632

ACCU - Pro
AUTO - INDEX
SPIN / RELIEF
REEL MOWER GRINDER
with ACCU-Touch

Patent No. 6,010,394

6,290,581 & 6,685,544

ASSEMBLY
and
SERVICE
MANUAL
WARNING
You must thoroughly read and understand this

manual before assembling or maintaining the
equipment, paying particular attention to the
Warning & Safety instructions.

1 6327962 (4-12)
 - ORIGINAL INSTRUCTIONS
SAFETY INSTRUCTIONS

Safety Awareness Symbols are inserted into this manual

to alert you to possible Safety Hazards. Whenever you
see these symbols, follow their instructions.

The Warning Symbol identifies special instructions The Caution Symbol identifies special instructions
or procedures which, if not correctly followed, could or procedures which, if not strictly observed, could
result in personal injury. result in damage to or destruction of equipment.

1. KEEP GUARDS IN PLACE and in working order. 12. DON'T OVERREACH. Keep proper footing and
balance at all times.
2. REMOVE WRENCHES AND OTHER TOOLS.
13. MAINTAIN GRINDER WITH CARE. Follow
3. KEEP WORK AREA CLEAN. instructions in Service Manual for lubrication and
preventive maintenance.
4. DON'T USE IN DANGEROUS ENVIRONMENT.
Don't use Grinder in damp or wet locations. 14. DISCONNECT POWER BEFORE SERVICING,
Machine is for indoor use only. Keep work area . .. or when changing the grinding wheel.
well lit.
15. DO NOT USE SHARP OBJECTS ON THE
5. KEEP ALL VISITORS AWAY. All visitors should .. TOUCH SCREEN. Do not clean the touch
be kept a safe distance from work area. screen with solvents.

6. MAKE WORK AREA CHILD-PROOF with 16. USE RECOMMENDED ACCESSORIES. Consult
padlocks or master switches. the manual for recommended accessories. Using
improper accessories may cause risk of personal
7. DON'T FORCE THE GRINDER. It will do the injury.
job better and safer if used as specified in this ......
manual. 17. CHECK DAMAGED PARTS. A guard or other
part that is damaged or will not perform its intended
8. USE THE RIGHT TOOL. Don't force the Grinder . function should be properly repaired or replaced.
or an attachment to do a job for which it was not ...
designed. 18. KNOW YOUR EQUIPMENT. Read this manual
carefully. Learn its application and limitations as
9. WEAR PROPER APPAREL. Wear no loose well as specific potential hazards.
clothing, gloves, neckties, or jewelry which may ....
get caught in moving parts. Nonslip footwear is 19. KEEP ALL SAFETY DECALS CLEAN AND
recommended. Wear protective hair covering to . . LEGIBLE. If safety decals become damaged or
contain long hair. illegible for any reason, replace immediately. Refer
to replacement parts illustrations in Service Manual
10. ALWAYS USE SAFETY GLASSES. for the proper location and part numbers of safety
decals.
11. SECURE YOUR WORK. Make certain that the .
cutting unit is securely fastened with the clamps ... 20. DO NOT OPERATE the grinder WHEN UNDER .
provided before operating. THE INFLUENCE OF DRUGS, ALCOHOL, OR
MEDICATION.

2
SAFETY INSTRUCTIONS - ORIGINAL INSTRUCTIONS

IMPROPER USE OF GRINDING WHEEL MAY CAUSE

BREAKAGE AND SERIOUS INJURY.

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

DO DON'T
1. Do always handle and store wheels in a 1. Don't use a cracked wheel or one that has
careful manner. been dropped or has become damaged.

2. Do visually inspect all wheels before mounting 2. Don't force a wheel onto the machine or
for possible damage. 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 marked on 3. Don't ever exceed maximum
wheel. operating speed established for the wheel.

4. Do check mounting flanges for equal and 4. Don't use mounting flanges on which the bearing
correct diameter. 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
7. Do always use a safety guard Safety Code B7.2 for exception).
covering at least one-half of the grinding wheel.
7. Don't start the machine until the wheel
8. Do allow newly mounted wheels to run at guard is in place.
operating speed, with guard in place, for at least one
minute before grinding. 8. Don't jam work into the wheel.

9. Do always wear safety glasses or some type 9. Don't stand directly in front of a
of eye protection when grinding. grinding wheel whenever a grinder is started.

10. Don't force grinding so that motor slows

noticeably or work gets hot.

Avoid inhalation of dust generated by grinding and cutting operations.

Exposure to dust may cause respiratory ailments. Use approved NIOSH or
MSHA respirators, safety glasses or face shields, and protective clothing.
Provide adequate ventilation to eliminate dust, or to maintain dust level below
the Threshold Limit Value for nuisance dust as classified by OSHA.

3
 - ORIGINAL INSTRUCTIONS

This machine is intended for grinding the reel of reel type mower units ONLY.
Any use other than this may cause personal injury and void the warranty.

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

ALL operators of this equipment must be thoroughly trained BEFORE

operating the equipment.

Do not use compressed air to clean grinding dust from the machine. This
dust can cause personal injury as well as damage to the grinder. Machine
is for indoor use only. Do not use a power washer to clean the machine.

Low Voltage Relay

The grinder is equipped with a igh-low voltage relay

which is factory preset at 100-140 VAC. If the power
supply line does not deliver 100-140 VAC power under
load, the relay will open and trip out the starter. If this
occurs, your power supply line is incorrect 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 11-14
Adjustments..........................................................................................................................Page 15-22
Machine Service...................................................................................................................Page 23-26
Electrical Troubleshooting Index .........................................................................................Page 28
Electrical Troubleshooting....................................................................................................Page 29-48
Mechanical Troubleshooting.................................................................................................Page 50-51
Parts Lists.............................................................................................................................Page 52-89
Electrical Diagrams ...............................................................................................................Page 90-97
-Separate Drawings Included in the Product Packet

4
service data - ORIGINAL INSTRUCTIONS

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 or ACCU-Master Grinder. 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 questions not answered in this manual, please call your distributor. They will contact the
manufacturer if necessary.

TORQUE REQUIREMENTS GRADE 2 GRADE 5 GRADE

8
Throughout this manual we refer to torque requirements
as "firmly tighten" or the like. For more specific
torque values, refer to the information below.
SMOOTH 3 MARKS 6 MARKS
Bolts Going Into a Nut, or Into a Thread Hole in HEAD on HEAD on HEAD
Steel 1/4 In. 6 ft-lbs 9 ft-lbs 13 ft-lbs
Refer to the table at the right. thread (0.8 kg-m) (1.25 kg-m) (1.8 kg-m)
5/16 In. 11 ft-lbs 18 ft-lbs 28 ft-lbs
Bolts Going Into a Thread Hole in Aluminum thread (1.5 kg-m) (2.5 kg-m) (3.9 kg-m)
Use the Grade 2 values in the table at the right. 3/8 In. 19 ft-lbs 31 ft-lbs 46 ft-lbs
thread (2.6 kg-m) (4.3 kg-m) (6.4 kg-m)
Socket-Head Screws Going Into a Nut or Steel 7/16 In. 30 ft-lbs 50 ft-lbs 75 ft-lbs
Use the Grade 8 values in the table at the right. thread (4.1 kg-m) (6.9 kg-m) (10.4 kg-m)

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

Machine Screws thread (6.2 kg-m) (10.4 kg-m) (15.9 kg-m)
No. 6 screws: 11 in.-lbs (0.125 kg-m)
No. 8 screws: 20 in.-lbs (0.23 kg-m)
No. 10 screws: 32 in.-lbs (0.37 kg-m)

5
ASSEMBLY INSTRUCTIONS - ORIGINAL INSTRUCTIONS

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

Remove the plastic bag, shrink wrap and bubble
74"
wrap. Remove the metal clips that secure the
(188 cm)
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.
20" (50 cm) R36"
(92 cm)

THE UNIT WEIGHS 1490

LBS. (676 kg). USE
POWER EQUIPMENT TO 50"
LIFT MACHINE. (127 cm)

91" (230 cm)

With Optional
Workstation
Remove shipping straps from traverse
carriage. Remove window protective sheets.

FIG.1
POSITION BASE

The ACCU-Pro Spin/Relief Grinder will require an

operating area of about 120" W x 140" D x 90" H (305
x 356 x 229 cm). The mower unit will be lifted from 85" (216 cm)
the front of the machine if using the optional winch & with Optional
boom or from the rear with the optional workstation. Manual
Winch &
The machine operator will operate the unit from the Boom
front of the machine. Position the machine to allow 88" (224 cm)
sufficient operating room in front of the machine (and 70 " with Optional
behind if using the optional workstation). See FIG. (178 cm) Electric
Winch &
1 and 2.
Boom

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.
FIG. 2

6
ASSEMBLY INSTRUCTIONS (Continued) - ORIGINAL INSTRUCTIONS

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

REEL
ADAPTERS

SPIN DRIVE
SPREADER BAR ASSEMBLY ADAPTER
(ONLY ON MODELS WITH BOOM)

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

FLASHER BULB
& LENS

HORIZONTAL EXTENSION
DRIP PAN (ALIGNMENT GAGE)

7
ASSEMBLY INSTRUCTIONS (Continued) - ORIGINAL INSTRUCTIONS

LEVEL BASE

Place a level on the top of the table and check the unit from
side to side for level. 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. 5
FIG. 4

INSTALL THE FLASHER LIGHT

Locate flasher bulb and lense in carton. Install bulb

and lense to the flasher assembly socket. This is
located on top of the front right frame member on
the 632 ACCU-Pro. See Fig. 6.

FIG. 6

8
ASSEMBLY INSTRUCTIONS (Continued) - ORIGINAL INSTRUCTIONS
apply power

before you apply power to the

grinder, refer to the "important
grounding instructions" on Page 10.

115 Volt Model Only. Plug the power cord into

a standard 115V AC 20-amp grounded receptacle. See FIG. 7.
220 Volt Model Only. For 220 Volt Applications order Part No.
632036, which includes a prewired 3 KVA 220 V step down to FIG. 7
110 V 50-60 Hz transformer should be ordered.

It is recommended that this reel mower The grinder is equipped with a high-
grinder has its own permanent power low voltage relay which is factory
connection from the power distribution preset at 100-140 VAC. If the
panel, with no other major power draw power supply line does not deliver
equipment on the same line. 100-140 VAC power under load,
the relay will open and trip out the
It is required that the power delivered to starter. If this occurs, your power
this grinder is 115 VAC - 20 amps. The supply line is inadequate and must
tolerance on this power requirement is be corrected before proceeding
+/- 5%. Therefore the minimum voltage further with the grinder.
REQUIREMENT is 109VAC with 20 amps. Voltage
must be checked with all equipment under
load (operating) on the circuit.

DO NOT operate this grinder with an

extension cord.

Do not operate this grinder on a Ground

Fault interupter (GFI) circuit. The (GFI) will
trip constantly.
PROPER GROUNDING OF THE RECEPTACLE GROUND
IN YOUR BUILDING MUST BE VERIFIED. IMPROPER
GROUNDING IN YOUR BUILDING MAY CAUSE THE
GRINDER TO MALFUNCTION.

When installing the grinder, the following guidelines should be

used to establish the wire size between the power panel in your
building and the grinder receptacle. Note that the wiring in your
building must be per code between main power panels and sub
panels.

FOR 20 AMP RATED LARGE MACHINES

For 0 to 40 Feet from panel to receptacle = Use 12 Ga. Wire.

For 40 to 60 Feet from panel to receptacle = Use 10 Ga. Wire.
For 60 to 100 Feet from panel to receptacle = Use 8 Ga. Wire.
For 100 to 160 Feet from panel to receptacle = Use 6 Ga. Wire.

For 0 to 12 Meters from panel to receptacle = Use 2.5mm Wire.

For 12 to 30 Meters from panel to receptacle = Use 4.0mm Wire.

