6,010,394 & 6,290,581 assembly and service manual · 6 service data skill and training required...

1

555AUTO - INDEXSPIN / RELIEF

REEL GRINDERPatent No. 5,321,9126,010,394 & 6,290,581

ASSEMBLYand

SERVICEMANUAL

55020 (10-05)

2

The Caution Symbol identifies specialinstructions or procedures which, if notstrictly observed, could result in damage toor destruction of equipment.

The Warning Symbol identifiesspecial instructions or procedureswhich, if not correctly followed,could result in personal injury.

Safety Awareness Symbols are insertedinto this manual to alert you to possibleSafety Hazards . Whenever you see thesesymbols, follow their instructions.

1. KEEP GUARDS IN PLACE and in workingorder.

2. REMOVE WRENCHES AND OTHERTOOLS.

3. KEEP WORK AREA CLEAN.

4. DON'T USE IN DANGEROUS ENVIRONMENT.Don't use Grinder in damp or wet locations.Machine is for indoor use only. Keep work areawell lit.

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

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

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

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

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

10. ALWAYS USE SAFETY GLASSES.

11. SECURE YOUR WORK. Make certain that thecutting unit is securely fastened with the clampsprovided before operating.

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

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

14. DISCONNECT POWER BEFORE SERVICING,or when changing the grinding wheel.

15. REDUCE THE RISK OF UNINTENTIONALSTARTING. Make sure all switches is OFF beforeplugging in the grinder.

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

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

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

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

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

SAFETY INSTRUCTIONS

3

SAFETY INSTRUCTIONS

IMPROPER USE OF GRINDING WHEEL MAY CAUSEBREAKAGE AND SERIOUS INJURY.

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

DO

1. DO always HANDLE AND STOREwheels in a careful manner.

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

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

4. DO CHECK MOUNTING FLANGES for equaland correct diameter.

5. DO USE MOUNTING BLOTTERS when suppliedwith wheels.

6. DO be sure WORK REST is properlyadjusted.

7. DO always USE A SAFETY GUARD COVERINGat least one-half of the grinding wheel.

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

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

DON'T

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

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

3. DON'T ever EXCEED MAXIMUM OPERATINGSPEED established for the wheel.

4. DON'T use mounting flanges on which the bearingsurfaces ARE NOT CLEAN, FLAT AND FREE OFBURRS.

5. DON'T TIGHTEN the mounting nut EXCESSIVELY.

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

7. DON'T start the machine until the WHEEL GUARDIS IN PLACE.

8. DON'T JAM work into the wheel.

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

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

AVOID INHALATION OF DUST generated by grinding and cutting operations. Exposureto dust may cause respiratory ailments. Use approved NIOSH or MSHA respirators,safety glasses or face shields, and protective clothing. Provide adequate ventilation toeliminate dust, or to maintain dust level below the Threshold Limit Value for nuisancedust as classified by OSHA.

4

TABLE OF CONTENTSThis 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 anyrepair work done by a qualified professional.

ALL operators of this equipment must be thoroughly trained BEFORE operatingthe equipment.

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

TABLE OF CONTENTS

Safety Instructions .................................................................................................................... Page 2-5Daily Maintenance .................................................................................................................... Service Data.............................................................................................................................. Page 6Assembly Instructions ............................................................................................................... Page 7-12Maintenance.............................................................................................................................. Page 13-19Adjustments .............................................................................................................................. Page 20-25Electrical Troubleshooting ......................................................................................................... Page 26-41Mechanical Troubleshooting ..................................................................................................... Page 42-43Exploded Views and parts Lists ................................................................................................ Page 44-75Wiring Diagram & Schematic ................................................................................................... Page 76-77

DAILY MAINTENANCE BY THE OPERATOR

On a daily basis, clean the machine by wiping it off.On a daily basis, remove all grinding grit from the grinding shaft, traverse shafts, and tooling bararea.On a daily basis, inspect the machine for loose fasteners or components.Contact your company's Maintenance Department if damaged or defective parts are found.

DO NOT USE COMPRESSED AIR TO CLEANGRINDING DUST FROM GRINDER

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

Low Voltage Relay

5

SAFETY INSTRUCTIONS

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

The Warning Symbol identifiesspecial instructions or procedureswhich, if not correctly followed,could result in personal injury.

PLEASE TAKE SPECIAL NOTE OF THE FOLLOWING WARNING DECALSLOCATED ON THE FRONT AND SIDES OF THE GRINDER.

The Caution Symbol identifies specialinstructions or procedures which , if notstrictly observed, could result in damageto, or destruction of equipment.

Symbol for Read operatorsmanual, wear safetyglasses and disconnectpower before servicing. Symbol to keep visitors a safe

distance away from the grinder.

Symbol identifying a panel, cover,or area as having live electricalcomponents within.

Symbol for sharp object which willcause serious injury.

Symbol for minimum safe ratedRPM of grinding wheel.

Symbol for hearingprotection required whenoperating this machine.

Symbol that operator andpeople in close proximitymust wear respirators orhave an adequateventilation system.

Symbol to keep exposed gasolineor flammables away from thegrinder because it operates with alarge amount of sparks.

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SERVICE DATA

SKILL AND TRAINING REQUIRED FOR SERVICING

This Service Manual is designed for technicians who have the necessary mechanical and electricalknowledge and skills to reliably test and repair the 555 Spin/Relief Grinder. For those without the background,service can be arranged through your local distributor.

This section presumes that you are already familiar with the normal operation of the Grinder. If not, youshould read the operators manual, or do the servicing in conjunction with someone who is familiar with itsoperation.

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

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

Throughout this manual we refer to torquerequirements as "firmly tighten" or the like. For morespecific torque values, refer to the informationbelow.

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

Bolts Going Into a Thread Hole In AluminumUse the Grade 2 values in the table at the right.

Socket-Head Screws Going Into a Nut or SteelUse the Grade 8 values in the table at the right.

Machine ScrewsNo. 6 screws: 11 in.- lbs (0.125kg - m)No. 8 screws: 20 in. - lbs (0.23 kg - m)No. 10 screws: 32 in. - lbs (0.37 kg - m)

TORQUE REQUIREMENTS

GRADE 2 GRADE 5 GRADE 8

SMOOTH 3 MARKS 6 MARKS HEAD on HEAD on HEAD

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





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Remove shipping straps and window protectivesheets.

ASSEMBLY INSTRUCTIONS

Remove the sides, front, and back of the crate.Remove the plastic bag, shrink wrap and bubblewrap. Remove the metal clips that secure thegrinder to the crate base. With a fork lift, raise thegrinder from the wood base and set it in its finalposition. See FIG. 22 and 23.

THE UNIT WEIGHS1450 LBS. [658 kg]. TOLIFT, USE POWEREQUIPMENT.

POSITION BASE

The 555 Spin/Relief Grinder will require an operating area of about 119" W x 127" D x 90" H (302 x 323x 229 cm). The machine operator will operate the unit from the front of the machine. Position the baseto allow sufficient operating room in front and to the rear of the machine. See FIG. 22 and 23.

The base should be placed on a relatively levelconcrete floor, with ample ceiling height to allow for the installation of the unit. Do not place the unitacross two concrete slab seams or across a large crack.

FIG. 22

FIG. 23

8

ASSEMBLY INSTRUCTIONS (Continued)

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

Multi position Brackets

Alignment Gage

Diamond Dresser

Drive Coupler

Raised RearSupport

Spanner WrenchProduct Packet Assembly(Operators & AssemblyManuals)

9


LEVEL BASE

Place level on the top of the table and check thelevelness of the unit from side to side. Adjust theleveling feet as necessary to bring to level. See FIG.25.

Place a level across the table from front to rear.Adjust the leveling feet on the end of the machineas necessary to level. See FIG. 26.

When both front to back and side to side levelingprocedures have been completed, thread the hexjam nuts up against the nut that is welded to thebottom until they lock into place. Be careful not tomove the leveling feet during this process. See FIG.24. Make certain that all four leveling feet are firmlycontacting the floor.

Recheck with level after locking nuts are firmlytightened.

FIG. 26

FIG. 25

FIG. 24

10


FIG. 27

APPLY POWER

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

115 Volt Model Only. Plug the control box power cord into astandard 115V AC 20-amp grounded receptacle. See FIG. 27.

220 Volt Model Only. For 220 Volt Applications order PartNo. 5550915 or 5550925, which includes a prewired 2 KVA220 V step down to 115V 50-60 Hz transformer. See detailson Page 11.

IT IS RECOMMENDED THAT THIS SPIN/RELIEF GRINDER HAS ITS OWNPERMANENT POWER CONNECTION FROMTHE POWER DISTRIBUTION PANEL, WITHNO OTHER MAJOR POWER DRAWEQUIPMENT ON THE SAME LINE.

IT IS REQUIRED THAT THE POWERDELIVERED TO THIS GRINDER IS 115 VAC -20 AMPS. THE TOLERANCE ON THISPOWER REQUIREMENT IS +/- 5%.THEREFORE THE MINIMUM VOLTAGEREQUIREMENT IS 109VAC WITH 20 AMPS.VOLTAGE MUST BE CHECKED WITH ALLEQUIPMENT UNDER LOAD (OPERATING) ONTHE CIRCUIT.

DO NOT OPERATE THIS GRINDER WITHAN EXTENSION CORD.

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

PROPER GROUNDING OF THERECEPTACLE GROUND IN YOUR BUILDINGMUST BE VERIFIED. IMPROPERGROUNDING IN YOUR BUILDING MAYCAUSE THE GRINDER TO MALFUNCTION.

FOR 20 AMP RATED LARGE MACHINESBelow is a list of required wire size in your building.

For 0 to 40 Feet from panel to receptacle = Use 12 Ga. Wire.For 40 to 60 Feet from panel to receptacle = Use 10 Ga. Wire.For 60 to 100 Feet from panel to receptacle = Use 8 Ga. Wire.For 100 to 160 Feet from panel to receptacle = Use 6 Ga. Wire.

For 0 to 12 Meters from panel to receptacle = Use 4.0mm Wire.For 12 to 18 Meters from panel to receptacle = Use 6.0mm Wire.For 18 to 30 Meters from panel to receptacle = Use 10.0mm Wire.For 30 to 48 Meters from panel to receptacle = Use 16.0mm Wire.

11

FOR 220 V 50 or 60Hz applicationsProduct No. 5550915 or 5550925should be ordered.

5550915 or 5550925 includes a2 KVA 220V, step down to 115 V50-60 Hz transformer.

The wiring diagram is shown in FIG.28.

The power cord has no connector. Aconnector which is appropriate foryour locality and 220 volt, 10 ampapplication should be installed.


FIG. 28

IMPORTANT GROUNDING INSTRUCTIONS

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

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

Before plugging in the Grinder, make sure it will be connected to a supply circuit protected by a properlysized circuit breaker or fuse.

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

ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FORYOUR MACHINE. AN IMPROPER CONNECTION CAN CAUSE ADANGEROUS ELECTRICAL SHOCK. IF YOU ARE UNSURE OFTHE PROPER ELECTRICAL GROUNDING PROCEDURE,CONTACT A QUALIFIED ELECTRICIAN.

USE ONLY A QUALIFIEDELECTRICIAN TO COMPLETETHE INSTALLATION.

12


FIG. 29

IINSTALLATION OF REEL LIFT ASSEMBLY ONMODEL 5550920

The reel lift has been fully assembled at the factory.The only installation required is to remove theshipping bolt and packing material between the liftramp and the lift body. See FIG. 29

SHIPPING BOLT

13

DO NOT GREASE BEARINGS FORFIRST 2 YEARS. THEY AREGREASED AT THE FACTORY ANDGREASING MAY CAUSE THEBEARINGS TO OVERHEAT AND FAILPREMATURELY.

1. Clean the dust tray located at the lowerfront of the machine monthly using avacuum or by removing it. Pull the trayout until the back of the tray is even withthe front of the frame and vacuum it out.To remove continue to pull straight outuntil the tray is free.

2. Inspect the Poly-V belt on the grindingmotor for cracking and make anynecessary adjustments every threemonths.

3. Wipe and relube with never-seez, thehorizontal adjustment shafts located onthe tooling every six months.

4. Wipe and relube with never-seez, thevertical adjustment shafts every sixmonths. Run the arms up and down tocoat the working areas of the shaft.

5. Inspect the traverse cog belt forcracking and defects every threemonths. Remove any grit or dust thatmay affect the function of the belt.Adjust tension if necessary perprocedures called out in the adjustmentsection.

6. Lubricate grinding shaft bearings withone shot of grease once every 2years.

DAILY MAINTENANCE IS SPECIFIED ON PAGE 4OF THE OPERATOR'S MANUAL, AND IS TO BEPERFORMED BY THE OPERATOR.

