assure that the belt is not misaligned The belt will walk off the pulley if the system is not aligned properly TRAVERSE BELT REPLACEMENT To replace the traverse belt remove the left side cover panel then loosen the nuts on the left side pulley that are used to tens
29. without the pads pinching the wheel On the spin grinding head assembly the pads can be adjusted in and out by loosening the screws located on the sides of the yokes Gap 1 should be adjusted to about 1 16 1 5 mm See FIG 42 FIG 42 4 SAFETY SWITCH ALIGNMENT REPLACEMENT The safety switch located on the right guard door must line up properly with the key located on the opposite door or the grinder will not function The switch and key must be within 1 4 6 mm and the 8 targets on the switches must line up in order for the switch to function properly See FIG 43A 43B and 43C The switch and key are attached to the guarding using FRONT DOOR SWITCH Torx style tamper resistant screws INSIDE UPPER RIGHT SIDE FIG 43A ur FIG 43B REAR DOOR SWITCH FIG 43C NON LIFT MACHINE LIFT MACHINE 22 ADJUSTMENTS Continued RELIEF GRINDING HEAD BEARING ADJUSTMENTS Support Bearing It may be necessary to adjust the guide bearings on the relief Assemblies head To adjust the position of the support bearings loosen the two positioning bolts located on the side of the support assembly Press on the support assembly until both support bearing assemblies are touching the hub Hold the support in place with the bearing assemblies touching the hub and tighten the two bolts positioning bolts Check to see if both bearing assemblies are touching or have minimal clearance to the hub by rotating the gri
30. 40 x 2 03 x 024T OD 3708425 Shoulder Bolt 313 D x 375 L 525 sa CAS 0 2 Thrust Washer 500 x 937 x 032 T 0 esas 3709886 Flat Washer 812 x 2 25 x 135 T S 00120 MD v E Key 3 10 sq x 1 00 Lg 59 EXPLODED VIEW 55451 PIVOT ARM AND GRINDING SHAFT ASSY 2 of 2 S 9 S 9 il PARTS LIST 55451 PIVOT ARM AND GRINDING SHAFT ASSY 2 of 2 DIAGRAM PART NUMBER NUMBER DESCRIPTION J nn s 22055 v M 5 40 X 188 Lg Socket Head Cap Screw B130605 6 32 x 3 8 Flat Head Socket Cap Screw B160411 8 32 x 1 4 Socket Head Cap Screw B190611 10 24 x 3 8 Socket Head Cap Screw B190831 10 24 x 1 2 Socket Head Cap Screw 2 M 2570520 3 8 16 x 1 2 Point Set Screw us a een J502000 1 2 13 Hex Jam Nut usss snn ns J507100_ AE 1 2 13 Locknut Full Nylon K161501 RP 8 Lockwasher Split jo 10 Lockwasher Split nun m 09068 Washer Conical 50 x 1 25 x 078T m EAN 09299 1 2 13 x 2 5 Lg Button Head Socket Cap Screw ACTION Di
31. 555 E Dust Tray Weldment Lo 4 82 25 Diameter x 3 4 long Roll Pin jJ 80421 A Retaining Clip Gas Spring 47 PARTS LIST 55470 REAR DOOR ASSEMBLY PARTS LIST 55470 REAR DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION A eee BIBI 10 24 x 1 2 Button Head Socket Cap Screw A EET EE EE 191034 10 32 x 5 8 Button Head Socket Screw O 29509 O uestis 1 4 20 x 1 2 Button Head Socket Cap Screw HERNE B3 2010 ac 3 8 16 x 1 25 Button Head Socket Cap Screw C OE 5 16 18 x 1 25 Socket Setscrew Cup Point 167000 8 32 Locknut Jam Nylon Insert UO OO n 10 24 Locknut Jam Nylon Insert sasa J257100 EEE 1 4 20 Locknut Full Nylon Insert SS UM dod AUOD a una etin 3 8 16 Locknut Jam Nylon Insert jo K370001 Flatwasher 3 8 PR E P E E E Lockwasher 3 8 Split eee JOB e Grab Handle ence 20407 Rear Door Slide 55400 EET e Rear Guard Door 10 ZEE 05400 na Rear Door Spacer Plate Rear Safety Switch Spacer Plate LP SION I Strain Relief Liquid Tight 19 30 C
32. 80419 cam Potentiometer Assembly 10K E 80420 Potentiometer Assembly 50K E E 9707009 Strain Relief Liquid Tight 27 47 Wire Dia TO s 3707029 Strain Relief Liquid Tight 19 30 Wire Dia 10 s E 3707075 Toggle Switch Boot 3707080 Toggle Switch 3707658 Strain Relief Liquid Tight 55 71 Wire Dia Pd EE 3707224 Cable Tie Mount een Cable Tie 6 5 Long x 18 Wide Not Shown AON Cable Tie 4 0 Long x 10 Wide Not Shown Z SUO FOE este Yellow E Stop Ring D H Rocker Switch c ana Rocker Switch 7 0 3707446 Potentiometer Knob 3 07564 Green Pushbutton o m Contact Block Normally Open ZO 3707506 TRA Switch Mounting Latch E 3707567_ uaa asas Red Stop Push Pull Pushbutton EE 3 07568 Contact Block Normally Closed SEREAER Door Safety Coded Magnet 55 3707549 Circuit Breaker 20 Amp 22
33. 97000 10 24 Locknut Jam Nylon Insert 4 2 718 0 EE 1 4 20 Locknut Jam Nylon Insert jo J377100 3 8 16 Locknut Full Nylon Insert Ja K160001 Flatwasher No 8 M Flatwasher No 10 M K250001 Flatwasher 1 4 2 m Flatwasher 3 8 10 Lockwasher 3 8 Split sss SS TA Lift Control Panel p c Lower Lift Guard Right Hand 10 aaa BAD Lower Lift Guard Left Hand eer 55444 Upper Lift Guard Right Hand DOJA Upper Lift Guard Left Hand ee ETE 355 M Lift Dust Shield D so 72 Lift Power Cord Not Shown 2 2109096 s Spacer 501 ID x 1 00 OD x 50 Long OA E 3707009 Strain Relief Liquid Tight 27 47 Dia Cord 20 TOTO n Strain Relief Liquid Tight 19 30 Dia Cord zr 3707224 ciat rhet Cable Tie Mount Not Shown ee Cable Tie 6 5 Long x 18 Wide Shown O 100000 Hole Plug 625 Dia n esate 3708458 NE sharp Warn
34. ENCE OF DRUGS provided before operating 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 safety we suggest you benefit from the experience of others and follow these rules DO 1 DO always HANDLE AND STORE wheels in a careful manner 2 DO VISUALLY INSPECT all wheels before mounting for possible damage 3 DO CHECK MACHINE SPEED against the established maximum safe operating speed marked on wheel 4 DO CHECK MOUNTING FLANGES for equal and correct diameter 5 DO USE MOUNTING BLOTTERS when supplied with wheels 6 DO be sure WORK REST is properly adjusted 7 DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel 8 DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding 9 DO always WEAR SAFETY GLASSES or some type of eye protection when grinding 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 mountin