9
assembly instructions (continued) - ORIGINAL INSTRUCTIONS
For 220 V 50 or 60Hz
applications Product No.
6320936 should be ordered.

These products includes a 3

KVA 220 Volt Step Down to
110 volt 50/60 Hz transformer
which is prewired.

The wiring diagram is shown in

FIG. 8.

The power cord has no

connector. A connector which
is appropriate for your locality
and 220 volt, 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 or 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 OF YOUR
MACHINE.

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

always provide a proper electrical ground for your machine.

an improper connection can cause a dangerous electrical
shock. if you are unsure of the proper electrical grounding
procedure, contact a qualified electrician.

10
periodic MAINTENANCE - ORIGINAL 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:

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 all 632 ACCU-Pro models).

2. Use the grease fitting provided to grease the dove

tail with high quality lithium grease monthly. Wipe
off excess grease. See FIG. 9.
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. 9.

4 Check the gib adjustment on the Grinding wheel

diameter adjustment every 3 months. See FIG. 9. FIG. 9

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 LEAD
six months. See FIG. 10. SCREW (2X)

7. Lift the bellows and wipe off the bearing rails monthly. ALIGNMENT
Lubricate linear bearing, follow the lubrication SHAFT (2X)
procedure on the following pages. Generally, this
will be every six months to a year.

FIG. 10

11
STORAGE PROCEDURE - ORIGINAL INSTRUCTIONS

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 - ORIGINAL INSTRUCTIONS

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. 11 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.

SHAFTS

TRAVERSE BASE ALONE

WITHOUT DUST PROTECTION
COMPONENTS

FIG. 11

13
MAINTENANCE (Continued) - ORIGINAL INSTRUCTIONS

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) - ORIGINAL INSTRUCTIONS
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 2. Main Scale
3. Battery compartment 4. Output Connection
5. Display 6. ON/OFF Power
7. ZERO/ABS switch 8. Origin Switch
9. Inch/mm Switch 10. Tapped hole
11. Slider

Battery Installation and Origin Setting

Set the origin of the scale after installing the battery. Otherwise,
the error sign("E" at the least significant digit) may appear,
resulting in incorrect measurements.
1) To install the battery, remove the compartment lid and
install the SR44 battery with its positive side facing up. After
the battery is installed, set the origin.
2) 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 hole
the ZERO/ABS buttton for 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.

Cleaning
Clean gage with CRC 3-36 Cleaning and Lubrication Oil. Wipe off
excess after cleaning. If CRC 3-36 is not available, use Denatured
Alcohol to clean, then apply light oil and wipe off excess.

15
ADJUSTMENTS (continued) - ORIGINAL INSTRUCTIONS

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. FIG. 14

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
attach a magnetic base dial indicator to the carriage then
use the bearing tester fork 3706055 to apply a load to the
bearin. Read the vertical movement above each bearing.
This movement should be within .003" (.07 mm) Also, when
pulling the carriage in the traversing direction, there should
be only approximately a 3 lb force, with the belt disengaged.
FRONT DUST
To check this attach a spring scale to the carriage and pull REAR DUST
SHIELD
parallel to the carriage shafts. To double check the assembly, SHIELD
slide the carriage assembly from "end of travel" to "end of
travel", it should have very uniform resistance through the FIG. 15
full range of travel.
STEP 6--Replace the bellows carriage mounting brackets
onto the carriage. Replace front and rear shields.
See FIG. 15.

16
adjustments (continued) - ORIGINAL INSTRUCTIONS
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 a 20 lbs. (44 kg) 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 FIG. 16
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 vacuum hose bracket, the two double tube clamps and FIG. 17
the belt cover. For grinding motor belt adjustment, loosen the
four socket head cap screws that attach the motor mounting
plate. Adjust the grinding motor for proper belt tension 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 to two pulleys with 5
lbs. [2 kg] of force and belt movement dimensions to be .12
inches [3 mm]. See FIG. 18.
.12 [3 mm]
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.

FIG. 18
17
adjustments (continued) - ORIGINAL INSTRUCTIONS
index finger proximity setting

Set all motor switches to the off position.

Press the machine system start switch, so the grinder is

operational.

Push down on the index finger until the stop pin is within
.06 inches (1.5 mm) of bottoming out. (You can use a
1/16" gage pin or rod stock between the stop pin and
index finger). Set the proximity switch to activate the light
at this setting. This assures the index finger to be close
to its final stop position so the reel is completely indexed
before the carriage starts to traverse. See FIG. 19.

The spring load force pushing up on the index finger brings

it away from the proximity when released. FIG. 19

STEPPPER INFEED TRAVEL LIMITS

The infeed stepper maximum extension is 6.0" (152

mm) and minimum compression is 3.5" (89 mm). If you
experience a situation where the grind does not properly
finish, check that you have not exceeded stepper travel
by checking the values per FIG. 20.

FIG. 20

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. 21.

FIG. 21

18
ADJUSTMENTS (Continued) - ORIGINAL INSTRUCTIONS

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. 22.

NOTE: The light on the proximity switch activates when metal

crosses over the switch.

FIG. 22

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. 23.

FIG. 23

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). .19" (5mm)
See FIG. 24.
(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.)

FIG. 24

19
 - ORIGINAL INSTRUCTIONS
ADJUSTMENTS (Continued)
SPIN GRINDING ATTACHMENT ADJUSTMENT

If free play develops so the crank handle wants to rotate with

free play when operating in the scissor action (raising and
lowering) on the spin grinding attachment, the free play can
be eliminated by tightening the set screw identified in FIG. 24.

If there is too much play in the spin drive pivot points, torque
down the hex nut tight so conical washer is compressed, then
back off 1/2 turn. See FIG. 24.

TRAVERSE BELT TENSION

FIG. 24
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 FIG. 25
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.
FIG. 26

20
 - ORIGINAL INSTRUCTIONS
ADJUSTMENTS (Continued)

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 out 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 the
assembly. CARRIAGE
MOUNTING BOLTS
CROSS SLIDE
FRAME
ASSEMBLY

PIN

BOLTS

FIG.
PIN PART OF 27FIG. 26
FRAME

21
ADJUSTMENTS (Continued) - ORIGINAL INSTRUCTIONS

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 stud and tap with plastic or rubber
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.
LOCKNUT
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 CROSS
setscrew to the flat located on the screw shaft, then SLIDE
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. LOCK
STEP 11--Lower the jack and retest the Cross Slide HANDLES
Assembly through full range of motion. If binding
occurs, follow the procedure under Cross Slide
Assembly located on page 21.

NOTE: It is also possible to remove the complete

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

NUT

DUTCHMAN SLIDE
SHAFTS

LOCKNUT
FIG. 28
SETSCREW
HANDWHEEL

22
machine service - ORIGINAL INSTRUCTIONS

traverse drive control board (TDC)

The Traverse Drive Control Board has nine potentiometers and
four switches as shown on drawing 6524511 which is included. Minimum Speed---MIN SPD
These potentiometers and switches have been set at the The potentiometer is factory preset to the
factory to the positions shown on the drawing. minimum full counterclockwise 8:30 position.
Also see FIG. 29A and FIG. 29B.
Tach---TACH
Fwd Accel & Rev Accel---FWD ACC & REV ACC The tach poteniometer is not used in this
The potentiometer is factory preset to the minimum full application. It should be a the factory setting
counterclockwise 8:30 position. This position turns the of 8:30.
Acceleration/Deceleration off for this application.
Armature Switch---ARMATURE 90-180
Maximum Speed---MAX SPD This switch is factory preset to the 90 position
The maximum speed potentiometer is preset to position for for a 90 VDC motor..
90 Volts DC output to the traverse motor at terminals A1 and A2.
Feedback Switch--- FEEDBACK ARM-TACH
IR Compensation---IR COMP This switch is factory preset to the ARM
The IR Comp control is preset to 3:00 position. Never adjust position.
past the 4:30 position.
The lower control board has two switches. Both
Regulation of the traverse motor may be improved by slight switches are factory preset to 115 for 115 VAC
adjustment of the IR COMP trim pot clockwise from its factory operation.
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 just disappear.

Rev Torque---REV TQ
The Reverse Torque setting determines the maximum current
limit for driving the motor in the reverse direction. The
potentiometer is preset to the 10:30 position. It should not
require adjustment.

Fwd Torque---FWD TQ
The Foward Torque setting determines the maximum current
limit for driving the motor in the forward direction. The
potentiometer is preset to the 10:30 position. It should not
require adjustment.

Deadband---DB
This motor control board has a potentiometer which must be set
for 50 HZ or 60 HZ operation. For 60 HZ set to 3:00 position. FIG. 29A
For 50 HZ set to 9:00 position.

FIG. 29B
Potentiometer Clock Terminal ends (Feet) are always at the 6:00 position,
Orientation no matter how the potentiometer is orientated on the board.

23
 - ORIGINAL INSTRUCTIONS
machine service (Continued)
SPIN DRIVE CONTROL BOARD (SDC)

The Spin Drive Control Board has four potentiometers, two switches and one dial as shown on
FIG. 26. These potentiometers,swtiches and dial have been set at the factory to the positions
shown on FIG. 26.

In the Relief Grinding Mode--

The Torque Shut Off mode selector allows you to turn on or off the Torque Shut Off feature.
When switch 1 is set to ON, the board will decrease the spin motor torque once the shut time is
achieved after leaving the right proximity sensor. The amount of time it takes before the torque is
decreased is set with the Torque Shut Off Delay dial. The spin motor toque will be increased to
the higher value once the right proximity switch is activated again. If the Torque Shut Off selector
is in the OFF position the torque will remain constant during relief grinding.

Torque Shut Off Delay dail is used to set the duration of time before the torque is decreased after
leaving the right proximity sensor during relief grinding. If the dial is turned clockwise (higher
number) the higher torque value will stay on for a longer period of time.

The Relief Speed (RSP) and the Relief Torque Pot (RTP) interact with each other. The (RSP) is
located on the spin board as a remote speed preset at 12:00 (20 Volts DC). See FIG. 26. The
(RTP) is located on the control panel and is for relief torque adjustment.

Relief Speed Pot (RSP) when rotated clockwise will increase spin drive speed (the speed at
which the reel indexes to the next blade). This speed should never be above the 3:00 setting.

Relief Torque Pot (RTP) is used to 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 spin motor
system to not operate smoothly.

Relief Idle Torque Pot (ITP) is used to vary the reel to finger holding torque once the shut time
is achieved after leaving the right proximity sensor if the Torque Shut Off Selector is set to on.

In the Spin Grinding Mode--

The Spin Torque Potentiometer (STP) and the Spin Speed Pot (SSP) interact with each other.
The (STP) is located on the spin board as remote torque preset at 2:00 for torque setting. See
FIG. 99. The (SSP) is located on the control panel and is for spin speed adjustment.

Spin Torque Pot (STP) controls maximum torque allowable in the spin grinding cycle only. This
should never be adjusted past the 3:00 position. If the reel does not turn check that the reel is
free turning by hand spinning with the power off and the spin drive disconected.

The Spin speed Pot (SSP) controls reel spin speed, adjust as required. This controls the spin
drive speed for spinning the reel.

IR COMP Pot--
The IR Compensation is factory set at 9:00.

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

24
 - ORIGINAL INSTRUCTIONS
machine service (Continued)
SPIN TORQUE RELIEF SPEED DELAY SET SWITCH 1 SET
POT (STP) 2:00 POT (RSP) 12:00 TO 1 TO OFF

12:00

9:00 3:00

6:00
Potentiometer
Clock Orientation

IR COMP IDLE TORQUE FIG. 30

POT 9:00 POT (ITP) 10:00

STEPPER INFEED CONTROLLER (SIC)

The Stepper Infeed Controller has as set of 8 dip switches and 1

position rotatable dial. See Figure 31.

Motor Selection Dial-

SET MOTOR
Set the motor selection Dial to 6. This will setting is best suited for the
DIAL TO 6
stepper motor that is used on this machine.