LISTED BELOW ARE PERIODIC MAINTENANCEITEMS TO BE PERFORMED BY YOURCOMPANY'S MAINTENANCE DEPARTMENT:

USE CAUTION WHEN PULLING THETRAY OUT AS THERE IS NOMECHANICAL STOP. WHENREMOVING TRAY PULL STRAGHTOUT AND SUPPORT IT TOPREVENT DUMPING.

PERIODIC MAINTENANCE

FIG. 31

FIG. 30

14

LUBRICATION

LUBRICATION OF GRINDING SHAFT AND LINEAR BEARINGS

STEP 1 – Thoroughly clean all three shafts.

STEP 2 – Flood spray all three shafts with WD40 until the lubricant is dripping off the shafts. Then runthe grinding head assemblies back and forth through their full range of travel. This will remove thedust and deposits from inside the wheel flanges. Repeat if necessary until lubrication is clear ofdeposits. Clean keyways located on the grinding shaft with soft brush.

STEP 3 – With a clean rag, wipe off the excess amount of lubricant from the shafts. Run the grindingassemblies through their range of travel and wipe the shafts after each traverse. Repeat until theshafts 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 andother appropriate parts of the unit should be flooded with lubricant and that lubricant left in place untilthe unit is brought back into service. When the unit is brought back into service the full lubricationprocedure as stated above should be repeated.

FIG. 32

15

MAINTENANCE (Continued)

REPLACEMENT OF GRINDING WHEEL

To replace the wheel first remove the left side coverpanel. Now, lower the left side of the grinding shaft andraise the right side. Loosen the two bolts that hold thebearings on the relief hub so that that bearings fallaway from the wheel and hub (toward the front of themachine). Press the index finger down and the wheeland hub assembly should move freely to the right.Loosen the setscrews on the bearing and remove thescrews that hold the bearing to the left arm.

Remove the bearing and lift the left end of the grindingshaft. Slide the grinding wheel hub assembly(s) off theshaft taking note of what side the nut is on. Using thespanner wrench (50014) remove and replace thegrinding wheel(s) on the hub assembly.

Place the ginding wheel hub assembly(s) back on thegrinding shaft and make sure the spin hub is locatedbetween the drive yoke assembly and the relief hub isto the right of the drive assembly.

Reinstall the bearing on the left side of the shaft makingsure to fit the pilot on the bearing into arm. Tightenmounting screws, and tighten the setscrews to theshaft. Reinstall the left side cover panel. Move bearingsupport back in place. See relief hub bearingadjustment complete details.

WHEEL DRESSING

If the grinding wheel becomes loaded with material itmay be necessary to dress the wheel. The 555 issupplied with a diamond dresser. To use, place thedresser on the spin drive horizontal arm in the areawhere the wheel is to be dressed. Adjust the dresserto the appropriate position and angle. Raise thegrinding wheel so it is nearly touching the dresser.

For dressing the spin grinding wheel, put the dresser inthe straight position. Close the doors and infeed the

MAKE SURE THE WHEEL(S) IS PLACED ONTHE SHAFT WITH THE SAME ORIENTATION ASSHOWN. FAILURE TO INSTALL CORRECTLYWILL CAUSE THE WHEEL NUT TO LOOSEN.(THE NUT ON THE RELIEF HUB SHOULD BETO THE RIGHT & THE NUT ON THE SPIN HUBSHOULD BE TO THE LEFT.)

FIG. 33

FIG. 34

NOTE: THE RELIEF HUB HAS A LEFTHAND THREAD FOR THE NUT. THE SPINHUB HAS A RIGHT HAND THREAD.

spin grinding wheel into the dresser and then movethe grinding wheel side to side against the dresserwhich will dress the full face of the wheel.

For dressing the relief wheel, put the dresser at thecorrect angle for normal helix reel or reverse helixreel. See pages 24 and 25 of the Operators Manual.Close the doors and infeed the relief grinding wheelinto the dresser. Do Not move the grinding wheelfrom side to side.

BEARING

RELIEF FLANGERELIEF WHEEL

RELIEF NUT

SPIN NUT

SPIN WHEELSPIN FLANGE

Loosen bolts and tip back.Press in indexing finger andthe wheel should slide freelyto the right.

16


GRINDING MOTOR BELT REPLACEMENT/ALIGNMENT

To replace or inspect the grinding motor belt,remove the right side cover panel. To remove thebelt, pull down on the tensioner pulley.

For the belt to function properly the grinding shaftpulley and the grinding motor pulley must be in linewith the tensioner pulley. To adjust the pulleyposition loosen the setscrews on the pulley.Locate the belt in the center of the idler pulley.Measure from the arm to the edge of the belt at theidler pulley. Adjust the two other pulley's until thesame measurement is achieved and tighten thepulley setscrews.

Before reinstalling the right side cover panel, run thegrind motor to assure that the belt is not misaligned.The belt will walk off the pulley if the system is notaligned properly.

TRAVERSE BELT REPLACEMENT

To replace the traverse belt, remove the left sidecover panel, then loosen the nuts on the left sidepulley that are used to tension the belt. Remove theright side cover panel. Loosen the screws holdingthe traverse motor and tilt the bottom of the motorout releasing any remaining tension on the belt. Onthe left side remove the nut from the bottom belttensioning screw, this will allow the belt to beremoved.

Place a new belt on the left pulley making sure it isseated properly in the cogged teeth and replace thelocknut. Feed the new belt throught the slot on theright arm and place on motor pulley. Use the motoras a lever to apply tension to the new belt. Tightenmotor screws and adjust the tension in the belt asspecified in the BELT TENSION section. Adjust theheight of the motor pulley if necessary so the belt islocated in the center of the traverse belt clamp.

Test the traverse motor and replace the left side andright side cover panels.

FIG. 36

FIG. 35

17


TRAVERSE SHAFT/LINEAR BEARINGREPLACEMENT

Remove the left side cover panel. Then remove thegrinding shaft by removing the left side bearing andloosening the setscrews on the right side bearing.Also remove the traverse belt.

To remove the traverse shafts first lower the grindingshaft so that it is in in's lowest position. Then removethe left side arm.

To remove the left arm, remove the bolt at the rear ofthe machine. (It may be necessary to clamp onto theshaft that the bolt is screwed into so that it does notspin.) After removing the bolt, pull the arm off therear shaft. Remove the front of the arm from thevertical adjuster housing, pull the arm straight off thetraverse shafts. (Caution should be used as theshafts may come out of the right side arm.)

Slide the grinding head assemblies off thetraverse shafts.

Replace the shafts if necessary or pressthe bearings out of the bearing housingsand replace with new bearings and seals. (Twobearings go in the front and 1 in the rear of the hous-ing).

Clean the 2 spherical bearings in the arm and placethe traverse shaft into the right arm. Replace thegrinding head assemblies (spin first). Clean thebearing in the left arm and slide onto traverse shaft.(Note: The sperical bearing in the arm has to belined up with the shafts for the shafts to slide into thebearings.) Replace and tighten items in the oppositeorder of removal. Make sure the wheels are properlylocated in the correct grinding head assembly withthe nut side of the wheel toward the left side of themachine (see Replacement of Grinding Wheel.)

Fig. 37

18


CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATEWINDOWS

Cleaning Instructions

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

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

Minimizing Hairline ScratchesScratches and minor abrasions can be minimized by using a mild automobile polish. Three suchproducts that tend to polish and fill scratches are Johnson paste Wax, Novus Plastic Polish #1 and #2,and Mirror Glaze plastic polish (M.G. M10). It is suggested that a test be made on a corner of thepolycarbonate window with the product selected following the polish manufacturer's instructions.

Some Important "DON'TS"¨ DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows.¨ Never scrape polycarbonate windows with squeegees, razor blades or other sharp

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

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

Graffiti Removal• Butyl cellosolve, (for removal of paints, marking pen inks, lipstick, etc.)• The use of masking tape, adhesive tape or lint removal tools works well for lifting off old

weathered paints.• To remove labels, stickers, etc., the use of kerosene, VM&P naphtha or petroleum spirits is

generally effective. When the solvent will not penetrate sticker material, apply heat (hairdryer) to soften the adhesive and promote removal.

GASOLINE SHOULD NOT BE USED!

19


DIGITAL GAGE

ImportantDo 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, ifany, from the battery may damage the unit.

Description of Parts1. Beam 2. Main Scale3. Battery compartment 4. Outp Connection5. Display 6. ON/OFF Power7. ZERO/ABS switch 8. Origin Switch9. Inch/mm Switch 10. Tapped hole11. Slider

Battery Installation and Origin SettingSet 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 toset as your origin. Turn the power on. Hold the ORIGINswitch down for more than one second. The "0.00"display appears, indication Origin setting is complete. Theorigin will be retained even if the power is turned off.

Incremental (INC) & Absolute (ABS) modeThe LCD will dispay measurements from the origin when turnedon (ABS mode). To set the origin see above. The display canbe 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 theABS mode hold the ZERO/ABS button form more than 2seconds.

Error Symptoms & Remedies� �� ERRC and display flickering: Occurs when the scale

surface is stained. Clean the scale surface and coat athin film of low viscosity oil to keep out moisture.

� �� E in the least significant digit: This occurs when theslider is moved too quickly, but it does not affect themeasurement. If it stays on when the slider stops, thescale surface is probably stained. If this is the case, takeremedies as for ERRC.

� �� B indication: Battery voltage is low. Replace thebattery as soon as possible.

20

ADJUSTMENTS

PROXIMITY SWITCH

For the proximity switch to perform properly andreverse the direction of the grinding head assembly,the sensor end of the prox must face toward thehead assembly that is in use and must be mountedsuch that it is located past the edge of the proxholder.

NOTE: The light on the proximity switch activateswhen metal is approximately 3/16" [4.6 mm] fromfront of proximity switch.

VERTICAL INFEED SHAFT DRAG

If the grinding shaft tends to walk during grinding,the drag on the vertical adjusters needs to beincreased. To increase the drag in the verticaladjustment shafts, tighten the setscrew on theback of the vertical adjustment housing.

FIG. 38

FIG. 39

21

ADJUSTMENTS (Continued)

TRAVERSE BELT TENSION

To adjust the tension on the traverse belt, tightenthe screws and nuts located to the left side of thetraverse belt behind the left side cover panel to aminimum of 1.75" [44 mm]. The traverse beltshould be level when adjusting the belt tension.

TRAVERSE CLAMP FORCE

If the traverse clamp is slipping during regularoperation it may be necessary to tighten the clamp.To tighten, loosen the jam nut and screw the tip out.Move the traverse belt out of the way and verify theclamped distance from the tip to the clamping block(shoe). Jam the nut against the clamp being carefulnot to move the tip.

The bracket that supports the clamp is alsoequpped with slots if further adjustments need to bemade. To move the bracket loosen the two screwsthat are holding it in place and slide forward orback. Retighten the screws and make sure they aretight or the bracket will move during clamping.Check the tip distance and make any necessaryadjustments.

THE TIP HAS BEEN FACTORY SET SO THATIT WILL SLIP IF THE GRINDING HEADASSEMBLY COMES IN CONTACT WITHSOMETHING. CAUTION SHOULD BE USEDAS ADJUSTING THE TIP WILL AFFECT THESLIP LOAD AND COULD DAMAGE THECLAMP TIP, BELT OR TRAVERSE DRIVESYSTEM.

DO NOT OVERTIGHTEN.OVERTIGHTENING COULDDAMAGE THE BELT ORTRAVERSE DRIVE SYSTEM.

FIG. 41

FIG. 40

.10[2.5 mm]

22


SPIN GRINDING HEAD WEAR PADS

The bronze wear pads used to move the spin wheelwill wear and may need to be adjusted or replaced.

Replace or flip the pads when they wear to within a1/16" [1.5 mm] of the screws. To accomplish the bestfit, the holes in the pads are offset. When installingnew pads flip or rotate the pads until Gap 2 is as smallas possible without the pads pinching the wheel.

On the spin grinding head assembly, the pads can beadjusted in and out by loosening the screws located onthe sides of the yokes. Gap 1 should be adjusted toabout 1/16" [1.5 mm]. See FIG. 42.

SAFETY SWITCH ALIGNMENT/REPLACEMENT

The safety switch located on the right guard door mustline up properly with the key located on the oppositedoor or the grinder will not function.

The switch and key must be within 1/4" [6 mm] and thetargets on the switches must line up in order for theswitch to function properly. See FIG. 43A, 43B and43C.

The switch and key are attached to the guarding usinga "Torx" style tamper resistant screws.

FIG. 42

FIG. 43A

FIG. 43B FIG. 43CREAR DOOR SWITCH(NON-LIFT MACHINE)

FRONT DOOR SWITCH(INSIDE UPPER RIGHT SIDE)

REAR DOOR SWITCH(LIFT MACHINE)

23

RELIEF GRINDING HEAD BEARING ADJUSTMENTS

It may be necessary to adjust the guide bearings on the reliefhead. To adjust the position of the support bearings, loosenthe two positioning bolts located on the side of the supportassembly. Press on the support assembly until both supportbearing assemblies are touching the hub. Hold the support inplace with the bearing assemblies touching the hub andtighten the two bolts positioning bolts. Check to see if bothbearing assemblies are touching or have minimal clearanceto the hub by rotating the grinding shaft.

