ASSEMBLY AND SERVICE MANUAL - Foley United - Service (2005-12) 6700902.pdf · 1 ACCU-Pro MODEL 670...

1

ACCU-ProMODEL 670

SEMI-AUTOMATICBEDKNIFE GRINDER

ASSEMBLYAND

SERVICEMANUAL

WARNINGYou must thoroughly read and understand thismanual before assembling or maintaining theequipment, paying particular attention to theWarning & Safety instructions.

6707956 (12-05)

2

SAFETY INSTRUCTIONS

Safety Awareness Symbols are inserted into thismanual to alert you to possible Safety Hazards .Whenever you see these symbols, follow theirinstructions.

The Caution Symbol identifies special instructionsor procedures which, if not correctly followed, couldresult in damage to or destruction of equipment.

The Warning Symbol identifies special instructions or procedures which, if not strictly observed, couldresult in personal injury.

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

13. MAINTAIN GRINDER WITH CARE. Followinstructions in Service Manual for lubrication andpreventive maintenance.

14. DISCONNECT POWER BEFORE SERVICING.

15. REDUCE THE RISK OF UNINTENTIONALSTARTING. Make sure the switch is OFF beforeplugging in the Grinder.

16. USE RECOMMENDED ACCESSORIES. Consultthe manual for recommended accessories. Usingimproper accessories may cause risk of personalinjury.

17. CHECK DAMAGED PARTS. A guard or otherpart that is damaged or will not perform itsintended function should be properly repaired orreplaced.

18. KNOW YOUR EQUIPMENT. Read this manualcarefully. Learn its application and limitations aswell as specific potential hazards.

19. KEEP ALL SAFETY DECALS CLEAN ANDLEGIBLE. If safety decals become damaged orillegible for any reason, replace immediately. Referto replacement parts illustrations in ServiceManual for the proper location and part numbersof safety decals.

20. DO NOT OPERATE THE GRINDER WHENUNDER THE INFLUENCE OF DRUGS,ALCOHOL, OR MEDICATION

1. KEEP GUARDS IN PLACE and in workingorder.

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 areawell lit.

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

6. MAKE WORK AREA CHILD-PROOF withpadlocks or master switches.

7. DON'T FORCE THE GRINDER. It will do the jobbetter and safer if used as specified in thismanual.

8. USE THE RIGHT TOOL. Don't force the Grinderor an attachment to do a job for which it was notdesigned.

9. WEAR PROPER APPAREL. Wear no looseclothing, gloves, neckties, or jewelry which mayget caught in moving parts. Nonslip footwear isrecommended. Wear protective hair covering tocontain long hair.

10. ALWAYS USE SAFETY GLASSES .

11. SECURE YOUR WORK. Make certain that thebedknife is securely fastened with theelectromagnets provided before operating.

3

SAFETY INSTRUCTIONS

DON'T1. DON'T use a cracked wheel or one that HAS

BEEN DROPPED or has become damaged.

2. DON'T FORCE a wheel onto the machine ORALTER the size of the mounting hole - ifwheel won't fit the machine, get one that will.

3. DON'T ever EXCEED MAXIMUMOPERATING SPEED established forthe wheel.

4. DON'T use mounting flanges on which thebearing surfaces ARE NOT CLEAN, FLATAND FREE OF BURRS.

5. DON'T TIGHTEN the mounting nutEXCESSIVELY.

6. DON'T grind on the SIDE OF THE WHEEL(see Safety Code B7.2 for exception).

7. DON'T start the machine until the WHEELGUARD IS IN PLACE.

8. DON'T JAM work into the wheel.

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

10. DON'T FORCE GRINDING so that motorslows 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 orMSHA respirators, safety glasses or face shields, and protective clothing.Provide adequate ventilation to eliminate dust, or to maintain dust levelbelow the Threshold Limit Value for nuisance dust as classified by OSHA.

IMPROPER USE OF GRINDING WHEEL MAY CAUSEBREAKAGE AND SERIOUS INJURY.

Grinding is a safe operation if the few basic rules listed below are followed.These rules are based on material contained in the ANSI B7.1 Safety Code for"Use, Care and Protection of Abrasive Wheels". For your safety, we suggestyou benefit from the experience of others and carefully follow these rules.

DO1. DO always HANDLE AND STORE wheels in a

CAREFUL manner.

2. DO VISUALLY INSPECT all wheels beforemounting for possible damage.

3. DO CHECK MACHINE SPEED against theestablished maximum safe operating speedmarked on wheel.

4. DO CHECK MOUNTING FLANGES for equaland correct diameter.

5. DO USE MOUNTING BLOTTERS whensupplied with wheels.

6. DO be sure WORK REST is properly adjusted.

7. DO always USE A SAFETY GUARDCOVERING at least one-half of the grindingwheel.

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

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

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

4

This machine is intended for grinding the bedknife from a reel mowingunit ONLY. Any use other than this may cause personal injury and voidthe warranty.

This machine is intended for indoor use only.

To assure the quality and safety of your machine and to maintain thewarranty, you MUST use original equipment manufactures replacementparts and have any repair work done by a qualified professional.

ALL operators of this equipment must be thoroughly trained BEFOREoperating the equipment.

Do not use compressed air to clean grinding dust from the machine. Thisdust can cause personal injury as well as damage to the grinder. Do not use apower washer to clean the machine.

CONTENTSWarnings ...................................................................................................... Page 2 - 5

Contents and Specifications ......................................................................... Page 4Assembly ..................................................................................................... Page 6 - 12Maintenance ................................................................................................ Page 13 - 15Adjustments ................................................................................................. Page 16 - 23Troubleshooting ............................................................................................ Page 24 - 33Electrical Schematic .................................................................................... Page 34Control Box Component I.D. ........................................................................ Page 35Parts List. ..................................................................................................... Page 36 - 49

SPECIFICATIONSElectrical Requirements .............................................................115V 50/60 Hz, 15-amp circuitNet Weight ....................................................................................................... 780 lbs [354 kg]Shipping Weight ............................................................................................... 920 lbs [417 kg]Maximum Grinding Length.................................................................................34 in. [863 mm]Sound Level..................................................................................................... Less than 75 Dba

The grinder is equipped with a low voltage relay whichis factory preset at 100 VAC. If the power supply linedoes not deliver 100 VAC power under load, the relaywill open and trip out the starter. If this occurs, yourpower supply line is inadequate and must be correctbefore proceeding further with the grinder.

Low Voltage Relay

5

SKILL AND TRAINING REQUIRED FOR SERVICING

This Service Manual is designed for technicians who have the neces-sary mechanical and electrical knowledge and skills to reliably testand repair the ACCU-Pro Bedknife Grinder. For those without thatbackground, service can be arranged through a local distributor.

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

PERSONS WITHOUT THE NECESSARYKNOWLEDGE AND SKILLS SHOULD NOTREMOVE THE CONTROL BOX COVER ORATTEMPT ANY INTERNALTROUBLESHOOTING, ADJUSTMENTS, ORPARTS REPLACEMENT!

If you have questions not answered in this manual, please call yourdistributor. 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, referto the information below.

Bolts Going into a Nut, or Into a Thread Hole in Steel.Refer to table at the right.

Bolts Going into a Thread Hole in Aluminum.Use the Grade 2 values in the table at the right.

Socket-Head ScrewsUse the Grade 8 values in the table at the right.

Machine ScrewNo. 6 Screws: 11in.-lbs [0.125 kg-m]No. 8 Screws: 20 in.-lbs [0.23 kg-m]No. 10 Screws: 32 in.-lbs [0.37kg-m]

GRADE 2 GRADE 5 GRADE 8

SMOOTH 3 MARKS 6 MARKS HEAD on HEAD on HEAD

1/4 In. 6 ft-lbs 9 ft-lbs 13 ft-lbs thread (0.8 kg-m) (1.25 kg-m) (1.8 kg-m)





6

ASSEMBLY INSTRUCTIONS

FIG. 2

FIG. 1

NOTE: For clarity, the Grinder is shown on the followingpages without the optional carriage bellows installed.

UNPACK THE CARTONSNOTE: Before you install the machine, read the followingassembly procedure completely. Then study "Getting toKnow Your Bedknife Grinder" in the Operators Manual.

Use care when unpacking. Double-check the packingcartons for any miscellaneous items before discarding.

Inspect all items for shipping damage as they areremoved from the shipping containers. If you find anydamage, notify the carrier's claims agent and do notproceed further until the damage has been inspected bythe agent. Refer also to the "Shipping and ReceivingInstructions" packed with the unit.

Remove the Coolant Tank carton from under the machine.

Remove the control box from under the machine. Becareful of the electrical wiring which was preconnected atthe factory.

Install the Control BoxAttach the control box to the right front end of themachine, using the two 3/8-16 x 5/8" hex-head bolts, andtwo lock washers provided. See FIG. 1. The fastenersare shipped in an envelope inside the control box carton.

Remove the Grinder from the PalletTo remove the Grinder from the wood pallet:1. Unbolt the brackets that hold each end of the Grinder

legs to the bottom of the pallet.

2. The Grinder's four leveling feet (FIG. 2) are seated incountersunk holes in the pallet. Lift one end of themachine until both feet are out of their holes.

3. Prop this first end up with sturdy boards or othersupports so the feet remain out of their holes, thenlift the other end and remove the Grinder from thepallet.

THE GRINDER WEIGHS 780LBS [354 KG]. TO LIFT, USEPOWER EQUIPMENT

Remove the shipping strap that secures the grindinghead and carriage to the left end of the machine duringshipment. Discard the leg screw and the shipping strap.

7

ASSEMBLY INSTRUCTIONS (Continued)LOCATE AND LEVEL THE GRINDERSet the Grinder on a level concrete floor, on a singleuncracked slab of concrete.

If the unit must be located near a wall, allow adequatespace for operating and servicing. Refer to FIG. 3 forrecommended and alternate locations near a wall.

