Foley 3096 Istruzioni operative

Model 3096

Accu-Spin Reel

Mower 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)

SAFETY INSTRUCTIONS

1. KEEP GUARDS IN PLACE and in working order.

2. REMOVE ADJUSTING KEYS AND WRENCHES.

3. KEEP WORK AREA CLEAN.

4. DON'T USE IN DANGEROUS ENVIRONMENT.

Don't use power tools in damp or wet locations, or

expose them to rain. Keep work area well lighted.

5. KEEP ALL VISITORS AWAY. All visitors should be

kept a safe distance from work area.

6. MAKE WORKSHOP CHILD-PROOF. With padlocks

or master switches.

7. DON'T FORCE THE GRINDER. It will do the

j ob better and safer if used as specified in this manual.

8. USE THE RIGHT TOOL. Don't force the grinder

or an attachment to do a job for which it was not

designed.

9. WEAR PROPER APPAREL. Wear no loose clothing,

gloves, neckties, or jewelry which may get caught in

moving parts. Nonslip foot wear is recommended.

Wear protective hair covering to contain long hair.

10. ALWAYS USE SAFETY GLASSES.

11. SECURE WORK. Mount the cutting unit in place

before grinding as prescribed in the operators

manual.

12. DO NOT OVERREACH. Keep proper footing and

balance at all times.

13. MAINTAIN GRINDER WITH CARE.

Follow instructions in Service Manual for

lubrication and preventive maintenance.

14. DISCONNECT POWER BEFORE SEVICING.

15. REDUCE RISK OF UNINTENTIONAL

STARTING. Make sure switch is in OFF

position before plugging 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 a complete

stop.

19. KNOW YOUR EQUIPMENT. Read this manual

carefully. Learn its application and limitations as

well as specified potential hazards.

20. KEEP ALL SAFETY DECALS CLEAN &

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.

21. DO NOT OPERATE THE GRINDER

WHEN UNDER the influence of drugs, alcohol,

or medication.

The Warning Symbol identifies special

instructions or procedures which, if not

correctly followed, could result in personal

injury, or loss of life.

The Caution Symbol identifies special

instructions or procedures which, if not strictly

observed, could result in damage to, or

destruction of equipment.

Safety Awareness Symbols are inserted in this

manual to alert you to possible Safety Hazards.

Whenever you see these symbols, follow their

Instructions

SAFETY INSTRUCTIONS

Grinding is a safe operation if the few basic rules listed below are followed. These

rules are based on material contained in the ANSI B7.1 Safety Code for "Use, Care

and Protection of Abrasive Wheels". For your safety, we suggest you benefit from the

experience of others and follow these rules.

1. DO always HANDLE AND STORE

wheels in a careful manner.

2. DO VISUALLY INSPECT all wheels before

mounting for possible damage.

3. DO CHECK MACHINE SPEED against the

established maximum safe operating speed

marked on wheel.

4. DO CHECK MOUNTING FLANGES for

equal and correct diameter.

5. DO USE MOUNTING BLOTTERS when

supplied with wheels.

6. DO be sure WORK REST is properly

adjusted.

7. DO always USE A SAFETY GUARD

COVERING at least one-half of the grinding

wheel.

8. DO allow NEWLY MOUNTED WHEELS to

run at operating speed, with guard in place,

for at least one minute before grinding.

9. DO always WEAR SAFETY GLASSES or

some type of eye protection when grinding.

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 the mounting nut

EXCESSIVELY.

6. DON'T grind on the SIDE OF THE WHEEL

(see Safety Code B7.2 for exception).

7. 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 of a

grinding wheel whenever a grinder is started.

10. DON'T FORCE GRINDING so that motor

slows noticeably or work gets hot.

AVOID INHALATION OF DUST generated by grinding and cutting operations.

Exposure to dust may cause respiratory ailments. Use approved NIOSH or MSHA

respirators, safety glasses or face shields, and protective clothing. Provide

adequate ventilation to eliminate dust, or to maintain dust level below the

Threshold Limit Value for nuisance dust as classified by OSHA.

IMPROPER USE OF GRINDING WHEEL MAY CAUSE

BREAKAGE AND SERIOUS INJURY.

21. DO NOT OPERATE THE GRINDER

TABLE OF CONTENTS

Maintenance & Lubrication…………………………… 4

Adjustments……………………………………………. 5-9

Troubleshooting……………………………………….. 10-23

Parts Lists & Exploded Views……………………….. 24-37

MAINTENANCE & LUBRICATION

MAINTENANCE

1. Clean excess dirt and grit from machine daily.

2. Wipe off the auto traverse drive shaft daily./

3. Carriage front rail boots should be lifted and

wiped off daily.

4. Replace the two (externaly) foam rail wipers

every 20 hours of operation.

5. Check all fastening bolts monthly to be sure

they are tight.

6. Check gib plate adjustment in the grinder car-

riage base monthly.

7. Check the brushes on the auto traverse drive

motor once a year. Replace as necessary.

LUBRICATION OF ACTUATOR AND

LINEAR BEARINGS

STEP 1– Thoroughly clean all three shafts and

seals. If you have compressed air available, blow

off the shafts, carriage, seals, grinder base, etc.