NOTE: EXCESSIVE PRELOAD OF THEBEARING ASSEMBLIES ON THE HUB CANCAUSE THE BEARINGS TO WEAR QUICKERAND COULD CAUSE THEM TO FAILPREMATURELY.

To adjust the traversing bearing assemblies use an allenwrench and 3/8" wrench. Use the allen wrench to loosen thescrews while using the 3/8" wrench to hold the bearingassembly shaft. After loosening the bearing assemblies pushthem away from the hub flange. Now Position the hub sothere is 1/32"-1/16" [0.8-1.6] clearance between the indexingfinger and the hub wheel flange. Now bring the LEFT travers-ing bearing assembly in until it just contacts the hub flange.Lock this bearing in place by tightening the screw. Press onthe wheel so that the hub flange is against the left traversingbearing and verify the clearance of the indexing finger to thewheel flange. Now bring the Right traversing bearing in untilthere is a minimum gap (approx. 1/32" [0.8]) between thebearing and the hub flange. Lock in place by tighten thescrew. Check to make sure bearing assemblies operatefreely and with minimum slop.

PositioningBolts

Support BearingAssemblies

TraversingBearingAssemblies Screws

HubFlange

Indexing Finger

Wheel

Hub WheelFlange

1/32"-1/16"

NOTE: EXCESSIVEPRELOAD OF THEBEARING ASSEMBLIESON THE HUB FLANGECAN CAUSE THEBEARINGS TO WEARQUICKER AND COULDCAUSE THEM TO FAILPREMATURELY.


24

REEL LIFT PIVOT BOLTS

There are four pivot bolts on the reel lift that must beadjusted correctly for proper lift function. Tighten thescrews and locknuts and then loosen 1/8 to 1/4 turnuntil the screw turns freely with fingers when the screwis under no load. See items marked "SCREWS ANDLOCKNUTS" below.


25

REEL LIFT SIDE BEARING ASSEMBLIES

There are four side bearing assemblies (two on each side) on the reel lift. The two onthe right side looking from the front of the grinder are fixed with screws and washers.The two on the left side looking from the front of the grinder are spring loaded againstthe lift frame. They must be adjusted correctly for proper lift function. These left sidescrews can be accessed by removing the left side lower lift guard. Tighten the screwsuntil tight (springs solid) with blue loctite no. 242, then back the screws out ONE fullturn. See items marke "B311613" below. When complete, reinstall the left side lowerlift guard.


LEFT SIDE LOOKING FROM FRONT OF GRINDER

RIGHT SIDE LOOKING FROM FRONT OF GRINDER

26

CONTROL BOARD POTENTIOMETER ADJUSTMENTSPOTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL (TDC)Min. Speed--Factory set at full (CCW) 8:30. Do not change this setting.

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

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

IR COMP--Factory set to 9:00. IR COMP is current (I) resistance (R) compensation (COMP). IR COMP adjusts theoutput voltage of the drive which balances load to motor RPM. Regulation of a traverse motor may be improved byslight adjustment of the IR COMP pot clockwise from its factory-set position. Overcompensation causes the motorto oscillate or to increase speed when fully loaded. If you reach such a point, turn the IR COMP potcounterclockwise until the symptoms disappear.

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

(Right Traverse) Forward Acceleration--Factory set at full (CCW) 8:30. Do not change this setting.

(Left Traverse) Reverse Acceleration--Factory set at full (CCW) 8:30. Do not change this setting.

(DB) Dead Band is the potentiometer setting for the 50 or 60 Hz cycle control. Factory set to 9:00, works for both50 and 60 Hz. Do not change this setting.

Calibrating the DWELL TIME rotary DIP switch adjusts the amount of time the process remains in the stop positionafter a limit switch is actuated. The DWELL TIME range is adjustable from 0-4 seconds. A DIP switch setting of 0sets the DWELL TIME to 0 seconds, while a setting of 9 sets the DWELL TIME to 4.5 seconds. Dwell time is presetto #4 setting for a 2 second dwell time when reversing at each end of stroke. A setting of 6, sets the dwell time at3 seconds, etc.

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

POWER indicates that AC power is being applied to the control.FORWARD indicates that the process is running in the forward direction

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

(traversing right).PROX 1 FWD LIMIT lights when the forward limit switch is actuated (left prox.).PROX 2 REV LIMIT lights when the reverse limit switch is actuated (right prox.).DWELL lights when the process remains stopped after a proximity switch is

actuated.

PotentiometerClock Orientation FIG. 44

27

CONTROL BOARD POTENTIOMETER ADJUSTMENTS (Continued)

The Spin Drive Control Board has three potentiometers on the lower board and two potentiometers on theupper board as shown on FIG. 45 and FIG. 46. These potentiometers have been set at the factory to thepositions shown on FIG. 45 and FIG. 46.

In the Relief Grinding Mode--The Relief Speed Pot (RSP) and the Relief Torque Pot (RTP) interact with each other. The (RSP) is located onthe upper spin board as a relief speed preset at 9:30 (20 Volts DC). See FIG. 45. The (RTP) is located on thecontrol panel and is for relief torque adjustment.

Relief Speed Pot (RSP) when rotated clockwise will increase maximum spin drive speed. This speed shouldnever be above the 10:30 setting.

Relief Torque Pot (RTP) can vary the reel to finger holding torque for relief grinding. The recommended startingpoint is 30 in/lbs of torque setting. Never adjust the (RTP) potentiometer dial past the red line marking. Settingthe reel to finger torque to high could cause the traverse motor system to not operate smoothly.

In the Spin Grinding Mode--The Spin Torque Potentiometer (STP) and the Spin Speed Pot (SSP) interact with each other. The (STP) islocated on the upper spin board as spin torque preset at 2:00 for torque setting. See FIG. 45. The (SSP) islocated 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 beadjusted past the 2:30 position. If the reel does not turn check that the reel is free turning by hand spinning.

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

POTENTIOMETERS ON THE LOWER BOARD OF THE SPIN DRIVE CONTROL (SDC) See FIG. 46.Maximum Speed Pot--The maximum speed is factory preset to 4:30 (fully clockwise) to allow for maximum spin speed.

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

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

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

SPIN DRIVE CONTROL BOARD (SDC)

FIG. 45

LOWER SPIN BOARD

FIG. 46

UPPER SPIN BOARD

28

This Electrical Troubleshooting section is designed for technicians who have the necessary electricalknowledge and skills to reliably test and repair the 555 electrical system. For those without that background,service can be arranged through your local distributor.

This section presumes that you are already familiar with the normal operation of the Grinder. If not, youshould read the front of this Manual, or do the servicing in conjunction with someone who is familiar with itsoperation.

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

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

AC Main Power Controls ..................................................................................................... Page 27-29Spin Drive Controls ............................................................................................................. Page 30-34Grinding Motor Controls ....................................................................................................... Page 35-36

Traverse Drive Controls-w/prox .......................................................................................... Page 37-38Traverse--stopping and reversing........................................................................................ Page 39-41

ELECTRICAL TROUBLESHOOTING

SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING

ELECTRICAL TROUBLESHOOTING INDEX

All wires on the 550 have a wire label at each end for troubleshooting. The wire label has a code which tellsyou wiring information. The wire label has a seven position code. The first two digits are the wire number: 01-99. The next three numbers or letters are the code for the component to which the wire attaches. Example:TDC for Traverse Drive Control. The last two numbers or letters are the number of the terminal on thecomponent to which the wire attaches.

WIRE LABELS

29

ELECTRICAL TROUBLESHOOTING (Continued)

PROBLEM--AC Main Power Controls: no electrical power to control panel.Verify all wires shown on the wiring diagram on page 76 are correct and pull on wire terminals withapproximately 3 lbs force to verify there are no loose terminal connections and/or no loose crimpsbetween wire and terminal. If problem persists, test as listedbelow.

Possible Cause Checkout Procedure

Emergency Stop Botton(ESS)is Depressed

You must push the SystemStart Switch (SSS) to getpower to control Panel

Main Power Cord is notplugged in

Guard doors must beclosed and ALL SwitchesMUST be turned OFFfor contactor to pull in.

Main 20 amp outlet circuitbreaker has tripped

No 120 Volts AC power toFilter (FTR)

No 120 Volts AC power outof Filter

No 120 Volts AC power toMain Circuit Breaker (MCB)

No 120 Volts AC power fromMain Circuit Breaker (MCB)

Machine worksYes--end troubleshootingNo--go to Step B. next

Machine worksYes--end troubleshootingNo--go to step C. next.

Machine worksYes--end troubleshootingNo--go to step D. next.

Machine worksYes--end troubleshootingNo--go to step E. next.

Machine worksYes--end troubleshootingNo--but light works in outlet--go toStep F. next.No--but light does not work in outlet.You must solve your power deliveryproblem independent of machine.

FTR "Line" Terminals for 120 Volts ACYes--Go to Step G. next.No--Replace Power Cord- 6059054

FTR "Load" Terminals for 120 Volts ACYes--Go to Step H. next.No--Replace Filter

MCB Bottom Terminal to TerminalBlock 4 (Blue) for 120 Volts ACYes--Go to Step I. next.No--Check wires & replace if needed.

MCB Top Terminal to Terminal Block 4(Blue) for 120 Volts ACYes--Go to Step J. next.No--Flip Switch on MCB to "ON" -Machine works-- end trouble shootingMachine does not work-- replace MCB

A. Pull Up on ESS Button

B. Listen for the Magnetic Starter(MAG) contacts to pull in with aclunk

C. Plug in main power cord

D. Close guard doors and turn offall switches.

E. Check circuit breaker in yourbuilding and reset if necessary.(Check wall outlet with a light to make sure it works)

F. Check for 120V at Cord intoFTR (Power Cord #32)

G. Check for 120V out of FTR

H. Check for 120V to MCB

I. Check for 120V to MCB

30


Checkout Procedure

120 Volts AC powernot delivered toTerminal Strip

Grinding MotorSwitch (GMS) notworking

Spin Motor Switch(SMS) not working

Bad EmergencyStop Switch (ESS)

Bad System StartSwitch (SSS)

Low Voltage Relay(REL) not operating

Bad Main Contactor(MAG)

Possible Causes

J. Check for 120 Volts AC atterminal strip.

K. Check for 120 Volts AC at GMSTerminals 1

L. Check for 120 Volts AC at SMSTerminals 1

M. Check voltage after the (ESS)MAKE SURE SWITCH IS PULLEDUP!

N. Hold in SSS and Check voltageafter the (SSS)

O. Hold in SSS and Check voltageat LVR. LVR must be installed in 8-pin socket.

P. Hold in SSS and Check voltageat MAG A1 & A2.

Terminal "11" on Terminal Strip 2"07TB2-11" to Terminal Block 4(Blue) for 120 Volts ACYes--Go to Step K. next.No--Check wires #7 & #3, CheckJumper on Terminal Blocks 1-3.

Measure 120 volts AC from GMSTerminal 1 to Term Block 4(Blue)Yes--Go to Step L. next.No--Flip Switch and check again-Works--Switch is upside down.Does not work-- Check wiring/Verify Continuity/ Replace Switch

Measure 120 volts AC from SMSTerminal 1 to Term Block 4(Blue)Yes--Go to Step M. next.No--Flip Switch and check again-Works--Switch is upside down.Does not work-- Check Wiring/Verify Continuity/ Replace Switch

Measure 120 Volts AC from (ESS)term 2 to Term Block 4(Blue)Yes--Go to Step N. nextNo--Check wire for continuity, thenverify switch continuity. If bad replaceESS contactor (NC)

Measure 120 Volts AC from (SSS)term 3 to Term Block 4(Blue)Yes--Go to Step O. nextNo--Check wire for continuity, thenverify switch continuity. If bad replaceSSS contactor (NO)

Measure 120 Volts AC from LVRterm 8 to Term Block 4(Blue)Yes--Go to Step P. nextNo--Check for 120 Volts AC fromLVR term 6 to term 7.Yes--Verify Continuity of term 1 toterm 8 on LVR. Replace LVR if bad.No--Verify Continuity of Wires.

Measure 120 Volts AC from MAGTerm A1 to Term A2Yes--MAG Should pull in with clunck,if not replace MAG.No--Verify Continuity of Wires.

