Foley 3096 Page 21 Maintenance, Troubleshooting, Adjustments And Parts Lists Download | Manualshive

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TROUBLESHOOTING:

STRAIGHTNESS OF GROUND REEL

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Summary of Contents for 3096

Page 1: ...er Grinder Maintenance Troubleshooting Adjustments And Parts Lists WARNING You must thoroughly read and understand this manual before operating the equipment paying particular attention to the Warning Safety instructions 3967922 7 91 ...

Page 2: ...ing in the grinder 16 USE RECOMMENDED ACCESSORIES Consult the manual for recommended accessories Using improper accessories may cause risk of personal injury 17 CHECK DAMAGED PARTS A guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced 18 NEVER LEAVE GRINDER RUNNING UNATTENDED TURN POWER OFF Do not leave back lapper until it comes to...

Page 3: ...nding DON T 1 DON T use a cracked wheel or one that HAS BEEN DROPPED or has become damaged 2 DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole if wheel won t fit the machine get one that will 3 DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel 4 DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURS 5 DON T TIGHTEN t...

Page 4: ...4 TABLE OF CONTENTS TABLE OF CONTENTS Maintenance Lubrication 4 Adjustments 5 9 Troubleshooting 10 23 Parts Lists Exploded Views 24 37 ...

Page 5: ... 2 Flood spray all three shafts with either WD40 or Tri Flow Lubricant or our lubricant part No 3708201 until the lubricant is dripping off the shafts Then run the carriage black and forth through its range of travel This will carry the lubricant into the actuator and bearings NOTE Because of the flood of lubricant you may find that the actuator slips and traversing is erratic or stalls This is no...

Page 6: ...the tapped hole in actuator Insert the pin driver item 2 through self aligning bearings item 38 and tighten STEP 8 Using a spring scale set the scale up to pull on the carriage parallel to actuator drive shaft item 24 Then while holding the drive shaft from rotating pull on carriage the pull force should be from 15 lbs To 45 lbs target 30 lbs Force See step 9 for readjustment if necessary STEP 9 I...

Page 7: ...embly lay it on its side on the floor STEP 2 Remove the 3 linear bearing pillow blocks item 12 fig 6 and discard STEP 3 Insert the three new linear bearing pillow blocks item 12 fig 6 Adjust the tension screw on the side of each bearing block so when you radially rotate the pillow block around the carriage shaft there should be no free play between bearing item 12 fig 6 and carriage shaft item 42 ...

Page 8: ... bosses Tighten the 2 socket head screws item 13 fig 6 visible from the rear on pillow block item 12 fig 6 Raise rear carriage shaft and carriage position the carriage between V groove bosses on the main base item 31 fig 6 and tighten the other 2 socket head screws Lower and bolt down the rear carriage shaft item 42 fig 6 solidly in the V grooves bosses with screws item 33 fig 6 The bearing tensio...

Page 9: ... 010 When alignment has been completed tighten the drive shaft support blocks Also refer to the Troubleshooting section Items J K Problem Reel ground in a concave convex shape or irregular shape GIB ADJUSTMENT It is very important to have the gib adjustment tight so as not to have any play while grinding Refer to the Troubleshooting section Item H Problem Reel ground in a concave convex shape or i...

Page 10: ...ompensate for increased or decreased motor loading Clockwise rotation of I R COMP trim pot will increase compensation 1 Set SPEED control pot at 50 2 Turn IR COMP pot CW until motor begins to hunt 3 Turn IR COMP pot CCW until hunting stops 4 Set IR Comp pot 1 3 of the span between where motor hunting stopped fully CCW position CUR LIM Current Limit Provides protection form excessive armature curre...

Page 11: ...th the 4 long x 50 diameter from one end to center groove side located on the right hand side when looking from operator position at the limit switch bracket for 3096 On the 3084 and 3055 the 4 long x 50 diameter is to be mounted on the left hand side REASON Installation positioning required for proper mechanical actuation of limit switch and wiring hookup DC motor to circuit board controls direct...

Page 12: ...sed has continuity and break switch open has no continuity when actuating the limit switch If not replace switch using ohm meter an open circuit switch open reads 0 ohms closed circuit switch closed ohms reads full scale REASON When one set of contacts are bad the carriage will not reverse allowing it to go in the opposite direction PROBLEM Carriage traverse will not reverse direction POSSIBLE CAU...

Page 13: ... one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 375 minimum length and look at wear pattern on commutator for arcing Replace brush if necessary REASON A short brush does not make an adequate electrical connection to run the electrical motor POSSIBLE CAUSE C Blown fuse REMEDY Replace the fuse and decrease stock removal rate REASON Extremely heavy grinding cuts...

