ACCU-Pro 670 Assembly And Service Manual

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ACCU-Pro 670 Assembly And Service Manual | Manualzz

ACCU-Pro

MODEL 670

SEMI-AUTOMATIC

BEDKNIFE GRINDER

ASSEMBLY

AND

SERVICE

MANUAL

WARNING

You must thoroughly read and understand this manual before assembling or maintaining the equipment, paying particular attention to the

Warning & Safety instructions.

6707956 (12-05)

1

SAFETY INSTRUCTIONS

Safety Awareness Symbols are inserted into this

manual to alert you to possible

Safety Hazards.

Whenever you see these symbols, follow their instructions.

The Warning Symbol identifies special instructions

or procedures which, if not strictly observed, could

result in personal injury.

The Caution Symbol identifies special instructions or procedures which, if not correctly followed, could

result in damage to or destruction of equipment.

1. KEEP GUARDS IN PLACE and in working order.

12. DON'T OVERREACH. balance at all times.

Keep proper footing and

2. REMOVE WRENCHES AND OTHER

TOOLS.

13. MAINTAIN GRINDER WITH CARE. Follow instructions in Service Manual for lubrication and preventive maintenance.

3. KEEP WORK AREA CLEAN.

4. DON'T USE IN DANGEROUS ENVIRONMENT

.

Don't use Grinder in damp or wet locations.

Machine is for indoor use only. Keep work area well lit.

14. DISCONNECT POWER BEFORE SERVICING.

15. REDUCE THE RISK OF UNINTENTIONAL

STARTING. Make sure the switch is OFF before plugging in the Grinder.

5. KEEP ALL VISITORS AWAY

. All visitors should be kept a safe distance from work area.

6. MAKE WORK AREA CHILD-PROOF with padlocks or master switches.

11. SECURE YOUR WORK. Make certain that the bedknife is securely fastened with the electromagnets provided before operating.

16. USE RECOMMENDED ACCESSORIES. Consult the manual for recommended accessories. Using improper accessories may cause risk of personal injury.

7. DON'T FORCE THE GRINDER. It will do the job better and safer if used as specified in this manual.

17. CHECK DAMAGED PARTS. A guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced.

8. USE THE RIGHT TOOL. Don't force the Grinder or an attachment to do a job for which it was not designed.

18. KNOW YOUR EQUIPMENT. Read this manual 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 get caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair.

10. ALWAYS USE SAFETY GLASSES

.

19. KEEP ALL SAFETY DECALS CLEAN AND

LEGIBLE. If safety decals become damaged or illegible for any reason, replace immediately. Refer to replacement parts illustrations in Service

Manual for the proper location and part numbers of safety decals.

20. DO NOT OPERATE THE GRINDER WHEN

UNDER THE INFLUENCE OF DRUGS,

ALCOHOL, OR MEDICATION

2

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 carefully follow these rules.

DO

1. DO always HANDLE AND STORE wheels in a

CAREFUL manner.

DON'T

1. DON'T use a cracked wheel or one that HAS

BEEN DROPPED or has become damaged.

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.

2. DON'T FORCE a wheel onto the machine OR

ALTER the size of the mounting hole - if

wheel won't fit the machine, get one that will.

3. DON'T ever EXCEED MAXIMUM

OPERATING SPEED established for

the wheel.

4. DON'T use mounting flanges on which the bearing surfaces ARE NOT CLEAN, FLAT

AND FREE OF BURRS.

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.

5. DON'T TIGHTEN the mounting nut

EXCESSIVELY.

6. DON'T grind on the SIDE OF THE WHEEL

(see Safety Code B7.2 for exception).

8. DO allow NEWLY MOUNTED WHEELS to run at operating speed, with guard in place, for at least one minute before grinding.

7. DON'T start the machine until the WHEEL

GUARD IS IN PLACE.

10. DO TURN OFF COOLANT before stopping to avoid creating an out-of-balance condition.

8. DON'T JAM work into the wheel.

9. DO always WEAR SAFETY GLASSES or some type of eye protection when grinding.

9. DON'T STAND DIRECTLY IN FRONT of a grinding wheel whenever a grinder is started.

10. DON'T FORCE GRINDING so that motor slows noticeably or work gets hot.

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.

3

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 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

The grinder is equipped with a low voltage relay which is factory preset at 100 VAC. If the power supply line does not deliver 100 VAC power under load, the relay will open and trip out the starter. If this occurs, your power supply line is inadequate and must be correct before proceeding further with the grinder.

CONTENTS

Warnings ...................................................................................................... Page 2 - 5

Contents and Specifications ......................................................................... Page 4

Assembly ..................................................................................................... Page 6 - 12

Maintenance ................................................................................................ Page 13 - 15

Adjustments ................................................................................................. Page 16 - 23

Troubleshooting ............................................................................................ Page 24 - 33

Electrical Schematic .................................................................................... Page 34

Control Box Component I.D. ........................................................................ Page 35

Parts List. ..................................................................................................... Page 36 - 49

SPECIFICATIONS

Electrical Requirements ............................................................. 115V 50/60 Hz, 15-amp circuit

Net Weight ....................................................................................................... 780 lbs [354 kg]

Shipping Weight ............................................................................................... 920 lbs [417 kg]

Maximum Grinding Length ................................................................................. 34 in. [863 mm]

Sound Level..................................................................................................... Less than 75 Dba

4

SKILL AND TRAINING REQUIRED FOR SERVICING

This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the ACCU-Pro 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 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 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

Use the Grade 8 values in the table at the right.

Machine Screw

No. 6 Screws:

No. 8 Screws:

11in.-lbs [0.125 kg-m]

20 in.-lbs [0.23 kg-m]

No. 10 Screws: 32 in.-lbs [0.37kg-m]

GRADE 2 GRADE 5 GRADE 8

SMOOTH 3 MARKS 6 MARKS

HEAD on HEAD on HEAD

1/4 In. 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-lbs 31 ft-lbs 46 ft-lbs

thread (2.6 kg-m) (4.3 kg-m) (6.4 kg-m)

7/16 In. 30 ft-lbs 50 ft-lbs 75 ft-lbs

thread (4.1 kg-m) (6.9 kg-m) (10.4 kg-m)

1/2 In. 45 ft-lbs 75 ft-lbs 115 ft-lbs

thread (6.2 kg-m) (10.4 kg-m) (15.9 kg-m)

5

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 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.

2. 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

Remove the shipping strap that secures the grinding head and carriage to the left end of the machine during shipment. Discard the leg screw and the shipping strap.

6

FIG. 1

FIG. 2

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 of the base. See

FIG. 2. Don't turn the leveling feet when tightening.

Again recheck the level after the nuts are firmly tightened.

FOR GRINDING ACCURACY, THE MACHINE

DOES NOT HAVE TO BE PERFECTLY LEVEL.

HOWEVER, IT IS CRITICAL THAT FRONT-TO-

BACK LEVELING BE IDENTICAL AT BOTH

ENDS OF 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.

A

Leveling Side-to-Side

FIG. 3

FIG. 4

Regular Hex Nut

Lock Nut

FIG. 5

7

ASSEMBLY INSTRUCTIONS (Continued)

APPLY POWER

BEFORE YOU APPLY POWER TO THE

GRINDER, REFER TO THE "IMPORTANT

GROUNDING INSTRUCTIONS" ON PAGE 9.

115 Volt Model Only. Plug the control box power cord into a standard 115V AC 15-amp grounded receptacle. See FIG. 7.

FIG. 7

220 Volt Model Only. For 220 Volt Applications order Part

No. 6700952, 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 POWER DISTRIBUTION PANEL, WITH

NO OTHER MAJOR POWER DRAW

EQUIPMENT ON THE SAME LINE.

