6600901 Service Manual
Contents
1. Wheel will glaze if not dressed often enough If grinding wheel is not extended 1 2 12 mm over bedknife it will glaze more quickly because there is less dressing Too light a grinding cut doesn t permit enough dressing action on the wheel so it glazes Too slow a traverse Speed can cause excessive heat buildup in the grinding wheel which glazes the wheel A grinding wheel which isn t properly trued up on outside or inside diameters can vibrate excessively and transfer that vibration to the motor PARTS LISTS amp EXPLODED VIEWS EXPLODED VIEW 6609523 CONTROL PANEL PARTS LIST 6609523 CONTROL PANEL DIAGRAM PART PART NUMBER NUMBER DESCRIPTION B161014 8 32 X 5 8 Pan Head Machine Screw B190813 10 24 X 1 2 Button Head Socket Cap Screw B191213 10 24 X 3 4 Button Head Socket Cap Screw 10 24 Locknut Nylon Full R000483 Washer Lock 10 Int Teeth R000553 Kep Nut 10 24 R000558 Kep Nut 8 32 Strain Relief Strain Relief Strain Relief Terminal Block 25 Spade Circuit Breaker 2 Amp Relay 120 Volt Block Contact Pushbutton Green Cap Block Contact N C Pushbutton Red Cap Circuit Breaker 1 amp Circuit Breaker 12 amp Decal Warning Electrical Decal Warning Safety Base Control Box Cover Control Box EXPLODED VIEW 6609523 CONTROL PANEL WIRING HJLIAS LAVIS WALSAS SSS 6 AV Hd CI LAS TR HILINS 9015 UND SS3 dN cl 30939 LINJA tg2. tain rail spacing against the Large Vee roller ecentric preload To correctly adjust the strut with no carriage large vee roller eccentric preload and the carriage and grinding head to one side measure the dimension over rails at each end of the grinder Average the two values and adjust the center strut to exactly the average value and tighten See FIG 17 Verify your ready after locking the strut assembly p 16 Now reset the carriage large vee roller eccentric per instructions on Page 14 TROUBLESHOOTING ELECTRICAL PROBLEM POSSIBLE CAUSE Grinding motor and coolant pump do not function no apparent power to machine A Main power source breaker is tripped power source switch is off or grinder is not plugged in B System Start Switch SSS is not on C Guard door is not closed D Grinding motor start circuit or coolant pump circuit breaker has tripped E Voltage is not going through interlock relay ELECTRICAL MAIN POWER REMEDY Reset breaker turn switch on and plug machine in Press System Start Switch Close the guard door Reset circuit breaker on end of control panel NOTE If circuit breaker tripping persists find the short in the appropriate circuit With the guard door closed and the system start switch latched check for 115 VAC at terminals 0 and 1 on both relays If no consult distributor If yes check for 115VAC at terminal Relay 2 term 2 to wire B
3. Block Contact N C Pushbutton Red Cap Circuit Breaker 1 amp Circuit Breaker 12 amp Pump Coolant 660 W13 Prox Assy Door W14 Cord GR Motor W15 Cord Power W10 Wire Assy W01 25 FER Wire Assy W02 25F FER Wire Assy W03 25F FER Wire Assy W04 25F FER Wire Assy W05 FER FER Wire Assy W06 25F 25F Wire Assy W07 25F 25F Wire Assy W08 25F 25F Wire Assy W09 25F 25F Wire Assy W11 2 Loop Wire Assy W12 2 Loop 6609523 CONTROL PANEL SCHEMATIC W NICH 10 did LNY DD C NT Q 1 6 JLLYW HJS 099 AN 1118 NoD NI NII JVA ST NWO THIS PAGE LEFT INTENTIONALLY BLANK FOR NOTE TAKING PURPOSES 6609524 BEDKNIFE SUPPORT EXPLODED VIEW OM 9 g JARE sj G 2 4 es E A PARTS LIST DIAGRAM NUMBER 6609524 BEDKNIFE SUPPORT PART DESCRIPTION NUMBER 8 32 x 1 4 Button Head Socket Cap Screw 10 24 x 1 2 10 24 x 1 2 Socket Head Cap Screw 10 24 x 1 2 Button Head Socket Cap Screw 1 4 20 x 3 8 Socket Head Cap Screw 1 4 20 x 1 2 Socket Head Cap Screw 1 4 20 x 3 4 Socket Head Cap Screw 1 4 20 x 1 Socket Head Cap Screw 1 4 20 x 1 Button Head Socket Cap Screw 5 16 18 x 1 4 Socket Set Screw 5 16 18 x 1 2 Socket Set Screw Pin Roll 25 Dia x 1 00 Long 3 8 16 Locknut Jam Nylon 1 4 Lockwasher Split Spacer 25 ID x 3750 D x 69 L Nylon Plug 3 16 Dia Washer F
4. dv c 5949 LIT ONTOS ASYHTSd dV T 333388 11040 18 diddl blk Xd d 4000 W GK 2 ATWA 0 SN COIN 009 I NB o SIN E 08 91 i e MD SOLOW N dal ND AWVONDD Oo ATWA ND T 7 Nn EIN g alt MD dnd IN 8 ow ANT B TSNE T at ES Tat 11 80 PARTS LIST DIAGRAM PART NUMBER NUMBER 3707009 3707029 3707439 3707442 3707507 3707508 3707521 6609079 6609082 6609523 CONTROL PANEL WIRING DESCRIPTION Strain Relief Liquid Tray 24 47 Strain Relief Liquid Tray 16 31 Strain Relief Liquid Tray 20 39 Terminal Block 25 Spade Circuit Breaker 2 amp Relay DPST 120V Coil Block Contact N O Latch MTG Pushbutton Green Cap
