ACCU-Pro 632 Spin/Relief Grinder Assembly and Service Manual

ACCU

-Pro 632

SPIN/RELIEF

GRINDER

ASSEMBLY and

SERVICE

MANUAL

1

6327954 (6-06)

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 spe-

cial instructions or procedures which, if not correctly followed, could result in personal injury.

The

Caution Symbol identifies special

instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

1. KEEP GUARDS IN PLACE and in working order.

2. REMOVE WRENCHES AND OTHER

TOOLS.

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.

5. KEEP ALL VISITORS AWAY. All visitors should be kept a safe distance from work area.

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

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

8. USE THE RIGHT TOOL. Don't force the

Grinder or an attachment to do a job for which it was not designed.

9. WEAR PROPER APPAREL. Wear no loose clothing, gloves, neckties, or jewelry which may get caught in moving parts. Nonslip foot wear is recommended. Wear protective hair covering to contain long hair.

10. ALWAYS USE SAFETY GLASSES.

11. SECURE YOUR WORK. Make certain that the cutting unit is securely fastened with the clamps provided before operating.

12. DON'T OVERREACH. Keep proper footing and balance at all times.

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

14. DISCONNECT POWER BEFORE SERVICING,

or when changing the grinding wheel.

15. REDUCE THE RISK OF UNINTENTIONAL

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

16. USE RECOMMENDED ACCESSORIES.

Consult the manual for recommended accessories

Using improper accessories may cause risk of personal injury.

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

18. KNOW YOUR EQUIPMENT. Read this manual carefully. Learn its application and limitations as

well as specific potential hazards.

19. KEEP ALL SAFETY DECALS CLEAN AND

LEGIBLE. If safety decals become damaged or illegible for any reason, replace immediately. Refer to replacement parts illustration 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 materiel 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 DON'T

1. DO always HANDLE AND STORE wheels in a CAREFUL manner.

1. DON'T use a cracked wheel or one that has become damaged.

2. DO VISUALLY INSPECT all wheels before mounting for possible damage.

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. DO CHECK MACHINE SPEED against the established maximum safe operating

speed.

3. DON'T ever EXCEED MAXIMUM

OPERATING SPEED established for the wheel.

4. DO CHECK MOUNTING FLANGES for equal and correct diameter.

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

AND FREE OF BURRS.

5. DO USE MOUNTING BLOTTERS when supplied with wheels.

5. DON'T TIGHTEN the mounting nut excessively.

6. DO be sure WORK REST is properly adjusted.

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

(see Safety Code B7. 2 for exception).

7. DO always USE A SAFETY GUARD

COVERING at least one-half of the grinding wheel.

7. DON'T start the machine until the WHEEL

GUARD IS IN PLACE.

8. DON'T JAM work into the wheel.

8. DO allow NEWLY MOUNTED WHEELS

to run at operating speed, with guard in place, for at least one minute before grinding.

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

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

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 maintain dust level below the

Threshold Limit Value for nuisance dust as classified by OSHA.

3

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 manufacturers 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 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

Safety Warnings ................................................................................................... Page 2- 4

Service Data ........................................................................................................ Page 5

Assembly Instructions ........................................................................................... Page 6 -10

Maintenance Instructions ...................................................................................... Page 11 -15

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

Machine Service .................................................................................................. Page 24 -26

Electrical Troubleshooting Index ........................................................................... Page 27-28

Electrical Troubleshooting .................................................................................... Page 29 -45

Mechanical Troubleshooting ................................................................................. Page 46 -47

Parts List ............................................................................................................. Page 48 -87

Electrical Diagrams .............................................................................................. Page 88-89

SPECIFICATIONS

Electrical Requirements ......................... 115V 50/60 Hz, 20 amp circuit

Net Weight ............................................. 1490 lbs (676 kg)-Boom Model 1670 lbs (758 kg)-Lift Model

Shipping Weight ..................................... 1770 lbs (803 kg)-Boom Model 1950 lbs (885 kg)-Lift Model

Maximum Grinding Length ...................... 34 inches (86cm)

4

SERVICE DATA

SKILL AND TRAINING REQUIRED FOR SERVICING

This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the ACCU-PRO Spin/Relief Grinder. For those without the background, service can be arranged through your local distributor.

This Manual presumes that you are already familiar with the normal operation of the Grinder. If not, you should read the Operators Manual, or do the servicing in conjunction with someone who is familiar with its operation.

Persons without the necessary knowledge and skills should not remove the control box cover or attempt any internal troubleshooting, adjustments, or parts replacement.

If you have questions not answered in this manual, please call your distributor. They will contact the manufacturer if necessary.

TORQUE REQUIREMENTS

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)

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

ASSEMBLY INSTRUCTIONS

Remove the sides, front, and back of the crate.

Remove the plastic bag, shrink wrap and bubble wrap around boom assembly. 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. 1 and 2.

THE UNIT WEIGHS

1490 LBS. (676 kg).

WITH BOOM OR

1670 LBS (758 kg)

WITH LIFT. USE

POWER EQUIPMENT

TO LIFT MACHINE.

Remove shipping straps from traverse carriage. Remove window protective sheets.

POSITION BASE

The ACCU-Pro Spin/Relief Grinder will require an operating area of about 150" W x 108" D x 87" H (381 x 274 x 221 cm). The mower reel will be lifted from the front of the machine if using the boom and the rear if a lift is installed. The machine operator will operate the unit from the front of the machine.

Position the base to allow sufficient operating room in front of the machine (and behind if using the rear lift). See FIG. 1 and 2.

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.

6

FIG.1

FIG. 2

ASSEMBLY INSTRUCTIONS (Continued)

Remove the carton and remove the contents from the carton onto a workbench. The carton includes:

SPREADER BAR ASSEMBLY

(ONLY ON MODELS WITH BOOM)

PRODUCT

PACKET

SPIN DRIVE

ADAPTER

5" (127mm) DIA. X 3/8" (10mm)

WIDE GRINDING WHEEL

3.5" (89mm) DIA. X 1" (25mm)

WIDE GRINDING WHEEL

3.5" (897mm) DIA. X 3/8" (10mm)

WIDE GRINDING WHEEL

ALIGNMENT GAGE

ALLEN WRENCH

REEL POSITION GAGE

DRIP PAN

HORIZONTAL EXTENSION

(ALIGNMENT GAGE)

7


LEVEL BASE

Place level on the top of the table. Adjust the leveling feet as necessary to bring to level.

See FIG. 4.

Place a level across the table from front to rear.

Adjust the leveling feet on the end of the machine as necessary to level. See FIG. 5

When both front to back and side to side leveling procedures have been completed, thread the hex jam nuts up against the nut that is welded to the bottom until they lock into place. Be careful not to move the leveling feet during this process.

See FIG. 3. Make certain that all four leveling feet are firmly contacting the floor.

Recheck with level after locking nuts are firmly tightened.

FIG. 3

FIG. 4

FIG. 5

8


APPLY POWER

BEFORE YOU APPLY POWER TO THE

GRINDER, REFER TO THE "IMPORTANT

GROUNDING INSTRUCTIONS" ON PAGE 10.

115 Volt Model Only. Plug the control box power cord into a standard 115V AC 20-amp grounded receptacle. See FIG. 7.

FIG. 7

220 Volt Model Only. For 220 Volt Applications order Part

No. 6320915 or 6320925, which includes a prewired 3 KVA

220V step down to 110V 50-60Hz transformer. See Page 10.

IT IS RECOMMENDED THAT THIS ACCU-

PRO SPIN/RELIEF GRINDER HAS ITS OWN

PERMANENT POWER CONNECTION FROM

THE POWER DISTRIBUTION PANEL, WITH

NO OTHER MAJOR POWER DRAW

EQUIPMENT ON THE SAME LINE.

IT IS REQUIRED THAT THE POWER

DELIVERED TO THIS GRINDER IS 115 VAC -

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 THE CIRCUIT.

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.

DO NOT OPERATE THIS GRINDER WITH

AN EXTENSION CORD.

PROPER GROUNDING OF THE RECEPTACLE

GROUND IN YOUR BUILDING MUST BE

VERIFIED. IMPROPER 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 0 to 12 Meters from panel to receptacle = Use 4.0mm Wire.




9


FOR 220 V 50 or 60Hz applications Product No.

6320915 or 6320925 should be ordered.

These models includes a 3

KVA 220V, step down to 110

V 50-60 Hz transformer.

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, 10 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 electrical breakdown, grounding reduces the risk of electrical shock by providing a path of least resistance for electrical current.

This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded according to all local or other appropriate electrical codes and ordinances.

Before plugging in the Grinder, make sure it will be connected to a supply circuit protected by a properly sized circuit breaker or fuse.SEE SERIAL NUMBER PLATE FOR FULL LOAD AMP RATING FOR YOUR

MACHINE.

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

ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOUR

MACHINE. AN IMPROPER CONNECTION CAN CAUSE A

DANGEROUS ELECTRICAL SHOCK. IF YOU ARE UNSURE OF THE

PROPER ELECTRICAL GROUNDING PROCEDURE, CONTACT A

QUALIFIED ELECTRICIAN.

10

PERIODIC MAINTENANCE

DAILY MAINTENANCE IS SPECIFIED ON

PAGE 4 OF THE OPERATOR'S MANUAL,

AND IS TO BE PERFORMED BY THE

OPERATOR. LISTED BELOW ARE

PERIODIC MAINTENANCE ITEMS

TO BE PERFORMED BY YOUR

COMPANY'S MAINTENANCE

DEPARTMENT:

1. Clean the tank and filter of the vacuum system weekly or more often depending on the number of reels ground. (VACUUM SYSTEM IS OPTIONAL

EQUIPMENT).

2. Use the grease fitting provided to grease the dove tail with high quality lithium grease monthly. Wipe off excess grease. See FIG. 7.

3. Wipe and re-oil with spray lubricant, the grinding wheel diameter adjusting lead screw every three months. Wipe off all excess lubricant. See FIG. 7.

4 Check the gib adjustment on the Grinding wheel diameter adjustment every 3 months. See FIG. 7.

5. Inspect the Grinding Wheel Poly-V belt for cracking and adjust the belt tension per procedure called out in the adjustment section every six months.

6. Wipe and relube with never-seez, the vertical and horizontal alignment shafts and lead screws, every six months. See FIG. 8.

7. Lift the bellows and wipe off the bearing rails monthly.

Lubricate linear bearing, follow the lubrication procedure on the following pages. Generally, this will be every six months to a year.

11

FIG. 7

FIG. 8

STORAGE PROCEDURE

It is important to follow the procedures below when placing your grinding in storage for an extended period of time. Proper care will help maintain the working functions of the grinder and decrease maintenance and problems that occur when storing the grinder.

BEFORE STORING THE GRINDER:

-Clean the machine thoroughly. (DO NOT USE COMPRESSED AIR OR A POWER WASHER

TO CLEAN THIS MACHINE!) See Maintenance section for instructions on cleaning

polycarbonate.

-Lubricate the following parts by flooding the area with a spray lubricant and leaving it in place: (Do not use a Teflon based lubricant)

Traverse Shafts & Linear bearings (see Lubrication section of manual)

Remove grinding wheel and spray the movable parts of the finger system

Cross slide shafts and adjustment screws (Right side of Traverse Base)

Scratches in the paint or any other bare metal surfaces

-Work the lubricant in by moving parts through their full range of motion.

-Make sure all controls are in the off position and unplug the unit from the wall. Turn off the digital alignment gage.

-Cover the unit if possible with a sheet or tarp.

BRINGING THE UNIT BACK INTO SERVICE:

-Remove the cover and reapply lubricant to the items stated above. Wipe off all excess lubricant.

(See Lubrication section for more details.)

-Plug the unit into the wall and test all electrical functions.

-Check the belts for cracking and adjust the tension if necessary.

-Check for damaged or missing parts.

12

LUBRICATION

LUBRICATION OF LINEAR BEARINGS

STEP 1--Thoroughly clean the shafts.

STEP 2--Flood spray the two shafts with a spray lubricant (do not use a teflon based

lubricant) until the lubricant is dripping off the shafts. See FIG. 10 Then run the carriage

back and forth through its range of travel. This will carry the lubricant into the bearings.