35. H Check TSP 10K on control panel J Check TSP for 10 000 ohms Remove three wires from TDC red from term 8 white from term 7 black from term 9 K Inspect Motor Brushes DISCONNECT POWER FROM MACHINE 40 Check TDC terminals A1 to A2 for 90 Volts DC Yes go to Step G next No go to Step H next Remove motor wires from Terminal Strip 1 terminals 7 amp 8 check for 0 ohms across the black and white wires Yes end troubleshooting motor should work if it does not replace motor No go to Step K next TDC Pin 8 to 7 Pot Full CCW Pot Full CW OVDC 9 75 VDC Pin 8 to 9 Pot Full CCW Pot Full CW 9 75 VDC 0 VDC Yes replace the TDC No go to Step J next Check for 10 000 ohms red to white wires Full CCW 0 ohms Full CW 10 000 ohms Hed to black wires Full CCW 10 000 ohms Full CW 0 ohms Yes replace the TDC No replace TSP Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Traverse Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse does not stop to reverse directions when flag goes under the proximity switch on the left side or right side of machine Gap between flag and prox is Incorrect Proximity Switch is bad A Gap between flag and prox should be 3 16 to 1 4 4 6 mm Prox LED does not light when flag is under prox B
36. Inspect the Poly V belt on the grinding motor for cracking and make any necessary adjustments every three months 3 Wipe and relube with never seez the horizontal adjustment shafts located on the tooling every six months 4 Wipe and relube with never seez the vertical adjustment shafts every six months Run the arms up and down to coat the working areas of the shaft o Inspect the traverse cog belt for cracking and defects every three months Remove any grit or dust that may affect the function of the belt Adjust tension if necessary per procedures called out in the adjustment section 6 Lubricate grinding shaft bearings with one shot of grease once every 2 years DO NOT GREASE BEARINGS FOR FIRST 2 YEARS THEY ARE GREASED AT THE FACTORY AND GREASING MAY CAUSE THE BEARINGS TO OVERHEAT AND FAIL PREMATURELY HIRTZTNTAL ADS WEN E 30 SHAFT FIG 31 13 LUBRICATION LUBRICATION OF GRINDING SHAFT AND LINEAR BEARINGS STEP 1 Thoroughly clean all three shafts STEP 2 Flood spray all three shafts with WD40 until the lubricant is dripping off the shafts Then run the grinding head assemblies back and forth through their full range of travel This will remove the dust and deposits from inside the wheel flanges Repeat if necessary until lubrication is clear of deposits Clean keyways located on the grinding shaft with soft brush STEP 3 With a clean rag wipe off the excess amount of lubri
37. LEVEL BASE Place level on the top of the table and check the levelness of the unit from side to side Adjust the leveling feet as necessary to bring to level See FIG 25 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 26 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 24 Make certain that all four leveling feet are firmly contacting the floor Recheck with level after locking nuts are firmly tightened FIG 26 ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT GROUNDING INSTRUCTIONS 115 Volt Model Only Plug the control box power cord into standard 115V AC 20 amp grounded receptacle See FIG 27 220 Volt Model Only For 220 Volt Applications order Part FIG 27 No 5550915 or 5550925 which includes a prewired 2 KVA 220 V step down to 115V 50 60 Hz transformer See details on Page 11 IT IS RECOMMENDED THAT THIS SPIN RELIEF 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 not
38. Long gt SSS 6509418 Pivot Plate Machined E s 6309349 usa Retainer Plate 5 m 6509359 Digital Gage Machined HO60302 Roll Pin 063 D x 188 Long Pll PO 2852 Knob T 1 4 20 x 1 18 Long es 6509442 Indicator Base Weldment 29 oo E sA 2282 2 Knob Assembly 1 5 3 8 16 x 2 25 Long M 6609501 Knob Assembly T 1 4 20 x 1 31 Long 71 EXPLODED VIEW 55456 SPIN DRIVE ASSEMBLY 72 PARTS LIST 55456 SPINDRIVE ASSENBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION asss 016 sesini 1 4 20 x 5 8 Button Head Socket Screw o cui 1 4 20 3 4 1 4 20 3 4 Button Head Socket Screw O B251411 1 4 20 x 7 8 Socket Head Cap Screw OCZNE K250001 Flat Washer 1 4 GS 1 4 Lockwasher Split Key 1 8 x 75 50280 Front Clamp Plate M pem Clamp Block 19 n 253 5 M Motor Spin Assembly Spin W13 LD 50570 T Knob Assembly 3 8 16 75 Dog Point DUS 2 m Spin Mount Weldment Ver
39. Proximity switch is not working properly or wire connections are loose If incorrect adjust per adjustment section of manual Yes end troubleshooting No go to Step B next First check to see if proximity light comes on When the light is on it means that there is electricity coming to proximity switch Actuate prox switches with steel tool to take measurements Left proximity PROX 1 check Traverse drive Control TDC between terminals 13 black wire and 15 brown wire Right proximity PROX check 14 black wire and 15 brown wire 41 The light coming on shows the proximity is getting electrical contact Proximity light on 0 Volts DC Proximity light off 12 Volts DC Proximity light on 0 Volts DC Proximity light off 12 Volts DC Replace proximity switch if the voltages do not read as above ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse speed control goes at one speed only Possible Cause Defective speed control potentiometer Wiring hookup to potentiometer is improper If components have been replaced Main circuit board dial pot settings not correct If board has not been replaced Checkout Procedure A Check potentiometer on control panel B Check potentiometer for 10 000 ohms Remove three wires from Traverse Drive Control red from term 8 white from term 7 black from term 9 C Check potentiometer wiring for proper hookup See that
40. RTING Make sure all switches is OFF before plugging in the grinder 5 KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area 16 USE RECOMMENDED ACCESSORIES Consult the manual for recommended accessories Using 6 MAKE WORK AREA CHILD PROOF with improper accessories may cause risk of personal padlocks or master switches injury 7 DON T FORCE THE GRINDER It will do the job 17 CHECK DAMAGED PARTS A guard or other better and safer if used as specified in this part that is damaged or will not perform its manual intended function should be properly repaired or replaced 8 USE THE RIGHT TOOL Don t force the grinder or an attachment to do a job for which it was not 18 KNOW YOUR EQUIPMENT Read this manual designed carefully Learn its application and limitations as well as specific potential hazards 9 WEAR PROPER APPAREL Wear no loose clothing gloves neckties or jewelry which may 19 KEEP ALL SAFETY DECALS CLEAN AND get caught in moving parts Nonslip footwear is LEGIBLE If safety decals become damaged or recommended Wear protective hair covering to illegible for any reason replace immediately contain long hair Refer to replacement parts illustrations in Service Manual for the proper location and part numbers 10 ALWAYS USE SAFETY GLASSES of safety decals 11 SECURE YOUR WORK Make certain thatthe 20 DO NOT OPERATE THE GRINDER WHEN cutting unit is securely fastened with the clamps UNDER THE INFLU