5. grinding straightness Looseness in roller causes erratic grind Looseness in roller causes erratic grind Strut holds the shafts parallel If not adjusted correctly grind will not be straight TROUBLESHOOTING Continued PROBLEM The top face of the bedknife is ground unevenly across the width Too coarse a grind on bedknife POSSIBLE CAUSE A Grinding wheel rim is not completely over the top face being ground B Small grinding Head Slide Vee Roller loose C Carriage Large Vee Rollers loose D Backlash in infeed handwheel Grinding head is traversing too fast REMEDY The wheel rim must extend over the bedknife top face by 1 2 13 mm whenever possible See Operators Manual If not possible dress the wheel more often Adjust Vee rollers per procedure on Page 18 Adjust Vee Roller per procedure on Page 14 Eliminate backlash in infeed handwheel see Page 15 Slow down the traversing speed BEDKNIFE GRINDING REASON When the rim doesn t extend over the top face it wears unevenly and causes grooves across the bed knife Looseness in rollers causes erratic grind Looseness in rollers causes erratic grind Backlash allows grinding wheel to move under load Traversing speed controls the grinding surface texture A slower traverse produces grind marks closer together TROUBLESHOOTING Continued PROBLEM The top face of the
6. AN EXTENSION CORD RECEPTACLE GROUND IN YOUR BUILDING MUST BE VERIFIED IMPROPER D GROUNDING IN YOUR BUILDING MAY CAUSE THE GRINDER TO MALFUNCTION I PROPER GROUNDING OF THE FOR 15 ANP RATED LARGE MACHINES Below is a list of required wire size in your building For 0 to 30 Feet from panel to receptacle Use 14 Ga Wire For 30 to 50 Feet from panel to receptacle Use 12 Ga Wire For 50 to 80 Feet from panel to receptacle Use 10 Ga Wire For 80 to 140 Feet from panel to receptacle Use 8 Ga Wire For 0 to 9 Meters from panel to receptacle Use 2 5mm Wire For 9 to 15 Meters from panel to receptacle Use 4 0mm Wire For 15 to 24 Meters from panel to receptacle Use 6 0mm Wire For 24 to 42 Meters from panel to receptacle Use 10 0mm Wire FOR 220 V 50 or 60Hz applications Product No 6600951 should be ordered 6600951 has a 2 KVA step down transformer from 220V 50 60 Hz input power to 115V 50 60 Hz machine power The wiring diagram is shown in FIG 7A The power cord has no connector A connector which is appropriate for your locality and 220 volt 8 amp application should be installed Use only a qualified electrician to complete the installation X G x m R H H H IMPORTANT GROUNDING INSTRUCTIONS In case of a malfunction of breakdown grounding reduces the risk of electrical shock by providing a path of least resistance for electrical current This Grinder has an electrical cord with an eq
7. and General Operating Information for important background explanations about the machine and about bedknife grinding Then read the Operating Instructions pages for step by step procedures on mounting the bedknife and grinding its top and front faces MAINTENANCE DAILY MAINTENANCE IS SPECIFIED ON PAGE 4 OF THE OPERATOR S MANUAL AND IS TO BE PERFORMED BY THE OPERATOR LISTED BELOW ARE PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY S MAINTENANCE DEPARTMENT Clean the Traverse Rails by wiping down with WD 40 or equivalent on a weekly basis Replace the four foam rail wipers FIG 10 every 6 months of operation Clean the interior of the Coolant Tray as necessary 10 and at least every 6 months MAINTENANCE Continued CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE WINDOWS Cleaning Instructions DO NOT USE GASOLINE Adherence to regular and proper cleaning procedures is recommended to preserve appearance and performance Washing to Minimize Scratching Wash polycarbonate windows with a mild dish washing liquid detergent and lukewarm water using a clean soft sponge or a soft cloth Rinse well with clean water Dry thoroughly with a moist cellulose sponge to prevent water spots Do not scrub or use brushes on these windows Also do not use butyl cellosolve in direct sunlight Fresh paint splashes and grease can be removed easily before drying by rubbing lightly with a good grade of
8. bedknife shows burn marks from being too hot Grinding wheel is glazing too quickly Grinding motor vibrates exces sively POSSIBLE CAUSE A Coolant not directed onto the bedknife and grinding wheel B Too heavy stock removal during grinding C Grinding wheel is glazing A Wheel needs dressing B Too light a cut when rough grinding C Grinding head is traversing too slow Grinding wheel is out of balance BEDKNIFE GRINDING REMEDY Direct coolant into the grinding wheel at the point of the grind See Operators Manual Take off about 002 to 003 05 to 075mm per pass during rough grind See Operators Manual Dress the wheel before the finish grinding pass on each bedknife See Operators Manual Dress the wheel before the finish grinding pass on each bedknife See Operators Manual Take off about 002 to 033 05 to 075 mm per pass during rough grind See Operators Manual Speed up traverse Visually check the outside diameter run out while slowly rotating the wheel Also check the motor without a wheel installed Replace the wheel if out of round REASON When the front face of the bedknife gets too hot the steel loses its temper softens Too much stock removal in one pass creates too much heat and softens the steel Wheel will glaze if not dressed often enough Also as a general rule use a higher traverse speed for the heavy grind