STEP 3--With a clean rag, wipe off the excess amount of lubricant from the shafts. Run the carriage back and forth through its range of travel and wipe the shafts after each traverse.

Repeat until the shafts are dry to the feel. This completes the lubrication process.

If the unit will be shut down for an extended period of time, more than four weeks, then the shafts and other appropriate parts of the unit should be flooded with lubricant and that lubricant left in place until the unit is brought back into service. When the unit is brought back into service the full lubrication procedure as stated above should be repeated.

TRAVERSE BASE ALONE

WITHOUT DUST PROTECTION

COMPNENTS

13

SHAFTS

FIG. 10

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!

14

MAINTENANCE (Continued)

DIGITAL GAGE

Important

-

Do not mark the scale unit with and electric engraver or scratch the scale.

Always use an SR44 battery (silver oxide cell)

-

If the scale will not be used for more than three months, remove the battery and store it properly. Otherwise, leakage, if any, from the battery may damage the unit.

Description of Parts

1. Beam

3. Battery compartment

5. Display

7. ZERO/ABS switch

9. Inch/mm Switch

11. Slider

2. Main Scale

4. Output Connection

6. ON/OFF Power

8. Origin Switch

10. Tapped hole

Battery Installation and Origin Setting

Set the origin of the scale after installing the battery. Otherwise, the error sign("E" at the least significant digit) may appear, resulting in incorrect measurements.

1)

To install the battery, remove the compartment lid and install the SR44 battery with its positive side facing up.

2)

After the battery is installed, set the origin.

To set the origin, move the slider to an area you wish to set as your origin. Turn the power on. Hold the ORIGIN switch down for more than one second. The "0.00" display appears, indication Origin setting is complete. The origin will be retained even if the power is turned off.

Incremental (INC) & 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 be set to zero at any desired position by pressing the ZERO/ABS switch. INC indicator will apper in the display (INC mode), permitting measurements from this zero point. To return to the

ABS mode hold the ZERO/ABS buttton form more than

2 seconds.

Error Symptoms & 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.

-

E in the least significant digit: This occurs when the slider is moved too quickly, but it does not affect the measurement. If it stays on when the slider stops, the scale surface is probably stained. If this is the case, take remedies as for ErrC.

-

B indication: Battery voltage is low. Replace the battery as soon as possible.

15

ADJUSTMENTS

CARRIAGE LINEAR BEARING REPLACEMENT

STEP 1

--Detach the bellows mounting brackets from the carriage. Detach front and rear shields. See FIG. 15.

STEP 2

--Remove the three screws of one linear bearing and slide the linear bearing off the end of the carriage shaft.

STEP 3

--Insert a new linear bearing onto the end of the carriage shaft with the tension adjustment screw pointing outward. See FIG. 14. Adjust the tension screw of the linear bearing so when you radially rotate the linear bearing around the carriage shaft there should be no free play between the linear bearing and the carriage shaft.

NOTE:

Tension is too tight if you feel a cogging action when you rotate the linear bearing around the shaft. This cogging is from the skidding of the bearing on the shaft and indicates tension screw is too tight.

Finally, sliding the bearing block back and forth should be a smooth uniform motion.

SETTING THE BEARING TENSION CORRECTLY

IS CRITICAL TO PROPER GRINDING. BEARINGS

WHICH ARE TOO TIGHT OR TOO LOOSE WILL

CAUSE POOR GRIND QUALITY. ALSO, BEARINGS

WHICH ARE TOO TIGHT WILL HAVE

SUBSTANTIALLY SHORTER LIVES AND MAY

DAMAGE THE SHAFT.

STEP 4

--Slide linear bearing under carriage and attach with the three screws.

NOTE: Repeat Steps 2 thru 4 with the other three linear bearings.

STEP 5

--After all four linear bearings are reattached to the carriage check for correct bearing tension. The bearing tension is correct when you try to lift the carriage and can feel no carriage movement, which is free play up and down.

The most dependable method of checking free play is to use a magnetic base dial indicator attached to the traverse frame weldment and reading the vertical movement above each bearing. This movement should be within .001" (.03

mm) Also, when pulling the carriage in the traversing direction, there should be only approximately a 3 lb force, with the belt disengaged. To check this attach a spring scale to the carriage and pull parallel to the carriage shafts. To double check the assembly, slide the carriage assembly from "end of travel" to "end of travel", it should have very uniform resistance through the full range of travel.

STEP 6-

-Replace the bellows carriage mounting brackets onto the carriage. Replace front and rear shields.

See FIG. 15.

FRONT DUST

SHIELD

16

FIG. 14

REAR DUST

SHIELD

FIG. 15

ADJUSTMENTS (Continued)

REEL FINGER DOVETAIL GIB AND

ADJUSTING KNOB ADJUSTMENTS

The reel finger slide to the reel finger positioner has a dovetail with an adjustable gib for tensioning. Tighten the gib set screws on the side so there is no free play in the dovetail slide. Check for movement when pushing on the relief finger side to side with 20 lbs. (44kg) force. Make sure the knob assembly for adjusting the relief finger to the grinding wheel is rotatable by hand.

The gib adjustment should be sufficient to maintain a rigid position of the reel finger. See FIG. 16.

Check the knob assembly rotating tension by checking the tightness of the nylon plug to the knob assembly threads. The tightness has to be sufficient so the knob assembly does not rotate during the relief grinding cycle.

See FIG. 17.

NOTE: To adjust the nylon plug you must lock the index finger assembly down and then adjust the reel finger positioner so the clearance holes line up with the nylon plug set screw.

Take up any free play between the tee knob assembly, reel finger slide and .375 threaded split shaft collar.

Loosen the shaft collar locking cap screw and rotate the shaft collar until there is no end play. Retighten locking cap screw on the threaded split shaft collar. See FIG.

16.

GRINDING HEAD BELT TENSION

ADJUSTMENT

The left side grip grinding wheel knob must be removed for belt tensioning adjustment. Remove the six screws holding, the two double tube clamps and the belt cover.

For grinding motor belt adjustment, loosen the four socket head cap screws that attach the motor. Adjust the grinding motor for proper belt tension by pushing back on the motor and tighten the four socket head cap screws. The proper belt tension for the grinding head is to push down on the poly V belt half way between the two pulleys with 5 lbs. (2KG) of force and belt movement dimensions to be .12 inches (3mm). See FIG.

18. To verify belt tension mount the belt guard with two screws. Turn the motor on. If the belt is tensioned correctly, start-up torque of the motor through the pulley to the belt should have zero slippage. If there is belt slippage when turning on the motor there will be a slight squeal before the belt comes up to speed. When you achieve correct tension, reassemble all of the remaining parts that have been removed.

17

FIG. 16

FIG. 17

FIG. 18


LOCKING INDEX FINGER PIN

To align the Index Finger Locking Pin to the hole in the

Index Finger Assembly loosen the two socket head cap screws so the index sensor block is movable.

Push down on the index finger assembly until the spring loaded index finger locks into hole with no binding. Tighten the two socket head cap screws so the index sensor block is secured, and the locking pin moves freely. See FIG. 19.

PROXIMITY SWITCH

For the proximity switch to perform properly and reverse the direction of the carriage at each end of the rails, a distance of 3/16" (4 mm) to 1/4" (6 mm) needs to be maintained between the carriage proximity flag bracket and the proximity switch.

See FIG. 20.

NOTE: Light on proximity activates when metal crosses in front of switch sensor.

18

FIG. 19

FIG. 20


ADJUSTABLE RELIEF TENSION

If the relief angle appears to vary during relief grinding, adjust the tension on the nylon plug and set screw. See FIG. 21.

FIG. 21

SAFETY SWITCH ALIGNMENT

For the safety switches to work properly they must be adjusted so the sender and receiver are parallel to each other with a maximum gap of .19 inches (5mm).

(Adjust by moving the doors or brackers. If this does not help, a special wrench is needed to adjust the safety screws used to hold the switch in place.) See FIG. 22.

.19" (5mm)

19

FIG. 22


SPIN GRINDING ATTACHMENT ADJUSTMENT

If play develops so crank handle wants to rotate in the scissor action on the spin grinding attachment, the play can be eliminated by tightening the set screw identified in FIG. 23.

If there is too much play in the spin drive pivot points, torque down the hex nut tight so conical washer is completely compressed, then back off

1/2 turn. See FIG. 23.

FIG. 23

REDUCER MOTOR ADAPTER

TO ACTUATOR DRIVE SCREW

CLAMPING COLLAR POSITIONING

The lower clamp collar, next to the reducer motor adapter, is to be positioned flush to the end of the actuator screw shaft and tighten down with 6 ft.

lbs (0.8 kg) of torque. See FIG. 25. The top clamp collar is factory adjusted and does not need any further adjustment. There is to be no slippage between the reducer motor adapter shaft and actuator screw when pushing down on grinding head and stalling the reducer motor.

20

FIG. 24


ADJUSTING CROSS SLIDE ASSEMBLY

If the cross slide becomes very difficult to turn it may become necessary to adjust the assembly. To relieve the tension on the assembly follow the procedure listed below:

STEP 1--Using a hydraulic jack, raise the traversing carriage base just enough to alleviate the weight stress on the Cross Slide Assembly.

STEP 2--Knock the pins on either side of the Mounting

Frame Adjuster and loosen the 4 bolts (B504801) that connect the Carriage Mounting Frame to the frame of the grinder.

STEP 3--Jack the traversing carriage base up to put a preload on the Cross Slide Assembly.

STEP 4--Tighten the 4 bolts on the Carriage Mounting

Frame to 75 ft-lbs.

STEP 5--Release the jack pressure and test the vertical and horizontal handwheels for ease of movement through their full range of motion.

STEP 6--If the Cross Slides tend to bind, repeat above steps jacking higher or lower (STEP 1) until the handwheels move freely.

STEP 7--When the Cross Slides move freely through their full range of motion, drill new holes and repin assembly.

CROSS SLIDE

ASSEMBLY

CARRIAGE

MOUNTING

FRAME

BOLTS

PIN

BOLTS

PIN

PART OF

FRAME

21


CROSS SLIDE SHAFT REPLACEMENT

If the cross slide shafts become scarred or gnarled, replace them by the following procedure:

STEP 1--Use a hydraulic jack to raise the weight off the Cross Slide Assembly.

STEP 2--Loosen the two nuts on the support casting that hold the locking studs and tap with plastic hammer to loosen.

STEP 3--Loosen the locking handles and tap the center stud with a plastic hammer.

STEP 4--Loosen locknut and setscrew and remove the handwheel.

STEP 5--Remove the Slide Shaft.

STEP 6--Remove all burrs and resurface the shaft to a clean, smooth, polished surface.

(OR REPLACE WITH A NEW SHAFT.)

STEP 7--Coat shaft with Never-Cease and re-install the shaft through the Support, Cross Slide Block and the three locking studs. The shaft must move freely inside the Cross Slide Block before reassembling.

STEP 8--Retightening the nuts at the end of the locking studs to lock shaft in place.

STEP 9--Reinstall the Handwheel by snugging the setscrew to the flat located on the screw shaft, then torque nut until tight and back off 1/2 turn. Torque the setscrew to 70 in-lbs.

STEP 10--Test the Cross Slide, the handwheel should turn freely.

STEP 11--Lower the jack and retest the Cross Slide

Assembly through full range of motion. If binding occurs, follow the procedure under Cross Slide

Assembly located on page 21.

LOCK

HANDLES

NOTE: It is also possible to remove the complete

Cross Slide Assembly and do the repairs on a bench then reinstall.

NUT

LOCKING STUD

LOCKNUT

CROSS

SLIDE

SLIDE

SHAFTS

LOCKNUT

22

SETSCREW

HANDWHEEL


TRAVERSE BELT TENSION

To adjust the tension on the traverse belt tighten the screws and nuts located at the left side of the traverse belt. Tighten nuts until the comprension springs measure 3/4". See FIG. 25. If the springs are not tensioned equally, uneven loading on the traverse system may cause parts to fail.

DO NOT OVERTIGHTEN.

OVERTIGHTENING COULD

DAMAGE THE BELT OR

TRAVERSE DRIVE SYSTEM.

TRAVERSE CLAMP FORCE

If the traverse clamp is slipping during regular operation it may be necessary to tighten the clamp. To tighten, loosen the jam nut on the clamp tip. Screw the tip out so there is

.10" gap between the tip and the Clamp Support Block.