Page 14: ...or bearings have developed flat spots REMEDY When the linear actuator spring pressure is set too high you can flat spot the actuator bearings Back off the spring tension to manual specifications Factory preset range is 15 45 lbs Pull Target tension is 30 lbs Replace all bearings For more detail see bearing replacement in adjustment section of the manual REASON Too high a spring pressure in linear ...

Page 15: ...imit switch does not stay engaged on the 50 diameter of the slide rod REMEDY With the actuator slide rod large 50 diameter over the limit switch plunger Adjust limit switch until you hear a click then go 005 010 farther for additional travel For more detail see limit switch in the adjustment section of the manual Turn speed pot to traverse at at faster speed setting REASON When the limit switch pl...

Page 16: ...orange wires needs 70 ohms Set dial at minimum speed setting Orange to red wires needs 100 ohms Red to white wires needs 70 ohms REASON Wiper inside of potentiometer controls speed Wiper may be bad and not making contact POSSIBLE CAUSE C Main circuit board dial pot settings not correct If board has been re placed REMEDY Check all pot settings on circuit board as shown in wiring diagram See manual ...

Page 17: ...ce which in turn will cause it to whip at high traverse speeds POSSIBLE CAUSE B Drive shaft is bent REMEDY Turn the actuator screw clockwise 1 4 1 2 turn to release actuator from the drive shaft Slide the carriage to one end of the machine Mount indicator in the middle of the two bearing support blocks Check for a maximum 015 indicator reading when you rotate the shaft Replace shaft if required NO...

Page 18: ...o eliminate reel movement during grinding POSSIBLE CAUSE B Overhead clamps and fixture clamps not holding mower unit tight REMEDY With the Tighten down eight locking hand knobs Four hand knobs for the square tube top and bottom clamps tow knobs for the mower holding clamps and two knobs for the mower clamp swivel Check alignment of overhead clamp so there is no binding before locking down of hand ...

Page 19: ... Two on the base for the adjusting arm locks and one for grinding wheel vertical height adjustment locking screw REASON To prevent grinding head from moving or pivoting during grinding When motor base and slide base mounting surface are not aligned to teach other the two adjusting arm locks will not hold the motor base rigid POSSIBLE CAUSE E Gibs loose on carriage REMEDY Tighten gib screws to prev...

Page 20: ...the fixed center is screwed in tight The adjustable center is screwed in tight The adjustable center is to locked tight Any clamps used ar to have tension on the locking surface REASON When the supports are not held tight to the square tube the reel can move during grinding Loose centers effect grinding accuracy Clamps must be tight to prevent movement during grinding PROBLEM Reel ground in a conc...

Page 21: ... period of time bearings may be noisy POSSIBLE CAUSE J Rails not straight Check rail towards the reel side for straightness in the hori zontal plane REMEDY Use a three foot long precision straight edge and using a feeler gage check for a maximum of 002 in straightness at the front edge of the front rail Consult factory REASON Rail straightness directly effects grind straightness of outside diamete...

Page 22: ...inute range for final grind range for final grinding sparkout NOTE This process refer to sparkout but what we are looking for is a near sparkout approximately a 99 reduction in grinding spark from normal grind Do not run sparkout until you have no sparks because this could be an extremely extended period REASON For close tolerance in round ness the sparking out process is critical on final grindin...

Page 23: ...usting arm locks will not hold the motor base rigid PROBLEM Grinding stock re moval from reel irregular when re versing directions of grind POSSIBLE CAUSE C Carriage has varying load in either direction from grinding grit buildup inside of linear bearings REMEDY With linear actuator released from the carriage check for a 2 to 3 lb Traversing load in both directions When there is a varying load or ...

Page 24: ...rom heavy grind passes POSSIBLE CAUSE Reel position not parallel to carriage travel REMEDY Use reel setup gage procedure touching off on reel hub to zero out the reel positoin from each end For more informa tion see reel setup gage procedure in manual REASON Reel hub has to be parallel to carriage traverse rails so reel is not cone shaped POSSIBLE CAUSE Large finger guide is mounted on backwards R...

Page 25: ...25 ...

Page 26: ...x Cap Screw 5 16 18 NC x 1 Long Lockwasher 5 16 Split Reel Hub Support Bottom Center Stand Lock Mower Support Center Stand Adjustable Center Stand Center Adjustable Center Handwheel Shaft Locking Stud 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 J372000 3969552 3969547 3969552 3969094 3649078 A313202 3969162 3969096 3709808 3969095 3109026 3969501 4509029 3589106 Hex Jam Nut 3 8 16 NC Knob Assembl...

Page 27: ...26 B311201 3889075 3709794 3889071 3969519 3709795 3889580 R000471 Hex Cap Screw 3 8 16 NC x 1 3 4 Long Hex Nut 3 8 16 NC Winch Hex Cap Screw 3 8 16 NC x 3 4 Long Plain Washer 3 8 SAE End Frame Hex Locknut 5 16 18 NC Grab Hook Chain Eye Bolt Assembly Plain Washer 5 16 SAE Hex Cap Screw 5 16 18 NC x 3 4 Long Spreader Hook and Cable Assembly Gusset Overhead Channel Pulley Grab Hook Assembly Lockwash...

