MODEL 111 & 181 REEL GRINDER OWNER’S MANUAL · MODEL 111 & 181 REEL GRINDER WARNING You must thoroughly read and understand this manual before ... Don't use Grinder in damp or wet

1 18100 (11-03)

MODEL 111 & 181REEL GRINDER

WARNINGYou must thoroughly read and understand this manual beforeoperating the equipment, paying particular attention to theWarning & Safety instructions.

OWNER’SMANUAL

2

SAFETY INSTRUCTIONS

Safety Awareness Symbols are inserted into this manual toalert you to possible Safety Hazards . Whenever you see thesesymbols, follow their instructions.

The Warning Symbol identifies special instructionsor procedures which, if not correctly followed, couldresult in personal injury.

The Caution Symbol identifies special instructionsor procedures which, if not strictly observed, couldresult in damage to or destruction of equipment.

13. MAINTAIN GRINDER WITH CARE. Followinstructions in this Manual for lubrication andpreventive maintenance.

14. DISCONNECT POWER BEFORESERVICING, or when changing the grindingwheel.

15. REDUCE THE RISK OF UNINTENTIONALSTARTING. Make sure the switch is OFFbefore plugging in the Grinder.

16. USE RECOMMENDED ACCESSORIES.Consult the manual for recommendedaccessories. Using improper accessoriesmay cause risk of personal injury.

17. CHECK DAMAGED PARTS. A guard or otherpart that is damaged or will not perform itsintended function should be properly repairedor replaced.

18. NEVER LEAVE GRINDER RUNNINGUNATTENDED. TURN POWER OFF. Do notleave grinder until it comes to a complete stop.

19. KNOW YOUR EQUIPMENT. Read thismanual carefully. Learn its application andlimitations as well as specific potentialhazards.

20. KEEP ALL SAFETY DECALS CLEAN ANDLEGIBLE. If safety decals become damagedor illegible for any reason, replace immediately.Refer to replacement parts illustrations inService Manual for the proper location and partnumbers of safety decals.

21. DO NOT OPERATE THE GRINDER WHENUNDER THE INFLUENCE OF DRUGS,ALCOHOL, OR MEDICATION.

1. KEEP GUARDS IN PLACE and in workingorder.

2. REMOVE WRENCHES AND OTHERTOOLS.

3. KEEP WORK AREA CLEAN.

4. DON'T USE IN DANGEROUSENVIRONMENT. Don't use Grinder indamp or wet locations. Machine is forindoor use only. Keep work area well lit.

5. KEEP ALL VISITORS AWAY. All visitorsshould be kept a safe distance from workarea.

6. MAKE WORK AREA CHILD-PROOF withpadlocks or master switches.

7. DON'T FORCE THE GRINDER. It will do thejob better and safer if used as specifiedin this manual.

8. USE THE RIGHT TOOL. Don't force theGrinder or an attachment to do a job forwhich it was not designed.

9. WEAR PROPER APPAREL. Wear noloose clothing, gloves, neckties, orjewelry which may get caught in movingparts. nonslip footwear is recommended.Wear protective hair covering to containlong hair.

10. ALWAYS USE SAFETY GLASSES.

11. SECURE YOUR WORK. Make certain thatthe cutting unit is securely fastened withthe clamps provided before operating.

12. DON'T OVERREACH. Keep properfooting and balance at all times.

3

SAFETY INSTRUCTIONS

IMPROPER USE OF GRINDING WHEEL MAYCAUSE BREAKAGE AND SERIOUS INJURY.