See FIG 26. Lock in place by tightening the jam nut against the clamp being careful not to move the tip. Verify the distance between the clamp tip and block is still .10".

The

.10" setting allows slippage in a jam situation and damage can occur if this adjustment is set to narrow.

CAUTION SHOULD BE USED

AS ADJUSTING THE TIP WILL

AFFECT THE SLIP LOAD AND

COULD DAMAGE THE CLAMP

TIP, BELT OR TRAVERSE

DRIVE SYSTEM.

23

FIG. 25

FIG. 26


REEL LIFT PIVOT BOLTS

There are four pivot bolts on the reel lift that must be adjusted correctly for proper lift function. Tighten the screws and locknuts and then loosen 1/8 to 1/4 turn until the screw turns freely with fingers when the screw is under no load. See items marked "SCREWS AND

LOCKNUTS" below.

24


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 through two holes on the inside of the vacuum chamber.

Remove the vacuum cover and take out the vacuum. There are two plastic plugs on the back wall of the vacuum chamber. Remove these plugs and raise or lower the lift until the spring retainer screws line up with the holes. Tighten the screws until tight

(springs solid) with blue loctite no. 242, then back the scres out ONE full turn. See items marke "B311613" below. When complete, reinstall plugs, vacuum and cover.

LEFT SIDE LOOKING FROM FRONT OF GRINDER

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) 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 factory preset to #4 setting for a 2 second dwell time when reversing at each end of stroke.

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

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

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

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

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

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

* DWELL lights when the process remains stopped after a proximity switch is actuated.

Potentionmeter

Clock Orientation

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. 27 and FIG. 28. These potentiometers have been set at the factory to the positions shown on FIG. 27 and FIG. 28.

In the Relief Grinding Mode--

The remote 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 remote speed preset at 9:30. See FIG. 27. The (RTP) is located on the control panel and is for relief torque adjustment.

Remote Relief Speed Pot (RSP) when rotated clockwise will increase maximum spin drive speed when in the relief mode. 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/lbs of torque setting. Never adjust the (RTP) potentiometer dial past the red line marking.

Setting the reel to finger torque to high could cause the traverse motor system to not operate smoothly.

In the Spin Grinding Mode-- the remote Spin Torque Potentiometer (STP) and the Spin Speed Pot (SSP) interact with each other. The

(STP) is located on the upper spin board as remote torque preset at 2:00 for torque setting. See FIG. 27. The

(SSP) is located on the control panel and is for spin speed adjustment.

The remote Spin 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. 28.

Maximum Speed Pot--

The maximum speed is factory preset to 4:30 (fully clockwise) to allow for maximum spin speed.

Minimum Speed Pot--

The minimum speed is factory preset at 8:30 (full counterclockwise) so zero speed is obtainable for spin speed.

IR Compensation Pot--

The IR Compensation is factory set at 9:00.

Regulation of the spin or relief grind spin motor may be improved by a slight adjustment of the IR COMP pot clockwise from its factory-set position. Overcompensation causes the motor to oscillate or to increase speed when fully loaded. If this occurs turn the IR COMP pot counterclockwise until symptoms disappear.

UPPER SPIN BOARD

LOWER SPIN BOARD

FIG. 27

27

FIG. 28

MACHINE SERVICE (Continued)

REPLACEMENT OF GRINDING HEAD SHAFT & BEARINGS

Remove grinding wheel and grinding wheel knob. The Grinding Head Spindle Assembly consists of the grinding head spindle and a ball bearing press fit together. The left side ball bearing is slip fit on the opposite end. To replace the spindle assembly remove the left side grinding wheel grip knob, square key and belt cover. See FIG. 29. Loosen the 4 socket head cap screws on the motor plate to remove the poly-V belt.

Loosen the 2 set screws on the spindle pulley and remove the pulley, square key and pulley spacer. Push on the right hand side of the spindle assembly to compress conical washers so there is no pressure on the shaft retaining ring. Using a retaining ring pliers remove the small external retaining ring from the spindle assembly. You can now remove the spindle assembly out the right side by lightly tapping on the left end with a rubber mallet. The second ball bearing can be removed from the belt side of the Grinding Head Housing.

To reassemble place the 4 conical washers (2 Pair nested and then place the 2 pairs back to back) against the ball bearing on the new spindle assembly. See FIG. 30. Thoroughly clean the housing bore and the outside diameter of both bearings. Apply blue Loctite #242 to the outside diameter of the two bearings. Slide the spindle assembly into the right side of the Grinding Head Housing. Install the bearing sleeve against the bearing on the spindle assembly. Slip fit the new left side ball bearing onto the spindle assembly and into grinding head housing. Install the 9/16-18 Locknut onto the spindle shaft and using a spanner wrench on the right side of the spindle and a 7/8 deepwell socket on the left side, torque the locknut to 30 Ft. Lbs.

Replace the square key and the pulley pushing the pulley against the locknut with no end play. Apply blue locktie to the pulley bore before installation. Next install blue Loctite #242 on the pulley setscrews and tighten the two pulley set screws. Then remount the poly-V belt. (See Grinding Head Belt Tension Adjustment in the adjusting section). Replace belt cover and square key and mount the left side grinding wheel grip knob and tighten the two set screws.

FIG. 29

28

FIG. 30

632 MANUAL CONTROL PANEL

Door Safety

Switch Monitor

(SSM)

24 VDC Power

Supply (PWR)

Low Voltage Relay

(LVR)

Terminal Strip #2

(TB2)

Magnetic

Contactor

(MAG)

Main Circuit

Breaker (MCB)

Grinding Motor

Relay (REL)

Termial Strip #1

(TB1)

Main Ground Lug

AC Filter

(FTR)

115 - 24 V

TRANSFORMER

(TFR)

BRIDGE

DIODE

(BD)

29

Traverse Drive

Control Board

(TDC)

Spin Drive

Control Board

(SDC)

VOLTAGE

REGULATOR

Blue Terminal

Blocks (TBB)

Grey Terminal

Blocks (TBG)

ELECTRICAL TROUBLESHOOTING

SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING

This Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowledge and skills to reliably test and repair the ACCU-Pro electrical system. For those without that background, service can be arranged through your local distributor.

This manual presumes that you are already familiar with the normal operation of the Grinder. If not, you should read the Operators Manual, or do the servicing in conjunction with someone who is familiar with its operation.

Persons without the necessary knowledge and skills should not remove the control box cover or attempt any internal troubleshooting, adjustments, or parts replacement.

If you have any question not answered in this manual, please call your distributor. They will contact the manufacturer if necessary.

WIRE LABELS

All wires on the ACCU-Pro 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 or more position code. The first two or three digits are the wire number: 01-999. The next three numbers or letters are the code for the component to which the wire attaches. Example: GMC for Grind Motor 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 29-31

Spin Drive Controls in Spin Mode ........................................................................................ Page 32-33

Spin Drive Controls in Relief Mode ...................................................................................... Page 34-36

Grinding Motor Controls ....................................................................................................... Page 37-38

Traverse Drive Controls-w/prox .......................................................................................... Page 39-40

Traverse--stopping and reversing ........................................................................................ Page 41-43

Infeed Controls .................................................................................................................... Page 44-45

30

ELECTRICAL TROUBLESHOOTING (Continued)

PROBLEM--AC Main Power Controls: no electrical power to control panel.

Verify all wires shown on the wiring diagram on pages 88 are correct and pull on wire terminals with approximately 3 lbs 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) is Depressed

A. Pull Up on ESS Button

You must push the System

Start Switch (SSS) to get power to control Panel

Main Power Cord is not plugged in

B. Listen for the Magnetic Starter

(MAG) contacts to pull in with a clunk

C. Plug in main power cord

Machine works

Yes--end troubleshooting

No--go to Step B. next

Machine works


No--go to step C. next.

Machine works


No--go to step D. next.

Guard doors must be closed and ALL Switches

MUST be turned OFF for contactor to pull in.

Main 20 amp outlet circuit breaker has tripped

D. Close guard doors and turn off all switches.

Machine works


No--go to step E. next.

E. Check circuit breaker in your building and reset if necessary.

(Check wall outlet with a light to

make sure it works)

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)

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

Machine works


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 I. next.

No--Check wires & replace if needed.

MCB Top Terminal to Terminal Block 4

(Blue) for 120 Volts 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

31


Possible Causes

120 Volts AC power not delivered to

Terminal Strip

Checkout Procedure

J. Check for 120 Volts AC at 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)

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 8pin socket.

P. Hold in SSS and Check voltage at MAG A1 & A2.

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 & #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


Yes--Go to Step M. next.



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.

32


PROBLEM--Machine Shuts off when you turn on Grind motor switch or Spin Motor

Switch.


Guard Doors are

Open

A. Close the front doors (and rear ramp - lift model)

Door Safety

Switches 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 Ramp Switch is Bad - (Lift Model

Skip to next step if boom model.)

Front Door Switch is

Bad

B. Check Alignment of Door Safety

Switches on Front doors (and rear ramp - lift model)

C. Check SSM for 24 Volts DC.

(Turn switches off and press start switch to pull in MAG before testing voltages)

D. Check PWR for 120 Volts AC.

(Turn switches off and press start switch to pull in MAG before testing voltages)

E. Verify 24Volts DC out to Door

Switches.

F. With Rear Ramp Closed Verify

24Volts DC back form rear Door

Switch. (Boom model verify jumper assembly is in place and terminals are on tight.)

G. With Front doors Cloded Verify

24Volts DC back form Front Door

Switch.

Machine works



See Alignment section of this Manual.

Machine works


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 &

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 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 Voltage to Term2 or 4 then replace front switch.

PROBLEM--(MAG) turns on only with

System Start Switch held in.

Possible Cause


(MAG) holding contact has failed

A. Check wiring to and from MAG holding contact in. Verify the magnetic starter holding contact is working.

Measure 120 Volts AC at MAG term L3 to

Term Block 4(Blue) after SSS is pushed.

Yes--Verify Wiring to LVR

No--Check voltage at T3. If 120 Volts AC

Replace MAG. If no 120 Volts AC verify wiring to T3.

33


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 pages 88 are correct and pull on wire terminals with approximately 3 lbs 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.

Spin Speed Pot

(SSP) set to zero

Spin Motor Switch

(SMS) is not on

Spin Rotation Switch

(SRS) is not on

A. Set (SSP) to 200 on the control panel.

B. Turn (SMS) switch on

Spin Motor works


No--go to Step B next

Spin Motor works



Spin Motor works



Circuit Breaker is

Tripped (4 AMP)

Spin Drive Control

(SDS) is not working

B. Turn (SRS) switch to direction of reel rotation required.

NOTE: CENTER POSITION

IS OFF

C. Reset Circiut Breaker on front of Control Panel. Push in if tripped. If circuit breaker is tripped, verify reel is free spinning.

D. Check (SDS) L1 to L2 for

120 Volts AC

Spin Motor works


No--go to Step D. next

E. Check (SDC) A1 & A2 for approx. 90+ Volts DC (Have

Spin Speed Pot set to 400

RPM)

F. Check for approx 90+ Volts

DC input to (SRS)

G. Check for approx 90+ Volts

DC out put from (SRS).

(SDC) Term L1 to term L2 for 120 volts AC

Yes--go to Step E. next

No--Verify Power to Circuit Breaker, SMS,

SRS and continuity of all wires. Replace any components found bad.

(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 & 14

(SRS) Term 6 to 7 for approx 90+ Volts DC

Yes--go to Step H. next

No--replace (SRS) switch

Spin Drive motor is bad

H. Check spin motor continuity

Disconnect Power from Machine!

Remove wires at Terminal Strip 1, Term 4 &

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

34


Possible Cause

Spin Speed Pot (SSP) is not working

Spin Torque Pot (STP) is not set correctly

(SSP) is not working

Worn Motor Brushes


L. (SSP) (10K) on control panel

M. Check (STP) remote torque on the top (SDC) board

N. (SSP) (10K) Remove 3

Remote Speed wires.

Red wire to term W

White wire to term L

Black wire to term H

P. Inspect Motor Brushes

DISCONNECT POWER

FROM MACHINE !