The grinder is equipped with a low voltage relay which is factory preset at 100 VAC. If the power supply line does not deliver 100 VAC power under load, the relay will open and trip out the starter. If this occurs, your power supply line is inadequate and must be correct before proceeding further with the grinder.

IT IS REQUIRED THAT THE POWER

DELIVERED TO THIS GRINDER IS 115 VAC -

15 AMPS. THE TOLERANCE ON THIS

POWER REQUIREMENT IS +/- 5%.

THEREFORE THE MINIMUM VOLTAGE

REQUIREMENT IS 109VAC WITH 15 AMPS.

VOLTAGE MUST BE CHECKED WITH ALL

EQUIPMENT UNDER LOAD (OPERATING)

ON THE CIRCUIT.

DO NOT OPERATE THIS GRINDER WITH

AN EXTENSION CORD.

PROPER GROUNDING OF THE RECEP-

TACLE GROUND IN YOUR BUILDING MUST

BE VERIFIED. IMPROPER GROUNDING IN

YOUR BUILDING MAY CAUSE THE GRINDER

TO MALFUNCTION.

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 Wire.

8

ASSEMBLY INSTRUCTIONS (Continued)

CHARGING THE UNINTERUPTABLE POWER SUPPLY

The Uninteruptable Power Supply (UPS) comes from the supplier with no charge. When the machine is ready for operation, plug it in and turn on the

UPS. The battery must charge for a minimum of 24 hours. For UPS functions, refer to the separate manual supplied with the grinder.

THE UPS WILL NOT FUNCTION PROPERLY IF THERE IS INSUFFICIENT

POWER TO THE MACHINE. INSUFFICIENT POWER MAY ALLOW THE

BEDKNIFE TO SLIP OR MOVE ON THE MAGNETS WHILE GRINDING. SEE

PREVIOUS PAGE FOR POWER REQUIREMENTS.

FOR 220 V 50 or 60Hz applications

Product No. 6700952 should be ordered.

6700952 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.

FIG. 8

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 properlysized circuit breaker or fuse. SEE SERIAL NUMBER PLATE FOR FULL LOAD AMP RATING OF YOUR

MACHINE.

Never modify the plug provided with the machine--if it won't fit the outlet, have a proper outlet and circuit installed by a qualified electrician.

ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOUR

MACHINE. AN IMPROPER CONNECTION CAN CAUSE A DANGEROUS

ELECTRICAL SHOCK. IF YOU ARE UNSURE OF THE PROPER

ELECTRICAL GROUNDING PROCEDURE, CONTACT A QUALIFIED

ELECTRICIAN.

9

ASSEMBLY INSTRUCTIONS (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: a. Crank the carriage all the way toward the front (that is, toward the operator's position).

b.

Remove the actuator mounting screw on top of the carriage. See FIG. 9. Loosen the setscrew on the collar that holds the actuator release lever in place (this is located behind the flap by the release lever handle). Remove the actuator release lever. (Keep track of all hardware. See page 40 for exploded view.)

Then push the carriage toward the right end of the Grinder.

c. Loosen the two set screws in the bearing pillow block at each end of the drive shaft.

Drive Shaft

Seal Plate

Loosen the two set screws in the drive coupling at the right end of the carriage.

d. Slide the drive shaft out the left end of the machine.

e. Remove the shaft seals from the actuator two screws each.

f.

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 (See Fig 10A). Retighten all set screws.

g. Push the carriage back to the left, and reattach the actuator with the mounting screw. See FIG. 9.

3. Remove the two rail wiper brackets from each side of the carriage - two screws each. (See Fig11A)

4. 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.

5.

Attach the right and left brackets to the underside of the carriage using two 1/4" button head screws and lockwashers on each side. (See Fig 11) Then attach the rear protective plate to the brackets just installed using two 1/4" screws and locknuts. Re-install the actuator release lever. Last attach the bellows to the brackets with the bolt heads on the bellows side of the brackets.

6. Press the bellows down until it snaps onto the carriage rails.

7. Reattach the left and right outside leg panels.

Actuator

Release

Lever

10

Actuator Mounting

Screw (under the rubber splash guard)

Linear Actuator

Actuator Bar Assembly

Actuator Release Lever

Flexible

Coupling

Drive

Shaft

Left Bellows

Bracket

1/8 to 1/4 in.

Right Bellows

Bracket

FIG. 10

Wiper

Brackets

FIG. 11A

FIG. 9

Traverse

Motor

FIG. 10A

Rear Plate

FIG. 11

ASSEMBLY INSTRUCTIONS (Continued)

INSTALL THE COOLANT TANK

Assemble the Coolant Tank as outlined in the instructions

(Part No. 3708785) in the coolant tank carton.

Center the Tank under the Grinder.

Install the 1" I.D. drain tubing over the barbed end of the plastic adapter on the coolant tray drain. Cut the tubing to the proper length to reach about 1-1/2" [40 mm] into the large opening on top of the Coolant Tank. See FIG. 12.

Read the coolant mixing directions and the electrical warnings in the Coolant Tank instructions.

THE COOLANT RATIO AS SPECIFIED MUST BE

USED. TO HIGH A CONCENTRATION OR LOW A

CONCENTRATION WILL CAUSE CORROSION

AND PERFORMANCE PROBLEMS.

1. 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 3.25 gallons of water and .5 pints of concentrate

(12.5 liters of water and 0.25 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.

Manual Reset

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 prepared to press STOP if there is any problem.

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.

Overload Sensor

Secure any excess electrical cord to a crossbar on the underside of the machine.

Manual/Auto

Selector

FIG. 12

Stop

FIG. 13

11

ASSEMBLY INSTRUCTIONS (Continued)

CHECK THE CARRIAGE TRAVERSE

Move the proximity switch assemblies to about 12" [300 mm] 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.

MAKE 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.

12

MAINTENANCE

DAILY MAINTENANCE IS SPECIFIED ON PAGE 6 OF

THE OPERATOR'S MANUAL, AND IS TO BE PER-

FORMED BY THE OPERATOR.

Adjustable Electromagnet Bellows

LISTED BELOW ARE PERIODIC MAINTENANCE

ITEMS TO BE PERFORMED BY YOUR COMPANY'S

MAINTENANCE DEPARTMENT:

1. Lift the bellows located on adjustable electromaget (see

FIG 14a) and wipe off the bearing rail monthly. Every 3 to 6 months throughly cleean the rail and flood spray with WD-40 or an equivalent lubricant. Run the adjustable electromagent back and forth through its full range of travel. With a clean rag, wipe off the excess lubricant. Run the carriage back and forth and wipe the rail after each pass. Repeat until the rail feels dry.

2. Lift the bellows, (See FIG. 14b) 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 located on the following page. Generally, this will be every 6 months to a year.

3. Replace the four foam rail wipers (FIG. 15) every 6 months of operation. Note: Wipers are removed if optional bellows are installed.

4. Clean the interior and the top cover of the Coolant Tank as necessary and at least every 6 months.

Right Side Tooling

Alignment Adjuster

Carriage

Bellows

Grinding Head

Height Adjuster

Drive Shaft

5. Clean the exterior of the diamond dresser arm and spray with WD-40 or equivalent at least every 6 months.

6. Clean the exterior of the grinding head hieght adjuster and spray with WD-40 or equivalent at least every 6 months. Move head through full range of motion to maintian function.

7. Clean the exterior of the right side tooling alignment adjuster and spray with WD-40 or equivalent at least every 6 months.