9. out of their holes then lift the other end and remove the Grinder from the pallet NOTE Fork lift brackets are located on the bottom side of the main frame as shown in FIG 1 use these brackets for moving the grinder THE GRINDER WEIGHS 670 LBS 304KG TO LIFT USE POWER EQUIPMENT Discard the leg screws and the shipping straps ASSEMBLY INSTRUCTIONS Continued LOCATE AND LEVEL THE GRINDER Set the Grinder on a level concrete floor on a single uncracked slab of concrete If the unit must be located near a wall allow ad equate space for operating and servicing Refer to FIG 3 for recommended and alternate locations near a wall Place a level on the front carriage rail near the center of the machine and check the level from left to right See FIG 4A Adjust the leveling feet until the machine is level Place the level across the front and rear carriage rails near the left end of the machine See FIG 4B Adjust the two leveling feet on the left end until level Place the level across the front and rear carriage rails near the right end of the carriage bed Level the right end in the same way as the left end For grinding accuracy the two ends must have the identical level within 01 25 mm so the frame is not twisted Recheck the level in both directions When satisfactory tighten the hex jam nuts on the level ing feet securely against the nuts welded to the bottom of the base See FIG 2 Don t
10. the groove must be toward the carriage up EXPLODED VIEW Torque to 18 ft lbs PARTS LIST DIAGRAM NUMBER 6609530 CARRIAGE ASSEMBLY PART NUMBER DESCRIPTION 3 8 16 x 2 Hex Head Cap Screw 1 2 13x 8 1 2 SocketHead Cap Screw 5 16 18 Locknut Nylon Jam 3 8 Lockwasher Split Handle Carriage Spacer Carriage Roller Bolt Eccentric Wiper Shaft Bracket Wiper Roller Assy Carriage Rear Roller Wiper Bracket RH Rear Roller Wiper Bracket LH 1 4 Lockwasher 1 4 20 x 1 2 Hex Head Cap Screw Rear Roller Spacer
11. turn the leveling feet when tightening Again recheck the level after the nuts are firmly tightened FOR GRINDING ACCURACY THE MACHINE DOES NOT HAVE TO BE PERFECTLY LEVEL HOWEVER IT IS CRITICAL THAT FRONT TO BACK LEVELING BE IDENTICAL AT BOTH ENDS OF THE MACHINE INSTALL THE SPINNING HANDLE Install the spinning handle on the horizontal handwheels See FIG 5 Handle parts are 3709374 HANDLE 3969065 SPACER 371501 3 8 LOCKWASHER 8373201 4 8 16 X 2 HEX HEAD CAP screy FIG 6 Machine can be located tight to the wall Wall 252000 1 4 20 HEX JAM NUT 3709370 HANDLE r 0225011 1 4 20 X 3 1 8 SOCKET HEAD SCREW ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT GROUNDING INSTRUCTIONS ON PAGE 9 115 Volt Model Only Plug the control box power cord into a standard 115V AC 15 amp grounded receptacle See FIG 7 IT IS RECOMMENDED THAT THIS ACCU 660 BEDKNIFE GRINDER HAS ITS OWN PERMANENT POWER CONNECTION FROM THE POWER DISTRIBUTION PANEL WITH NO OTHER MAJOR POWER DRAW EQUIPMENT ON THE SAME LINE IT IS REQUIRED THAT THE POWER DELIVERED TO THIS GRINDER IS 115 VAC 15 AMPS THE TOLERANCE ON THIS POWER REQUIREMENT IS 5 THEREFORE THE MINIMUM VOLTAGE REQUIREMENT IS 109VAC WITH 15 AMPS VOLTAGE MUST BE CHECKED WITH ALL EQUIPMENT UNDER LOAD OPERATING ON THE CIRCUIT DO NOT OPERATE THIS GRINDER WITH
12. 28 ft lbs Ba ee 3 8 I 19 ft lb 31 ft lb 46 ft lb IDS IOS IOS Use the Grade 8 values in the table at the right 7116 In 30ftlbs 50ftibs 75 ft lbs No 6 Screws 11in lbs 0 125 kg m 1 21 45ftlbs 75ftlbs 115 ft lbs No 8 Screws 20 in Ibs 0 23 kg m kg ny S Kom No 10 Screws 32 in lbs 0 37kg m ASSEMBLY INSTRUCTIONS UNPACK THE CARTONS NOTE Before you install the machine read the following assembly procedure completely Then study Getting to Know Your Bedknife Grinder in the Operators Manual Use care when unpacking Double check the packing cartons for any miscellaneous items before discarding Inspect all items for shipping damage as they are removed from the shipping containers If you find any damage notify the carrier s claims agent and do not proceed further until the damage has been inspected by the agent Refer also to the Shipping and Receiving Instructions packed with the unit Remove the shipping strap that secures the carriage to the left end of the machine during shipment Fork Lift Brackets INSTALLATION OF UPPER GRINDING HEAD ASSEMBLY To remove the load from the large V rollers during shipping the upper grinding head assembly is shipped on the crate base To install the upper grinding head assembly remove the two feed screw guide screws that are temporarily installed in the carriage and set aside Remove the manual traversing handle a