DO

1. DO always HANDLE AND STORE wheelsin a CAREFUL manner.

2. DO VISUALLY INSPECT all wheels beforemounting for possible damage.

3. DO CHECK MACHINE SPEED against theestablished maximum safe operating speedmarked on wheel.

4. DO CHECK MOUNTING FLANGES forequal and correct diameter.

5. DO USE MOUNTING BLOTTERS whensupplied with wheels.

6. DO be sure WORK REST is properlyadjusted.

7. DO always USE A SAFETY GUARDCOVERING at least one-half of the grindingwheel.

8. DO allow NEWLY MOUNTED WHEELS torun at operating speed, with guard in place,for at least one minute before grinding.

9. DO always WEAR SAFETY GLASSES orsome type of eye protection when grinding.

DON'T

1. DON'T use a cracked wheel or one that HASBEEN DROPPED or has become damaged.

2. DON'T FORCE a wheel onto the machine ORALTER the size of the mounting hole - if wheelwon't fit the machine, get one that will.

3. DON'T ever EXCEED MAXIMUM OPERAT-ING SPEED established for the wheel.

4. DON'T use mounting flanges on which thebearing surfaces ARE NOT CLEAN, FLATAND FREE OF BURNS.

5. DON'T TIGHTEN the mounting nut exces-sively.

6. DON'T grind on the SIDE OF THE WHEEL(see Safety Code B7.2 for exception).

7. DON'T start the machine until the WHEELGUARD IS IN PLACE.

8. DON'T JAM work into the wheel.

9. DON'T STAND DIRECTLY IN FRONT of agrinding wheel whenever a grinder is started.

10. DON'T FORCE GRINDING so that motorslows 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 MSHArespirators, safety glasses or face shields, and protective clothing. Provide adequateventilation to eliminate dust, or to maintain dust level below the Threshold. LimitValue for nuisance dust as classified by OSHA.

Grinding is a safe operation if the few basic rules listed below are followed. These rules arebased on material contained in the ANSI B7.1 Safety Code for "Use, Care and Protection ofAbrasive Wheels". For your safety, we suggest you benefit from the experience of others andcarefully follow these rules.

4

GETTING TO KNOW YOUR GRINDER

The Model 111/181 Reel Sharpening System is offered in several versions:

Feature 111 181

Single Blade Relief Grinding Yes YesSpin and Relief Grinding YesBack Lapper included for Spin Drive YesElevator for ease in loading Yes YesInfeed, Manual Control Yes YesTravel, Manual YesTravel, Automatic YesTransformer for 220 Volts, 50/60 Hz OptionalBedknife Kit - 6000555 Optional OptionalPull-Gang Vert. Mount Kit - 18574 Optional Optional

SPECIFICATIONS

POWER REQUIREMENT:115 Volts, 50/60 Hz, 15 Amps

DIMENSIONS:68” long (+14” for spin drive when mountedon left) x 33” wide x 79” high (to the topof the elevator, 55” to top of frame)

SHIPPING DIMENSIONS:70” long x 41” wide x 72” high, 800#, 120 cubicfeet

This machine is intended for reel mower reel blade grinding ONLY. Any use otherthan this may cause personal injury and void the warranty.

To assure the quality and safety of your machine and to maintain thewarranty, 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 trainedBEFORE operating the equipment.

Do not use compressed air to clean grinding dust from themachine. This dust can cause personal injury as well as damage to the grinder.Machine is for indoor use only. Do not use a power washer to clean the machine.

5

GETTING TO KNOW YOUR GRINDER (Continued)

Symbols for Read operators manual, wear safety glasses anddisconnect power before servicing.

Symbols for sharp object which will cause serious injury andsymbol for keep visitors a safe distance away from machine.

Symbols for caution relating toRPM of motor and minimum saferated RPM of the grinding wheel.

Symbol identifying a panel, cover, orarea as having live electricalcomponents within.

Symbol for hearing protectionrequired when operating thismachine.

Symbol that operators and people in theclose proximity must wear respiratorsor have adequate ventilation systems.

The grinder is equipped with a low voltage relay which is factory preset at 100 VAC. If thepower supply line does not deliver 100 VAC power under load, the relay will open and tripout the starter. If this occurs, your power supply line is inadequate and must be correctbefore proceeding further with the grinder.

Low Voltage Relay

6

ASSEMBLY

PACKING LIST: Upon arrival make sure that all parts are included in shipment.

