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OPERATING INSTRUCTIONS (Continued)

1. PARTS LIST 27544 CHANNEL 8 TRAVEL ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 8 32 x 3 8 Button Head Socket Cap Screw 1 4 20 x 3 4 Socket Head Cap Screw 1 4 20 x 1 4 Socket Head Cap Screw Full Thread 1 4 20 x 1 1 2 Socket Head Cap Screw 1 4 20 x 4 Socket Head Cap Screw 3 8 16 x 1 Button Head Socket Cap Screw 1 4 20 Locknut Thin 8 Lockwasher Split 1 4 Lockwasher Split 3 8 Lockwasher Split Support Travel Pulley Channel Machined Guard Travel RH Shaft Travel Pulley Pulley Cog Drive Motor Assembly Travel W34 Guard Traverse Pulley Idler Pulley Assembly Washer Thrust 751D x 1 250D Belt Cog Spring Compression Ring Retaining Ext Shaft Carrier Spacer 281 ID x 62 OD x 38 Long 18504 CARRIAGE ASSEMBLY PARTS LIST PARTS LIST 18504 CARRIAGE ASSEMBLY DIAGRAM NO PART NO DESCRIPTION B191011 10 24x5 8 Socket Head Cap Screw B250601 1 4 20x3 8 Hex Head Cap Screw 1 4 20x1 1 4 Button Head Socket Cap Screw 1 4 20x2 Button Head Socket Cap Screw J252000 1 4 20 Hex Jam Nut K251501 1 4 Split Lockwasher Carriage Base Traverse Clamp Assembly Traverse Clamp Block Traverse Clamp Spacer Clamp Support Block Ball Bushing Bearing Sponge Wiper Holder Foam Wiper Belt Clamp Tip 18520 GRINDING HEAD ASSEMBLY PARTS LIST LEFT SIDE ASSEMBLED VIEV PARTS LIST Continued 371100 K370001 PART NO B191
2. IAV 1334 e se asf O18 5 134 01 IND JO Swe ul 5 89 4 01 INP SUOISUAUWIP 9594 910N 41135 1334 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 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 If not you should read the Operators section of this manual or do the servicing in conjunction with someone who 15 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 as firmly tighten or the like For more specific torque values refer to the information GRADE 5 GRADE 8 below Bolts Going Into a Nut or Into a Thread Hole in SMOOTH HEAD Steel Refer to the table at the right 1 4 In 6 ft lbs 9 ft lbs 13 ft lbs thread 0 8 kg m 1 25 kg m
3. TSP is not working TSP 10K is bad Worn motor brushes Checkout Procedure F Check for 90 Volts DC across terminals 1 to HA2 this voltage drives the DC traverse motor NOTE Traverse must be on and have TSP turned full CW to maximum voltage of 90 VDC G Check grinding motor continuity A H Check TSP 10K on control panel FROM MACHINE Check TSP for 10 000 ohms Remove three wires from TDC red from term 8 white from term 7 black from term 9 J Inspect Motor Brushes DISCONNECT POWER FROM MACHINE DISCONNECT POWER Check TDC terminals A1 to A2 for 90 Volts DC Yes go to Step G next No go to Step H next Remove motor wires from Terminal Strip 1 terminals 7 amp 48 check for 0 ohms across the black and white wires Yes end troubleshooting traverse should work if not replace motor No go to Step J next Pin 8 to 7 Pot Full CCW Pot Full CW 0 VDC 9 75 VDC Pin 8109 Pot Full CCW Pot Full CW 9 75 VDC 0 VDC Yes replace the TDC No go to Step I next Check for 10 000 ohms red to white wires Full CCW 0 ohms Full CW 10 000 ohms Red to black wires Full CCW 10 000 ohms Full CW 0 ohms Yes replace the TDC No replace TSP Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Traverse Motor ELECTRICA
4. 1 8 kg m Bolts Going Into a Thread Hole In Aluminum a In Mise Mis 28 Use the Grade 2 values in the table at the right thread Sm Le 199490 3 8 In 19 ft lbs 31 ft lbs 46 ft lbs 2 6 kg 4 3 kg 4 kg Socket Head Screws Going Into Nut Steel thread PERO A AA Use the Grade 8 values in the table at the right 7 16 In 301 406 50 ft lbs 75 ft lbs thread 4 1 kg m 6 9 kg m 10 4 kg m Machine Screws 1 2 In 45 ft lbs 75 ft lbs 115 ft lbs No 6 screws 11 in Ibs 0 125kg m med 6 2 ee 113 3 kgm No 8 screws 20 in lbs 0 23 kg m No 10 screws 32 in lbs 0 37 kg m ASSEMBLY INSTRUCTIONS UNPACK CARTONS Remove the wood board structure and plastic wrap around the unit The cartons should be opened and assembled in the following sequence 1 Carton Assembly 2 Setup Gage Remove the two 2 boxes carton assembly and set up gauge box and place aside If any problems occur refer to the shipping and receiving instruction Double check the cartons for any miscellaneous items or other manuals before disposing of cartons UNSTRAP CARRIAGE Remove the shipping strap which holds the carriage in place The bolt that holds the shipping strap to the frame can be discarded REMOVE GRINDER FROM WOOD PALLET Remove the grinder base from the wood pallet This is accomplished by unbolting the four bracket that holds each frame side to the bottom of the wood pallet
5. DIAL INDICATOR SET UP FIXTURE The dial indicator set up fixture is designed to be quickly mounted into position and or quickly Attach Fixture with removed this Screw Knob The fixture is mounted to the front left corner of the grinding head assembly as shown in FIG 40 When the fixture is not in use it is quickly removed and stored OPERATING INSTRUCTIONS Continued REEL ALIGNMENT USING THE DIAL INDICATOR SET UP GAGE ASSEMBLY Overhead Clamp A Mount the set up gage into position on the left Rod Adjusting Knob front side of the grinding head assembly The gage assembly can be set on the roll pin on the grinding head slide base This will line up the tee knob with the threaded hole in the casting for an easy install See FIG 40 The left side over head clamp rod adjusting knob See FIG 41 must be loose to allow the mower assembly which is mounted on the mower support bar to move freely when doing horizontal and vertical adjustments The overhead clamp rods will generally be used as described below 1 If the mowing unit is mounted with the ground roller clamped to the roller supports with the chain vice clamp because the geometry does not offer enough stability or rigidity the overhead clamp rod on the fixed end right side in the operator s position should be kept tight If the mowing unit is mounted in centers and only being stabilized by the overhead clamp Vertical Adjustment Knob rods
6. SET UP GAUGE ASSEMBLY 1 Remove the dial indicator assembly from carton 2 Remove anvil on dial indicator Mount dial into the casting Remount anvil Adjust dial indicator so anvil can be fully depressed without touching the casting and tighten set screw in casting to firmly mount dial indicator to casting MALFUNCTION OF THE DIAL INDICATOR DO OVERTIGHTEN OR DAMAGE OR CAN OCCUR 3 Mount the complete assembly to the machine See FIG 79 and 80 or store when completed ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT GROUNDING INSTRUCTIONS ON PAGE 45 120 VOLT MODEL ONLY Plug the control box power cord into a standard 120V AC 15 amp grounded receptacle See FIG 81 IT IS RECOMMENDED THAT GRINDER HAS ITS OWN PERMANENT POWER CONNECTION FROM THE POWER O DISTRIBUTION PANEL WITH NO OTHER MAJOR POWER DRAW EQUIPMENT ON The grinder is equipped with a low voltage relay THE SAME LINE which is factory preset at 100 VAC If the power supply line does not deliver 100 VAC power under IT IS REQUIRED THAT THE POWER load the relay will open and trip out the starter DELIVERED TO THIS GRINDER IS 120 VAC fthis occurs your power supply line is inadequate 15 AMPS THE TOLERANCE ON THIS and must be correct before proceeding further with POWER REQUIREMENT IS 5 the grinder THEREFORE THE MINIMUM VOLTAGE REQUIREMENT IS 114 VAC WITH 15 AMPS VOLTAGE MUST B
7. SPIN DRIVE RPM IS VERY IMPORTANT IN ACHIEVING A QUALITY GRIND USE CARE IN ESTABLISHING THE SPIN DRIVE RPM PER THE INSTRUCTIONS BELOW Generally the Spin Drive RPM will be between 180 RPM 45 and 300 RPM 80 The speed required to spin a specific reel is dependant on reel diameter the number of reel blades and reel hardness For all reels there is an optimum Spin Speed where there is an AGGRESSIVE yet smooth grind as you spin grind the reel Your objective is to spin grind the reel as aggressively and as fast as possible while maintaining top quality It is recommended to start grinding each reel at a Spin Speed of 200 RPM 50 and evaluate the RPM by adjusting higher and lower to optimize the Spin Speed for that reel If the Spin Speed is incorrectly set you can experience two problems grinding wheel dressing or grinding wheel resonance Each of these problems is explained below On some reels especially small diameter high blade count reels ifthe Spin Speed RPM is set to high the reel act as dresser to the grinding wheel There can develop what appears to be a very aggressive grind as if the infeed has self infed and then a sudden stop of grinding with no grinding wheel to reel contact If this occurs your Spin Speed was set to high and you effectively dressed your grinding wheel Some reels have a resonant RPM where the reel goes into harmonics with the grinding wheel and the resonance vibrates the grinder
8. SYSTEM START SWITCH Powers all control panel systems Pulls in the main magnetic starter NOTE The guard doors must be shut and all switches must be off for the machine to start SPIN DRIVE SWITCH ON OFF Turns the spin drive motor ON OFF Guard doors must be shut for the spin drive to operate SPIN SPEED DIAL RPM Adjusts the speed of reel rotation when you have the grind selector switch set at variable speed spin GRIND SELECTOR SWITCH Variable Speed Spin Switch must be up to perform spin grinding operations Variable Torque Relief Switch must be down to perform relief grinding operations GETTING KNOW YOUR GRINDER Continued RELIEF TORQUE DIAL Adjusts the Spin Drive Motor torque the torque holding the reel blade to the relief finger when Grind Selector Switch is set at variable Torque Relief GRINDING WHEEL MOTOR SWITCH ON OFF Turns the Grinding Wheel Motor on and off Guard doors must be shut for Grinding Motor to operate SPIN DRIVE ROTATION SWITCH Forward Off Reverse This switch reverses rotation of the spin drive motor Toggle in middle is off position and stops rotation NOTE Because the spin drive can mount on either side of the reel rotation direction will vary THE MOTOR MUST COME TO A COMPLETE STOP BEFORE CHANGING DIRECTIONS IF THE MOTOR DOES NOT COME TO A COMPLETE STOP SERIOUS DAMAGE TO THE CONTROL MAY RESULT TRAVERSE MOTOR SWITCH ON OFF Turns the trave
9. THE HAND KNOBS ON THE SQUARE BAR MUST BE VERY TIGHT OR THE REEL CAN LOOSEN amp CAUSING POOR GRIND QUALITY CENTER BRACKETS The centers mounting brackets consist of a stationary center bracket and an adjustable center bracket The stationary bracket will normally be used on the right hand side of the mounting bar when facing the reel loading position See FIG 5 These centering fixtures are used primarily on greens mowers and the OPTIONAL Bedknife Attach Kit 6000555 OPTIONAL PULL GANG BRACKETS The OPTIONAL Pull Gang Reel Mount Kit 18574 consists of a lower mounting bracket that fits over the square tooling mounting bar and two threaded locking screws Attached to this is the upper V bracket that cradle the reel hub when in position There are three vertical adjustments on this fixture but will normally be used in the upper hole position See FIG 6 These brackets can be mounted on the square mounting bar with offset either forward or backwards but the normal position will be with the V centered over the bar or with the offset facing the back of the machine The hold down swing arm has an upper and lower mounting position depending on mower hub size The rear roller of the pull gang mowing unit attaches to the roller supports as shown in FIG 7 Vice Grip Chain Clamp GETTING KNOW YOUR GRINDER Continued TRAVERSE ACTUATOR RELEASE The actuator that drives the grinding carriage left an
10. THE UNIT WEIGHS 817 LBS 371 KG USE POWER EQUIPMENT TO LIFT THE UNIT POSITION BASE The grinder will require an operating area about 138 351 cm x 114 D 290cm x 90 H 229 cm The mowing unit will be lifted from behind the machine and the machine operator will operate the unit from the operator s position on the opposite side of the unit Position the base to allow sufficient operating room in both front and behind the machine See FIG 73 The base should be placed on a relatively level concrete _ floor with ample ceiling height to allow for the installation and operation of the reel winch and boom Do not place the unit across two concrete slab seams or across a large crack If the unit must be placed near wall we recommend the wall be located as per FIG 74 THAT IS BADLY OUT OF LEVEL OR BROKEN WILL AFFECT GRINDING QUALITY PLACING THE GRINDER FLOORING Nr O E o E O o Q O gt O E pum o gt Y O E O O E E lt O Q O O O ASSEMBLY INSTRUCTIONS Continued ASSEMBLY INSTRUCTIONS Continued LEVEL BASE Each leveling screw has been factory preadjusted so it does not protrudes from the
11. minimal clearance between the reel blade and the grinding wheel Adjust the index finger positioning by rotating the back stop knob on the bottom forward of the grinding head This position must allow approximately 1 32 1 mm free play of the index finger when the blade is resting on the high point of the relief finger See FIG 66 and 68 NORMAL HELIX For a NORMAL HELIX reel the grinding wheel will wear to match the angle of the reel blade NOTE The square faced grinding wheel as from the factory can be used for normal helix reels and will wear to match the reel blade spiral RIGHT SIDE OF VAREL NUST CONTACT FIRST NATCHING ANGLE ACTUAL GRINDING VHEEL CONTACT POINT penunuo2 SNOLLONHLSNI 9NILVH3dO REVERSE HELIX For a REVERSE HELIX reel the grinding wheel should be a wheel that has been used for NORMAL HELIX reels and has worn to match the angle of the reel blade The grinding wheel must be reversed from a normal helix so the wheel angle matches the angle as illustrated If you do not use a preworn grinding wheel so the right side contacts first you may not relief grind part of the last 3 8 10 mm of the blade NOTE Awheel that has been worn to matcha normal helix can generally be removed and reversed to grinder reverse helix reels 1 NATCHING ANGLE RIGHT SIDE OF WHEEL MUST CONTACT FIRST ACTUAL GRINDING WHEEL CONTACT POINT penunuo2 SNOILONYLSNI 9NILVH3dO OPERATING INSTRUCTIONS
