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ACCU-Pro 632 AUTO - INDEX SPIN / RELIEF REEL MOWER GRINDER Patent No. 6,010,394 6,290,581 & 6,685,544 ASSEMBLY SERVICE MANUAL WARNING You must thoroughly read and understand this manual before operating the equipment, paying particular attention to the Warning & Safety instructions.
SAFETY INSTRUCTIONS Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards. Whenever you see these symbols, follow their instructions. The Caution Symbol identifies special The Warning Symbol identifies spe- instructions or procedures which, if not cial instructions or procedures which, if strictly observed, could result in damage not correctly followed, could result in...
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SAFETY INSTRUCTIONS IMPROPER USE OF GRINDING WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY Grinding is a safe operation if the few basic rules listed below are fol- lowed. These rules are based on materiel contained in the ANSI B7.1 Safety Code for "Use, Care and Protection of Abrasive Wheels".
This machine is intended for grinding the reel of reel type mower units ONLY. Any use other than this may cause personal injury and void the warranty. To assure the quality and safety of your machine and to maintain the warranty, you MUST use original equipment manufacturers replacement parts and have any repair work done by a qualified professional.
SERVICE DATA SKILL AND TRAINING REQUIRED FOR SERVICING This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the ACCU-PRO Spin/Relief Grinder. For those without the background, service can be arranged through your local distributor. This Manual presumes that you are already familiar with the normal operation of the Grinder.
ASSEMBLY INSTRUCTIONS Remove the sides, front, and back of the crate. Remove the plastic bag, shrink wrap and bubble 74" wrap. Remove the metal clips that secure the (188 cm) grinder to the crate base. With a fork lift, raise the grinder from the wood base and set it in its final position.
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ASSEMBLY INSTRUCTIONS (Continued) Remove the carton and remove the contents from the carton onto a workbench. The carton includes: PRODUCT PACKET 5" (127mm) DIA. X 3/8" (10mm) 3.5" (89mm) DIA. X 1" (25mm) WIDE GRINDING WHEEL WIDE GRINDING WHEEL SPIN DRIVE ADAPTER ALLEN WRENCH 3.5"...
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ASSEMBLY INSTRUCTIONS (Continued) LEVEL BASE Place level on the top of the table. Adjust the leveling feet as necessary to bring to level. See FIG. 4. Place a level across the table from front to rear. Adjust the leveling feet on the end of the machine as necessary to level.
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ASSEMBLY INSTRUCTIONS (Continued) APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER, REFER TO THE "IMPORTANT GROUNDING INSTRUCTIONS" ON PAGE 10. 115 Volt Model Only. Plug the control box power cord into a standard 115V AC 20-amp grounded receptacle. See FIG. 7. FIG.
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ASSEMBLY INSTRUCTIONS (Continued) FOR 220 V 50 or 60Hz applications Product No. 6320916 should be ordered. These models includes a 3KVA 220V, step down to 110 V 50-60 Hz transformer. The wiring diagram is shown in FIG. 8. The power cord has no connector.
PERIODIC MAINTENANCE DAILY MAINTENANCE IS SPECIFIED ON PAGE 4 OF THE OPERATOR'S MANUAL, AND IS TO BE PERFORMED BY THE OPERATOR. LISTED BELOW ARE PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY'S MAINTENANCE DEPARTMENT: 1. Clean the tank and filter of the vacuum system weekly or more often depending on the number of reels ground.
STORAGE PROCEDURE It is important to follow the procedures below when placing your grinding in storage for an extended period of time. Proper care will help maintain the working functions of the grinder and decrease maintenance and problems that occur when storing the grinder. BEFORE STORING THE GRINDER: -Clean the machine thoroughly.
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LUBRICATION LUBRICATION OF LINEAR BEARINGS STEP 1--Thoroughly clean the shafts. STEP 2--Flood spray the two shafts with a spray lubricant (do not use a teflon based lubricant) until the lubricant is dripping off the shafts. See FIG. 10 Then run the carriage back and forth through its range of travel.
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.
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MAINTENANCE (Continued) DIGITAL GAGE Important Do not mark the scale unit with and electric engraver or scratch the scale. t t e i l v e l l ) If the scale will not be used for more than three months, remove the battery and store it properly.
ADJUSTMENTS CARRIAGE LINEAR BEARING REPLACEMENT STEP 1 --Detach the bellows mounting brackets from the carriage. Detach front and rear shields. See FIG. 15. STEP 2 --Remove the three screws of one linear bearing and slide the linear bearing off the end of the carriage shaft. STEP 3 --Insert a new linear bearing onto the end of the carriage shaft with the tension adjustment screw pointing...