DIP SWITCH SETTING:

SW1 and SW2 are used to set the maximum current. Too high of settion
will overload the DC power supply:

SW1 - OFF SW8 - OFF

SW2 - ON SW7 - ON
SW6 - OFF
SW3 - OFF This switch adjusts the load inertia. SW5 - OFF
SW4 - ON Reduces the current when the motor is not on. If this is SW4 - ON
set to the OFF position the motor will get very hot. SW3 - OFF
SW2 - ON
SW5, SW6 and SW7 are used to set the speed of the motor. If the speed SW1-OFF
is not correct the motor will rotate too fast or too slow:

SW5 - ON
SW6 - OFF
SW7 - ON

SW8 - OFF Leave in OFF for normal operation. For testing move to
the ON position. The drive will automatically rotate the FIG. 31
motor back and forth two turns in each direction.

25
machine service (Continued) - ORIGINAL INSTRUCTIONS

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. 32. 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. 33. Thoroughly clean the housing bore and the
outside diameter of both bearings. Apply blue Loctite #243 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. Apply blue Loctite #243 to the INSIDE THREAD
of the 9/16-18 NUT and install onto the spindle shaft with the grooved side toward the bearing. 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 15 Ft. Lbs.

Apply blue Loctite #243 to the bore of the pulley before installation. Replace the
square key and install the new pulley pushing the counterbore side of the pulley against the spindle nut with
no end play. Next install blue Loctite #243 on the pulley setscrews and tighten the
two pulley set screws. Then install the new external retaining ring on the spindle shaft. Mount the
new poly-V belt. (See Grinding Head Belt Tension and Alignment Adjustments in the adjusting sectionof
the manual). Install the new belt cover gasket on the belt cover and install the belt cover and square key.
Mount the left side grinding wheel grip knob with a slight gap to the cover and tighten the two set screws.

FIG. 33

FIG. 32

26
 - ORIGINAL INSTRUCTIONS

- THIS PAGE IS LEFT INTENTIONALLY BLANK FOR NOTE TAKING PURPOSES. -

27
 - ORIGINAL INSTRUCTIONS

ACCU-TOUCH CONTROL PANEL

Touch Screen
Stepper Infeed
Controller
(SIC)

Door Safety Vacuum Relay

Switch Monitor (RE34)
(SSM)

Spin Drive
Terminal Strip #2 Control Board
(TB2) (SDC)

Traverse Drive
Control Board
Programmable (TDC)
Logic Controller
(PLC)
24 VDC Power
Supply (PWR)
Relay Board
(RT1)
Blue Terminal
Blocks (TBB)

Grey Terminal
Termial Strip #1 Blocks (TBG)
(TB1)
Low Voltage Relay
(LVR)
Grinding Motor Magnetic
Relay (REL) Contactor
(MAG)

Main Ground Lug Main Circuit

Breaker (MCB)

AC Filter
(FTR)

28
electrical troubleshooting - ORIGINAL INSTRUCTIONS

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-Touch 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-Master have a wire label at each end for assembly and troubleshooting. The
wire label has a code which tells you wiring information. The first set of two or three numbers are the
Foley wire number. The next group of letters or numbers are the code for the component to which the
wire attaches. Example: RT1 for Relay Terminal 1. The last set of numbers or letters is the name of the
terminal on the component to which the wire attaches.

electrical troubleshooting index

AC Main Power Controls .....................................................................................................Page 30

E-Stop..................................................................................................................................Page 31
Spin Drive Controls in Spin Mode........................................................................................Page 32-33
Spin Drive Controls in Relief Mode......................................................................................Page 34-35
Machine Light.......................................................................................................................Page 36
Grinding Motor Controls.......................................................................................................Page 37
Dust Collector Controls........................................................................................................Page 38
Winch Controls.....................................................................................................................Page 39
Traverse Drive Controls--w/prox...........................................................................................Page 40-41
Stepper Infeed Controls--.....................................................................................................Page 42-43
System Error Messages.......................................................................................................Page 44-47
Flashing Light.......................................................................................................................Page 48

29
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS
PROBLEM--AC Main Power Controls: no electrical power to control panel.

In your Product Packet Assembly, there are a series of prints. Find the print
titled ACCU-Touch Wiring Diagram, before starting the troubleshooting below. Verify all wires shown
on that drawing 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 Checkout Procedure

You must turn ON the A. Look for Touch screen to Machine works
Switch on the top of come on. Yes--end troubleshooting
the control panel. No--go to Step B. next

Main Power Cord is not B. Plug in main power cord Machine works
plugged in Yes--end troubleshooting
No--go to Step C. next

Main 20 amp outlet circuit C. Check circuit breaker and Machine works
breaker has tripped in build- reset Yes--end troubleshooting
ing panel if necessary. (Check wall outlet No--but a light works in outlet--go to
with a light to make sure it works) Step D. next
No--but light does not work in outlet.
You must solve your power delivery
problem independent of machine.

Main 20 amp circuit breaker D. Check circuit breaker and Machine works
has tripped in machine reset if necessary. Yes--end troubleshooting
panel No----go to Step E. next

No 115 Volts AC to Main E. Check for incoming power Check 115 Volts AC from (MCB)
Circuit Breaker (MCB) for 115 Volts AC 01MBC- brown wire to Blue Terminal
Block TBB17 light blue wire.
Yes--go to Step F. next
No--Verify Filter function, check wiring.

No 115 Volts AC power from F. Check for 115 Volts AC from Check 115 Volts AC from 2-Amp CB
2-Amp Circuit Breaker 2-Amp Circuit Breaker "157CB13-BL" to Blue Terminal Block
TBB17 light blue wire.
Yes--go to Step H. next
No--Check continuity of CB and replace.

No 115 Volts AC power from H. Check for 115 Volts AC from Check 115 Volts AC from PSW terminal
Power Switch (PSW) Power Switch #3 to Blue Terminal Block TBB17.
Yes--go to Step I. next
No--Check continuity of Switch and
replace

No 24 Volts DC power from I. Check for 24 Volts DC from Check 24 Volts DC from PWR V+ to V-
Power Supply Power Supply (PWR) Yes--Verify wiring to Touch Screen
No--Verify power to PWR. Replace
power supply.
30
 - ORIGINAL INSTRUCTIONS
electrical troubleshooting (Continued)
PROBLEM--Red E-Stop screen displayed on Touch Screen

In your Product Packet Assembly, there are a series of prints. Find the print
titled ACCU-Touch Wiring Diagram, before starting the troubleshooting below. Verify all wires shown
on that drawing 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 Checkout Procedure

You must push the green A. Listen for magnetic contactor Machine works
Push to Start Switch (PSS) (MAG) to pull in with a clunk. Yes--end troubleshooting
No--go to Step B. next
Pull red e-stop button out B. Repeat push the green button Machine works Yes--end troubleshooting
(SSS) again. No--go to Step C. next

115V power not delivered to C. Check at Magnetic contactor coil (MAG) Term #A1 to A2 for 115 Volts AC
MAG coil for 115 Volts AC with main electrical Yes--replace magnetic starter if not
power on and pushing (SSS) pulling in with click. No--go to Step D.
next

Controller E-stop ouput relay D. Check relay teminal blocks (RT1) Light is:
on for light on for output "F" (toward Off-- Go to Step I
bottom) On-- go to step E. next

Controller E-stop relay no E. With the machine power on, (RT1) terminals F+ to F- for 115 Volts AC
continuity Relay light on, measure across Yes-- Replace output relay F in (RT1)
relay contacts. No-- go to step F. next

(SSS) Is bad F. With the machine power on, mea- (SSS) Term #3 to #4 for 115 Volts AC
sure across normally open contacts (SSS) not pushed, "0" Volts AC (SSS)
of (SSS) pushed. No-- Replace (PSS)
Yes-- go to step G. next

(ESS) Is bad G. With the machine power on, mea- (ESS) Term #1 to #2 for "0" Volts
sure across normally closed contacts (ESS) pulled out, 115 Volts AC (ESS)
of (ESS) pressed in. No-- Replace (ESS)
Yes-- go to step H. next

Bad wires H. With the machine power off,

verify continuity of wires and Measure continuity of wires #11, 12, 15,
connections. 22, 35, 37, 50, 59, 60, 146, 147, 148,
149, & 150. Replace any bad wires or
repair loose connections.

Relay Terminal Block (RT1-F) I. No power to relay coil

Bad Check for 24 VDC from RT1 - F - A1 to
A2.
Yes - Replace Relay Terminal Block
No -Step J
No SSignal from PLC J. Check for PLC output YF
Light on PLC at YF is on. YES- Verify
jumper in RT1 connecting A1 is in place.
Replace output cable.
NO- Replace PLC

31
 - ORIGINAL INSTRUCTIONS
electrical troubleshooting (Continued)
PROBLEM--Spin Drive not working in (manual) jog mode and in SPIN MODE.

Assuming 115 Volts AC to control panel and all other manual (jog) mode functions are working.

In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-Touch
Wiring Diagram before starting the troubleshooting below. Verify all wires shown on that drawing
are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose
terminal connections and/or loose crimps between wire and terminal. If loose terminals are found,
tighten and retest system. If problem persists, test as listed below.

Possible Cause Checkout Procedure

Spin Speed Pot (SSP) set A. Set (SSP) to 200 on the control Spin Motor works
to zero panel. Yes--end troubleshooting
No--go to Step B. next

Spin Motor Switch not on B. Turn spin drive switch on (touch Spin Motor works
on Touch Screen green area) from SPIN MANUAL Yes--end troubleshooting
screen. No--go to Step C. next

Door is open C. Alarm on screen should indicate Spin Motor works

that the door must be closed for the Yes--end troubleshooting
spin drive to operate. Close door. No--go to step D. next

Circuit breaker 42 is D. Reset circuit breaker switch Spin Motor works

tripped (4A) (Tripped by current overload) Yes--end troubleshooting
check that reel is free spinning No--go to step E. next

No Power to (SDC) E. Power Light on (SDC) next to PWR light is ON:

"PWR" should be ON. Yes--Skip to step I.
No-- go to Step F. next

Relay 9 (RT1) is not F. Check (RT1) for light #9 to be on Light #9 is ON:

working verify Light is on (Door must be closed and spin drive Yes--go to Step G. next
switch on) No--Bad PLC, RT9 Terminal Block,
cables, or Software.

Verify Continutiy of G. With light #9 on, Check 115V AC Verify 115 VAC from (RT1) Term 9- to
relay 9 in RT1 into (RT1) relay 9. 02FTRBU (Filter blue wire) .
Yes--got to Step H. next
No-Check 4amp-Circuit Breaker (CB42)
Remove wires, verify continuity (ohms)
Replace CB if bad.

Spin Drive Controller (SDC) H. With light #9 on, Check 115V AC Remove wires L1 & L2 at (SDC) and
not functioning. into (SDC) check for 115 AC between wires.
Yes-- Replace (SDC)
No-- Replace (RT1) Relay 9

Drive is not in Relief Mode. I. Check for the LED light on (SDC) Light on (SDC) next to "SPD" is on.
next to "SPD" to verify Broad is in Yes--skip to Step L. next
Spin Mode. No--If "TQ" light is on then board is in
Torque "Relief" mode. go to Step J. next

32
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

Possible Cause Checkout Procedure

Relay #4 is bad J. Check (RT1) for light #4 to be on Light is:On-- go to Step K. next
Insure that Spin Drive switch Off-- Unplug machine to reset, if problem
has been pressed on from SPIN is still there contact factory.
MANUAL screen at least once

K. With light #4 on, verify continuity Temporarily remove one of the wires at
(reinstall wire after testing). Wire Terminal 4, measure (RT1) 4+ to 4- for
has line power, use care "0" Ohms
not to short out control Yes--Replace (SDC)
No--replace Relay 4 (RT1)

No Power out of (SDC) L. Check (SDC) output. Have Spin (SDC) term A1 to term A2 measure
speed pot (SSP) set at 400 approx 90 Volts DC
Yes--go to step M. Next
No-- Skip to step O.