41. SEMBLY INSTRUCTIONS Continued FOR 220 V 50 or 60Hz applications Product No 5550915 or 5550925 should be ordered 5550915 or 5550925 includes IE V z 2 KVA 220V step down to 115 V 50 60 Hz transformer FUMER 001 BL The wiring diagram is shown in FIG 28 NEUTRAL A BLALK WHITE NEUTRAL The power cord has no connector A connector which is appropriate for T your locality and 220 volt 10 amp application should be installed ELECTRICIAN TO COMPLETE x Xj X 4 HIQHS HI Hb THE INSTALLATION YIRE MIT TRANSFERNER LEADS Hi H7 ANO HB THE GREEN SUPPLIED INIO THE TERMINAL ELLE IN THe HLE PPLEITE WIRE 3 AS SHOWN TU INSTALL THE WIRE IMSERT SMALL INTO THE CAVITY MARKED amp TO OPEN THE WIFE HOLE USE ONLY QUALIFIED THE OTHER END OF IHE GREEN WIRE SUPPLIED 10 IHE STUD ON THE TRANSFORMER FIG 28 IMPORTANT GROUNDING INSTRUCTIONS In case of a malfunction or breakdown grounding reduces the risk of electrical shock by providing a path of least resistance for electrical current This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded according to all local or other appropriate electrical codes and ordinances Before plugging in the Grinder ma
42. ated on the control panel and is for relief torque adjustment Relief Speed Pot RSP when rotated clockwise will increase maximum spin drive speed This speed should 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 30 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 operate smoothly In the Spin Grinding Mode The Spin Torque Potentiometer STP and the Spin Speed Pot SSP interact with each other The STP is located on the upper spin board as spin torque preset at 2 00 for torque setting See FIG 45 The SSP is located on the control panel and is for spin speed adjustment opin Torque Pot STP controls maximum torque allowable in the spin grinding cycle only This should never be adjusted past the 2 30 position If the reel does not turn check that the reel is free turning by hand spinning 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 LOWER BOARD OF THE SPIN DRIVE CONTROL SDC See FIG 46 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
43. bs 75 ft lbs 115 ft Ibs thread 6 2 kg m 10 4 kg m 15 9 kg m ASSEMBLY INSTRUCTIONS 118 Remove the sides front and back of the crate DE Remove the plastic bag shrink wrap and bubble wrap Remove the metal clips that secure the grinder to the crate base With a fork lift raise the grinder from the wood base and set it in its final position See FIG 22 and 23 THE UNIT WEIGHS 1450 LBS 658 kg TO LIFT USE POWER EQUIPMENT Remove shipping straps and window protective sheets 24 i POSITION BASE FIG 22 The 555 Spin Relief Grinder will require an operating area of about 119 W x 127 D x 90 H 302 x 323 x 229 cm The machine operator will operate the unit from the front of the machine Position the base to allow sufficient operating room in front and to the rear of the machine See FIG 22 and 23 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 3r FIG 23 OPTIONAL ASSEMBLY INSTRUCTIONS Continued Remove the carton and remove the contents from the carton onto a workbench The carton includes Alignment Gage Diamond Dresser Drive Coupler Sa Spanner Wrench Product Packet Assembly P Operators amp Assembly Manuals ASSEMBLY INSTRUCTIONS Continued
44. cant from the shafts Run the grinding assemblies through their 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 LR IND SHAFT TRAVERSE SHAFTS FIG 32 14 MAINTENANCE Continued REPLACEMENT OF GRINDING WHEEL To replace the wheel first remove the left side cover panel Now lower the left side of the grinding shaft and raise the right side Loosen the two bolts that hold the bearings on the relief hub so that that bearings fall away from the wheel and hub toward the front of the machine Press the index finger down and the wheel and hub assembly should move freely to the right Loosen the setscrews on the bearing and remove the screws that hold the bearing to the left arm Remove the bearing and lift the left end of the grinding shaft Slide the grinding wheel hub assembly s off the shaft taking note of what side the nut is on Using the spanner wrench 50014 remove and replace the grinding wheel s on the hub assembly HAND THREAD FOR THE NUT THE SPIN NOTE THE RELIEF
45. ck White wire L terminal to Red wire W terminal for Pot CCW 2 Volts DC Pot CW DC 0 Volts DC Yes go to Step M next No go to Step N next RSP to the top SDC board should be set at 9 30 See pages 24 and 25 Adjust if incorrect and check Relief Torque func tion Yes end of troubleshooting No replace SDC Check for 50 000 ohms Hed wire to white wire Full CCW 0 ohms Full CW 50 000 ohms Hed wire to black wire Full CCW 50 0000 ohms Full CW 0 ohms Yes Replace SDC No replace RTP Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm mini mum length Yes replace motor brushes No replace Spin Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Spin drive speed goes at one speed only Possible Cause Wiring hookup to potentiometer is improper If components have been replaced Defective spin speed control SSP potentiometer Main circuit board dial pot settings not correct If board has been replaced IR Comp trim pot not adjusted properly Torque to rotate the reel too high Check all terminal connections for tightness Remedy A Check potentiometer wiring for proper hookup See that speed pot is wired per electrical diagram B SSP 10K Remove 3 remote speed wires red wire to term W white wire to term L black wire to term H C Check all pot settings on both boards as of the SDC shown on
46. cknut Hex Nylok Full ACTA ee 3 8 Lockwasher Split I o SS E E A sss R000453 Flat Washer 31 x 88 x 104T p 3707690 Motor 1HP 90205 Traverse Shaft o M S 50236 SER Pulley 2 45 Diameter Poly V J SUA u E nets Pulley 3 72 Diameter Poly V DS D 50200 NT Grinding Wheel Shaft 50279 NE Tensioner Bar OE 50280 Tensioner Pivot Shaft 202 Tensioner Pulley Shaft DOZDA Pivot Support Shaft 5 e rr Prox Switch Holder R H 2 E 0000 c r Prox Switch Holder L H EE OCE CE 55404 Arm Assembly R H 25 EN pion Arm Assembly L H E as C190420 10 24 x 1 4 Cup Point Set Screw 09680 M P Torrington Bearing 20 BOZIC ae Piloted Bearing Flange P ns PT Key 25 1 25 Lg 80342 Torsion Spring 2 un 009429 Conical Washer 539 x 862 x 014T OO Y 80349 Idler Pulley 4 0 Diameter OE 903950 u Poly V Belt gt NN Conical Washer 1