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

Red wire to white wire

Full CCW--0 ohms

Full CW-10,000 ohms

Red wire to black wire

Full CCW--10,000 ohms

Full CW--0 ohms

Yes--replace (SDC)

No--replace (SSP)

Remove the brushes one at a time and maintain orientation for reinsertion. See if brush is worn short 3/8" (10 mm) minimum length.

Yes--replace motor brushes

No--replace Spin Drive Motor

35


PROBLEM--Spin Drive not working in relief mode.


Verify all wires shown on the wiring diagram on pages 88 are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose terminal connections and/or no loose crimps between wire and terminal. If loose terminals are found, retighten and retest system. If problem persists, test as listed below.

Possible Cause

Relief Torque Pot

(RTP) set to zero

Spin Motor Switch

(SMS) is not on

Spin Rotation Switch

(SRS) is not on

Circuit Breaker is

Tripped (4 AMP)

Spin 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

Spin Motor works



Spin Motor works



Spin Motor works


No--go to step D. next

C. Turn (SRS) switch to direction of reel rotation required. NOTE: center position is off

D. Reset Circiut Breaker on fornt of Control Panel. Push in if tripped.

Spin Motor works


No--go to step E. next

E. Check (SDS) L1 to L2 for

120 Volts AC

F. Check (SDC) A1 & 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).

I. Check spin motor continuity


FROM THE MACHINE

(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


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 & 14

(SRS) Term 6 to 7 for approx 20 Volts

DC

Yes--go to Step I. next

No--replace (SRS) switch

Remove wires at Terminal Strip 1, Term

4 & 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

36


Possible Cause

(RTP) Relief Torque Pot is not working


L. Check (RTP) (50K) on control panel (check voltage with pots at fully clockwise and counterclockwise positions)

Relief Speed Pot (RSP) is not set correctly.

(RTP) is not working

Worn Motor Brushes

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


FROM MACHINE !

On(SDC), Remote Torque check Black wire H terminal to Red wire W terminal for:

Pot CCW--) 0 volts DC

Pot CW--.2 Volts DC

Check 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 function.


No--replace (SDC)



Full CCW--0 ohms

Full CW--50,000 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) minimum length

37

ELECTRICAL TROUBLESHOOTING (Continued) SPIN DRIVE

PROBLEM : Spin drive speed goes at one speed only.

Possible Cause

Remedy

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

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

Defective spin speed control (SSP) potentiometer.

B. (SSP) 10K Remove 3 remote speed wires.

red wire to term W white wire to term L black wire to term H

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

C. Check all pot settings on both boards as of the (SDC) shown on Pages 24 and 25. (See

Adjustment Section Spin Drive

Control [SDC] Board Setting).

PROBLEM: Spin drive motor speed varies

If wiring is wrong, correct and test.


No--Go to Step B. next



Full CCW--0 ohms




Full CW--0 ohms

Yes-- Go to Step C. next

No--Replace (SSP)

Yes-- end of troubleshooting

No--replace (SDC)

IR Comp trim pot not adjusted properly.

Torque to rotate the reel too high.

Check all terminal connections for tightness.

A. See adjustment section for trim pot setting on Page 24.

B. Readjust bearing preload for the reel. Maximum torque load 25 in./lb 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.

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.

38


PROBLEM-- Grinding motor not working.


Verify all wires shown on the wiring diagram on pages

74-76

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

Grinding Motor

Switch (GMS) is not on

Guard doors are not closed

10 Amp Circuit

Breaker (CB) is tripped

GMS not working


A. Turn switch on

B. Close Front guard doors

(and rear ramp - lift option)

C. Check 10 amp CB on front of Control panel. Press in if tripped.

D. Check for power to GMS

Grinding Motor works









GMS term 5 to Terminal Block 9 (Blue) for

120 Volts AC


No--With power off, check continuity of wires to GMS.

Grinding Motor Relay not working

No Power to Relay

Contacts

E. Check for power from

GMS

F. Check for power to relay

Coil (Relay should click when GMS is turned on.)

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.

G. Verify Power to Relay

Contacts

(REL) Term L1 to Term L2 for 120 Volts (AC)

Yes--Go to Step H. next

No--Check wires to REL Term L1 & L2

39



Bad Contacts in Grinding motor Relay

Bad Circuit Breaker

Bad Grinding Motor

H. Verify power out of Grinding

Motor Relay.

I. Verify Power out of Circuit

Breaker.

J. Verify Power to Grinding motor Cord.

(REL) Term T1 to Term T2 for 120

Volts (AC)

Yes--Go to Step I. next

No--Replace Gringing Motor Relay

Check for 120 Volts (AC) from 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.

Verify wiring at terminals 1, 2 & 3 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.

40


PROBLEM--Traverse Drive not working.


Verify all wires shown on the wiring diagram on pages

88

are correct and pull on wire terminals with approximately 3lbs force to verify there are no loose terminal connections and/or no loose crimps between wire and terminal. If loose terminals are found, retighten and retest system. If problem persists, test as listed below.

Possible Cause

Traverse Motor Switch

(TMS) is not on


A. Turn on (TMS)

Traverse Speed Pot

(TSP) set to zero

Fuse on Traverse Drive

Control (TDC) has failed

B. Set (TSP) to 35 on the control panel

Traverse works


No--got to Step B. next

Traverse works



Traverse works



Traverse Drive Control

(TDC) is bad

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 needs replacing MUST use a 3 amp slo-blo fuse.

Part Number 3707546.

D. Check for 120 Volts (AC) incoming to (TDC)

Bad Traverse Motor

Switch (TMS)

E. Check for 120 Volts AC at

(TMS). (Make certain (TMS) is on)

On (TDC) Terminal L1 to L2 for 120 Volts

AC


No--Go to Step E. next

Measure 120 volts AC from TMS


Yes--Go to Step L. next.



Does not work-- Check wiring/Verify

Continuity/ Replace Switch

41


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


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


FROM MACHINE

H. Check (TSP) (10K) on control panel

Check (TDC) terminals #A1 to #A2 for 90

Volts DC


No--go to Step H. next

Remove motor wires from Terminal Strip 1 terminals #7 & #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

0VDC 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

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


FROM MACHINE

Check for 10,000 ohms red to white wires

Full CCW--0 ohms


Red to black wires


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

42


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.

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.

If incorrect, adjust per adjustment section of manual.



P r o x i m i t y

Switch is bad.

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

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).

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


12 Volts DC

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

43


PROBLEM--Traverse speed control goes at one speed only.


Defective speed control potentiometer

A. 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

Yes--Pot is OK

No--Go to Step B. next

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


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.

Wiring hookup to potentiometer is improper.

(If components have been replaced.)

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

Main circuit board dial pot settings not correct.

(If board has not been replaced.)

D. Check all pot settings on circuit board as shown in wiring diagram.

(See adjustment section Traverse

Motor Control Board Settings.)

Wrong wire hookup effects traverse control.

Reversing red and orange wires to potentiometer to the D C motor will run at zero speed but maximum will be too slow.

Reversing red and white wires does not affect speed control.

Check for Proper function.


No--Go to Step D. next

Minimum and maximum pot settings effect traverse speed.

44


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

Possible Cause Remedy

Proximity switch is not working properly or wire connections are loose

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.

Reason

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

Left proximity (PROX1) check

Traverse drive Control (TDC) between terminals #14 (black wire) and #15

(brown wire).

Right proximity (PROX) check (TDC) between terminals #13 (black wire) and

#15 (brown wire).

Proximity light on-

0 Volts DC


12 Volts DC

Proximity light on-

0 Volts DC


12 Volts DC

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

PROBLEM--Insufficient hesitation at carriage stops prior to reversing traverse.

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

Reset dwell time as required. One increment increases Dwell time by

1/2 second.

PROBLEM--Traverse changes directions erratically while running in traverse cycle.

Loose wire to proximity switch.

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

A loose wire connection will give intermittent electrical contact.

45


PROBLEM--Infeed motor not working.

Assuming (SSS) System Start Switch is on with 115 Volts AC to control panel and all other functions are working.

Possible Cause

Infeed Jog Switch (IJS) is not held to on position

Infeed Speed Switch

(IJS) is not on high speed


A. (IJS) Hold switch on in either direction

Infeed motor works



High speed works



Infeed motor/reducer drive coupling is loose

No DC voltage to Grinding Wheel Infeed Motor

(GIM)

B. Put (IJS) on high speed for ease of checkout. (Note: Infeed motor will always be in low if the grinding motor switch is on.)

C. Open infeed motor coupling inspection plate to check for loose coupling. Retighten coupling to drive actuator screw. See adjustment section of manual.

D. Check for 12+ Volts DC across terminals labeled 2 and

5 of the (IJS) with (IJS) held on.

Infeed works--



Infeed Motor/Reducer will not function

E. Check for 12 Volts DC at the

(GIM) terminals

F. Disconnect (GIM) from the infeed actuator and check (GIM) function under no load.

Check term 2 & 5 of (IJS) for 12+ Volts

DC.


No--go to Step G. next

Check for 12 Volts DC at Term marked

73 GIMBL and 3 GIMRD. You will need jumpers to check.


No--Replace cord wire no. 94

Check (GIM) function when disengaged from Infeed Actuator.

Yes--Replaced Infeed Actuator

No--Replace (GIM)

Switch (IJS) is bad G. Check for 12+ Volts to (IJS).

No DC Voltage from the

Voltage Regulator.

H. Check for 12 volts DC at

Bridge Diode output.

Check for 12+ Volts DC at Term 6 & 4 and

3 & 1 of (IJS).

Yes--Replace (IJS)

No--go to Step H. next.

Check for 12 Volts DC at term 120BD-+ and 133BD--

Yes--Replace Voltage Regulator

No--Go to Step I. next.

46


PROBLEM--Infeed motor not working.

Assuming (SSS) System Start Switch is on with 115 volts AC to control panel and all other functions are working

Possible Cause

Bad Bridge Diode


I. Verify voltage to bridge diode.

No AC Voltage to the input side of transformer

J. Check for 115 Volts AC at transformer input black wires.

Check 12.6 Volts AC at input of

Bridge Diode (BD1) Term (~) to

Term (~)

Yes--Replace Bridge Diode BD1

No--Go to Step J. next

Check for 115 Volts AC at Term.

TBW-13 and TBG-9.

Yes-- Replace Transformer

No-- Follow separate trouble shooting procedure on AC main power.

47

MECHANICAL TROUBLESHOOTING (Continued)

Possible Cause


PROBLEM--Reels ground have high/low blades

Traverse Speed set too fast.

Check roundness using a magnetic base dial indicator. Traverse speed should be set approximately

12 ft/min. (4 meters/ min.) if roundness is varying.

Lineal bearings for the grinding head carriage are out of adjustment (loose) or have grit buildup causing uneven traversing load.

Relubricate and adjust linear bearings per adjustment section. If problem persists, replace lineal bearings on the carriage base. Check for any holes in the bellows that would permit any grinding grit penetration. See adjustment section for lineal bearing replacement.

PROBLEM--Excessive grinding stock being removed when traversing to the right in the relief grinding mode.

Gib adjustment for the relief finger assembly is loose so reel finger has movement. When traversing to the right minimum grinding stock removal should be seen as compared with heavy stock removal when traversing to the left.

Tighten the set screws for the gib adjustment. See procedure in the adjustment section in the manual.

PROBLEM-- Grinding stock removal from reel is irregular during spin grinding.

Lineal bearings on the grinding head carriage are too loose .

The lineal bearing must be preloaded to the traverse shafts with no vertical movement. See manual adjustment section for carriage bearing adjustments.

PROBLEM--Carriage traversing varies speed while grinding.

Lineal bearings in the carriage do not rotate freely.

Check for grinding grit getting into the lineal bearings and causing excessive driving torque of carriage.

Abrasive noise is detectable when excessive grit is in the lineal bearings. Replace the four lineal bearings in the main carriage. Check bellows for holes and replace if necessary.

Belt is slipping

Traverse Belt tension to loose

Belt Clamp may have moved. See manual adjustment section for Traverse Clamp Force.

Check the spring length on left side of travese belt.

See manual adjustment section for Traverse Belt

Tension.

48

MECHANICAL TROUBLESHOOTING (Continued)


PROBLEM--Too heavy a burr on cutting edge of reel blades.