Reversing relay(s) bad M. Measure voltage at spin motor (RT1) Term A+ to term D+ should read
(RT1) (these terminals are on the left side the same 90 Volts DC measured at step
of the block) L.
Note polarity
Yes--Skip to Step P.
No-- go to Step N. next

N. Reverse direction of spin motor (RT1) Term A+ to term D+ should read

from SPIN MANUAL touch screen the same 90-120 Volts DC measured at
step K., but opposite polarity
Yes--Skip to Step P.
No--Replace relays A, B, C, & D in (RT1)

Spin Speed Pot (SSP) O. (SSP) on Main Panel. Remove Check Black wire of (SSP)- H to Red
is not working wires and check for resistance - wire of (SSP)-W
Ohms of the Pot. Pot full CCW Pot Full CW
10,000 Ohms 0 Ohms
White wire of (SSP)- L to Red wire of
(SSP)-W
Pot full CCW Pot Full CW
0 Ohms 10,000 Ohms
Yes-- Replace (SDC)
No-- Replace (SSP)

Spin Drive motor is bad P. With machine power off, At TB1-4 to TB1-5 check approx. 0 ohms
Check spin motor continuity across the black and white wires
Yes-- Motor should work, end
troubleshooting.
No--go to Step Q. next

Worn motor brushes Q. Inspect motor brushes Remove the brushes one at a time and
maintain orientation for reinsertion.
See if brush is worn short 3/8" [10mm]
minimum length.
Yes-- replace motor brushes
No-- replace Spin Drive motor
33
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

PROBLEM--Spin Drive not working in (manual) jog mode and in RELIEF MODE.

Assuming 115 Volts AC to control panel and all other manual (jog) mode functions are working.

In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-Touch
Wiring Diagram, before starting the troubleshooting below. Verify all wires shown on that drawing
are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose
terminal connections and/or loose crimps between wire and terminal. If loose terminals are found,
tighten and retest system. If problem persists, test as listed below.

Possible Cause Checkout Procedure

Relief Torque Pot (RTP) set A. Set (SSP) to 20 on the control Spin Motor works
to zero panel. Yes--end troubleshooting
No--go to Step B. next

Spin Motor Switch not on B. Turn spin drive switch on (touch Spin Motor works
on Touch Screen green area) from RELIEF MANUAL Yes--end troubleshooting
screen. No--go to Step C. next

Door is open C. Alarm on screen should indicate Spin Motor works

that the door must be closed for the Yes--end troubleshooting
spin drive to operate. Close door. No--go to step D. next

Circuit breaker 42 is D. Reset circuit breaker switch Spin Motor works

tripped (4A) (Tripped by current overload) Yes--end troubleshooting
check that reel is free spinning No--go to step E. next

No Power to (SDC) E. Power Light on (SDC) next to PWR light is ON:

"PWR" should be ON. Yes--Skip to step I.
No-- go to Step F. next

Relay 9 (RT1) is not F. Check (RT1) for light #9 to be on Light #9 is ON:

working verify Light is on (Door must be closed and spin drive Yes--go to Step G. next
switch on) No--Bad PLC, RT1, cables, or Software.

Verify Continutiy of G. With light #9 on, Check 115V AC Verify 115 VAC from (RT1) Term 9- to
relay 9 in RT1 into (RT1) relay 9. (Terminal RT1-9 02FTRBU (Filter blue wire) .
is the top terminal on the left side of Yes--got to Step H. next
RT1) No-Check 4amp-Circuit Breaker (CB42)
Remove wires, verify continuity (ohms)
Replace CB if bad.

Spin Drive Controller (SDC) H. With light #9 on, Check 115V AC Remove wires L1 & L2 at (SDC) and
not functioning. into (SDC) check for 115 AC between wires.
Yes-- Replace (SDC)
No-- Replace (RT1) Relay 9

Drive is not in Relief Mode. I. Check for the LED light on (SDC) Light on (SDC) next to "TQ" is on.
next to "TQ" to verify Broad is in Yes--skip to Step L.
Relief Mode. No--If "SPD" light is on then board is in
Speed "Spin" mode. go to Step J. next

34
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

Possible Cause Checkout Procedure

Relay 4 (RT1) not working J. Check (RT1) for light #4 to be off Light is:
Insure that Spin Drive switch has Off-- go to Step K. next
been pressed on from RELIEF On-- Contact factory
MANUAL screen at least once

Relay #4 is bad K. With light #4 on, verify continuity Temporarily remove one of the wires at
(Replace wire aferr testing) Terminal 4, measure (RT1) 4+ to 4- for "0"
WARNING-WIRE MAY HAVE LINE Ohms
POWER Yes--Replace relay 4 (RT1)
No--replace (SDS)

Spin Drive Controller is L. Check (SDC) output. Have Relief (SDC) term A1 to term A2 measure approx
bad (SDC) Torque pot (RTP) set at Red Line 13 Volts DC
Yes--go to step M. Next
No-- Skip to step O.

Reversing relay(s) bad M. Measure voltage at (RT1). (RT1) Term A+ to term D+ should read the
(RT1) (terminal A+ and B+ are the center same 13 Volts DC measured at step L.
hole on the left side of RT1) Note polarity
Yes--Skip to Step P.
No-- go to Step N. next

N. Reverse direction of spin motor (RT1) Term A+ to term D+ should read the
from SPIN MANUAL touch screen same 12 Volts DC measured at step H., but
opposite polarity
Yes--Skip to Step P.
No--Replace relays A, B, C, & D in (RT1)

Relief Torque Pot (RTP) O. (RTP) on (SDC). Remove wires Check Black wire of (RTP)- H to Red wire
is not working and check for resistance - Ohms of of (RTP)-W
the Pot. Pot full CCW Pot Full CW
10,000 Ohms 0 Ohms
White wire of (RTP)- L to Red wire of
(RTP)-W
Pot full CCW Pot Full CW
0 Ohms 10,000 Ohms
Yes-- Replace (SDC)
No-- Replace (RTP)

Spin Drive motor is bad P. With machine power off, At TB1-4 to TB1-5 check approx. 0 ohms
Check spin motor continuity across the black and white wires
Yes-- Motor should work, end
troubleshooting.
No--go to Step Q. next

Worn motor brushes Q. Inspect motor brushes Remove the brushes one at a time and
maintain orientation for reinsertion. See if
brush is worn short 3/8" [10mm] minimum
length.
Yes-- replace motor brushes
No-- replace Spin Drive motor
35
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

PROBLEM--Machine light is not working

In your Product Packet Assembly, there are a series of prints. Find the print
titled ACCU-Touch Wiring Diagram, before starting the troubleshooting below. Verify all wires
shown on that drawing 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 Checkout Procedure

Light switches are A. Turn on machine light toggle Light works

not turned on or there switch on light. Check the light bulb Yes--end troubleshooting
is a bad bulb in another light fixture or replace with No--go to Step B. next
a new bulb. Plug a different light that
is known to work into light plug.

Wire cord is bad B. Check for 115 Volts AC at Check for 115 Volts AC across termi-
Terminal Strip nals # 6 & 7 on Terminal Strip 2 (TB2)
Yes--replace cord for light
No--go to Step C. next

Wiring is bad C. Check continuity of wiring from Check wiring and tighten or replace
MAG to Terminal Block any damaged or loose parts.

*NOTE: The light may flicker

on and off when the grinding
motor is turned on. This is due
to the high current draw on the
system when starting the grind
motor.

36
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS
PROBLEM--Grinding motor not working in (manual) jog mode.

Assuming 115 Volts AC to control panel and all other manual (jog) mode functions are working.

In your Product Packet Assembly there are a series of prints. Find the print titled ACCU-Touch
Wiring Diagram, before starting the troubleshooting below. Verify all wires shown in the drawing
are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose
terminal connections and/or loose crimps between wire and terminal. If loose terminals are found,
tighten and retest system. If problem persists, test as listed below.

Possible Cause Checkout Procedure

Grinding Motor Switch is A. Turn switch on from either SPIN Grinding Motor works
not on MANUAL screen or RELIEF MANU- Yes--end troubleshooting
AL screen No--go to Step B. next

Circuit Breaker (CB28) B. Reset circuit breaker switch Grinding Motor works
15A is tripped (tripped by current overload) Yes--end troubleshooting
No--go to step C. next

Grinding Motor Relay is C. Check for (REL) incoming (REL) Term #L1 to #L2 for 115 Volts AC
not working (REL) 115 Volts AC Yes--go to step D. next
No--Verify wiring, replace Circuit Breaker
(CB28)

D. Check for (REL) output voltage (REL) Term #T1 to #T2 for 115 Volts AC
of 115 Volts AC Yes-- Verify 115 VAC at TB1-1 & TB1-2,
Check terminals, replace Grind motor.
No--go to step E. next

Relay (REL) coil or contacts E. Check for (REL) input of 24 (REL) Term A1 to Term A2 for
are not working Volts DC at the coil. Reminder, 24 Volts DC
Grind Drive switch must be on and Yes--Replace (REL)
doors must be closed. No--Skip to Step F.

Relay 5 (RT1) is not F. (RT1) check that the light is on Light is:
working for relay 5, make sure grind drive On-- Go to Step I. next
swich is on Off--Contact Factory

I. Light is on for Relay 5, check (RT1) Term 5+ to 5-, measure DC volt-

continuity age
0 Volts DC-- Check wiring, Relay (REL)
should work, end troubleshooting.
24 Volts DC-- Replace relay 5 (RT1)

37
 - ORIGINAL INSTRUCTIONS
electrical troubleshooting (Continued)
PROBLEM--Dust Collector not working in (manual) jog mode.

Assuming 115 Volts AC to control panel and all other manual (jog) mode functions are working.
In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-Touch
Wiring Diagram, before starting the troubleshooting below. Verify all wires shown on that drawing
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, tighten and retest system. If problems persists, test as listed below.

Possible Cause Checkout Procedure

Dust Collector Switch is A. Turn on switch located on top Dust Collector works--
not on (Vacuum) of Vacuum in the back right of Yes--end troubleshooting
corner of the machine. No--go to Step B. next

Dust Collector Switch B. Turn switch on from SPIN Dust Collector works--
(Vacuum) on touch screen MANUAL or RELIEF MANUAL Yes--end troubleshooting
is not on screen. No--go to Step C. next

Vacuum not working C. Check for 115 Volts AC at the Light works
receptacle plug by plugging in a Yes--Replace Vacuum
hand drill or light. No--go to Step D. next

(RT1) relay E is not working D. With Vacuum switch on, Light is on:
Check for (RT1) Relay E on Yes--go to step E. next
No--Contact Factory

E. (RT1) Relay E, verify (RT1) Term E+ to E- for 115 Volts AC

continuity. (Terminal E+ and E1 Yes--replace Relay E (RT1)
are on the left side of RT1) No--go to Step F. next

Circuit Breaker (CB32) is F. Check for power out of circuit Terminal Block 17 (light blue wire) #02 to
not working (3-amp) breaker (CB32) (CB32) (brown) #156 for 115 Volts AC
Yes--go to Step G. next
No--replace (CB2)

Relay 34 (RE34) is not G. Check for (RE34) input of (RE34) Term 0 to term 1 for 115 Volts AC
working 115 Volts AC at coil. Yes-- go to Step H. next
No--Check continuity of wires.

H. Check for (RE34) input of (RE34) Term 8 to term 4 for 115 Volts AC
115 Volts AC at contacts Yes--go to Step I. next
No--Check continuity of wires.

I. Check for (RE34) output of (RE34) Term 6 to term 2 for 115 Volts AC
115 Volts AC at contacts Yes--Replace Plug
No--replace (RE34)

38
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

PROBLEM--Winch does not work in either direction.