Feature 111 181

18100 Operator’s Manual Yes YesElevator Yes YesModel 18556 Back Lapper YesLapper Shelf YesElectrical Control Box Yes3702508 Dressing Brick Yes Yes18561 Dial Indicator Style Set Up Gauge Yes3880941 Rod Style Set Up Gauge Yes

If any item is MISSING from the shipment, notify your dealer so that they can contact a Service Representative.

SITE REQUIREMENTS:

� Indoors� Dry� Reasonably level Concrete floor� Good Lighting� 115 Volts, 50/60 Hz, 15 Amp outlet, dedicated circuit� We suggest a space about 13’ x 10’ based on the following drawing

7

ASSEMBLY (Continued)

ASSEMBLY

Tools Required For Assembly:

� Hammer� Level� Utility Knife� Screw Driver

The Model 111/181 is shipped on a pallet, fullyassembled, except for the electrical control box,elevator, gauge, backlapper and lapper shelf. Theseitems are in boxes under the machine or in the trayof the frame.

1. Remove the crate from the machine using ahammer.

2. Carefully use the utility knife to remove theprotective wrapping.

3. Remove the straps that secure the grinding headfor shipment.

4. Move the machine to the desired location. Screwslocated in the legs of the machine may be usedto eliminate rocking of the machine.

5. Assemble the Elevator to the frame.

6. Model 181, attach the set up gauge to the carriage.

7. Model 181, remove the electrical control box fromthe carton and hang it on the right side of themachine using the dove tail brackets.

8. Model 181, Hang the back lapper shelf on the rightside of the frame.

9. Model 181, Unpack the Back Lapper and attach tothe shelf as shown on the following pages.

10. Model 181, Install the spin drive adapter to theshaft of the back lapper.

11. Model 181, Check to assure that the main powerswitch is “OFF” by pushing it “IN”.

12. Model 111, check to assure that the toggle switchon the motor is turned off.

13. Then plug the Model 111/181 into the wall outlet.THIS MUST BE GROUNDED 115 VOLT, 50/60HERTZ OUTLET RATED FOR 15 AMPS.

INSPECT THE GRINDING WHEELThe grinder has been supplied with a medium grit wheelPart #3700090. With proper use and care, this wheelwill provide maximum grinding capability, accuracy, andsafety. Prior to starting the machine, visually inspectthe wheel for possible damage in shipment.

IF THE GRINDING WHEEL APPEARSTO BE DAMAGED, DO NOT START

THE GRINDER. ALWAYS WEARPROPER SAFETY EYEWEAR,

HEARING AND RESPIRATOREQUIPMENT WHEN

OPERATING THE MODEL111/181.

The Model 111/181 is now fully assembled and ready forthe review of the operating instructions.

BEFORE OPERATING THISGRINDER, READ THE

OPERATING INSTRUCTIONS.

8

APPLY POWER

BEFORE YOU APPLY POWER TO THEGRINDER, REFER TO THE "IMPORTANTGROUNDING INSTRUCTIONS".

115 Volt Model Only. Plug the control box power cord into a standard115V AC 15-amp grounded receptacle. See FIG. 2.

220 Volt Model Only. For Model 181, 220 Volt Applications order PartNo. 1800951, which includes a 220 to 115 Volt Step Down Transformer.For Model 111, 220 Volt Applications, rewire the motor as described onpage 9. Cut off plug and replace for 220 Volt 60/50 Hz. Application.

ASSEMBLY INSTRUCTIONS (Continued)

FIG. 2

IT IS RECOMMENDED THAT THIS GRINDER HASITS OWN PERMANENT POWER CONNECTIONFROM THE POWER DISTRIBUTION PANEL, WITH

NO OTHER MAJOR POWER DRAWEQUIPMENT ON THE SAME LINE.