Traverse speed set too high causing a heavy burr on the reel blade when spin grinding.

Traverse speed should be set lower approximately 12 ft/min. (meters/min.) for a smaller burr on cutting edge.

PROBLEM--Cone shaped reel after grinding.

Grinding head travel not parallel to the reel center shaft.

Grinding head travel was not setup parallel to the reel center shaft in vertical and horizontal planes. See Align the Reel Section in operator's Manual

PROBLEM--Relief grind on the reel blades do not go the full length of the reel.

The right side corner of the grinding wheel is always to be in contact with the reel blade. This is high point of the relief finger.

The right hand side of the grinding wheel is not in full contact for relief grinding.

See Operators Manual for NORMAL HELIX AND

REVERSE HELIX.

PROBLEM-- Traverse speed is too slow.

Possible Cause Remedy

Lineal bearing in the carriage are set too tight.

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

Reason

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

When traverse belt is disengaged, the proper traverse load is 2 to 3 lbs. Use a tension scale to check. (A general guide only.)

PROBLEM--Spin Drive cranks up and down too hard.

The two top and two bottom pivot screws are compressing the conical washer too tight.

A. Tighten down the locknut until it bottoms out and back off 1/2 turn.

Check to see if there is a cone shape to the washer. Four (4) pivot points.

Check screw adjustment tension on nylon plug riding against the screw thread.

B. Loosen set screw and check.

(See adjustment section.)

Have enough play so the crank turns snugly but during operation it is free.

49

PARTS LIST

6329532 CANOPY ASSEMBLY - WINCH & BOOM MODEL

50

PARTS LIST

6329532 CANOPY ASSEMBLY - WINCH & BOOM MODEL

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

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

2 ....................................... B251001 ................ Hex Head Cap Screw 1/4-20 x 5/8 Long



5 ....................................... B371611 ................ Socket Head Cap Screw 3/8-16 1 Long

6 ....................................... J257000 ................ 1/4-20 Nylon Jam Locknut

7 ....................................... J257100 ................ 1/4-20 Nylon Locknut


9 ....................................... K250001 ................ 1/4 Flat Washer

10 ..................................... K251501 ................ 1/4 Split Lockwasher

11 ..................................... K370001 ................ 3/8 Flat Washer SAE


13 ..................................... R000454 ................ Flat Washer (1 OD x .44 ID )

14 ..................................... 09394 .................... 2 Prong Knob

15 ..................................... 3589106 ................ Flat Washer (1.38 OD x .39 ID)

16 ..................................... 3707009 ................ Liquid Tight Strain Relief .27-.47 Wire



19 ..................................... 3707595 ................ 7/8 Hole Plug

20 ..................................... 3707597 ................ 5/8 Hole Plug

21 ..................................... 3708448 ................ Electrical Warning Decal

22 ..................................... 3708458 ................ Sharp Warning Decal

23 ..................................... 3708521 ................ Plastic Rivet

24 ..................................... 3708605 ................ Respirator Warning Decal

25 ..................................... 3708606 ................ Hearing Protection Warning Decal

26 ..................................... 3708612 ................ No Fuel Warning Decal

27 ..................................... 3708703 ................ Multiple Safety Symbols Decal

28 ..................................... 3708869 ................ Spring Hinge

29 ..................................... 3708872 ................ Patent Decal

30 ..................................... 3709990 ................ Foley United Decal

31 ..................................... 6309039 ................ Gage Mounting Pin

32 ..................................... 6329022 ................ Side Frame Spacer Plate

33 ..................................... 6329024 ................ Canopy Boom Support Bracket

34 ..................................... 6329029 ................ Hinged Walker Panel

35 ..................................... 6329053 ................ ACCUPro Decal

36 ..................................... 6329047 ................ Door Guide Bracket RH

37 ..................................... 6329048 ................ Door Slide

38 ..................................... 6329049 ................ Door Guide Bracket LH

39 ..................................... 6329059 ................ Canopy Support Bracket

40 ..................................... 6329503 ................ Rear Top Filler Weldment

41 ..................................... 6329505 ................ Guard Weldment RH

42 ..................................... 6329506 ................ Guard Weldment - Boom LH

43 ..................................... 6329520 ................ Rear Panel Weldment

44 ..................................... 6329533 ................ Front Guard Door Assembly (see page 60)

51

PARTS LIST

6059526 WINCH AND BOOM ASSEMBLY (Optional)

52

PARTS LIST (Cont.) 6059526 WINCH AND BOOM ASSEMBLY (Optional)

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

1 ............................ B371601 .......................... Hex Head Cap Screw 3/8-16 x 1Long

2 ............................ B372801 .......................... Hex Head Cap Screw 3/8-16 x 1 3/4 Long

3 ............................ J371000 ........................... 3/8-16 hex Nut

4 ............................ J377100 ........................... 3/8-16 Nylon Locknut

5 ............................ K370001 .......................... 3/8 Flat Washer

6 ............................ K371501 .......................... 3/8 Split Lockwasher

7 ............................ 3708456 ........................... Warning Decal - Boom Capacity

8 ............................ 3708578 ........................... Winch

9 ............................ 3708647 ........................... 7" Winch Handle

10 .......................... 3709407*.......................... Hook and Cable Assembly

11 .......................... 3709795 ........................... Pulley

12 .......................... 6059003 ........................... Pulley Guard Bracket

13 .......................... 6059527 ........................... Boom Weldment

14 .......................... 6309036 ........................... Boom Capacity Decal

15 .......................... 6309037 ........................... Winch Warning Decal

* Hook & Cable Assembly is packed in carton assembly. Install as shown (cable runs down middle of boom tube).

53

PARTS LIST

6329534 CANOPY ASSEMBLY -REAR LIFT OPTION

54

PARTS LIST

DIAGRAM

NUMBER


PART

NUMBER

DESCRIPTION

1 ....................................... B191213 ................ Button Head Cap Screw #10-24 x 3/4 Long





6 ....................................... B371611 ................ Socket Head Cap Screw 3/8-16 1 Long

7 ....................................... C311620 ................ Socket Set Screw Cup Pt. 5/16-18 x 1 Long

8 ....................................... J167000 ................ #8-32 Nylon Jam Locknut

9 ....................................... J197100 ................ #10-24 Nylon Locknut

10 ..................................... J257000 ................ 1/4-20 Nylon Jam Locknut

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

12 ..................................... K160001 ................ #8 Flat Washer

13 ..................................... K190001 ................ #10 Flat Washer

14 ..................................... K250001 ................ 1/4 Flat Washer


16 ..................................... K370001 ................ 3/8 Flat Washer SAE


18 ..................................... R000454 ................ Flat Washer (1 OD x .44 ID )

19 ..................................... 09394 .................... 2 Prong Knob

20 ..................................... 3589106 ................ Flat Washer (1.38 OD x .39 ID)




24 ..................................... 3707595 ................ 7/8 Hole Plug

25 ..................................... 3707597 ................ 5/8 Hole Plug


27 ..................................... 3708458 ................ Sharp Warning Decal

28 ..................................... 3708521 ................ Plastic Rivet

29 ..................................... 3708605 ................ Respirator Warning Decal

30 ..................................... 3708606 ................ Hearing Protection Warning Decal

31 ..................................... 3708612 ................ No Fuel Warning Decal

32 ..................................... 3708703 ................ Multiple Safety Symbols Decal

33 ..................................... 3708820 ................ Button Head Safety Screw #8-32 x 1/2 Long

34 ..................................... 3708872 ................ Patent Decal

35 ..................................... 3708882 ................ Spring Latch

36 ..................................... 3709788 ................ Knob

37 ..................................... 3709990 ................ Foley United Decal

38 ..................................... 6309039 ................ Gage Mounting Pin

39 ..................................... 6329022 ................ Side Frame Spacer Plate

40 ..................................... 6329047 ................ Door Guide Bracket RH

55

PARTS LIST


56

PARTS LIST

DIAGRAM

NUMBER


PART

NUMBER

DESCRIPTION

41 ..................................... 6329048 ................ Door Slide

42 ..................................... 6329049 ................ Door Guide Bracket LH

43 ..................................... 6329050 ................ Rear Panel RH - Lift

44 ..................................... 6329051 ................ Rear Panel LH - Lift

45 ..................................... 6329053 ................ ACCUPro Decal

46 ..................................... 6329059 ................ Canopy Support Bracket

47 ..................................... 6329083 ................ Door Switch Mounting Plate

48 ..................................... 6329084 ................ Door Switch Mounting Bracket

49 ..................................... 6329085 ................ Latch Spacer Plate

50 ..................................... 6329505 ................ Guard Weldment RH

51 ..................................... 6329519 ................ Guard Weldment - Lift LH

52 ..................................... 6329533 ................ Front Guard Door Assembly (see page xx)

53 ..................................... 3707607 ................ Door Safety Switch Assembly

......................................... 6329097 ................ Rear Door Switch Cord

54 ..................................... 6209102 ................ Lift Control Decal

55 ..................................... 3707428 ................ Rocker Switch

56 ..................................... 3707156 ................ 6-Amp Circuit Breaker

57 ..................................... 6209101 ................ Lift Control Box

58 ..................................... 3707066 ................ Strain Relief .22-.25 Wire

59 ..................................... 3707273 ................ Strain Relief .33-.36 Wire

60 ..................................... 3709019 ................ Thrust Washer .94 OD x .50 ID

61 ..................................... 80048 .................... Button Head Cap Screw 1/2-13 x 1 1/2 Long

62 ..................................... 6209100 ................ Lift Access Panel

63 ..................................... B250805 ................ Flat Head Cap Screw 1/4-20 x 1/4 Long

57

PARTS LIST 6200720 REEL LIFT ASSEMBLY (Optional)

58

PARTS LIST

DIAGRAM

NUMBER

PART

NUMBER

6200720 REEL LIFT ASSEMBLY (Optional)

DESCRIPTION




4 ....................................... J197000 ................ #10-24 Nylon Jam Locknut

5 ....................................... J257100 ................ 1/4-20 Nylon Locknut

6 ....................................... R000483 ................ #10 Lockwasher

7 ....................................... R000553 ................ #10-24 Kep Nut

8 ....................................... 3707009 ................ Liquid Tight Strain Relief .27-.47 Wire

9 ....................................... 3707648 ................ 6-Amp Circuit Breaker

10 ..................................... 3707428 ................ Rocker Switch Momentary on-off-on

11 ..................................... 3707526 ................ 25-Amp Bridge Diode

12 ..................................... 3707644 ................ Thermistor Assembly


14 ..................................... 6209101 ................ Lift Electrical Control Box

15 ..................................... 6209102 ................ Lift Control Decal

16 ..................................... 6209110 ................ Lift Actuator Cord

17 ..................................... 6209111 ................. Lift Controls Harness

18 ..................................... 6329082 ................ Lift Power Cord

19 ..................................... 6309134 ................ Diode Jumper Assembly

59

PARTS LIST 6200720 REEL LIFT ASSEMBLY (Optional)

60

PARTS LIST

DIAGRAM

NUMBER

PART

NUMBER

6200720 REEL LIFT ASSEMBLY (Optional)

DESCRIPTION


2 ....................................... B371611 ................ Socket Head Cap Screw 3/8-16 x 1 Long

3 ....................................... B372011 ................ Socket Head Cap Screw 3/8-16 x 1 1/4 Long



6 ....................................... B502405 ................ Flat Head Cap Screw 1/2-13 x 1 1/2 Long

7 ....................................... B503211 ................ Socket Head Cap Screw 1/2-13 x 2 Long

8 ....................................... J377100 ................ 3/8-16 Nylon Locknut


10 ..................................... J507000 ................ 1/2-13 Nylon Locknut

11 ..................................... K370001 ................ 3/8 Flat Washer


13 ..................................... K500001 ................ 1/2 Flat Washer


15 ..................................... 80048 .................... Button Head Cap Screw

16 ..................................... 3599029 ................ Flat Washer

17 ..................................... 3707373 ................ Electro Mechanical Actuator

......................................... 3707663 ................ Motor - Service Electro Mechanical Actuator

18 ..................................... 3708868 ................ Compression Spring

19 ..................................... 3708870 ................ External Snap Ring

20 ..................................... 3709019 ................ Thrust Washer

21 ..................................... 3709700 ................ Cam Follower

22 ..................................... 3709702 ................ Flanged Bronze Bushing

