VALPAR VCWS08 User manual

COMPONENT WORK SAMPLE 8
SIMULATED ASSEMBLY
MAINTENANCE MANUAL
REVISED MARCH 15, 2003 TO PRESENT

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Table of Contents
Section Title Page
Introduction ..................................................................................1
7Trouble Shooting Table.................................................................2
March 15, 2003 to Present
7Trouble Shooting Table.................................................................3
March 15, 2003 to Present
8A Checking the Motor and Speed Control.........................................4
Circuit March 15, 2003 to Present
8B Checking the Counter and Microswitch.........................................4
March 15, 2003 to Present
8C Adjusting the Wheel Rotation Speed for Standard.........................4
Operation March 15, 2003 to Present
8D Adjusting the Wheel Rotation Speed for B-Kit..............................5
Operation March 15, 2003 to Present
8E Microswitch Adjustment and Replacement ...................................5
March 15, 2003 to Present
8F Replacing the Counter...................................................................6
March 15, 2003 to Present
8G Replacing the Kick-Off Angle.......................................................6
March 15, 2003 to Present
8H Gaining Access to the inside of the Work Sample .........................7
March 15, 2003 to Present
8I Speed Control Replacement..........................................................8
March 15, 2003 to Present
8J Set Screw Tightening Procedures..................................................9
March 15, 2003 to Present

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Table of Figures Page
9.1 Work Sample Diagram................................................................11
9.2 Wiring Diagram..........................................................................12
9.2A Wiring Codes..............................................................................13
9.2B Wiring Codes..............................................................................14
9.3 Microswitch Arm Diagram..........................................................15
9.4 Microswitch Height Diagram......................................................16
9.5 Speed Control..............................................................................17

1
INTRODUCTION:
This VCWS08 Maintenance Manual is written as an aid for our Valpar VCWS08
customers. The VCWS08 Maintenance Manual covers the current model of the work
sample built from March 15, 2003 to present.
Please note that this Maintenance Manual does not include information or “inside the
unit” wiring diagrams for the VCWS08 speed control. Valpar considers this proprietary
information. Any problems that may occur with the speed control must be referred to
Customer Service at Valpar International Corporation. The toll-free line is [phone].
Removal and installation of speed control is covered in this manual.

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7VCWS08 TROUBLE SHOOTING TABLE
MARCH 15, 2003 TO PRESENT
PROBLEM POSSIBLE CAUSE SOLUTION
1) BLOWN FUSE REPLACE FUSE
2) DEFECTIVE SPEED
CONTROL REPLACE SPEED CONTROL REFER TO
SECTION 8I
3) BREAK IN WIRES REWIRE, REFER TO
DIAGRAM 9.2
7A VCWS08 WILL NOT
RUN
4) DEFECTIVE MOTOR REFER PROBLEM TO
VALPAR CUSTOMER
SERVICE
1) SPEED ADJUSTED
INCORRECTLY ADJUST WHEEL SPEED REFER TO SECTION 8C
OR 8D
2) DEFECTIVE SPEED
CONTROL REPLACE SPEED CONTROL REFER TO
SECTION 8I
3) DEFECTIVE LAZY
SUSAN REFER PROBLEM TO VALPAR CUSTOMER
SERVICE
7B VCWS08 RUNS BUT
THE SPEED IS
ERRATIC OR HAS
JERKEY MOTION
4) DEFECTIVE MOTOR REFER PROBLEM TO
VALPAR CUSTOMER
SERVICE
1) IMPROPER
MICROSWITCH BEND REALIGN MICROSWITCH REFER
TO SECTIONS 8E, 9.3, 9.4
2) MICROSWITCH
DEFECTIVE REPLACE MICROSWITCH REFER
TO SECTION 8E
3) COUNTER
DEFECTIVE REPLACE COUNTER REFER TO SECTION 8F
7C VCWSO8 RUNS BUT
DOES NOT COUNT
4) BREAK IN WIRES REWIRE, REFER TO
DIAGRAM 9.2