Place a level on the front carriage rail near the center ofthe machine and check the level from left to right. SeeFIG. 4A. Adjust the leveling feet until the machine is level.

Place the level across the front and rear carriage rails nearthe left end of the machine. See FIG. 4B. Adjust the twoleveling feet on the left end until the rear rail (the oneclosest to the coolant tray) is slightly lower than the frontrail--so any coolant on the carriage, main base, or optionalbellows will drain back into the coolant tray.

Place the level across the front and rear carriage rails nearthe right end of the carriage bed. Level the right end inthe same way as the left end. For grinding accuracy, thetwo ends must have the identical backward slant within +/-.01" [.25 mm] so the frame is not twisted.

Recheck the level in both directions. When satisfactory,tighten the hex jam nuts on the leveling feet securelyagainst the nuts welded to the bottom of the base. SeeFIG. 2. Don't turn the leveling feet when tightening.

Again recheck the level after the nuts are firmly tightened.

FOR GRINDING ACCURACY, THE MACHINEDOES NOT HAVE TO BE PERFECTLY LEVEL.HOWEVER, IT IS CRITICAL THAT FRONT-TO-BACK LEVELING BE IDENTICAL AT BOTHENDS OF THE MACHINE.

INSTALL THE SPINNING HANDLESInstall the spinning handle on the horizontal handwheels.See FIG. 5. Handle parts are packed in an envelopetaped to the wheel.

FIG. 4

FIG. 5

Regular Hex Nut

Lock Nut

A Leveling Side-to-Side

FIG. 3

8

ASSEMBLY INSTRUCTIONS (Continued)

FIG. 7

APPLY POWER

BEFORE YOU APPLY POWER TO THEGRINDER, REFER TO THE "IMPORTANTGROUNDING INSTRUCTIONS" ON PAGE 9.

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

220 Volt Model Only. For 220 Volt Applications order PartNo. 6700952, which includes a 220 to 110 Volt Step DownTransformer. See Details on page 9.

IT IS RECOMMENDED THAT THIS ACCU-PRO BEDKNIFE GRINDER HAS ITS OWNPERMANENT POWER CONNECTION FROMTHE POWER DISTRIBUTION PANEL, WITHNO OTHER MAJOR POWER DRAWEQUIPMENT ON THE SAME LINE.

IT IS REQUIRED THAT THE POWERDELIVERED TO THIS GRINDER IS 115 VAC -15 AMPS. THE TOLERANCE ON THISPOWER REQUIREMENT IS +/- 5%.THEREFORE THE MINIMUM VOLTAGEREQUIREMENT IS 109VAC WITH 15 AMPS.VOLTAGE MUST BE CHECKED WITH ALLEQUIPMENT UNDER LOAD (OPERATING)ON THE CIRCUIT.

DO NOT OPERATE THIS GRINDER WITHAN EXTENSION CORD.

The grinder is equipped with a low voltage relaywhich is factory preset at 100 VAC. If the powersupply line does not deliver 100 VAC power underload, the relay will open and trip out the starter. Ifthis occurs, your power supply line is inadequateand must be correct before proceeding further withthe grinder.

PROPER GROUNDING OF THE RECEP-TACLE GROUND IN YOUR BUILDING MUSTBE VERIFIED. IMPROPER GROUNDING INYOUR BUILDING MAY CAUSE THE GRINDERTO MALFUNCTION.

FOR 15 AMP RATED LARGE MACHINES

For 0 to 30 Feet from panel to receptacle = Use 14 Ga. Wire.For 30 to 50 Feet from panel to receptacle = Use 12 Ga. Wire.For 50 to 80 Feet from panel to receptacle = Use 10 Ga. Wire.For 80 to 140 Feet from panel to receptacle = Use 8 Ga. Wire.

For 0 to 9 Meters from panel to receptacle = Use 2.5mm Wire.For 9 to 15 Meters from panel to receptacle = Use 4.0mm Wire.For 15 to 24 Meters from panel to receptacle = Use 6.0mm Wire.For 24 to 42 Meters from panel to receptacle = Use 10.0mm Wire.

9

FOR 220 V 50 or 60Hz applicationsProduct No. 6700952 should be ordered.

6700952 includes a 2 KVA 220 Volt StepDown to 110 volt 50/60 Hz transformerwhich is prewired.

The wiring diagram is shown in FIG. 8.

The power cord has no connector. Aconnector which is appropriate for yourlocality and 220 volt, 8 amp applicationshould be installed.


FIG. 8

IMPORTANT GROUNDING INSTRUCTIONS

In case of a malfunction of breakdown, grounding reduces the risk of electrical shock by providing a pathof least resistance for electrical current.

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

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

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

ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOURMACHINE. AN IMPROPER CONNECTION CAN CAUSE A DANGEROUSELECTRICAL SHOCK. IF YOU ARE UNSURE OF THE PROPERELECTRICAL GROUNDING PROCEDURE, CONTACT A QUALIFIEDELECTRICIAN.

USE ONLY A QUALIFIEDELECTRICIAN TO COMPLETETHE INSTALLATION.

CHARGING THE UNINTERUPTABLE POWER SUPPLYThe Uninteruptable Power Supply (UPS) comes from the supplier with nocharge. When the machine is ready for operation, plug it in and turn on theUPS. The battery must charge for a minimum of 24 hours. For UPS functions,refer to the separate manual supplied with the grinder.

THE UPS WILL NOT FUNCTION PROPERLY IF THERE IS INSUFFICIENTPOWER TO THE MACHINE. INSUFFICIENT POWER MAY ALLOW THEBEDKNIFE TO SLIP OR MOVE ON THE MAGNETS WHILE GRINDING. SEEPREVIOUS PAGE FOR POWER REQUIREMENTS.

10


INSTALL THE OPTIONALCARRIAGE BELLOWS (if ordered)Optional carriage bellows are available to keep excessgrindings, dirt, etc. out of the carriage assembly. Toinstall the two bellows:1. Remove the left and right outside leg panels.2. Remove the shaft seal on each side of the linear

actuator. See FIG. 9. NOTE: When the bellows areused, the shafts don't get lubricated and the sealswould run dry. They would then become noisy andnot operate properly. To remove the seals:

a. Crank the carriage all the way toward thefront (that is, toward the operator's position).

b. Remove the actuator mounting screw on topof the carriage. See FIG. 9. Loosen thesetscrew on the collar that holds the actuatorrelease lever in place (this is located behindthe flap by the release lever handle). Removethe actuator release lever. (Keep track of allhardware. See page 40 for exploded view.)Then push the carriage toward the right end ofthe Grinder.

c. Loosen the two set screws in the bearingpillow block at each end of the drive shaft.Loosen the two set screws in the drivecoupling at the right end of the carriage.

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

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

f. Reinstall the drive shaft. The right end of theshaft (inside the coupling) should be 1/8 - 1/4"[3 to 6.5 mm] from the end of the motorshaft (See Fig 10A). Retighten all set screws.

g. Push the carriage back to the left, andreattach the actuator with the mountingscrew. See FIG. 9.

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

4. Attach the outer end of each bellows to the Grinderleg panel. See FIG. 10. Use six bolts, and hexnuts, at each end. The bolt heads go on the bellowsside of the brackets.

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

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

7. Reattach the left and right outside leg panels.

FIG. 9

Actuator MountingScrew (under the rubbersplash guard)

Drive Shaft

Actuator Bar Assembly

Linear Actuator

Seal Plate Actuator Release Lever

DriveShaft

FlexibleCoupling

TraverseMotor

1/8 to 1/4 in.

FIG. 10A

FIG. 11

Left Bellows Bracket

Right BellowsBracket

Rear Plate

ActuatorReleaseLever

FIG. 10

FIG. 11A

WiperBrackets

11


FIG. 12

FIG. 13

INSTALL THE COOLANT TANKAssemble the Coolant Tank as outlined in the instructions(Part No. 3708785) in the coolant tank carton.

Center the Tank under the Grinder.

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

Read the coolant mixing directions and the electricalwarnings in the Coolant Tank instructions.

THE COOLANT RATIO AS SPECIFIED MUST BEUSED. TO HIGH A CONCENTRATION OR LOW ACONCENTRATION WILL CAUSE CORROSIONAND PERFORMANCE PROBLEMS.

1. Be sure the COOLANT PUMP switch is OFF. Mix (PartNo. 3708620) coolant in the coolant tank, at a ratioof 50 parts water to 1 part concentrate. This will takeabout 3.25 gallons of water and .5 pints of concentrate(12.5 liters of water and 0.25 liter of concentrate).

Refer also to the label on the coolant container, and theinstructions packed with the Coolant Tank.

CHECK THE COOLANT PUMPPlug the pump motor cord (from the top of the Tank) to thefemale connector from the control box.

RISK OF ELECTRICAL SHOCK!MAKE CERTAIN THAT THE ABOVEELECTRICAL CONNECTION ISSECURED ABOVE AND AWAY FROMPOSSIBLE CONTACT WITH THECOOLANT.

Turn all control panel switches OFF. Close the guard doorand press START. Press Coolant Pump Switch to ON.Check that the Coolant System functions properly. Beprepared to press STOP if there is any problem.

NOTE: If the unit doesn't begin to pump coolant, press thereset button on the motor contactor inside the control box.See FIG. 13.

Secure any excess electrical cord to a crossbar on theunderside of the machine. Manual/Auto

Selector

Manual Reset

Overload Sensor

Stop

12


CHECK THE CARRIAGE TRAVERSEMove the proximity switch assemblies to about 12" [300 mm] fromthe ends of the machine, and tighten their knobs.

Visually check that the grinding head will be able to traverse to bothsides of the machine without contacting anycomponents.