47. d 15 brown wire Right proximity PROX check TDC between terminals 13 black wire and 15 brown wire Reason The light coming on shows the proximity is getting electrical contact Proximity light on Volts DC Proximity light off 12 Volts DC Proximity light on Volts DC Proximity light off 12 Volts DC Replace proximity switch if the volt ages do not read as above PROBLEM Insufficient hesitation at carriage stops prior to reversing traverse The dwell time on the Reset dwell time as required One traverse drive control not set properly increment increases Dwell time by 1 2 second PROBLEM Traverse changes directions erratically while running in traverse cycle Loose wire to proximity Check wire connections from the prox switch imity switches and tighten down Screws 43 A loose wire connection will give Intermittent electrical contact MECHANICAL TROUBLESHOOTING PROBLEM Excessice noise or vibration on one end of the machine Possible Cause oet screws on bearings are not tight on grinding shaft PROBLEM Grinding wheel traverse binding Possible Cause Shafts are dirty Grinding shaft is at a severe angle PROBLEM Handwheel or vertical indicator gage walks during grinding Possible Cause Bracket connecting gage to vertical adjuster is loose Plug and set screw loose PROBLEM Reels ground have high low blades Possible Cause Traverse Spee
48. d set too fast Checkout Procedure Tighten set screws located on bearings 80336 Checkout Procedure Clean the shafts as specified in the maintenance section of this manual Raise or lower one end of the shaft until approximately level This grinder is not designed to operate at a severe angle Adjust reel or setup until the shaft is approximately level Checkout Procedure Push lightly up and down on the digital gage to see if it is loose Tighten the screws on the bracket to the vertical adjuster or remove the gage and tighten the screws from the bracket to the gage Tighten the drag on the vertical shafts by tightening the setscrew located on the back of the vertical adjuster husing See Vertical Infeed Shaft Drag in the adjustment section Checkout Procedure Check roundness using the digital gage Traverse speed should be set approximately 12 ft min 4 meters min if roundness is varying MECHANICAL TROUBLESHOOTING Continued PROBLEM Uneven traverse speed or grinding stock removal from reel is irregular Possible Cause Linear bearings are damaged or have grit buildup causing uneven traversing load Grinding shaft or wheels have grit buildup causing uneven loading Left side traverse pulley is full of grit causing the pulley not to turn freely on shaft PROBLEM Traverse Belt Slips Possible Cause Clamping tip is not adjusted properly Too heavy a grind for traverse speed PROBLEM Too heavy a
49. 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 20 AMPS THE TOLERANCE ON THIS POWER REQUIREMENT IS 5 THEREFORE THE MINIMUM VOLTAGE REQUIREMENT IS 109VAC WITH 20 AMPS VOLTAGE MUST BE CHECKED WITH ALL EQUIPMENT UNDER LOAD OPERATING ON XN NES Ax a Eum FACTORY PRESET THE CIRCUIT TRIP LIGHT DO NOT OPERATE THIS GRINDER WITH INDICATES LOW AN EXTENSION CORD VOLTAGE DELIVERED PROPER GROUNDING OF THE RECEPTACLE GROUND IN YOUR BUILDING TO GRINDE MUST BE VERIFIED IMPROPER DLL GROUNDING IN YOUR BUILDING MAY CAUSE THE GRINDER TO MALFUNCTION FOR 20 AMP RATED LARGE MACHINES Below is a list of required wire size in your building For 0 to 40 Feet from panel to receptacle Use 12 Ga Wire For 40 to 60 Feet from panel to receptacle Use 10 Ga Wire For 60 to 100 Feet from panel to 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 10 AS
50. e should NEVER be used on polycarbonate windows DO NOT clean polycarbonate windows in hot sun or at elevated temperatures Graffiti Removal e Butyl cellosolve for removal of paints marking pen inks lipstick etc e The use of masking tape adhesive tape or lint removal tools works well for lifting off old weathered paints 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 18 MAINTENANCE Continued DIGITAL GAGE Important E Do not mark the scale unit with and electric engraver or scratch gt the scale Always use an SR44 battery silver oxide cell z I If the scale will not be used for more than three months remove A the battery and store it properly Otherwise leakage if F gt e any from the battery may damage the unit Ea Description of Parts 1 Beam 2 Main Scale 3 Battery compartment 4 Outp Connection o 098 4 1 2 5 Display 6 ON OFF Power LT ma 7 ZERO ABS switch 8 Origin Switch n aa 9 Inch mm Switch 10 Tapped hole zi m 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
51. eel 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 24 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 must be adjusted correctly for proper lift function These left side screws can be accessed by removing the left side lower lift guard Tighten the screws until tight springs solid with blue loctite no 242 then back the screws out ONE full turn See items marke B311613 below When complete reinstall the left side lower lift guard 2 8311513 EN NE LEFT SIDE LOOKING FROM FRONT GRINDER 3589109 BETWEEN SIDE PLATE AND BEARING SHAFT E 4 PLACES B311013 RIGHT SIDE LOOKING FROM FRONT OF GRINDER 25 CONTROL BOARD POTENTIOMETER ADJUSTMENTS POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL TDC Min Speed Factory set at full CCW 8 30 Do not change this setting Right Traverse Forward Torque Factory set at full CW 4 30 Do not change this setting Left Traverse Re
52. embly 0 PPC Belt Clamp AA ss 2007 Traverse Guard ER BUSES lern een Shield Mount Bracket rte 503924 Spark Shield 55 25 M Spin Support ll 512151272 Bearing Housing Assembly ros S SSS 09404 Linear Bearing or 3709200 Oil Seal 1 ID x 1 57 OD x 187 o SID Denen Adjustable Handle 3 8 16 x 1 56 Long 515 A UCC nee Adjustable Handle 1 4 20 x 1 25 Long 21 mec 386 ID 50 OD 75 Long o a Destaco 602 Clamp E a DOSE T knob Assembly 3099 10D Washer Lr H BI9TOSI ana 10 32 x 5 8 Socket Head Cap Screw SS11 ZARA Finger Rotate Base dO PRO ROSEN 6009057 Spacer 265 ID x 48 OD x 50 Long 224122 Knob 1 4 20 x 1 Diameter NENNE C190360 10 32 x 3 16 Socket Head Set Screw AS ES os EOL RSE 3708838 Star Knob 1 Diameter SS 55112 e ROEE AE Cam Plate 2 A 205 P M Cam Follower 1 2 Diameter 32