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7VCWS08 TROUBLE SHOOTING TABLE
MARCH 15, 2003 TO PRESENT
PROBLEM POSSIBLE CAUSE SOLUTION
1) IMPROPER
MICROSWITCH BEND REALIGN MICROSWITCH REFER
TO SECTIONS 8E, 9.3, 9.4
7D PINS JAM BEHIND
THE MICROSWITCH
2) WHEEL SPEED IS TO
GREAT ADJUST WHEEL SPEED REFER TO SECTION 8C
OR 8D
1) SPEED ADJUSTED
INCORRECTLY ADJUST THE WHEEL SPEED REFER TO
SECTION 8C OR 8D
2) LID OF #8 IS OPEN
CHECK FOR OBSTRUCTIONS, CLOSE
LID AND SNAP
LATCHES
3) KICK-OFF ANGLE IS
MISSING OR NOT
ALIGNED
CORRECTLY
REPLACE KICK OFF-
ANGLE REFER TO
SECTION 8G
7E PINS AND COLLARS
DO NOT SORT OR
DROP PROPERLY
4) DEFECTIVE MOTOR REFER PROBLEM TO
VALPAR CUSTOMER
SERVICE
1) IMPROPER
MICROSWITCH BEND REALIGN MICROSWITCH REFER
TO SECTIONS 8E, 9.3, 9.4
7F COLLARS JAM AT
BACK OF WHEEL OR
LAND IN THE
CENTER 2) KICK-OFF ANGLE IS
MISSING OR NOT
ALIGNED
CORRECTLY
REPLACE KICK OFF-
ANGLE REFER TO
SECTION 8G
1) IMPROPER
MICROSWITCH BEND
REALIGN
MICROSWITCH REFER
TO SECTIONS 8E, 9.3, 9.4
2) CLIENT LOSES PARTS REMOVE PARTS FROM
INSIDE REFER TO
SECTION 8H
7G PARTS ARE LOST
INSIDE THE VCWS08
3) IMPROPER DROP
BOARD ANGLE REFER PROBLEM TO VALPAR CUSTOMER
SERVICE
7H MOTOR RUNS BUT
THE WHEEL DOES
NOT TURN
1) LOOSE PEDESTAL
SET SCREWS TIGHTEN SET SCREW REFER TO SECTION 8J

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8A CHECKING THE MOTOR AND SPEED CONTROL CIRCUIT
MODELS BUILT FROM MARCH 15, 2003 TO PRESENT
The following steps will be helpful in determining the problem with your
VCWS08. Plug the work sample into a standard wall outlet. Turn the VCWS08 on
with the switch on the left side of the work sample box. If the work sample fails to
come on, refer to 7A of this troubleshooting guide. Open the work sample lid.
Check the wheel speed with a second hand watch. The timing marks on the wheel
and on the table should meet every twenty seconds. To adjust your VCWS08 refer to
8C or 8D of this maintenance manual. If the speed cannot be adjusted, or if after it is
adjusted it wanders, refer to 7 B of this manual.
8B CHECKING THE COUNTER AND MICROSWITCH
MODELS BUILT FROM MARCH 15, 2003 TO PRESENT
While the work sample is running, depress the microswitch arm. The counter
should increase by an increment of one each time the microswitch arm is depressed.
Refer to 7D of this guide if either the counter or microswitch fail to work. Proper
microswitch adjustment is critical for the VCWS08 to function properly. Check and
adjust according to the instructions in 8E of this maintenance manual.
8C ADJUSTING THE WHEEL ROTATION SPEED FOR STANDARD SPEED
OPERATION. MODELS BUILT FROM MARCH 15, 2003 TO PRESENT
Turn the VCWS08 on with the switch on the left side of the work sample. Open
the work sample lid and locate the speed control in right corner of unit. Set the
speed control knob on the speed control to the standard indicator. Use a stop watch
to check the wheel rotation speed. The timing mark on the wheel should pass the
timing mark on the table every twenty seconds, if it does not, adjust the speed
control knob until correct timing is achieved. If correct timing cannot be achieved
and/or timing doesn’t stay consistent, the speed control will need to be replaced.
Please call Valpar Customer Service.
Note: It is ok for the timing to vary up to plus or minus two seconds.
The wheel rotation speed is factory set for standard operation.