Turn all control panel switches OFF. Set the TRAVERSE FT/MINknob to zero. Close the guard door and press START. PressCARRIAGE TRAVERSE to ON. Set TRAVERSE FT/MIN to a lowspeed, and check that the grinding head runs through a completetraverse cycle. Be prepared to press STOP if there is anyinterference. Watch carefully forobstructions to the head travel, and check that the grinding motorcord and proximity switch cords are not stretched.

NOTE: If the unit doesn't begin a traverse cycle, press the resetbutton on the motor contactor inside the control box. See FIG. 13.

CHECK THE GRINDING MOTORTurn all control panel switches OFF. Close the guard door to connectthe interlock. Press START. Press Grinding Motor Switch to ON.Check that the grinding head runs properly. Be prepared to pressSTOP if there is any problem.

NOTE: If the grinding head doesn't begin properly, press the resetbutton on the motor contactor inside the control box. See FIG. 13.

MAKE FINAL PREPARATIONS FOR OPERATIONCarefully read the operating instructions in the Operators Manual.

First, study the pages titled "Getting to Know Your Grinder" and"General Operating Information" for important backgroundexplanations about the machine and about bedknife grinding. Then,read the "Operating Instructions" pages for step-by-step procedureson mounting the bedknife and grinding its top and front faces.

13

MAINTENANCE

FIG. 14b

FIG. 15

DAILY MAINTENANCE IS SPECIFIED ON PAGE 6 OFTHE OPERATOR'S MANUAL, AND IS TO BE PER-FORMED BY THE OPERATOR.

LISTED BELOW ARE PERIODIC MAINTENANCEITEMS TO BE PERFORMED BY YOUR COMPANY'SMAINTENANCE DEPARTMENT:

1. Lift the bellows located on adjustable electromaget (seeFIG 14a) and wipe off the bearing rail monthly. Every 3to 6 months throughly cleean the rail and flood spraywith WD-40 or an equivalent lubricant. Run the adjust-able electromagent back and forth through its full rangeof travel. With a clean rag, wipe off the excess lubri-cant. Run the carriage back and forth and wipe the railafter each pass. Repeat until the rail feels dry.

2. Lift the bellows, (See FIG. 14b) if used, and wipe off thetraverse driveshaft and the bearing rails monthly. Whena squeaking noise is coming from the actuator bearings,follow the lubrication procedure for actuator and linearbearings located on the following page. Generally, thiswill be every 6 months to a year.

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

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

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

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

7. Clean the exterior of the right side tooling alignmentadjuster and spray with WD-40 or equivalent at leastevery 6 months.

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

THE UNINTERUPTABLE POWER SUPPLY (UPS) WHICH ISUSED AS A BACKUP TO HOLD THE BEDKNIFE TO THEELECTROMAGNETS DURING A POWER INTERUPTIONHAS A BATTERY. THIS BATTERY HAS A THREE YEAR LIFEAND MUST BE REPLACED AFTER THREE YEARS OFSERVICE LIFE. SEE THE PARTS LIST FOR REPLACE-MENT BATTERY PART NUMBER.

Carriage RailsFoam RailWipers

Drive Shaft

CarriageBellows

DiamondDresser Arm

Grinding HeadHeight Adjuster

FIG. 14a

Adjustable Electro-magnet Bellows

Right Side ToolingAlignment Adjuster

14

MAINTENANCE (Continued)

LUBRICATION

Actuator and Linear BearingsDo the following every six months (or more often if the linearactuator seals are squeaking):

1. Thoroughly clean the carriage rails, drive shaft, andshaft seals. Wipe the shafts and seals thoroughly witha clean rag.

While cleaning, traverse the carriage several times toclean the full length of the drive shaft and rails.

2. Flood-spray all three shafts with WD-40 or an equivalentlubricant (do not use a Teflon-based lubricant) untillubricant drips off the shafts. Then run the carriage backand forth through its range of travel, to carry lubricantonto the outer surface of the actuator bearings and theinner surface of the seals.

NOTE: Because of the flood of lubricant, you may findthat the actuator slips and traversing is erratic or stalls.This is not a problem, as it will be corrected in Step 3.

3. With a clean rag, wipe the excess lubricant from theshafts. Run the carriage back and forth through itsrange of travel, and wipe the shafts after each

traverse. Repeat u ntil the shafts feel dry.

LUBRICATION FOR EXTENDED DOWN TIME/STORAGE:

If the machine will be shut down for more than one month, floodthe shafts and other appropriate parts with lubricant as outlinedabove, and leave the lubricant in place until the unit will be usedagain. Then repeat the above lubrication procedure beforeoperating. This procedure applies to the bearing rail andbearing for the moveable right side electomagnet as well.

15

MAINTENANCE (Continued)

CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATEWINDOWS

Cleaning Instructions

DO NOT USE GASOLINEAdherence to regular and propercleaning procedures is recommendedto preserve appearance and performance.

Washing to Minimize ScratchingWash polycarbonate windows with a mild dish washing liquid detergent and lukewarm water, using a cleansoft sponge or a soft cloth. Rinse well with clean water. Dry thoroughly with a moist cellulose sponge toprevent water spots. Do not scrub or use brushes on these windows. Also, do not use butyl cellosolve indirect sunlight.Fresh paint splashes and grease can be removed easily before drying by rubbing lightly with a goodgrade of VM&P naphtha or isopropyl alcohol. Afterward, a warm final wash should be made, using a milddish washing liquid detergent solution and ending with a thorough rinsing with clean water.

Minimizing Hairline ScratchesScratches and minor abrasions can be minimized by using a mild automobile polish. Three suchproducts 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 thepolycarbonate 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 (hairdryer) to soften the adhesive and promote removal.

GASOLINE SHOULD NOT BE USED!

16

TO REPLACE THE LINEAR ACTUATOR BEARINGSNOTE: Do not remove the linear actuator from the driveshaft. Only remove the bearings from the actuator block.

1. Crank the horizontal handwheel until the carriage isall the way forward (toward the operator position).

2. Turn the actuator release lever 1/2 turn clockwiseto release the linear actuator bearings from thedrive shaft. Slide the actuator release lever outof actuator bar assembly by loosening the retainershaft collar, which preloads the holding spring.See FIG. 18A and 18B.

3. Remove the feed screw guide two mounting screwsand slide the grinding head assembly back. Lift therubber splash guard to expose the actuator mountingscrew (FIG. 17) on the top side of the carriage base.Remove the mounting screw, to disconnect the linearactuator from the carriage. Slide the carriageassembly to one side.

4. Disconnect the shaft seal plate (FIG. 17) from eachside of the linear actuator. Slide the seals down thedrive shaft until they are out of the way. (If the optionalcarriage bellows were installed, the shaft seals mayalready have been removed).

5. Remove the shoulder bolts holding the six bearings(three on each side) to the actuator block. Removethe old bearings and discard them, but save the insidewashers and shoulder bolts.

Inspect the hole from which the bearing and shoulderbolt were removed, for foreign matter. Cleanthoroughly.

6. Wipe the drive shaft clean and dry.

If oil is left on the drive shaft, the pullingforce may have to be set too high in thefollowing procedure. This will shortenthe bearing life.

7. Insert the shoulder bolts through the new bearingsand through the inside washers (saved in Step 6).Then install the complete bearing assemblies into theactuator block and tighten the shoulder bolts.

Be very careful not to cross-thread thebearing bolts!

Reinstall the shaft seal plates if applicable. Be surethe seal plates are mounted concentric to the driveshaft.

ADJUSTMENTS

FIG. 17


Drive ShaftLinear Actuator



FIG. 18A

FIG. 18B

Actuator Engaged

Actuator Released

Feed Screw Guide Mounting Screws

17

TO REPLACE THE LINEAR ACTUATOR BEARINGS

8. Slide the carriage over the actuator, and line up thehole in the carriage with the tapped hole in the top oftheactuator block. Insert the actuator mounting screwthrough the self-adjusting bearing, and tighten the screw.

9. Install the two feed screw guide mounting screws.Install the actuator release lever into the actuator barassembly. Turn the actuator release levercounterclockwise 1/2 turn to engage the actuator.

10.Connect a spring scale so it pulls on the carriageparallel to the drive shaft. Hold the drive shaft fromrotating while you pull on the carriage. See FIG. 19.

To overcome the actuator, the pulling force should be45 to 60 lbs (20-27 kg), with 50 lbs (23 kg) being ideal.If not within those specifications, the actuator tensionmust be adjusted. See "Adjusting the Pulling Force"below.

Exceeding 60 lbs force won't greatlyimprove drive performance - and it willshorten the bearing life.

Adjusting the Pulling Force

If the pulling force is not within specification (Step 10 above),adjust it:

1. With the actuator bearings engaged to the drive shaft,readjust the two outboard screws with springs that holdthe actuator together. To reach these screws, you mustremove the actuator bar assembly. See FIG. 17.Turn each outboard screw an equal amount whenresetting. Turn clockwise for more tension.

2. Check the force again (repeat Step 10 above).Continue adjusting and rechecking until withinspecification.

NOTE: The factory-adjusted position to reach tensionspecifications is to compress the spring until there is.22 in. (5.5 mm) clearance between the underside ofthewasher and the actuator block. See FIG. 20. Usethis as a starting point unless you are already close to thespecified tension.

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

ADJUSTMENTS (Continued)

FIG. 19

FIG. 20

If the actuator release lever istightened too much, it willcontact the outboard screwheads and override theiradjustment, which couldcause a traverse malfunction.Make certain that you havefull engagement when youreengage the actuator.

Hold the drive shaft fromrotating while you checkthe pulling force.

.22 (5.5mm)

18

TO REPLACE THE CARRIAGE LINEAR BEARINGSNOTE: Set a small bench or table near the centerfront of the machine for use in the following procedure.

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

2. Remove the complete carriage assembly from themachine:

A. Remove the two feed screw guide mountingscrews and remove the grinding head assembly fromthe carriage. Set the ginding head on a bench takingcare as to not damage the power cord. Removethe actuator mounting screw, to disconnect the ac-tuator from the carriage (this is located on the topside of the carriage base See Fig. 22).