8. Check the brushes on the auto traverse drive motor once every 36 months. Replace as necessary.

Foam Rail

Wipers

THE UNINTERUPTABLE POWER SUPPLY (UPS) WHICH IS

USED AS A BACKUP TO HOLD THE BEDKNIFE TO THE

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 REPLACE-

MENT BATTERY PART NUMBER.

13

FIG. 14a

FIG. 14b

Diamond

Dresser Arm

Carriage Rails

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.

2. 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.

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 u ntil the shafts feel dry.

LUBRICATION FOR EXTENDED DOWN TIME/STORAGE:

If the machine will be shut down for more than one month, flood the shafts and other appropriate parts 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. This procedure applies to the bearing rail and bearing for the moveable right side electomagnet as well.

14

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&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 manufacturer's instructions.

Some Important "DON'TS"

¨

DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows.

¨

Never scrape polycarbonate windows with squeegees, razor blades or other sharp

instruments.

Benzene, gasoline, acetone or carbon tetrachloride should NEVER be used on polycarbonate windows.

¨

DO NOT clean polycarbonate windows in hot sun or at elevated temperatures.

Graffiti Removal

• Butyl cellosolve, (for removal of paints, marking pen inks, lipstick, etc.)

The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

• To remove labels, stickers, etc., the use of kerosene, VM&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!

15

ADJUSTMENTS

TO REPLACE THE LINEAR ACTUATOR BEARINGS

NOTE: Do not remove the linear actuator from the drive

shaft. Only remove the bearings from the actuator block.

Actuator Mounting

Screw (under the rubber splash guard)

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 18B.

3. Remove the feed screw guide two mounting screws 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.

4. 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).

5. 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 washers and shoulder bolts.

Drive Shaft

Seal Plate

Linear Actuator

Actuator Bar Assembly

Actuator Release Lever

FIG. 17

Inspect the hole from which the bearing and shoulder bolt were removed, for foreign matter. Clean thoroughly.

6. Wipe the drive shaft clean and dry.

Feed Screw Guide

Mounting Screws

Actuator Engaged

FIG. 18A

If oil is left on the drive shaft, the pulling force may have to be set too high in the following procedure. This will shorten the bearing life.

7. 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 seal plates if applicable. Be sure the seal plates are mounted concentric to the drive shaft.

Actuator Released

FIG. 18B

16

ADJUSTMENTS (Continued)

TO REPLACE THE LINEAR ACTUATOR BEARINGS

8. Slide the carriage over the actuator, 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-adjusting bearing, and tighten the screw.

Hold the drive shaft from rotating while you check the pulling force.

9. 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 lbs (20-27 kg), with 50 lbs (23 kg) being ideal.

If not within those specifications, the actuator tension must be adjusted. See "Adjusting the Pulling Force" below.

Exceeding 60 lbs force won't greatly improve drive performance - and it will 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 must remove the actuator bar assembly. See FIG. 17.

Turn each outboard screw an equal amount when resetting. Turn clockwise for more tension.

2. Check the force again (repeat Step 10 above).

Continue adjusting and rechecking until within specification.

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.

3. When the tension adjustment is correct, reinstall the actuator bar assembly and actuator release lever.

FIG. 19

.22 (5.5mm)

FIG. 20

If the actuator release lever is tightened too much, it will contact the outboard screw heads and override their adjustment, which could cause a traverse malfunction.

Make certain that you have full engagement when you reengage the actuator.

17

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.

1. Remove the optional carriage bellows (if used) from the carriage. Remove the actuator release lever from the linear actuator.

2. Remove the complete carriage assembly from the machine:

A. Remove the two feed screw guide mounting screws and remove the grinding head assembly from the carriage. Set the ginding head on a bench taking care as to not damage the power cord. Remove the actuator mounting screw, to disconnect the actuator from the carriage (this is located on the top side of the carriage base See Fig. 22).

B. 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 grinding head assembly weighs about 50 lbs (23 kg).

The carriage assembly weighs about 50 lbs (23 kg). Take appropriate action when lifting.

C. Lift the complete assembly (carriage and carriage shafts) out onto a table in front of the Grinder.

3. Slide the rails out of the bearings one at a time.

4. Remove the three linear bearing pillow blocks and wiper brackets (four screws each) from the bottom of the carriage, and discard the bearings.

5. One at a time, slide the three new linear bearing pillow blocks onto the carriage rails.

6. Adjust the tension screw (FIG. 23) on the side of each bearing block so that when you radially rotate the pillow 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.

Tension

Adjustment

Screw

Actuator Mounting

Screw (under the rubber splash guard)

Actuator Bar Assembly

Drive Shaft

Seal Plate

Linear Actuator

Actuator Release Lever

FIG. 22

Carriage

Radial Rotation

Bearings which are too tight or too loose will cause poor grinding quality. Bearings which are too tight will also have a much shorter life, and could damage the rail.

18

ADJUSTMENTS (Continued)

TO REPLACE THE CARRIAGE LINEAR BEARINGS

7.

Attach the three linear bearing pillow blocks and wiper brackets loosely to the bottom of the carriage, with their tension adjustment screws (FIG. 23) facing outward.

8. Clean the carriage rails.

NOTE: The two rails are interchangeable and are also reversible (end-for-end).

9. Insert a rail through the rear two pillow blocks, and align the rear pillow blocks to each other with a straight edge laid along their sides. See FIG. 25. When aligned, tighten 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.

10. 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.

11. 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.

12. 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 lb. 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.

Straightedge

Rear Pillow Blocks

Underside of

Carriage

FIG. 25

19

ADJUSTMENT (Continued)

TO ALIGN THE MOTOR SHAFT AND DRIVE

SHAFT

There must be 0.12 to 0.50 in. (3.0 to 12.7 mm) end clearance between the traverse motor output shaft and the drive shaft, inside the flexible coupling (FIG.27).

To prevent drive shaft "whipping" at higher traverse speeds, the two shafts must be aligned so they are 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. Loosen 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 compression or extension load on the coupling, then tighten the coupling screws.

6. Check that the bearing load block is at 90 o 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 support 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 surfaces is 3.375"+/- .010 [85.75 mm +/- 0.25]. See FIG.

29.Then tighten the support block bolts.

3. Check that the bearing support blocks are still at

90 o

to the drive shaft (within +/- 1/4 degree).

Use a precision square held against the bearing shoulder and the rear rail.

4. If you have difficulty obtaining the above alignment, check the straightness of the carriage rails (see

below).

NOTE: The vertical and horizontal straightness of the

rails is very accurately set at the factory, so they are unlikely to be incorrect. Contact the factory if you suspect a problem after making the following tests.

If the drive shaft is adjusted, you may have to realign the motor shaft and drive shaft (see above).

20

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.

3/16in.±1/32

(4.75mm±0.75)

Between sensing bracket

& switch

Proximity

Switch

Mounting

Nuts

FIG. 33

ADJUSTING THE PRELOAD TENSION ON THE

SMALL GRINDING HEAD SLIDE VEE ROLL-

ERS

Setscrew and

Nylon Ball

The small grinding head slide vee rollers are positioned two fixed on the left and one adjustable on the right side. To set the correct preload on the right side adjuster, tighten the setscrew in FIG. 34 until the spring is fully compressed solid, then back off 1/2 turn.

TO ELIMINATE MOVEMENT IN THE DIAMOND

DRESSER ADJUSTMENT COLLAR

The adjustment collar on the diamond dresser (See

Fig. 34) has a nylon ball and setscrew to put a holding drag on the diamond dresser shaft. If the adjustment collar is moving when not wanted or moving too freely, tighten the setscrew (this will put more load on the nylon ball). If the adjustment collar is difficult to turn, loosen the setscrew decreasing the load on the nylon ball.