31


Possible Cause

Guard Doors areOpen

Door SafetySwitches are notworking properly

No 24 Volts DC toSafety Monitor(SSM)

No Power into 24Volt DC PowerSupply (PWR)

No Power Out toDoor Switches

Rear Door Switch orRear Ramp Switchis Bad

Front Door Switch isBad

Measure 120 Volts AC at MAG term L3 toTerm Block 4(Blue) after SSS is pushed.Yes--Verify Wiring to LVRNo--Measure 120 Volts AC at MAG term T3to Term Block 4(Blue) after SSS is pushed.If 120 Volts AC Replace MAG. If no 120 VoltsAC verify wiring to T3.

PROBLEM--(MAG) turns on only with System Start Switch held in.

Checkout Procedure

A. Check wiring to and from MAGholding contact in. Verify themagnetic starter holding contact isworking.

Possible Cause

(MAG) holdingcontact has failed

Machine worksYes--end troubleshootingNo--go to Step B. next

See Alignment section of this Manual.Machine worksYes--end troubleshootingNo--go to Step C. next

Measure 24 volts DC from SSM Terminal A1+to Terminal A2-Yes--Go to Step E. next.No--Go to Step D. next.

Measure 120 volts AC from PWR Terminal L toTerminal NYes--Verify 24 VDC out of PWR (V+ to V-).Replace if no Voltage out; or Check Wiring &Verify Continuity to SSM if there is 24 VDC.No--Verify Wiring and Continuity from PWRto terminal blocks.

Measure approximately 24 volts DC fromTerminal Strip 1 Terminal 17 to Terminal Strip 2Terminal 3Yes--Go to Step F. next.No--Verify Continuity of Wires to Terminalstrip, Replace SSM if wires check OK.

Measure approximately 24 volts DC fromTerminal Strip 2 Terminal 3 to Terminal Strip 1Terminals 14 and 15.Yes--Go to Step G. next.No--Check Alingment of Rear door switch. Ifno Voltage to Term14 or 15 then replace rearswitch. If still not working replace cord.

Measure approximately 24 volts DC fromTerminal Strip 1 Terminal 17 to Terminal Strip 2Terminals 2 and 4.Yes--Replace SSMNo--Check Alingment of Front door switch. Ifno Voltage to Term2 or 4 then replace frontswitch.

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

B. Check Alignment of Door SafetySwitches on front doors and reardoor (and rear ramp - lift model)

C. Check SSM for 24 Volts DC.(Turn switches off and press startswitch to pull in MAG beforetesting voltages)

D. Check PWR for 120 Volts AC.(Turn switches off and press startswitch to pull in MAG beforetesting voltages)

E. Verify 24Volts DC out to DoorSwitches.

F. With Rear Door closed or RearRamp Closed Verify 24Volts DCback form rear Door Switch.

G. With Front doors Closed Verify24Volts DC back form Front DoorSwitch.

Checkout Procedure

PROBLEM-- Machine Shuts off when youturn on Grind motor switch or Spin MotorSwitch.

32


PROBLEM--SPIN DRIVE NOT WORKING IN SPIN MODE.

Assuming (SSS) System Start Switch is on with 120 volts AC to control panel and all other functionsare working.

Verify all wires shown on the wiring diagram on page 76 are correct and pull on wire terminals withapproximately 3 lbs force to verify there are no loose terminal connections and/or not loose crimpsbetween wire and terminal. If loose terminals are found, retighten and retest system. If problempersists, test as listed below.

Spin Speed Pot(SSP) set to zero

Spin Motor Switch(SMS) is not on

Spin Rotation Switch(SRS) is not on

Circuit Breaker isTripped (4 AMP)

Spin Drive Control(SDS) is not working

Spin Drive motor isbad

A. Set (SSP) to 200 on thecontrol panel.

B. Turn (SMS) switch on

B. Turn (SRS) switch todirection of reel rotationrequired. NOTE: CENTERPOSITION IS OFF

C. Reset Circiut Breaker onthe side of the machine abovethe electrical panel cover.Push in if tripped.

D. Check (SDS) L1 to L2 for120 Volts AC

E. Check (SDC) A1 & A2 forapprox. 90 Volts DC (HaveSpin Speed Pot set to 400RPM)

F. Check for approx 90 VoltsDC input to (SRS)

G. Check for approx 90 VoltsDC out put from (SRS).

H. Check spin motorcontinuity

Spin Motor worksYes--end troubleshootingNo--go to Step B next

Spin Motor worksYes--end troubleshootingNo--go to Step C. next


Spin Motor worksYes--end troubleshootingNo--go to Step D. next

(SDC) Term L1 to term L2 for 120 volts ACYes--go to Step E. nextNo--Verify Power to Circuit Breaker and SMSand continuity of wires. Replace CB or SMSif needed.

(SDC) Term A1 to A2 for approx 90 volts DCYes--go to Step F. nextNo--go to Step L. next

(SRS) Term 2 to 3 for approx 90 Volts DCYes--go to Step G. nextNo--replace wires 13 & 14

(SRS) Term 6 to 7 for approx 90 Volts DCYes--go to Step H. nextNo--replace (SRS) switch

Remove wires at Terminal Strip 1, Term 4 &5 check 0 ohms across the black and whitewiresYes--end troubleshooting, motor should work(if it does not, replace motor)No--go to Step P. next

Disconnect Powerfrom Machine!

33


Spin Speed Pot (SSP)is not working

Spin Torque Pot (STP)is not set correctly

(SSP) is not working

Worn Motor Brushes


L. Check (SSP) (10K) oncontrol panel

M. Check (STP) remotetorque on the top (SDC)board

N. (SSP) (10K) Remove 3Remote Speed wires.Red wire to term WWhite wire to term LBlack wire to term H

P. Inspect Motor Brushes

On (SDC), Remote Speed check Blackwire H terminal to Red wire W terminal for:Pot Full CCW --O volts DCPot Full CW--4.4 Volts DCCheck White wire L terminal to Red wireW terminal for:Pot Full CCW --4.4 Volts DCPot Full CW-- DC 0 Volts DCYes--Go to Step MNo--Go to Step N.

(STP) on (SDC) remote torque should beset at 2:00 o'clock position. See Pages 24and 25. Adjust if incorrect and check SpinDrive Function.Yes--end of troubleshootingNo--Replace (SDC)

Check for 10,000 ohmsRed wire to white wire Full CCW--0 ohms Full CW-10,000 ohmsRed wire to black wire Full CCW--10,000 ohms Full CW--0 ohmsYes--replace (SDC)No--replace (SSP)

Remove the brushes one at a time andmaintain orientation for reinsertion. See ifbrush is worn short 3/8" (10 mm) minimumlength.Yes--replace motor brushesNo--replace Spin Drive Motor

DISCONNECT POWERFROM MACHINE !

34


PROBLEM--Spin Drive not working in relief mode.

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

Verify all wires shown on the wiring diagram on page 76 are correct and pull on wireterminals with approximately 3 lbs force to verify there are no loose terminal connectionsand/or no loose crimps between wire and terminal. If loose terminals are found, retightenand retest system. If problem persists, test as listed below.

DISCONNECT POWERFROM THE MACHINE

Relief Torque Pot(RTP) set to zero

Spin Motor Switch(SMS) is not on

Spin Rotation Switch(SRS) is not on

Circuit Breaker isTripped (4 AMP)

Spin Drive Control (SDS)is not working

Spin Drive motor is bad

Spin Motor worksYes--end troubleshootingNo--go to Step B. next


Spin Motor worksYes--end troubleshootingNo--go to step D. next

Spin Motor worksYes--end troubleshootingNo--go to step E. next

(SDC) Term L1 to term L2 for 120 VoltsACYes--go to Step F. nextNo--Verify Power to Circuit Breaker andSMS and continuity of wires. ReplaceCB or SMS if needed.

(SDC) Term A1 to A2 for approx 20 VoltsDCYes--go to Step G. nextNo--go to Step L. next

(SRS) Term 2 to 3 for approx 20 VoltsDCYes--go to Step H. nextNo--replace wires 13 & 14

(SRS) Term 6 to 7 for approx 20 VoltsDCYes--go to Step I. nextNo--replace (SRS) switch

Remove wires at Terminal Strip 1, Term4 & 5 check 0 ohms across the blackand white wiresYes--end troubleshooting, motor shouldwork (if it does not, replace motor)No--go to Step P. next

A. Set (RTP) to 20 on thecontrol panel.

B. Turn (SMS) switch on

C. Turn (SRS) switch todirection of reel rotationrequired. NOTE: CENTERPOSITION IS OFF

D. Reset Circiut Breaker onthe side of the grinder abovethe control cover. Push in iftripped.

E. Check (SDS) L1 to L2 for120 Volts AC

F. Check (SDC) A1 & A2 forapprox. 20 Volts DC (HaveRelief Torque set to Red Line)

G. Check for approx 20 VoltsDC input to (SRS)

H. Check for approx 20 VoltsDC out put from (SRS).

I. Check spin motor continuity

35

ELECTRICAL TROUBLESHOOTING (Continued) SPIN DRIVE


(RTP) Relief Torque Potis not working

Relief Speed Pot (RSP)is not set correctly.

(RTP) is not working

Worn Motor Brushes

L. Check (RTP) (50K) oncontrol panel (check voltagewith pots at fully clockwise andcounterclockwise positions)

M. Check (RSP) remotespeed (10k) on (SDC) topboard (this is preset to 9:30)

N. (RTP) (50K) Remove3 Remote Torque Wiresred wire to term Wwhite wire to term L.black wire to term H.

P. Inspect Motor Brushes

On (SDC), Remote Torque check Blackwire H Terminal Red wire W terminal for:Pot CCW--) 0 volts DCPot CW--.2 Volts DCCeck White wire L terminal to Red wire Wterminal for:Pot CCW--.2 Volts DCPot CW-- DC 0 Volts DCYes--go to Step M. nextNo--go to Step N. next

(RSP) to the top (SDC) board should beset at 9:30. See pages 24 and 25. Adjust ifincorrect and check Relief Torque func-tion.Yes--end of troubleshootingNo--replace (SDC)

Check for 50,000 ohmsRed wire to white wire Full CCW--0 ohms Full CW--50,000 ohmsRed wire to black wire Full CCW--50,0000 ohms Full CW--0 ohmsYes--Replace (SDC)No--replace (RTP)

Remove the brushes one at a time andmaintain orientation for reinsertion. See ifbrush is worn short 3/8" (10 mm) mini-mum lengthYes--replace motor brushesNo--replace Spin Drive Motor

DISCONNECT POWERFROM MACHINE !

36


Remedy

PROBLEM : Spin drive speed goes at one speed only.

Possible Cause

A. Check potentiometer wiring forproper hookup. See that speedpot is wired per electrical diagram

B. (SSP) 10K Remove 3 remotespeed wires.red wire to term Wwhite wire to term Lblack wire to term H

C. Check all pot settings on bothboards as of the (SDC) shownon Pages 24 and 25. (SeeAdjustment Section Spin DriveControl [SDC] Board Setting).

A. See adjustment section fortrim pot setting on Page 24.

B. Readjust bearing preload forthe reel. Maximum torque load 25in./lb to rotate reel.

C. When .250 female spadeterminals are not tight, removeand crimp slightly together. Whenreinstalling, push on pressureshould have increased for goodcontact.

If wiring is wrong, correct andtest.Yes--end of troubleshootingNo--Go to Step B. next

Check for 10,000 ohmsRed wire to white wire Full CCW--0 ohms Full CW--10,000 ohmsRed wire to black wire Full CCW--10,000 ohms Full CW--0 ohmsYes-- Go to Step C. nextNo--Replace (SSP)

Yes-- end of troubleshootingNo--replace (SDC)

Original adjustment was not setproperly

Too much load on drive motor willcause motor to hunt and varyspeed.

When connections are not tightthe control board varies voltageto the DC motor which thenvaries speed.

Wiring hookup to potentiometeris improper. (If componentshave been replaced)

Defective spin speedcontrol (SSP) potentiometer.

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

IR Comp trim pot not adjustedproperly.

Torque to rotate the reel toohigh.

Check all terminal connectionsfor tightness.

37


PROBLEM-- Grinding motor not working.

Assuming (SSS) System Start Switch is on with 120 volts AC to control panel and all otherfunctions are working.

Verify all wires shown on the wiring diagram on page 76 are correct and pull on wire termi-nals with approximately 3lbs force to verify there are no loose terminal connections and/orno loose crimps between wire and terminal. If loose terminals are found, retighten and retestsystem. If problem persists, test as listed below.

Possible Cause

Grinding MotorSwitch (GMS) is noton

Guard doors are notclosed

15 Amp CircuitBreaker (CB) istripped

GMS not working

Grinding Motor Relaynot working

No Power to RelayContacts

A. Turn switch on

B. Close front and rearguard doors (and rear ramp- lift option)

C. Check 15 amp CB on theside of the grinder above thecontrol cover. Press in iftripped.

D. Check for power to GMS

E. Check for power fromGMS

F. Check for power to relayCoil (Relay should clickwhen GMS is turned on.)

G. Verify Power to RelayContacts

Grinding Motor worksYes--end troubleshootingNo--go to Step B. next

Grinding Motor worksYes--end troubleshootingNo--go to Step C. next

Grinding Motor worksYes--end troubleshootingNo--go to Step D. next

GMS term 5 to Terminal Block 9 (Blue) for120 Volts ACYes--go to Step E. nextNo--With power off, check continuity ofwires to GMS.