IT IS REQUIRED THAT THE POWERDELIVERED TO THIS GRINDER IS 115 VAC -15 AMPS. THE TOLERANCE ON THISPOWER REQUIREMENT IS +/- 5%.

THEREFORE THE MINIMUM VOLTAGEREQUIREMENT IS 109VAC WITH 15 AMPS.VOLTAGE MUST BE CHECKED WITH ALLEQUIPMENT UNDER LOAD (OPERATING) ON THECIRCUIT.

DO NOT OPERATE THIS GRINDER WITH ANEXTENSION CORD.

PROPER GROUNDING OF THERECEPTACLE GROUND IN YOURBUILDING MUST BE VERIFIED.IMPROPER GROUNDING IN YOURBUILDING MAY CAUSE THE GRINDER TO

MALFUNCTION.

FOR 15 AMP RATED LARGE MACHINES

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.

The grinder is equipped with a low voltagerelay which is factory preset at 100 VAC. If thepower supply line does not deliver 100 VACpower under load, the relay will open and tripout the starter. If this occurs, your powersupply line is inadequate and must be correctbefore proceeding further with the grinder.

9

FOR MODEL 181 220 V 50 or 60Hz applicationsProduct No. 1810951 should be ordered.

1810951 includes a 2 KVA 220 Volt Step Down to115 volt 50/60 Hz transformer which is prewired.

The wiring diagram is shown in FIG. 3.

The power cord has no connector. A connectorwhich is appropriate for your locality and 220 volt,8 amp application should be installed.

ASSEMBLY INSTRUCTIONS (Continued)

FIG. 3

IMPORTANT GROUNDING INSTRUCTIONS

In case of a malfunction of breakdown, grounding reduces the risk of electrical shock by providing a path of leastresistance for electrical current.

This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug. The plug mustbe plugged into a matching outlet that is properly installed and grounded according to all local or other appropriateelectrical codes and ordinances.

Before plugging in the Grinder, make sure it will be connected to a supply circuit protected by a properly-sizedcircuit breaker or fuse.

Never modify the plug provided with the machine--if it won't fit the outlet, have a proper outlet and circuit installedby a qualified electrician.

ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOUR MACHINE. ANIMPROPER CONNECTION CAN CAUSE A DANGEROUS ELECTRICAL SHOCK.IF YOU ARE UNSURE OF THE PROPER ELECTRICAL GROUNDINGPROCEDURE, CONTACT A QUALIFIED ELECTRICIAN.

Use only a qualified electrician tocomplete the installation.

FOR 111 MODEL: To convert this grinder tooperate on 220 V 50/60Hz 1 phase current, cutthe plug off from the cord and replace it with theappropriate plug for your locality. For plug andcircuit breaker sizing, see motor nameplateratings. Use only a qualified electrician.

To convert the grinder from 115 Volt to 220 Volt,disconnect the four wires coming from the motorinternally and reconnect them as shown to theright. One additional wire nut will be required.NOTE: This motor will operate correctly on 60Hzor 50Hz power.

To convert to wiring.

10

GETTING TO KNOW YOUR GRINDER

GETTING TO KNOW YOUR MACHINEThe following is an explanation of the machinecomponents you will be using when setting up reelsto grind on your new Spin Grinder. You shouldfamiliarize yourself with each part as this grinder hasbeen engineered to spin and relief grind almost everytype and make of reel mowers available today. Anadjustment of the various fixtures will be necessaryfor different types of reels.

OVERHEAD MOWER CLAMP ASSEMBLYEach overhead mower clamp assembly consists oftwo rectangular bar clamps (top and bottom), whichalso contain adjustable holding fixtures into which isplaced the mower clamps. These clamps will bepositioned on the overhead square bar as shown inFIG. 4 and FIG 5. They are designed to lock into placeand not move during the grinding procedure.Included are two sizes of clamp lips, normally the smallerwill be used.