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8D ADJUSTING THE WHEEL ROTATION SPEED FOR B-KIT OPERATION
MODELS BUILT FROM MARCH 15, 2003 TO PRESENT
Turn the VCWS08 on with the switch on the left side of the work sample. Open
the work sample lid and locate the speed control in right corner of unit. Set the
speed control knob on the speed control to the B-kit indicator. Use a stopwatch to
check the wheel rotation speed. The timing mark on the wheel should pass the
timing mark on the table every ten seconds, if it does not, adjust the speed control
knob until correct timing is achieved. If correct timing cannot be achieved and/or
timing doesn’t stay consistent, the speed control will need to be replaced. Please call
Valpar Customer Service.
Note: It is ok for the timing to vary up to plus or minus two seconds.
The wheel rotation speed is factory set for standard operation.
8E MICROSWITCH ADJUSTMENT AND REPLACEMENT
MODELS BUILT FROM MARCH 15, 2003 TO PRESENT
Note: Be sure the work sample is unplugged before proceeding.
I) Microswitch Adjustment
The curve of the microswitch arm is critical for the work sample to function
properly. Use Figure 9.3 as a template to adjust the curve. Bend the microswitch arm
as needed to match the figure.
Adjust the height of the microswitch as shown in Figure 9.4. The top of the collar
assembly should meet the top of the microswitch arm. Do not make this adjustment
by bending the microswitch arm. Loosen the mounting screws and reposition the
aluminum bracket to make the adjustment. When the microswitch is in the correct
position, tighten the mounting screws.
II) Microswitch Replacement
Remove the old microswitch from the aluminum bracket. Loosen the screws on
the back of the microswitch where the wires are connected. Connect the wires to the
new microswitch. One wire is connected to the common screw and the other is
connected to the open screw. The screws are marked on the back of the microswitch.
Remount the microswitch and adjust it using the above procedure.

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8F REPLACING THE COUNTER
MODELS BUILT FROM MARCH 15, 2003 TO PRESENT
Remove the two mounting screws from the face of the counter. Gently pull the
counter out from the side of the work sample until the wires are exposed. Unplug the
wires from the old counter. Be careful not to let the wires fall inside the work
sample. Plug the wires into the new counter. Mount the counter to the work sample
using the same two screws.
8G REPLACING THE KICK-OFF ANGLE
MODELS BUILT FROM MARCH 15, 2003 TO PRESENT
If the assembly parts are not sorting correctly, or if they jam, or land on the
middle of the wheel, the kick off angle needs to be replaced. Open the work sample
lid. The proper location for the kick-off angle is one half inch from the bottom of the
lid retainer ring (the retainer ring is the curved piece on the inside of the lid). Mount
the new angle under the bottom center of the ring with the screws facing to the right.

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8H GAINING ACCESS TO THE INSIDE OF THE WORK SAMPLE
MODELS BUILT FROM MARCH 15, 2003 TO PRESENT
Note: It is very important to follow these procedures. Failure to do so will result
in damage to the work sample. If the wheel is removed from the table it will
have to be shipped to Valpar for realignment.
Step 1: Unplug the VCWS08.
Step 2: Open the lid by releasing the outside latches. Remove only the end of
the lid support that is attached to the box (one screw only). Lower the
lid over the back of the box. (Caution: Support the lid to avoid
overextending the hinge.) Remove the microswitch bracket by
removing the two screws, and set it aside. It is not necessary to
disconnect the wires.
Step 3: Locate speed control in right corner of VCWS08. Remove the two
screws from the speed control. Gently remove speed control to
access wire connections on rear of unit.
Note: Refer to the speed control drawing diagram 9.5 or section 8I
of this manual when removing and reconnecting wires to speed
control.
Step 4: Remove the motor ground wire (green w/ yellow stripe) that is
connected with the motor harness cable. Next, unplug the motor
harness connector from speed control. Remove the AC 100-115V-
ground wire (green w/ yellow stripe) that is connected with the AC
power cable. Next, remove the plastic terminal cover from the AC
power connection terminal. Remove the black wire from the “L”
terminal and the red wire from the “N” terminal. Remove speed
control.
Step 5: Remove the five Phillips head screws located behind the black
retaining ring. Lift up on the retaining ring and place the retaining
ring out of your way.
Step 6: Remove the two Phillips head screws located on each side of the
work sample box just below the latches. The table is now loose.
Step 7: Lift (do not pull forward while lifting) and remove table from
VCWS08 box.
Step 8: Reverse the above steps to reassemble the work sample. Make sure
all screws line up with their original holes.