12. the square mounting bar by use of the winch cable Then place a V bracket 1 2 that distance on the left side of the mounting bar and securely fasten use both locking knobs Now place a V bracket on the right side of the mounting bar the same distance from the center point but loosely attach as it might have to be moved when reel is lifted into place The roller support brackets should be placed 6 to 8 inside the reel supports with the V facing the back of the machine and securely fastened with both locking knobs The V s have an offset so they can be installed high or low depending on the reel See FIG 23 FIRMLY TIGHTEN ALL LOCKING KNOBS BEFORE GRINDING ANY LOOSENESS WILL ADVERSELY AFFECT GRINDING QUALITY OPERATING INSTRUCTIONS Continued LIFTING MOWING UNIT INTO POSITION WHEN USING ROLLER SUPPORTS Position the mowing unit behind the grinder on the floor so the front of the mower faces the front of the machine Hook the reel elevator spreader bar onto the mowing unit The hooks on the bar should be spaced evenly along the mowing unit so they do not slip or slide as it is being raised See FIG 24 THE OPERATOR SHOULD BE POSITIONED AWAY FROM THE REEL DO NOT STAND UNDERNEATH THE REEL AS IT IS BEING RAISED GUIDE REEL AT ARMS LENGTH Slowly raise the mowing unit by cranking the winch handle with the right hand and steadying the reel with the left hand Your left arm should be extended during the lifting ope
13. Continued Turn the Torque Potentiometer to zero Turn the Spin Drive motor on NOTE The spin drive will apply torque load against the fingers Slowly turn the Relief Torque Potentiometer up to approximately 15 NOTE Free turning reels may need a lower value than 15 Stiff reels or reels with a drive train may need a higher torque than 15 Do not exceed 45 on the relief torque potentiometer setting Jog the traverse all the way to the left prox switch watching for proper clearance between the grinding wheel and the blade When the grinding head reaches the left prox the index finger should pop forward See FIG 70 The grinding wheel should come off from the reel blade but reel blade should remain on the fixed relief finger See FIG 69 If not adjust the left side proximity switch position until correct Check for proper clearance between the index finger and the front side of the blade on the return trip to the home right hand prox position See FIG 71 Also verify clearance between the index finger and the reel blade support spiders Stop the traverse in home position and check for a proper blade index See FIG 72 The fixed relief finger should come off the reel blade the relief torque from the spin drive should rotate the reel so the next blade contacts the index finger and pushes the index finger back against its stop The traverse drive control is factory set with a two second dwell time before it reverses the carria
14. HORIZONTAL PARALLELISM Continued F To adjust reel position first determine the direction the reel has to move for alignment The direction that the reel will have to be moved can be determined by pulling back on the dial indicator stop bar and if the dial moves back to the 0 position you will have to move the reel towards you If that cannot be done the reel will have to be moved away from you There are two adjusting steps for final positioning of the reel as follows 1 With the reel set gauge still in the left hand side of the reel turn the horizontal adjusting handwheel FIG 49 in the direction required to match the initial indicator reading on the right hand reel position See FIG 51 2 Now travel farther by half the amount already traveled The reason for this is that the square mounting bar pivots on one end and adjusted on the opposite end Anytime the adjusting end is moved to change the left side dimension the right side dimension is also changing at a ratio to the left side By over compensating at the adjusting end you will compensate for this movement and get the reel aligned much faster G Now move the set up stand back to the right side of the reel Set indicator rod on the same spot you used the first time and reset large dial on 0 Make sure you read the setting on the small scale and note Then proceed with paragraph E 8 F again This should give final adjustment When you have done this procedure a f
15. OF 002 05 ON THE RING SCALE LOCATED ON THE INSIDE OF THE INFEED HANDLE If grinding wheel is only making contact in one part of the reel adjust the traverse stop so the carriage traverses slightly further than the contacted area As you infeed and wheel makes full contact in this area move traverse stop away 3 7 6 cm to 5 12 7 cm This will speed up the grinding process of getting a cone shaped reel into a true cylinder See FIG 65 Spin grinding is completed when full contact is made across the entire length of the reel and the entire width of all blades and the cutting edge is sharp It is required to have a sparkout to complete grinding the outside diameter to a true diameter For sparking out the process is to infeed the grinding head for approximately 002 05 MM stock removal one line on the ring scale and let the grinding wheel sparkout For sparking out in grinding process always traverse the grinding head at least 20 passes with no additional infeed Set traverse at slow speed on dial setting approximately 4 to 8 feet per minute range for final grinding sparkout After sparkout shut the grinder completely off NOTE This process refers to sparkout but what we are looking for is a near sparkout approximately a 99 reduction in grinding sparks from normal grind Do not run sparkout until you have no sparks because this could be an extremely extended period NOTE Greatest accuracy and best finish i
16. clamp rod under the tubing cross bar as shown in FIG 30 Itis recommended to mount them under the tubing cross bar whenever possible Before tightening the overhead clamps you must correctly position the mowing unit When using the roller supports or the centers you can pivot the cutting unit with the overhead clamps With the relief grinding wheel and the relief guard with fingers installed you must pivot the cutting unit so you have clearance of the relief finger to the frame clearance of the next blade to be relieved to the grinding wheel and clearance of the grinding wheel to the front roller Clamp Lips Bottom Portion Long Threaded Knob Assembly DO NOT TIGHTEN THE LEFT HAND FIG 31 SLIDE ROD CLAMP WHERE RODS ARE INSERTED INTO THE LOWER PART OF THE CLAMP UNTIL REEL HAS BEEN ALIGNED SEE FIG 32 FIRMLY TIGHTEN ALL LOCKING KNOBS BEFORE GRINDING ANY LOOSENESS WILL ADVERSELY AFFECT GRINDING QUALITY OPERATING INSTRUCTIONS Continued ATTACHING THE VARIABLE SPEED SPIN DRIVE UNIT TO THE REEL When spin grinding the reel should turn in the same direction as the grinding wheel See FIG 33 The normal position for the spin drive unit is on the right side of the square mounting bar when viewing from the mowing unit loading position A Before positioning the spin drive unit familiarize GRINOINGWHEEL yourself with the available adjustments and coupler i j REEL TURNS IN SAME DIRECTION drive assembli
17. disappear ADJUSTMENTS Continued UPPER SPIN BOARD Potentiometer Clock Orientation LOWER SPIN BOARD 4 30 FULL CW e 9 00 M SPD TORQUE IR COMP s SPD Vel 8 30 FULL CCW 199 234 PROXIMITY ITCH For the proximity switch to perform properly and reverse the direction of the carriage at each end of the rails a distance of 4 mm 156 to 6 mm 234 needs to be maintained between the proximity sensing bracket and the proximity switch See FIG 36 NOTE Light on proximity activates when metal crosses over the switch ADJUSTMENTS Continued 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 IR COMP is current I resistance compensation COMP IR COMP adjusts the output voltage of the drive which balances load to motor RPM Regulation of a traverse motor may be improved by slight adjustment of the IR COMP trim pot clockwise from its factory set position O
18. frame tube See FIG 3 Place a level on the top of the front carriage rail near one end of the machine and check the level of the unit from side to side See FIG 5 Adjust the leveling screws as necessary to bring to level Place a level across the front and rear carriage rails near the left end of the carriage bed See FIG 6 As viewed from the operator s position adjust the leveling screw on the left end of the machine as necessary to level the left end This adjustment is critical to proper operation of your unit Place a level across the two carriage rails at the right end of the machine and adjust to level See FIG 6 This adjustment is critical These two steps will level the machine from front to back as viewed from the operator s position Left End of Unit When both front to back and side to side leveling procedures have been completed thread the hex jam nuts up against the nut that is welded to the inside of the frame tube until they lock into place Be careful not to move the leveling screws during this process See FIG 3 Recheck with level after locking nuts are firmly tightened YOUR GRINDER OR BUMPING IT FAILURE TO PROPERLY LEVEL OR OFF LEVEL WILL ADVERSELY AFFECT GRIND ASSEMBLY INSTRUCTIONS Continued INSTALL WINCH AND BOOM With the use of a stool or ladder install the boom assembly into the boom receiver tube that is welded in the frame See FIG 78
19. in the roller brace wrap the chain vise clamp around the roller and Vise Chain Clamp around the stud on the roller brace Firmly tighten See FIG 29 FIRMLY TIGHTEN ALL LOCKING KNOBS BEFORE GRINDING ANY LOOSENESS WILL ADVERSELY AFFECT GRINDING QUALITY OPERATING INSTRUCTIONS Continued ATTACHING THE OVERHEAD CLAMPING ARMS Your grinder is supplied with two clamp rods and two sizes of clamp lips Overhead Clamps Determine which clamp lips to use in your grinding application You have three choices First the large lip clamps which are primarily attached to the front rollers Second the small lip clamps are primarily attached to a mowing unit cross bar or a mounting lug or bolt Third you can remove the clamping lips turn the clamp rods 90 degrees and attach the clamp rods directly to the mowing unit using the hole on the end of the clamp rod attached to a stud or bolt on the mowing unit frame Loosen the two 2 screw handles on each overhead clamp and move them to where the overhead clamp rods with or without clamping lips can be attached to the mowing unit Tighten the clamping lips to the FIG 30 mower then securely tighten the two 2 locking handles on each overhead clamp See FIG 30 and Slide Bar Clamp FIG 31 Clamp Rod Handwheel Assembly Top Portion The overhead clamps can be mounted with the Clamp Rod clamping rod above the tubing cross bar as shown in FIG 31 or they can be mounted with the
20. on the traverse system may cause parts to fail DO NOT OVERTIGHTEN OVERTIGHTENING COULD DAMAGE THE BELT OR TRAVERSE DRIVE SYSTEM TRAVERSE CLAMP FORCE If the traverse clamp is slipping during regular operation it may be necessary to tighten the clamp To tighten loosen the jam nut and screw the tip out Move the traverse belt out of the way and verify the clamped distance from the tip to the clamping block shoe See FIG 93 Lock in place by tightening the jam nut against the clamp being careful not to move the tip Do not set the adjustment at less than 10 2 5 mm The 10 2 5 mm setting allows slippage in a jam situation and damage can occur if this adjustment is set to narrow CAUTION SHOULD BE USED AS ADJUSTING THE TIP WILL THE SLIP LOAD AND COULD DAMAGE THE CLAMP TIP BELT OR TRAVERSE DRIVE SYSTEM ADJUSTMENTS Continued BELT TENSION The belt must be tensioned so when the lock handle is locked the maximum belt deflection is 12 3 mm at a 10lb 4 5 Kg load ADJUSTMENTS Continued ALIGNMENT FIXTURE ADJUSTMENT The body of the dial indicator should be flush with the casting it is mounted in The anvil should be able to be depressed fully without touching the casting To adjust properly loosen the set screw in the indicator mounting casting and adjust accordingly See FIG 95 Tighten dial indicato
21. procedure STEP 1 Loosen the two nuts on the support casting that hold the locking studs and tap with plastic hammer to loosen STEP 2 Loosen the locking handles and tap the center stud with a plastic hammer STEP 3 Loosen locknut and setscrew and remove the handlwheel STEP 4 Remove the Slide Shaft STEP 5 Remove all burrs and resurface the shaft to a clean smooth polished surface OR REPLACE WITH A NEW SHAFT STEP 6 Coat shaft with Never Cease and re install the shaft through the Support Cross Slide Block and the three Locking studs The shaft must move freely inside the Cross Slide Block before reassembling STEP 7 Retightening the nuts at the end of the locking stud to lock shaft in place STEP 8 Reinstall the Handwheel by snuging the setscrew to the flat located on the screw shaft then torque nut until tight and back off 1 2 turn Torque the setscrew to 70 in lbs STEP 9 Test the Cross Slide the handwheel should turn freely NOTE It is also possible to remove the complete Cross Slide Assembly and do the repairs on a bench then reinstall See FIG 90 and 91 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 19 mm See FIG 92 Ifthe springs are not tensioned equally uneven loading
22. rotate the linear bearing around the shaft This cogging is from the skidding of the bearing on the shaft and indicates the tension screw is to tight Sliding the bearing block back and forth should be a smooth uniform motion TENSION ADJUSTMENT SCREW Repeat Steps 1 through 3 with the other two linear bearings POSITION FACING QUT Note Both bearings on the shaft nearest the reel must come off the left side of the rail BEARINGS WHICH ARE TOO TIGHT OR TOO LOOSE WILL CAUSE POOR GRIND QUALITY ALSO BEARINGS WHICH ARE TOO TIGHT WILL HAVE SUBSTANTIALLY SHORTER LIVES AND MAY DAMAGE THE SHAFT SETTING THE BEARING TENSION CORRECTLY IS CRITICAL TO PROPER GRINDING STEP 4 Slide linear bearing under carriage and attach with the four screws STEP 5 After all three linear bearings are secured to the carriage check for correct bearing tension The bearing tension is correct when you try to lift the carriage and can feel no carriage movement If there is movement this means there is up and down free play The most dependable method of checking free play is to use a magnetic base dial indicator attached to the traverse frame weldment and reading the vertical movement above each bearing This movement should be within 001 03 mm When pulling the carriage in the traversing direction there should be only approximately a three lbs force with the belt clamp disengaged To double check the assembly slide the carriage from end of travel to e