53. ext Spin Motor works Yes endtroubleshooting No go to step E next SDC Term L1 to term L2 for 120 Volts AC Yes go to Step F next No Verify Power to Circuit Breaker and SMS and continuity of wires Replace CB or SMS if needed SDC Term A1 to A2 for approx 20 Volts DC Yes go to Step G next No go to Step L next SRS Term 2 to 3 for approx 20 Volts DC Yes go to Step H next No replace wires 13 amp 14 SRS Term 6 to 7 for approx 20 Volts DC Yes go to Step l next No replace SRS switch Remove wires at Terminal Strip 1 Term 4 amp 5 check 0 ohms across the black and white wires Yes end troubleshooting motor should work if it does not replace motor No go to Step P next ELECTRICAL TROUBLESHOOTING Continued Possible Cause RTP Relief Torque Pot is not working Relief Speed Pot RSP is not set correctly RTP is not working Worn Motor Brushes Checkout Procedure L Check RTP 50K on control panel check voltage with pots at fully clockwise and counterclockwise positions M Check RSP remote speed 10k on SDC top board this is preset to 9 30 N RTP 50K Remove 3 Remote Torque Wires red wire to term W white wire to term L black wire to term H P Inspect Motor Brushes DISCONNECT POWER FROM MACHINE 35 SPIN DRIVE On SDC Remote Torque check Black wire H Terminal Red wire W terminal for Pot CCW 0 volts DC Pot CW 2 Volts DC Ce
54. g 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 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 TABLE OF CONTENTS This machine is intended for grinding the reel of reel type mower units ONLY Any use other than this may cause personal injury and void the warranty To assure the quality and safety of your machine and to maintain the warranty you MUST use original equipment manufactures replacement parts and have any repair work done by a qualified professional ALL operators of this equipment must be thoroughly trained BEFORE operating the equipment 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
55. g in relief mode Assuming SSS System Start Switch is on with 115 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram on page 76 are correct and pull on wire terminals with approximately 3 16 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 Relief Torque Pot RTP set to zero opin Motor Switch SMS is not on opin Rotation Switch SRS is not on Circuit Breaker is Tripped 4 AMP opin Drive Control SDS is not working Spin Drive motor is bad A Set RTP to 20 on the control panel B Turn SMS switch on C Turn SRS switch to direction of reel rotation required NOTE CENTER POSITION IS OFF D Reset Circiut Breaker on the side of the grinder above the control cover Push in if tripped E Check SDS L1 to L2 for 120 Volts AC F Check SDC A1 amp A2 for approx 20 Volts DC Have Relief Torque set to Red Line G Check for approx 20 Volts DC input to SRS H Check for approx 20 Volts DC out put from SRS Check spin motor continuity A DISCONNECT POWER FROM THE MACHINE 34 Spin Motor works Yes endtroubleshooting No go to Step B next Spin Motor works Yes endtroubleshooting No go to Step C next Spin Motor works Yes endtroubleshooting No go to step D n
56. gital Scale 6 Mitutoyo 572 J 3 6 0 gt Mounting Block ee Gage Mounting Bracket 5 SS Soy Handwheel 1 2 13 ID Juss DOES Arm Support Pivot SS 5522 Vertical Adjustment Shaft 112 SUSE Vertical Adjuster Assembly R Assembly EEN EEC 80344 Hex Acorn Nut 1 2 13 H 3709042 en Ball Bearing Thrust Nice 603 1 4 ZE ss 7469149 Nylon Plug 5 16 61 EXPLODED VIEW 55563 TRAVERSE DRIVE ASSENBLY Oc PARTS LIST 55563 TRAVERSE DRIVE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION PNY 5251011 u GEE 1 4 20 X 5 8 Socket Head Cap Screw BZOZ2J Ao s 1 4 20 x 4 5 Socket Head Cap Screw e q g p 1 4 20 Locknut Thin K250001 Flat Washer 1 4 mc 1 4 Lockwasher Split EEEE Traverse Pulley Shaft DOGO Cog Pulley Drive AE 6059062 Motor Assembly Trav W16 l o 3050 as Traverse Pulley Guard E 55552 ini Cog Pulley Driven 375 P 50W 50959 M Die Spring 34 ID x 2 0 Lg J 80354
57. ing Decal Not Shown C 3708820 PR 8 32 x 50 Button Head Safety Screw o 9708988 Spring Latch O 578 222727 Knob 5 16 18 Female Oval 3 nace a as 3700010 Thrust Washer 500 ID x 937 OD x 032 Thick O 2 Door Safety Switch Assembly Rear 6329083 Door Safety Switch Mounting Plate 30 6929082 A Door Switch Mounting Plate EPEE 6329085 Latch Spacer Plate o M 6209100 Lift Access Panel S 3707647 Door Safety Coded Magnet Li qan Dunia B250805 een hem 1 4 20 x 1 2 Flat Head Cap Screw Al COT Strain Relief P J507000 1 2 13 Locknut Nylon Insert 51 PAR PARTS LIST 6200970 REEL LIFT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Jus 5190818 zen Button Head Cap Screw 10 24 x 1 2 Long a ee Socket Head Screw 3 8 16 x 1 Long E Socket Head Screw 3 8 16 1 1 4 Long A sas snn ns BA Mem Socket Head Cap Screw 3 8 16 x 2 1 2 Long c e T Socket Head Cap Screw 3 8 16 x 4 1 2 Long OO B5024095 uuu aaa Flat Head Cap Screw 1 2 13 x 1 1 2 Long 509211
58. ion the belt Remove the right side cover panel Loosen the screws holding the traverse motor and tilt the bottom of the motor out releasing any remaining tension on the belt On the left side remove the nut from the bottom belt tensioning screw this will allow the belt to be removed Place a new belt on the left pulley making sure it is seated properly in the cogged teeth and replace the locknut Feed the new belt throught the slot on the right arm and place on motor pulley Use the motor as a lever to apply tension to the new belt Tighten motor screws and adjust the tension in the belt as specified in the BELT TENSION section Adjust the height of the motor pulley if necessary so the belt is located in the center of the traverse belt clamp Test the traverse motor and replace the left side and right side cover panels 16 GRIND SHAFT PULLEY MOTOR BELT TENSIONER FULLEY GRIND MATAR PHI Fy FIG 35 TRAVERSE TRAVERSE BELI TRAVERSE PULLEY TENSION SPRINGS FIG 36 MAINTENANCE Continued TRAVERSE SHAFT LINEAR BEARING REPLACEMENT 2 REMOVE REAR Remove the left side cover panel Then remove the grinding shaft by removing the left side bearing and loosening the setscrews on the right side bearing Also remove the traverse belt 1 REMOVE RIDING SHAFT amp TRAVERSE BEL To remove the traverse shafts first lower the grinding shaft so that it is in in s lowest positi