FIG. 34

Tension Adjust

Setscrew

21

ADJUSTMENTS (Continued)

TO ELIMINATE INFEED HANDWHEEL

BACKLASH

If there is backlash in the Grinder Head Infeed handwheel (FIG. 35A), there are two adjustment points on each to check:

1. 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).

B. Tighten the hex lock nut which secures the handwheel to 100 in. lbs. [1.15 kg-m], then back off 1/2 turn.

C. Check for .015 in. [.04mm] gap between the wave washer and the flat washer. See FIG.

35B.Readjust the hex lock nut if necessary.

D. Tighten the setscrew holding the handwheel to the shaft. Install and tighten the calibration ring setscrew.

2. Check the nylon ball tension on the adjustment shaft threads at the grinding head slide. See FIG.

35A.

When you turn the handwheel there should be no free play in the handwheel before the grinding head slide moves. If there is free play, tighten the setscrew that pushes the nylon ball against the acme thread of the adjustment shaft.

The nylon ball preloads the free play out of the threaded joint between the adjustment shaft and the tooling bar slide block. Apply tension only enough to zero the free play. DO NOT over tension as the adjuster will be difficult to turn.

Setscrew with nylon ball

Infeed

Handwheel

Hex Nut

.015 in.

gap

Wave and flat washers

FIG. 35A

FIG. 35B

22

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--Factory set at full (CW) 4:30. Do not change this setting.

(Left Traverse) Reverse Torque--Factory set at full (CW) 4:30. Do not change this setting.

IR COMP--Factory set to 9:00. IR COMP is current (I) resistance (R) compensation (COMP).

IR COMP adjusts the output voltage of the drive which balances load to motor RPM. Regulation of a traverse motor may be improved by slight adjustment of the IR COMP trim pot clockwise from its factory-set position.

Overcompensation causes the motor to oscillate or to increase speed when fully loaded. If you reach such a point, turn the IR COMP trim pot counterclockwise until the symptoms disappear.

Max. Speed--Set at 3:30 for maximum voltage of 90 Volts DC to the traverse motor. When voltage is above 90 volts DC, the traverse motor will start to pulsate and not run smoothly.

(Right 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 0 sets the DWELL TIME to 0 seconds, while a setting of 8 sets the DWELL TIME to 4 seconds. Dwell time is preset to #2 setting for a 1 second dwell time when reversing at each end of stroke.

Diagnostic LED's indicate the function that is currently being performed:

* POWER indicates that ac power is being applied to the control.

* FORWARD indicates that the process is running in the forward direction (traversing left).

* REVERSE indicates that the process is running in the reverse direction (traversing right).

* PROX 1 FWD LIMIT lights when the forward limit switch is actuated (left prox).

* PROX 2 REV LIMIT lights when the reverse limit switch is actuated (right prox).

Potentionmeter

Clock Orientation

23

TROUBLESHOOTING

--ELECTRICAL--

--PROBLEM---POSSIBLE CAUSE--

Grinding motor do not function

(no apparent power to machine).

ELECTRICAL MAIN POWER

--REMEDY---REASON--

A--Grinding Motor Switch (GMS) is not on.

Turn switch on.

B--Main power source breaker is tripped, power source switch is off, or grinder is not plugged in.

Reset breaker, turn switch on and plug machine in.

C--System Start Switch (SSS) is not on.

Press System Start Switch.

D--Guard door is not closed

E--Insufficient Line Voltage to power the low voltage relay.

F--Voltage not going to magnetic starter.

Close the guard door.

Because the guard door is interlocked to the grinding motor, the grinding motor will not operate if door is open.

Check status of the low voltage relay (LVR) inside the control box. Note: Check light while turning on the grind motor. It will show trip and then reset to normal.

If "norm" light is lit, relay is satisfied and line voltage is acceptable.

If "trip" light is lit, line voltage to the grinder is inadequate and must be corrected.

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.

AC voltage power source required.

Solenoid in magnetic starter does not pull in.

Solenoid pulls in, but no voltage out of magnetic starter.

Check for 115 volt AC between terminals T1 (black) and T3

(white). T1 and T3 are main power out lines. NOTE: T2 is jumpered to L3. 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.

Overload may have been tripped when moving machine or machine grinding head motor overload or electrical power surge.

G--Voltage is not going through interlock relay.

Check for loose connections on magnetic starter. Check for 115

Volts AC across starter coil A1 to A2. NOTE: Contactor clicks when engaging.

These wires control magnetic starter voltage for main power.

Check for 115 VAC at incoming side of relay. Terminals 4 & 8.

Check for 115 VAC at output side of relay terminals 2 & 6.

Checks must be done with guard door close, Relay Coil engaged.

Interlock relay may not be getting coil power or may be malfunctioning.

24

TROUBLESHOOTING (Continued)

--ELECTRICAL--

--PROBLEM---POSSIBLE CAUSE---REMEDY--

Insufficient hesitation at carriage stops prior to reversing traverse direction for relief grinding.

The dwell time on the traverse drive control not set properly.

Reset dwell time on traverse control board as required; one increment increases dwell time by 1/2 second. See Page 23.

TRAVERSING

--REASON--

If the carriage traverses to one end of stroke or the other and it stops and does not reverse direction .

Proximity switch is not working properly or wire connections are loose.

First check to see if proximity light comes on when placing a steel piece over the prox switch.

When the light is on it means that there is electricity coming to proximity switch.

The light coming on shows the proximity is getting electrical contact.

Left proximity (PROX 1) check

Traverse Drive Control (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).

Proximity light on--

0 Volts DC

Proximity light off--

12 Volts DC

Proximity light on--

0 Volts DC

Proximity light off--

12 Volts DC

If the carriage traverses past the proximity switch and keeps on traversing in same direction.

The two proximity switches have been reversed on the slide bar.

Proximity switch has failed

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.

This will only happen if the main Traversing board has been replaced and not rewired to electrical diagram.

A loose wire connection will give intermittent electrical contact.

Traverse changes directions erratically while running in traverse cycle.

Left proximity (PROX 1) check

(TDC) between terminals #14

(black wire) and #15 (brown wire).

Right proximity (PROX 2) check

(TDC) between terminals #14

(black wire) and #15 (brown wire).

Loose wire to proximity switch.

Replace proximity switch if the voltages do not read as above.

Check wire connections from the proximity switches and tighten down screws.

Proximity light on--0 Volts DC

Proximity light off--

12 Volts DC

Proximity light on--0 Volts DC

Proximity light off--

12 Volts DC

25

TROUBLESHOOTING (Continued)

--PROBLEM---POSSIBLE CAUSE--

Traverse motor does not work.

A--Traverse Motor Switch is not on.

B--Blown fuse.

C--No voltage going to motor.

D--Bad traverse motor.

--REMEDY--

Turn on motor switch.

TRAVERSING

--REASON--

Replace the 3 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 lb. 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 maximum dial reading for 90 volts.

Check for incoming voltage at

L1 to L2 for at least 115 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 commutator for arcing. Replace brushes if necessary. Replace motor if brushes are good.

Remove wires from A1 to A2 from the spin motor. Check with the ohm meter for "0" ohms across the white and black wires.

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.

26

TROUBLESHOOTING (Continued)

--PROBLEM--

Traverse speed control goes at one speed only.

--POSSIBLE CAUSE--

A--Wiring hookup to potentiometer is improper. (If components have been replaced.)