B. Remove the bolts which secure the front and rearcarriage rails to the Grinder base (six screws foreach rail, accessible from beneath the machine).

The grinding head assemblyweighs about 50 lbs (23 kg).The carriage assembly weighsabout 50 lbs (23 kg). Takeappropriate action when lifting.

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

3. Slide the rails out of the bearings one at a time.4. Remove the three linear bearing pillow blocks and wiper

brackets (four screws each) from the bottom of the car-riage, and discard the bearings.

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

6. Adjust the tension screw (FIG. 23) on the side of eachbearing block so that when you radially rotate the pillowblock around the carriage (See FIG. 24) rail there is nofree play between the bearing and rail. You should feel astrong drag.

Repeat this adjustment to all three pillow blocks, andthen remove the pillow blocks from the carriage rail.

NOTE: The tension is too tight if you feel a coggingaction when you rotate a pillow block around the rail. Thiscogging is caused by the bearing skidding on the rail.Rocking the bearing block back and forth should be asmooth uniform motion.

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

ADJUSTMENT (Continued)

FIG. 22


Drive ShaftLinear Actuator



Radial Rotation

Carriage

TensionAdjustment Screw

19


FIG. 25

TO REPLACE THE CARRIAGE LINEAR BEARINGS7. Attach the three linear bearing pillow blocks and wiper brack-

ets loosely to the bottom of the carriage, with their tensionadjustment screws (FIG. 23) facing outward.

8. Clean the carriage rails.NOTE: The two rails are interchangeable and are alsoreversible (end-for-end).

9. Insert a rail through the rear two pillow blocks, and alignthe rear pillow blocks to each other with a straight edgelaid along their sides. See FIG. 25. When aligned, tightenthe four socket-head screws which hold each rear pillowblock. Slide the other carriage shaft through the frontbearing, but do not tighten the socket head screws.

10. Lift the complete carriage assembly back onto theGrinder main base, and secure the rear carriage railto its V-groove bosses with the six bolts.

11. With the front rail resting in the V-groove bosses and thecarriage approximately centered on the machine, tightenthe two outside socket-head screws which secure the frontpillow block. Lift the front of the carriage, and tighten thetwo inside pillow-block screws. Secure the front carriagerail to its V-groove bosses with the six bolts.

12. Recheck the bearing tension. The tension is correct whenyou try to lift the carriage and can feel no free carriage move-ment up or down. Check for excessive carriage-traverseload by using a spring scale to pull on the carriage parallelto the drive shaft (as in FIG. 19). There should be only abouta 3 lb. pulling force.To double-check, manually slide the carriage assembly fromone end of its travel to the other. There should be uniformresistance through the full range of travel.

13. Slide the linear actuator under the carriage, and line up thehole in the carriage with the tapped hole in the top of theactuator block. Insert the actuator mounting screw throughthe self-aligning bearing, and tighten it. Be careful not tocross-thread the screw.

14. Reinstall the feed screw guide mounting screws and then theactuator release lever into the linear actuator.

15. If being used, reattach the two carriage bellows. Refer tothe assembly section of this manual.

Rear Pillow Blocks

Underside ofCarriage

Straightedge

20


TO ALIGN THE MOTOR SHAFT AND DRIVESHAFT

There must be 0.12 to 0.50 in. (3.0 to 12.7 mm) endclearance between the traverse motor output shaft andthe drive shaft, inside the flexible coupling (FIG.27).To prevent drive shaft "whipping" at higher traversespeeds, the two shafts must be aligned so they areconcentric within .010 in. [0.25 mm]. To align:1. Loosen the two set screw in the coupling.2. Remove the cover on the outside of the right leg.3. Loosen the two bolts which secure the motor

assembly to the leg.4. Visually align the two shafts, then tighten the

motor mounting bolts. Reinstall the leg cover.5. Check that the spiral gaps in the flexible

coupling are equally spaced, with no compressionor extension load on the coupling, then tighten thecoupling screws.

6. Check that the bearing load block is at 90o

to the drive shaft (within +/- 1/4 degree). Use aprecision square held against the bearingshoulder and the rear rail, as in FIG. 26.

TO ALIGN THE REAR RAIL AND DRIVE SHAFT

The rear carriage rail and the drive shaft must beprecisely aligned:

1. Loosen the two bolts holding the bearing supportblocks at each end of the drive shaft. FIG. 28.

2. Align the drive shaft and rear carriage rail (FIG.29) so the distance between their facing surfacesis 3.375"+/- .010 [85.75 mm +/- 0.25]. See FIG.29.Then tighten the support block bolts.

3. Check that the bearing support blocks are still at90o to the drive shaft (within +/- 1/4 degree).Use a precision square held against the bearingshoulder and the rear rail.

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

NOTE: The vertical and horizontal straightness of therails is very accurately set at the factory, so they areunlikely to be incorrect. Contact the factory if you sus-pect a problem after making the following tests.

If the drive shaft is adjusted, youmay have to realign the motor shaftand drive shaft (see above).

21


FIG. 33

FIG. 34

TO ADJUST THE PROXIMITY SWITCHES

For the proximity switches to work properly andreverse the direction of the carriage at each end of atraverse, a distance of 3/16 in. +/- 1/32 [4.75 mm +/- 0.75] must be maintained between the top of theswitch and the actuator bracket on the bottom of thecarriage. See FIG. 33.

To adjust the clearance, loosen one of the switchmounting nuts while tightening the other.

ADJUSTING THE PRELOAD TENSION ON THESMALL GRINDING HEAD SLIDE VEE ROLL-ERS

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

TO ELIMINATE MOVEMENT IN THE DIAMONDDRESSER ADJUSTMENT COLLAR

The adjustment collar on the diamond dresser (SeeFig. 34) has a nylon ball and setscrew to put aholding drag on the diamond dresser shaft. If theadjustment collar is moving when not wanted ormoving too freely, tighten the setscrew (this will putmore load on the nylon ball). If the adjustment collaris difficult to turn, loosen the setscrew decreasingthe load on the nylon ball.

Tension AdjustSetscrew

ProximitySwitch

MountingNuts

3/16in.±1/32(4.75mm±0.75)Betweensensing bracket

& switch

Setscrew andNylon Ball

22


TO ELIMINATE INFEED HANDWHEELBACKLASH

If there is backlash in the Grinder Head Infeedhandwheel (FIG. 35A), there are two adjustmentpoints on each to check:

1. Washers behind the handwheel:

A. Remove the setscrew holding the calibrationring to the handwheel.Go through the setscrew hole and loosen the setscrew holdingthe handwheel to the shaft (about one-half turn).

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

C. Check for .015 in. [.04mm] gap betweenthe wave washer and the flat washer. See FIG.35B.Readjust the hex lock nut if necessary.

D. Tighten the setscrew holding the handwheelto the shaft. Install and tighten the calibrationring setscrew.

2. Check the nylon ball tension on the adjustmentshaft threads at the grinding head slide. See FIG.35A. When you turn the handwheel there shouldbe no free play in the handwheel before thegrinding head slide moves. If there is free play,tighten the setscrew that pushes the nylon ballagainst the acme thread of the adjustment shaft.The nylon ball preloads the free play out of thethreaded joint between the adjustment shaft andthe tooling bar slide block. Apply tension onlyenough to zero the free play. DO NOT over ten-sion as the adjuster will be difficult to turn.

FIG. 35ASetscrew with nylon ball

FIG. 35B

InfeedHandwheel

Wave andflat washers

.015 in. gap

Hex Nut

23


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 traversemotor 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 apoint, 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 90volts 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 forboth 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 stopposition after a limit switch is actuated. The DWELL TIME range is adjustable from 0 - 4 seconds. A DIPswitch setting of 0 sets the DWELL TIME to 0 seconds, while a setting of 8 sets the DWELL TIME to 4 sec-onds. Dwell time is preset to #2 setting for a 1 second dwell time when reversing at each end of stroke.

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

* POWER indicates that ac power is being applied to the control.* FORWARD indicates that the process is running in the forward direction (traversing left).* REVERSE indicates that the process is running in the reverse direction (traversing right).* PROX 1 FWD LIMIT lights when the forward limit switch is actuated (left prox).* PROX 2 REV LIMIT lights when the reverse limit switch is actuated (right prox).

3:00

12:0

0

9:00

PotentionmeterClock Orientation

6:00

24

TROUBLESHOOTING ELECTRICAL MAIN POWER

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

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

B--Main power source breakeris tripped, power source switchis off, or grinder is not pluggedin.

C--System Start Switch (SSS) isnot on.

D--Guard door is not closed

E--Insufficient Line Voltage topower the low voltage relay.

F--Voltage not going to mag-netic starter.

Solenoid in magnetic starterdoes not pull in.

Solenoid pulls in, but no voltageout of magnetic starter.

G--Voltage is not going throughinterlock relay.

Turn switch on.

Reset breaker, turn switch onand plug machine in.

Press System Start Switch.

Close the guard door.

Check status of the low voltagerelay (LVR) inside the controlbox. Note: Check light whileturning on the grind motor. It willshow trip and then reset tonormal.

With the volt meter set on ACvoltage, check L1 (black) to L2(white) for lines coming in of 115volt. Check power source fuse.

Check for loose connections onmagnetic starter. Check for 115Volts AC across starter coil A1to A2. NOTE: Contactor clickswhen engaging.

Check for 115 volt AC betweenterminals T1 (black) and T3(white). T1 and T3 are mainpower out lines. NOTE: T2 isjumpered to L3. Check resetoverload on starter by pushingdown on blue button. Checkterminal connections betweencontactor and overload relay. Ifno voltage on output, replacemagnetic starter.

Check for 115 VAC at incomingside of relay. Terminals 4 & 8.Check for 115 VAC at outputside of relay terminals 2 & 6.Checks must be done withguard door close, Relay Coilengaged.