GMS Term 6 to Terminal Block 4 (Blue) for120 Volts ACYes--Go to Step F. nextNo--replace GMS

Check for 120 Volts (AC) from A1 to A2 ofGrinding motor Relay.Yes--Go to Step G. nextNo-- check continuity of wires to Grindingmotor Relay.

(REL) Term L1 to Term L2 for 120 Volts (AC)Yes--Go to Step H. nextNo--Check wires to REL Term L1 & L2

38


Checkout ProcedurePossible Cause

(REL) Term T1 to Term T2 for 120Volts (AC)Yes--Go to Step I. nextNo--Replace Gringing Motor Relay

Check for 120 Volts (AC) fromterminals TB2-6 to Terminal Block4 (Blue)Yes--Go to Step J. nextNo--Check circuit breaker forcontinuity. Verify wiring and replaceif needed.

Verify wiring at terminals 1, 2 & 3on Terminal Strip 1. Check TB1-1to TB1-2 for 120 Volts (AC).Yes-- Check terminals on motorcord. If tight replace motor.No-- Check wires from GrindingMotor Relay and Circuit Breaker toTerminal Strip 1.

Bad Contacts inGrinding motor Relay

Bad Circuit Breaker

Bad Grinding Motor

H. Verify power out of GrindingMotor Relay.

I. Verify Power out of CircuitBreaker.

J. Verify Power to Grindingmotor Cord.

39


PROBLEM--Traverse Drive not working.

Assuming (SSS) System Start Switch is on with 120 volts AC to control paneland all other functions are working.

Verify all wires shown on the wiring diagram on page 76 are correct and pullon wire terminals with approximately 3lbs force to verify there are no looseterminal connections and/or no loose crimps between wire and terminal. Ifloose terminals are found, retighten and retest system. If problem persists,test as listed below.

Checkout Procedure

A. Turn on (TMS)

B. Set (TSP) to 35 on the controlpanel

C. Check fuse and replace iffailed. See Page 23. Too heavy agrind causes grinding headtraverse motor to overload andblow the fuse,NOTE: Fuse can not be checkedvisually. Use Ohm test to checkfuse. If the fuse needs replacingyou MUST use a 3 amp slo-blofuse. Part Number 3707546.

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

E. Check for 120 Volts AC at(TMS). (Make certain (TMS) ison)

Traverse worksYes--end troubleshootingNo--got to Step B. next

Traverse worksYes--end troubleshootingNo--go to Step C. next

Traverse worksYes--end troubleshootingNo--go to Step D. next

On (TDC) Terminal L1 to L2 for 120 VoltsACYes--Go to Step F. nextNo--Go to Step E. next

Measure 120 volts AC from TMSTerminal 5 to Term Block 4(Blue)Yes--Go to Step L. next.No--Flip Switch and check again-Works--Switch is upside down.Does not work-- Check wiring/VerifyContinuity/ Replace Switch

Possible Cause

Traverse Motor Switch(TMS) is not on

Traverse Speed Pot(TSP) set to zero

Fuse on Traverse DriveControl (TDC) hasfailed

Traverse Drive Control(TDC) is bad

Bad Traverse MotorSwitch (TMS)

40


Checkout Procedure

F. Check for 90 Volts DC across(TDC) terminals #A1 to #A2 thisvoltage drives the DC traversemotor. NOTE: Traverse must beon and have (TSP) turned full CWto maximum voltage of 90 VDC

G. Check traverse motor continuity

H. Check (TSP) (10K) on controlpanel

J. Check (TSP) for 10,000 ohms.Remove three wires from (TDC)red from term #8white from term #7black from term #9

K. Inspect Motor Brushes

Possible Cause

No DC Voltage from(TDC) Traverse DriveControl

Traverse Motor is bad

(TSP) is not working

(TSP) (10K) is bad

Worn motor brushes

Check (TDC) terminals #A1 to #A2 for 90Volts DCYes--go to Step G. nextNo--go to Step H. next

Remove motor wires from Terminal Strip 1terminals #7 & #8 check for 0 ohms acrossthe black and white wiresYes--end troubleshooting, motor shouldwork (if it does not, replace motor)No--go to Step K. next

(TDC) Pin #8 to #7Pot Full CCW Pot Full CW 0VDC 9.75 VDCPin #8 to 9Pot Full CCW Pot Full CW 9.75 VDC 0 VDCYes--replace the (TDC)No--go to Step J. next

Check for 10,000 ohms red to white wiresFull CCW--0 ohmsFull CW--10,000 ohmsRed to black wiresFull CCW--10,000 ohmsFull CW--0 ohmsYes--replace the (TDC)No--replace (TSP)

Remove the brushes one at a time andmaintain orientation for reinsertion. See ifbrush is worn short, 3/8" (10 mm) minimumlength.Yes--replace motor brushesNo--replace Traverse Motor

DISCONNECT POWERFROM MACHINE

DISCONNECT POWERFROM MACHINE

41


PROBLEM--Traverse does not stop to reverse directions when flag goes under the proximityswitch on the left side or right side of machine.

Gap betweenflag and prox isincorrect.

P r o x i m i t ySwitch is bad.

A. Gap between flag andprox should be 3/16 to1/4" (4-6 mm). ProxLED does not light whenflag is under prox.

B. Proximity switch isnot working properly orwire connections areloose.

The light coming onshows the proximity isgetting electricalcontact.

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

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

Replace proximityswitch if the voltagesdo not read as above.

If incorrect, adjust per adjustmentsection of manual.Yes--end troubleshootingNo--go to Step B. next

First check to see if proximity lightcomes on. When the light is on, itmeans that there is electricitycoming to proximity switch.Actuate prox switches with steeltool to take measurements.

Left proximity (PROX 1) checkTraverse drive Control (TDC)between terminals #13 (blackwire) and #15 (brown wire).

Right proximity (PROX) check#14 (black wire) and #15 (brownwire).

42


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

Traverse Drive Control Pin #8 to 7Pot full CCW Pot Full CW 0 VDC 9.75 VDCPin #8 to 9Pot full CCW Pot Full CW 9.75 VDC 0 VDCYes--Pot is OKNo--Go to Step B. next

Check for 10,000 ohmsRed to White wiresFull CCW - 0 ohmsFull CW - 10,000 ohmsRed to Black wiresFull CCW - 10,000 ohmsFull CW - 0 ohmsYes--Go to Step C. nextNo--replace potentiometer.Wiper inside of potentiometer controlsspeed. Wiper may be bad and not makingcontact.

Verify potentiomter White wire to terminal7, Red wire to terminal 8 and Black wire toterminal 9, if not, correct.Check for Proper function.Yes--end troubleshootingNo--Go to Step D. next

Minimum and maximum pot settings effecttraverse speed.

Checkout Procedure

A. Check potentiometer on controlpanel.

B. Check potentiometer for 10,000ohms.Remove three wires fromTraverse Drive Controlred from term #8white from term #7black from term #9

C. Check potentiometer wiring forproper hookup. See that speed potis wired per electrical diagram

D. Check all pot settings on circuitboard as shown in wiring diagram.(See adjustment section TraverseMotor Control Board Settings.)

Possible Cause

Defective speed controlpotentiometer

Wiring hookup topotentiometer isimproper.(If components havebeen replaced.)

Main circuit board dialpot settings not correct.(If board has not beenreplaced.)

43

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

Possible Cause

Proximity switch is notworking properly or wireconnections are loose

The dwell time on thetraverse drive control notset properly.

Loose wire to proximityswitch.

Remedy

First check to see of proximity lightcomes on. When the light is on, itmeans that there is electricity comingto proximity switch.Actuate prox switches with steel toolto take measurements.

Left proximity (PROX1) checkTraverse drive Control (TDC) betweenterminals #14 (black wire) and #15(brown wire).

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

Reset dwell time as required. Oneincrement increases Dwell time by1/2 second.

Check wire connections from the prox-imity switches and tighten downscrews.

Reason

The light coming on shows theproximity is getting electrical contact.

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

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

Replace proximity switch if the volt-ages do not read as above.

A loose wire connection will giveintermittent electrical contact.

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

PROBLEM--Traverse changes directions erratically while running in traversecycle.


44

MECHANICAL TROUBLESHOOTING

PROBLEM-- Excessice noise or vibration onone end of the machine.

Possible Cause

Set screws on bearings are not tight on grindingshaft.

PROBLEM--Grinding wheel traverse binding.

Possible Cause

Shafts are dirty.

Grinding shaft is at a severe angle.

PROBLEM-- Handwheel or vertical indicatorgage "walks" during grinding.

Possible Cause

Bracket connecting gage to vertical adjuster isloose.

Plug and set screw loose.

PROBLEM--Reels ground have high/low blades

Possible Cause

Traverse Speed set too fast.

Checkout Procedure

Tighten set screws located on bearings (#80336)

Checkout Procedure

Clean the shafts as specified in the maintenancesection of this manual.

Raise or lower one end of the shaft untilapproximately level. This grinder is not designedto operate at a severe angle. Adjust reel or setupuntil the shaft is approximately level.

Checkout Procedure

Push lightly up and down on the digital gage tosee if it is loose. Tighten the screws on thebracket to the vertical adjuster or remove thegage and tighten the screws from the bracket tothe gage.

Tighten the drag on the vertical shafts bytightening the setscrew located on the back of thevertical adjuster husing. (See Vertical InfeedShaft Drag in the adjustment section.)

Checkout Procedure

Check roundness using the digital gage.Traverse speed should be set approximately 12 ft/min. (4 meters/min.) if roundness is varying.

45

MECHANICAL TROUBLESHOOTING (Continued)

PROBLEM-- Uneven traverse speed or grindingstock removal from reel is irregular.

Possible Cause

Linear bearings are damaged or have grit buildupcausing uneven traversing load.

Grinding shaft or wheels have grit buildup causinguneven loading.

Left side traverse pulley is full of grit causing thepulley not to turn freely on shaft.

PROBLEM--Traverse Belt Slips

Possible Cause

Clamping tip is not adjusted properly.

Too heavy a grind for traverse speed.

PROBLEM-- Too heavy a burr on cutting edgeof reel blades.

Possible Cause

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

PROBLEM--Cone shaped reel after grinding.

Possible Cause

Grinding head travel not parallel to the reel centershaft.

PROBLEM--Relief grind on the reel blades donot go the full length of the reel.

Possible Cause

Need to adjust the finger stop.

Need to dress the Wheel to the correct angle

Checkout Procedure

Clean shafts and bearings according to the lubricationof Grinding Shaft and Linear Bearings instructions inthe Maintance Section of the manual. If problempersists replace linear bearings according to thereplacement of linear bearings instructions.

Clean the wheel flanges and shaft (see Lubrication ofGrinding Shaft). Replace flanges or shaft ifnecessary.

Clean and lubricate the shaft and pulley.

Checkout Procedure

Adjust the clamping tip as specified in the TraverseClamp Force section of this manual.

Slow the traverse speed or back off on the amountthat is being infed.

Checkout Procedure

Traverse speed should be set lower approximately 12ft./min (4 meters/min.) for a smaller burr on the cuttingedge.

Checkout Procedure

Grinding head travel was not setup parallel to the reelcenter shaft in vertical and horizontal planes. SeeAlign the Reel Section.

Checkout Procedure

Adjust finger stop and check for contact full length.

Dress the wheel (For more detail, see relief grindingsection in operating instructions of the manual.)