TRAVERSING

--REMEDY--

Check potentiometer wiring for proper hookup. See that speed pot is wired per electrical diagram.

--REASON--

Wrong wire hookup effects traverse control. Reversing red and orange wires to potentiometer the DC motor will run at zero speed but maximum will be too slow. Reversing red and white wires does not affect speed control.

B--Defective speed control potentiometer.

Check Potentiometer on control panel.

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

If Yes, pot is O.K.

If No, go to step below

Check Petentiometer for 10,000 ohms. Remove the following three wires from Traverse Drive

Control: red from term #8 white from term #7 black from term #9

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

C--Main circuit board dial pot settings not correct. (If board has been replaced.)

Check all pot settings on circuit board as shown in wiring diagram. (See adjustment section Traverse Motor Control

Board Settings.)

Minimum and maximum pot settings effect traverse speed.

27

TROUBLESHOOTING (Continued)

--PROBLEM---POSSIBLE CAUSE--

--MECHANICAL--

Carriage traversing (varies speed) while grinding.

A--Oil on carriage drive shaft.

B--Lineal bearings in carriage do not rotate freely.

--REMEDY--

TRAVERSING

--REASON--

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.)

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.

Traverse speed is too slow.

A--Lineal bearings in the carriage are set too tight.

B--Actuator springs set too tight.

Readjust bearings for proper tension. (For more detail see lineal bearing replacement in the adjustment section of the manual.)

When bearing preload is too tight, it causes excessive loading to drive the carriage.

When lineal actuator is disengaged, the proper traverse load is 3 lb. Use a tension scale to check.

(A general guide only.)

NOTE: Check with linear actuator released.

Check to see if actuator bearings have been overloaded, causing the bearings to not rotate freely. (For more detail, see actuator setting in the adjustment section of the manual.)

When actuator spring tension is excessive bearings will not rotate freely causing carriage to not run freely.

28

TROUBLESHOOTING (Continued)

--PROBLEM---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.

TRAVERSING

--REASON---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 actuator 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.

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.

Loosen two bolts holding the motor. Align the motor shaft concentric to the drive shaft.

See if coupling spiral gaps are equally spaced when realigned. (For more detail, see

Traverse Motor Coupling in the adjustment section.)

Side load at the shaft end will bend the shaft and cause it to whip at high speed traversing.

29

TROUBLESHOOTING (Continued)

--PROBLEM--

--POSSIBLE CAUSE--

Electromagnets do not function.

--REMEDY--

ELECTROMAGNETS

--REASON--

A--Make certain elecromagnet switch is on.

B--Verify that Uninteruptable

Power Supply (UPS) is turned on and that there is 120 VAC at the ouput.

C--Verify 12 VAC at the input to the bridge diode.

If switch is off, turn on the switch.

With switch on, electromagnets work, troubleshooting done. With switch on electromagnets do not work, Go to B.

Check for 12VAC at termials

71BD2-S and 66BD2-S. If yes, Go to E. If no, Go to D.

Switch must be on for electromagnets to work.

If the UPS is off, turn it on.

With UPS on, electromagnets work, end of troubleshooting.

With UPS on, electromagnets do not work, check for 120VAC at the female receptacle at the back of the UPS. If yes, Go to C. If No, check continuity of cord #52 from

MAG to UPS. If bad replace cord.

If good, replace or fully charge the

UPS and retest.

UPS must be turned on and charged for electromagnet to work properly.

Power must come thru the transformer and fuse to the bridge diode.

D--Verify that the 12 Amp fuse between the transformer and bridge diode is good.

E--Verify 12 VDC at the output of the bridge diode.

F--Verify 12 VDC at electromagnet switch input.

G--Verify 12 VDC at electromagnet switch output.

NOTE: With 12 VAC at the bridge diode input, the light inside the control box should be ON. If not replace the bulb.

With a multimeter set to continuity verify a 0.0 reading when touching both ends of the fuse. If yes, check continuity of the cord #51 from the UPS to the transformer. If good, replace the transformer. If bad replace the cord. If the fuse continuity checks bad, replace the fuse and retry.

Fuse, cord and transformer must be in working order.

Check for 12 VDC at terminals

62BD2-+ and 63DB2--. If yes, Go to F. If no, replace bridge diode.

Bridge diode must be in working order.

Check for 12 VDC at terminals

63EMS-1 and 62EMS-4. If yes,

Go to G. If no, replace wires 62 and 63.

Power must get to switch input.

Check for 12 VDC at terminals

58EMS-2 and 59EMS-5. If yes, Go to H. If no, replace switch.

Power must pass through the switch and go out to the electromagnets.

NOTE: With 12 VDC at electromagnet switch terminals 58EMS-2 and 59EMS-5 the light above the switch on the ouside of the panel should be ON. If not, replace the bulb.

30

TROUBLESHOOTING (Continued)

--PROBLEM---POSSIBLE CAUSE--

Electromagnets do not function.

(Continued)

H--Verify 12 VDC at the electromagnet connections at the bottom of the electrical box.

Tooling Bar

Rotation Actuator does not function.

A--Verify 120 VAC at transformer input.

B--Verify 12 VAC at the input to the bridge diode.

C--Verify the 10 Amp circuit breaker is not tripped and CB is good.

D-- Verify 12 VDC output from the bridge diode.

E--Verify 12 VDC at the actuator switch input.

F-- Push the actuator switch and verify 12 VDC+ or 12VDCat the actuator switch output.

G-- Verify 12 VDC at the actuator connections at the left side of the grinder under the left leg cover.

TRAVERSING

--REASON---REMEDY--

Check for 12 VDC at terminals

58MGTBL and 59MGTRD, there is one set of terminals for each magnet. If yes, Call

Factory Customer Service for assistance. If no, replace wires

58 and 59.

Power must pass to the electromagnet cords.

Poer must be delivered to the transformer.

Check for 120 VAC at terminal

65TF2BL and 64TF2BL. If yes,

Go to B. If no, verify power is through the MAG. If yes, replace wire 64 and 65.

Check for 12 VAC at terminals

46DB1-S and 67BD1-S. If yes,

Go to D. If no, Go to C.

Check continuity of the circuit breaker at 0.00 with the wires removed. If yes, replace transformer. If continuity of circuit breaker is no, reset or replace circuit breaker.

Power must come through the transformer and circuit breaker.

Power must pass through the transformer and circuit breaker.

Power must pass through the bridge diode.

Check for 12 VDC at terminals

60DB1-+ and 61BD--. If yes,

Go to E. If no, replace bridge diode.

Check for 12 VDC at terminals

60AMS-2 and 61AMS-5. If yes, Go to F. If no, replace wires 60 and 61.

Check for 12 VDC+ or 12 VDCat terminals 50AMS-1 and

50AMS-4 or 50AMS-3 and

50AMS-6 depending on which way you push the switch. If yes, Go to G. If no, replace switch.

Check for 12 VDC+ or 12 VDCat terminals 50ACTBL and

50ACTRD with the actuator switch pushed. If yes, replace the actuator motor. If no, replace cord wire number 50.

Power must get to switch input.

Power must pass through the switch when pushed.

Power must pass through the cord and to the motor.

31

TROUBLESHOOTING

--PROBLEM--

Top face of bedknife is ground in a 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--Carriage has varying load in either direction, because of grit buildup inside linear bearings.

D--Rails not straight.

--REMEDY--

BEDKNIFE GRINDING

--REASON--

Dress the wheel prescribed in the Operators Manual.

Follow the procedures in the

Operators Manual. On the final pass, adjust only about

.001" [.025 mm]. Let the wheel spark out for 10-20 passes at about 5 ft/min, with no additional infeed.