13. 8 Cover Coolant Pump Pump Coolant 660 W13 6609526 LEG ASSEMBLY EXPLODED VIEW PARTS LIST DIAGRAM NUMBER 6609526 LEG ASSEMBLY PART DESCRIPTION NUMBER 5 16 18 x 75 Button Head Socket Cap Scre 3 8 16 x 3 4 Hex Head Cap Screw 3 8 16 x 3 Socket Head Cap Screw 5 16 18 Locknut Nylon Full 3 18 16 Locknut Hex Nylok 1 2 13 Hexnut 3 8 Lockwasher Split Washer Flat Plug Hole 3 4 Dia Leveling Bolt Adjustable Decal Foley United Large Strap Anchor Panel Leg Center Pin Base Leg Weldment 660 EXPLODED VIEW 6609528 MAIN BASE ASSEMBLY PARTS LIST DIAGRAM NUMBER 6609528 MAIN BASE ASSEMBLY PART DESCRIPTION NUMBER 5 16 18 X 1 2 Button Head Socket Cap Screw 5 15 18 x 5 8 Hex Head Cap Screw 5 16 18 x 75 Button Head Socket Cap Screw 3 8 16 x 1 2 Socket Set Screw Cup Point 5 16 18 Locknut Nylon Jam 5 16 Lockwasher Split 1 2 18 Hexnut Strip Foam Strut Door Pipe Plug 3 4 NPT Decal Foley United Large Base Main Machined Shaft Carriage Traverse Hinge Door Door Tank Cover Block Brace Front Block Brace Rear Plate Door Hinge Shaft Brace Washer Thrust 6609529 GRINDING HEAD ASSEMBLY EXPLODED VIEW DIAGRAM PART PART DIAGRAM PART PART NUMBER NUMBER DESCRIPTION NUMBER NUMBER DESCRIPTION 10 24 x 3 8 Socket Head Cap Screw Washer Conical 10 24 x 3 4 Button Head Socke
14. ACCU 660 MANUAL BEDKNIFE GRINDER ASSEMBLY AND SERVICE MANUAL WARNING You must thoroughly read and understand this manual before assembling or maintaining the equipment paying particular attention to the Warning amp Safety instructions 6607954 6 03 SAFETY INSTRUCTIONS Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards Whenever you see these symbols follow their instructions The Warning Symbol identifies special instructions or procedures which if not strictly observed could result in personal injury KEEP GUARDS IN PLACE and in working order REMOVE WRENCHES AND OTHER TOOLS KEEP WORK AREA CLEAN DON T USE IN DANGEROUS ENVIRONMENT Don t use Grinder in damp or wet locations Machine is for indoor use only Keep work area well lit KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area MAKE WORK AREA CHILD PROOF with padlocks or master switches DON T FORCE THE GRINDER It will do the job better and safer if used as specified in this manual USE THE RIGHT TOOL Don t force the Grinder or an attachment to do a job for which it was not designed WEAR PROPER APPAREL Wear no loose clothing gloves neckties or jewelry which may get caught in moving parts Nonslip footwear is recommended Wear protective hair covering to contain long hair ALWAYS USE SAFETY GLASSES SECURE YOUR WORK Make certain that th
15. DUCE VOMITING HAZARD POTENTIAL APPLIES TO CONCENTRATE AND IS LESS AT NORMAL USE DILUTION Mixing the Coolant Mix Part No 3708620 Coolant in a separate container at a ratio of 50 parts water to 1 part concentrate Refer also to the label on the Coolant container If the coolant tray is empty this will take about 8gallons of water and 1 3 pint of concentrate 30 liters of water and O 6 liter of concentrate Fill with coolant until the coolant level is 25 50 6 12 mm above the top of the coolant pump USED TO HIGH A CONCENTRATION OR LOW A CONCENTRATION WILL CAUSE CORROSION AND PERFORMANCE PROBLEMS THE COOLANT RATIO AS SPECIFIED MUST BE ASSEMBLY INSTRUCTIONS Continued CHECK THE CARRIAGE TRAVERSE Visually check that the grinding head will be able to traverse to both sides of the machine without contacting any components Manually move the grinding head through a complete cycle Watch carefully for obstructions to the head travel and check that the grinding motor cord and coolant hose are not stretched CHECK THE GRINDING MOTOR Close the guard door to connect the interlock Press START Check that the grinding head runs properly Be prepared to press STOP if there is any problem Also check that the coolant system functions properly MAKE FINAL PREPARATIONS FOR OPERATION Carefully read the operating instructions in the Operators Manual First study the pages titled Getting to Know Your Grinder