In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-Touch
Wiring Diagram, before starting the troubleshooting below. Verify all wires shown on that drawing
are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose
terminal connections and/or loose crimps between wire and Terminal. If loose terminals are found,
tighten and retest system. If problem persists, test as listed below.

Possible Cause Checkout Procedure

7 amp circuit breaker on A. Reason: Check for a lifting Winch works--

winch motor is tripped overload condition or wiring Yes--end troubleshooting
shorted to ground. Reset No--go to Step B. next
breaker located at end of winch
motor.

No voltage to motor B. Check that motor coil cord from Winch works--
DC motor is plugged in Yes--end troubleshooting
No--go to Step C. next

C. Check for 115 Volts AC at the Drill works--

plug end winch cord wire #6 by Yes--replace winch
plugging in a hand drill No-- go to Step D. next

D. Check for Machine is plugged in Winch works--

Start button is pressed. (Red Yes--end troubleshooting
E-Stop Screen must not be up) No--go to Step E. next

E. Verify wiring from MAG to Measure 115 Volts AC from TB2-6 to

Terminal Strip 2. TB2-7.
Yes--replace cord to winch
No--Verify power out of mag. Replace
bad wiring.

39
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

PROBLEM--Traverse Drive not working in (manual) jog mode

Assuming 115 Volts AC to control panel and all other manual (jog) mode functions are working.

In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-Touch
Wiring Diagram, before starting the troubleshooting below. Verify all wires shown on that drawing
are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose
terminal connections and/or loose crimps between wire and terminal. If loose terminals are found,
tighten and retest system. If problem persists, test as listed below.

Possible Cause Checkout Procedure

Traverse Speed Pot (TSP) A. Set (TSP) to 35 on the control Traverse works
set to zero panel Yes--end troubleshooting
No--go to step B. next

Traverse Belt Clamp B. Insure release lever is in adjusted Traverse works

release lever released properly. See Adjustments section Yes--end troublshooting
of this manual. No--go to Step C. next

Circuit Breaker 32 (CB32) C. Too heavy a grind causes Traverse works

(3 amp) tripped grinding head traverse motor to Yes--end troublshooting
overload and trip the circuit breaker. No--go to Step D. next
Reset (CB32)

Traverse Drive Control D. Check for 115 Volts AC On (TDC) Term L1 to

(TDC) do not have power incoming to (TDC) (insure L2 for 115 Volts AC
traverse right or left has been Yes--Skip to Step H.
pressed at least once) No--go to Step E. next

Relay 8 (RT1) is bad E. Check for relay 8 (RT1) Light is:

light on (insure traverse right On-- go to Step F. next
or left has been pressed at least Off-- Contact Factory
once)

Circuit Breaker 32 (CB32) F. Check relay 8 for continuity, (RT1) Term 8+ to 8- read
bad Insure relay 8 light is on. (Terminal 115 Volts AC
8+ and 8+ are on the left side of Yes-- Replace Relay 8 (RT1)
RT1) No-- go to Step G. next

G. Check CB32 for voltage (CB32) from Line neutral, Light Blue
wire at the line filter wire # 02FTRBU,
to wire #156CB32-BL at CB32
measure 115 Volts AC:
No-- Replace CB32
Yes-- Verify continutiy of wires to RT1.
Replace or repair bad wire(s)

40
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

Possible Cause Checkout Procedure

No DC Voltage from (TDC) H. Check for 90 Volts DC across Check (TDC) terminals
Traverse Drive Control (TDC) terminals A! to A2 this A1 to A2 for 90 Volts DC
voltage drives the DC traverse Yes--go to step I. next
motor. NOTE: Traverse must be on No--go to Step J. next
and have (TSP) turned full CW to
maximum voltage of 90 VDC Note:If voltage is less than 90 VDC
verify pots on TDC. See page 24

Traverse Motor is bad I. Check traverse motor continuity Remove wires from terminals
A1 & A2 0 ohms across
the black and white wires
Yes--go to Step J. next
No--go to Step N.

Check Relays 2 and 3 J. (RT1) Verify that relay 2 light Lights come:
comes on when Traverse Right is On-- go to step K. next
pressed, and that relay 3 light comes Off-- Skip to step L.
on when Traverse Left is pressed

(TSP) (10K) is bad K. Check (TSP) for 10,000 ohms Check for 10,000 ohms red to white
Remove three wires from (TDC) wires
red from term S2 Full CCW--0 ohms
white from term S0 Full CW--10,000 ohms
black from inline connector (Wire 39) Red to black wires
Full CCW--10,000 ohms
Full CW--0 ohms
Yes--go to Step L. next
No--replace (TSP)

Gap between flag and prox L. Gap between flag and Prox If incorrect, adjust per adjustment
is incorrect. should be 3/16" to 1/4" [4-6mm]. section of manual.
Prox light does not light when flag is Traverse works--
under prox. Yes-- End troubleshooting
No-- go to step M. next

Proximity switch is bad M. From the Touch screen, Enter Follow instructions on screen to verify
"HELP" screen from main menu. traverse proximity switches are ok.
Switch is
Good-- Replace (TDC)
Bad-- Replace switch

Worn motor brushes N. Inspect Motor Brushes 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 Drive Motor

41
 - ORIGINAL INSTRUCTIONS
electrical troubleshooting (Continued)
PROBLEM--Stepper Infeed not working in (manual) jog mode.

Assuming 115 Volts AC to control panel and all other manual (jog) mode functions are working.

In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-Touch
Wiring Diagram, before starting the troubleshooting below. Verify all wires shown on that drawing
are correct and pull on wire terminals with approximately 3 lbs force all terminals to verify there are
no loose terminal connections and/or loose crimps between wire and terminal. If loose terminals are
found, tighten and retest system. If problem persists, test as listed below.

Possible Cause Checkout Procedure

Infeed Jog Switch is not A. Hold switch on in Stepper motor works

held to on position either direction Yes--end troubleshooting
No--go to Step B. next

Actuator is at physical limit B. Move stepper in opposite direction Stepper Motor works
Yes--end troubleshooting
No--go to step C. next

Circuit Breaker (CB13) C. Reset circuit breaker switch Stepper Motor works
is tripped (2 amp) (tripped by current overload) Yes--end troubleshooting
Grinding head stepper infeed No--go to step D. next
mechanism jammed causing overload

High Low Switch is not on D. Put switch on high speed High speed works
high speed (rabbit) for ease of checkout of Yes--end troubleshooting
Stepper Infeed Control (SIC) No--go to Step E. next

Stepper motor drive E. You can feel stepper pulses on Stepper works--
coupling is loose motor when (HLS) is on high or low Yes--end troubleshooting
& (IJS) switch is depressed in either No--go to Step F. next
up or down direction. Open stepper
infeed inspection plate to check for
loose coupling. Retighten coupling to
drive actuator screw. See
adjustment section of manual.

Inccorect DC voltage to F. Look at LEDs on SIC: (SIC) LED code:

Stepper Infeed Control Flashing Green- go to step G. next
(SIC) Flashin Red-- Machine in E-stop
Code Error
(verify other functions work). If
solid green no alarm, motor disabled other function work replace SIC.
flashing green no alarm, motor enabled 1 Green, 6 Red-- check motor
flashing red configuration or memory error wiring, replace motor assembly.
1 green, 4 red power supply voltage too high Other -- Check for 24 VDC to
1 green, 5 red over current / short circuit terminals V+ and V-. If voltage is
1 green, 6 red open motor winding not correct replace Power Supply,
2 green, 3 red internal voltage out of range if voltage is correct replace SIC.
2 green, 4 red power supply voltage too low

42
 - ORIGINAL INSTRUCTIONS
electrical troubleshooting (Continued)
Possible Cause Checkout Procedure

SIC or motor bad G. Move SIC dip switch SW8 to ON Motor rotates in test mode (SW8- ON)
position for Test. Motor should rotate YES--Go to Step H. next
each direction 2 turns. TURN OFF NO-- Replace infeed stepper motor.
AFTER TEST.

No Step pulse from PLC I. Check light Y0 on PLC. While Light comes on:
pressing up or down it should light Yes-- go to step J. next
(pressing down Y1 will also light) No-- check continuity of wires from PLC
to SIC. If OK, replace PLC.

No V+ to Step or Direction J. Check for 24VDC at Dir + and Measure 24 VDC from V- on the SIC to
of SIC Step + of (SIC). 60SICS+. if 24VDC then measure from
V- to 60SICD+ for 24VDC
YES-- If both measure 24VDC then heck
continuity of wires from PLC to SIC. If
OK, replace PLC.
NO-- Check wire 60, replace if bad.

43
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

PROBLEM--No Manual (jog) cycle or Auto Cycle stops because of a system error message
on Touch Screen.

System Error Message Checkout Procedure Message Status

Store finger for spin grind A. Rotate index finger assembly to Clears--Proceed to next system
spin position error message you have or con-
tinue running.
Remains--go to Step B. next

B. Check (PLC) input from Finger From "Help" Screen verify Fin-
Stored/Down prox ger Stored/Down prox input is
on (Red) Follow instructions on
screen.

Rotate head down for A. Rotate grind head assmbly down Clears--Proceed to next system
spin grind error message you have or
Continue running.
Remains--go to Step B. next

B. Check (PLC) input from Head in From "Help" Screen verify Head
Relief Pos. (Position) prox in Relief Pos. prox input is
working. Follow instructions on
screen.

Home Traverse (To Right A. Jog Grind head to right prox with Clears--Proceed to next system
Prox) to start touch screen controls error message you have or
Continue running.
Remains--go to Step B. next

From "Help" Screen verify Right

B. Check (PLC) input from Right Traverse Prox input is working.
Traverse prox switch Follow instructions on screen.

Rotate head up for Relief A. Rotate grind head assmbly up Clears--Proceed to next system
Grind error message you have or
Continue running.
Remains--go to Step B. next

From "Help" Screen verify Head

B. Check (PLC) input from Head in in Relief Pos. prox input is
Relief Pos. prox working. Follow instructions on
screen.

44
 - ORIGINAL INSTRUCTIONS
electrical troubleshooting (Continued)
System Error Message Checkout Procedure Message Status

Release finger for relief A. Release finger. Make sure Clears--Proceed to next system error
that the finger is allowed to come message you have or continue running.
foreward at least once. Remains--go to Step B. next

B. Check (PLC) input from Door From "Help" Screen verify Finger
Saftey Switch Stored / Down prox input is working.
Follow instructions on screen.

Enter number of blades A. Blade count is required to run Clears--Proceed to next system error
Relief grind. Count blades and message you have or continue running.
enter the number under the
Blade # Field.

Low Voltage detected A. Input line voltage has dropped Clears--Proceed to next system error
below 100V. Plug machine into message you have or continue running.
a better source of power. See
Power requirements at front of
manual.

Door must be closed to A. For safety reasons, door must Clears--Proceed to next system error
operate be closed to operate spin and / message you have or continue running.
or grind motors. Close and latch Remains--go to Step B. next
door.

B. Check (PLC) input from Door From "Help" Screen verify Head in
Saftey Switch Relief Pos. prox input is working.
Follow instructions on screen.

Increase torque knob A. An excessive amount of Clears--Proceed to next system error

setting time has passed between blade message you have or continue running.
indexes or at the start of a relief
cycle. Increase the Relief Torque
Pot.

Torque knob low or A. An excessive amount of time Clears--Proceed to next system error
direction wrong has passed at the beginning of a message you have or continue running.
Relief grind cycle before the finger
down prox was detected. Verify
Torque pot setting and / or spin
direction. Reminder: Blade
should push finger down.

45
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

PROBLEM--No Manual (jog) cycle or Auto Cycle stops because of a system error
message on Touch Screen (Continued)

System Error Message Checkout Procedure Message Status

Finger not A. During a relief grind cycle, the Clears--Proceed to next system
released, check PLC did not see the finger released error message you have or con-
lh prox pos at the left prox position. Verify that tinue running.
(Position) the setting of the left traverse prox al- Remains--go to Step B. next
lows the finger to come off the blade.