REEL SUPPORT

CENTER MOUNTING BRACKETSThe centers mounting brackets consist of a lowerportion that fits on the square mounting bar, astationary center fixture and an adjustable centeringfixture. The stationary fixture will normally be usedon the left hand side of the mounting bar whenfacing the reel loading position. There are threevertical positions for the center fixture but they willnormally be used in the lower position as shown inthe picture. These brackets should be mounted tothe square bar so that the centering pins are facingthe back of the machine and directly over the squaremounting bar. These centering fixtures are usedon greens mowers or any reel that does not have ahub that can fit into the "V" bracket. FIG. 6

FIG. 4

FIG. 5

Rotation & LengthLock Knob

Top Clamp

Clamp Rod

Clamp Lips

Bottom Clamp

Horz. Lock Knobs

11

GETTING TO KNOW YOUR GRINDER (Continued)

THE HARD KNOBS ON THE SQUAREBAR MUST BE VERY TIGHT OR THEREEL CAN LOOSEN CAUSING POORGRIND QUALITY. KNOBS CAN BEADDITIONALLY TIGHTENED WITHAN ALLEN WRENCH TO ENSUREMAXIMUM LOCKING POWER.

ROLLER SUPPORTSThere are two roller supports that are mounted tothe square mounting bar. They may be mountedso that the "V" faces the back of the machine aspictured, (see FIG. 8) or with the “V” facing up (seeFIG. 7).

Use the vice grip chain clamp to secure the reel tothe roller supports.

REEL GUIDE FINGERSThere are two reel guide fingers included with yourgrinder. They are used to relief grind reels afterthe reel has been spun ground. The wider factorymounted finger will normally be used, See FIG. 9 &10, but on reels where there is not enough roombetween blades or reel to end frame clearance, thestamped narrow finger will have to be used. SeeFIG. 11.

At the factory, the finger is installed with the highpoint of the finger positioned at the left hand cornerof the grinding wheel for a normal helix reel, viewedfrom the relief finger side. It might be necessaryon reels that have a reverse helix to reposition thesupport finger. When using the stamped thin fingerit is necessary to dress the grinding wheel so thatthe high point of the finger is positioned where thegrinding wheel makes contact with the reel.

End View of the ReelGrinder Finger & Support

Vice Grip Chain Clamps

FIG. 7

FIG. 8

FIG. 9

FIG. 10 FIG. 11

12

OPERATING INSTRUCTIONS

OPERATION

The Controls for the Model 111:The Model 111 grinder is a manual reel singleblade relief grinder. The only switch control is thegrinding motor on/off switch.

The Controls for the Model 181:Learn the function of each switch and knob on thecontrol box. As you read and learn about eachknob you are encouraged to turn that knob on andview that particular operation. See FIG. 12.

ALWAYS WEAR PROPER SAFETYEYEWEAR WHEN OPERATING

YOUR GRINDER. NEVER TURNON YOUR GRINDER WITHOUT

FIRST PUTTING ON SAFETYEYEWEAR.

ON/OFF CONTROLThis is the red knob, the main power switch.Pulling out will turn the main power on and pushingin will turn power off. The large button type designallows a quick stop of all power in an emergencysituation.

GRIND CONTROLThe grind control knob turns the Grinding Wheelon and off.

SPIN CONTROLThe spin control knob turns the spin motor on andoff. There is a direction switch and speed controldial located on the Spin Drive/Backlapper. (Referto Backlapper manual for more details.)

GRIND

SPINCONTROL

TRAVELPOWER

MAIN POWERON/OFFEMERGENCY STOP

TRAVEL SPEEDCONTROL

FIG. 12

THE SPIN DRIVE/BACK LAPPER MUST BE PLUGGED INTO THE OUTLET ON THEBACK OF THE BOX IN ORDER TO BE CONTROLLED BY THIS SWITCH. BECAUSETHE SPIN DRIVE CAN BE MOUNTED ON EITHER SIDE OF THE MACHINE, IT ISNECESSARY TO CHANGE THE DIRECTION OF ROTATION OF THE SPIN DRIVE.THE SWITCH ON THE BACK OF THE LAPPER MUST BE TURNED ON, ANDSWITCHED TO THE PROPER DIRECTION FOR YOUR SET UP. WHEN SET UPPROPERLY, THE REEL TURNS BACKWARDS FROM THE CUTTING DIRECTION.