NOTE: Always point the compressed air nozzle

away from the seals bearings to insure you do not

drive foreign material into the bearings. Then

wipe off the shafts and seals and blow off a

second time. If you do not have compressed air,

then thoroughly wipe off the shafts and seals. As

part of this cleaning the carriage should be trav-

ersed several times to insure all areas are clean.

STEP 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 not a problem as it will be cor-

rected in the subsequent steps.

STEP 3- With a clean rag, wipe off the excess

amount of lubricant from the shafts. Run the

carriage back and forth through its range of travel

and wipe the shafts after each traverse. Repeat

until the shaft are dry to the feel. This completes

the lubrication process.

LUBRICATION FREQUENCY

The lubrication frequency should be every four

hours of grinder operation or more often if a

squeaking noise is coming from the linear

actuator. If the unit will be shut down for an

extended period of time, more than two weeks,

then the shafts and other appropriate parts of

the unit should be flooded with lubricant and that

lubricant left in place until the unit is brought

back into service. When the unit is brought back

into service the full lubrication procedure as

stated above should be repeated.

Fig. 1

Fig. 2

ADJUSTMENT:

LINEAR ACTUATOR ADJUSTMENT & BEARING REPLACEMENT

LINEAR ACTUATOR BEARING REPLACEMENT

STEP 1- Unscrew the pin driver (item 2) that passes through the

self aligning bearing, (item 38) in the carriage (item 11) and unscrew

where it is threaded in to the actuator block (fig. 3). Slide the car-

riage off to one side to expose the actuator.

STEP 2- Turn the actuator screw (item 25) as much as required

clockwise to disengage the bearings from the drive shaft so it moves

freely.

STEP 3- Remove the two outboard seal mounts (item 31).

STEP 4- Remove shoulder bolts (fig. 4) fastening the bearings

(item 41) to the actuator block (item 29). Remove the old bearings

and discard, saving the inside washer (fig. 4). Inspect the hole that

the bearing and shoulder bolt were removed from and the actuator

bore for foreign material. If any is observed, thoroughly clean.

Insert the shoulder bolt through the new bearings and through the

saved inside washer. Then install this assembly into the actuator

and tighten the shoulder bolts.

STEP 5- Turn actuator screw (item 25) counterclockwise until all 6

bearings are in contact with the drive shaft (item 24). The actuator

screw washer (item 27) should be 1/32” clear of the outboard screw

heads. (see fig 4)

STEP 6– Remount the outboard seal mounts (item 31) making sure

the seal is concentric to the carriage drive shaft (item 24). Also

square up the seal mount blocks (item 31) to the actuator block

(item 29) within 1/32”.

STEP 7- Slide the carriage (item 11) over the actuator block (item

29) to line up the hole in the carriage with 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- If readjustment is required to achieve pull force within

specification, with actuator bearings engaged to drive shaft,

readjust the two outboard screws with springs (fig. 4) that hold the

actuator together. To reach these screws, the actuator screw,

washer and spring must be removed. Turn each screw an equal

amount when resetting for more or less tension, clockwise is more

tension. Repeat Step 8 and verify pull force. Continue to adjust

until within specification. The factory preadjusted tension is 9/32”

from under the washer holding the spring to the actuator block.

This should give the 15 to 45 lbs. Carriage pull force specified.

When adjustment is correct reinstall the actuator screw (fig. 3 item

25) with its spring (fig. 3 item 28) and flatwasher (fig. 3 item 27)

and tighten to within 1/32” of the outboard screw heads.

The pull force is to be checked when shaft is

wiped clean and dry. If checked when oily, too

much tension will be set and affect bearing

life.

If the actuator screw is tightened too much, it

will contact the outboard screw heads and

override their adjustment which could cause

traverse malfunction. Always maintain the

1/32” gap except when purposefully overriding

per Step 2 above.

Overtightening of actuator above the 45 lbs.

Maximum will not improve drive performance.

It will only shorten the bearing life.

Fig. 3

Fig. 4

ADJUSTMENT:

CARRIAGE LINEAR BEARING ADJUSTMENT & REPLACEMENT

CARRIAGE LINEAR BEARING REPLACEMENT

STEP 1- Loosen & remove the limit switch bracket

(item 17, fig. 3) and place it as the electrical lead will

allow. Unplug the electrical lead from the motor and

place it to one side.

On the 3096 model only, release all spring tension by

removing the horizontal adjusting screw assembly. On

the 3096 model only, remove the rubber boots from

both sides of the carriage on the front shaft. (see fig.

Remove pin driver (item 2, fig. 3) from linear actuator

(item 29, fig. 3). Then remove the screws (item 33, fig.

6) from the front and rear carriage shafts. Then slide

the carriage assembly to the right end of the carriage

shafts (fig. 6) Lift eh carriage assembly and carriage

shafts (fig. 6), slide the carriage assembly to the right

off first the rear carriage shaft and ten off the front

shaft. The shafts must be gripped by hand and pulled

left while the carriage assembly is moved right. After

removing the carriage assembly, 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, fig. 6). Repeat this

adjustment to all three pillow blocks and then remove

the pillow blocks from the carriage shaft.