B. Check (PLC) input from Finger From "Help" Screen verify Fin-
Stored/Down prox ger Stored/Down prox input is
Working. Follow instructions on
screen.

Move not possible in A. Press "Resume" on touch screen Clears--Proceed to next system
pause mode to finish current cycle. error message you have or
Continue running.

Machine is in pause A. Machine was left in pause mode Clears--Proceed to next system
mode, press resume after last cycle. Press "resume" on error message you have or
touch screen. Continue running.

door opened while grind A. Door was opened while poten- Clears--Proceed to next system
Dnd / or spin on tially dangerous operations were still error message you have or
on. Turn off motors, pause, or finish Continue running.
cycle before opening doors.

Increase traverse knob

setting A. An excessive amount of time has Clears--Proceed to next system
passed at the beginning of an auto error message you have or
cycle before the grind head assy. has Continue running.
moved. Increase Traverse Speed pot
or check that carriage is not released.
Traverse Timeout, check
pot or setup A. An excessive amount of time Clears--Proceed to next system
has passed during a traverse cycle. error message you have or
Increase Traverse Speed pot or verify Continue running.
that carriage assembly is not re-
leased or hitting an obstruction.

46
electrical troubleshooting (Continued) - ORIGINAL INSTRUCTIONS

System Error Message Checkout Procedure Message Status

Accept values before run- A. Before an auto cycle can be Clears--Proceed to next system error
ning started, verify the values in the dis- message you have or continue run-
played boxes and accept them by ning.
pressing the "Accept Values" button
on the touch screen.

Open door to reset light A. Before an auto cycle can be Clears--Proceed to next system error
started, the last cycle completed message you have or continue run-
must be cleared. Open the door or ning.
press the "Cycle Complete" button
on the main screen to reset.

47
 - ORIGINAL INSTRUCTIONS
electrical troubleshooting (Continued)
PROBLEM--Flasher light does not turn on at end of automatic cycle.

In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-Touch
Wiring Diagram, before starting the troubleshooting below. Verify all wires shown on that
drawing are correct and pull on wire terminals with approximately 3 lbs force to verify there are no
loose terminals. If loose terminals are found, tighten and retest system. If problem persists, test as
listed below.

Possible Cause Checkout Procedure

Bulb is burned out A. Remove bulb and test continuity Bulb- Measure approx 300 Ohms
Yes--go to Step B. next
No--Replace bulb

No 115 Volts AC to flasher B. After a cycle has completed, (RT1) Term. 7+ to Blue Term Block 17
measure voltage to Flasher. Measure 115 Volts AC
Yes-- Verify continuity in cord,
Replace flasher
No-- go to step C. next

Relay 7 (RT1) is bad C. After a cycle has completed, Light is on:

check (RT1) for light 7 to be on Yes-- go to step D. next
No-- Contact Factory

D. Check continuity of relay 7 (RT1) Term 7+ to 7- Measure 115 Volts

(Terminal 7+ and 7- are on the left AC
side of RT1) Yes-- Replace Relay 7 (RT1)
No-- go to step E. next

Circuit Breaker (CB32) E. Reset CB32 Press in on Circuit breaker CB32 on front
tripped of control panel. Works
Yes--End Troubleshooting
No-- Replace CB32

48
ELECTRICAL TROUBLESHOOTING (Continued) - ORIGINAL INSTRUCTIONS

PROBLEM-- Error Message "DOOR MUST BE CLOSED TO OPERATE" is present with doors closed
when turning on the spin motor, grind motor, or atuo mode.

In your Product Packet Assembly, there are a series of prints. Find the print titled ACCU-Touch Wiring
Diagram, before starting the troubleshooting below. Verify all wires shown on that drawing
are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose
terminals. If loose terminals are found, tighten and retest system.
Possible Cause Checkout Procedure

Guard Doors are A. Close the front doors and rear Machine works
Open slide up door or workstation ramp Yes--end troubleshooting
depending on option installed. No--go to Step B. next

Door Safety Switch- B. Check Alignment of Door Safety See Alignment section of this Manual.
es are not aligned Switches on Front doors Machine works
properly Yes--end troubleshooting
No--go to Step C. next

No 24 Volts DC C. Check SSM for 24 Volts DC. Measure 24 volts DC from SSM Terminal A1+
to Safety Monitor (Screen must NOT be in E-Stop) to Terminal A2-
(SSM) Yes--Go to Step D. next.
No--Verify continuity of wires 64 and 66.

No Power Out to D. Verify 24Volts DC out to Door Measure approximately 24 volts DC from
Door Switches Switches. Terminal Strip 2 Terminal 3 to terminal S2 -C
(Left side of SSM, Top screw (toward touch
screen))
Yes--Go to Step E. next.
No--Verify Continuity of Wires to Terminal
strip2 , Replace SSM if wires check OK.

Front Door Switch is E. With Front doors Closed Verify Measure approximately 24 volts DC from
Bad 24Volts DC back form Front Door Terminal S2-C on SSM to Terminal Strip 2
Switch. Terminals 2 and 4.
Yes--Go to Step F. next.
No--Check Alingment of Front door switch. If
no Voltage to Term2 or 4 then replace front
switch.

Relay on Safety F. With door closed the Green light Green light on SSM is ON when door is
should be ON. (If not check the closed and goes OFF when the door is
Monitor is bad opened.
jumper wires on SSM at terminals
S2 termial c, S22 and S32) Yes--Go to Step G. next.
No-Check installation of jumper wires on
SSM at S2 terminals C, S22 and S32.
Replace SSM if everything else checks out.
G. With door closed and the Green Measure approximately 24 Volts DC from
light on the SSM ON. Check for Terminal A+ on SSM to Terminal 13 on SSM
power out of SSM at terminal 13. (wire labeled 69SSM-13)
Yes--Go to Step H. next.
No-Replace SSM.

Light on PLC next to XO is on?

Bad input Ribbon H. Look for light on PLC labeled Yes--Machine should work. Verify by going
Cable to PLC XO to be on. to the Help screen on the touch screen.
Contact the factory if not working.
No--Check continutiy of wires from SSM
to PLC. [components involved: input rib-
bon cable (6529030), Wires not properly
connected in terminal block below PLC, or
bad wire #69 from SSM to terminal block
(69INP-xO).]
49
 - ORIGINAL INSTRUCTIONS
Mechanical troubleshooting

Possible Cause Checkout Procedure

Problem--Reels ground have high/low blades.

Traverse Speed set to 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 Relubricate and adjust linear bearings per adjustment
carriage are out of adjustment (loose) section. If problem persists, replace lineal bearings on
or have grit buildup causing uneven the carriage base. Check for any holes in the bellows that
traversing load. would permit any grinding grit penitration. 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 Tighten the set screws for the gib adjustment. See
assembly is loose so reel finger has procedure in the adjustment section in the manual.
movement. When traversing to the right
minimum grinding stock removal should
be seen as compared with heavy stock
removal when traversing to the left.

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

Lineal bearings on the grinding head The lineal bearing must be preloaded to the traverse
carriage are too loose. shafts with no vertical movement. See manual adjustment
section for carriage linear bearing adjustments.

Problem--Carriage traversing varies speed while grinding.

Lineal bearings in the carriage do not Check for grinding grit getting into the lineal bearings
rotate freely. and cause 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.

Traverse Belt is slipping.

Check the spacing of the clamp to the support block.
Clamp tip may need to be adjusted if the belt is slipping.
The belt may also be too loose. See Adjustments section
for proper measurements of clamp gap and belt tension.

50
Mechanical troubleshooting (continued) - ORIGINAL INSTRUCTIONS

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

Possible Cause Checkout Procedure

Traverse speed set to high causing a heavy Traverse speed should be set lower approximately 12 ft/min.
burr on the reel blade when spin grinding. [4 meters/min.] for a smaller burr on cutting edge.

Problem--Cone shaped reel after grinding.

Grinding head travel not parallel to the reel Grinding head travel was not setup parallel to the reel center
center shaft. 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 The right hand side of the grinding wheel is not in full
is always to be in contact with the reel contact for relief grinding.
blade. This is high point of the relief finger. See Operator's Manual for normal helix and
reverse helix for information of dressing the grinding
wheel.

51
PARTS LIST 6329549 CANOPY ASSEMBLY

5
6 42
52

43
4
22
30 11
12
11 4
50
6 12 57 41 12
56
15
9 54
8 49
11
3 55
32 47
37 11
4 8
31 10 2
38 40
40 11
8 30
33 6
36 9
20
53 32

23 28
23
2

44 1 39
51 27 11
13
48
23 24
35 4
26
2
29

17 8
17 18
16
18
16 16 25
19 18
1 34 34
21

14

52
PARTS LIST 6329549 CANOPY ASSEMBLY
DIAGRAM PART
NUMBER NUMBER DESCRIPTION
1.............................................B250816..................... Button Head Cap Screw 1/4-20 x 1/2 Long
2.............................................B250801..................... Hex Head Cap Screw 1/4-20 x 1/2 Long
3.............................................B251616..................... Button Head Cap Screw 1/4-20 x 1 Long
4.............................................B371216..................... Button Head Cap Screw 3/8-16 x 3/4 Long
5.............................................B371611..................... Socket Head Cap Screw 3/8-16 1 Long
6.............................................J257000...................... 1/4-20 Nylon Jam Locknut
7.............................................B372016..................... Button Head Cap Screw 3/8-16 x 1 1/4 Long
8.............................................J377000...................... 3/8-16 Nylon Jam Locknut
9.............................................K250001..................... 1/4 Flat Washer
10...........................................K251501..................... 1/4 Split Lockwasher
11............................................K370001..................... 3/8 Flat Washer SAE
12...........................................K371501..................... 3/8 Split Lockwasher
13...........................................3706036..................... Compression Spring .72 OD x 1.25 long
14...........................................09394......................... 2 Prong Knob
15...........................................3589106..................... Flat Washer (1.38 OD x .39 ID)
16...........................................3707009..................... Liquid Tight Strain Relief .27-.47 Wire
17...........................................3707029..................... Liquid Tight Strain Relief .19-.30 Wire
18...........................................3707093..................... Liquid Tight Strain Relief .43-.55 Wire
19...........................................3707595..................... 7/8 Hole Plug
20...........................................6329146..................... Catch Plate
21...........................................3708448..................... Electrical Warning Decal
22...........................................J197000...................... 10-24 Lock Nut - Jam
23...........................................3706037..................... Shoulder Bolt 1/5 OD x 3/4 long
24...........................................3708605..................... Respirator Warning Decal
25...........................................3708606..................... Hearing Protection Warning Decal
26...........................................3708612..................... No Fuel Warning Decal
27...........................................3708703..................... Multiple Safety Symbols Decal
28...........................................3707279..................... Strain Relief
29...........................................3708872..................... Patent Decal
30...........................................3709990..................... Foley United Decal
31...........................................3706044..................... Gage Mounting Pin
32...........................................6329022..................... Side Frame Spacer Plate
33...........................................6329024..................... Canopy Boom Support Bracket
34...........................................R000536..................... Internal Tooth Lock Washer 1/4
35...........................................6329053..................... ACCUPro Decal
36...........................................3708214..................... Conical Washer .69 Dia
37...........................................3708861..................... Conical Washer .69 Dia
38...........................................3859016..................... Spacer 3/4 OD x .25 Thick
39...........................................6329059..................... Canopy Support Bracket
40...........................................6329148..................... Door Overhead Arm
41...........................................6329543..................... Guard Weldment RH
42...........................................6329542..................... Guard Weldment LH
43...........................................6329112...................... Boom Hole Cover Panel
44...........................................6329533..................... Front Guard Door Assembly (see page 55)
45...........................................R000480..................... #8 Lock Washer
46...........................................R000558..................... #8-32 Kep Nut
47...........................................6529019..................... Flasher Base Assembly
48...........................................6329144..................... Door Catch Bracket RH
49...........................................6329109..................... Rear Right Hand Guard Panel
50...........................................6329110...................... Rear Left Hand Guard Panel
51...........................................6329145..................... Door Catch Bracket LH
52...........................................B190613..................... 10-24 x 3/8 Long Button Head Socket Cap Screw
53...........................................4609063..................... Spacer .63 OD x .25 Long
54...........................................3706133.....................
55...........................................3706134.....................
56...........................................3706135.....................
57...........................................3706136.....................