23. then the clamp rod on the fixed end must be kept tight If the mowing unit is clamped in the OPTIONAL Pull Gang Reel Mount Kit 18574 V brackets and the ground roller is clamped with chain vice clamp then both overhead clamp rod adjusting knobs can be loose Loosen the two locking knobs on the cross slide assembly on the left side of the square mounting bar so that it can be adjusted in both the vertical and horizontal plane See FIG 42 Vertical Lock Handle Horizontal Lock Handle Horizontal Adjustment Knob OPERATING INSTRUCTIONS Continued ALIGNING REELS IN THE Alignment Rod VERTICAL PARALLELISM PLANE A Move the grinding head assembly until the set up fixture is approximately 1 from the right side of the reel Lock the Knob A within approximately 1 8 125 of center shaft of the reel See FIG 45 Parallelsim Raise the indicator slide casting on the vertical support so that the indicator rod can be extended over or under the center shaft of the reel See FIG 43 and 44 Lower the indicator slide by turning the vertical fine adjustment Knob B until the alignment rod lightly touches the top or bottom of the reel center shaft See FIG 47 Pull rod back and lock Knob See FIG 45 Traverse to the other side of reel same distance from end Loosen Knob C and extend alignment rod If the left side is lower than the right turn the vertical adjusting handwheel in the cross slide assembly clo
24. 009024 6009025 6009026 6009030 6009031 6059082 6009041 6009044 4 50 Dia Modified Handwheel 6009083 6009084 6009088 6009136 6009587 6059023 6059550 3708448 3707155 6059081 3707009 18520 GRINDING HEAD ASSEMBLY PART NO PART NAME 3 8 16 Adj Handle Rod End Bearing Conical Washer V Belt 375 Dia x 38 Lg Shoulder Bolt Clear Indicator 62 Bore Pulley Adjusting Arm 40610 x 1Lg Steel Spacer 1 2 10 ACME Backlash Nut Gib Plate Tapped Pivot Sleeve ACME Adjusting Shaft Keeper Plate Shaft Locking Stud 386 ID x 56Lg Steel Spacer Calibrated Ring Angle Locking Pin Grinding Head Slide Base Grinding Head Pivot Base Grinding Head Swivel Base Feed Screw Guide Rear Belt Guard ACME Adjusting Shaft Grinding Wheel Knob V Belt Pulley Knob Grinding Head Arbor Assembly Front Belt Guard Spinning Knob Index Finger Assembly Electrical Warning Decal Black Wire Nut w Setscrew Grind Motor Cord Strain Relief 50 Dia Hole Plug 3 4 HP Motor 1 4 20x1 2 Button Head Cap Screw 5 8 18 Thin Locknut Traverse Belt Clamp Bracket Destaco Clamp Front Bearing Dust Plate Sharp Warning Decal PARTS LIST 6059550 INDEX FINGER ASSEMBLY PARTS LIST 6059550 INDEX FINGER ASSEMBLY DIAGRAM NO PART NO DESCRIPTION B190634 10 32 x 3 8 Long Button Head Socket Cap Screw B191031 10 32 x 5 8 Long Socket Head Cap Screw C190467 10 32 x 1
25. 01 199 The next three numbers or letters are the code for the component to which the wire attaches Example GMC for Grind Motor Control The last two numbers or letters are the number of the terminal on the component to which the wire attaches ELECTRICAL TROUBLESHOOTING INDEX AC Main Power Controls Page 60 61 Spin Drive Controls in Spin Mode Page 62 63 Spin Drive Controls in Relief Mode Page 64 65 Spin Drive Controls General Grinding Motor Controls Traverse Drive Controls w prox Page 68 69 Traverse stopping and reversing Page 70 72 ELECTRICAL TROUBLESHOOTING Continued PROBLEM AC Main Power Controls no electrical power to control panel Verify all wires shown on the wiring diagram on pages 74 76 are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If problem persists test as listed below Possible Cause Emergency Stop Botton ESS is Depressed You must push the System Start Switch SSS to get power to control Panel Main Power Cord is not plugged in ALL switches MUST be turned OFF for contactor to pull in Main 15 amp outlet circuit breaker has tripped No 120 Volts AC power to Filter FTR No 120 Volts AC power out of Filter No 120 Volts AC power to Main Circuit Breaker MCB No 120 Volts AC power from Main Circuit Breaker MCB Checkout Procedure A Pull Up on ESS B
26. 20 Volts AC power not delivered to Terminal Strip Grinding Motor Switch GMS not working Spin Motor Switch SMS not working Bad Emergency Stop Switch ESS Bad System Start Switch SSS Low Voltage Relay REL not operating Bad Main Contactor MAG ELECTRICAL TROUBLESHOOTING Continued Checkout Procedure J Check for 120 Volts AC at terminal strip K Check for 120 Volts AC at GMS Terminals 1 L Check for 120 Volts AC at SMS Terminals 1 M Check voltage after the ESS MAKE SURE SWITCH IS PULLED UP N Hold in SSS and Check voltage after the SSS O Hold in 555 and Check voltage at LVR LVR must be installed in 8 pin socket P Hold in SSS and Check voltage at MAG A1 amp 2 Terminal 11 on Terminal Strip 2 7TB2 11 to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step K next No Check continuity of wires 7 amp Check Jumper on Terminal Blocks 1 3 Replace if bad Measure 120 volts AC from GMS Terminal 1 to Term Block 4 Blue Yes Go to Step L next No Flip Switch and check again Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch Measure 120 volts AC from SMS Terminal 1 to Term Block 4 Blue Yes Go to Step M next No Flip Switch and check again Works Switch is upside down Does not work Check Wiring Verify Continuity Replace Switch Measure 120 Volts AC from ESS term 2 to Term Block 4 Blue Yes Go
27. 233 PART NAME 10 32x3 4 Pan Head Machine Screw 10 32x3 8 Pan Head Machine Screw 1 4 20x1 2 Truss Head Machine Screw 1 4 20x1 Button Head Cap Screw 1 4 20x3 1 8 Socket Head Cap Screw 5 16 18x1 2 Socket Head Cap Screw 5 16 18x5 8 Hex Head Cap Screw 5 16 18x7 8 Hex Head Cap Screw 1 4 20x1 4 Socket Setscrew Cup Pt 1 4 20x5 8 Socket Setscrew Cup Pt 1 4 20x1 1 2 Socket Setscrew Cup Pt 5 16 18x1 4 Socket Setscrew Cup Pt 3 8 16x1 1 4 Socket Setscrew Cup Pt 25 Dia x 1 75Lg Roll Pin 31 Dia x 1 Lg Roll Pin 38 Dia x 1 25 Lg Roll Pin 50 Dia x 1 25 Lg Dowel Pin 1 4 20 Hex Nut 1 4 20 Hex Jam Nut 1 4 20 Thin Locknut 3 8 24 Hex Nut 3 8 16 Locknut Jam Nylon 3 8 16 Locknut Hex Nylok Full 10 Flat Washer 1 4 Split Lock Washer 5 16 Flat Washer 5 16 Split Lock Washer 3 8 Flat Washer 3 8 Split Lock Washer 2 Prong Knob Nylon Plug 3 16 Dia Spacer 191 ID x 438 OD x 43 Lg Grinding Wheel 6 Dia x 375 Wide Cord Clip Handwheel 4 5 Dia 24 OD x 62 Lg Comp Spring RPM Warning Decal 3 8 16x1 56Lg Adj Handle Conical Washer Thrust Washer Handle J251000 J252000 J257000 0377000 21877100 2 K190001 K310001 K311501 K371501 3579109 3700091 3707933 3708213 3708461 3708561 3709062 3709304 3709370 DIA NO 3709437 3709463 3709620 3709764 3709809 3809047 3889059 1 13 OD 2 0 Lg Compr Spring 6
28. 4 Socket Setscrew Nylock Cup Point K310001 5 16 Flat Washer Index Finger Spring Block Compression Spring 5 16 18 x 5 8 Long Adjustable Handle Knob Assembly 1 8 Diameter Nylon Ball Grinding Wheel Guard Finger Support Fixed Finger Index Finger Assembly Finger Support Assembly Index Stop Pin PARTS LIST 18506 MOWER SUPPORT ASSEMBLY PARTS LIST 18506 MOWER SUPPORT ASSEMBLY DIAGRAM NO PART NO DESCRIPTION A313601 5 16 18 x 2 1 4 Long Hex Head Cap Screw B371201 3 8 16 x 3 4 Long Hex Head Cap Screw B371616 3 8 16 x 1 Long Button Head Socket Cap Screw H371602 au 375 Dia x 1 Long Roll Pin J371000 3 8 16 Hex Nut K371501 3 8 Lockwasher Cross Slide Assembly Tooling Bar Weldment Spacer 406 ID x 75 Long Flat Washer 5 16 18 T Knob Flat Washer Center Stand Lock Top Clamp Bottom Clamp Clamp Bar Locking Stud Shaft Lip Clamp Mower Clamp Weldment Adjustable Center Adjustable Center Stand Fixed Center Stand Fixed Center Assembly T Knob Assembly 3 8 16 x 1 5 Long T Knob Assembly 3 8 16 x 3 25 Long T Knob Assembly 3 8 16 x 2 25 Long PARTS LIST 6059523 SPIN DRIVE ASSEMBLY 90 PARTS LIST Continued 6059523 SPIN DRIVE ASSEMBLY DIAGRAM NO PART NO DESCRIPTION Reducer 10 1 Ratio Motor Electric 90 VDC 25 HP 1 4 20 x 7 8 Socket Head Cap Screw Flange Coupler 50 Sleeve Coupler Flange Coupler 5 8 Adapter Drive Coupling Hot Warning Decal Knob 2 Prong 1 4 20 x 50 Long
29. AD REPOSITION SPIN UNIT d Square Drive Adapter a Rubber Coupler Socket short and Long Available FIG 35 OPERATING INSTRUCTIONS Continued NOTE The 1 2 square drive socket that is places on Spin Drive Unit the reel when spin grinding is NOT included with the grinder You must purchase this from an appropriate local supplier of tools Many of today s reels have a spline at the end of the reel shaft to receive the hydraulic motor shaft The cutting unit manufacturer has adapters you can purchase to drive these reels The following procedures will make setting up the spin drive unit easier 1 Move spin drive unit close to the reel Align the shaft on the spin drive with the drive component on reel by completing the necessary adjustments discussed on the previous page Now slide the spin drive unit approximately 7 from the reel drive coupling point and securely fasten to Spin Drive Square the square mounting bar tightening both locking Scissor Bars Mounting Bar knobs Place the proper 1 2 square drive socket or adapter on the reel drive component and then insert Adapter Sleeve the square drive shaft into the socket Place the 3709584 adapter sleeve over the drive shaft and insert the drive coupler adapter assembly into it Finally place the rubber coupler onto the drive coupler adapter See FIG 36 By holding the square drive shaft firmly into position with your left hand you will be able to move the other com
30. C approx 120 Volts DC Have Yes go to Step next Spin Speed Pot set to 400 No go to Step L next RPM ELECTRICAL TROUBLESHOOTING Continued Possible Cause Spin Drive motoris bad Spin Speed Pot SSP is not working Spin Torque Pot STP is not set correctly SSP is not working Worn Motor Brushes Checkout Procedure F Check for approx 120 Volts DC input to SRS G Check for approx 120 Volts DC out put from SRS H Check spin motor continuity DISCONNECT POWER FROM MACHINE L SSP 10K on control panel M Check STP remote torque on the top SDC board N SSP 10K Remove 3 Remote Speed wires Red wire to term W White wire to term L Black wire to term H DISCONNECT POWER FROM MACHINE P Inspect Motor Brushes SRS Term 6 to 7 for approx 120 VDC Yes go to Step next No Check continuity of wires and replace if bad SRS Term 2 to 3 for approx 120 VDC Yes go to Step H next No replace SRS switch Remove wires at Terminal Strip 1 Term 4 amp 5 check 0 ohms across the black and white wires Yes end troubleshooting spin drive should run if not replace motor No go to Step P next Spin Drive Control SDC Term s Remote Speed W to H Pot Full CCW O volts DC Pot Full CW 4 4 Volts DC SDC Term s Remote Speed W to L Pot Full CCW 4 4 Volts DC Pot Full CW DC 0 Volts DC Yes Go to Step M No Go to Step N STP on top SDC board label
31. D IS IN PLACE 10 DON T JAM work into the wheel DON T STAND DIRECTLY IN FRONT grinding wheel whenever grinder is started 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 GETTING KNOW YOUR GRINDER This machine is intended for reel mower reel blade grinding 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 ALL operators of this equipment must be thoroughly trained BEFORE O operating the equipment 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 Adjustable Reel Clamping Mechanisms for ease of installation One chain vise grips included to secure any size roller Positive Vertical and Horizontal Reel Adjustments for fast alignment of the reel in the machine Dial Indicator Setup Gauge to align reels with accuracy u
32. E CHECKED WITH ALL EQUIPMENT UNDER LOAD OPERATING THE CIRCUIT GE pi DO NOT OPERATE THIS GRINDER WITH TRIP LIGHT AN EXTENSION CORD INDICATES LOW PROPER GROUNDING OF THE Y VOLTAGE RECEPTACLE GROUND IN YOUR DELIVERED BUILDING MUST BE VERIFIED IMPROPER f TO GRINDER GROUNDING IN YOUR BUILDING MAY Cag CAUSE THE GRINDER TO MALFUNCTION SS SSSSSSSS Y FOR 15 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 ASSEMBLY INSTRUCTIONS Continued FOR 220 V 50 60Hz applications Product No 1810952 should be ordered GREEN CR LNI 1810952 includes a 2 KVA 220 Volt Step Down to 110 volt 50 60 Hz transformer which is prewired The wiring diagram is shown in FIG 82 The power cord has no connector connector which is appropriate for your locality and 220 volt 8 amp application should be installed FIG 82 X2 X4 H10H5 HI Hb INDIVIDUALL
33. ERSE ORIVE CONTROL AIRE 5956406 o 2 11 illis V E X uoc sol Ma sak om PTE mma PY cx E la L K Sm C V mu
34. IGHTEN ALL LOCKING KNOBS BEFORE GRINDING ANY LOOSENESS WILL ADVERSELY e AFFECT GRINDING QUALITY OPERATING INSTRUCTIONS Continued INITIAL SET UP OF SUPPORTS Continued INITIAL SET UP OF ROLLER SUPPORTS The roller support brackets should be placed facing up with the V ribs 1 to 2 narrower than the width of the rear roller with the offset either forward or back depending on mowing unit requirements NOTE Tighten the side locking knob first so the bracket is forced against the mounting bar Then tighten the bottom bracket See FIG 21 CENTERS BRACKET SET UP When mounting greens mower mowing units centers may be used to hold the mower unit See FIG 22 To mount measure the outside distance of the mower frame Using the center point of the square mounting bar position the fixed centering bracket 1 2 that distance on the left side and securely fasten Then place the adjustable centering bracket that distance plus 1 4 on the right side of the mounting bar and loosely fasten be necessary to move this bracket when lifting reel into place even though it can be adjusted The adjusting cone should be retracted as far as possible as it will be easier to secure reels when in place OPTIONAL PULL GANG BRACKET SET UP On ground drive mowing units with exposed hubs you will be using the OPTIONAL Pull Gang Reel Mount Kit 18574 measure the distance from the outside of the hubs and subtract one inch Determine the middle of