46

EXPLODED VIEW: 55453 CABINET AND DOOR ASSEMBLY

47

DIAGRAMNUMBER

1 ................................................B191013 ....................... 10-24 x 5/8 Button Head Socket Cap Screw2 ................................................B251001 ....................... 1/4-20 x 5/8 Hex Head Cap Screw3 ................................................B371616 ....................... 3/8-16 x 1.0 Button Head Socket Cap Screw4 ................................................B373216 ....................... 3/8-16 x 2 Button Head Socket Cap Screw5 ................................................D280808 ....................... 1/4-20 x 1/2 Thread Cutting Screw "F"6 ................................................ J197000 ........................ 10-24 Locknut Jam Nylon Insert7 ................................................ J311000 ........................ 5/16-18Hex Full Nut8 ................................................ J317000 ........................ 5/16 Locknut Jam Nylon Insert9 ................................................ J377100 ........................ 3/8-16 Locknut Full Nylon Insert10 .............................................. J507000 ........................ 1/2-13 Locknut Jam Nylon Insert

11 ...............................................K251501 ....................... 1/4 Lockwasher Split12 ..............................................K370101 ....................... 3/8 Flatwasher - Heavy13 ..............................................R000453 ....................... 5/16 ID x 7/8 OD x 1/8 Thick Washer14 .............................................. 09891 ........................... Grab Handle Enclosure15 .............................................. 50234 ........................... Tooling Bar-Machined16 .............................................. 55396 ........................... Side Cover Panel - Right Hand17 .............................................. 50399 ........................... Side Cover Panel - Left Hand18 .............................................. 55423 ........................... Door Weldment19 .............................................. 55430 ........................... Arm Weldment - Short20 .............................................. 55431 ........................... Arm Weldment - Long Right Hand

21 .............................................. 55433 ........................... Arm Weldment - Long Left Hand22 .............................................. 55447 ........................... Neary 555 SRI Decal23 .............................................. 55450 ........................... Cabinet Weldment24 .............................................. 55465 ........................... Polycarbonate Window - Formed25 .............................................. 80416 ........................... Air Spring26 .............................................. 80418 ........................... Air Spring Stud27 .............................................. 3708159........................ Spirol Pin .25 Dia. x .50 Long28 .............................................. 3708378........................ Foam Strip .25 Thick (Sold per Foot)29 .............................................. 3708458........................ Sharp Warning Decal30 .............................................. 3708461........................ 3600 RPM Warning Decal

31 .............................................. 3708605........................ Respirator Warning Decal32 .............................................. 3708606........................ Hearing Protection Warning Decal33 .............................................. 3708703........................ Safety Symbol Warning Decal34 .............................................. 3708872........................ Patent Decal35 .............................................. 3708889........................ Foam Seal .50 High (Sold per Foot)36 .............................................. 3708890........................ Storage Hook37 .............................................. 6309039........................ Gage Mounting Pin38 .............................................. 6309111 ........................ Up/Down Decal39 .............................................. 6509110 ........................ Window Retaining Bracket - Long40 .............................................. 6509182........................ Window Retaining Bracket - Medium

41 .............................................. 55513 ........................... Dust Tray Weldment42 ..............................................H251202 ....................... .25 Diameter x 3/4" long Roll-Pin43 .............................................. 80421 ........................... Retaining Clip - Gas Spring

PARTNUMBER DESCRIPTION

PARTS LIST: 55453 CABINET AND DOOR ASSEMBLY

48

PARTS LIST: 55470 REAR DOOR ASSEMBLY

49

PARTS LIST: 55470 REAR DOOR ASSEMBLY

DIAGRAMNUMBER

1 ................................................B190813 ....................... 10-24 x 1/2 Button Head Socket Cap Screw2 ................................................B191034 ....................... 10-32 x 5/8 Button Head Socket Cap Screw3 ................................................B250816 ....................... 1/4-20 x 1/2 Button Head Socket Cap Screw4 ................................................B372016 ....................... 3/8-16 x 1.25 Button Head Socket Cap Screw5 ................................................C312020 ....................... 5/16-18 x 1.25 Socket Setscrew Cup Point6 ................................................ J167000 ........................ 8-32 Locknut Jam Nylon Insert7 ................................................ J197000 ........................ 10-24 Locknut Jam Nylon Insert8 ................................................ J257100 ........................ 1/4-20 Locknut Full Nylon Insert9 ................................................ J377000 ........................ 3/8-16 Locknut Jam Nylon Insert10 ..............................................K370001 ....................... Flatwasher 3/8

11 ...............................................K371501 ....................... Lockwasher 3/8 Split12 .............................................. 09891 ........................... Grab Handle13 .............................................. 55467 ........................... Rear Door Slide14 .............................................. 55468 ........................... Rear Guard Door15 .............................................. 55469 ........................... Rear Door Spacer Plate16 .............................................. 55471 ........................... Rear Safety Switch Spacer Plate17 .............................................. 3707029........................ Strain Relief - Liquid Tight .19-.30 Cord18 .............................................. 3707595........................ Hole Plug - .875 Dia.19 .............................................. 3707597........................ Hole Plug - .625 Dia.20 .............................................. 3707647........................ Door Safety Magnet - Coded

21 .............................................. 3708819........................ 8-32 x .75 Button Head Safety Screw22 .............................................. 3708820........................ 8-32 x .50 Button Head Safety Screw23 .............................................. 3708869........................ Spring Hinge24 .............................................. 3708882........................ Spring Latch25 .............................................. 3708887........................ Knob - 5/16-18 Female Oval26 .............................................. 3709767........................ Rubber Bumper27 .............................................. 6059021........................ Door Safety Switch Assembly - Rear28 .............................................. 6329029........................ Walker Hinged Panel


50

PARTS LIST: 55466 LIFT COMPONENT ASSEMBLY

51

PARTS LIST: 55466 LIFT COMPONENT ASSEMBLY

DIAGRAMNUMBER

1 ................................................B191213 ....................... 10-24 x 3/4 Button Head Socket Cap Screw2 ................................................B250816 ....................... 1/4-20 x 1/2 Button Head Socket Cap Screw3 ................................................B251201 ....................... 1/4-20 x 3/4 Hex Head Cap Screw4 ................................................B371216 ....................... 3/8-16 x 3/4 Button Head Socket Cap Screw5 ................................................B503216 ....................... 1/2-13 x 2.0 Button Head Socket Cap Screw6 ................................................C311620 ....................... 5/16-18 x 1.0 Socket Setscrew Cup Point7 ................................................ J167000 ........................ 8-32 Locknut Jam Nylon Insert8 ................................................ J197000 ........................ 10-24 Locknut Jam Nylon Insert9 ................................................ J257000 ........................ 1/4-20 Locknut Jam Nylon Insert10 .............................................. J377100 ........................ 3/8-16 Locknut Full Nylon Insert

11 ...............................................K160001 ....................... Flatwasher No. 812 ..............................................K190001 ....................... Flatwasher No. 1013 ..............................................K250001 ....................... Flatwasher 1/4"14 ..............................................K370001 ....................... Flatwasher 3/8"15 ..............................................K371501 ....................... Lockwasher 3/8 Split16 .............................................. 55371 ........................... Lift Control Panel17 .............................................. 55435 ........................... Lower Lift Guard - Right Hand18 .............................................. 55436 ........................... Lower Lift Guard - Left Hand19 .............................................. 55444 ........................... Upper Lift Guard - Right Hand20 .............................................. 55445 ........................... Upper Lift Guard - Left Hand

21 .............................................. 55464 ........................... Lift Dust Shield22 .............................................. 55475 ........................... Lift Power Cord (Not Shown)23 .............................................. 2109096........................ Spacer .501 ID x 1.00 OD x .50 Long24 .............................................. 3707009........................ Strain Relief - Liquid Tight .27-.47 Dia. Cord25 .............................................. 3707029........................ Strain Relief - Liquid Tight .19-.30 Dia. Cord26 .............................................. 3707224........................ Cable Tie Mount (Not Shown)27 .............................................. 3707225........................ Cable Tie 6.5 Long x .18 Wide (Not Shown)28 .............................................. 3707597........................ Hole Plug - .625 Dia.29 .............................................. 3708458........................ Sharp Warning Decal (Not Shown)30 .............................................. 3708820........................ 8-32 x .50 Button Head Safety Screw

31 .............................................. 3708882........................ Spring Latch32 .............................................. 3708887........................ Knob - 5/16-18 Female Oval33 .............................................. 3709019........................ Thrust Washer .500 ID x .937 OD x .032 Thick34 .............................................. 6059021........................ Door Safety Switch Assembly - Rear35 .............................................. 6329083........................ Door Safety Switch Mounting Plate36 .............................................. 6329084........................ Door Switch Mounting Plate37 .............................................. 6329085........................ Latch Spacer Plate38 .............................................. 6209100........................ Lift Access Panel39 .............................................. 3707647........................ Door Safety Coded Magnet

40 ..............................................B250805 ....................... 1/4-20 x 1/2 Flat Head Cap Screw41 .............................................. 3707273........................ Strain Relief42 .............................................. J507000 ........................ 1/2-13 Locknut Nylon Insert


52

PARTS LIST: 6200970 REEL LIFT ASSEMBLY

53

PARTS LIST: 6200970 REEL LIFT ASSEMBLY

DIAGRAMNUMBER

1 ................................................B190813 ....................... Button Head Cap Screw #10-24 x 1/2 Long2 ................................................B371611 ....................... Socket Head Cap Screw 3/8-16 x 1 Long3 ................................................B372011 ....................... Socket Head Cap Screw 3/8-16 x 1 1/4 Long4 ................................................B374011 ....................... Socket Head Cap Screw 3/8-16 x 2 1/2 Long5 ................................................B377211 ....................... Socket Head Cap Screw 3/8-16 x 4 1/2 Long6 ................................................B502405 ....................... Flat Head Cap Screw 1/2-13 x 1 1/2 Long7 ................................................B503211 ....................... Socket Head Cap Screw 1/2-13 x 2 Long8 ................................................ J377100 ........................ 3/8-16 Nylon Locknut9 ................................................ J377000 ........................ 3/8-16 Nylon Jam Locknut10 .............................................. J507000 ........................ 1/2-13 Nylon Locknut

11 ...............................................K370001 ....................... 3/8 Flat Washer12 ..............................................K371501 ....................... 3/8 Split Lockwasher13 ..............................................K500001 ....................... 1/2 Flat Washer14 ..............................................K501501 ....................... 1/2 Split Lockwasher15 .............................................. 80048 ........................... Button Head Cap Screw16 .............................................. 3599029........................ Flat Washer17 .............................................. 3707373........................ Electro Mechanical Actuator.................................................. 3707663........................ Motor - Service Electro Mechanical Actuator18 .............................................. 3708868........................ Compression Spring19 .............................................. 3708870........................ External Snap Ring20 .............................................. 3709019........................ Thrust Washer

21 .............................................. 3709700........................ Cam Follower22 .............................................. 3709702........................ Flanged Bronze Bushing23 .............................................. 6209070........................ Lift Long Arm24 .............................................. 6209071........................ Lift Swing Arm25 .............................................. 6209072........................ Lift Short Arm26 .............................................. 6209073........................ Bearing Plate27 .............................................. 6209074........................ Bearing Plate Arm Block28 .............................................. 6209089........................ Ramp Support Strap29 .............................................. 6209095........................ Anti-Rollback Plate30 .............................................. 6209097........................ Pivot Pin

31 .............................................. 6209116 ........................ Lift Cross Support32 .............................................. 6509507........................ Lift Bearing Assembly33 .............................................. 6509570........................ Lift Frame Weldment34 .............................................. 6509572........................ Load Carrier Weldment35 .............................................. 6209573........................ Actuator Top Block Assembly36 .............................................. 6209574........................ Ramp Weldment37 .............................................. 3708456........................ Capacity Warning Decal (Not Shown)38 .............................................. 6309036........................ Capacity Warning Decal - Text (Not Shown)39 ..............................................B311013 ....................... 5/16-18 x 5/8 Button Head Socket Cap Screw40 .............................................. 3589109........................ Flat Washer .315 ID x .50 OD x .035 Thick


54

PARTS LIST 6200720 REEL LIFT ASSEMBLY

55

PARTS LIST 6200720 REEL LIFT ASSEMBLY

DIAGRAMNUMBER

1 ................................................B190813 ....................... Button Head Cap Screw #10-24 x 1/2 Long2 ................................................B191213 ....................... Button Head Cap Screw #10-24 x 3/4 Long3 ................................................B251016 ....................... Button Head Cap Screw 1/4-20 x 5/8 Long4 ................................................ J197000 ........................ #10-24 Nylon Jam Locknut5 ................................................ J257100 ........................ 1/4-20 Nylon Locknut6 ................................................R000483 ....................... #10 Lockwasher7 ................................................R000553 ....................... #10-24 Kep Nut8 ................................................ 3707009........................ Liquid Tight Strain Relief .27-.47 Wire9 ................................................ 3707648........................ 6-Amp Circuit Breaker10 .............................................. 3707428........................ Rocker Switch Momentary on-off-on

11 ............................................... 3707526........................ 25-Amp Bridge Diode12 .............................................. 3707644........................ Thermistor Assembly13 .............................................. 3708448........................ Electrical Warning Decal14 .............................................. 6209101........................ Lift Electrical Control Box15 .............................................. 6209102........................ Lift Control Decal16 .............................................. 6209110 ........................ Lift Actuator Cord17 .............................................. 6209111 ........................ Lift Controls Harness18 .............................................. 6329082........................ Lift Power Cord19 .............................................. 6309134........................ Diode Jumper Assembly