53
PARTS LIST 6329533 FRONT GUARD DOOR ASSEMBLY

54
PARTS LIST 6329533 FRONT GUARD DOOR ASSEMBLY

DIAGRAM PART
NUMBER NUMBER 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.............................. 3706042............................. Pan Head 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

...............................................

55
PARTS LIST 6329575 REAR SLIDE UP GUARD DOOR ASSEMBLY

56
PARTS LIST 6329575 REAR SLIDE UP GUARD DOOR ASSEMBLY
DIAGRAM PART
NUMBER NUMBER DESCRIPTION
1.............................. B190411............................. Socket Head Cap Screw 10-24 x 1/4 Long
2.............................. B190613............................. Button Head Socket Cap Screw 10-24 x 3/8 Long
3.............................. B250816............................. Button Head Socket Cap Screw 1/4-20 x 1/2 Long
4.............................. B251016............................. Button Head Socket Cap Screw 1/4-20 x 5/8 Long
5.............................. B251216............................. Button Head Socket Cap Screw 1/4-20 x 3/4 Long
6.............................. B310813............................. Button Head Socket Cap Screw 5/16-18 x 1/2 Long
7.............................. B370801............................. Hex Head Cap Screw 3/8-16 x 1/2 Long
8.............................. B370816............................. Button Head Socket Cap Screw 3/8-16 x 1/2 Long
9.............................. B372001............................. Hex Head Cap Screw 3/8-16 x 1-1/4 Long
10............................ B372016............................. Button Head Socket Cap Screw 3/8-16 x 1-1/4 Long

11............................. B372401............................. Hex Head Cap Screw 3/8-16 x 1-1/2 Long

12............................ B372416............................. Button Head Socket Cap Screw 3/8-16 x 1-1/2 Long
13............................ H371202............................ 3/8 Diameter Roll Pin x 3/4 Long
14............................ J167000............................. #8-32 Jam Locknut
15............................ J191000............................. #10-24 Jam Locknut
16............................ J252000............................. 1/4-20 Hex Jam Nut
17............................ J257000............................. 1/4-20Jam Locknut
18............................ J257100............................. 1/4-20 Locknut Full
19............................ J371000............................. 3/8-16 Hex Nut

20............................ J377000............................. 3/8-16 Jam Locknut

21............................ J627100............................. 5/8-11 Locknut
22............................ K190001............................. #10 Flat Washer
23............................ K191501............................. #10 Lock Washer
24............................ K250001............................. 1/4 Flat Washer
25............................ K251501............................. 1/4 Lock Washer
26............................ K370001............................. 3/8 Flat Washer
27............................ K371501............................. 3/8 Lock Washer
28............................ 09054................................. Flat Washer .63 OD x .39 ID
29............................ 55492................................. Door Switch Spacer

30............................ 80406................................. Flat Washer .5 OD x .27 ID

31............................ 80418................................. Gas Spring Stud
32............................ 80421................................. Retaining Clip for Gas Spring
33............................ 3249153............................. Flat Washer .38 OD x .25 ID
34............................ 3706032............................. Ball Bearing R10
35............................ 3706097............................. Pulley 1.75 OD x .37 ID
36............................ 3706098............................. Pulley 1.50 OD x .25 ID
37............................ 3706099............................. Clevis Rod End
38............................ 3706100............................. Gas Spring 3.9 Stroke
39............................ 3706101............................. Cable Assembly

40............................ 3707279............................. Strain Relief

41............................ 3707647............................. Coded Door Magnet
42............................ 3708820............................. #8-32 x 1/2 Long Button Head Safety Screw
43............................ 3708869............................. Spring Hinge
44............................ 3708998............................. Wave Spring
45............................ 3709597............................. Ball Bearing R4
46............................ 6209165............................. Lower Guide Bar
47............................ 6329131............................. Catch
48............................ 6329133............................. Catch Pin
49............................ 6329136............................. Rear Slide Spacer Plate

57
PARTS LIST 6329575 REAR SLIDE UP GUARD DOOR ASSEMBLY

58
PARTS LIST 6329575 REAR SLIDE UP GUARD DOOR ASSEMBLY

DIAGRAM PART
NUMBER NUMBER DESCRIPTION
50............................ 6329163............................. Rear Door Arm
51............................ 6329164............................. Pulley Block
52............................ 6329165............................. Door Switch Bracket (Rear Door)
53............................ 6329166............................. Cable Guide
54............................ 6329167............................. Bearing Block
55............................ 6329172............................. Rear Door Inner Slide
56............................ 6329173............................. Cable Bracket (Door)
57............................ 6329174............................. Rear Door Lift Handle
58............................ 6329175............................. Rear Door Stiffener
59............................ 6329177............................. Rear Door Sliding

60............................ 6329179............................. Rear Door Outer Plate

61............................ 6329180............................. Door Stop Block
62............................ 6329181............................. Hinged Walker Panel
63............................ 6329182............................. Door Stop Spacer Plate
64............................ 6329183............................. Door Catch Bracket

67............................ 6329184............................. Door Switch Assembly

68............................ 6509040............................. Panel Acess LH Small

...............................................

59
PARTS LIST 6329545 MAIN CABINET ASSEMBLY

60
PARTS LIST 6329545 MAIN CABINET ASSEMBLY

DIAGRAM PART DESCRIPTION

NUMBER NUMBER
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
15............................................... K311501......................... 5/16 Split Lockwasher
16............................................... K371501......................... 3/8 Split Lockwasher
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............................................... 3706044......................... Gage Pin Mounting
28............................................... 6329098......................... 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............................................... B250816......................... 1/4-20 x 1/2 Button Head Socket Cap Screw
47............................................... 50382............................. Hinge
48............................................... 3659083......................... Bumper
49............................................... 3708458......................... Warning Decal - Sharp
50............................................... B370816......................... 3/8-16 x 1/2 Button Head Socket Cap Screw

61
PARTS LIST 6329525 TRAVERSE BASE ASSEMBLY

62
PARTS LIST 6329525 TRAVERSE BASE ASSEMBLY

DIAGRAM PART
NUMBER 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
7................... B251211...................Socket Head Cap Screw 1/4-20 x 3/4 Long
8................... B251411...................Socket Head Cap Screw 1/4-20 x 7/8 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

11.................. B256411...................Socket Head Cap Screw 1/4-20 x 4 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
14................. B503211...................Socket Head Cap Screw 1/2-13 x 2 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
24................. K311501...................5/16 Split Lockwasher
25................. K501501..................1/2 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

63
PARTS LIST (Continued) 6329525 TRAVERSE BASE ASSEMBLY

64
PARTS LIST (Continued) 6329525 TRAVERSE BASE ASSEMBLY

DIAGRAM PART
NUMBER 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 6.00 Long (Prior to 8-08)
........................... 6329141...................Motor Extension Shaft 5.75 Long (After 8-08)
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)

65
PARTS LIST 6509565 CROSS SLIDE ASSEMBLY

66
PARTS LIST 6509565 CROSS SLIDE ASSEMBLY

DIAGRAM PART DESCRIPTION

NUMBER NUMBER

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
25.......................................K371501..................3/8 Split Lockwasher
26.......................................6509010..................Traverse Base Adjuster Bracket

67
PARTS LIST 6329526 GRINDING HEAD ASSEMBLY

68
PARTS LIST 6329526 GRINDING HEAD ASSEMBLY
DIAGRAM PART
NUMBER NUMBER 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....................... 6509494....................... 9/16-18 Spindle Nut
19....................... 6329523....................... Grinding Head Spindle Assembly
20....................... 6509237....................... Grinding Wheel knob

21............................................................ Grinding Wheel (see page 93)

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

69
PARTS LIST 6329527 CARRIAGE ASSEMBLY

70
PARTS LIST 6329527 CARRIAGE ASSEMBLY

DIAGRAM PART
NUMBER 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

71
PARTS LIST 6309573 FINGER AND BODY ASSEMBLY

72
PARTS LIST 6309573 FINGER AND BODY ASSEMBLY

DIAGRAM PART
NUMBER 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
18.......................................3708107.................. Compression Spring
19.......................................3708175.................. Compression Spring
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 - High
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

............................................... 73
PARTS LIST 6509574 STEPPER & MOUNTING ASSEMBLY

74
PARTS LIST (Continued) 6509574 STEPPER & MOUNTING ASSEMBLY
DIAGRAM
NO. PART NUMBER DESCRIPTION

1 B190613 Button Head Cap Screw #10-24 x 3/8 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 6509381 Base Cover Plate

6 J377200 3/8-24 Nylok Jam Locknut

7 6509384 Infeed Stepper Assy.
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 3708629 Flex Coupling

16 3708424 Spiral Retaining Ring

17 B190811 Socket Head Cap Screw 10-24 x 1/2 Long
18 K191501 No. 10 Lock Washer
19 6509470 Stepper Infeed Motor

75
PARTS LIST 6329535 MOWER SUPPORT ASSEMBLY

76
PARTS LIST 6329535 MOWER SUPPORT ASSEMBLY

DIAGRAM PART
NUMBER NUMBER 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

77
PARTS LIST 6509465 SPIN DRIVE ASSEMBLY

78
PARTS LIST (Continued) 6509465 SPIN DRIVE ASSEMBLY

DIAGRAM PART
NUMBER NUMBER DESCRIPTION
1.........................................6329160............................. Gearmotor, DC (Spin)
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

79
PARTS LIST 6329529 MISCELLANEOUS PARTS

4
35 3
36
5
2
34
1
31
39 24

28
29 25
27
38
23

32
33 17 22
13
19
20

30
7
16 18 40
37
6
15
14
21

41
8 24

11
9
25
10

23 26
12

13

80
PARTS LIST (Continued) 6329529 MISCELLANEOUS PARTS
DIAGRAM PART
NUMBER NUMBER DESCRIPTION

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

2.............................. 3700086............................. Grinding Wheel 3.5" Dia. x 1" Wide
3.............................. 3700087............................. Grinding Wheel 5" Dia. x .38" Wide
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.............................. 6329555............................. Alignment Extension Weldment
10............................ 6329518............................. Gage Bar Weldment

11............................. 6509349............................. Retaining Plate

12............................ 6509418............................. Plate-Pivot
13............................ 3708094............................. Adjustable Handle 5/16-18 x 1.25 Long
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
................................ 3707712............................. Battery Cover - Digital Gage

21............................ 6329556............................. 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
28............................ 3707603............................. Blue Lens
29............................ 3707465............................. Flasher bulb

* 3700089- Grinding wheel is installed on grinding head when shipped. The other wheels are located in the carton assembly.
81
PARTS LIST 6529525 CONTROL PANEL ASSEMBLY

4/8/2014 11:57 AM 6529528.SLDDRW

8
18
12
10
9
11 16
7
6
21

13

26
23
25

24

1 15
4 17
14
2

19

1
5

20

22

82
PARTS LIST 6529525 CONTROL PANEL ASSEMBLY

DIAGRAM PART
NUMBER NUMBER DESCRIPTION

1.........................................B190834..................Button Head Cap Screw 10-32 x 1/2 Long