16. E MOVEMENT IN THE DIAMOND DRESSER ADJUSTMENT COLLAR The adjustment collar on the diamond dresser See FIG 14 has a nylon ball and setscrew to put a holding drag on the diamond dresser shaft If the adjustment collar is moving when not wanted or moving too freely tighten the setscrew and put more load on the nylon ball If the adjustment collar is very difficult to turn loosen the setscrew and put less load on the nylon ball Setscrew and Nylon Ball TO SET THE ZERO DEGREE ON THE TOOLING ROTATION PROTRACTOR To set the zero value on the tooling rotated pointer put a magnetic based angle finder on the top machined surface of the tooling bar Loosen the rotation lock lever and rotate the bar to the lower front face grinding position rotate until the magnetic base angle finder reads zero and lock the lock lever Loosen the setscrew on the pointer and rotate the pointer to zero degrees on the protractor decal See FIG 15 ADJUSTMENTS CONTINUED ADJUSTING THE PRELOAD TENSIION ON THE SMALL GRINDING HEAD SLIDE VEE ROLLERS The small grinding head slide vee rollers are positioned two fixed on the left and one adjustable on the right side To set the correct preload on the right side adjuster tighten the setscrew in FIG 16 until the spring is fully compressed solid then back off 1 2 turn Tension Adjust Setscrew ADJUSTING THE TRAVERSE RAIL CENTER STRUT ADJUSTMENT The grinder is equipped with a center strut to main
17. HEEL BACKLASH If there is backlash in the Grinder Head Infeed handwheel FIG 12A there are two adjustment 1 points on each to check 1 Washers behind the handwheel A Loosen about half a turn the setscrew holding the handwheel to the shaft This set Screw is accessed by removing the calibration ring set screw and rotating the calibration ring to access the handwheel setscrew B Tighten the hex lock nut which secures the handwheel to 100 in Ibs 1 15 kg m then back off 1 2 turn C Check for 015 in 04mm gap between the wave washer and the flat washer See FIG 12B Readjust the hex lock nut if necessary D Tighten the setscrew holding the handwheel to the shaft Install and tighten the calibration ring setscrew 2 Check the nylon ball tension on the adjustment shaft threads at the grinding head slide See FIG 12A When you turn the handwheel there should be no free play in the handwheel before the grinding head slide moves If there is free play tighten the setscrew that pushes the nylon ball against the acme thread of the adjustment shaft The nylon ball preloads the free play out of the threaded joint between the adjustment shaft and the tooling bar slide block Apply tension only enough to zero the free play DO NOT over tension as the adjuster will be difficult to turn FIG 12A Setscrew with nylon ball Infeed Handwheel Hex Nut flat washers gt lt 015 in gap FIG 12B ADJU
18. STMENT Continued TO ADJUST THE CARRIAGE VEE ROLLERS ECCENTRIC The carriage large Vee rollers are adjusted for zero free play with an eccentric on the single roller attachment bolt closest to the operator To adjust the eccentric position the Grinding Head and Carriage Assembly to center it on the traverse rail center strut assembly Move the Grinding Head inward with the infeed handwheel to expose the vee roller lock nut See FIG 11 Put a 3 4 wrench on the hex head eccentric bolt bottom side Loosen the top side locknut with a 1 2 socket only enough to move the eccentric bolt The roller spacer washer under the carriage and above the roller assembly must be completely flush with no air gaps If you have air gaps the eccentric bolt is to loose With the eccentric bolt and locknut loose only enough to move the eccentric turn the 3 4 wrench eccentric bolt only enough to take the free play out of the large vee rollers Determine zero free play by grasping the carriage and trying to move it up and down firmly Tighten the eccentric only enough for zero free play When correct retighten the top side lock nut Make certain the roller spacer and bracket are tightened square to the car riage with no air gaps then verify no free play DO NOT OVERTIGHTEN THE ECCENTRIC OVERTIGHTENING CAN OVERLOAD THE TRAVERSE SHAFTS AND CAUSE A BAD GRIND FIG 11 Vee Roller Lock Nut ADJUSTMENTS Continued TO ELIMINATE INFEED HANDW
19. STMENTS Continued TO ELIMINATE ALIGNMENT ADJUSTMENT BACKLASH If there is backlash in the alignment adjustment handwheels FIG 13A there are two adjustment points on each to check 1 Washers behind the handwheel A Loosen about half a turn the setscrew holding the handwheel to the shaft B Tighten the hex lock nut which secures the handwheel to 100 in Ibs 1 15 kg m then back off 1 2 turn C Check for 015 in 04mm gap between the wave washer and the flat washer See FIG 13B Readjust the hex lock nut if necessary D Tighten the setscrew holding the handwheel to the shaft 2 Check the nylon ball tension on the adjustment shaft threads at the tooling bar slide blocks See FIG 13A When you turn the handwheel there should be no free play in the handwheel before the tooling bar slide block moves If there is free play tighten the setscrew that pushes the nylon ball against the acme thread of the adjustment shaft The nylon ball preloads the free play out of the threaded joint between the adjustment shaft and the tooling bar slide block Apply tension only enough to zero the free play Do NOT over tension as the adjuster will be difficult to turn The setscrew for the right side tooling bar slide block is under the protractor decal plate FIG 13A Setscrew with nylon ball Infeed Handwheel Hex Nut Wave and Flat Wash 2 015 in gap FIG 13B ADJUSTMENTS CONTINUED TO ELIMINAT