23 ..................................... 6209070 ................ Lift Long Arm

24 ..................................... 6209071 ................ Lift Swing Arm

25 ..................................... 6209072 ................ Lift Short Arm

26 ..................................... 6209073 ................ Bearing Plate

27 ..................................... 6209074 ................ Bearing Plate Arm Block

28 ..................................... 6209089 ................ Ramp Support Strap

29 ..................................... 6209095 ................ Anti-Rollback Plate

30 ..................................... 6209097 ................ Pivot Pin

31 ..................................... 6209116 ................ Lift Cross Support

32 ..................................... 6209507 ................ Lift Bearing Assembly

33 ..................................... 6209570 ................ Lift Frame Weldment

34 ..................................... 6209572 ................ Load Carrier Weldment

35 ..................................... 6209573 ................ Actuator Top Block Assembly

36 ..................................... 6209574 ................ Ramp Weldment

37 ..................................... 3708456 ................ Capacity Warning Decal (Not Shown)

38 ..................................... 6309036 ................ Capacity Warning Decal - Text (Not Shown)

39 ..................................... B311013 ................ 5/16-18 x 5/8 Button Head Socket Cap Screw

40 ..................................... 3589109 ................ Flat Washer .315 ID x .50 OD x .035 Thick

61

PARTS LIST

6329533 FRONT GUARD DOOR ASSEMBLY

62

PARTS LIST

DIAGRAM

NUMBER

PART

NUMBER

6329533 FRONT GUARD DOOR ASSEMBLY

DESCRIPTION

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

2 ............................ B252416 .......................... Button Head Cap Screw 1/4-20 x 1 1/2 Long

3 ............................ D161266 .......................... Pan Head Machine Screw #8 x 3/4 Long

4 ............................ J167000 ........................... 8-32 Nylon Jam Locknut

5 ............................ J257000 ........................... 1/4-20 Nylon Jam Locknut

6 ............................ K250001 .......................... 1/4 Flat Washer

7 ............................ R000453 .......................... Flat Washer

8 ............................ 3707647 ........................... Door Safety Switch Coded Magnet

9 ............................ 3708458 ........................... Sharp Warning Decal

10 .......................... 3708675 ........................... 3/16 Blind Rivet

11 .......................... 3708820 ........................... Button Head Safety Screw #8-32 x 1/2 Long

12 .......................... 3708855 ........................... Extension Spring

13 .......................... 3708857 ........................... Black Pull Handle

14 .......................... 6059013 ........................... Front Outside Window

15 .......................... 6059029 ........................... Front Center Hinge

16 .......................... 6059030 ........................... Front End Hinge

17 .......................... 6059036 ........................... Center Window Support

18 .......................... 6059044 ........................... Spring Cover Sleeve

19 .......................... 6059021 ........................... Door Safety Switch (Front)

20 .......................... 6059066 ........................... Bottom Window Support

21 .......................... 6059067 ........................... Top Window Support

22 .......................... 6059068 ........................... Short Window Support

23 .......................... 6059069 ........................... Front RH Window Frame Weldment

24 .......................... 6059072 ........................... Front LH Window Frame Weldment

25 .......................... 6309038 ........................... Door Bracket

26 .......................... 6329046 ........................... Front Inside Window

27 .......................... 6329071 ........................... Window Retainer/ Switch Mount

28 .......................... 6329512 ........................... Front RH Inside Window Frame Weldment

29 .......................... 6329513 ........................... Front LH Inside Window Frame Weldment

63

PARTS LIST 6329530 MAIN CABINET ASSEMBLY

64

PARTS LIST 6329530 MAIN CABINET ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

1 ........................................... B251001 .................... Hex Head Cap Screw 1/4-20 x 5/8

2 ........................................... B251011 .................... Socket Head Cap Screw 1/4-20 x 5/8

3 ........................................... B310813 .................... Button Head Socket Cap Screw 5/16-18 x 1/2

4 ........................................... B311213 .................... Button Head Socket Cap Screw 5/16-18 x 3/4

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

6 ........................................... B502801 .................... Hex Head Cap Screw 1/2-13 x 1 3/4

7 ........................................... B504801 .................... Hex Head Cap Screw 1/2-13 x 3

8 ........................................... B506801 .................... Hex Head Cap Screw 1/2-13 x 4.25

9 ........................................... H371602 .................... Roll Pin .375 Dia. x 1 Long

10 ......................................... H372002 .................... Roll Pin .375 Dia. x 1 1/4 Long

11 ......................................... J317100 ..................... 5/16-18 Locknut

12 ......................................... J507100 ..................... 1/2-13 Locknut

13 ......................................... K251501 .................... 1/4 Split Lockwasher

14 ......................................... K310001 .................... 5/16 Flat Washer SAE



17 ......................................... K500001 .................... 1/2 Flat Washer SAE

18 ......................................... R000453 .................... Flat Washer (.88 OD x .31 ID x .104 T)

19 ......................................... 3707595 ..................... 7/8" Hole Plug

20 ......................................... 3708419 ..................... Wave Spring

21 ......................................... 3708421 ..................... Flat Washer (1.0 OD x .75 ID x .08T)

22 ......................................... 3708542 ..................... 5/8" Hole Plug

23 ......................................... 3708612 ..................... Fuel Warning Decal

24 ......................................... 3708867 ..................... Swell Latch

25 ......................................... 3709372 ..................... 1/2" Hole Plug

26 ......................................... 6309111 ..................... Decal - Up/Down

27 ......................................... 6309039 ..................... Gage Pin Mounting

28 ......................................... 6329017 ..................... Vac Door

29 ......................................... 3707601 ..................... Proximity Switch Head

30 a ...................................... 6329075 ..................... LH Traverse Proximity Switch Cord

30 b ...................................... 6329076 ..................... RH Traverse Proximity Switch Cord

31 ......................................... 3707459 ..................... Proximity Switch Nut

32 ......................................... 6329501 ..................... Cabinet Weldment

33 ......................................... 6329504 ..................... Front Panel Weldment

34 ......................................... 6329525 ..................... Traverse Base Assembly (see page 64)

35 ......................................... 6329535 ..................... Mower Support Assembly (see page 78)

36 ......................................... 6509035 ..................... Cross slide Mount

37 ......................................... 6509389 ..................... Tooling Bar Shim

38 ......................................... 6509465 ..................... Spin Drive Assembly (see page 80)

39 ......................................... 6509510 ..................... Tooling Bar Weldment

40 ......................................... 6509560 ..................... Proximity Switch Bracket Weldment RH

41 ......................................... 6509561 ..................... Proximity Switch Bracket Weldment LH

42 ......................................... J992000 ..................... 1-8 Hex Jam Nut

43 ......................................... A993201 .................... Adjustable Leveling Bolt

44 ......................................... 6509039 ..................... Right-Hand Access Panel

45 ......................................... 6509040 ..................... Left-Hand Access Panel - Small

46 ......................................... 80400 ........................ Hole Plug - 1.75 Diameter

65

PARTS LIST 6329525 TRAVERSE BASE ASSEMBLY

66

PARTS LIST 6329525 TRAVERSE BASE ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

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

2 .................. B191211 ................ Socket Head Cap Screw 10-24 x 3/4 Long

3 .................. B250616 ................ Button Head Socket Cap Screw 1/4-20 x 3/8 Long

4 .................. B250811 ................ Socket Head Cap Screw 1/4-20 x 1/2 Long

5 .................. B250818 ................ Pan Head Machine Screw 1/4-20 x 1/2 Long

6 .................. B250819 ................ Button Head Socket Cap Screw 1/4-20 x 1/2 Long



9 .................. B252011 ................ Socket Head Cap Screw 1/4-20 x 1 1/4 Long

10 ................ B253211 ................ Socket Head Cap Screw 1/4-20 x 2 Long


12 ................ B310813 ................ Button Head Socket Cap Screw 5/16-18 x 1/2 Long

13 ................ B311611 ................. Socket Head Cap Screw 5/16-18 x 1 Long


15 ................ C250420 ................ Socket Head Set Screw Cup Point 1/4-20 x 1/4 Long

16 ................ H184002 ................ 3/8 Diameter Roll Pin x 2 1/2 Long

17 ................ J257000 ................. 1/4-20 Nylon Locknut Thin

18 ................ J257100 ................. 1/4-20 Nylon Locknut

19 ................ J627200 ................. 5/8-18 Nylon Locknut Thin

20 ................ J757300 ................. 3/4-16 Nylon Locknut

21 ................ K191501 ................ No. 10 Washer

22 ................ K250001 ................ 1/4 Flat Washer SAE

23 ................ K251501 ................ 1/4 Split Lockwasher



26 ................ R000376 ................ Square Key 1/8 x 3/4 Long

27 ................ R000377 ................ Square Key 3/16 x 3/4 Long

28 ................ 28192 ..................... Traverse Pulley Support

29 ................ 50309 ..................... Traverse Pulley Shaft

30 ................ 50354 ..................... Drive Pulley (Cog)

31 ................ 55553 ..................... Idler Pulley Assembly

32 ................ 80335 ..................... Destaco Clamp

33 ................ 80354 ..................... Cog Belt

34 ................ 80355 ..................... Thrust Washer (1 1/4OD x 3/4 ID)

35 ................ 3708195 ................. External Retaining Ring

36 ................ 3708419 .................. Wave Spring (.78 ID)

37 ................ 3708436 .................. Wave Spring

38 ................ 3708658 .................. Compression Spring

39 ................ 3708884 .................. Spacer 5/8 OD x 9/32 ID x 3/8 Long

40 ................ 3709044 .................. Linear Ball Bearing

67

PARTS LIST (Continued) 6329525 TRAVERSE BASE ASSEMBLY

68

PARTS LIST (Continued) 6329525 TRAVERSE BASE ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

41 ...................... 3709072 ................. Compression Spring

42 ...................... 3709331 ................. External Retaining Ring

43 ...................... 6059062 ................. Traverse Motor Assembly

44 ...................... 6309573 ................. Finger & Body Assembly (see page 74)

45 ...................... 6329032 ................. Traverse Base

46 ...................... 6329034 ................. 5/8 Shaft Coupler

47 ...................... 6329035 ................. Motor Extension Shaft

48 ...................... 6329036 ................. Pulley Mount Bracket

49 ...................... 6329507 ................. Prox Flag Bracket Weldment

50 ...................... 6329511 ................. Shaft Support Block Assembly

51 ...................... 6329526 ................. Grinding Head Assembly (see page 70)

52 ...................... 6329527 ................. Carriage Assembly (see page 72)

53 ...................... 6509020 ................. Traverse Base Adjuster End Cap

54 ...................... 6509021 ................. Bellows Bracket Carriage Mount

55 ...................... 6509025 ................. Bellows Bracket End Mount

56 ...................... 6509054 ................. Plunger Pin Retainer

57 ...................... 6509055 ................. Belt Cover

58 ...................... 6509063 ................. Carrier Shaft

59 ...................... 6509210 ................. Belt Cover Gasket

60 ...................... 6509221 ................. Traverse Base Fixed Bracket

61 ...................... 6509238 ................. Grinding Wheel Grip Knob

62 ...................... 6509250 ................. Bellows - Way cover

63 ...................... 6509253 ................. Carriage Dust Cover Bracket

64 ...................... 6509484 ................. Plunger Pin

65 ...................... 6509565 ................. Cross Slide Assembly (see page 68)

69

PARTS LIST

6509565 CROSS SLIDE ASSEMBLY

70

PARTS LIST 6509565 CROSS SLIDE ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

1 ....................................... C311220 ................ Socket Set Screw CPPT 5/16-18 x 3/4 Long

2 ....................................... J371000 ................ 3/8-16 Hex Nut

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

4 ....................................... K371501 ................ 3/8 Split Lockwasher

5 ....................................... 3579109 ................ 3/16 Dia. Nylon Plug

6 ....................................... 3708148 ................ Handwheel 4.5 Dia. .38 Bore

7 ....................................... 3709062 ................ Bell V Washer .75 O. D. x .035 T

8 ....................................... 3709304 ................ Thrust Washer

9 ....................................... 3708705 ................ Adjustable Handle 5/16-18 Female - Orange