Grinding motordo not function(no apparentpower tomachine).

Because the guard door isinterlocked to the grindingmotor, the grinding motorwill not operate if door isopen.

If "norm" light is lit, relay issatisfied and line voltage isacceptable.If "trip" light is lit, line voltageto the grinder is inadequateand must be corrected.

AC voltage power sourcerequired.

These wires controlmagnetic starter voltage formain power.

Overload may have beentripped when movingmachine or machinegrinding head motoroverload or electrical powersurge.

--ELECTRICAL--

Interlock relay may not begetting coil power or may bemalfunctioning.

25

Reset dwell time on traversecontrol board as required; oneincrement increases dwell timeby 1/2 second. See Page 23.

First check to see if proximitylight comes on when placing asteel piece over the prox switch.When the light is on it meansthat there is electricity coming toproximity switch.

Left proximity (PROX 1) checkTraverse Drive Control (TDC)between terminals #14 (blackwire) and #15 (brown wire)

Right proximity (PROX 2) check(TDC) between terminals #13(black wire) and #15 (brownwire).

Replace proximity switch if thevoltages do not read as above.

Reverse the switch assembly onthe slide bar

Make sure the proximity light iscoming on when placing a steelpiece over the prox switch.Check proximity spacing to thesensor. If no light, first checkadjustment section for proximitysetting. If there is a light, itmeans that there is electricitycoming to the proximity switch.

Left proximity (PROX 1) check(TDC) between terminals #14(black wire) and #15 (brown wire).

Right proximity (PROX 2) check(TDC) between terminals #14(black wire) and #15 (brown wire).

Replace proximity switch if thevoltages do not read as above.

Check wire connections from theproximity switches and tightendown screws.

TROUBLESHOOTING (Continued) TRAVERSING


Insufficient hesitationat carriage stopsprior to reversingtraverse direction forrelief grinding.

If the carriagetraverses to one endof stroke or the otherand it stops and doesnot reverse direction .

If the carriagetraverses past theproximity switch andkeeps on traversingin same direction.

Traverse changesdirections erraticallywhile running intraverse cycle.

The light coming on showsthe proximity is gettingelectrical contact.

Proximity light on--0 Volts DC

Proximity light off--12 Volts DC

Proximity light on--0 Volts DC

Proximity light off--12 Volts DC

This will only happen if themain Traversing board hasbeen replaced and notrewired to electrical dia-gram.

A loose wire connection willgive intermittent electricalcontact.

Proximity light on--0 Volts DCProximity light off--12 Volts DC

Proximity light on--0 Volts DCProximity light off--12 Volts DC

The dwell time on the traversedrive control not set properly.

Proximity switch is not workingproperly or wire connectionsare loose.

The two proximity switcheshave been reversed on theslide bar.

Proximity switch has failed

Loose wire to proximity switch.

--ELECTRICAL--

26



A--Traverse Motor Switch isnot on.

B--Blown fuse.

C--No voltage going to motor.

D--Bad traverse motor.

Traverse motordoes not work.

Extremely heavy grindingcuts cause excessiveloading of the motor.

Worn and binding actuatorscauses heavy loading tomotor.

Grinding grit over a periodof time does get into thelineal bearings and causesexcessive drive torque ofcarriage.

This checks to see thatvoltage is getting to thecontrol board.

A short brush does notmake an adequate electricalconnection to run theelectrical motor. NOTE:Brushes are long lived andseldom need replacing.

Turn on motor switch.

Replace the 3 amp slo-blo fuseon the control board anddecrease stock removal rate.

Replace actuator bearings ifthey are worn and do notrotate freely. (For more detail,see actuator maintenance inthe adjustment section of themanual.)

Replace the lineal bearings inthe main carriage. Carriageshould traverse freely with a 3lb. maximum loading. Alsocheck for excessive bearingpreload. (For more detail seecarriage bearing replacementin the adjustment section ofthe manual.)

Check for 90 volt DC at thecircuit board leads going to themotor. Across terminals A1and A2, check reading with avoltage meter. When there isvoltage from the circuit boardbut DC motor does not run,check wiring and connections.The voltage reading varieswith speed pot setting.NOTE: Make sure speed potsetting is towards the maxi-mum dial reading for 90 volts.Check for incoming voltage atL1 to L2 for at least 115 VoltsAC Red power light is on.

Remove the brushes one at atime and maintain orientationfor reinsertion. See if brush isworn short 3/8" [9.5 mm]minimum length, and look atwear pattern on commutatorfor arcing. Replace brushes ifnecessary. Replace motor ifbrushes are good.Remove wires from A1 to A2from the spin motor. Checkwith the ohm meter for "0"ohms across the white andblack wires.

27


--POSSIBLE CAUSE-- --REMEDY-- --REASON----PROBLEM--A--Wiring hookup to potentiom-eter is improper. (If compo-nents have been replaced.)

B--Defective speed controlpotentiometer.

C--Main circuit board dial potsettings not correct. (If boardhas been replaced.)

Traverse speedcontrol goes atone speed only.

Wrong wire hookup effectstraverse control. Reversing redand orange wires topotentiometer the DC motor willrun at zero speed but maximumwill be too slow. Reversing redand white wires does not affectspeed control.

Traverse Drive ControlPin #8 to 7Pot Full CCW Pot Full CW

0 VDC 9.75 VDCPin #8 to 9Pot Full CCW Pot Full CW 9.75 VDC 0 VDCIf Yes, pot is O.K.If No, go to step below

Check for 10,000 ohmsred to white wiresFull CCW--10,000 ohmsFull CW--0 ohmsRed to black wiresFull CCW--0 ohmsFull CW--10,000 ohmsIf Yes, pot is O.K.If No, replace potentiometer

Minimum and maximum potsettings effect traverse speed.

Check potentiometer wiring forproper hookup. See thatspeed pot is wired per electri-cal diagram.

Check Potentiometer oncontrol panel.

Check Petentiometer for 10,000ohms. Remove the followingthree wires from Traverse DriveControl:red from term #8white from term #7black from term #9

Check all pot settings on circuitboard as shown in wiringdiagram. (See adjustmentsection Traverse Motor ControlBoard Settings.)

28



A--Oil on carriage drive shaft.

B--Lineal bearings in carriagedo not rotate freely.

A--Lineal bearings in thecarriage are set too tight.

B--Actuator springs set tootight.

Carriagetraversing (variesspeed) whilegrinding.

Traverse speedis too slow.

Driving torque is lostbecause the oil isdecreasing friction fordriving linear actuatorbearings.

Grinding grit over a periodof time does get into thelineal bearings and causeexcessive drive torque ofcarriage. Abrasive noise isdetectable when excessivegrit is in the lineal bearings.

When bearing preload is tootight, it causes excessiveloading to drive the carriage.When lineal actuator isdisengaged, the propertraverse load is 3 lb. Use atension scale to check.(A general guide only.)

NOTE: Check with linearactuator released.

When actuator springtension is excessive bear-ings will not rotate freelycausing carriage to not runfreely.

Wipe oil completely from shaft.Spray down with WD-40 andwipe off.

Replace the lineal bearings inthe main carriage. (For moredetail, see lineal bearingreplacement in the adjustmentsection of the manual.)

Readjust bearings for propertension. (For more detail seelineal bearing replacement inthe adjustment section of themanual.)

Check to see if actuatorbearings have been over-loaded, causing the bearingsto not rotate freely. (For moredetail, see actuator setting inthe adjustment section of themanual.)

--MECHANICAL--

29



A--Bearing shaft supportblocks are not perpendicular tocarriage shaft.

B--Drive shaft is bent.

C--DC drive motor shaft notconcentric to drive shaft.

Actuator driveshaft whippingexcessively athigh traversespeed.

Misalignment of shaftsupport blocks to carriagetraverse rod causes a bowin the rod. This bow willcause an out of balancewhich in turn will cause it towhip at high traversespeeds.

Excessive bend in the shaftwill cause the shaft to whipat high traverse speeds.

Side load at the shaft endwill bend the shaft andcause it to whip at highspeed traversing.

Loosen the screws that retainthe shaft support blocks oneach end of the actuator shaft.Use a square to align bearingface 90 degrees to the frontrail and holding the actuatorshaft to the front rail to 3.375dimension. (For more detail,see align front rail and driveshaft in the adjustment sectionin the manual.

Turn the actuator screwclockwise 1/4 to 1/2 turn torelease actuator from the driveshaft. Slide the carriage toone end of the machine.Mount indicator in the middleof the two bearing supportblocks. Check for a maximumof .015 indicator reading whenyou rotate the shaft. Replaceshaft if required. NOTE: ItemA above must be done properto this step.

Loosen two bolts holding themotor. Align the motor shaftconcentric to the drive shaft.See if coupling spiral gaps areequally spaced when re-aligned. (For more detail, seeTraverse Motor Coupling in theadjustment section.)

30

TROUBLESHOOTING (Continued) ELECTROMAGNETS


A--Make certain elecromagnetswitch is on.

B--Verify that UninteruptablePower Supply (UPS) is turnedon and that there is 120 VAC atthe ouput.

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

D--Verify that the 12 Amp fusebetween the transformer andbridge diode is good.

E--Verify 12 VDC at the outputof the bridge diode.

F--Verify 12 VDC at electro-magnet switch input.

G--Verify 12 VDC at electro-magnet switch output.

Electromagnetsdo not function.

Switch must be on forelectromagnets to work.

UPS must be turned on andcharged for electromagnet towork properly.

Power must come thru thetransformer and fuse to thebridge diode.

Fuse, cord and transformermust be in working order.

Bridge diode must be inworking order.

Power must get to switchinput.

Power must pass throughthe switch and go out to theelectromagnets.

If switch is off, turn on the switch.With switch on, electromagnetswork, troubleshooting done. Withswitch on electromagnets do notwork, Go to B.