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ADJUSTMENTS (Continued) REEL FINGER DOVETAIL GIB AND ADJUSTING KNOB ADJUSTMENTS The reel finger slide to the reel finger positioner has a dovetail with an adjustable gib for tensioning. Tighten the gib set screws on the side so there is no free play in the dovetail slide.
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ADJUSTMENTS (Continued) LOCKING INDEX FINGER PIN To align the Index Finger Locking Pin to the hole in the Index Finger Assembly loosen the two socket head cap screws so the index sensor block is movable. Push down on the index finger assembly until the spring loaded index finger locks into hole with no binding.
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ADJUSTMENTS (Continued) ADJUSTABLE RELIEF TENSION If the relief angle appears to vary during relief grinding, adjust the tension on the nylon plug and set screw. See FIG. 21. FIG. 21 SAFETY SWITCH ALIGNMENT For the safety switches to work properly they must be adjusted so the sender and receiver are parallel to each other with a maximum gap of .19 inches (5mm).
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ADJUSTMENTS (Continued) SPIN GRINDING ATTACHMENT ADJUSTMENT If play develops so crank handle wants to rotate in the scissor action on the spin grinding attachment, the play can be eliminated by tightening the set screw identified in FIG. 25. If there is too much play in the spin drive pivot points, torque down the hex nut tight so conical washer is completely compressed, then back off 1/2 turn.
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ADJUSTMENTS (Continued) ADJUSTING CROSS SLIDE ASSEMBLY If the cross slide becomes very difficult to turn it may become necessary to adjust the assembly. To relieve the tension on the assembly follow the procedure listed below: STEP 1--Using a hydraulic jack, raise the traversing carriage base just enough to alleviate the weight stress on the Cross Slide Assembly.
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ADJUSTMENTS (Continued) CROSS SLIDE SHAFT REPLACEMENT If the cross slide shafts become scarred or gnarled, replace them by the following procedure: STEP 1--Use a hydraulic jack to raise the weight off the Cross Slide Assembly. STEP 2--Loosen the two nuts on the support casting that hold the locking studs and tap with plastic hammer to loosen.
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ADJUSTMENTS (Continued) TRAVERSE BELT TENSION To adjust the tension on the traverse belt tighten the screws and nuts located at the left side of the traverse belt. Tighten nuts until the comprension springs measure 3/4". See FIG. 29. If the springs are not tensioned equally, uneven loading on the traverse system may cause parts to fail.
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CONTROL BOARD POTENTIOMETER ADJUSTMENTS SPIN DRIVE CONTROL BOARD (SDC) The Spin Drive Control Board has four potentiometers, two switches and one dial as shown on FIG. 31. These potentiometers,swtiches and dial have been set at the factory to the positions shown on FIG.
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CONTROL BOARD POTENTIOMETER ADJUSTMENTS DELAY SET SWITCH 1 SET SPIN TORQUE RELIEF SPEED TO 1 TO -OFF POT (STP) 2:00 POT (RSP) 12:00 IR COMP IDLE TORQUE FIG. 31 POT (ITP) 9:00 10:00 3:00 12:00 6:00 9:00 Potentiometer Clock Orientation...
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CONTROL BOARD POTENTIOMETER ADJUSTMENTS POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL (TDC) Min. Speed--Factory set at full (CCW) 8:30. Do not change this setting. (Right Traverse) Forward Torque--Factory set at full (CW) 4:30. Do not change this setting. (Left Traverse) Reverse Torque--Factory set at full (CW) 4:30. Do not change this setting. IR COMP--Factory set to 9:00.
MACHINE SERVICE (Continued) REPLACEMENT OF GRINDING HEAD SHAFT & BEARINGS Remove grinding wheel and grinding wheel knob. The Grinding Head Spindle Assembly consists of the grinding head spindle and a ball bearing press fit together. The left side ball bearing is slip fit on the opposite end. To replace the spindle assembly remove the left side grinding wheel grip knob, square key and belt cover.
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632 MANUAL CONTROL PANEL Door Safety Switch Monitor (SSM) 24 VDC Power Supply (PWR) Low Voltage Relay (LVR) Terminal Strip #2 Traverse Drive (TB2) Control Board (TDC) Magnetic Contactor (MAG) Secondary Circuit Breaker (SCB) Main Circuit Spin Drive Breaker (MCB) Control Board (SDC) Grinding Motor...