20. VM amp P naphtha or isopropyl alcohol Afterward a warm final wash should be made using a mild dish washing liquid detergent solution and ending with a thorough rinsing with clean water Minimizing Hairline Scratches Scratches and minor abrasions can be minimized by using a mild automobile polish Three such products that tend to polish and fill scratches are Johnson paste Wax Novus Plastic Polish 1 and 2 and Mirror Glaze plastic polish M G M10 It is suggested that a test be made on a corner of the polycarbonate window with the product selected following the polish manufacturer s instructions Some Important DON TS DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows Never scrape polycarbonate windows with squeegees razor blades or other sharp instruments Benzene gasoline acetone or carbon tetrachloride should NEVER be used on polycarbonate windows DO NOT clean polycarbonate windows in hot sun or at elevated temperatures Graffiti Removal Butyl cellosolve for removal of paints marking pen inks lipstick etc The use of masking tape adhesive tape or lint removal tools works well for lifting off old weathered paints To remove labels stickers etc the use of kerosene VM amp P naphtha or petroleum spirits is generally effective When the solvent will not penetrate sticker material apply heat hair dryer to soften the adhesive and promote removal GASOLINE SHOULD NOT BE USED ADJU
21. aximum Grinding Length 32 in B13 mm Sound Level Less than 75 Dba TRAINING REQUIRED TORQUE REQUIREMENTS SKILL AND TRAINING REQUIRED FOR SERVICING This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the ACCU 660 Bed knife Grinder For those without that background service can be arranged through a local distributor This Manual presumes that you are already familiar with the normal operation of the Grinder If not you should read the Operators Manual or do the servicing in con junction with someone who is familiar with its operation PERSONS WITHOUT THE NECESSARY KNOWLEDGE AND SKILLS SHOULD NOT REMOVE THE CONTROL BOX COVER OR ATTEMPT ANY INTERNAL TROUBLESHOOTING ADJUSTMENTS OR PARTS REPLACEMENT If you have questions not answered in this manual please call your distributor They will contact the manufacturer if necessary TORQUE REQUIREMENTS Throughout this manual we refer to torque requirements GRADE 2 GRADE 5 GRADE 8 as firmly tighten or the like For more specific torque values refer to the information below Bolts Going into a Nut or Into a Thread Hole in Steel SMOOTH aMARKS 6 MARKS Refer to table at the right HEAD on HEAD on HEAD T 1 41n 6 ft lbs 9 ft lbs 13 ft lbs Bolts Going into a Thread Hole in Aluminum Use the Grade 2 values in the table at the right 5 16 In 11 ft lbs 18 ft lbs
22. e bedknife is securely fastened with the electromagnets provided before operating 12 DON T OVERREACH Keep proper The Caution Symbol identifies special instructions or procedures which if not correctly followed could result in damage to or destruction of equipment MAINTAIN GRINDER WITH CARE Follow instructions in Service Manual for lubrication and preventive maintenance DISCONNECT POWER BEFORE SERVICING REDUCE THE RISK OF UNINTENTIONAL STARTING Make sure the switch is OFF before plugging in the Grinder USE RECOMMENDED ACCESSORIES Consult the manual for recommended accessories Using improper accessories may cause risk of personal injury CHECK DAMAGED PARTS A guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced KNOW YOUR EQUIPMENT Read this manual carefully Learn its application and limitations as well as specific potential hazards KEEP ALL SAFETY DECALS CLEAN AND LEGIBLE If safety decals become damaged or illegible for any reason replace immediately Refer to replacement parts illustrations in Service Manual for the proper location and part numbers of safety decals DO NOT OPERATE THE GRINDER WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS IMPROPER USE OF GRINDING WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY Grinding is a safe operation if the few basic rules lis