59. ipped No 120 Volts AC power to Filter FTR No 120 Volts AC power out of Filter No 120 Volts AC power to Main Circuit Breaker MCB No 120 Volts AC power from Main Circuit Breaker MCB B Listen for the Magnetic Starter MAG contacts to pull in with a clunk C Plug in main power cord D Close guard doors and turn off all switches E Check circuit breaker in your building and reset if necessary Check wall outlet with a light to make sure it works F Check for 120V at Cord into FTR Power Cord 32 G Check for 120V out of FTR H Check for 120V to MCB I Check for 120V to MCB 29 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 go to step D next Machine works Yes end troubleshooting No go to step E next Machine works Yes end troubleshooting No but light works in outlet go to Step F next No but light does not work in outlet You must solve your power delivery problem independent of machine FTR Line Terminals for 120 Volts AC Yes Go to Step G next No Replace Power Cord 6059054 FTR Load Terminals for 120 Volts AC Yes Go to Step H next No Replace Filter MCB Bottom Terminal to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step l next No Check wires amp replace if needed MCB Top Terminal to Terminal Block 4 Blue for 120 V
60. ke 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 INSTRUCTIONS Continued INSTALLATION OF REEL LIFT ASSEMBLY ON MODEL 5550920 The reel lift has been fully assembled at the factory The only installation required is to remove the shipping bolt and packing material between the lift ramp and the lift body See FIG 29 SHIPPING BOLT FIG 29 12 PERIODIC MAINTENANCE DAILY MAINTENANCE IS SPECIFIED ON PAGE 4 OF THE OPERATOR S MANUAL AND IS TO BE PERFORMED BY THE OPERATOR LISTED BELOW ARE PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY S MAINTENANCE DEPARTMENT 1 Clean the dust tray located at the lower front of the machine monthly using a vacuum or by removing it Pull the tray out until the back of the tray is even with the front of the frame and vacuum it out To remove continue to pull straight out until the tray is free USE CAUTION WHEN PULLING THE TRAY OUT AS THERE IS NO MECHANICAL STOP WHEN REMOVING TRAY PULL STRAGHT OUT AND SUPPORT IT TO PREVENT DUMPING
61. l Board A 9707224 Cable Tie Mount Not Shown T 3 0722 2 Cable Tie 6 5 x 18 Wide Not Shown SES Wire Shown SONS TATL E S Wire Assembly W99 Not Shown POZ 10001 ee Wire Assembly Not Shown 52 P H VOTO o eC Wire Harness Spin Drive Not Shown OO eT PTT Wire Safety Monitor Shown ee ee oic PE Terminal Block Tag 1 10 Not Shown OP H H 2707638 Terminal Block Tag 11 20 Not Shown 77 WIRING DIAGRAM 55455 1 FIP FELIEF T0FALE S P FIE NFL Gr PIM AF BERR ANAT IIR EOR WERE 2 EAEE SEP SICH SEV STEM XT SPIELE 01 ICH HI THMIRL VOLTAGE TC TATE FFT IH TERA AL BARON TP IEMERSE SPEED FM IF PELE DTE 8 rms l di 78 mU HEHE EEEE
62. nding shaft NOTE EXCESSIVE PRELOAD OF THE BEARING ASSEMBLIES ON THE HUB CAN CAUSE THE BEARINGS TO WEAR QUICKER AND COULD CAUSE THEM TO FAIL Q PREMATURELY To adjust the traversing bearing assemblies use an allen wrench and 3 8 wrench Use the allen wrench to loosen the screws while using the 3 8 wrench to hold the bearing assembly shaft After loosening the bearing assemblies push them away from the hub flange Now Position the hub so Positioning there is 1 32 1 16 0 8 1 6 clearance between the indexing Bolts finger and the hub wheel flange Now bring the LEFT travers ing bearing assembly in until it just contacts the hub flange Lock this bearing in place by tightening the screw Press on the wheel so that the hub flange is against the left traversing bearing and verify the clearance of the indexing finger to the wheel flange Now bring the Right traversing bearing in until there is a minimum gap approx 1 32 0 8 between the Indexing Finger bearing and the hub flange Lock in place by tighten the screw Check to make sure be freely and with minimum slop E NOTE EXCESSIVE PRELOAD OF THE uu BEARING ASSEMBLIES ON THE HUB FLANGE CAN CAUSE THE 1 32 1 16 BEARINGS TO WEAR QUICKER AND COULD CAUSE THEM TO FAIL PREMATURELY a S Hub Flange Wheel Traversing 7 Bearing Hub Wheel Assemblies Flange 23 ADJUSTMENTS Continued REEL LIFT PIVOT BOLTS There are four pivot bolts on the r
63. nti Rollback Plate c m 209097 Pivot Pin S aE eee 520 9 TIO ne Lift Cross Support 9582 5 Lift Bearing Assembly OUI Uses ait Lift Frame Weldment OF 250 215 Load Carrier Weldment RE 2748 5 575 rac deere sas Actuator Top Block Assembly o 62095 4 Ramp Weldment IM M 3708450 P Capacity Warning Decal Not Shown c 690909390 Capacity Warning Decal Text Not Shown OD BOOS 5 16 18 x 5 8 Button Head Socket Screw n P 3589109 22 22 tas Flat Washer 315 ID x 50 OD x 035 Thick 53 PARTSLIST 6200720 REEL LIFT ASSEMBLY 54 PARTSLIST 6200720 REEL LIFT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION m n B190813 Button Head Cap Screw 10 24 x 1 2 Long Button Head Screw 10 24 3 4 Long B251016 Button Head Cap Screw 1 4 20 x 5 8 Long J197000 10 24 Nylon Jam Locknut EE J257100_ a ua 1 4 20 Nylon Locknut a R000483 10 Lockwasher fo sn R000559 10 24 Kep Nut usss H DOT Irene Liquid Tight Strain Relief 27 47 Wire
64. olts AC Yes Go to Step J next No Flip Switch on MCB to ON Machine works end trouble shooting Machine does not work replace MCB Possible Causes 120 Volts AC power not delivered to Terminal Strip Grinding Motor Switch GMS not working Spin Motor Switch SMS not working Bad Emergency Stop Switch ESS Bad System Start Switch SSS Low Voltage Relay REL not operating Bad Main Contactor MAG Checkout Procedure J Check for 120 Volts AC at terminal strip K Check for 120 Volts AC at GMS Terminals 1 L Check for 120 Volts AC at SMS Terminals 1 M Check voltage after the ESS MAKE SURE SWITCH IS PULLED UP N Hold in SSS and Check voltage after the SSS O Hold in SSS and Check voltage at LVR LVR must be installed in 8 pin socket P Hold in SSS and Check voltage at MAG A1 amp A2 30 ELECTRICAL TROUBLESHOOTING Continued Terminal 11 on Terminal Strip 2 07TB2 11 to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step K next No Check wires 7 amp 3 Check Jumper on Terminal Blocks 1 3 Measure 120 volts AC from GMS Terminal 1 to Term Block 4 Blue Yes Go to Step L next No Flip Switch and check again Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch Measure 120 volts AC from SMS Terminal 1 to Term Block 4 Blue Yes Go to Step M next No Flip Switch and check again Works Switch is upside down