ELECTRICAL TROUBLESHOOTING SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING This Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowledge and skills to reliably test and repair the ACCU-Pro electrical system. For those without that background, service can be arranged through your local distributor. This manual presumes that you are already familiar with the normal operation of the Grinder.
ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--AC Main Power Controls: no electrical power to control panel. Verify all wires shown on the wiring diagram on pages 80-81 are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose terminal connections and/or no loose crimps between wire and terminal.
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ELECTRICAL TROUBLESHOOTING (Continued) Possible Causes Checkout Procedure No 120 Volts AC J. Check for 120VAC in to Check for 120 VAC from SCB (03SCB--) to blue wire power to Secondary "02FTRBU" out of FTR Circuit Breaker Yes--Go to Step K. next. (SCB) 6 Amp.
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Machine Shuts off when you turn on Grind motor switch or Spin Motor Switch. Possible Cause Checkout Procedure Machine works A. Close the front doors and rear Guard Doors are Yes--end troubleshooting Open slide up door or workstation ramp No--go to Step B.
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM-- Grinding motor not working. Assuming (SSS) System Start Switch is on with 120 volts AC to control panel and all other functions are working. are correct and pull on wire termi- 80-81 r i f y i r e i r i n nals with approximately 3lbs force to verify there are no loose terminal connections and/or...
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--SPIN DRIVE NOT WORKING IN SPIN MODE. Assuming (SSS) System Start Switch is on with 120 volts AC to control panel and all other functions are working. Verify all wires shown on the wiring diagram on page 80-81 are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose terminal connections and/or not loose crimps between wire and terminal.
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ELECTRICAL TROUBLESHOOTING (Continued) Possible Cause Checkout Procedure Spin Torque Pot (STP) H. Check (STP) remote (STP) on (SDC) board, should be set as torque on the top (SDC) labled on pages 24 and 25. Adjust if is not set correctly board incorrect and check Spin Drive Function.
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Spin Drive not working in relief mode. Assuming (SSS) System Start Switch is on with 120 volts AC to control panel and all other functions are working. Verify all wires shown on the wiring diagram on pages 80-81 are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose terminal connections and/or no loose crimps between wire and terminal.
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ELECTRICAL TROUBLESHOOTING (Continued) Possible Cause Checkout Procedure Board is in spin mode. J. Spin Torque Selector not Light next to TQ on board should be ON. working If not remove wires 41SDCMOD and 44SDCCOM from SDC control board. Machine works. Yes--Machine was in spin mode.
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ELECTRICAL TROUBLESHOOTING (Continued) SPIN DRIVE PROBLEM : Spin drive speed goes at one speed only. Possible Cause Remedy A. Check potentiometer wiring for Wiring hookup to potentiometer If wiring is wrong, correct and proper hookup. See that speed is improper. (If components test.
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Traverse Drive not working. Assuming (SSS) System Start Switch is on with 120 volts AC to control panel and all other functions are working. Verify all wires shown on the wiring diagram on pages are correct and pull on wire terminals with approximately 3lbs force to verify there are no loose terminal connections and/or no loose crimps between wire and terminal.
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ELECTRICAL TROUBLESHOOTING (Continued) Possible Cause Checkout Procedure Check (TDC) terminals #A1 to #A2 for 90 No DC Voltage from G. Check for 90 Volts DC across Volts DC (TDC) Traverse Drive (TDC) terminals #A1 to #A2 this Yes--go to Step H. next Control voltage drives the DC traverse No--go to Step I.
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Traverse does not stop to reverse directions when flag goes under the proximity switch on the left side or right side of machine. Possible Cause Checkout Procedure Gap between A. Gap between flag and If incorrect, adjust per adjustment prox should be 3/16 to 1/ flag and prox is section of manual.
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Traverse speed control goes at one speed only. Possible Cause Checkout Procedure Defective speed control A. Check potentiometer on control Traverse Drive Control Pin #8 to 7 potentiometer panel. Pot full CCW Pot Full CW 0 VDC 9.75 VDC Pin #8 to 9 Pot full CCW...
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--If the carriage traverses to one end of stroke or the other and it stops and does not reverse direction. Possible Cause Remedy Reason Proximity switch is not First check to see of proximity light The light coming on shows the working properly or wire comes on.
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Infeed motor not working. Assuming (SSS) System Start Switch is on with 115 Volts AC to control panel and all other functions are working. Possible Cause Checkout Procedure Infeed motor works A. (IJS) Hold switch on in either Infeed Jog Switch (IJS) Yes--end troubleshooting is not held to on position...