35. ING 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 pages 72 75 are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or not loose crimps between wire and terminal If loose terminals are found retighten and retest system If prob lem persists test as listed below Possible Cause Checkout Procedure Spin Speed Pot A Set SSP to 200 on the Spin Motor works SSP set to zero control panel Yes end troubleshooting No go to Step B next Spin Motor Switch B Turn SMS switch on Spin Motor works SMS is not on Yes end troubleshooting No go to Step C next Spin Rotation Switch B Turn SRS switch to the Spin Motor works SRS is not on direction of reel rotation Yes end troubleshooting required NOTE Center No go to Step C next position is off Circuit Breaker is C Reset Circiut Breaker on Spin Motor works Tripped 4 AMP front of Control Panel Push Yes end troubleshooting in if tripped No go to Step D next Spin Drive Control D Check SDS L1 to L2 for SDC Term L1 to term L2 for 120 volts SDS is not working 120 Volts AC Yes go to Step E next No Verify Power to Circuit Breaker and SMS and continuity of wires Replace CB or SMS if needed E Check SDC A1 amp A2 for SDC Term A1 to A2 for approx 120 V D
36. L 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 Gap between flag and prox is incorrect Proximity Switch is bad A Gap between flag and prox should be 3 16 to 1 4 4 6 mm Prox LED does not light when flag is under prox B Proximity switch is not working properly or wire connections are loose Ifincorrect adjust per adjustment section of manual Yes end troubleshooting No go to Step B next First check to see if proximity light comes on When the light is on it means that there is electricity coming to proximity switch Actuate prox switches with steel tool to take measurements Left proximity PROX 1 check Traverse drive Control TDC between terminals 14 black wire and 15 brown wire Right proximity PROX check between terminals 14 black wire and 15 brown wire The light coming on shows the proximity is getting electrical contact Proximity light on 0 Volts DC Proximity light off 12 Volts DC Proximity light on 0 Volts DC Proximity light off 12 Volts DC Replace proximity switch if the voltages do not read as above ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse speed control goes at one speed only Possible Cause Checkout Procedure Defective speed control Check potentiometer on control Traverse Drive Control Pin 8 to 7 pote
37. MIT lights when the forward limit switch is actuated left prox PROX 2 REV LIMIT lights when the reverse limit switch is actuated right prox DWELL lights when the process remains stopped after a proximity switch is actuated PROX 1 LEMIT REVERSE C Potentionmeter Clock Orientation 37 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 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 not you should read the Operators section of this manual or do the servicing in conjunction 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 any question not answered in this manual please call your distributor They will contact the manufacturer if necessary WIRE LABELS All wires on the grinder have a wire label at each end for troubleshooting The wire label has a code which tells you wiring information The wire label has a seven or eight position code The first two or three digits are the wire number
38. MODEL 181 AUTO INDEX SPIN RELIEF REEL MOWER GRINDER OPERATORS MANUAL SAFETY INSTRUCTIONS Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards When ever you see these symbols follow their instructions Caution Symbol identifies special instructions or procedures which if not strictly observed could result in damage to or destruction of equipment The Warning Symbol identifies special instructions or procedures which if not correctly followed could result in personal injury KEEP GUARDS IN PLACE and in working order 13 MAINTAIN GRINDER WITH CARE Follow 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 the c
39. No go to Step B next Grinding Motor works Yes end troubleshooting No go to Step C next GMS term 5 to Terminal Block 4 Blue for 120 V AC Yes go to Step D next No With power off check continuity of wires to GMS GMS Term 6 to Terminal Block 4 Blue for 120 VAC Yes Go to Step E next No replace GMS REL Term s A1 to A2 for 120 VAC Yes Go to Steep F next REL should pull in if not replace REL No Check wires to Term s 1 2 if bad replace REL Term L1 to Term L2 for 120 Volts AC Yes Go to Step G next No Check wires to REL Term L1 and L2 REL Term T2 to Term T2 for 120 VAC Yes Go to Step H next No Replace the relay REL CB 1 input term to Terminal Block 4 Blue for 120 VAC Then CB 1 output term to Terminal Block 4 Blue for 120 VAC Yes Go to Step I next No Check appropriate wire and CB 1 if bad replace Measure 120 Volts AC at Grinding Motor Cord Grind Motor End Yes Reconnect Motor motor No Verify Continuity of grind motor wire and replace if bad If it does not work replace 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 74 76 are correct and pull on wire terminals with approximately 3lbs force to verify there are no loose terminal connections and or n
40. OF THIS 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 Check gib plate adjustment on the grinder carriage base monthly See Troubleshooting Section for adjustment 2 Wipe off and re oil with spray lubricant the grinding wheel infeed adjusting lead screw and the grinding head height adjustment lead screw every three months Wipe off all excess lubricant 3 Inspect the V belt for glasing or cracking and adjust the belt tension per procedure specified in the adjustment section every three months 4 Replace the four foam rail wipers every six months of operation See FIG 83 5 Follow the lubrication procedure for linear bearings Generally this will be every six months to a year 6 Lubricate the gib area on the grinder carriage base with high quality litium grease every six months Wipe off excess grease 7 Wipe off and relube with never seez the vertical and horizontal cross slide shafts and lead screws every six months Wipe of excess grease 8 Check the free play in the grinding wheel shaft bearing once a year Replace if excessive play exists 9 Check the brushes on the auto traverse drive motor and spin motor every 36 months Replace as necessary See Troubleshooting Section MAINTENANCE amp LUBRICATION LUBRICATION OF LINEAR BEARINGS step 1 Thoroughly clean all both shafts Step 2 Flood spray t
41. Operators Manual Lip Clamp Grinding Wheel 6 OD x 1 Wide x 502 Bore Dressing Stick 75 x 75 x 3 0 Long Warning Decal 3600 RPM Retaining Ring External Chain Clamp Center Stand Lock V Bracket Mower Mount Grinding Wheel Guard T Knob Assembly 3 8 16 x 1 5 Long B372011 3 8 16 x 1 25 Long Socket Head Cap Screw 4317100 5 16 18 Hex Locknut Warning Decal Boom Capacity Decal Spreader Bar 5 16 18 U Bolt Spreader Bar Grab Hook Square Key 3 16 x 75 Long Knob 2 Prong 1 4 20 x 50 Long Flange Coupler 625 Bore Drive Adapter 3 5 Long Drive Coupling Adapter Sleeve Coupler 18558 WINCH 8 BOOM ASSEMBLY PARTS LIST PARTS LIST 18558 WINCH amp BOOM ASSEMBLY DIAGRAM NO PART NO DESCRIPTION 3 8 16X1 3 4 Hex Head Cap Screw 3 8 16 Hex Nut 7 Winch Handle 3 8 16 Locknut Nylon Full 3 8 Flat Washer Boom Capacity Warning Decal Hook amp Cable Assembly Boom Capacity Warning Decal Winch Warning Decal 101 18400 WIRING DIAGRAM 55 START m4 1 10534 102 CBI CIRCUNT BREAKER 1 B2 CIACUJT BREAKER 2 ESS EHERGENLY STOP SWITCH FTR LINE FILTER ENS GRENDING MOTOR SWITCH RIP RELIEF TORGIE POT SOL SPIN DRIVE CONTROL SMS SPIN MOTOR SWITCH SRS SPIN ROTATION SWITCH SP PIN POT SSS SYSTEM START SMCTEH SIS S VTIRRE SELCTOR SWITCH _ STRIP TED TERMENAL STRIP 2 BLOCK GREY TEN TERMENAL BLOCK WHITE TSP TRAVERSE SPEED TOL TRAV
42. Retaining Ring Drive Adapter 1 2 Square PARTS LIST 6009527 REEL SET UP GAUGE ASSEMBLY PARTS LIST 6009527 REEL SET UP GAUGE ASSEMBLY DIAGRAM NO PART NO DESCRIPTION Slide Setup Gage Tube Gage Slide Tee Knob Assembly 1 75 lg 6009049 Block Adjust Slide K250001 1 4 Flat SAE Washer T Knob Assembly 88 Long Locknut Nylon 1 4 20 Full 3579123 Dial Indicator 250420 SKSS 1 4 20 x 1 4 Bar Indicator Stop Spring Compression Spring Guide Rod Push on Ring Saddle Stop Tee Knob Assembly Rod Gage Alignment Domed Anvil 3 8 SKSS CP PT 1 4 20 x 3 4 1 4 20 Jam Nut 6009050 Clamp Spring Loaded C310420 555 5 16 18 x 1 4 CP PT Nylon Plug Shoulder Bolt 1 4 D x 3 4 Set Collar 1 4 with SSS Tee Knob Assembly 2 25 Lg Plug Spacer Tee Knob Assembly Nylon 18523 CONTROL PANEL ASSEMBLY PARTS LIST PARTS LIST 18523 CONTROL PANEL ASSEMBLY DIAGRAM NO PART NO DESCRIPTION 1 4 20 x 1 2 Long Thread Cutting Screw 1 4 Internal Teeth Lock Washer Control Panel Weldment Control Panel Sub Assembly Toggle Switch Boot Toggle Switch Strain Relief 43 55 Cord Diameter Yellow E Stop Ring Rocker Switch On Off DPST Rocker Switch On Off DPDT 4 Amp Circuit Breaker 12 Amp Circuit Breaker Potentiomoter Knob Green St
43. TSELF MAKE SURE THE STOP IS SET SO THAT THE GRINDING WHEEL WILL NOT RUN INTO FRAME WHEN GRINDING IT IS POSSIBLE THAT IN SOME CASES THIS WILL MEAN THE GRINDING WHEEL WILL NOT CLEAR THE END OF THE REEL WHEN GRINDING Repeat this procedure for the other side of the reel Then set the traverse speed dial to 10 and let the carriage traverse back and forth to make sure that the stops are set properly Move grinding carriage to the high side end of the reel and stop carriage Put the Grind Selector Switch to Variable Speed Spin Turn on spin drive motor and check to see if reel is spinning freely and that coupling components are properly aligned With the spin drive running at 200 RPM turn on grinding wheel motor on main control panel Verify that the spin rotation is the same as the grinding wheel clockwise looking at the right end of the reel from the operators position See FIG 64 Now slowly infeed the grinding wheel until it just make contact with the reel OPERATING INSTRUCTIONS Continued GRINDING REEL INTO A TRUE CYLINDER BY SPIN GRINDING Continued J Set traverse speed knob to approximately 12 then turn on the traverse switch and begin grinding If reel is in bad condition traverse slower as more material can be removed Conversely if the reel is in good condition speed can be increased MAXIMUM RECOMMENDED STOCK REMOVABLE PER PASS IS 008 NOTE THE INFEED HANDLE IS CALIBRATED IN O INCREMENTS
44. This grinder is equipped with two grinding wheels and two grinding wheel guards Prior to relief grinding install or verify installation of the 3 8 9 5 MM wide grinding wheel and the relief wheel guard FIG 66 which has the relief and index fingers attached See FIG 66 Back Stop Knob Check to see if your mowing unit is normal or reverse helix NOTE As you look into the guide finger on PAGE 35 IT SHOWS THE NORMAL REEL HELIX The high point of the relief finger is on the right hand side of the grinding wheel As you look into the guide finger on PAGE 36 IT SHOWS THE REVERSE REEL HELIX The high point of the relief finger is on the right hand side of the grinding wheel Most mowing units are normal helix Reset Traverse Limit Proximity Switch so the grinding wheel clears the reel at both ends by approximately 1 16 1 5 mm or the reel blade comes off the relief finger on the right side See FIG 69 72 D Set Grind Selector to variable torque relief NOTE THE SPIN DRIVE ROTATION SWITCH MUST BE IN THE OFF POSITION WHEN CHANGING GRIND SELECTOR SWITCH Set Spin Drive Rotation switch to rotate the reel into the stop finger counterclockwise CCW when looking at the right side NOTE Relief torque reel rotation is always opposite spin rotation OPERATING INSTRUCTIONS Continued REEL SPIRAL Continued E There are three 3 lock handles to loosen Two 2 on the base for the adjusting arm locks and on
45. Y WIRE NUT TRANSFORNER LEADS H7 H8 AND HB USE ONLY A QUALIFIED INSTALL THE GREEN VIRE SUPPLIED INTO THE TERMINAL BLOCK IN THE HLE ELECTRICIAN TO OPPOSITE WIRE X3 AS SHOWN INSTALL THE WIRE INSERT SMALL COMPLETE THE SCREVORIVER INTO THE CAVITY MARKED A TO OPEN THE WIRE HOLE INSTALLATION ATTACH THE OTHER END OF THE GREEN VIRE SUPPLIED TO THE GROUND STUD ON THE TRANSFORMER 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 equipment 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 MAINTENANCE amp LUBRICATION DAILY MAINTENANCE IS SPECIFIED ON PAGE 5 OF THE OPERATOR S SECTION
46. ability to spin leave the elevator hooks and spreader connected to the reel with slight tension on the wire cable OPERATING INSTRUCTIONS Continued LIFTING MOWING UNIT INTO POSITION WHEN USING THE OPTIONAL PULL GANG MOUNTING BRACKETS CONTINUED There are two 2 roller supports that are mounted to the square mounting bar so that the V faces the back of the machine as pictured in FIG 28 There are four 4 OPTIONAL long set screws on these brackets which are used to hold the OPTIONAL FIG 28 extender plates when it is necessary to move mower roller back further to help expose the drive nut in the reel These set screws will also be used to attach the chain vise clamp when reels are in position Position the roller supports so the reel roller is centered on the two 2 supports and firmly lock in place NOTE On some reels the V grooves of the roller supports will be positioned on top of the support bar Roller Brace Stud This application is used primarily for fairway and greens mowers See FIG 28B If extender plates are necessary to move mowing unit back further simply pull the mowing unit back out of the way and slide extender plate onto both long socket head set screws and tighten down with 3 8 16 nuts and 3 8 lockwashers See FIG 28C MAKE SURE THAT THE ELEVATOR CABLE IS ATTACHED TO THE REEL AND THAT SOME TENSION IS ON CABLE BEFORE PULLING REEL BACK When the reel roller is positioned correctly