23. ing nut EXCESSIVELY DON T grind on the SIDE OF THE WHEEL see Safety Code B7 2 for exception DON T start the machine until the WHEEL GUARD IS IN PLACE 8 DON T JAM work into the wheel 9 DON T STAND DIRECTLY IN FRONT ofa grinding wheel whenever a grinder is started 10 DON T FORCE GRINDING so that motor slows noticeably or work gets hot SAFETY INSTRUCTIONS SPECIFICATIONS This machine is intended for grinding the bedknife from a reel mowing unit ONLY Any use other than this may cause personal injury and void the warranty To assure the quality and safety of your machine and to maintain the warranty you MUST use original equipment manufactures replacement parts and have any repair work done by a qualified professional i ALL operators of this equipment must be thoroughly trained BEFORE operating the equipment Ge Do not use compressed air to clean grinding dust from the machine This dust can cause personal injury as well as damage to the grinder This machine is intended for indoor use only Do not use a power washer to clean the machine CONTENTS Safety Instructions Specifications Training Required Torque Requirements Assembly Page 6 13 Maintenance Page 14 15 Adjustments Page 16 20 Troubleshooting Page 21 24 Parts Lists Exploded Views Page 25 43 SPECIFICATIONS Electrical Requirements 115V 50 60 Hz 15 amp circuit Net Weight 670 lbs 304 kg Shipping Weight 700 lbs 318 kg M
24. lat 39 x 1 38 x 125 Handwheel 4 5 Dia 38 Bore Knob T 2 5 1 2 13F T Knob Assy 3 8 16 Handle Adj 3 8 16 x 1 97 Washer Cncl Spring Compressor 600 Od x 2 5 Long Washer Flat 41 x 1 63 x 047 Washer Cncl 382 x 75 x 035 Washer Thrust 375 x 812 Shaft Adjusting Acme Left Hand Lock Bar Left Hand Adjuster Lock Bar Thread Left Hand Adjuster Base Gage Short C bore Block Slide Left Hand Block Slide Right Hand Shaft Gage Magnet Tooling 660 Arm Center Adjuster Screw Gage Lock Guide Slide Block Block Adj Mount Strap Slide Right Hand Bar Lock Slide Right Hand Plate Index Decal Decal Protractor Decal Tooling Handwheel Knob Assy T 1 4 20 x 2 1 2 Hex Head Cap Screw Pin Roll 25Dia x 2 0 Long Tooling Bar Machined Pin Tooling Bar Left Hand Rotate Arm Weldement Tooling Mount Weldment Left Hand Mount Weldment Right Hand Center Assy Index Brkt Weldement 10 24 x 1 2 Socket Set Screw 6609525 COOLANT PUMP ASSEMBLY EXPLODED VIEW PARTS LIST DIAGRAM NUMBER 6609525 COOLANT PUMP ASSEMBLY PART DESCRIPTION NUMBER 10 24 X 1 Socket Head Cap Screw 8 32 x 5 8 Socket Set Screw 8 32 Locknut Jam Nylon 10 Flat Washer 10 Lockwasher Split Connector Shut off Valve Connector Barbed Insert Coolant Flood amp Mist Pint Connector Barbed Female Valve Shut Off Needle Coolant Line Assy Tube Coolant 1 4 ID x 8
25. lock Light Blue for grinding motor Relay 2 term 6 to wire Block Light Blue for coolant pump If no consult distributor REASON Because the guard door is interlocked to the grinding motor the grinding motor will not operate if door is open TROUBLESHOOTING Continued PROBLEM Top face of bedknife is ground in a convex shape high in the center or convex shape high in the center POSSIBLE CAUSE A Grinding wheel loading up with grinding grit B Too heavy a grind on the final grinding pass C Small Grinding Head Slide Vee Roller loose D Carriage Large Vee Rollers loose E Traverse Rail Center Strut out of adjustment BEDKNIFE GRINDING REMEDY Dress the wheel prescribed in the Operators Manual Follow the procedures in the Operators Manual On the final pass infeed only about 001 025 mm Let the wheel spark out for 10 20 passes at about slow speed with no additional infeed Adjust Vee Rollers per proce dure on Page 18 Adjust Vee Roller per proce dure on Page14 Adjust center strut per procedures on Page18 REASON A loaded wheel creates undue pressure on the surface being ground Both ends of bedknife move because of this pressure allowing bedknife to rock on the middle support For precise grinding sparking out process is critical It eliminates excessive final grinding pressure on centers and middle support which helps maintain