With linear actuator released from the carriage, check for a

3lb [1.36 kg] maximum traversing load in both directions. If load varies, or carriage 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.)

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 excessive final-grinding pressure on centers and middle support, which helps maintain grinding straightness.

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 critical for accuracy of grinding.

32

TROUBLESHOOTING (Continued)

--PROBLEM--

Top face of bedknife is ground in a convex shape

(high in the center)

B--Too heavy a grind on the final grinding pass.

BEDKNIFE GRINDING

--POSSIBLE CAUSE---REMEDY--

A--Grinding wheel loading up with grinding grit.

Dress the wheel prescribed in the Operators Manual.

Follow the procedures in the

Operators Manual. On the final pass, adjust only about

.001" [.025 mm]. Let the wheel spark out for 10-20 passes at about 5 ft/min, with no additional infeed.

--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 excessive finalgrinding pressure on centers and middle support, which helps maintain grinding straightness.

C--Carriage has varying load in either direction, because of grit buildup inside linear bearings.

With linear actuator released from the carriage, check for a

3lb [1.63 kg] maximum traversing load in both directions. If load varies, or carriage linear bearings are excessively noisy, replace bearings See Page 19).

D--Rails not straight.

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.)

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 critical for accuracy of grinding.

33

TROUBLESHOOTING (Continued)

--PROBLEM---POSSIBLE CAUSE--

The top face of the bedknife is ground unevenly across the width.

A--Grinding wheel rim is not completely over the top face being ground.

--REMEDY--

BEDKNIFE GRINDING

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.

--REASON--

When the rim doesn't extend over the top face, it wears unevenly and causes grooves across the bedknife.

Too coarse a grind on bedknife.

Grinding head is traversing too fast.

Slow down the traversing speed to 12 FT/MIN.

Traversing speed controls the grinding surface texture.

A slower traverse produces grind marks closer together.

34

TROUBLESHOOTING (Continued)

--PROBLEM---POSSIBLE CAUSE--

The top face of the bedknife shows burn marks from being too hot.

A--Coolant not directed onto the bedknife and grinding wheel.

B--Too heavy stock removal during grinding.

C--Grinding wheel is glazing.

--REMEDY--

BEDKNIFE GRINDING

--REASON--

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.

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.

Grinding wheel is glazing too quickly.

A--Wheel needs dressing.

B--Too light a cut when rough grinding.

Dress the wheel before the finish-grinding pass on each bedknife. See Operators

Manual.

Take off about .002 to .033"

[.05 to .075 mm] per pass during rough grind. See

Operators Manual.

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.

C--Grinding head is traversing too slow.

Set the traversing speed to 12

FT/MIN.

Too slow a traverse speed can cause excessive heat buildup in the grinding wheel, which glazes the wheel.

Grinding motor vibrates excessively.

Grinding wheel is out of balance.

Visually check the outsidediameter run out while slowly rotating the wheel. Also check the motor without a wheel installed. Replace the wheel if out-of -round.

Loosen wheel flange and rotate the wheel 90°. Hand tighten wheel flange and retry. Repeat process 3 times if necessary.

A grinding wheel which isn't properly trued up on outside or inside diameters can vibrate excessively and transfer that vibration to the motor.

35

ELECTRIC SCHEMATIC 67095233

36

CONTROL BOX

Traverse Board

Transformer for Actuator

Bridge Diode for

Actuator

Circuit Breaker for Actuator

12 Amp Fulse for

Electromagnets

Transformer for Electro

Magnets

Bridge Diode for

Electomagnets

Door Switch

Relays

Low Voltage Relay

(LVR)

Mag Starter &

Overload Relay

37

2 Amp Fuse for Coolant

Pump

1 Amp Start

Circuit Fuse

PARTS LIST 6709534 MAIN BASE ASSEMBLY

38

PARTS LIST (Continued)

DIA. NO.

1

61

62

63

64

57

58

59

60

53

54

55

56

49

50

51

52

65

66

67

45

46

47

48

41

42

43

44

37

38

39

40

33

34

35

36

29

30

31

32

25

26

27

28

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

5

6

7

8

2

3

4

PART NO.

B190613

6709101

6709505

6709512

6709129

3708378

6709131

6709133

B251616

B311613

B311213

6709125

B251016

R000454

6709155

3707132

J167000

3708819

3708818

3707563

6009033

6009510

6709022

6709153

6709139

6709154

6709119

6709138

6709137

6709124

6709048

6709117

6709062

6709063

6709071

3707129

J501000

K250001

K251501

K370001

K371501

3708388

6709132

3708604

3849294

3708569

3708572

3708577

3709563

3709990

4509457

6009008

B190834

B250816

B251201

B310813

B371201

B371211

B371601

D191067

H371602

J197000

J251000

J257000

J317000

J317100

J371000

39

6709534 MAIN BASE ASSEMBLY

DESCRIPTION

Button Head Cap Screw 10-24 x 3/8

Button Head Cap Screw 10-32 x 1/2

Button Head Cap Screw 1/4-20 x 1/2

Hex Head Cap Screw 1/4-20 x 3/4

Button Head Cap Screw 5/16-18 x 1/2

Hex Head Cap Screw 3/8-16 x 3/4

Socket Head Cap Screw 3/8-16 x 3/4

Hex Head Cap Screw 3/8-16 x 1

Thread Cutting Screw AB #10

Roll Pin .375D x 1.00LG

Insert Locknut Jam 10-24

Hex Nut 1/4-20

Thin Locknut 1/4-20

Nylon Locknut Jam 5/16-18

Nylon Locknut 5/16-18

Hex Nut 3/8-16

Hex Nut 1/2-13

Flat Washer 1/4

Split Lockwasher 1/4

Flat Washer 3/8

Split Lockwasher 3/8

Male Barb Connector 1" 4509457

Plate-Door Spring R.H.

Warning Decal - Safety

Return Hose, 1"

Gas Spring #24

Stud Ball 10mm

D Handle

Adjustable Leveling Bolt

Large Foley United Decal

Grommet

Leg Brace

Right Hand Leg Frame Cover

Right Hand Leg Frame Weldment

Back Upper Tank Panel

Right Hand Upper Tank Panel

Left Hand Upper Tank Panel

Door Spring Bracket - R.H.

Tank Cover Door

Left Hand Leg Cover

Left Hand Upper Cover

UPS Bracket

Machined Traverse Base

Hinge Cover

Upper Tank Side Bracket

Rubber Trim 36"

Ferrule Handle

Guard Door Safety Switch

ACCU-Pro Decal

Water Tank Base Weldment

Left Hand Leg Frame Weldment

Door Plate

Foam Strip .25 Thick

Door Spring Bracket L.H.

Plate - Door Spring L.H.