47. akes contact Now fine adjust using Knob B until at the center of the center shaft of the reel See FIG 51 Now loosen Knob D on the indicator stop bar Holding the indicator rod firmly against the reel shaft move the indicator stop bar back until no contact is made with the indicator rod plunger Now move indicator stop bar forward until contact is made and then an additional 1 2 This will set the plunger at about its midpoint and allowing it to move in both directions See FIG 53 Now set the outer dial indicator to the 0 position Read and note the position of the smaller 100 dial You must know this reading when setting up the other side Pull back and lock with Knob C See FIG 45 Move the alignment gauge to the left side of the reel carefully retracting the indicator rod so as not to damage or change setting Set indicator rod on the same position on the reel as you had on the right side that is 1 from the end and centered on the shaft See FIG 52 Now read the dial indicator to determine the distance the reel is out of position NOTE Because the set up gauge is mounted to the carriage you can unlock the actuator drive system and traverse manually from end to end Indicator Rod Plunger FIG 52 When you pull the indictor rod back there is a wing screw C to snug up so you do not have to hold the rod in the back position Indicator Stop Bar OPERATING INSTRUCTIONS Continued ALIGNING REELS IN THE
48. and results in a very bad grind By changing the Spin Speed to a higher or lower RPM you will move out ofthe resonant range After determining the best Spin Speed RPM for a reel note the RPM on a Setup Chart that you will make By noting the correct RPM you will avoid evaluating the Spin Speed the next time you grind the reel TRAVERSE DRIVE RPM The Traverse Speed potentiometer is adjustable from approximately 5 feet per minute 1 5 meters per minute to 35 feet per minute 11 meters per minute It is recommended to grind between 15 and 20 feet per minute 4 and 6 meters per minute Grinding at a slower traverse speed 10 feet per minute 3 meters per minute as an example will give a better finish but will extend the grind cycle time Grind finish versus grind cycle time is controlled by the choice of the operator OPERATING INSTRUCTIONS Continued GRINDING REEL INTO A TRUE CYLINDER BY SPIN GRINDING This grinder is equiped with two grinding wheels and two grinding wheel guards Priorto spin grinding install or verify installation of the 1 25 MM wide grinding wheel and the spin wheel guard which has no fingers attached See FIG 59 A Before you proceed any further check all knobs to insure they are tight FIRMLY TIGHTEN ALL LOCKING KNOBS BEFORE GRINDING ANY LOOSENESS WILL ADVERSELY AFFECT GRIND There are three 3 lock handles for locking the grinding wheel vertically Two 2 on the base fo
49. art Pushbutton Normal Open Contact Block Mounting Switch Latch Push Pull Red E Stop Normal Closed Contactt Block Safety Symbol Decal Respirator Warning Decal Hear Protection Decal No Fuel Decal Control Panel Decal Patent Decal Traverse Potentiometer Relief Torque Potentiometer Spin Speed Potentiometer ASSEMBLY 18524 ELETRICAL PANEL SUB PARTS LIST PARTS LIST 18524 ELETRICAL PANEL SUB ASSEMBLY DIAGRAM NO PART NO DESCRIPTION D160666 8 x 3 8 Long Pan Head Tapping Screw D161266 8 x 3 4 Long Pan Head Tapping Screw 8 Lock Washer External Teeth Terminal Strip Decal 8 Pin Socket Primary Ground Decal Primary Ground Lug Din Rail 14 Power Line Filter Traverse Motor Control Board Magnetic Starter 1 HP Low Voltage Relay End Stop Terminal Block Jumper Terminal Block End Plate Terminal Block Terminal Block Grey Terminal Block Blue LVR Warning Decal Electrical Sub Panel 15 Amp Circuit Breaker Terminal Strip 19 Pole Straight Double Spade Terminal Single 90 Spade Terminal Double 90 Spade Terminal Spin Drive Motor Control Board Cable Tie Mount Not Shown Cable Tie 6 5 Long x 18 Wide Not Shown Cable Tie 4 0 Long x 10 Wide Not Shown 18522 CARTON ASSEMBLY PARTS LIST PARTS LIST 18522 CARTON ASSEMBLY DIAGRAM NO PART NO DESCRIPTION A313601 5 16 18 x 2 25 Long Hex Hd Cap Screw Full Thd Drive Adapter 10 5 Long
50. ckwise raising the mounting bar and the reel until the center shaft of the reel lightly touches the extended indicator rod See FIG 35 Vertical Top of Carrier Shaft OPERATING INSTRUCTIONS Continued VERTICAL ALIGNMENT Continued F Take note of the vertical adjusting knob so you know from where you are starting See FIG 49 Now turn the vertical adjusting handwheel an additional 1 2 revolution This 1 2 revolution is to compensate for the fact that as you adjust the left side the right side is also moving at a proportioned amount This should almost align your reel in the vertical parallelism plane See FIG 49 Move the alignment fixture back to the right hand side of the reel and readjust the alignment rod so that it lightly touches the top of reel center shaft Move is back to the left side to make sure the reel is in correct vertical position If not move vertical adjustment handwheel up or down so that it just touches alignment rod on both sides When it does retest right and left sides until the same If the left side of the reel is found to be higher than the right lower the mounting bar and reel until alignment rod lightly touches the top of the reel center shaft and then turn the vertical adjusting Vertical handwheel an additional 1 2 revolution This 1 2 Adjustment revolution is to compensate for the fact that as Knob you adjust the left side the right side is also moving at a proportioned amount This should li
51. connect power before servicing Symbol to keep visitors a safe distance away from the grinder Symbol for hot surface which could cause burns Symbol for sharp object which will cause serious injury Symbol for caution relating to RPM of the motor and minimum safe Symbol identifying a panel cover or area as having live electrical rated RPM of the grinding wheel 522 components within Symbol that operators and people in the close proximity must wear respirators or have adequate ventilation systems Symbol for hearing protection required when operating this machine Symbol to keep exposed gasoline or flammables away from the grinder because it operates with a large amount of sparks Symbol for maximum weight capacity for winch Y d gt LOW VOLTAGE RELAY TRIPLIGHT The grinder is equipped with a low voltage relay which is factory preset at 100 If the power supply line INDICATES LOW does not deliver 100 VAC power under load the relay VOLTAGE Y will open and trip out the starter If this occurs your DELIVERED power supply line is inadequate and must be correct TO GRINDER 2 before proceeding further with the grinder ZZ 2 y 2 RRR RRR DAILY MAINTENANCE BY THE OPERATOR On a daily basis clean the grinder by wiping it off On a daily basis remove all grinding grit from the grinding head and traverse rail areas On a daily basis inspect the grinder for loose fasteners or compone
52. d on the reel blades does not go full length Possible Cause The right side corner of the grinding wheel is always to be in contact with the reel blade This is high point of the relief finger Checkout Procedure The right hand side of the grinding wheel is not in full contact for relief grinding See Operators Manual for NORMAL HELIX AND REVERSE HELIX for information on using the grinding wheel PROBLEM Too heavy a burr on cutting edge of reel blades Possible Cause Traverse speed set too high causing a heavy burr on the reel blade when spin grinding Too heavy a grind on the final grinding passes PROBLEM Cone shaped reel after grinding Grinding head travel not parallel to the reel center shaft PROBLEM Traverse speed is too slow Possible Cause Lineal bearing in the carriage are set too tight Traverse drive belt tension springs set too tight Checkout Procedure Traverse speed should be set lower approximately 12 meters min for a smaller burr on cutting edge Grind out reel using correct sparkout procedure as specified in the Operators Manual Grinding head travel was not setup parallel to the reel center shaft in vertical and horizontal planes See Align the Reel Section in operator s Manual Remedy Readjust linear bearings for proper tension per the adjustment section of this manual Check to see if traverse drive belt tension springs have been overloaded causing the bearings
53. d right can be released to allow manual movement of the grinding carriage The actuator release arm is located at the front of the carriage under the infeed handwheel See FIG 8 Rotate the release arm up to release actuator and rotate the release arm down to engage actuator Traverse Belt Proximity Switch Traverse Engagement Lever PROXIMITY SENSORS The Spin Relief Grinder is equipped with proximity sensors to change the traversing directions These are adjustable by sliding them along the rail to control traverse distance See FIG 10 Proximity Sensor GETTING KNOW YOUR GRINDER Continued GRINDING WHEEL AND GUARD FOR SPIN GRINDING Spin grinding requires a 1 00 wide 25 4 mm grinding wheel and a simple flat grinding wheel guard See FIG 11 GRINDING WHEEL AND FINGER GUARD ASSEMBLY FOR RELIEF GRINDING Relief grinding requires a 3 8 375 9 5 mm grinding wheel and a wheel guard that carries the fixed relief finger and the moveable index finger See FIG 12 RELIEF GRINDING FINGER ADJUSTMENTS The relief Index Finger Assembly has three adjustments as follows FIG 12 1 The index pin is adjustable in height with the loosening of its locking setscrew The height of Locking the finger can be raised to catch the next blade Setscrew on small diameter reels or it can be lowered to avoid interference with the reel spider See FIG 13 o FIG 13 2 The moveable finger has a knob tolimi
54. e Remedy Reason Proximity switch is not First check to see of proximity light light coming on shows the working properly or wire comes on When the light is on it proximity is getting electrical contact connections are loose means that there is electricity coming to proximity switch Actuate prox switches with steel tool to take measurements Left proximity PROX1 check Proximity light on Traverse drive Control TDC between 0 Volts DC terminals 14 black wire and 15 Proximity light off brown wire 12 Volts DC Right proximity PROX check TDC Proximity light on between terminals 13 black wire and 0 Volts DC 15 brown wire Proximity light off 12 Volts DC Replace proximity switch if the voltages do not read as above The dwell time on the Reset dwell time as required One traverse drive control not increment increases Dwell time by set properly 1 2 second NOTE Factory dwell setting is 4 Loose wire to proximity Check wire connections from the loose wire connection will give switch proximity switches and tighten down intermittent electrical contact Screws MECHANICAL TROUBLESHOOTING PROBLEM Reel ground concave convex or with irregular shape Possible Cause Checkout Procedure Too heavy a grind on the final grinding passes Grind out reel using correct sparkout procedure as specified in the Operators Manual Overhead clamps and tooling bar clamps not tight Tighten all locking hand k
55. e for the grinding wheel vertical height adjustment lock Raise the grinding head up approximately seven 7 turns so the reel blade can rest on the reel guide finger It will be necessary to infeed the grinding wheel to accomplish this See FIG 67 Now you can adjust the back angle you wish to put on the reel blade The average recommended manufacturer s angle is 20 to 40 degrees When in doubt check with each reel manufacturer as to the exact angle required By looking down the reel from the operator s position you can see the reel blade and its relative position to the grinding wheel See FIG 70 By raising the grinding wheel you will decrease the relief angle and conversely by lowering the grinding wheel you will increase the relief angle When the relief angle is correct traverse the grinding wheel assembly to the right side of the reel Retighten all three 3 lock handles The Index Finger position must be set to stop the reel blade and allow traversing to the left without the blade hitting the side of the relief finger This position must also allow approximately 1 32 1 mm free play of the index finger when the blade is resting on the high point of the relief finger See FIG 68 Turn the traverse speed pot to zero then turn the traverse drive motor on Using the speed pot to slowly move and stop the grinding wheel jog left until the reel blade on the relief finger Adjust the grinding head forward until there is
56. e on the reel Do not connect at this time just make sure that the connections are close enough to attach at a later time Lock Knob Adjustable Center Knob FIRMLY TIGHTEN ALL LOCKING KNOBS BEFORE GRINDING ANY LOOSENESS WILL ADVERSELY AFFECT GRINDING QUALITY THE ADJUSTABLE CENTER MUST BE FIRMLY TIGHTENED INTO THE REEL BUT EXCESSIVE FORCE CAN DISTORT THE REEL FRAME CAUSING BINDING AND POOR QUALITY OPERATING INSTRUCTIONS Continued LIFTING MOWING UNIT INTO POSITION WHEN USING THE OPTIONAL PULL GANG MOUNTING BRACKETS Position the mowing unit as described on the previous page using roller supports See FIG 26 Slowly raise the mowing unit when the hub of the reel has been raised above the top of the V bracket slowly position the left side of the reel into the bracket and lower until you make contact with the bracket Now reposition the right V bracket if necessary and lower the reel completely into both brackets Securely tighten the right bracket using both locking knobs NOTE On reels that have a square or hexagon shaped hub make sure that the surface of the hub is Handl against the flat machined surface of the V bracket When the reel is correctly positioned in the V bracket swing the clamping handles into place and firmly lock in place See FIG 27 NOTE The clamping handles have two mounting positions for large and small hubs NOTE Unless the elevator hooks interfere with the reels
57. ed Possible Cause Checkout Procedure RTP Relief Torque Pot L Check RTP 50K on SDC Term s Remote Torque W to H is not working control panel check voltage Pot CCW 0 volts DC with pots at fully clockwise and Pot CW 2 Volts DC counterclockwise positions SDC Term s Remote Torque W to L Pot CCW 2 Volts DC Pot CW DC 0 Volts DC Yes go to Step M next No go to Step N next Relief Speed Pot RSP M Check RSP remote RSP on the top SDC board labeled is not set correctly speed 10k on SDC top P501 should be set at 9 30 See pages board this is preset to 9 30 xx and xx Adjust if incorrect and check Relief Torque function Yes end of troubleshooting No replace SDC RTP is not working N RTP 50K Remove Check for 50 000 ohms 3 Remote Torque Wires Red wire to white wire red wire to term W Full CCW 0 ohms white wire to term L Full CW 50 000 ohms black wire to term H Red wire to black wire Full CCW 50 0000 ohms Full CW 0 ohms Yes Replace SDC No replace RTP Worn Motor Brushes P Inspect Motor Brushes Remove the brushes one at a time and maintain orientation for reinsertion See DISCONNECT TOWER if brush is worn short 3 8 10 mm FROM MACHINE minimum length Yes replace motor brushes No replace Spin Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Spin drive speed goes at one speed only Possible Cause Wiring hookup to potentiometer is improper If compone