Page 28: ...28 EXPLODED VIEW MODEL 3960561 SPIN DRIVE ASSEMBLY ...

Page 29: ...ar Box Cover Rocker Switch Motor Cord Kep Nut 10 32 NF Plain Washer 10 SAE Motor Assembly Socket Cap Assy 1 4 20 NC x 1 2 Long Oil Seal 5 8 Gear Box Cover Gear Box Gasket Gear Box Housing Pipe Plug Rollpin 3 32 Dia X 1 2 Long Worm Rollpin 1 8 Dia X 1 Long Worm Gear Oil Seal 1 2 Spin Grind Brg Assembly Hex Nut 3 8 16 NC Mower Support Center Stand Lock Knob Assembly Bar Support Drive Hex Cap Screw 3...

Page 30: ...30 EXPLODED VIEW MODEL 3096 GRINGING HEAD ASSEMBLY ...

Page 31: ...ex Cap Screw 3 8 16 NC x 1 Long Adjusting Arm Lock Spacer Knob V Belt Socket Set Screw Nylok 1 4 20 NC x 3 8 Handwheel Pulley Motor 1 2 HP 115V Phase 60 Hz Hex Nut 5 16 18 NC Plain Washer 5 16 SAE Hex Cap Screw 3 8 16 NC x 7 8 Long Lockwasher 3 8 Split Hex Cap Screw 5 16 18 NC x 7 8 Long Motor Plate Rubber Splash Guard Dressing Stick Guard Support Pad Hex Cap Screw 1 4 20 x 5 8 Long Knob Wheel Gua...

Page 32: ...32 EXPLODED VIEW MODEL 3096 AUTO REEL GRINDER ...

Page 33: ...per Holder Sponge Holder Carriage Base Assembly Ball Bushing Bearing Socket Cap Screw 10 24 NC x 5 8 Long Handwheel Assembly Rollpin 1 8 Dia X 3 4 Long Thrust Washer Feed Screw Hex Cap Screw 1 4 20 NC x 1 Long End Cap 44 45 46 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 3579109 3709777 3809069 3709563 J501000 3969164 R000469 B25...

Page 34: ...34 EXPLODED VIEW MODEL 3096 VARIABLE SPEED TRAVERSE ...

Page 35: ...lip Phillips Head Screw 10 24 NC x 5 16 Long Set Collar Ball Bearing Shaft Support Block Flange Coupler Sleeve Coupler Flange Coupler Phillips Rnd Hd Screws 1 4 20 NC x 5 8 Tool Tray Socket Cap Screw 1 4 20 NC x 1 Long D C Motor D C Motor Brush optional Hex Cap screw 1 4 20 NC Kep Nut 1 4 20 NC Lockwasher 1 4 Split 10 Inch Allen Key 3 16 Hex Cap Screw 1 4 20 NC x 1 2 Long Tie Down Mount Cord Tie S...

Page 36: ...ief Power Cord Sheet Metal Screw 10 x 5 8 Tinnerman Nut Cover Receptacle Panel Decal Snap In Outlet Cord Socket Ass y Switch Mount Rubber Tip 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 3969045 3709047 B190801 3707313 3707180 3707273 3969083 3709345 3707219 3969544 3707254 R000531 B130812 J131000 R000479 Shaft Bushing Hex Head Cap Screw 10 24 NC x 1 2 Limit Switch Connector Strain Relief Set Coll...

Page 37: ...8 9 10 3969581 3969576 3707953 3707173 3969034 3707155 3969028 3969548 3969549 3707266 Cord Socket Assembly Wire Assembly Black Wire Nut Yellow Cord Set Wire Green Set Screw Connector Wire White Limit Switch Receptacle Assembly D C Motor Receptacle Assembly Potentiometer ...

Page 38: ...38 EXPLODED VIEW REEL SETUP GAGE ASSEMBLY ...

Page 39: ...c Handle Gage Handle Plain Washer 5 16 SAE Hex Cap Screw 5 16 18 NC x 1 1 2 Long Hex Nut 1 4 28 NF Extension Spring Socket Head Cap Screw 1 4 28 NF x 1 2 Long Hex Jam Nut 1 4 20 NC Socket Cap Screw 1 4 20 NC x 1 3 4 Long Socket Set Screw 5 16 18 NC x 2 Long Hex Jam Nut 5 16 18 NC Rollpin 1 4 Diameter x 1 2 Long Rollpin 3 8 Diameter x 1 3 4 Long Gage Base Locator Gage Slide Push on Ring Saddle Stop...

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