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ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Infeed motor has no low speed (turtle) function. Assuming (SSS) System Start Switch is on with 115 volts AC to control panel and all other functions are working and infeed motor works in high speed (rabbit position). Checkout Procedure Possible Cause Check...
MECHANICAL TROUBLESHOOTING (Continued) Checkout Procedure Possible Cause PROBLEM--Reels ground have high/low blades Check roundness using a magnetic base dial Traverse Speed set too fast. indicator. Traverse speed should be set approximately 12 ft/min. (4 meters/ min.) if roundness is varying. Relubricate and adjust linear bearings per adjustment Lineal bearings for the grinding head carriage are out section.
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MECHANICAL TROUBLESHOOTING (Continued) Possible Cause Checkout Procedure PROBLEM--Too heavy a burr on cutting edge of reel blades. Traverse speed set too high causing a heavy burr Traverse speed should be set lower approximately 12 on the reel blade when spin grinding. ft/min.
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28 ..........B190613 ......10-24 x 3/8 Button Head Socket Cap Screw 29 ..........3708872 ......Patent Decal 30 ..........3709990 ......Foley United Decal 31 ..........3706044 ......Gage Mounting Pin 32 ..........6329022 ......Side Frame Spacer Plate 33 ..........
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PARTS LIST 6329533 FRONT GUARD DOOR ASSEMBLY...
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PARTS LIST 6329533 FRONT GUARD DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 1 ......B250816 ......Button Head Cap Screw 1/4-20 x 1/2 Long 2 ......B252416 ......Button Head Cap Screw 1/4-20 x 1 1/2 Long 3 ......3706042 ......Pan Head Screw #8 x 3/4 Long 4 ......
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PARTS LIST 6329575 REAR SLIDE UP GUARD DOOR ASSEMBLY...
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PARTS LIST 6329575 REAR SLIDE UP GUARD DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 1 ......B190411 ......Socket Head Cap Screw 10-24 x 1/4 Long 2 ......B190613 ......Button Head Socket Cap Screw 10-24 x 3/8 Long 3 ......B250816 ......Button Head Socket Cap Screw 1/4-20 x 1/2 Long 4 ......
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PARTS LIST 6329575 REAR SLIDE UP GUARD DOOR ASSEMBLY...
PARTS LIST 6329575 REAR SLIDE UP GUARD DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 50 ......6329163 ......Rear Door Arm 51 ......6329164 ......Pulley Block 52 ......6329165 ......Door Switch Bracket (Rear Door) 53 ......6329166 ......Cable Guide 54 ......
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PARTS LIST 6329545 MAIN CABINET ASSEMBLY...
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PARTS LIST 6329545 MAIN CABINET ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 ..........B250801 ......Hex Head Cap Screw 1/4-20 x 1/2 2 ..........B251011 ......Socket Head Cap Screw 1/4-20 x 5/8 3 ..........B310813 ......Button Head Socket Cap Screw 5/16-18 x 1/2 4 ..........
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PARTS LIST 6329525 TRAVERSE BASE ASSEMBLY...
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PARTS LIST 6329525 TRAVERSE BASE ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 ....B190611 ....Socket Head Cap Screw 10-24 x 3/8 Long 2 ....B191211 ....Socket Head Cap Screw 10-24 x 3/4 Long 3 ....B250616 ....Button Head Socket Cap Screw 1/4-20 x 3/8 Long 4 ....
PARTS LIST (Continued) 6329525 TRAVERSE BASE ASSEMBLY...
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PARTS LIST (Continued) 6329525 TRAVERSE BASE ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 41 ..... 3709072 ....Compression Spring 42 ..... 3709331 ....External Retaining Ring 43 ..... 6059062 ....Traverse Motor Assembly 44 ..... 6309573 ....Finger & Body Assembly (see page 74) 45 .....
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PARTS LIST 6509565 CROSS SLIDE ASSEMBLY...
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PARTS LIST 6509565 CROSS SLIDE ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 ........C311220 ....Socket Set Screw CPPT 5/16-18 x 3/4 Long 2 ........J371000 ....3/8-16 Hex Nut 3 ........J377000 ....3/8-16 Hex Jam Nylon Locknut 4 ........K371501 ....3/8 Split Lockwasher 5 ........
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6329526 GRINDING HEAD ASSEMBLY PARTS LIST...