Button Head Socket Screw 1/4-20 x 1

Button Head Socket Cap Screw 5/16-18 x 1.0

Button Head Socket Cap Screw 5/16-18 x 3/4

UPS Top Shield

Button Head Socket Cap Screw 1/4-20 5/8

Flat Washer .437 x 1.0 x .08T

Safety Key Spacer Block

Safety Switch Dey

#8-32 Locknut

#8-32 x .75 long Button Head Safety Screw

#8-32 x 1.25 long Button Head Safety Screw

Strain Relief

PARTS LIST (Continued) 6609529 GRINDING HEAD ASSEMBLY

40

DIAGRAM

NUMBER

PART

NUMBER

PART

DESCRIPTION

DIAGRAM

NUMBER

PART

NUMBER

PART

DESCRIPTION

1...............B190611...............10 - 24 x 3/8 Socket Head Cap Screw

2...............B191213...............10 - 24 x 3/4 Button Head Socket Cap Screw

3...............B250816...............1/4 -20 x 1/2 Button Head Socket Cap Screw

4...............B251216...............1/4 - 20 x 3/4 Button Head Socket Cap Screw

5...............B251616...............1/4 - 20 x 1 Button Head Socket Cap Screw

6...............B252016...............1/4 - 20 x 1 - 1/4 Button Head Socket Cap Screw

7...............B371211............... 3/8 - 16 x 3/4 Socket Head Cap Screw

8...............C190820...............10 - 24 x 1/2 Socket Set Screw

9...............C250420...............1/4 - 20 x 1/4 Socket Set Screw

10.............C250820...............1/4 - 20 x 1/2 Socket Set Screw

11.............C310420...............5/16 - 18 x 1/4 Socket Set Screw

12.............C621060...............5/8 - 18 x 5/8 Socket Set Screw

13.............J377000...............3/8 - 16 Locknut Jam Nylon

14.............K190001...............No. 10 Flat Washer

15.............K191501...............No. 10 Lockwasher Split

16.............K251501...............1/4 Lockwasher Split

17.............K371501...............3/8 Lockwasher Split

18.............3589081...............Spacer

19.............K310101...............5/16 Flat Cut Washer

20.............3700409...............Bushing - Reducer

21.............3700411...............Grinding Wheel Straight Cup 6" dia x 2" deep

22.............3702086...............Diamond Dresser

23.............3708121...............Clamp - Double Tube

24.............3708543...............Shoulder Bolt

25.............3708553...............Spring Compression

26.............3708561...............Adjustable Handle

27.............3708657...............Roller Dual Vee

28.............3708658...............Spring Compression

29.............3709062...............Washer Conical

30.............3709304...............Washer - Thrust

31.............3709526..............Knob

32.............3708103...............Washer Conical

33.............3709705..............Nylon Ball

34.............3809047...............Indicator Clear

35.............6009023...............Shaft Adjusting

36.............6059082...............Ring Calibrated

37.............6009044...............Handwheel

38.............6609004...............Base Carriage Slide

39.............6609027...............Arm - Roller Pivot

40.............6609028...............Bushing-V Roller Short

41.............6609029...............Bracket - Dresser Lock

42.............6609030...............Guide - Feed Screw

43.............6609058...............Bushing-V Roller Long

44.............6709035...............Stud

45.............3707009...............Strain Relief

46.............6609502...............Motor Assy 3/4 HP

47.............3708448...............Decal Warning Electrical

48.............3708458...............Decal Warning Sharp

49.............3708461...............Decal Warning 3600 RPM

50.............6609505...............Motor Pivot Assy

51.............6709038...............Collar - Adjuster

52.............6709103...............Flange - Outer

53.............6709501...............Tee Knob Assy

54.............6709503...............Eccentric Pin Assy

55.............6709509...............Dresser Arm Weldment

56.............6709552...............Grinding Wheel Guard Weldment

58.............B255011...............

Socket Head Cap Screw 1/4-20 x 3-1/8Long

59.............3709370...............Handle

60.............J252000...............Hex Jam Nut 1/4 - 20

61.............J257000...............1/4 - 20 Nylok Lock Nut

PARTS LIST (Continued)

6709531 TRAVERSE & CARRIAGE ASSEMBLY

42

PARTS LIST (Continued)

DIA. NO.

PART NO.

35

36

37

38

39

30

31

32

33

34

25

26

27

28

29

20

21

22

23

24

15

16

17

18

19

10

11

12

13

14

7

8

5

6

9

3

4

1

2

55

56

57

58

59

50

51

52

53

54

60

61

45

46

47

48

49

40

41

42

43

44

3708147

3708454

3708457

3709183

3709583

3709613

3709635

3849239

3969032

6009068

6009070

6709146

6709148

6009108

6009109

6009152

6009153

6009155

6009198

6009548

B191233

B250801

B251017

B251611

B251811

B311001

B371201

J251000

K190001

K191501

K250001

K251501

K310001

K311501

K370001

K371501

3589081

3619224

3708046

6009549

6009572

B191011

B190811

B252211

K251501

3559117

3709040

3709044

6709147

3969064

28211

3709668

3709597

3709596

3709469

B253211

3708691

J197000

6709039

6709149

B311001

6709531 TRAVERSE & CARRIAGE ASSEMBLY

DESCRIPTION

Phillip's Head Machine Screw 10-32 x 3/4

Hex Head Cap Screw 1/4-20 x 1/2

Round Head Machine Screw 1/4-20 x 5/8

Socket Head Cap Screw 1/4-20 x 1

Socket Head Cap Screw 1/4-20 x 1-1/8

Hex Head Cap Screw 5/16-18 x 5/8

Hex Head Cap Screw 3/8-16 x 3/4

Hex Nut 1/4-20

Flat Washer #10

Split Lockwasher #10

Flat Washer 1/4

Split Lockwasher 1/4

Flat Washer 5/16

Split Lockwasher 5/16

Flat Washer 3/8

Split Lockwasher 3/8

Spacer .191ID x .438OD x .43L

Compression Spring

Grommet

Shoulder Bolt .375D x .625L

Warning Decal - Release Actuator

Warning Decal - Hot Surface

Wiper Seal

Flexible Coupling

Star Knob 5/16-18

Pillow Block Brearing

Carriage Drive Shaft

Seal Mount

Proximity Support Rail

Proximity Bracket

Proximity Sensing Bracket

Rubber Pad

Left-hand Traverse Proximity Switch

Right-hand Traverse Proximity Switch

Shaft Collar

Rubber Washer

Modified Release Actuator

Traverse Motor Assembly

Actuator Bar Assembly

Release Arm Weldment

Proximity Rail Weldment Clamp

Socket Head Cap Screw 10-24 x 5/8

Socket Head Cap Screw 10-24 x 1/2

Socket Head Cap Screw 1/4-20 x 1 3/8

Split Lockwasher 1/4

Carrier Shaft

Spherical Bearing

Bushing Ball Bearing

Carriage Base

Sponge Wiper

Sponge Wiper Holder

Socket Head Screw

Sealed Bearing

Spacer

Compression Spring

Socket Head Cap Screw 1/4-20 x 2

Flat Washer

Locknut 10-24

Rubber Cover Bracket

Rubber Cover

Hex Head Cap Screw 5/16-18 x 5/8 Long

43

PARTS LIST (Continued) 6709533 BEDKNIFE SUPPORT ASSEMBLY

44

61

62

63

64

57

58

59

60

52

53

54

55

48

49

50

51

44

45

46

47

40

41

42

43

36

37

38

39

32

33

34

35

69

70

71

72

65

66

67

68

73

74

75

76

28

29

30

31

24

25

26

27

20

21

22

23

16

17

18

19

12

13

14

15

8

9

10

11

6

7

4

5

1

2

3

6709107

6709008

6709011

6709012

6709013

6709015

6709164

6709021

6709134

6709151

6709108

6709136

6709152

6709501

6709556

3708593

3708563

3708564

3708330

3708702

3708694

6709135

3708701

3708581

3709016

3709062

3709304

6009035

6009036

6009095

6709004

6709532

6709556

B251411

3708691

B371211

C250627

B191211

K310101

H251602

J371000

J377000

J377100

J507000

K191501

K250001

K251501

K371501

3579109

6709142

6709519

3708245

3708393

3708554

B190411

B190605

B191011

B191611

B250611

B251211

B253611

B371611

C190420

C310420

6709162

H250802

H251202

H251406

H251802

09054

6709163

K250101

K250611

K500001

2109096

PARTS LIST (Continued) 6709533 BEDKNIFE SUPPORT ASSEMBLY

DIA. NO.