If the UPS is off, turn it on.With UPS on, electromagnetswork, end of troubleshooting.With UPS on, electromagnets donot work, check for 120VAC at thefemale receptacle at the back ofthe UPS. If yes, Go to C. If No,check continuity of cord #52 fromMAG to UPS. If bad replace cord.If good, replace or fully charge theUPS and retest.

Check for 12VAC at termials71BD2-S and 66BD2-S. If yes, Goto E. If no, Go to D.

NOTE: With 12 VAC at the bridgediode input, the light inside thecontrol box should be ON. If notreplace the bulb.

With a multimeter set to continuityverify a 0.0 reading when touchingboth ends of the fuse. If yes,check continuity of the cord #51from the UPS to the transformer. Ifgood, replace the transformer. Ifbad replace the cord. If the fusecontinuity checks bad, replace thefuse and retry.

Check for 12 VDC at terminals62BD2-+ and 63DB2--. If yes, Goto F. If no, replace bridge diode.

Check for 12 VDC at terminals63EMS-1 and 62EMS-4. If yes,Go to G. If no, replace wires 62and 63.

Check for 12 VDC at terminals58EMS-2 and 59EMS-5. If yes, Goto H. If no, replace switch.

NOTE: With 12 VDC at electro-magnet switch terminals 58EMS-2and 59EMS-5 the light above theswitch on the ouside of the panelshould be ON. If not, replace thebulb.

31



H--Verify 12 VDC at theelectromagnet connections atthe bottom of the electricalbox.

A--Verify 120 VAC at trans-former input.

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

C--Verify the 10 Amp circuitbreaker is not tripped and CBis good.

D-- Verify 12 VDC output fromthe bridge diode.

E--Verify 12 VDC at the actua-tor switch input.

F-- Push the actuator switchand verify 12 VDC+ or 12VDC-at the actuator switch output.

G-- Verify 12 VDC at theactuator connections at the leftside of the grinder under the leftleg cover.

Electromagnetsdo not function.(Continued)

Tooling BarRotation Actuatordoes not func-tion.

Power must pass to theelectromagnet cords.

Poer must be delivered tothe transformer.

Power must come throughthe transformer and circuitbreaker.

Power must pass throughthe transformer and circuitbreaker.

Power must pass throughthe bridge diode.

Power must get to switchinput.

Power must pass throughthe switch when pushed.

Power must pass throughthe cord and to the motor.

Check for 12 VDC at terminals58MGTBL and 59MGTRD,there is one set of terminals foreach magnet. If yes, CallFactory Customer Service forassistance. If no, replace wires58 and 59.

Check for 120 VAC at terminal65TF2BL and 64TF2BL. If yes,Go to B. If no, verify power isthrough the MAG. If yes,replace wire 64 and 65.

Check for 12 VAC at terminals46DB1-S and 67BD1-S. If yes,Go to D. If no, Go to C.

Check continuity of the circuitbreaker at 0.00 with the wiresremoved. If yes, replacetransformer. If continuity ofcircuit breaker is no, reset orreplace circuit breaker.

Check for 12 VDC at terminals60DB1-+ and 61BD--. If yes,Go to E. If no, replace bridgediode.

Check for 12 VDC at terminals60AMS-2 and 61AMS-5. Ifyes, Go to F. If no, replacewires 60 and 61.

Check for 12 VDC+ or 12 VDC-at terminals 50AMS-1 and50AMS-4 or 50AMS-3 and50AMS-6 depending on whichway you push the switch. Ifyes, Go to G. If no, replaceswitch.

Check for 12 VDC+ or 12 VDC-at terminals 50ACTBL and50ACTRD with the actuatorswitch pushed. If yes, replacethe actuator motor. If no,replace cord wire number 50.

32

TROUBLESHOOTING BEDKNIFE GRINDING


A--Grinding wheel loading upwith grinding grit.

B--Too heavy a grind on thefinal grinding pass.

C--Carriage has varying load ineither direction, because of gritbuildup inside linear bearings.

D--Rails not straight.

Dress the wheel prescribed inthe Operators Manual.

Follow the procedures in theOperators Manual. On thefinal pass, adjust only about.001" [.025 mm]. Let the wheelspark out for 10-20 passes atabout 5 ft/min, with no addi-tional infeed.

With linear actuator releasedfrom the carriage, check for a3lb [1.36 kg] maximum travers-ing load in both directions. Ifload varies, or carriage linearbearings are excessively noisy,replace bearings (See Page19).

Check straightness. If notstraight, consult the factorythrough your distributor. (Thisis carefully checked at thefactory, so it is unlikely to bethe cause.)

Top face ofbedknife isground in aconcave shape(low in thecenter)

A loaded wheel createsundue pressure on thesurface being ground. Bothends of bedknife movebecause of this pressure,allowing bedknife to rock onthe middle support.

For precise grinding,sparking-out process iscritical. It eliminates exces-sive final-grinding pressureon centers and middlesupport, which helpsmaintain grinding straight-ness.

Uneven loading because ofgrit buildup in bearings canaffect the straightness ofgrinding. When grit buildupis excessive, bearings maybe noisy and must bereplaced.

Straightness of rails iscritical for accuracy ofgrinding.

33

TROUBLESHOOTING (Continued) BEDKNIFE GRINDING

--POSSIBLE CAUSE-- --REASON----PROBLEM--

Top face ofbedknife isground in aconvex shape(high in thecenter)

A--Grinding wheel loading upwith grinding grit.

B--Too heavy a grind on thefinal grinding pass.

C--Carriage has varying load ineither direction, because of gritbuildup inside linear bearings.

D--Rails not straight.

A loaded wheel createsundue pressure on thesurface being ground. Bothends of bedknife movebecause of this pressure,allowing bedknife to rock onthe middle support.

For precise grinding, spark-ing-out process is critical. Iteliminates excessive final-grinding pressure on centersand middle support, whichhelps maintain grindingstraightness.

Uneven loading because ofgrit buildup in bearings canaffect the straightness ofgrinding. When grit buildupis excessive, bearings maybe noisy and must bereplaced.

Straightness of rails iscritical for accuracy ofgrinding.

Dress the wheel prescribed inthe Operators Manual.

Follow the procedures in theOperators Manual. On thefinal pass, adjust only about.001" [.025 mm]. Let the wheelspark out for 10-20 passes atabout 5 ft/min, with no addi-tional infeed.

With linear actuator releasedfrom the carriage, check for a3lb [1.63 kg] maximum travers-ing load in both directions. Ifload varies, or carriage linearbearings are excessively noisy,replace bearings See Page 19).

Check straightness. If notstraight, consult the factorythrough your distributor. (Thisis carefully checked at thefactory, so it is unlikely to bethe cause.)

--REMEDY--

34



A--Grinding wheel rim is notcompletely over the top facebeing ground.

Grinding head is traversing toofast.

The top face ofthe bedknife isground unevenlyacross the width.

Too coarse agrind on bed-knife.

When the rim doesn'textend over the top face, itwears unevenly and causesgrooves across the bed-knife.

Traversing speed controlsthe grinding surface texture.A slower traverse producesgrind marks closer together.

The wheel rim must extendover the bedknife top face by1/2" [13 mm] wheneverpossible. See OperatorsManual. If not possible, dressthe wheel more often.

Slow down the traversing speedto 12 FT/MIN.

35



Direct coolant into the grindingwheel, at the point of the grind.See Operators Manual.

Take off about .002 to .003"[.05 to .075mm] per passduring rough grind. SeeOperators Manual.

Dress the wheel before thefinish-grinding pass on eachbedknife. See OperatorsManual.

Dress the wheel before thefinish-grinding pass on eachbedknife. See OperatorsManual.

Take off about .002 to .033"[.05 to .075 mm] per passduring rough grind. SeeOperators Manual.

Set the traversing speed to 12FT/MIN.

Visually check the outside-diameter run out while slowlyrotating the wheel. Also checkthe motor without a wheelinstalled. Replace the wheel ifout-of -round.

Loosen wheel flange and rotatethe wheel 90°. Hand tightenwheel flange and retry. Repeatprocess 3 times if necessary.

The top face ofthe bedknifeshows burnmarks from beingtoo hot.

Grinding wheel isglazing tooquickly.

Grinding motorvibrates exces-sively.

When the front face of thebedknife gets too hot, thesteel loses its temper(softens).

Too much stock removal inone pass creates too muchheat and softens the steel.

Wheel will glaze if notdressed often enough.Also, as a general rule, usea higher traverse speed forthe heavy grind.

Wheel will glaze if notdressed often enough. Ifgrinding wheel is notextended 1/2" [12 mm] overbedknife, it will glaze morequickly because there isless dressing.

Too light a grinding cutdoesn't permit enoughdressing action on thewheel, so it glazes.

Too slow a traverse speedcan cause excessive heatbuildup in the grindingwheel, which glazes thewheel.

A grinding wheel which isn'tproperly trued up on outsideor inside diameters canvibrate excessively andtransfer that vibration to themotor.

A--Coolant not directed ontothe bedknife and grindingwheel.

B--Too heavy stock removalduring grinding.

C--Grinding wheel is glazing.

A--Wheel needs dressing.

B--Too light a cut when roughgrinding.

C--Grinding head is traversingtoo slow.

Grinding wheel is out ofbalance.