10 ..................................... 6509390 ................ Adjusting ACME Shaft

11 ..................................... 6009035 ................ Locking Stud Shaft

12 ..................................... 6009082 ................ Cross Slide Support

13 ..................................... 6009095 ................ Slide Shaft

14 ..................................... 6509011 ................ Cross Slide

15 ..................................... 6509015 ................ Cross Slide Horizontal support

16 ..................................... C310820 ............... Socket Set Screw 5/16-18 x 5/8 Long

17 ..................................... 3708665 ................ Flat Washer

18 ..................................... 6309115 ................ Grey Decal

19 ..................................... 6309114 ................ Orange Decal

20 ..................................... 6309113 ................ 5/16-18 Locking Stud

21 ..................................... 3708706 ................ Adjustable Handle 5/16-18 Female - Grey

22 ..................................... 3969065 ................ Spacer .406 ID x .75 OD x 1.0 Long

23 ..................................... B372011 ................ Socket Head Cap Screw 3/8-16 x 1 1/4 Long

24 ..................................... H371602 ................ Rollpin 3/8 Dia. x 1 Long


26 ..................................... 6509010 ................ Traverse Base Adjuster Bracket

71

PARTS LIST

6329526 GRINDING HEAD ASSEMBLY

72

PARTS LIST

DIAGRAM

NUMBER

PART

NUMBER

6329526 GRINDING HEAD ASSEMBLY

DESCRIPTION

1 ........................ B251411 ..................... Socket Head Cap Screw 1/4-20 x 7/8 Long

2 ........................ B371611 ..................... Socket Head Cap Screw 3/8-16 x 1 Long

3 ........................ C250627 ..................... Socket Set Screw Cup Pt 1/4-20 x 3/8 Long - Lock Patch

4 ........................ K250001 ..................... 1/4 Flat Washer SAE

5 ........................ K251501 ..................... 1/4 Split Lockwasher

6 ........................ K371501 ..................... 3/8 Split Lockwasher

7 ........................ R000376 ..................... Square Key 1/8 x 3/4 Long

8 ........................ 3707690...................... 1 HP 120 VAC Motor

9 ........................ 3708193...................... Conical Washer 1.36 OD x .88 OD

10 ...................... 3708194...................... Internal Retaining Ring

11 ...................... 3708204...................... Double Row Ball Bearing

12 ...................... 3708202...................... Poly-V Belt

13 ...................... 6329089...................... Bearing Sleeve

14 ...................... 6329041...................... Motor Mount Plate

15 ...................... 6329042...................... Pulley - Poly V 1.80 Diameter

16 ...................... 6329100...................... Pulley - Poly V 1.44 Diameter

17 ...................... 6509018...................... Grinding Head Housing

18 ...................... J567200 ...................... 9/16-18 Locknut Nylon Insert Jam

19 ...................... 6329523...................... Grinding Head Spindle Assembly

20 ...................... 6509237...................... Grinding Wheel Knob

21 ........................................................... Grinding Wheel (see page 83)

22 ...................... 3708870...................... Retaining Ring - External .50 Shaft Heavy Duty

73

PARTS LIST 6329527 CARRIAGE ASSEMBLY

74

PARTS LIST 6329527 CARRIAGE ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

1 ....................... B250616 ........................ Button Head Cap Screw 1/4-20 x 3/8 Long

2 ....................... B252016 ........................ Button Head Cap Screw 1/4-20 x 1 1/4 Long

3 ....................... B253216 ........................ Button Head Cap Screw 1/4-20 x 2 Long

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

5 ....................... J252000 ........................ 1/4-20 Jam Nut

6 ....................... J887300 ........................ 7/8-14 Nylon Jam Locknut

7 ....................... R602031 ........................ #4 x .31 Drive Screw

8 ....................... 28187 ............................ Traverse Clamp Block

9 ....................... 28188 ............................ Traverse Clamp Spacer Plate

10 ..................... 28189 ............................ Clamp Support Block

11 ..................... 50310 ............................ Belt Clamp Tip

12 ..................... 3708105 ........................ Compression Spring

13 ..................... 3708184 ........................ Retaining Ring

14 ..................... 3708186 ........................ Ball Bearing

15 ..................... 3708208 ........................ Shoulder Bolt .250 Dia. x .387 Long

16 ..................... 3708462 ........................ Decal - RPM, Symbol

17 ..................... 6329040 ........................ Traverse Clamp

18 ..................... 6329058 ........................ Carriage Base

19 ..................... 6509023 ........................ Grinder Head Pivot Shaft

20 ..................... 6509251 ........................ Swing Door Latch

21 ..................... 6509584 ........................ Swing Door Weldment

75

PARTS LIST 6309573 FINGER AND BODY ASSEMBLY

76

PARTS LIST 6309573 FINGER AND BODY ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

1 ....................................... B190631 ................ Socket Head Cap Screw 10-32 x 3/8 Long

2 ....................................... B190634 ................ Button Head Socket Cap Screw 10-32 x 3/8 Long

3 ....................................... B251011 ................ Socket Head Cap Screw 1/4-20 x 5/8 Long

4 ....................................... B254811 ................ Socket Head Cap Screw 1/4-20 x3 Long

5 ....................................... C190460 ............... Socket Set Screw 10-24 x 1/4

6 ....................................... C190467 ............... Socket Set Screw - Nylok Cup 10-32 x .25 Long

7 ....................................... C190860 ............... Socket Set Screw - CP-PT 10-32 x 1/2 Long

8 ....................................... C190860 ............... Socket Set Screw - 10-32 x 1/2 Long

9 ....................................... H122002 ................ Roll Pin 1/8 Dia. x 1 1/4 Long

10 ..................................... H250813 ................ Dowel Pin 1/4 Dia. x .5 Long

11 ..................................... H253202 ................ Drive Lock Pin 1/4 x 1.75 Long

12 ..................................... J191100 ................. 10/32 Hex Nut

13 ..................................... J377200 ................ 3/8-24 Jam Nylok Locknut

14 ..................................... K191501 ................ No. 10 Lock Washer

15 ..................................... R000351 ................ Square Key .093 x .75 Long

16 ..................................... 3579284 ................ 1/8 Dia. Nylon Plug

17 ..................................... 3709304 ................ Thrust Washer



20 ..................................... 3708199 ................ 3/8-16 Dia. Split Shaft Collar

21 ..................................... 3709472 ................ Straight Grease Fitting

22 ..................................... 6509432 ................ Relief Finger

23 ..................................... 6509004 ................ Reel Finger Slide

24 ..................................... 6509357 ................ Reel Finger Positioner

25 ..................................... 6509007 ................ Index Stop Pin

26 ..................................... 6509008 ................ Index Sensor Block

27 ..................................... 6509009 ................ Slide Washer

28 ..................................... 6509058 ................ Eccentric Index Pin

29 ..................................... 6509060 ................ Gib Stop Plate

30 ..................................... 6509215 ................ Adjustable Index Lever

31 ..................................... 6509229 ................ Locking Index Finger Pin

32 ..................................... 3579284 ................ 1/8" Diameter Nylon Plug

33 ..................................... 6509239 ................ Anti Rotation Plate

34 ..................................... 6509258 ................ Dovetail Gib

35 ..................................... 6509501 ................ Tee Knob Assembly

36 ..................................... 6509547 ................ Knob Assembly

37 ..................................... 6329592 ................ Index Finger Assembly

38 ..................................... 6329593 ................ Index Lock Handle Weldment

39 ..................................... 6509592 ................ Index Finger Positioner Weldment

40 ..................................... H120402 ................ 1/8" Diameter x 1/4" Long Pin Roll

41 ..................................... 6509358 ................ Stop Plate

42 ..................................... 6509356 ................ Reel Positioner Adjuster

77

PARTS LIST 6309574 STEPPER & MOUNTING ASSEMBLY

78

PARTS LIST 6309574 STEPPER & MOUNTING ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER DESCRIPTION

1 .................. B161811 ................ Socket Head Cap Screw 8-32 x 1 1/8 Long

2 .................. B252011 ................ Socket Head Cap Screw 1/4-20 x 1 1/4 Long

3 .................. C250825 ................ Socket Set Screw 1/4-20 x 1/2

4 .................. C251020 ................ 1/4-20 x 5/8" Set Screw

5 .................. 6309500 ................. DC Motor/Reducer Assembly

6 .................. J377200 ................. 3/8-24 Nylok Jam Locknut

7 .................. K161501 ................ #8 Split Lockwasher

8 .................. 3708187 ................. Ball Bearing

9 .................. 3708189 ................. Retaining Ring

10 ................ 3708192 ................. Hose Clamp 2.25 Dia.

11 ................ 3709304 ................. Thrust Washer

12 ................ 6509048 ................. Hex Pivot Pin

13 ................ 6509051 ................. Trunion Block

14 ................ 6509056 ................. Bellows, 1.88 I.D.

15 ................ 6309052 ................. Actuator Motor Mounting Bracket

16 ................ 6309053 ................. Calibration ring

17 ................ B191611 ................ Socket Head Cap Screw 10-24 x 1" Long

18 ................ K191501 ................ #10 Lockwasher

19 ................ B160407 ................ 8-32 x 1/4 Button Head Socket Cap Screw

20 ................ 3708424 ................. Retaining Ring Ext. 1.75

21 ................ 6509384 ................. Infeed Stepper Assembly

22 ................ 3708629 ................. Split Shaft Collar .25 I.D.

23 ................ 6309055 ................. Window

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

25 ................ C160420 ................ 8-32 x 1/4 Socket Set Screw

26 ................ 6309040 ................. Adapter

27 ................ 6509381 ................. Base Cover Plate

28 ................ B190613 ................ Socket Head Cap Screw 10-24x 3/8 Long

79

PARTS LIST 6329535 MOWER SUPPORT ASSEMBLY

80

PARTS LIST

DIAGRAM

NUMBER

PART

NUMBER

6329535 MOWER SUPPORT ASSEMBLY

DESCRIPTION

1 ....................... B190614 ...................... Pan Head Machine Screw 10-24 x 3/8 Long

2 ....................... K191501 ...................... No.10 Lockwasher

3 ....................... 6009577 ...................... Knob Assembly

4 ....................... 3708364 ...................... Quick Release Pin .31 Dia.

5 ....................... 3708158 ...................... Shoulder Bolt .375 Dia. x .50 Long

6 ....................... 3708366 ...................... 6" type B Lanyard

7 ....................... 6509128 ...................... Horizontal Scale Decal RH

8 ....................... 6329072 ...................... Vertical Scale Decal

9 ....................... 6509507 ...................... Bar Mounting Weldment Bracket

10 ..................... 6509517 ...................... L.H. Front Roller Horiz. Weldment Bracket

11 ..................... 6329587 ...................... L. H. Roller Clamp Weldment Bracket

12 ..................... 6509559 ...................... Knob Assembly

13 ..................... 6509564 ...................... L.H. Front Roller Clamp Weldment

14 ..................... 6509588 ...................... Knob Assembly

15 ..................... 6509515 ...................... R.H. Front Roller Horiz. Welment Bracket

16 ..................... 6329586 ...................... R.H. Roller Clamp Weldment Bracket

17 ..................... 3709304 ...................... Thrust Washer

18 ..................... B311211 ...................... Socket Head Cap Screw 5/16-18 x 3/4 Long

19 ..................... K311501 ...................... 5/16 Lockwasher

20 ..................... 70512 .......................... Rear Roller Support Bracket Weldment

21 ..................... C500861 ...................... 1/2-20 x 1/2 Flat Pt Socket Head Set Screw

22 ..................... 6509576 ...................... R.H. Front Roller Clamp Weldment

23 ..................... 3708881 ...................... Rear Clamp

24 ..................... 6329514 ...................... Rear Clamp Base Weldment

25 ..................... 6509304 ...................... Horizontal Scale Decal LH

81

PARTS LIST 6509465 SPIN DRIVE ASSEMBLY

82

PARTS LIST (Continued) 6509465 SPIN DRIVE ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

1 .........................................