56

EXPLODED VIEW: 55583 GRINDING HEAD ASSEMBLY

57

DIAGRAMNUMBER


PARTS LIST: 55583 GRINDING HEAD ASSEMBLY

1 ...................................................... B191011 .......................... 10-24 X 5/8 Socket Head Cap Screw2 ...................................................... 3708848 .......................... 1/4-28 x 1/2 Socket Head Cap Screw w/ patch3 ...................................................... B251211 .......................... 1/4-20 x 3/4 Socket Head Cap Screw4 ...................................................... B250816 ......................... 1/4-20 x 1/2 Button Head Socket Cap Screw5 ...................................................... 80407 .............................. 1/4-20 x 1.00 Socket HeadCap Screw - Low Head6 ...................................................... B251216 ......................... 1/4-20 x 3/4 Button Head Socket Cap Screw7 ...................................................... B253211 .......................... 1/4-20 x 2.00 Socket Head Cap Screw8 ...................................................... H250802 ......................... Roll Pin .25D x .50 Lg9 ...................................................... J252000 .......................... 1/4-20 Hex Jam Nut10 .................................................... J627200 .......................... 5/8-18 Locknut Jam Nylon12 .................................................... K250001 ......................... Flat Washer 1/413 .................................................... K251501 ......................... 1/4 Lockwasher Split14 .................................................... J257000 .......................... 1/4-20 Locknut Jam Nylon15 .................................................... 05720 .............................. Grinding Wheel 6 x 2.75B x 1.5W 46G16 .................................................... 05731 .............................. Grinding Wheel 6 x 2.75B x .38W 24G Type 117 .................................................... 3708839 .......................... 3/8-16 x 1/2 Screw w/locking Flange18 .................................................... 50037 .............................. Spin Flange Nut19 .................................................... 50039 .............................. Spin Wheel Flange20 .................................................... 50073 .............................. Wear Pad21 .................................................... 55200 .............................. Relief Wheel Flange22 .................................................... 55201 .............................. Relief Flange Nut23 .................................................... 50204 .............................. Spin Yoke24 .................................................... 55126 .............................. Bearing Support Bracket25 .................................................... 55280 .............................. Double Bearing Assembly26 .................................................... 80406 .............................. Spacer washer27 .................................................... 50297 .............................. Traverse Shoe28 .................................................... 50298 .............................. Traverse Clamp Bracket29 .................................................... 55296 .............................. Single Bearing Assembly30 .................................................... 50310 .............................. Belt Clamp Tip31 .................................................... 50320 .............................. Traverse Guard32 .................................................... 50321 .............................. Shield Mount Bracket33 .................................................... 50324 .............................. Spark Shield34 .................................................... 50329 .............................. Spin Support35 .................................................... 55582 .............................. Bearing Housing Assembly36 .................................................... 09404 .............................. Linear Bearing37 .................................................... 3709209 .......................... Oil Seal 1"ID x 1.57"OD x .18738 .................................................... 3708561 .......................... Adjustable Handle 3/8-16 x 1.56 Long39 .................................................... 3708835 .......................... Adjustable Handle 1/4-20 x 1.25 Long40 .................................................... 27115 .............................. Spacer - .386 ID x .50 OD x .75 Long41 .................................................... 80335 .............................. Destaco 602 Clamp42 .................................................... 80337 .............................. T-knob Assembly43 .................................................... 3589106 .......................... Washer44 .................................................... B191031 ......................... 10-32 x 5/8 Socket Head Cap Screw45 .................................................... 55119 .............................. Finger Rotate Base46 .................................................... 6009057 .......................... Spacer .265 ID x .48 OD x .50 Long47 .................................................... 55144 .............................. Knob - 1/4-20 x 1" Diameter........................................................ C190360 ......................... 10-32 x 3/16 Socket Head Set Screw

48 .................................................... 3708838 .......................... Star Knob - 1" Diameter49 .................................................... 55112 .............................. Cam Plate50 .................................................... 80392 .............................. Cam Follower - 1/2" Diameter51 .................................................... 55113 .............................. Finger Slide52 .................................................... 55117 .............................. Fixed Finger53 .................................................... B190634 ......................... 10-32 x 3/8" Button Head Socket Cap Screw54 .................................................... 55118 .............................. Stop Pin55 .................................................... 55116 .............................. Index Finger Stop Block56 .................................................... H181202 ......................... 3/16 x 3/4" long Roll Pin57 .................................................... 55579 .............................. Locking Plate Weldment58 .................................................... 3708833 .......................... Spacer - .252 ID x .50 OD x .125 Long59 .................................................... C190467 ......................... 10-32 x 1/4" Socket Head Set screw60 .................................................... 55127 .............................. 3/16 Diameter Index Stop Pin61 .................................................... 55581 .............................. Indexing Finger Assembly62 .................................................... 3708107 .......................... Compression Spring

58

PARTS LIST: 55451 PIVOT ARM AND GRINDING SHAFT ASSY 1 of 2

59


DIAGRAMNUMBER

1 ................................................B313601 ....................... 5/16-18 x 2-1/4 Hex Head Cap Screw2 ................................................B371611 ....................... 3/8-16 x 1 Socket Head Cap Screw3 ................................................B372411 ....................... 3/8-16 x 1-1/2 Socket Head Cap Screw4 ................................................B373601 ....................... 3/8-16 x 2-1/4 Hex Head Cap Screw5 ................................................B752001 ....................... 3/4-10 x 1.25 Hex Head Cap Screw6 ................................................C250820 ....................... 1/4-20 x 1/2 Cup Point Set Screw7 ................................................ J317000 ........................ 5/16-18 Locknut Nylon Jam8 ................................................ J377100 ........................ 3/8-16 Locknut Hex Nylok Full9 ................................................K371501 ....................... 3/8 Lockwasher Split10 ..............................................R000453 ....................... Flat Washer .31 x .88 x .104T

11 ............................................... 3707690........................ Motor 1HP12 .............................................. 50235 ........................... Traverse Shaft13 .............................................. 50236 ........................... Pulley 2.45 Diameter Poly V14 .............................................. 50237 ........................... Pulley 3.72 Diameter Poly V15 .............................................. 50256 ........................... Grinding Wheel Shaft16 .............................................. 50279 ........................... Tensioner Bar17 .............................................. 50280 ........................... Tensioner Pivot Shaft18 .............................................. 50281 ........................... Tensioner Pulley Shaft19 .............................................. 50282 ........................... Pivot Support Shaft20 .............................................. 50311 ............................ Prox Switch Holder R.H.

21 .............................................. 50318 ........................... Prox Switch Holder L.H.22 .............................................. 55404 ........................... Arm Assembly R.H.23 .............................................. 55407 ........................... Arm Assembly L.H.24 ..............................................C190420 ....................... 10-24 x 1/4 Cup Point Set Screw25 .............................................. 09680 ........................... Torrington Bearing26 .............................................. 80336 ........................... Piloted Bearing Flange27 .............................................. 80338 ........................... Key .25 sq x 1.25 Lg28 .............................................. 80342 ........................... Torsion Spring29 .............................................. 80343 ........................... Conical Washer .539 x .862 x .014T30 .............................................. 80349 ........................... Idler Pulley 4.0 Diameter

31 .............................................. 80350 ........................... Poly V Belt32 .............................................. 80351 ........................... Conical Washer 1.40 x 2.03 x .024T33 .............................................. 3708425........................ Shoulder Bolt .313 D x .375 L34 .............................................. 3709019........................ Thrust Washer .500 x .937 x .032 T35 .............................................. 3709886........................ Flat Washer .812 x 2.25 x.135 T36 .............................................. 80126 ........................... Key 3/10 sq x 1.00 Lg


60

EXPLODED VIEW: 55451 PIVOT ARM AND GRINDING SHAFT ASSY 2 of 2

61


DIAGRAMNUMBER

1 ................................................B120311 ....................... 5-40 X .188 Lg Socket Head Cap Screw2 ................................................B130605 ....................... 6-32 x 3/8 Flat Head Socket Cap Screw3 ................................................B160411 ....................... 8-32 x 1/4 Socket Head Cap Screw4 ................................................B190611 ....................... 10-24 x 3/8 Socket Head Cap Screw5 ................................................B190831 ....................... 10-24 x 1/2 Socket Head Cap Screw6 ................................................C370820 ....................... 3/8-16 x 1/2 Cup Point Set Screw7 ................................................ J502000 ........................ 1/2-13 Hex Jam Nut8 ................................................ J507100 ........................ 1/2-13 Locknut Full Nylon9 ................................................K161501 ....................... #8 Lockwasher Split10 ..............................................K191501 ....................... #10 Lockwasher Split

11 ............................................... 09068 ........................... Washer Conical .50 x 1.25 x .078T12 .............................................. 09299 ........................... 1/2-13 x 2.5 Lg Button Head Socket Cap Screw13 .............................................. 09707 ........................... Digital Scale, 6" Mitutoyo #57214 .............................................. 50095 ........................... Mounting Block15 .............................................. 50283 ........................... Gage Mounting Bracket16 .............................................. 55472 ........................... Handwheel 1/2-13 ID17 .............................................. 50325 ........................... Arm Support Pivot18 .............................................. 50348 ........................... Vertical Adjustment Shaft19 .............................................. 50573 ........................... Vertical Adjuster Assembly20 .............................................. 50591 ........................... Cap Assembly

21 .............................................. 80344 ........................... Hex Acorn Nut 1/2-1322 .............................................. 3709042........................ Ball Bearing Thrust Nice #603-1/423 .............................................. 7469149........................ Nylon Plug 5/16 Diameter


62

EXPLODED VIEW: 55563 TRAVERSE DRIVE ASSEMBLY

63

DIAGRAMNUMBER

1 ................................................B251011 ....................... 1/4-20 X 5/8 Socket Head Cap Screw2 ................................................B257211 ....................... 1/4-20 x 4.5 Socket Head Cap Screw3 ................................................ J257000 ........................ 1/4-20 Locknut Thin4 ................................................K250001 ....................... Flat Washer 1/45 ................................................K251501 ....................... 1/4 Lockwasher Split6 ................................................ 50309 ........................... Traverse Pulley Shaft7 ................................................ 50354 ........................... Cog Pulley Drive8 ................................................ 6059062........................ Motor Assembly Trav W169 ................................................ 50363 ........................... Traverse Pulley Guard10 .............................................. 55553 ........................... Cog Pulley Driven .375 P .50W

11 ............................................... 80353 ........................... Die Spring .34 ID x 2.0 Lg12 .............................................. 80354 ........................... Cog Belt13 .............................................. 80355 ........................... Thrust Washer .75 ID x 1.25 OD14 .............................................. 3709331........................ Retaining Ring15 ..............................................C250460 ....................... 1/4-28 x 1/4 Socket Head Set Screw16 .............................................. 80126 ........................... 3/16 SQ x 1.00 Key


PARTS LIST: 55563 TRAVERSE DRIVE ASSEMBLY

64

EXPLODED VIEW: 55452 MOWER SUPPORT ASSEMBLY

65

DIAGRAMNUMBER

1 ................................................B251016 ....................... 1/4-20 X 5/8 Button Head Cap Screw2 ................................................B251216 ....................... 1/4-20 x 3/4 Button Head Cap Screw3 ................................................C250420 ....................... 1/4-20 x 1/4 Cup Point Set Screw4 ................................................ J377000 ........................ 3/8-16 Locknut Jam Nylon5 ................................................ J502000 ........................ 1/2-13 Hex Jam Nut6 ................................................K251501 ....................... 1/4 Lockwasher Split7 ................................................ 09853 ........................... Knob 4 prong 1/2-13 F8 ................................................17119............................ Threaded Stud 1/2-13 x 65 Lg9 ................................................ 50242 ........................... Roller Clamp Weldment10 .............................................. 50288 ........................... Tooling Block Adjustment

11 ............................................... 50290 ........................... Front Clamp Plate12 .............................................. 50291 ........................... Clamp Block13 .............................................. 55449 ........................... Tooling Base Plate14 .............................................. 55376 ........................... Tooling Spacer15 .............................................. 55374 ........................... Acme Shaft L.H. Tooling16 .............................................. 50568 ........................... V Roller Weldment L.H.17 .............................................. 50570 ........................... T-Knob Assembly 3/8-16 x .75 Dog Point18 .............................................. 80396 ........................... Knob Assembly 1/4-20 x 1.0 Lg19 .............................................. 55506 ........................... V Roller Weldment R.H.20 .............................................. 50584 ........................... Rear Roller Clamp Weldment

21 .............................................. 70512 ........................... Roller Roller Bracket Weldment22 .............................................. 80346 ........................... Bolt T Slot 3/8-16 x 2.0 Lg23 .............................................. 3708245........................ Knob T 235 3/8-16 F24 .............................................. 3708393........................ Handwheel 3.50 Diameter25 .............................................. 3709062........................ Conical Washer .382 x .75 x .035 T26 .............................................. 3889045........................ Spacer .406 ID x .88 OD x .38Long27 .............................................. 80347 ........................... Quick Clamp Handle28 ..............................................H251002 ....................... Roll Pin .25 Dia. x 5/8 Long