2.........................................B250816..................Button Head Cap Screw 1/4-20 x 1/2 Long
3.........................................D250800..................Thread Cutting Screw 1/4-20 x 1/2 Long
4.........................................J257000..................1/4-20 Nylon Jam Locknut
5.........................................R000536..................1/4 Lock Washer
6.........................................3707342..................Yellow Emergency Stop Ring
7.........................................3707367..................Rocker Switch DPST
8.........................................3707399..................3-Amp Circuit Breaker
9.........................................3707442..................2-Amp Circuit Breaker
10.......................................3707443..................4-Amp Circuit Breaker

11........................................3707446..................Potentiometer Knob
12.......................................3707547..................15-Amp Circuit Breaker
13.......................................3707564..................Green Start Pushbutton
14.......................................3707565..................Normaly Open Contact Block
15.......................................3707566..................Switch Mounting Latch
16.......................................3707567..................Push/Pull Red Emergency Stop Button
17.......................................3707568..................Normaly Closed Contact Block
18.......................................3707725..................Touch Screen
19.......................................6329070..................Hinge
20.......................................6329509..................Control Box Weldment

21.......................................6529051..................Control Panel Decal

22.......................................6529526..................Electrical Panel Sub-Assembly
23.......................................6529545..................Control Panel Top Weldment
24.......................................6529053..................Potentiometer Assembly - Spin Speed
25.......................................6529052..................Potentiometer Assembly - Relief Torque
26.......................................6509049..................Potentiometer Assembly - Traverse Speed
27.......................................3707624..................2 Conductor Terminal Block - Ground
28.......................................3707626..................Terminal Block Jumper
29.......................................3707628..................2 Conductor Terminal Block - Grey

Cords Not Shown

...........................................6329078..................Main Power Cord

...........................................6529036..................Light Receptacle
...........................................6529037..................Dust Collector Receptacle
...........................................6529039..................Flasher Cord
...........................................6329124..................Rear Sliding Door Safety Swich Cord
...........................................3707224..................Cable Tie Mount
...........................................3707225..................Cable Tie 6.5 Long x .18 Wide
...........................................3707255..................Cable Tie 4.0 Long x .10 Wide

...........................................
83
PARTS LIST 6529528 CONTROL PANEL SUB-ASSEMBLY
4/1/2014 6529529.SLDDRW 3:46 PM

2
2
2
1
19
11 1
17
12
27
25 29
27
26 13 7
22
20 30 18 6
2 28
29
29
5 27
28
3 32
21 2
24
16 30
10
5 25
26
33 28
14
2 26

15
9
8
4

31

84
PARTS LIST 6529526 CONTROL PANEL SUB-ASSEMBLY

DIAGRAM PART
NUMBER NUMBER DESCRIPTION

1.........................................D130608..................Pan Head Self-Tapping Screw #6 x 3/8 Long

2.........................................D160666..................Pan Head Self-Tapping Screw #8 x 3/8 Long
3.........................................D161266..................Pan Head Self-Tapping Screw #8 x 3/4 Long
4.........................................R000480..................#8 Lockwasher
5.........................................55223......................Terminal Strip Decal
6.........................................80259......................20-Amp Main Circuit Breaker
7.........................................3707073..................8-Pin socket
8.........................................3707163..................Primary Ground Decal
9.........................................3707164..................Primary Ground Lug
10.......................................3707186..................24VDC Contactor

11........................................3707697..................Traverse Control Board

12.......................................3707839..................Power Supply 50 Watt - 24VDC
13.......................................3707328..................Door Safety Switch Monitor
14.......................................3707378..................14" Din Rail
15.......................................3707764..................Power Line Filter
16.......................................3707447..................Relay - DPDT 120VAC Coil
17.......................................3707830..................Spin/Relief Control Board
18.......................................3707556..................Magnetic Starter
19.......................................3707688..................Low Voltage Sensor Relay
20.......................................3707569..................Aromat PLC

21.......................................3707571..................Output Block with Relays

...........................................3707574..................5-amp Relay
22.......................................3707577..................Stepper Drive - 2-Amp
23.......................................3707593..................6Pin Terminal Strip (for Stepper Drive)
24.......................................3707606..................9" Din Rail
25.......................................3707624..................2-Conductor Terminal Block - Ground
26.......................................3707625..................Screwless Terminal Bock End Stop
27.......................................3707626..................Terminal Block Jumper
28.......................................3707627..................Terminal Block End Plate
29.......................................3707628..................2-Conductor Terminal Block - Grey
30.......................................3707629..................2-Conductor Terminal Block - Blue

32.......................................6529031..................Electrical Sub Panel

...........................................3707631..................Terminal Block Marker - 1-10
...........................................3707632..................Terminal Block Marker - 11-20
...........................................3707656..................Ground Wire Assembly W99
...........................................6509449..................PLC to Output Block Cable
...........................................6529047..................PLC to Touchscreen Cable
...........................................6529030..................PLC to Inputs Cable

...........................................

85
WIRING DIAGRAM 6524528 - AC
CB42-4 AMP CKT BREAKER(SPIN)
CB28-15 AMP CKT BREAKER(GRIND)
CB13-2 AMP CKT BREAKER (DC PWR)
CB32-3AMP CKT BREAKER (TRAVERSE)
ESS- EMERGENCY STOP SWITCH
FTR- FILTER
INP- INPUT TERMINAL BLOCK
LVR- LOW VOLTAGE RELAY
MAG- MAGNETIC STARTER
MCB- MAIN CIRCUIT BOARD 20 AMP
PLC- PROGRAMMABLE LOGIC
CONTROLLER
PSW- POWER SWITCH CONTROL BOX
PWR- DC POWER SUPPLY
REL- GRIND MOTOR RELAY
RT-1 RELAT TERMINAL BLOCK
RTP- RELIEF TORQUE POT
SDC- SPIN DRIVE CONTROL
SIC- STEPPER INFEED CONTROL
SSM- SAFETY SWITCH MONITOR
SSP- SPIN SPEED POT
SSS-SYSTEM START SWITCH
TB1-TERMINAL BLOCK 1
TB2- TERMINAL BLOCK 2
TBB- TERMINAL BLOCK BLUE
TBG- TERMINAL BLOCK GREY
TCH- TOUCH SCREEN
TDC- TRAVERSE DRIVE CONTROL
TSP- TRAVERSE SPEED POT

GROUND SCREW

WIRE CONNECTION

TERM. TO TERM CONNECTION

86
WIRING DIAGRAM 6524528 - AC

87
WIRING DIAGRAM 6524525 - DC
CB42-4 AMP CKT BREAKER(SPIN)
CB28-15 AMP CKT BREAKER(GRIND)
CB13-2 AMP CKT BREAKER (DC PWR)
CB32-3AMP CKT BREAKER (TRAVERSE)
ESS- EMERGENCY STOP SWITCH
FTR- FILTER
INP- INPUT TERMINAL BLOCK
LVR- LOW VOLTAGE RELAY
MAG- MAGNETIC STARTER
MCB- MAIN CIRCUIT BOARD 20 AMP
PLC- PROGRAMMABLE LOGIC
CONTROLLER
PSW- POWER SWITCH CONTROL BOX
PWR- DC POWER SUPPLY
REL- GRIND MOTOR RELAY
RT-1 RELAT TERMINAL BLOCK
RTP- RELIEF TORQUE POT
SDC- SPIN DRIVE CONTROL
SIC- STEPPER INFEED CONTROL
SSM- SAFETY SWITCH MONITOR
SSP- SPIN SPEED POT
SSS-SYSTEM START SWITCH
TB1-TERMINAL BLOCK 1
TB2- TERMINAL BLOCK 2
TBB- TERMINAL BLOCK BLUE
TBG- TERMINAL BLOCK GREY
TCH- TOUCH SCREEN
TDC- TRAVERSE DRIVE CONTROL
TSP- TRAVERSE SPEED POT

GROUND SCREW

WIRE CONNECTION

TERM. TO TERM CONNECTION

88
WIRING DIAGRAM 6524525 - DC

89
WIRING SCHEMATIC

90
WIRING SCHEMATIC

91
WIRING SCHEMATIC

92
WIRING SCHEMATIC

93
WIRING SCHEMATIC
5
100(+)
301 FROM LINE
3-110

302

303

304

305

306

307

308 OUTPUTS - RELAY TERMINAL BLOCKS (RT1)

RT1-Y2
309
TRAVERSE RIGHT
OUTPUT SEE -LINE 2-38
310
RT1-Y3
311
TRAVERSE LEFT
OUTPUT SEE -LINE 2-39
312
RT1-Y4
313
SPEED ON/TORQUE OFF
OUTPUT SEE -LINE 2-45
314
RT1-Y5
315
GRIND DRIVE POWER
OUTPUT SEE -LINE 3-112
316

317

318
RT1-Y7
319
FLASHING LIGHT
OUTPUT SEE -LINE 2-32
320

321

322

323

324 94
WIRING SCHEMATIC 6
100(+)
326 FROM LINE
5-325

327

328

329
RT1-Y8
330
TRAVERSE DRIVE POWER
OUTPUT SEE - LINE 2-36
331

RT1-Y9
332
SPIN DRIVE POWER
333 OUTPUT SEE -LINE 2-44

RT1-YA
334
SPIN DIRECTION A
OUTPUT SEE -LINE 2-45
335
RT1-YB
336
SPIN DIRECTION B
OUTPUT SEE -LINE 2-46
337
RT1-YC
338
SPIN DIRECTION B'
OUTPUT SEE -LINE 2-47
339
RT1-YD
340
SPIN DIRECTION A'
341 OUTPUT SEE -LINE 2-48

RT1-YE
342
VACUUM ON
OUTPUT SEE -LINE 2-34
343
RT1-YF
344
E-STOP LOOP
OUTPUT SEE -LINE 1-13
345

346

347

348

349

350 95
PLC INPUT AND OUTPUT LIGHTS
PLC INPUT LIGHTS
X0 DOOR SAFETY SWITCH
LIT WHEN DOORS CLOSED
X1 LEFT TRAVERSE PROX
LIT WHEN ACTIVATED PLC
X2 RIGHT TRAVERSE PROX
LIT WHEN ACTIVATED
X3 FINGER POSITION PROX INPUT
LIT WHEN FINGER DOWN LIGHTS
X4 HEAD POSITION PRX
LIT WHEN HEAD IN RELIEF
X5 LOW VOLTAGE RELAY
LIT WHEN RELAY IS GREEN OUTPUT
X6 E – STOP LIGHTS
LIT WHEN E-STOP IS DOWN – PUSHED IN

PLC OUTPUT LIGHTS

Y0 STEP SIGNAL TO INFEED DRIVE
LIT WHEN INFEED MOVING (DIM)
Y1 DIRECTION SIGNAL TO INFEED DRIVE
LIT WHEN FEEDING OUT
Y2 TRAVERSE RIGHT TO TRAVERSE BOARD
LIT WHEN OUTPUTING
Y3 TRAVERSE LEFT TO TRAVERSE BOARD
LIT WHEN OUTPUTING
Y4 SPIN ON / TORQUE OFF TO SPIN BOARD
LIT WHEN IN SPIN POSITION
Y5 GRIND DRIVE POWER
LIT WHEN OUTPUTING
Y6 SPARE
Y7 FLASHING LIGHT
LIT WHEN OUTPUTING
Y8 TRAVERSE DRIVE POWER
LIT WHEN OUTPUTING
Y9 SPIN DRIVE POWER
LIT WHEN OUTPUTNG
YA SPIN DRIVE DIRECTION A (ON WITH YD)
LIT WHEN SPIN SET TO CW
YB SPIN DRIVE DIRECTION B (ON WITH YC)
LIT WHEN SPIN SET TO CCW
YC SPIN DRIVE DIRECTION B’ (ON WITH YB)
LIT WHEN SPIN SET TO CCW
YD SPIN DRIVE DIRECTION A’ (ON WITH YA)
LIT WHEN SPIN SET TO CW
YE VACUUM POWER
LIT WHEN OUTPUTING
YF E – STOP LOOP
LIT WHEN PROGRAM RUNNING & LVR IS GREEN

96