NOTE: Tension is too tight if you feel a cogging action

when you rotate pillow block around the shaft. This

cogging is from the skidding of the bearing on the shaft

and indicates tension screw is too tight. As a final

check, sliding the bearing back and forth on the shaft

should be a smooth uniform motion.

The carriage assembly weighs

approximately 40 lbs. Be prepared to

handle the weight or get assistance in

handeling.

Setting the bearing tension correctly is

critical to proper grinding. Bearings which

are too tight or too loose will cause poor

grind quality. Also, bearings which are too

tight will have a substantially shortened life

and will damage the shaft

Fig. 5

Fig. 6

ADJUSTMENT:

CARRIAGE LINEAR BEARING ADJUSTMENT & REPLACEMENT

STEP 4- Assemble the three linear bearing pillow

blocks (item 12, fig. 6) loosely to carriage (item

11, fig. 6) with the tension adjustment screws

pointing outward. Insert the previously cleaned

carriage shaft (item 42, fig. 6) thru the front two

linear bearing pillow blocks and align them to

each other with a straight edge underneath the

carriage and tighten down the socket head screws

(item 13, fig. 6). Lift the carriage assembly back

onto the main grinder base and solidly bolt down

the front carriage shaft (item 42, fig. 6) with

screws (item 33, fig. 6).

On the 3096 model only, attach a center screw

into the carriage shaft loosely, then attach the

horizontal adjusting springs to the carriage shaft

and install and tighten the screws.

STEP 5- To set the distance between the front

pillow blocks, already tight, and the rear pillow

block, slide the rear carriage shafts thru the pillow

block and position it into its “V” groove 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 tension is correct when you try to

lift the carriage and can feel no carriage

movement, free play up and down. Also, when

pulling the carriage in the traversing direction,

there should be only approximately a 3 lb. force

using a scale system similar to Step 8 of Linear

Actuator Bearing Replacement. To double check

the assembly, slide the carriage assembly from

“end of travel” to “end of travel,” it should have

very uniform resistance through the full range of

travel. When bearing tension is correct, reinstall

linear actuator pin driver (item 2 fig. 5).

STEP 6- Reinstall the limit switch bracket and

reconnect the electrical lead to the motor. On the

3096 model only, reinstall the rubber boots on the

front shaft and reinstall the horizontal adjusting

screw assembly (see fig. 5).

Fig. 7

ADJUSTMENTS

ALIGN FRONT RAIL & DRIVE SHAFT

The front rail and drive shaft need to be perfectly

aligned (± .010). The adjustment is made by

loosening the drive shaft support blocks and

aligning the shaft to the front rail to within ± .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 irregular shape.

Fig. 8

Fig. 9

ADJUSTMENTS

CONTROL BOARD SETTINGS- The control board adjusting knobs inside the control box should

be set as follows:

Min. Speed (Minimum Speed)- Allows adjustment of the motor speed when the main speed knob is

set at minimum. This permits the user to eliminate the “Dead Band” on the main speed control

permitting zero calibration. Clockwise rotation of “MIN,” trim pot increases speed. This trim pot allows

for adjustment of 30% of maximum speed.

ACC. (Acceleration)- Allows adjustment of the motor acceleration form a minimum of .2 seconds to

10 seconds maximum.

DECEL. (Deceleration)- Permits adjustments of the motor deceleration from a minimum of 1 second

to 10 seconds maximum.

MAX. SPEED (Maximum Speed)- Provides for adjustment of the motor speed when the main speed

knob is set a maximum. This permits the user to eliminate the “Dead Band” on the main speed

control to have full speed at maximum rotation. Rotation of “MAX,” trim pot in the clockwise direction

increases maximum motor speed. The “MAX” trim pot allows for adjustment of 70% of base speed.

I.R. COMP (Speed Regulation)- This allows for adjustment of the circuitry that controls the speed

regulation of the motor. The circuitry controls armature voltage by changing the armature voltage to

compensate 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 current by limiting the

maximum torque the motor can deliver. Torque adjustment (CUR. LIM.) is preset at 125% of rated

motor torque (Current) based on horsepower. Clockwise rotation of “CUR. LIM.” pot increases the

torque (Current) the control will provide. This control is adjustable to 200% of rated motor torque.

THESE SETTINGS ARE PRESET AT FACTORY.

MOVE ONLY AFTER CONSULTING WITH

FACTORY.

NOTE: The only two settings that ever need to be

adjusted are the acceleration dial and the IR comp

dial. Consult factory before adjusting any of these

dials.

The manufacturer recommends

that the maximum speed be set

no higher than shown for safety

considerations.

Alteration of Current Limit could

damage the motor.

LIMIT SWITCH ADJUSTMENT

When the switch (#20) is riding on the high side

of the shaft (#17), it should be actuated by

only .005 to .010”. It is actuated when you hear

a click inside.

With the actuator slide rod (.50 diameter) over

the limit switch plunger, adjust the limit switch

until you hear a click, then go .005/.010 farther

for additional travel.

Fig. 11

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