36

ELECTRIC SCHEMATIC 67095233

37

CONTROL BOX

Traverse Board

Low Voltage Relay (LVR)

Mag Starter &Overload RelayDoor Switch

Relays

Transformerfor ElectroMagnets

Transformerfor Actuator

Bridge Diode forActuator

Circuit Breakerfor Actuator

12 Amp Fulse forElectromagnets

Bridge Diode forElectomagnets

2 Amp Fusefor CoolantPump

1 Amp StartCircuit Fuse

38

PARTS LIST 6709534 MAIN BASE ASSEMBLY

39

DIA. NO.123456789

10111213141516171819202122232425262728293031323334353637383940414243444546474849505152535455565758596061626364656667

PART NO.B190613B190834B250816B251201B310813B371201B371211B371601D191067H371602J197000J251000J257000J317000J317100J371000J501000K250001K251501K370001K3715013708388670913237086043849294370856937085723708577370956337099904509457600900860090336009510670902267091536709139670915467091196709138670913767091246709048670911767090626709063670907137071296709101670950567095126709129370837867091316709133B251616B311613B3112136709125B251016R00045467091553707132J167000370881937088183707563

DESCRIPTIONButton Head Cap Screw 10-24 x 3/8Button Head Cap Screw 10-32 x 1/2Button Head Cap Screw 1/4-20 x 1/2Hex Head Cap Screw 1/4-20 x 3/4Button Head Cap Screw 5/16-18 x 1/2Hex Head Cap Screw 3/8-16 x 3/4Socket Head Cap Screw 3/8-16 x 3/4Hex Head Cap Screw 3/8-16 x 1Thread Cutting Screw AB #10Roll Pin .375D x 1.00LGInsert Locknut Jam 10-24Hex Nut 1/4-20Thin Locknut 1/4-20Nylon Locknut Jam 5/16-18Nylon Locknut 5/16-18Hex Nut 3/8-16Hex Nut 1/2-13Flat Washer 1/4Split Lockwasher 1/4Flat Washer 3/8Split Lockwasher 3/8Male Barb Connector 1" 4509457Plate-Door Spring R.H.Warning Decal - SafetyReturn Hose, 1"Gas Spring #24Stud Ball 10mmD HandleAdjustable Leveling BoltLarge Foley United DecalGrommetLeg BraceRight Hand Leg Frame CoverRight Hand Leg Frame WeldmentBack Upper Tank PanelRight Hand Upper Tank PanelLeft Hand Upper Tank PanelDoor Spring Bracket - R.H.Tank Cover DoorLeft Hand Leg CoverLeft Hand Upper CoverUPS BracketMachined Traverse BaseHinge CoverUpper Tank Side BracketRubber Trim 36"Ferrule HandleGuard Door Safety SwitchACCU-Pro DecalWater Tank Base WeldmentLeft Hand Leg Frame WeldmentDoor PlateFoam Strip .25 ThickDoor Spring Bracket L.H.Plate - Door Spring L.H.Button Head Socket Screw 1/4-20 x 1Button Head Socket Cap Screw 5/16-18 x 1.0Button Head Socket Cap Screw 5/16-18 x 3/4UPS Top ShieldButton Head Socket Cap Screw 1/4-20 5/8Flat Washer .437 x 1.0 x .08TSafety Key Spacer BlockSafety Switch Dey#8-32 Locknut#8-32 x .75 long Button Head Safety Screw#8-32 x 1.25 long Button Head Safety ScrewStrain Relief

PARTS LIST (Continued) 6709534 MAIN BASE ASSEMBLY

40

PARTS LIST (Continued) 6609529 GRINDING HEAD ASSEMBLY

41

PAR

TS

LIST

(Continued)

6609529 GR

IND

ING

HE

AD

AS

SE

MB

LY

DIAGRAMNUMBER

PARTNUMBER

PARTDESCRIPTION

1...............B190611...............10 - 24 x 3/8 Socket Head Cap Screw2...............B191213...............10 - 24 x 3/4 Button Head Socket Cap Screw3...............B250816...............1/4 -20 x 1/2 Button Head Socket Cap Screw4...............B251216...............1/4 - 20 x 3/4 Button Head Socket Cap Screw5...............B251616...............1/4 - 20 x 1 Button Head Socket Cap Screw6...............B252016...............1/4 - 20 x 1 - 1/4 Button Head Socket Cap Screw7...............B371211............... 3/8 - 16 x 3/4 Socket Head Cap Screw8...............C190820...............10 - 24 x 1/2 Socket Set Screw9...............C250420...............1/4 - 20 x 1/4 Socket Set Screw10.............C250820...............1/4 - 20 x 1/2 Socket Set Screw11.............C310420...............5/16 - 18 x 1/4 Socket Set Screw12.............C621060...............5/8 - 18 x 5/8 Socket Set Screw13.............J377000...............3/8 - 16 Locknut Jam Nylon14.............K190001...............No. 10 Flat Washer15.............K191501...............No. 10 Lockwasher Split16.............K251501...............1/4 Lockwasher Split17.............K371501...............3/8 Lockwasher Split18.............3589081...............Spacer19.............K310101...............5/16 Flat Cut Washer20.............3700409...............Bushing - Reducer21.............3700411...............Grinding Wheel Straight Cup 6" dia x 2" deep22.............3702086...............Diamond Dresser23.............3708121...............Clamp - Double Tube24.............3708543...............Shoulder Bolt25.............3708553...............Spring Compression26.............3708561...............Adjustable Handle27.............3708657...............Roller Dual Vee28.............3708658...............Spring Compression29.............3709062...............Washer Conical30.............3709304...............Washer - Thrust31.............3709526..............Knob

DIAGRAMNUMBER

PARTNUMBER

PARTDESCRIPTION

32.............3708103...............Washer Conical33.............3709705..............Nylon Ball34.............3809047...............Indicator Clear35.............6009023...............Shaft Adjusting36.............6059082...............Ring Calibrated37.............6009044...............Handwheel38.............6609004...............Base Carriage Slide39.............6609027...............Arm - Roller Pivot40.............6609028...............Bushing-V Roller Short41.............6609029...............Bracket - Dresser Lock42.............6609030...............Guide - Feed Screw43.............6609058...............Bushing-V Roller Long44.............6709035...............Stud45.............3707009...............Strain Relief46.............6609502...............Motor Assy 3/4 HP47.............3708448...............Decal Warning Electrical48.............3708458...............Decal Warning Sharp49.............3708461...............Decal Warning 3600 RPM50.............6609505...............Motor Pivot Assy51.............6709038...............Collar - Adjuster52.............6709103...............Flange - Outer53.............6709501...............Tee Knob Assy54.............6709503...............Eccentric Pin Assy55.............6709509...............Dresser Arm Weldment56.............6709552...............Grinding Wheel Guard Weldment58.............B255011...............Socket Head Cap Screw 1/4-20 x 3-1/8Long59.............3709370...............Handle60.............J252000...............Hex Jam Nut 1/4 - 2061.............J257000...............1/4 - 20 Nylok Lock Nut

42

PARTS LIST (Continued) 6709531 TRAVERSE & CARRIAGE ASSEMBLY

43

PARTS LIST (Continued) 6709531 TRAVERSE & CARRIAGE ASSEMBLYDIA. NO.

123456789

10111213141516171819202122232425262728293031323334353637383940414243444546474849505152535455565758596061

PART NO.

B191233B250801B251017B251611B251811B311001B371201J251000K190001K191501K250001K251501K310001K311501K370001K3715013589081361922437080463708147370845437084573709183370958337096133709635384923939690326009068600907067091466709148600910860091096009152600915360091556009198600954860095496009572B191011B190811B252211K25150135591173709040370904467091473969064

282113709668370959737095963709469B2532113708691J19700067090396709149B311001

DESCRIPTION

Phillip's Head Machine Screw 10-32 x 3/4Hex Head Cap Screw 1/4-20 x 1/2Round Head Machine Screw 1/4-20 x 5/8Socket Head Cap Screw 1/4-20 x 1Socket Head Cap Screw 1/4-20 x 1-1/8Hex Head Cap Screw 5/16-18 x 5/8Hex Head Cap Screw 3/8-16 x 3/4Hex Nut 1/4-20Flat Washer #10Split Lockwasher #10Flat Washer 1/4Split Lockwasher 1/4Flat Washer 5/16Split Lockwasher 5/16Flat Washer 3/8Split Lockwasher 3/8Spacer .191ID x .438OD x .43LCompression SpringGrommetShoulder Bolt .375D x .625LWarning Decal - Release ActuatorWarning Decal - Hot SurfaceWiper SealFlexible CouplingStar Knob 5/16-18Pillow Block BrearingCarriage Drive ShaftSeal MountProximity Support RailProximity BracketProximity Sensing BracketRubber PadLeft-hand Traverse Proximity SwitchRight-hand Traverse Proximity SwitchShaft CollarRubber WasherModified Release ActuatorTraverse Motor AssemblyActuator Bar AssemblyRelease Arm WeldmentProximity Rail Weldment ClampSocket Head Cap Screw 10-24 x 5/8Socket Head Cap Screw 10-24 x 1/2Socket Head Cap Screw 1/4-20 x 1 3/8Split Lockwasher 1/4Carrier ShaftSpherical BearingBushing Ball BearingCarriage BaseSponge WiperSponge Wiper HolderSocket Head ScrewSealed BearingSpacerCompression SpringSocket Head Cap Screw 1/4-20 x 2Flat WasherLocknut 10-24Rubber Cover BracketRubber CoverHex Head Cap Screw 5/16-18 x 5/8 Long

44

PARTS LIST (Continued) 6709533 BEDKNIFE SUPPORT ASSEMBLY

45

PARTS LIST (Continued) 6709533 BEDKNIFE SUPPORT ASSEMBLYDIA. NO.

123456789

101112131415161718192021222324252627282930313233343536373839404142434445464748495051525354555758596061626364656667686970717273747576

PART NO.