65. on Then remove the left side arm To remove the left arm remove the bolt at the rear of the machine It may be necessary to clamp onto the shaft that the bolt is screwed into so that it does not spin After removing the bolt pull the arm off the rear shaft Remove the front of the arm from the vertical adjuster housing pull the arm straight off the traverse shafts Caution should be used as the shafts may come out of the right side arm Slide the grinding head assemblies off the traverse shafts 3 LIFT ARM FF REAR PIVOT SAFT AND SLIDE ARFA BACK IHN Replace the shafts if necessary or press Fig 37 the bearings out of the bearing housings and replace with new bearings and seals Two bearings go in the front and 1 in the rear of the hous ing Clean the 2 spherical bearings in the arm and place the traverse shaft into the right arm Replace the grinding head assemblies spin first Clean the bearing in the left arm and slide onto traverse shaft Note The sperical bearing in the arm has to be lined up with the shafts for the shafts to slide into the bearings Replace and tighten items in the opposite order of removal Make sure the wheels are properly located in the correct grinding head assembly with the nut side of the wheel toward the left side of the machine see Replacement of Grinding Wheel 17 MAINTENANCE Continued CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE WINDOWS Cleaning In
66. ord 10 vere URS Hole Plug 875 Dia ES S DIAS T senden Hole Plug 625 Dia STORE zaw nen Door Safety Magnet Coded 37089 O 8 32 x 75 Button Head Safety Screw D 3708820 8 32 x 50 Button Head Safety Screw 2 S SS I M Spring Hinge WW 9708988 Spring Latch SR zai G Knob 5 16 18 Female Oval a e T 97 09 07 S Rubber Bumper N 6OS90Zl Door Safety Switch Assembly Rear 5 6329029 Walker Hinged Panel 49 PARTS LIST 55466 LIFT COMPONENT ASSEMBLY 50 PARTS LIST 55466 LIFT COMPONENT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION i EE es 10 24 x 3 4 Button Head Socket Cap Screw B250816 1 4 20 x 1 2 Button Head Socket Cap Screw O M 251201 au iiss 1 4 20 x 3 4 Hex Head Cap Screw iain BO ZI Owo 3 8 16 x 3 4 Button Head Socket Cap Screw OE EE BODOZIO 1 2 13 x 2 0 Button Head Socket Screw SEE PCE C311620 5 16 18 x 1 0 Socket Setscrew Cup Point m 8 32 Locknut Jam Nylon Insert J1
67. rsing at each end of stroke A setting of 6 sets the dwell time at 3 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 ta ate c VE 10 4 ie co A m C rA E NE Ele 2 Per Hm FMI LiT C w ale OE da DC xe as Potentiometer cn Clock Orientation n E 26 CONTROL BOARD POTENTIOMETER ADJUSTMENTS Continued 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 FIG 45 and FIG 46 These potentiometers have been set at the factory to the positions shown on FIG 45 and FIG 46 In the Relief Grinding Mode The Relief Speed Pot RSP and the Relief Torque Pot RTP interact with each other The RSP is located on the upper spin board as a relief speed preset at 9 30 20 Volts DC See FIG 45 The RTP is loc
68. rt switch to pull in MAG before testing voltages D Check PWR for 120 Volts AC Turn switches off and press start switch to pull in MAG before testing voltages E Verify 24Volts DC out to Door owitches F With Rear Door closed or Rear Ramp Closed Verify 24Volts DC back form rear Door Switch G With Front doors Closed Verify 24Volts DC back form Front Door Switch PROBLEM MAG turns on only with System Start Switch held in Possible Cause MAG holding contact has failed Checkout Procedure A Check wiring to and from MAG holding contact in Verify the magnetic starter holding contact is working 31 ELECTRICAL TROUBLESHOOTING Continued Machine works Yes end troubleshooting No go to Step B next See Alignment section of this Manual Machine works Yes end troubleshooting No go to Step C next Measure 24 volts DC from SSM Terminal A1 to Terminal A2 Yes Go to Step E next No Go to Step D next Measure 120 volts AC from PWR Terminal L to Terminal N Yes Verify 24 VDC out of PWR V to V Replace if no Voltage out or Check Wiring amp Verify Continuity to SSM if there is 24 VDC No Verify Wiring and Continuity from PWR to terminal blocks Measure approximately 24 volts DC from Terminal Strip 1 Terminal 17 to Terminal Strip 2 Terminal 3 Yes Go to Step F next No Verify Continuity of Wires to Terminal strip Replace SSM if wires check OK Measure approximately 24 volts
69. 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 j 2 To set the origin move the slider to an area you wish to ua set as your origin Turn the power on Hold the ORIGIN switch down more than one second The 0 00 ap 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 set the origin see above The display can ABS fg 145 be set to zero at any desired position by pressing the ZERO v E ABS switch INC indicator will apper in the display INC mode E permitting measurements from this zero point To return to the AE uu ABS mode hold the ZERO ABS button form more than 2 PON seconds Error Symptoms amp Remedies ERRC and display flickering Occurs when the scale surface is stained Clean the scale surface and coat a thin film of low viscosity oil to keep out moisture 1 P E in the least significant digit This occurs when the Erri slider is moved too quickly but it does not affect the measurement it stays on when the slider stops the 3 scale surface is probably s
70. speed pot is wired per electrical diagram D Check all pot settings on circuit board as shown in wiring diagram See adjustment section Traverse Motor Control Board Settings 42 Traverse Drive Control Pin 8 to 7 Pot full CCW Pot Full CW 0 VDC 9 75 VDC Pin 8 to 9 Pot full CCW Pot Full CW 9 75 VDC 0 VDC Yes Pot is OK No Go to Step B next Check for 10 000 ohms Red to White wires Full CCW 0 ohms Full CW 10 000 ohms Red to Black wires Full CCW 10 000 ohms Full CW 0 ohms Yes Go to Step C next No replace potentiometer Wiper inside of potentiometer controls speed Wiper may be bad and not making contact Verify potentiomter White wire to terminal 7 Red wire to terminal 8 and Black wire to terminal 9 if not correct Check for Proper function Yes end troubleshooting No Go to Step D next Minimum and maximum pot settings effect traverse speed ELECTRICAL TROUBLESHOOTING Continued PROBLEM If the carriage traverses to one end of stroke or the other and it stops and does not reverse direction Possible Cause Proximity switch is not working properly or wire connections are loose Remedy First check to see of proximity light comes on When the light is on it means that there is electricity coming to proximity switch Actuate prox switches with steel tool to take measurements Left proximity PROX1 check Traverse drive Control TDC between terminals 14 black wire an