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6329526 GRINDING HEAD ASSEMBLY PARTS LIST DIAGRAM PART NUMBER NUMBER DESCRIPTION 1 ....... B251411 ....Socket Head Cap Screw 1/4-20 x 7/8 Long 2 ....... B371611 ....Socket Head Cap Screw 3/8-16 x 1 Long 3 ....... C250627 ....Socket Set Screw Cup Pt 1/4-20 x 3/8 Long - Lock Patch 4 .......
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PARTS LIST 6329527 CARRIAGE ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 .......B250616 ......Button Head Cap Screw 1/4-20 x 3/8 Long 2 .......B252016 ......Button Head Cap Screw 1/4-20 x 1 1/4 Long 3 .......B253216 ......Button Head Cap Screw 1/4-20 x 2 Long 4 .......K251501 ......
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PARTS LIST 6309573 FINGER AND BODY ASSEMBLY...
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PARTS LIST 6309573 FINGER AND BODY ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 .......... B190631 ....Socket Head Cap Screw 10-32 x 3/8 Long 2 .......... B190634 ....Button Head Socket Cap Screw 10-32 x 3/8 Long 3 .......... B251011 ....Socket Head Cap Screw 1/4-20 x 5/8 Long 4 ..........
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PARTS LIST 6309574 STEPPER & MOUNTING ASSEMBLY...
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PARTS LIST 6329578 STEPPER & MOUNTING ASSEMBLY DIAGRAM PART NUMBER DESCRIPTION NUMBER 1 ....B161811 ....Socket Head Cap Screw 8-32 x 1 1/8 Long 2 ....B252011 ....Socket Head Cap Screw 1/4-20 x 1 1/4 Long 3 ....C250825 ....Socket Set Screw 1/4-20 x 1/2 4 ....
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PARTS LIST 6329535 MOWER SUPPORT ASSEMBLY...
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PARTS LIST 6329535 MOWER SUPPORT ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 .......B190614 ..... Pan Head Machine Screw 10-24 x 3/8 Long 2 .......K191501 ..... No.10 Lockwasher 3 .......6009577 ..... Knob Assembly 4 .......3708364 ..... Quick Release Pin .31 Dia. 5 .......3708158 .....
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PARTS LIST (Continued) 6329529 MISCELLANEOUS PARTS DIAGRAM PART NUMBER DESCRIPTION NUMBER 1 ......3700088 ......Grinding Wheel 3.5" Dia. x .38 Wide 2 ......3700086 ......Grinding Wheel 3.5" Dia. x 1" Wide 3 ......3700087 ......Grinding Wheel 5" Dia. x .38" Wide 4 ......
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PARTS LIST 6329571 CONTROL PANEL ASSEMBLY...
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PARTS LIST 6329571 CONTROL PANEL ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 ........B190834 ....Button Head Cap Screw 10-32 x 1/2 Long 2 ........B250816 ....Button Head Cap Screw 1/4-20 x 1/2 Long 3 ........D250800 ....Thread Cutting Screw 1/4-20 x 1/2 Long 4 ........
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PARTS LIST 6329576 CONTROL PANEL SUB-ASSEMBLY...
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6329576 CONTROL PANEL SUB-ASSEMBLY PARTS LIST DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 ........D160666 ....No. 8 x 3/8 Pan Head Self Tapping Screw 2 ........D161266 ....No. 8 x 3/4 Pan Head Self Tapping Screw 3 ........R000480 ....Lockwasher No. 8 External Teeth 4 ........
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6324576 WIRING DIAGRAM CB1 - CIRCUIT BREAKER 1 15 AMP CB2 - CIRCUIT BREAKER 2 4 AMP DSS1 - FRONT DOOR SAFETY SWITCH DSS2 - REAR DOOR SAFETY SWITCH ESS - EMERGENCY STOP SWITCH FTR - LINE FILTER GMS - GRINDING MOTOR SWITCH ICB - INFEED CONTROL BOARD IJS - INFEED JOG SWITCH ISS - INFEED SPEED SWITCH...
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632 WIRING SCHEMATIC CB1 - CIRCUIT BREAKER 1 15 AMP CB2 - CIRCUIT BREAKER 2 4 AMP DSS1 - FRONT DOOR SAFETY SWITCH DSS2 - REAR DOOR SAFETY SWITCH ESS - EMERGENCY STOP SWITCH GMS - GRINDING MOTOR SWITCH ICB - INFEED CONTROL BOARD IJS - INFEED JOG SWITCH ISS - INFEED SPEED SWITCH LVR - LOW VOLTAGE RELAY...
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