3708391 ........................... Reducer: 10:1 Ratio

2 ....................................... 6329069 ........................... Motor, DC .20 HP TEFC

3 ....................................... B251411 ........................... Socket Head Cap Screw 1/4-20 x 7/8 Long

4 ....................................... 3709586 ........................... Flange Coupler .50

5 ....................................... 3709585 .......................... Sleeve Coupler

6 ....................................... 3709584 ........................... Flange Coupler 5/8

7 ....................................... 6009217 ........................... Drive Coupling Adapter

9 ....................................... 09394 ............................... Tee Knob Assembly

10 ..................................... 3709073 ........................... Retaining Ring

11 ..................................... 6009051 ........................... Drive Adapter 1/2 Square

12 ..................................... 6009052 ........................... Adapter

13 ..................................... R000376 ........................... Square Key 1/8 x .75 Long

14 ..................................... 6009078 ........................... Gearbox Slide Bracket

15 ..................................... 3707279 ........................... Strain Relief Wire

16 ..................................... 6009079 ........................... Gearbox Clamp Bracket

17 ..................................... 6009580 ........................... Gearbox Slide Weldment Bracket

18 ..................................... 3708262 ........................... T-Knob - 5/16-18

19 ..................................... 6009045 ........................... Linkage Spacer 2.29 Long

20 ..................................... 6009046 ........................... Linkage Spacer R.H. Thread

21 ..................................... 3709062 ........................... Belleville .75 Dia. x .35 T

22 ..................................... 3709809 ........................... Shoulder Bolt .375 Dia. x .375 Long

23 ..................................... 3709705 ........................... Nylon Ball 5/32 Dia.

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

25 ..................................... 6009047 ........................... Linkage spacer L. H. Thread

26 ..................................... 6009048 ........................... Linkage Spacer 2.5 Long

27 ..................................... B375611 ........................... Socket Head Cap Screw

28 ..................................... J377100 ........................... Nylok Hex Locknut 3/8-16

29 ..................................... 6509519 ........................... Support Bracket Weldment

30 ..................................... 3708148 ........................... Handwheel 4.5 Dia.

31 ..................................... 3709370 ........................... Handle

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

33 ..................................... J257000 ........................... 1/4-20 Nylok Locknut

34 ..................................... C310620 .......................... Socket Set Screw 5/16-18 x 3/8 Long

35 ..................................... 6009076 ........................... Double Thread Rod

36 ..................................... 6009555 ........................... Knob Assembly

37 ..................................... 6509114 ........................... Spin Drive Plate Lock

38 ..................................... 6009067 ........................... Geared Linkage

39 ..................................... B255011 ........................... Socket Head Cap Screw 1/4-20 x 3 1/8 Long

40 ..................................... R000377 ........................... Square Key 3/16 x .75 Long

41 ..................................... 3707623 ........................... DC Motor Brush

83

PARTS LIST 6329529 MISCELLANEOUS PARTS

84

PARTS LIST (Continued)

DIAGRAM

NUMBER

PART

NUMBER

6329529 MISCELLANEOUS PARTS

DESCRIPTION

1 ............................ 3700088 ........................... Grinding Wheel 3.5" Dia. x .38 w

2 ............................ 3700086 ........................... Grinding Wheel 3.5" Dia. x 1" Wide

3 ............................ 3700087 ........................... Grinding Wheel 5" Dia. x .3/8" Side

4 ............................ 3700089*.......................... Grinding Wheel 5" Dia. x 1" Wide

5 ............................ R000863 .......................... 5/16 Allen Key

6 ............................ K251501 .......................... 1/4 Lockwasher

7 ............................ 80396 ............................... T-Knob Assembly

8 ............................ 3529069 ........................... Space

9 ............................ 6329517 ........................... Alignment Extension Weldment

10 .......................... 6329518 ........................... Gage Bar Weldment

11 .......................... 6509349 ........................... Retaining Plate

12 .......................... 6509418 ........................... Plate-Pivot

13 .......................... 6509567 ........................... Knob Assembly

14 .......................... 3708894 ........................... T-Knob Assembly

15 .......................... B120611 ........................... Socket Head Cap Screw 5-40 x .38 Long

16 .......................... B161011 ........................... Socket Head Cap Screw 8-32 x 5/8 Long

17 .......................... J161000 ........................... 8-32 Hex Nut

18 .......................... K121501 .......................... No. 5 Split Lockwasher

19 .......................... K161501 .......................... No. 8 Lockwasher

20 .......................... 6509359 ........................... Digital Gage

21 .......................... 6509412 ........................... Base Weldment Indicator

22 .......................... H060302 .......................... 1/16 x 3/16L Roll Pin

23 .......................... B190811 ........................... Socket Head Cap Screw 10-24 x 1/2

24 .......................... J197100 ........................... 10-24 Nylok Locknut

25 .......................... 3708384 ........................... Magnet

26 .......................... 6509474 ........................... Reel Positioner Gage

27 .......................... 6509557 ........................... Drip Pan Weldment

(SPREADER BAR ASSEMBLY COMES ON BOOM MACHINES ONLY)

30 .......................... B372011 ........................... Socker Head Cap Screw 3/8-16 x 1 1/4" Long

31 .......................... J317100 ........................... 5/16-18 Lock Nut

32 .......................... J377100 ........................... 3/8-16 Nylok Locknut

33 .......................... 3599028 ........................... Flat Washer (1.00 OD x .375 ID x .188 T)

34 .......................... 3708456 ........................... Warning Capacity Decal

35 .......................... 3708856 ........................... Spreader Bar Decal

36 .......................... 3709316 ........................... 5/16-18 x 3" U-Bolt 1 1/2"

37 .......................... 6009102 ........................... Grab Hook

38 .......................... 6329061 ........................... Chain

39 .......................... 6509590 ........................... Spreader Bar Weldment

* 3700089- Grinding wheel is installed on grinding head when shipped. The other wheels are located in the carton assembly.

85

PARTS LIST 6329531 CONTROL PANEL ASSEMBLY

86

PARTS LIST 6329531 CONTROL PANEL ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

1 ....................................... B190834 ................ Button Head Cap Screw 10-32 x 1/2 Long


3 ....................................... D250800 ............... Thread Cutting Screw 1/4-20 x 1/2 Long


6 ....................................... R000536 ................ 1/4 Lock Washer

7 ....................................... 3707075 ................ Toggle Switch Boot

8 ....................................... 3707080 ................ Toggle Switch

9 ....................................... 3707342 ................ Yellow Emergency Stop Ring

10 ..................................... 3707367 ................ Rocker Switch DPST

11 ..................................... 3707428 ................ Rocker Switch Momentary (On-Off-On)

12 ..................................... 3707429 ................ Rocker Switch DPDT


14 ..................................... 3707446 ................ Potentiometer Knob


16 ..................................... 3707564 ................ Green Start Push-button

17 ..................................... 3707565 ................ Normally Open Contact Block

18 ..................................... 3707566 ................ Switch Mounting Latch

19 ..................................... 3707567 ................ Push/Pull Red Emergency Stop Button

20 ..................................... 3707568 ................ Normally Closed Contact Block

21 ..................................... 6329054 ................ Control Panel Decal

22 ..................................... 6329528 ................ Control Panel Top Weldment

23 ..................................... 6329070 ................ Hinge

24 ..................................... 6329509 ................ Control Box Weldment

25 ..................................... 6329516 ................ Electrical Panel Sub-Assembly

26 ..................................... 6509446 ................ Potentiometer Assembly - Spin Speed

27 ..................................... 6509447 ................ Potentiometer Assembly - Relief Torque

28 ..................................... 6059050 ................ Potentiometer Assembly - Traverse Speed

Cords Not Shown

......................................... 6329078 ................ Main Power Cord

......................................... 6329079 ................ Infeed Motor Cord

......................................... 6329080 ................ Light Receptacle

......................................... 6329081 ................ Dust Collector Receptacle

......................................... 3707224 ................ Cable Tie Mount (used throughout machine)

......................................... 3707225 ................ Cable Tie 6.5 Long x .18 Wide

......................................... 3707255 ................ Cablle Tie 4.0 Long x .10 Wide

87

PARTS LIST 3707375 & 6329516 CONTROL PANEL SUB-ASSEMBLY

88

PARTS LIST

3707375 & 6329516 CONTROL PANEL SUB-ASSEMBLY

DIAGRAM

NUMBER

PART

NUMBER

DESCRIPTION

1 ....................................... D160666 ............... Pan Head Self-Tapping Screw #8 x 3/8 Long

2 ....................................... D161266 ............... Pan Head Self-Tapping Screw #8 x 3/4 Long

3 ....................................... R000480 ................ #8 Lockwasher

4 ....................................... 55223 .................... Terminal Strip Decal

5 ....................................... 3707073 ................ 8-Pin socket

6 ....................................... 3707163 ................ Primary Ground Decal

7 ....................................... 3707164 ................ Primary Ground Lug

8 ....................................... 3707378 ................ 14" Din Rail

9 ....................................... 3707403 ................ Power Line Filter

10 ..................................... 3707550 ................ Traverse Control Board

11 ..................................... 3707556 ................ Magnetic Starter

12 ..................................... 3707558 ................ Low Voltage Sensor Relay

13 ..................................... 3707625 ................ Screwless Terminal Bock End Stop

14 ..................................... 3707626 ................ Terminal Block Jumper

15 ..................................... 3707627 ................ Terminal Block End Plate

16 ..................................... 3707628 ................ 2-Conductor Terminal Block - Grey

17 ..................................... 3707629 ................ 2-Conductor Terminal Block - Blue

18 ..................................... 3708826 ................ Low Voltage Warning Decal

19 ..................................... 6009270 ................ Electrical Sub Panel

20 ..................................... 80259 .................... 20-Amp Circuit Breaker

21 ..................................... 3707706 ................ 19 Pole Terminal Strip

22 ..................................... 3707707 ................ Double Spade Terminal

23 ..................................... 3707709 ................ Single Spade Terminal 90°

24 ..................................... 3707708 ................ Double Spade Terminal 90°

25 ..................................... 3707328 ................ Door Safety Switch Monitor

26 ..................................... 3707333 ................ 24VDC Power Supply

27 ..................................... 3707389 ................ Transformer Assembly

28 ..................................... 3707524 ................ Spin/Relief Control Board

29 ..................................... 3707526 ................ 25-Amp Bridge Diode

30 ..................................... 3707594 ................ Voltage Regulator Assembly

31 ..................................... 3707602 ................ 6" Din Rail

32 ..................................... 3707624 ................ Ground Terminal Block

89

90

6324531 WIRING DIAGRAM

91

92

632 WIRING SCHEMATIC

ACCU-Pro 632 Spin/Relief Grinder Assembly and Service Manual

Assistant Bot

-Pro 632

SPIN/RELIEF

GRINDER

ASSEMBLY and

SERVICE

MANUAL

Safety Awareness Symbols are inserted into this manual to alert you to possible

Safety Hazards.

Whenever you see these symbols, follow their instructions.

Warning Symbol identifies spe-

Caution Symbol identifies special

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 materiel 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 DON'T

Low Voltage Relay

CONTENTS

SPECIFICATIONS

SKILL AND TRAINING REQUIRED FOR SERVICING

TORQUE REQUIREMENTS

THE UNIT WEIGHS

1490 LBS. (676 kg).

WITH BOOM OR

1670 LBS (758 kg)

WITH LIFT. USE

POWER EQUIPMENT

TO LIFT MACHINE.

POSITION BASE

Remove the carton and remove the contents from the carton onto a workbench. The carton includes:

LEVEL BASE

FIG. 3

FIG. 4

FIG. 5

APPLY POWER

IMPORTANT GROUNDING INSTRUCTIONS

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:

BEFORE STORING THE GRINDER:

TO CLEAN THIS MACHINE!) See Maintenance section for instructions on cleaning

BRINGING THE UNIT BACK INTO SERVICE:

lubricant) until the lubricant is dripping off the shafts. See FIG. 10 Then run the carriage

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

Minimizing Hairline Scratches

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

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

Graffiti Removal

GASOLINE SHOULD NOT BE USED!

DIGITAL GAGE

Important

Description of Parts

Battery Installation and Origin Setting

Incremental (INC) & Absolute (ABS) mode

Error Symptoms & Remedies

CARRIAGE LINEAR BEARING REPLACEMENT

STEP 1

STEP 2

STEP 3

NOTE:

STEP 4

STEP 5

STEP 6-

FIG. 14

FIG. 15

REEL FINGER DOVETAIL GIB AND