8
8I VCWS08 SPEED CONTROL REPLACEMENT
MODELS BUILT FROM MARCH 15, 2003 TO PRESENT
Step 1: Unplug the VCWS08.
Step 2: Open the VCWS08 lid. Locate speed control in right corner of
VCWS08. Remove the two screws from the speed control. Gently
remove speed control to access wire connections on rear of unit.
Note: Refer to the speed control diagram below when removing and
reconnecting wires to speed control.
Step 3: Remove the motor ground wire (green w/ yellow stripe) that is
connected with the motor harness cable. Next, unplug the motor
harness connector from speed control. Remove the AC 100-115V-
ground wire (green w/ yellow stripe) that is connected with the AC
power cable. Next, remove the plastic terminal cover from the AC
power connection terminal. Remove the black wire from the “L”
terminal and the red wire from the “N” terminal.
Step 4: Reverse steps 2 and 3 to install new speed control.
MOTOR GROUND
GREEN W/ YELLOW
STRIPE
MOTOR HARNESS
CONNECTION
BLACK WIRE
RED WIRE
AC 100-115V GROUND
GREEN W/ YELLOW
STRIPE

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8J SET SCREW TIGHTENING PROCEDURES
MODELS BUILT FROM MARCH 15, 2003 PRESENT
Note: It is very important to follow these procedures. Failure to do so will
result in damage to the work sample. If the wheel is removed from the table it
will have to be shipped to Valpar for realignment.
Step 1: Unplug the VCWS08.
Step 2: Open the lid by releasing the outside latches. Remove only the end of
the lid support that is attached to the box (one screw only). Lower the
lid over the back of the box. (Caution: Support the lid to avoid
overextending the hinge.) Remove the microswitch bracket by
removing the two screws, and set it aside. It is not necessary to
disconnect the wires.
Step 3: Locate speed control in right corner of VCWS08. Remove the two
screws from the speed control. Gently remove speed control to
access wire connections on rear of unit.
Note: Refer to the speed control drawing diagram 9.5 or section 8I
of this manual when removing and reconnecting wires to speed
control.
Step 4: Remove the motor ground wire (green w/ yellow stripe) that is
connected with the motor harness cable. Next, unplug the motor
harness connector from speed control. Remove the AC 100-115V-
ground wire (green w/ yellow stripe) that is connected with the AC
power cable. Next, remove the plastic terminal cover from the AC
power connection terminal. Remove the black wire from the “L”
terminal and the red wire from the “N” terminal. Remove speed
control.
Step 5: Remove the five Phillips head screws located behind the black
retaining ring. Lift up on the retaining ring and place the retaining
ring out of your way.
Step 6: Remove the two Phillips head screws located on each side of the
work sample box just below the latches. The table is now loose.
Step 7: Lift (do not pull forward while lifting) and remove table from
VCWS08 box and gently place upside down on clean surface.
Step 8: Locate the set screw on pedestal. Tighten set screw with a 1/8” x10”
Allen wrench (provided).

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Step 9: Reverse the above steps to reassemble the work sample. Make sure
all screws line up with their original holes.

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FIGURE 9.1
WORK SAMPLE DIAGRAM

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FIGIRE 9.2
WIRING DIAGRAM
MARCH 15, 2003 TO PRESENT

13
NO. COLOR DESCRIPTION
1BK, W, G Power Cord (2” Sheath Rem.) 58
3BK Pigtails on Trans. (Trim 2”) 58
4DkG Pigtails On Trans. (Trim 4”)
5G19” 59 58
6G19” 21
7G14” 58
8G2” 58 58
9G10”
10 BK 17” 58 58
11 BK 23” 60 58
12 BK 14” 58
13 W14” 58
14 BR 2” 58
15 BR 17” 61 58
16 BR 2” 58
17 BR 49” 58 58
18 BR 61” 61 58
19 BL 10”
20 Y10”
21 BK 4” 60 58
FIGURE 9.2A
WIRING CODES

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CONNECTIONS:
Solder Connection
58 Fork Term. (17H06)
59 Ring Term.(S) (17H07)
60 Slip Term. (L)
61 Slip Term. (S)
21 Ring Term. (L) (17H08)
FIGURE 9.2B
WIRING CODES
COLORS (WIRES):
BK –BLACK
W –WHITE
G –GREEN
BR –BROWN
BR –BROWN (RIBBED)
Y –YELLOW
BL –BLUE
DkG –DARK GREEN

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FIGURE 9.3
MICROSWITCH ARM DIAGRAM

16
FIGURE 9.4
MICROSWITCH HEIGHT DIAGRAM

17
MOTOR GROUND
GREEN W/ YELLOW
STRIPE
MOTOR HARNESS
CONNECTION
BLACK WIRE
RED WIRE
AC 100-115V GROUND
GREEN W/ YELLOW
STRIPE
FIGURE 9.5
SPEED CONTROL