B190411B190605B191011B191611B250611B251211B253611B371611C190420C3104206709162H250802H251202H251406H251802K310101H251602J371000J377000J377100J507000K191501K250001K251501K371501357910967091426709519370824537083933708554370856337085643708330370870237086946709135370870137085813709016370906237093046009035600903660090956709004670953267091076709008670901167090126709013670901567091646709021670913467091516709108670913667091526709501670955637085936709556B2514113708691B371211C250627B191211

090546709163K250101K250611K5000012109096

DESCRIPTION

Socket Head Cap Screw 10-24 x 1/4Flat Head Socket Cap Screw 10-24 x 3/8Socket Head Cap Screw10-24 x 3/8Socket Head Cap Screw 10-24 x 1"Socket Head Cap Screw 1/4-20 x 3/8Socket Head Cap Screw 1/4-20 x 3/4Socket Head Cap Screw 1/4-20 x 2-1/4Socket Head Cap Screw 3/8-16 x 1Set Screw Cup Point 10-24 x 1/4Set Screw Cup Point 5/16-18 x 1/4Shaft - Gage Spring RetainerRoll Pin .25D x .50LGRoll Pin .25D x .75LGDrive Lock Pin .25D x .875LGRoll Pin .25D x 1.125LGFlat Washer 5/16Roll Pin .25D x 1.00LGHex Nut 3/8-16Nylon Locknut Jam 3/8-16Nylon Hex Locknut 3/8-16Nylon Locknut 1/2-13 thinSplit Lockwasher #10Flat Washer 1/4Split Lockwasher 1/4Split Lockwasher 3/8Nylon Plug 3/16 DiameterElectromechanical ActuatorPivot Bearing AssemblyT-Knob 2.5 3/8-16FHandwheel 3.5 DiameterCompression Spring .6250D x 3.0LRetaining Extension Ring 5100-118Oilite Thrust Bearing 1.25IDShoulder Bolt .50D x 4.0LButton Head Socket Cap Screw M3-.5 x 30Linear Bearing WideRail Bellows 25/70Button Head Socket Cap Screw M3-.5 x 16Inch Dial IndicatorThrust WasherConical Washer .382 x .75 x .035Thrust WasherLocking Stud ShaftAcme Adjusting ShaftSlide ShaftMachined Tooling BarTooling Mounting Bracket AssemblyTooling Slide MountingLeft-hand Pivot PlateIndex Stop BracketRight-Hand Gage BaseLeft-Hand Gage BaseRetainer Block GageGage ShaftGage TipBearing Block Lock BlockDecal - Upper Tooling IndexCross Slide SupportWide Machined Rail 25/70Decal - Lower Tooling IndexTee Knob AssemblyMagnet Repair Assembly - INAKey 5/16 SQ x 1/2Magnet Repair Assembly - INASocket Head Cap Screw 1/4 -20 x 7/8Washer .25 x .62 OD x .12Socket Head Cap Screw 3/8 - 16 x 3/4Set Screw Cap Point 1/4 -20 x 3/8Socket Head Cap Screw 10-24 x 3/43/8 ID x 5/8 OD X 1/16 Thick Flat WasherFlag - Gage ShaftWasher - Flat .31 x .73 x .052TSocket Head Cap Screw 1/4 - 20 x 3/8Washer - Flat 1/2Spacer .50 ID x 1.00 OD x .50 L

46

PARTS LIST (Continued) 6709536 CONTROL PANEL ASSEMBLY

50

47

PARTS LIST (Continued) 6709536 CONTROL PANEL ASSEMBLYDIAGRAM NO.

123456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051525354555657585960

PART NO.

B130812B161014B190809B192013B193211B371001J317100K371501R000480R000483R000553R000557R0005583707066370882637070913707279370737037075503707416370742837074293707367370744637074473707487370748837074893707564370707337075263707567370844837098093709864600906260091996709068670907067090726709073670909167095073707273370930437075263707558B161614370753967091683707548370755637075576709122H12130267091233707547370756637075653707568

DESCRIPTION

Phillip's Head Machine Screw 6-32 x 1/2Phillip's Head Machine Screw 8-32 x 5/8Round Head Machine Screw 10-24 x 1/2Button Head Cap Screw 10-24 x 1.25Socket Head Cap Screw 10-24 x 2.00Hex Head Cap Screw 3/8-16 x 5/8Nylon Locknut 5/16-18Split Lockwasher 3/8External Teeth Lock Washer #8Internal Teeth Lock Washer #10Kep Nut 10-24Kep Nut 6-32Kep Nut 8-32Strain Relief Wire .22/.23Low Voltage Warning DecalFuse BlockStrain Relief Wire .30Diode Heat Sink BridgeTraverse Control BoardStrain Relief Wire .33/.36On/Off Switch-MomentaryOn/Off SwitchOn/Off SwitchPot Knob with Pointer120V CoilPilot Lamp SocketAmber Fluted Dome LensLamp 24V .073AMPStart Pushbutton Assembly8 Pin SocketDiode Bridge - 25 AMPStop Pushbutton AssemblyWarning Decal - ElectricalShoulder Bolt .375D x .375LTinnerman NutElectrical Box CoverTraverse Pot AssemblyPainted Pivot Bracket BoxControl Panel DecalActuator Transformer AssemblyMagnetic Transformer AssemblyWarning DecalControl Box WeldmentStrain ReliefThrust WasherBridge Diode - 25 AMPVoltage Sensor - 100VACPhillip's Head Machine Screw 8-32 x 1Green Fluted Dome LensBattery AssemblyMagnetic StarterOverload Relay for StarterSwitch Guard Cover1/8" Roll Pin x .81 LongSwitch Guard Base15-Amp Circuit BreakerPush Button MountContact Block - NO (Normally Open)Contact Block - NC

48

PARTS LIST (Continued) 6709536 ELECTRICAL ASSEMBLY

49

PARTS LIST (Continued) 6709536 ELECTRICAL ASSEMBLYDIAGRAM NO.

123456789

101112131415a15b161718192021222324252627282930313233343536373839404142434445464748495051525354555657585960616263646566676869707172

PART NO.6009196610905237075476709084600919837075266109053370755060091803707429

SEE PAGE 44SEE PAGE 44

B192013370721937075563707557R0004833707091670911237070926709087600911060091096009108600911360092026709099R000553600911760091186009204670911367090936009181370748937074886009199370721960092016009104670907267090743707487670907767090856709073670908667091286709157670909267090886709098670909067090896709078670908167090796709080670909767090966709082670908367090956709094370742837075263707447370751837073676709110670911137070733707539

DESCRIPTIONCord Assembly Main Power W32Receptacle Cor W4115 Amp Circuit BreakerCord Assembly -Grind Motor W45Traverse Motor Assembly W34Bridge Diode - 25 AMPWire Assembly .25F/.25F W42Traverse Control BoardWire Assembly .25F/6FK W02Rocker Switch On/OffStop PushbuttonStart PushbuttonButton Head Cap Screw 10-24 x 1.25Fuse 2 AMP Slo-BloMagnetic Starter 1 HPOverload Relay for Magnetic StarterInternal Tooth Lock WasherFuse BlockWire Assembly STR/FK W75Fuse 1 AMP Slo-BloWire Assembly 2 Loop W70Wire Assembly 6FK/6FK W18Right Hand Traverse Proximity Switch W38Left Hand Traverse Proximitiy Switch W37Wire Assembly 6FK/6FK W16Wire Assembly 6FK/6FK W23Wire Assembly 2 Loop W72Kep Nut 10-24Wire Assembly .25F/6FK W28Wire Assembly 6FK/10RG W30Wire Assembly 6FK/6FK W15Wire Assembly STR/Fk W76Wire Assembly .25 F/6FK W53Wire Assembly .25F/6FK W03Lamp 24V - 073 AMPAmber Fluted LensTraverse Pot Assembly W35Fuse 2 AMP Slo-BloWire Assembly 6FK/6FK W39Wire Assembly .25FK/6FK W29Actuator Transformer Assembly W46Magnet Assembly W47Pilot Lamp SocketWire Assembly .25F/.25F W49Actuator Cord Assembly Switch W50Magnetic Transformer Assemby W71Transformer Cord Assembly W51Battery Assembly W52Door Safety Switch Cord W110Wire Assembly .25F/6FK W55Wire Assembly 3 Loop W56Wire Assembly 2 Loop W57Wire Assembly 3Loop W58Wire Assembly 3 Loop W59Wire Assembly .25F/.25F W60Wire Assembly .25F/.25F W61Wire Assembly .25F/.25F W62Wire Assembly .25F/.25F W63Wire Assembly .25F/6FK W64Wire Assembly .25F/6FK W65Wire Assembly .25F/.25F W66Wire Assembly .25F/.25F W67Wire Assembly .25F/6FK W68Wire Assembly .25F.6FK W69Rocker Switch Mom On/OffBridge Diode - 25 AMPRelay DPST 120V CoilFuse 12AMP Slo-BloOn/Off SwitchWire Assembly STR/FK W73Wire Assembly STR/FK W748 Pin SocketGreen Fluted Lens

50

PARTS LIST (Continued) 3708784 COOLANT PUMP/TANK ASSEMBLY

15

51

PARTS LIST (Continued) 3708784 COOLANT PUMP/TANK ASSEMBLY

1 ........................................... 3709642 ................... Swivel Nozzle2 ........................................... 3679116 ................... Connector Shut - Off Valve3 ........................................... K190001 ................... #10 Flat Washer4 ........................................... B191611 ................... 10-24 x 1 Socket Head Cap Screw5 ........................................... K191501 ................... #10 Lockwasher Split6 ........................................... 3709595 ................... Shut Off Valve7 ........................................... 3709593 ................... Barbed Connector8 ........................................... 3707532 ................... Pump 115V9 ........................................... 3708339 ................... Connector - Barbed Insert10 ......................................... 3708725 ................... Tank - Coolant11 ......................................... 3708774 ................... Cover - Coolant Tank12 ......................................... 3708775 ................... Divider - Coolant Tank 5”13 ......................................... 3708778 ................... Divider - Coolant Tank 6.5”14 ......................................... 3708785 ................... Instruction Sheet - Coolant Tank15 ......................................... 3389039 ................... Coolant Hose

DIAGRAMNUMBER

PARTNUMBER DESCRIPTION

52

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