PARTS LIST: 55452 MOWER SUPPORT ASSEMBLY

66

EXPLODED VIEW: 55460 VERTICAL MOWER SUPPORT ASSEMBLY

67

DIAGRAMNUMBER

1 ................................................B371601 ....................... 3/8-16 X 1 Hex Head Cap Screw2 ................................................C250420 ....................... 1/4-20 x 1/4 Cup Point Cap Screw3 ................................................ J377000 ........................ 3/8-16 Locknut Jam Nylon4 ................................................K371501 ....................... 3/8 Lockwasher Split5 ................................................ 17519 ........................... Knob T Assembly 1/2-13 x 6.5"6 ................................................ 50288 ........................... Tooling Block Adjustment7 ................................................ 55376 ........................... Tooling Spacer8 ................................................ 55374 ........................... Acme Shaft L.H. Tooling9 ................................................ 50592 ........................... Knob T 3/8-16 x 1.0 Lg10 .............................................. 55282 ........................... Hanger "V"

11 ............................................... 55343 ........................... Clamp Weldment Large L.H.12 .............................................. 55358 ........................... Clamp Weldment Large R.H.13 .............................................. 55511 ............................ Tooling Post Assembly L.H.14 .............................................. 55512 ........................... Tooling Post Assembly R.H.15 .............................................. 3708393........................ Handwheel 3.50 Dia.16 .............................................. 3709062........................ Conical Washer .382 Id x .75 OD x .035 Thick


PARTS LIST: 55460 VERTICAL MOWER SUPPORT ASSEMBLY

68

EXPLODED VIEW: 55454 CARTON ASSEMBLY

69

DIAGRAMNUMBER

1 ................................................ 50014 ........................... Spanner Wrench2 ................................................C190320 ....................... #10-24 x 3/16 Socket Head Setscrew3 ................................................H250802 ....................... 1/4" x 1/2" Roll Pin4 ................................................ 09394 ........................... 1/4-20 2-prong Knob5 ................................................ 55122 ........................... Dresser Support Block6 ................................................ 55461 ........................... Dresser Support Weldment7 ................................................ 3708845 ........................ 3/4 Wide x 1/4 Thick Diamond Dresser8 ................................................ 6509588 ........................ T-Knob Assembly9 ................................................R000377 ....................... Sq Key 3/16 x .7510 .............................................. 3709073 ........................ Retaining Ring

11 ...............................................3709584 ........................ Flange Coupler .625 Bore12 .............................................. 6009051 ........................ Drive Adapter 1/2 sq 3.5 Lg13 .............................................. 6009052 ........................ Adapter14 .............................................. 6009217 ........................ Driver Coupler Adapter15 .............................................. 3709585 ........................ Sleeve Coupler


PARTS LIST: 55454 CARTON ASSEMBLY

70

EXPLODED VIEW: 55571 ALIGNMENT GAGE ASSEMBLY

71

DIAGRAMNUMBER

1 ................................................B120611 ....................... 5-40 x .38 Socket Head Cap Screw2 ................................................B161011 ....................... 8-32 x 5/8 Socket Head Cap Screw3 ................................................B251016 ....................... 1/4-20 x 5/8 Button Head Socket Cap Screw4 ................................................B251216 ....................... 1/4-20 x 3/4 Button Head Socket Cap Screw5 ................................................B252001 ....................... 1/4-20 x 1-1/4 Hex Head Cap Screw6 ................................................ J161000 ........................ 8-32 Hex nut7 ................................................K121501 ....................... #5 Lockwasher Split8 ................................................K161501 ....................... #8 Lockwasher Split9 ................................................K251501 ....................... 1/4 Lockwasher Split10 .............................................. 50290 ........................... Front Clamp Plate

11 ...............................................50291 ........................... Clamp Block12 .............................................. 50570 ........................... T-Knob Assembly 3/8-16 x .75 Dog Point13 .............................................. 50586 ........................... Gage Base Weldment14 .............................................. 50597 ........................... Gage Bar Assembly Vertical15 .............................................. 3529069 ........................ Spacer .25 ID x .375 OD x .69 Long16 .............................................. 6509418 ........................ Pivot Plate Machined17 .............................................. 6509349 ........................ Retainer Plate19 .............................................. 6509359 ........................ Digital Gage Machined20 ..............................................H060302 ....................... Roll Pin .063 D x .188 Long

21 .............................................. 80396 ........................... Knob T 1/4-20 x 1.18 Long22 .............................................. 6509412 ........................ Indicator Base Weldment23 .............................................. 6509567 ........................ Knob Assembly T 1.5 3/8-16 x 2.25 Long24 .............................................. 6609501 ........................ Knob Assembly T 1/4-20 x 1.31 Long


PARTS LIST: 55571 ALIGNMENT GAGE ASSEMBLY

72

EXPLODED VIEW: 55456 SPIN DRIVE ASSEMBLY

73

DIAGRAMNUMBER

1 ................................................B251016 ....................... 1/4-20 x 5/8 Button Head Socket Cap Screw2 ................................................B251211 ....................... 1/4-20 x 3/4 Socket Head Cap Screw3 ................................................B251216 ....................... 1/4-20 x 3/4 Button Head Socket Cap Screw4 ................................................B251411 ....................... 1/4-20 x 7/8 Socket Head Cap Screw5 ................................................K250001 ....................... Flat Washer 1/46 ................................................K251501 ....................... 1/4 Lockwasher Split7 ................................................R000376 ....................... Sq Key 1/8 x .758 ................................................ 50290 ........................... Front Clamp Plate9 ................................................ 50291 ........................... Clamp Block10 .............................................. 55151 ........................... Motor Spin Assembly Spin W13

11 ............................................... 50570 ........................... T-Knob Assembly 3/8-16 x .75 Dog Point12 .............................................. 50585 ........................... Spin Mount Weldment Vertical13 .............................................. 55437 ........................... Spin Mount Weldment14 .............................................. 55442 ........................... Spin Arm Weldment Horizontal15 .............................................. 3708391........................ Reducer 10:1 Ratio16 .............................................. 3709586........................ Flange Coupler .50 Bore17 .............................................. 6509588........................ Knob Assembly T 2.5 3/8-16 x 1.00L18 .............................................. 6329072........................ Decal - Scale19 .............................................. 3707623........................ DC Motor Brush (Not Shown)


PARTS LIST: 55456 SPIN DRIVE ASSEMBLY

74

EXPLODED VIEW: 55457 CONTROLS ASSEMBLY

75

DIAGRAMNUMBER

1 ................................................D160608 ....................... Thrd Cutting Screw 8-32 x 3/8 "F Type"2 ................................................D250800 ....................... Thrd Cutting Screw 1/4-20 x 1/2 "F Type" Hex Hd3 ................................................D250808 ....................... Thrd Cutting Screw 1/4-20 x 1/2 "F Type" Pan Hd4 ................................................ J167000 ........................ 8-32 Nylon Insert Lock Nut Jam5 ................................................R000536 ....................... Lockwasher 1/4" Internal Teeth6 ................................................ 55373 ........................... Control Panel Decal7 ................................................ 55413 ........................... Electrical Cover Panel8 ................................................ 55422 ........................... Control Service Panel9 ................................................ 55455 ........................... Control Panel Sub-Assembly (See Page 74-75)10 .............................................. 55458 ........................... Control Panel Cord (Not Shown)

11 ............................................... 55459 ........................... Potentiometer Cord (Not Shown)12 .............................................. 55474 ........................... Wire Harness - 555 (Not Shown)13 .............................................. 80419 ........................... Potentiometer Assembly - 10K14 .............................................. 80420 ........................... Potentiometer Assembly - 50K15 .............................................. 3707009........................ Strain Relief - Liquid Tight .27-.47 Wire Dia.16 .............................................. 3707029........................ Strain Relief - Liquid Tight .19-.30 Wire Dia.17 .............................................. 3707075........................ Toggle Switch Boot18 .............................................. 3707080........................ Toggle Switch19 .............................................. 3707658........................ Strain Relief - Liquid Tight .55-.71 Wire Dia.20 .............................................. 3707224........................ Cable Tie Mount

21 .............................................. 3707225........................ Cable Tie - 6.5 Long x .18 Wide (Not Shown)22 .............................................. 3707255........................ Cable Tie - 4.0 Long x .10 Wide (Not Shown)23 .............................................. 3707342........................ Yellow E-Stop Ring24 .............................................. 3707367........................ Rocker Switch25 .............................................. 3707429........................ Rocker Switch26 .............................................. 3707446........................ Potentiometer Knob27 .............................................. 3707564........................ Green Pushbutton28 .............................................. 3707565........................ Contact Block - Normally Open29 .............................................. 3707566........................ Switch Mounting Latch30 .............................................. 3707567........................ Red Stop Push/Pull Pushbutton

31 .............................................. 3707568........................ Contact Block - Normally Closed32 .............................................. 3707647........................ Door Safety Coded Magnet33 .............................................. 3707549........................ Circuit Breaker - 20 Amp34 .............................................. 3707653........................ Circuit Breaker - 4 Amp35 .............................................. 3708378........................ Foam Strip - .25 Thick {Sold by the foot]36 .............................................. 3708675........................ Blind Rivet .188 Dia.37 .............................................. 3708820........................ 8-32 x .50 Button Head Safety Screw38 .............................................. 6059040........................ Door Safety Switch Assembly - Front39 .............................................. 6059093........................ Light Receptacle Cord (Not Shown)40 .............................................. 6329065........................ Traverse Proximity Switch - Left Hand (Not Shown)

41 .............................................. 6329066........................ Traverse Proximity Switch - Right Hand (Not Shown)42 .............................................. 6329391........................ Main Power Cord (Not Shown)43 .............................................. 6509391........................ Power Cord Warning Tag (Not Shown)44 .............................................. 3708448........................ Electrical Warning Decal45 .............................................. 55476 ........................... Door Switch Bracket


PARTS LIST: 55457 CONTROLS ASSEMBLY

76

EXPLODED VIEW: 55455 ELECTRIC PANEL SUB ASSEMBLY

77

DIAGRAMNUMBER

1 ................................................D160666 ....................... No. 8 x 3/8 Pan Head Self Tapping Screw2 ................................................D161266 ....................... No. 8 x 3/4 Pan Head Self Tapping Screw3 ................................................R000480 ....................... Lockwasher No. 8 External Teeth4 ................................................ 55223 ........................... Terminal Strip Decal5 ................................................ 3707073........................ 8 Pin Socket6 ................................................ 3707163........................ Primary Ground Decal7 ................................................ 3707164........................ Primary Ground Lug8 ................................................ 3707378........................ Din Rail - 14" Long9 ................................................ 3707654........................ Power Line Filter10 .............................................. 3707550........................ Traverse Control Board

11 ............................................... 3707556........................ Magnetic Starter 1 HP12 .............................................. 3707558........................ Voltage Sensor Relay13 .............................................. 3707625........................ Terminal Block End Stop14 .............................................. 3707626........................ Terminal Block Jumper15 .............................................. 3707627........................ Terminal Block End Plate16 .............................................. 3707628........................ 2 Conductor Geey Terminal Block17 .............................................. 3707629........................ 2 Conductor Blue Terminal Block18 .............................................. 3708826........................ Low Voltage Relay Warning Decal19 .............................................. 6009270........................ Electrical Panel20 .............................................. 80259 ........................... Circuit Breaker - 20 Amp

21 .............................................. 3707706........................ Terminal Strip - 2 Row 19 Pole22 .............................................. 3707707........................ Terminal Strip Double Flat Spade23 .............................................. 3707709........................ Terminal Strip Single 90° Spade24 .............................................. 3707708........................ Terminal Strip Double 90° Spade25 .............................................. 3707624........................ Ground Terminal Block26 .............................................. 3707328........................ Door Safety Switch Monitor27 .............................................. 3707333........................ Power Supply 24 VDC 0.3 Amp28 .............................................. 3707524........................ Spin Control Board29 .............................................. 3707224........................ Cable Tie Mount (Not Shown)30 .............................................. 3707225........................ Cable Tie 6.5" x .18 Wide (Not Shown)

31 .............................................. 3707615........................ Wire Harness - Common (Not Shown)32 .............................................. 3707656........................ Wire Assembly W99 (Not Shown)33 .............................................. 18091 ........................... Wire Assembly (Not Shown)34 .............................................. 3707616........................ Wire Harness - Spin Drive (Not Shown)35 .............................................. 3707617........................ Wire Harness - Safety Monitor (Not Shown)36 .............................................. 3707631........................ Terminal Block Tag 1-10 (Not Shown)37 .............................................. 3707632........................ Terminal Block Tag 11-20 (Not Shown)


PARTS LIST: 55455 ELECTRIC PANEL SUB ASSEMBLY

78

WIRING DIAGRAM 55455-1

6,010,394 & 6,290,581 assembly and service manual · 6 service data skill and training required...

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