58. ed P501 should be set at 2 00 o clock position See Pages xx and xx Adjust if incorrect and check Spin Drive Function Yes end of troubleshooting spin drive should run No Replace SDC Check for 10 000 ohm Red wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Red wire to black wire Full CCW 10 000 ohms Full CW 0 ohms Yes replace SDC No replace SSP Remove the brushes at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Spin Drive Motor 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 74 76 are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause Relief Torque Pot RTP set to zero Spin Motor Switch SMS is not on Spin Rotation Switch SRS is not on Circuit Breaker is Tripped 4 AMP Spin Drive Control SDS is not working Spin Drive motoris bad Checkout Procedure A Set RTP to 20 on the control panel B Turn SMS switch on T
59. es AS GRINDING WHEEL KNOB A FIG 33 Adjusts the scissor bar to move the unit up and down KNOB B 2 EACH Allows the spin unit to be loosened and moved in and out KNOB C amp D Allow the spin assembly to be loosened from the support bar frame and moved side to side When positioning the spin unit it will be necessary to complete several of the above adjustments to properly align the spin unit to the reel 34a Rubber Sleeve Coupler This is placed in the corresponding flange coupler already mounted in the spin drive shaft 34b Drive Coupler Assembly This is mounted to the rubber coupler 34c Adapter Sleeve Connects the rubber coupler to the square drive adapter a 34d Square Drive Adapter This is inserted into the bro drive coupler adapter and should be able to be Knob A Knob D FIG 34 moved approximately 2 It will be necessary to move this when attaching reel to spin drive unit b Drive Coupler Assembly c Adapter Sleeve It is then inserted into any 1 2 square drive socket This square shaft has a groove machined into it on the opposite end of the snap ring This groove is there to advise that you have reached the maximum extension of the square drive shaft If you cannot connect to the reel without extending past this groove then the spin unit must be repositioned on the tooling bar or the longer square drive shaft that is supplied with the grinder can be used DO NOT EXTEND SQUARE SHAFT PAST GROOVE INSTE
60. ew times you will find this procedure will become very easy IT IS ESSENTIAL THAT CARE IS TAKEN WHEN SETTING THE REEL UP IN THE HORIZONTAL POSITIONS IN ORDER TO GRIND IT INTO A CYLINDER SHAPE O ANY MISALIGNMENT WILL CAUSE YOU TO GRIND INTO A CONE SEE FIG 56 H When the horizontal parallelism has been adjusted to within 003 076 MM end to ena tighten the horizontal adjustment locking handle See FIG 54 and both overhead clamp adjusting knobs See FIG 55 When tightening the knob it is very important that you have the dial indicator located at that side of the reel and watch it as you tighten It must not move in the tightening process After both knobs are tight recheck alignment Vertical Adjustment Knob Horizontal Lock Handle Horizontal Adjustment Knob Vertical Lock Handle FIG 54 Overhead Clamps Slide Bar Clamp FIG 55 OPERATING INSTRUCTIONS Continued CHECKING REEL FOR CONE SHAPE REEL ROUNDNESS AND STRAIGHTNESS OF REEL OUTSIDE DIAMETER BEFORE GRINDING A Before storing the set up gauge it is very effective to use it to check the ungrounded reel to determine the amount the reel is F Cone Shape conical shape and which end has the larger INCORRECT CORRECT diameter See FIG 56 Start with the set up FIG 56 gauge at the right end of the reel Loosen the knob the indicator stop bar holding the indicator rod firmly against one blade See FIG 53 Pull the indicator st
61. ge travel This is to allow time for the reel to rotate and the index finger to catch the next blade If necessary the dwell time can be adjusted refer to Control Board Potentiometer Adjustments section on Pages 23 in the Assembly and Service section of this manual Allow the grinder to traverse down and back to verify everything is properly set up Turn the traverse potentiometer to zero once the home position is reached Turn on the Grinding Wheel Motor Turn on the traverse speed pot to a proper grinding speed Slowly infeed the grinding wheel until you are able to grind the full length of the reel blade evenly You can infeed between 005 to 012 ata time Be sure you have ground all the blades before infeeding further NOTE Traverse speed should be approximately 15 fom If you are removing small amount of stock on initial infeeds faster traverse speeds suggested If you are removing a large amount of stock on later infeeds slower traverse speed may be required WHEN YOU HAVE SUCCESSFULLY COMPLETED THE SPIN GRIND AND RELIEF GRIND ON AGIVEN MOWING UNIT TYPE THEN MEASURE AND COMPLETE THE SETUP CHART ON PAGE 38 REEL SETUP CHART NOILISOd 3dAL NOILISOd ONILLI3S ONILLI3S DNILL3S NOILISOd 39NVLSIA INNON INNOM INNOW LNNON 1020 40 LHDISH 5 dWV19 9NITOOL DNITOOL 1300N SALON SSYSAVEL NIdS QV3HH3 AO
62. he shafts with a spray lubricant do not use a teflon based lubricant until the lubricant is dripping off the shafts Then run the carriage back and forth through its range of travel This will carry the lubricant into the bearings 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 shafts are dry to the feel This completes the lubrication process LUBRICATION FREQUENCY The lubrication frequency is to check the shaft monthly during grinder operation 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 STORAGE PROCEDURE Itis 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 DO NOT USE COMPRESSED AIR OR A POWER WASHER TO CLEAN THIS MACHINE Lubricate the following parts by flooding the area with a spray lubricant and leav
63. hunt and vary speed When connections are not tight the control board varies voltage to the DC motor which then varies speed 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 ELECTRICAL TROUBLESHOOTING Continued Verify all wires shown on the wiring diagram on pages 74 76 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 If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause Grinding Motor Switch GMS is not on 10 Amp Circuit Breaker CB is tripped GMS not working Relay REL coil not working Relay contacts not working Circuit breaker 1 not working Relay Not Working Remedy A Turn switch on B Check 10 amp CB on front of Control panel Press in if tripped C Check for power to GMS D Check for power from GMS E Check for power to the REL coil F Check for power to REL relay contacts G Check for power from the REL relay H Check the power to and from the 10 amp circuit breaker Turn off Power and disconnect wire to motor Reconnect Power Turn on GMS Check for 120 Volts AC at end of cord DISCONNECT POWER FROM MACHINE Grinding Motor works Yes end troubleshooting
64. ing it in place Do not use a Teflon based lubricant Traverse shafts linear bearings see Lubrication section of manual Remove grinding wheel and spray the movable parts of the finger system Cross slide shafts and adjustment screws Scratches in the paint or any other bare metal surfaces Work the lubricant in by moving parts through their full range of motion Make sure all controls are in the off position and unplug the unit from the wall Cover the unit if possible with a sheet or tarp BRINGING THE UNIT BACK INTO SERVICE Remove the cover and reapply lubricant to the items stated above Wipe off all excess lubricant See Lubrication section for more details Plug the unit into the wall and test all electrical functions Check the V belt for cracking and adjust the tension if necessary Check for damaged or missing parts ADJUSTMENTS CARRIAGE LINEAR BEARING REPLACEMENT STEP 1 Remove the four screws of one linear bearing and slide the linear bearing off the left end of the carriage shaft LINEAR BEARING STEP 2 Insert a new linear bearing onto the end of the carriage shaft with the tension adjustment screw pointing outward See FIG 86 STEP 3 Adjust the tension screw of the linear bearing so when you radially rotate the linear bearing around the carriage shaft there should be no free play between the linear bearing and the carriage shaft NOTE Tension is too tight if you feel a cogging action when you
65. ld cause the spin motor system to not operate smoothly In the Spin Grinding Mode The Spin Torque Potentiometer STP and the Spin Speed Pot SSP interact with each other The STP is located on the upper spin board as remote torque preset at 2 00 for torque setting See FIG 33 The SSP is located on the control panel and is for spin speed adjustment Spin Torque Pot STP controls maximum torque allowable in the spin grinding cycle only This should never be adjusted past the 2 30 position If the reel does not turn check that the reel is free turning by hand spinning with the power off and the spin drive disconected The Spin speed Pot SSP controls reel spin speed adjust as required This controls the spin drive speed for spinning the reel POTENTIOMETERS ON THE LOWER BOARD OF THE SPIN DRIVE CONTROL SDC See FIG 34 MAX Speed Pot The maximum speed 15 factory preset to 4 30 fully clockwise to allow for maximum spin speed MIN Speed Pot The minimum speed is factory preset at 8 30 full counterclockwise so zero speed is obtainable for spin speed IR COMP Pot The IR Compensation is factory set at 9 00 Regulation of the spin or relief grind spin motor may be improved by a slight adjustment of the IR COMP pot clockwise from its factory set position Overcompensation causes the motor to oscil late or to increase speed when fully loaded If you reach such a point turn the IR COMP pot counterclockwise until symptoms just
66. m then back it off 1 2 turn C Check for 015 in 4 mm gap between the wave washer and flat washer See insert to FIG 98 Reajust the hex nut if necessary D Tighten the set screw holding the handwheel to the shaft Reinstall the calibration ring setscrew Carriage Infeed Handwheel SET SCREW DIAL RING HANDWHEEL NYLoK ADJUSTING NUT HEX NUT T ee du CONICAL WASHER HDN WASHER CONICAL WASHER TE ane FIG 98 ADJUSTMENTS Continued SPIN DRIVE CONTROL BOARD SDC The Spin Drive Control Board has three potentiometers on the lower board and two potentiometers on the upper board as shown on FIG 33 and FIG 34 These potentiometers have been set at the factory to the positions shown on FIG 33 and FIG 34 In the Relief Grinding Mode The Relief Speed Pot RSP and the Relief Torque Pot RTP interact with each other The RSP is located on the upper spin board as a remote speed preset at 9 30 20 Volts DC See FIG 33 The RTP is located on the control panel and is for relief torque adjustment Relief Speed Pot RSP when rotated clockwise will increase maximum spin drive speed This speed should never be above the 10 30 setting Relief Torque Pot RTP can vary the reel to finger holding torque for relief grinding The recommended starting point is 30 in lbs of torque setting Never adjust the RTP potentiometer dial past the red line marking Setting the reel to finger torque to high cou
67. nd of travel it should have very uniform resistance through its full range 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 87 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 See FIG 24 TO ADJUST THE CARRIAGE GIB PLATE Carriage The gib plate must be readjusted occasionally to eliminate free play Otherwise the grinding head can A move from side to side and the reel may be ground unevenly The gib must allow the carriage to be cranked freely forward and back without any side play See FIG 88 To adjust 1 Crank the carriage all the way forward toward the operator position 2 Tighten the front gib screw until the carriage has no side play but the horizontal handwheel can still be cranked 3 Crank the carriage gradually back away from the operator position and adjust the remaining gib screws as you go ADJUSTABLE FINGER BACKSTOP TENSION If the relief backstop appears to vary during relief grinding adjust the tension on the nylon plug and set screw See FIG 89 ADJUSTMENTS Continued CROSS SLIDE SHAFT REPLACEMENT If the cross slide shafts become scarred or gnarled replace them by the following
68. ne the reel up accurately on both sides Then continue with procedures found and above Now lock the vertical adjusting screw locking handle See FIG 49 Alignment Rod NOTE This alignment is not as critical as the horizontal plane but care should be taken on all reel set ups The accuracy should be within approximately 010 NOTE The pivot end of the support bar is pinned to the frame permanently The adjustable end can be adjusted Vertical L independently both vertically and horizontally SIDCSU DON Lock Handle Handle CAREFULLY REVIEW THE CORRECT IDENTIFICATION OF THE LOCKING KNOBS IN FIG 49 MAKE CERTAIN YOU ARE LOCKING AND UNLOCKING THE CORRECT KNOBS Horizontal Adjustment Knob OPERATING INSTRUCTIONS Continued ALIGNING REELS IN THE Horizontal HORIZONTAL PARALLELISM Inside Reel of Shaft Parallelism Alignment Rod THIS IS A CRITICAL SET UP AND CARE SHOULD BE TAKEN WHEN MAKING THESE ADJUSTMENTS IF REEL IS OUT OF POSITION IN THE Outside of O HORIZONTAL PLANE IT WILL BE Carrier Shaft GROUND CONE SHAPED SEE FIG 56 Move set up gauge on the right hand side of reel approximately 1 from the end See FIG 51 Lower the indicator slide casting on the vertical support so the indicator rod can make contact with the center of the reel shaft within approximately 1 16 062 1 5 MM and lock Knob A See FIG 45 Center shaft should be clean and free of rust where rod m