26. nd set aside Remove the double wire clip and screw and set aside Cut the plastic strap that holds the upper grinding head assembly to the crate base Remove the blue die spring from the infeed handwheel where it has been taped and install the spring between the carriage slide and the small vee roller arm setscrew Loosen the setscrew so it is flush to the outside of the arm Lift the upper grinding head assembly and install the small vee rollers onto the V cut on the carriage Adjust the preload tension on the small vee roller arm per the procedure on page 20 Install the two feed infeed guide screws Install the manual traversing handle Install the motor cord and coolant hose through the double wire clip leaving enough slack for motor infeed movement and install to the carriage Cable tie the motor cord and coolant hose to the cable tie mount in the center of the grinder under the coolant tank lip Do not pull the cable tie tight or you will restrict coolant flow ASSEMBLY INSTRUCTIONS Continued Remove the Grinder from the Pallet To remove the Grinder from the wood pallet 1 Unbolt the brackets that hold each end of the Grinder legs to the bottom of the pallet The Grinder s four leveling feet FIG 2 are seated in countersunk holes in the pallet Lift one end of the machine until both feet are out of their holes of Machine Prop this first end up with sturdy boards or other supports so the feet remain
27. t Cap Screw Nylon Ball 1 4 20 x 1 2 Button Head Socket Cap Screw Indicator Clear 1 4 20 x 3 4 Button Head Socket Cap Screw Shaft Adjusting 1 4 20 x 1 Button Head Socket Cap Screw Ring Calibrated 1 4 20 x 1 1 4 Button Head Socket Cap Screw Handwheel 3 8 16 x 3 4 Socket Head Cap Screw Base Carriage Slide 10 24 x 1 2 Socket Set Screw Arm Roller Pivot 1 4 20 x 1 4 Socket Set Screw Bushing V Roller Short 1 4 20 x 1 2 Socket Set Screw Bracket Dresser Lock 5 16 18 x 1 4 Socket Set Screw Guide Feed Screw 5 8 18 x 5 8 Socket Set Screw 3 8 16 Locknut Jam Nylon No 10 Flat Washer No 10 Lockwasher Split Motor Assy 3 4 HP 1 4 Lockwasher Split Decal Warning Electrical 3 8 Lockwasher Split Decal Warning Sharp 3589081 Spacer Decal Warning 3600 RPM K310101 5 16 Flat Cut Washer Motor Pivot Assy Bushing Reducer Collar Adjuster Grinding Wheel Straight Cup 6 dia x 2 deep Flange Outer Diamond Dresser Tee Knob Assy Clamp Double Tube Eccentric Pin Assy Shoulder Bolt Dresser Arm Weldment Spring Compression Grinding Wheel Guard Weldment Adjustable Handle Socket Head Cap Screw 1 4 20 x 3 1 8 Long Roller Dual Vee Handle Spring Compression Hex Jam Nut 1 4 20 Washer Conical 1 4 20 Nylok Lock Nut Washer Thrust 1511 SLHVd ATAINSSSV QV3H ONIGNIHO 6256099 6609530 CARRIAGE ASSEMBLY Torque to 18 ft Ibs Note At time of installation the side of the three V rollers with
28. ted below are followed These rules are based on material contained in the ANSI B7 1 Safety Code for Use Care and Protection of Abrasive Wheels For your safety we suggest you benefit from the experience of others and carefully follow these rules DO DO always HANDLE AND STORE wheels in a CAREFUL manner DO VISUALLY INSPECT all wheels before mounting for possible damage DO CHECK MACHINE SPEED against theestablished maximum safe operating speed marked on wheel DO CHECK MOUNTING FLANGES for equal and correct diameter DO USE MOUNTING BLOTTERS when supplied with wheels DO be sure WORK REST is properly adjusted DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding DO always WEAR SAFETY GLASSES or some type of eye protection when grinding 10 DO TURN OFF COOLANT before stopping to avoid creating an out of balance condition DON T DON T use a cracked wheel or one that HAS BEEN DROPPED or has become damaged DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole If wheel won t fit the machine get one that Will DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURRS DON T TIGHTEN the mount
29. uipment grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded according to all local or other appropriate electrical codes and ordinances Before plugging in the Grinder make sure it will be connected to a supply circuit protected by a properly sized circuit breaker or fuse Never modify the plug provided with the machine if it won t fit the outlet have a proper outlet and circuit installed by a qualified electrician ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOUR MACHINE AN IMPROPER CONNECTION CAN CAUSE A DANGEROUS ELECTRICAL SHOCK IF YOU ARE UNSURE OF THE PROPER ELECTRICAL GROUNDING PROCEDURE CONTACT A QUALIFIED ELECTRICIAN This Page Left Intentionally Blank for Note Taking Purposes ASSEMBLY INSTRUCTIONS Cont INSTALL THE COOLANT ALWAYS READ THE MATERIAL SAFETY DATA SHEET MSDS FOR THE COOLANT YOU ARE USING BELOW ARE WARNINGS THAT APPLY TO MOST COOLANTS AVOID CONTACT OF COOLANT WITH EYES IT WILL CAUSE EYE IRRITATION WEAR FACE SHIELD OR GOGGLES WHEN HANDLING CONCENTRATE IN CASE OF CONTACT FLUSH EYES WITH WATER FOR 15 MINUTES AND CONTACT A PHYSICIAN AVOID BREATHING MISTS PROVIDE LOCAL VENTILATION KEEP CONCENTRATED BOTTLE CLOSED WHEN NOT IN USE CONTINUED CONTACT OF CONCENTRATE ON SKIN MAY CAUSE IRRITATION WASH WITH SOAP AND WATER AFTER CONTACT DO NOT TAKE INTERNALLY IF INGESTED CONSULT PHYSICIAN AND DO NOT IN
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