71. structions 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 ocratches and minor abrasions can be minimized by using a mild automobile polish Three such products that tend to polish and fill scratches are Johnson paste Wax Novus Plastic Polish 1 and 2 and Mirror Glaze plastic polish M G M10 Itis suggested that a test be made on a corner of the polycarbonate window with the product selected following the polish manufacturer s instructions Some Important DON TS DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows Never scrape polycarbonate windows with squeegees razor blades or other sharp instruments Benzene gasoline acetone or carbon tetrachlorid
72. tained If this is the case take fe 486 remedies as for ERRC B indication Battery voltage is low Replace the battery as soon as possible 19 ADJUSTMENTS PROXIMITY SWITCH For the proximity switch to perform properly and reverse the direction of the grinding head assemb the sensor end of the prox must face toward the head assembly that is in use and must be mounte such that it is located past the edge of the prox holder NOTE The light on the proximity switch activates when metal is approximately 3 16 4 6 mm from front of proximity switch VERTICAL INFEED SHAFT DRAG If the grinding shaft tends to walk during grinding the drag on the vertical adjusters needs to be increased To increase the drag in the vertical adjustment shafts tighten the setscrew on the back of the vertical adjustment housing HILLER LIGHT END HEAL ASSEMBLY END MUST HE PAST HOLDER END FIG 38 VERTICAL INFEED SHAFT DRAG SETSCREW LULA TEL BACK OF EACH TOWER 20 ADJUSTMENTS Continued TRAVERSE BELT TENSION To adjust the tension on the traverse belt tighten the screws and nuts located to the left side of the traverse belt behind the left side cover panelto a minimum of 1 75 44 mm The traverse belt should be level when adjusting the belt tension DO NOT OVERTIGHTEN OVERTIGHTENING COULD DAMAGE THE BELT OR e TRAVERSE DRIVE SYSTEM
73. tical DOA Spin Mount Weldment 55442 P Spin Arm Weldment Horizontal 5 m TOG Reducer 10 1 Ratio VO ee 3709580 asa Flange Coupler 50 Bore NENA 6809588 Knob Assembly T 2 5 3 8 16 x 1 00L TO O 6329072 ssa Decal Scale 112 ym DC Motor Brush Shown 73 EXPLODED VIEW 55457 CONTROLS ASSEMBLY PARTS LIST 55457 CONTROLS ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION Jaa s D160608 Thrd Cutting Screw 8 32 x 3 8 F Type Den ee D250800 Thrd Cutting Screw 1 4 20 x 1 2 F Type Hex M 3250800 See Thrd Cutting Screw 1 4 20 x 1 2 F Type Pan Hd 2 J167000 8 32 Nylon Insert Lock Nut Jam OE R000536 Lockwasher 1 4 Internal Teeth e 12675 Control Panel Decal S S OE u uama Electrical Cover Panel 2187 Control Service Panel S E ter OO NE Control Panel Sub Assembly See Page 74 75 LO 55450 A Control Panel Cord Not Shown PE 55459 Potentiometer Cord Not Shown 55474 ER Wire Harness 555 Not Shown o
74. tion 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 Throughout this manual we refer to torque requirements as 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 Refer to the table at the right Bolts Going Into a Thread Hole In Aluminum Use the Grade 2 values in the table at the right Socket Head Screws Going Into a Nut or Steel Use the Grade 8 values in the table at the right Machine Screws No 6 screws 11 in lbs 0 125kg m No 8 screws 20 in lbs 0 23 kg m No 10 screws 32 in lbs 0 37 kg m SMOOTH MARKS 6 MARKS HEAD on HEAD HEAD 6 ft lbs 9 ft lbs 13 ft lbs thread 0 8 kg m 1 25 kg m 1 8 kg m 5 16 In 11 ft lbs 18 ft lbs 28 ft lbs thread 1 5 kg m 2 5 kg m 3 9 kg m 3 8 In 19 ft Ibs 31 ft Ibs 46 ft Ibs thread 2 6 kg m 4 3 kg m 6 4 kg m 7 16 In 30 ft lbs 50 ft Ibs 75 ft lbs thread 4 1 kg m 6 9 kg m 10 4 kg m 1 2 In 45 ft I
75. use a power washer to clean the machine Low Voltage Relay EEEE The grinder is equipped with a low voltage relay which 2 WARN NG 15 factory preset at 100 VAC If the power supply line 112 does not deliver 100 VAC power under load the relay E FACTORY PRESET will open and trip out the starter If this occurs your P d ly line is inadequate and must be correct TRIPLIGHT B Los proq before proceeding further with the grinder INDICATES LOW VOL TAGE DELIVERED ur E c pum Er TABLE OF CONTENTS oafety Instructions Daily Maintenance Service Data Assembly Instructions Maintenance Page 13 19 Adjustments Page 20 25 Electrical Troubleshooting Page 26 41 Mechanical Troubleshooting Page 42 43 Exploded Views and parts Lists Page 44 75 Wiring Diagram amp Schematic Page 76 77 DAILY MAINTENANCE BY THE OPERATOR On a daily basis clean the machine by wiping it off On a daily basis remove all grinding grit from the grinding shaft traverse shafts and tooling bar area On a daily basis inspect the machine for loose fasteners or components Contact your company s Maintenance Department if damaged or defective parts are found DO NOT USE COMPRESSED AIR TO CLEAN GRINDING DUST FROM GRINDER SAFETY INSTRUCTIONS Safety Awareness Symbols are inserted in this manual to alert you to possible Safety Hazards Whenever you see these symbols heed their instructions The Warning Symbol identifies The Caution
76. verse Torque Factory set at full CW 4 30 Do not change this setting IR COMP Factory set to 9 00 IR COMP is current 1 resistance R compensation COMP IR COMP adjusts the output voltage of the drive which balances load to motor RPM Regulation of a traverse motor may be improved by slight adjustment of the IR COMP 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 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 0 4 seconds A DIP switch setting of O sets the DWELL TIME to 0 seconds while a setting of 9 sets the DWELL TIME to 4 5 seconds Dwell time is preset to 4 setting for a 2 second dwell time when reve
77. zero speed is obtainable for spin speed IR Compensation Pot The IR Compensation is factory set at 9 00 Regulation of the spin or relief grind spin motor may be improved by a slight adjustment of the IR COMP 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 pot counterclockwise until symptoms just disappear UPPER SPIN BOARD LOWER SPIN BOARD 291 w 9 00 Xj 4 aM IR DMP u etu E AL D eZ M CH FIG 46 FIG 45 27 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 555 electrical system For those without that background service can be arranged through your local distributor This section presumes that you are already familiar with the normal operation of the Grinder If not you should read the front of this 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 panel 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

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