PART NO.

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 Head 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

Shaft - Gage Spring Retainer

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 1.25ID

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

Magnet Repair Assembly - INA

Key 5/16 SQ x 1/2

Magnet Repair Assembly - INA

Socket 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

3/8 ID x 5/8 OD X 1/16 Thick Flat Washer

Flag - Gage Shaft

Washer - Flat .31 x .73 x .052T

Socket Head Cap Screw 1/4 - 20 x 3/8

Washer - Flat 1/2

Spacer .50 ID x 1.00 OD x .50 L

45

PARTS LIST (Continued) 6709536 CONTROL PANEL ASSEMBLY

50

46

PARTS LIST (Continued)

DIAGRAM NO.

6709536 CONTROL PANEL ASSEMBLY

PART NO.

DESCRIPTION

B161614

3707539

6709168

3707548

3707556

3707557

6709122

H121302

6709123

3707547

3707566

3707565

3707568

3707567

3708448

3709809

3709864

6009062

6009199

6709068

6709070

6709072

6709073

6709091

6709507

3707273

3709304

3707526

3707558

3707091

3707279

3707370

3707550

3707416

3707428

3707429

3707367

3707446

3707447

3707487

3707488

3707489

3707564

3707073

3707526

B130812

B161014

B190809

B192013

B193211

B371001

J317100

K371501

R000480

R000483

R000553

R000557

R000558

3707066

3708826

55

56

57

58

59

60

51

52

53

54

47

48

49

50

43

44

45

46

39

40

41

42

35

36

37

38

31

32

33

34

27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

5

6

3

4

1

2

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

Low Voltage Warning Decal

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 Pointer

120V Coil

Pilot Lamp Socket

Amber Fluted Dome Lens

Lamp 24V .073AMP

Start Pushbutton Assembly

8 Pin Socket

Diode Bridge - 25 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

Magnetic Starter

Overload Relay for Starter

Switch Guard Cover

1/8" Roll Pin x .81 Long

Switch Guard Base

15-Amp Circuit Breaker

Push Button Mount

Contact Block - NO (Normally Open)

Contact Block - NC

47

PARTS LIST (Continued) 6709536 ELECTRICAL ASSEMBLY

48

PARTS LIST (Continued)

DIAGRAM NO.

55

56

57

58

59

50

51

52

53

54

45

46

47

48

49

40

41

42

43

44

65

66

67

68

69

60

61

62

63

64

70

71

72

35

36

37

38

39

30

31

32

33

34

25

26

27

28

29

20

21

22

23

24

15b

16

17

18

19

11

12

13

14

15a

6

7

8

9

10

1

2

3

4

5

PART NO.

6709072

6709074

3707487

6709077

6709085

6709073

6709086

6709128

6709157

6709092

6709088

6709098

6709090

6709089

6709078

6709081

6709079

6709080

6709097

6709096

6709082

6709083

6709095

6709094

3707428

3707526

3707447

3707518

3707367

6709110

6709111

3707073

3707539

6709087

6009110

6009109

6009108

6009113

6009202

6709099

R000553

6009117

6009118

6009204

6709113

6709093

6009181

3707489

3707488

6009199

3707219

6009201

6009104

6009196

6109052

3707547

6709084

6009198

3707526

6109053

3707550

6009180

3707429

SEE PAGE 44

SEE PAGE 44

B192013

3707219

3707556

3707557

R000483

3707091

6709112

3707092

6709536 ELECTRICAL ASSEMBLY

DESCRIPTION

Cord Assembly Main Power W32

Receptacle Cor W41

15 Amp Circuit Breaker

Cord Assembly -Grind Motor W45

Traverse Motor Assembly W34

Bridge Diode - 25 AMP

Wire Assembly .25F/.25F W42

Traverse Control Board

Wire Assembly .25F/6FK W02

Rocker Switch On/Off

Stop Pushbutton

Start Pushbutton

Button Head Cap Screw 10-24 x 1.25

Fuse 2 AMP Slo-Blo

Magnetic Starter 1 HP

Overload Relay for Magnetic Starter

Internal Tooth Lock Washer

Fuse Block

Wire Assembly STR/FK W75

Fuse 1 AMP Slo-Blo

Wire Assembly 2 Loop W70

Wire Assembly 6FK/6FK W18

Right Hand Traverse Proximity Switch W38

Left Hand Traverse Proximitiy Switch W37

Wire Assembly 6FK/6FK W16

Wire Assembly 6FK/6FK W23

Wire Assembly 2 Loop W72

Kep Nut 10-24

Wire Assembly .25F/6FK W28

Wire Assembly 6FK/10RG W30

Wire Assembly 6FK/6FK W15

Wire Assembly STR/Fk W76

Wire Assembly .25 F/6FK W53

Wire Assembly .25F/6FK W03

Lamp 24V - 073 AMP

Amber Fluted Lens

Traverse Pot Assembly W35

Fuse 2 AMP Slo-Blo

Wire Assembly 6FK/6FK W39

Wire Assembly .25FK/6FK W29

Actuator Transformer Assembly W46

Magnet Assembly W47

Pilot Lamp Socket

Wire Assembly .25F/.25F W49

Actuator Cord Assembly Switch W50

Magnetic Transformer Assemby W71

Transformer Cord Assembly W51

Battery Assembly W52

Door Safety Switch Cord W110

Wire Assembly .25F/6FK W55

Wire Assembly 3 Loop W56

Wire Assembly 2 Loop W57

Wire Assembly 3Loop W58

Wire Assembly 3 Loop W59

Wire Assembly .25F/.25F W60

Wire Assembly .25F/.25F W61

Wire Assembly .25F/.25F W62

Wire Assembly .25F/.25F W63

Wire Assembly .25F/6FK W64

Wire Assembly .25F/6FK W65

Wire Assembly .25F/.25F W66

Wire Assembly .25F/.25F W67

Wire Assembly .25F/6FK W68

Wire Assembly .25F.6FK W69

Rocker Switch Mom On/Off

Bridge Diode - 25 AMP

Relay DPST 120V Coil

Fuse 12AMP Slo-Blo

On/Off Switch

Wire Assembly STR/FK W73

Wire Assembly STR/FK W74

8 Pin Socket

Green Fluted Lens

49

PARTS LIST (Continued) 3708784 COOLANT PUMP/TANK ASSEMBLY

15

50

PARTS LIST (Continued) 3708784 COOLANT PUMP/TANK ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

1 ........................................... 3709642 ................... Swivel Nozzle

2 ........................................... 3679116 ................... Connector Shut - Off Valve

3 ........................................... K190001 ................... #10 Flat Washer

4 ........................................... B191611 ................... 10-24 x 1 Socket Head Cap Screw

5 ........................................... K191501 ................... #10 Lockwasher Split

6 ........................................... 3709595 ................... Shut Off Valve

7 ........................................... 3709593 ................... Barbed Connector

8 ........................................... 3707532 ................... Pump 115V

9 ........................................... 3708339 ................... Connector - Barbed Insert

10 ......................................... 3708725 ................... Tank - Coolant

11 ......................................... 3708774 ................... Cover - Coolant Tank

12 ......................................... 3708775 ................... Divider - Coolant Tank 5”

13 ......................................... 3708778 ................... Divider - Coolant Tank 6.5”

14 ......................................... 3708785 ................... Instruction Sheet - Coolant Tank

15 ......................................... 3389039 ................... Coolant Hose

51

52

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