69. nobs Four knobs on the tooling bar four knobs on the overhead bar clamp and two on the overhead clamp swivels When using center brackets insure the fixed center is tight as well as the moveable center lock knob Cross slide lock handles not tight Tighten the horizontal and vertical cross slide lock handles Grinding head lock handles not tight Tighten the two lock handles on the adjusting arm slots and one on the vertical height adjustment Loose gibs on the carriage Adjust the gibs per the procedure in the adjustment section in this manual Linear bearings on the grinding head carriage are lineal bearing must be preloaded to the traverse bound with grit loose or damaged shafts with no vertical movement See manual adjustment section for carriage linear bearing adjustments Lubricate the linear bearings per the procedure as specified in this manual Replace bearings if they cannot be properly adjusted PROBLEM Roundness of reel varies High low reel blades are observed Possible Cause Checkout Procedure Grind out reel using correct sparkout procedure as Too heavy a grind on the final grinding passes specified in the Operators Manual PROBLEM Stock removal much differant traversing left compared to traversing right The possible causes and checkout procedures are the same as listed above for concave convex or with irregular shape MECHANICAL TROUBLESHOOTING Continued PROBLEM Relief grin
70. ntiometer panel Pot full CCW Pot Full CW 0 VDC 9 75 VDC Pin 8 to 9 Pot full CCW Pot Full CW 9 75 VDC 0 VDC Yes Pot is OK No Go to Step B next B Check potentiometer for Check for 10 000 ohms 10 000 ohms Red to White wires Remove three wires from Full CCW 0 ohms Traverse Drive Control Full CW 10 000 ohms red from term 8 Red to Black wires white from term 7 Full CCW 10 000 ohms black from term 9 Full CW 0 ohms Yes Go to Step C next No replace potentiometer Wiper inside of potentiometer controls speed Wiper may be bad and not making contact Wiring hookup to C Check potentiometer wiring for Wrong wire hookup effects traverse control potentiometer is proper hookup See that speed pot Check for Proper function improper is wired per electrical diagram Yes end troubleshooting If components have No Go to Step D next been replaced Minimum and maximum pot settings effect traverse speed Main circuit board dial D Check all pot settings on circuit Incorrect potentiometer settings effects pot settings not correct board as shown in wiring diagram traverse control If board has not been See adjustment section Traverse Check for proper function replaced Motor Control Board Settings Yes end of troubleshooting No replace TDC 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 Caus
71. nts have been replaced Defective spin speed control SSP potentiometer Main circuit board dial pot settings not correct If board has been replaced Remedy A Check potentiometer wiring for proper hookup See that speed pot is wired per electrical diagram B SSP 10K Remove 3 remote speed wires red wire to term W white wire to term L black wire to term H C Check all pot settings on both boards as of the SDC shown on Pages 24 and 25 See Adjustment Section Spin Drive Control SDC Board Setting PROBLEM Spin drive motor speed varies IR Comp trim pot not adjusted properly Torque to rotate the reel too high Check all terminal connections for tightness A See adjustment section for trim pot setting on Page 24 B Readjust bearing preload for the reel Maximum torque load 25 in Ib to rotate reel C When 250 female spade terminals are not tight remove and crimp slightly together When reinstalling push on pressure should have increased for good contact If wiring is wrong correct and test Yes end of troubleshooting No Go to Step B next Check for 10 000 ohms Red wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Red wire to black wire Full CCW 10 000 ohms Full CW 0 ohms Yes Go to Step C next No Replace SSP Yes end of troubleshooting No replace SDC Original adjustment was not set properly Too much load on drive motor will cause motor to
72. nts and tighten Contact your company s Maintenance Department if damaged or defective parts are found AIR TO CLEAN GRINDING DUST DO NOT USE COMPRESSED FROM THE GRINDER GETTING KNOW YOUR GRINDER Continued GETTING TO KNOW YOUR MACHINE The following is an explanation of the machine components you will be using when setting up reels to grind on your new Spin Grinder You should familiarize yourself with each part as this grinder has been engineered to spin and relief grind almost every type and make of reel mower available today Adjustment of the various fixtures will be necessary for different types of reels OVERHEAD MOWER CLAMP ASSEMBLY Each overhead mower clamp assembly consists of two rectangular bar clamps top and bottom which also contain adjustable holding fixtures into which is placed the mower clamps These clamps will be Clamp Rod positioned on the overhead square bar as shown in Portion Clamp Rod Handwheel Assembly FIG 2 and FIG 3 They are designed to lock into place and not move during the grinding procedure Included are two sizes of clamp lips normally the smaller will be used Clamp Lips Bottom Portion ROLLER SUPPORTS There are two roller supports that are mounted to the square mounting bar so that the V faces the back of the machine and the offset can be mounted high or low The roller brackets can also face upward with the offset either forward or to the rear See FIG 4
73. o loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause Traverse Motor Switch TMS is not on Traverse Speed Pot TSP set to zero Fuse on Traverse Drive Control TDC has failed Traverse Drive Control TDC is bad Bad Traverse Motor Switch TMS Checkout Procedure A Turnon TMS B Set TSP to 35 on the control panel C Check fuse and replace if failed See Page 23 Too heavy a grind causes grinding head traverse motor to overload and blow the fuse NOTE Fuse can not be checked visually Fuses must be continuity checked D Check for 120 Volts AC incoming to TDC E Check for 120 Volts AC at TMS Make certain TMS is on Traverse works Yes end troubleshooting No got to Step B next Traverse works Yes end troubleshooting No go to Step C next Traverse works Yes end troubleshooting No go to Step D next On TDC Terminal L1 to L2 for 120 VAC Yes Go to Step F next No Go to Step E next Measure 120 volts AC from TMS Terminal 5 to Term Block 4 Blue Yes Check wires to the TDC and replace if bad No Flip Switch and check again Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch or wires ELECTRICAL TROUBLESHOOTING Continued Possible Cause No DC Voltage from TDC Traverse Drive Control Traverse Motor is bad
74. op bar back until it clears the plunger then advance it forward until it contacts the plunger and advances it 1 2 inch further Lock in place This sets the plunger at its midpoint and allows adequate movement in both directions Set outer dial at zero and note position of pointer on small dial Now move it to the left side of reel and indicate the same blade From the reading determine the amount the reel is cone shaped This also determines high point for grinding Grinding of a reel must always start at the high point AFTER GRINDING A After grinding a reel check the roundness on each end of the reel and center before removing ground reel See FIG 57 Loosen the knob on the indicator rod firmly against one blade Pull the indicator stop bar back until there is a 1 32 gap between it and the set screw This is to Indicator Stop Bar permit rotation of the reel blades to ride on the Indicator Rod Plunger domed anvil only See FIG 58 At each location left right and center turn the reel by Indicator Rod hand and observe the indicator variations All readings should be within 002 Straightness of reel outside diameter Take indicator readings at both ends of reel Compare readings between each end of reel for straightness All reading should be within 002 C Carefully remove the setup gage and store it OPERATING INSTRUCTIONS Continued SETUP PROCEDURE FOR SPIN DRIVE RPM VERSUS TRANSVERSE SPEED SPIN DRIVE RPM
75. p to 001 Accessible Control Panel with independent switches for grinding motor carriage traverse with variable speed control spin drive with variable speed control and safety stop button Positive Infeed and Height Adjustment for exact positioning of the reel and measured metal removal Electro Magnetic Traversing Switch for easily adjustable traversing length SPECIFICATIONS Traversing Switches Solid state non contacting proximity switches Carriage Travel 38 97 cm Overall Width 67 170 cm Overall Height 58 147 cm Machine 83 211 cm Boom Overall Depth 42 107 cm 817 Ibs 371 kg Machine Weight 1000 Ibs 454 kg Shipping Weight Base Construction Precision Machined heavy duty reinforced welded steel base Carriage Rails Precision Ground Hardened Steel 1 000 Dia 25 4 mm Grind Head Motor 3 4 HP at 60 HZ 5 8 HP at 50 HZ 3450 RPM at 60 HZ 2875 RPM at 50 HZ Elevator 400 Ibs 180 kg capacity Spin Drive Reversible variable speed 0 380 RPM DC Gear Motor 20 Hp Sound Level More than 75 Dba Less than 95 Dba Auto Traverse Belt drive with variable speed control and overload protection Grinding Head 90 degrees rotatable head with pin lock locations for grinding bedknives Control System Reversible Spin drive with variable spin speed or variable relief torque Control System Variable traverse speed control GETTING TO KNOW YOUR GRINDER Continued Symbols for Read operators manual wear safety glasses and dis
76. ponents to the right and insert the rubber coupler into the flange on the spin drive unit When this is done tighten the Tee Knob on the adapter sleeve to hold all parts in place See FIG 37 Finally readjust the spin drive unit if it is not in alignment NOTE It is not necessary to have perfect alignment Square Drive but it must be close enough so that the coupler Socket or Adapter Rubber Coupler remains engaged and that excess torque is not applied Adapter 6009051 3709585 to the reel When intalling large reels into the grinder there may not be room to install the full spin drive adapter assembly The Spin Drive Adapter Assembly has been designed so that you can remove the 6009051 Square Drive Adapter and the 6009052 Adapter by loosening the two 1 4 20 Knobs This will expose the square end of 6009217 Drive Coupler Adapter This can then be short coupled to the reel See FIG 38 OPERATING INSTRUCTIONS Continued SPREADER BAR ASSEMBLY In most cases it is recommended to leave the spreader bar and chains hooked up to the mowing unit as an added safety precaution The cable should be winch tight to insure the chain hook and spreader bar will not become engaged with the reel during sharpening REMOVING SPREADER BAR FROM REEL If the hooks will not clear the spinning reel then remove the spreader bar and hooks from the mowing unit Place hooks over the top channel on the boom and crank up excessive slack See FIG 39
77. r set screw enough to lightly hold the indicator in place Never overtighten so plunger does not have free travel SET UP GAUGE ADJUSTMENT There should be no backlash in the fine adjustment screw on the set up gauge slide See FIG 96 Adjust hex nut tight so conical washer is completely pressed then back off 1 2 turn Make sure the set screw is compressing the nylon plug tightly on the vertical adjusting screw DIAL INDICATOR BODY FLUSH WITH CASTING FIG 95 CONICAL WASHER NYLOK ADJUSTMENTS Continued TO ELIMINATE CARRIAGE INFEED BACKLASH If there is backlash in the carriage infeed handwheel See FIG 97 there are two adjusting points to check Shoulder Bolt 8 Brass Nut 1 Conical washers behind the shaft adjusting nut A Unscrew the shoulder bolt P B Hold the horizontal handwheel and turn the shaft adjusting nut counterclockwise until the conical washers are touching each other Continue turning the nut counterclockwise until the next notch is centered over the shoulder bolt hole Then turn the nut one notch 40 degrees further Reinstall the shoulder bolt to lock the nut in position 2 Washers behind the handwheel Loosen about one half turn the set screw holding the handwheel to the shaft You will have to remove the calibration ring setscrew and go through the hole to ac cess the handwheel setscrew B Tighten the hex nut which secures the handwheel to 100 in Ibs 1 15 kg
78. r the adjusting arm locks and one for grinding wheel vertical height adjustment locking screw See FIG 60 Position the height of the grinding wheel center so that itis O to 1 below the reel center See FIG 61 Infeed the grinding wheel until it just makes contact with a reel blade while rotating the reel by hand Now tighten the two locking knobs on the locking arms and the locking knob for the height adjustment screw Back the grinding wheel off so it just clears the reel Lock Blanda Lock Handle Adjusting Arms Vertical Adjustment 1 each side Lock MOWER REEL 0 to 1 ig tr THE AND GRINDING WHEEL TO IN THE SAME DIRECTION OPERATING INSTRUCTIONS Continued GRINDING REEL INTO A TRUE CYLINDER BY SPIN GRINDING Continued E Move the grinding wheel back from the reel and frame so it will clear at all points Set proximity switches so they line up approximately with the endof the frame and tighten them securely See FIG 62 8 63 Adjust the traverse speed knob to zero and turn traverse switch to on Increases the traverse speed knob so the carriage will traverse slowly across the reel When the carriage has come to a momentary stop against proximity switch turn traverse switch off In this position check to see that grinding wheel has cleared the end of the reel If not readjust stop so the reel clears the end of the reel CAUTION IF THE REEL FRAME EXTENDS BELOW THE REEL I
79. ration This will help keep the operator from under the mower NOTE The winch has a spring loaded handle that automatically actuates a brake when the handle is released The winch clicks as it is being raised when this brake is engaged Slowly move the reel into position and carefully lower the cutting unit onto the roller supports Firmly tighten both locking knobs on the roller supports Make certain the spin drive can be attached to a drive device on the reel Do not connect at this time just make sure that the connections are close enough to attach at a later time When the reel roller is positioned correctly in the roller supports wrap the chain vise clamp around the roller and around the square tubing tooling bar Firmly tighten LIFTING MOWING UNIT INTO POSITION WHEN USING CENTER BRACKETS Position the mowing unit as described above using roller supports Slowly raise the mowing unit into position and insert the fixed centering pin into predetermined hole in the mowing unit frame While holding the mowing unit firmly against the fixed centering pin raise or lower the mowing unit so the adjustable centering bracket can be moved and the inserted corresponding hole the opposite side of mowing unit frame Now very firmly tighten both locking knobs on the adjustable bracket and then tighten the adjustable centering pin locking knob See FIG 25 Make certain the spin drive can be attached to drive devic
80. re 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 the established 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 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 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 BURRS DON T TIGHTEN the mounting 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 _ GUAR
81. rse drive motor on and off GETTING KNOW YOUR GRINDER Continued TRAVERSE SPEED DIAL FT MIN Adjusts the speed of the left amp right movement of the grinding wheel carriage EMERGENCY STOP BUTTON Cuts all power to the control panel functions Stops all motors including grinding motor traverse motor spin motor etc To restore power pull up on the button and press the start button PUSHING THE EMERGENCY STOP BUTTON DOES NOT STOP ALL POWER TO THE GRINDER POWER IS STILL DELIVERED TO THE INFEED SIDE OF THE MAGNETIC CONTACTOR DISCONNECT THE CORD AT THE WALL OUTLET BEFORE PERFORMING SERVICE SAFETY INSTRUCTIONS PLEASE TAKE SPECIAL NOTE OF THE FOLLOWING WARNING DECAL LOCATED NEAR THE WINCH OF THE MODEL 181 WARNING Lifting winch capacity 400 lbs maximum Always have the lifting hooks securely attached and balanced on the cutting unit before lifting Stand well clear of the cutting unit when winching into position Guide with extended arms only The winch is equipped with a safety ratchet Do not defeat or override this safety feature Read warning label on winch handle and the assembly and operating manual before using the winch OPERATING INSTRUCTIONS PREPARE MOWER FOR SHARPENING Preparation of the mowing unit prior to sharpening It is recommended that the mowing unit to be sharpened is thoroughly cleaned Remove wheels and bed bar if possible from the reel All bedknives mus
82. s obtained when reel is sparked out Use your set up gauge prior to relief grinding to check the reels for roundness This is very important when first learning the operation of your machine M Verify the reel straightness and roundness Install the alignment gage Index reel blade until you read the high point on the indicator Now loosen the knob and set the indicator stop block to a 1 32 gap as shown in FIG 57 8 58 Mark this blade as 1 and set the large dial of indicator setting to 0 then check each blade for maximum and minimum reading Check each end of reel and at the center After becoming familiar with the process you will not have to check each reel IT IS VERY IMPORTANT IN SPIN GRINDING THAT YOU THOROUGHLY SPARKOUT AT THE END OF THE GRIND CYCLE THE DIFFERENCE BETWEEN ACHIEVING 005 OR 003 TOTAL INDICATOR READING IS ACCOMPLISHED THROUGH PROPER SPARKOUT OPERATING INSTRUCTIONS Continued REEL SPIRAL OR HELIX When standing behind the mowing unit when the mowing unit is sitting in normal position on the ground If the spiral is such that the right side of the blade cuts before the left it is a right hand lead in or a right hand spiral reel If the spiral is such that the left side of the blade cuts before the right it is a left hand lead in or left hand spiral reel Most reels made today are right hand spiral and are referred to as normal helix RELIEF GRINDING TO COMPLETE THE REEL GRINDING PROCESS A
83. t be ground when reels are sharpened Inspect adjust and or replace any worn or damaged bearings Make sure reel bearings are adjusted properly so the reel turns easily by hand REELS WITH EXCESS TENSION ON THE BEARINGS WILL BE EXTREMELY DIFFICULT TO SPIN GRIND AND COULD CAUSE DAMAGE TO THE REEL OR THE SPIN DRIVE MECHANISM ON YOUR GRINDER NO MORE THAN 25 IN LBS MAXIMUM TORQUE LOAD TO ROTATE THE REEL IS ALLOWED OR DAMAGE TO THE SPIN DRIVE COULD OCCUR REELS GROUND WITH BEARINGS WHICH HAVE WEAR AND OR FREE PLAY WILL NOT HOLD DIAMETER CYLINDRICAL SHAPE OR STRAIGHTNESS SPECIFICATIONS INITIAL SET UP OF REEL SUPPORTS A The preferred method of mounting fairway units and greens mower units is to set the rear roller on the roller supports facing up with the offset either forward or back depending on mowing unit requirements Chain clamp around the Centering Bracket roller and the tooling bar See FIG 18 With greens mowers you may use the centers mounting brackets See FIG 19 On ground drive fairway mowers with exposed hubs you should use the OPTIONAL Pull Gang Reel Mount Kit 18574 Normally they will be positioned in the top two holes of the lower supports with the offset V facing the rear of the machine See FIG 20 Centering Pin NOTE Because of the many different reels available the position of the V bracket to the lower support can be adjusted to three different height settings and two offset positions FIRMLY T
84. t the amount of back travel The back travel of the finger is limited so the reel blade makes a smooth transition from the moveable finger onto the fixed finger without interferences The fixed finger is the working finger during the grind See FIG 14 Moveable Finger Travel 3 The lock handle on the side of the guard Limit Knob carrier plate is an adjustment for grinding wheel wear Use this to hold the fingers in the correct position to the grinding wheel See FIG 15 FIG 14 Lock Handle GETTING KNOW YOUR GRINDER Continued DIAL INDICATOR SET UP FIXTURE The dial indicator set up fixture is designed to be quickly mounted into position and or quickly removed The fixture is mounted to the front left corner of the grinding head assembly as shown in FIG 16 When the fixture 15 not in use it is quickly removed and can be stored on the tool tray Attach Fixture with this Screw Knob CONTROL PANEL The control panel has 10 control switches and knobs See FIG 17 Details of the function of each are shown on pages 12 13 and 14 Additionally there are two circuit breakers on the control panel The 10 amp circuit breaker is to protect the grinding motor circuit and the 4 amp circuit breaker is to protect the spin drive circuit GETTING KNOW YOUR GRINDER Continued CONTROL PANEL COMPONENT IDENTIFICATION Review the following control panel component descriptions before proceeding with the instructions
85. to Step N next No Check wire for continuity then verify switch continuity If bad replace ESS contactor NC Measure 120 Volts AC from SSS term 3 to Term Block 4 Blue Yes Go to Step O next No Check wire for continuity then verify switch continuity If bad replace SSS contactor NO Measure 120 Volts AC from LVR term 8 to Term Block 4 Blue Yes Go to Step P next No Check for 120 Volts AC from LVR term 6 to term 7 Yes Verify Continuity of term 1 to term 8 on LVR Replace LVR if bad No Verify Continuity of Wires Measure 120 Volts AC from MAG Term A1 to Term A2 Yes MAG Should pull in with clunck if not replace MAG No Verify Continuity of Wires ELECTRICAL TROUBLESHOOTING Continued PROBLEM MAQ turns on only with System Start Switch held in Possible Cause Checkout Procedure No Power to MAG A Check voltage to MAG holding Measure 120 Volts AC at MAG term to holding Contact contact in Term Block 4 Blue with E Stop Pulled out Do NOT press start button while checking Yes Go to Step B next No Verify continuity of wiring to MAG T3 MAG holding B Verify the magnetic starter MAG Disconnect Wire to MAG L3 and Measure contact has failed holding contact is working 120 Volts from MAG term L3 to Term Block 4 Blue Press and hold Green Start button to hold in MAG contacts while checking Yes Verify continuity of wiring from MAG L3 No Replace MAG PROBLEM SPIN DRIVE NOT WORK
86. to not rotate freely Verify proper adjustment per the adjustment section of this manual THIS PAGE LEFT INTENSIONALLY BLANK FOR NOTE TAKING REASONS 18521 CABINET ASSEMBLY PARTS LIST PARTS LIST 18524 CABINET ASSEMBLY DIAGRAM NO PART NO DESCRIPTION B251016 Button Head Socket Cap Screw 1 4 20 x 5 8 Long B251216 Button HeadSocket Cap Screw 1 4 20 x 3 4 Long B371616 Button Head Socket Cap Screw 3 8 16 x 1 Long B502401 Hex Head Cap Screw 1 2 13 x 1 1 2 Long 1 4 20 Hex Locknut 1 2 13 Hex Jam Nut 3 8 Lockwasher Decal 181SRI Cabinet Weldment Tooling Bar Extension Weldment Proximity Head 18MM DC Proximity Cord Traverse Left Hand Proximity Cord Traverse Right Hand Channel Support Bar Strain Relief 27 47 Cord Diameter Strain Relief 19 30 Cord Diameter Wave Spring 78 ID Flatwasher 75 ID x 1 0 OD x 075 Thick Warning Decal Electrical T Knob Assembly 3 8 16 x 75 Long PARTS LIST 18518 CROSS SLIDE ASSEMBLY 78 PARTS LIST 18518 CROSS SLIDE ASSEMBLY DIAGRAM NO PART NO DESCRIPTION 1 4 20 x 1 4 Long Socket Set Screw 5 16 18 x 3 4 Long Socket Set Screw 3 8 16 Hex Nut 377000 3 8 16 Jam Locknut K371501 3 8 Split Lockwasher 3 16 Dia Nylon Plug Handwheel Conical Washer Thrust Washer 3 8 16 Adjustable Handle Acme Adjusting Shaft 3 8 16 Locking Stud Shaft Cross Slide Cross Slide Support Slide Shaft 27544 CHANNEL 8 TRAVEL ASSEMBLY PARTS LIST
87. urn SRS switch to direction of reel rotation required NOTE Center position is off D Reset Circiut Breaker on front of Control Panel Push in if tripped E Check SDS L1 to L2 for 120 Volts AC F Check SDC 1 amp 2 for approx 20 Volts DC Have Relief Torque set to Red Line G Check for approx 20 Volts DC output to SRS H Check for approx 20 Volts DC out put from SRS Check spin motor continuity DISCONNECT POWER FROM THE MACHINE Spin Motor works Yes end troubleshooting No go to Step B next Spin Motor works Yes end troubleshooting No go to Step C next Spin Motor works Yes end troubleshooting No go to step D next Spin Motor works Yes end troubleshooting No go to step E next SDC Term L1 to term L2 for 120 VAC Yes go to Step F next No Verify Power to Circuit Breaker and SMS and continuity of wires Replace CB or SMS or wires if needed SDC Term A1 to A2 for approx 20 Volts DC Yes go to Step G next No go to Step L next SRS Term 6 to 7 for approx 20 V DC Yes go to Step H next No Check continuity of wires and re place if bad SRS Term 2 to 3 for approx 20 V DC Yes go to Step I next No replace SRS switch Remove wires at Terminal Strip 1 Term 4 amp 5 check 0 ohms across the black and white wires Yes end troubleshooting motor should work if it does not replace motor No go to Step P next ELECTRICAL TROUBLESHOOTING Continu
88. utting unit is securely fastened with the clamps provided before operating DON T OVERREACH Keep proper footing and balance at all times instructions in Service Manual for lubrication and preventive maintenance DISCONNECT POWER BEFORE SERVICING or when changing the grinding wheel 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 NEVER LEAVE GRINDER RUNNING UNATTENDED TURN POWER OFF Do not leave grinder until it comes to a complete stop 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 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 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 listed below are followed These rules a
89. utton B Push the SSS Listen for the Magnetic Starter MAG contacts to pull in with clunk C Plug in main power cord D Turn all switces off E Check circuit breaker in your building and reset if necessary Check wall outlet with a light to make sure it works F Check for 120 at Cord into FTR Power Cord Wire No 32 G Check for 120 out of FTR H Check for 120VAC to MCB I Verify that is ON or flip switch to ON position Then check for 120 out of MCB Machine works Yes end troubleshooting No go to Step B next Machine works Yes end troubleshooting No go to step next Machine works Yes end troubleshooting No go to step D next Machine works Yes end troubleshooting No go to step E next Machine works Yes end troubleshooting No go to step F next You have 120VAC at Filter input Yes but light works in outlet go to Step G next No Replace Power Cord You have 120VAC at Filter output Yes go to step H next No Replace the Filter You 120VAC at MCB input MCB Bottom Terminal to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step I next No Verify continuity of wires from Filter to MCB and replace if bad You have 120 at MCB output MCB Top Terminal to Terminal Block 4 Blue for 120 Volts AC Yes If machine works end of troubleshooting if not go to Step J next No Replace MCB Possible Causes 1
90. vercompensation causes the motor to oscillate or to increase speed when fully loaded If you reach such a point turn the IR COMP trim pot counterclockwise until the symptoms disappear Max Speed Set at 3 30 for maximum voltage of 90 Volts DC to the traverse motor When voltage is above 90 volts DC the traverse motor will start to pulsate and not run smoothly Right Traverse Forward Acceleration Factory set at full CCW 8 30 Do not change this setting Left Traverse Reverse Acceleration Factory set at full CCW 8 30 Do not change this setting DB Dead Band is the potentiometer setting for the 50 or 60 Hz cycle control Factory set to 9 00 works for both 50 and 60 Hz Do not change this setting Calibrating the DWELL TIME rotary DIP switch adjusts the amount of time the process remains in the stop position after a limit switch is actuated The DWELL TIME range is adjustable from 0 4 seconds switch setting of 0 sets the DWELL TIME to 0 seconds while a setting of 8 sets the DWELL TIME to 4 seconds Dwell time is preset to 4 setting for a 2 second dwell time when reversing at each end of stroke Diagnostic LED s indicate the function that is currently being performed POWER indicates that ac power is being applied to the control FORWARD indicates that the process is running in the forward direction traversing left REVERSE indicates that the process is running in the reverse direction traversing right PROX 1 FWD LI

OPERATING INSTRUCTIONS (Continued)

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