13

TRAVEL ON/OFF CONTROLThe travel control knob turns the travel motor on andoff controlling the side to side movement of the carriageand grinding head.

TRAVEL SPEED CONTROLThis control knob determines the speed of travel forthe grinding carriage. When turned on to minimum,the carriage should stop. When turned to themaximum, the carriage moves back and forth at fullspeed. When learning to use this machine, it is agreat idea to set this speed at minimum, start the otherfunctions, then slowly increase the speed to observethat your operation and set up are correct.

TRAVEL MECHANISM RELEASETo move the grinding head from side to side manually,there is a release located on the front, bottom of thecarriage. To disingage the carriage drive system,rotate the red handled engagement lever to the downposition. To engage the carriage drive system, rotatethe red handled engagement lever to the up position.See FIG 13.

PROXIMITY SWITCHESTwo movable switches determine the left and rightlimits of carriage traverse. An LED on the switch lightswhen the switch actuator on the bottom of the carriagegets close to the head of the switch. Note, there shouldbe a 3/16 gap between the proximity switch head andthe traverse actuator bracket. See FIG. 46 on Page42.

SINGLE BLADE RELIEF VS. SPIN/ RELIEF GRINDING

MODEL 111 SINGLE BLADE RELIEF GRINDINGThe reels are ground one blade at a time, removingmaterial at an angle as shown in figure 14.

OPERATING INSTRUCTIONS (CONTINUED)

FIG. 13

Blade of Reel

Grinding WheelRelief Guide

CuttingEdge

FIG. 14

Proximity Switch

Traverse Engagement Lever

Traverse Belt

14


MODEL 181 SPIN GRINDINGThe reel is rotated while grinding renewing all cuttingedges at the same time.

A correctly ground and maintained reel is cylindrical inshape, meaning that all reel blades are the same distancefrom the center reel shaft. The reel will wear to a coneshape if it is improperly maintained or ground. Spingrinding removes the conical shape and restores thereel back to a sharp cylindrical shape with all bladecutting edges ground to the same distance from the reelshaft.

MODEL 181 RELIEF GRINDINGThe relief grinding is performed as a secondaryoperation, removing back edge of the blade. This is doneone blade at a time.

RELIEF GRINDING/SINGLE BLADE GRINDING

Relief Grinding removes the excess steel behind thecutting edge (particularly on reels with thick blades) toallow the reel to operate with less wear and friction onits cutting surface and to mow with less powerconsumption by the mower. On the Model 111 whichonly relief grinds, the reel cylindrical shape can berestored through relief grinding followed by backlapping.

WHY REELS LOSE THEIR CYLINDRICAL SHAPEWhen manufactured, mower reels are ground to beperfect cylinders. The diameter at all points is equal.The bed knife is mounted so it is perfectly parallel tothe blade surface across the full width of the mower.The best quality of cut is a result of grinding the reel toa true cylinder, grinding the bed knife to a straight trueedge, and properly aligning and adjusting the reel andbed knife in the cutting unit.

Usually two things happen to cause a reel to wear toa cone shape.1) Some cutting units are adjusted in the field to

compensate for wear at the cutting edge. Ifadjusted more on one side than the other, the reelwill wear more on that side and the reel willbecome cone shaped.

2) Reels also lose their cylindrical shape because ofthe very nature of the reels themselves. The helix(or twist) in the reel blades causes the “lead in”end of the reel to wear faster. The diameter at theend becomes smaller. Each time you adjust themower, the accelerated wear continues and the“lead in” diameter becomes even smaller. If youuse the simple “touch method” of alignment forsharpening, where you contact each end of thereel with the grinding wheel, the reel’s conical ortapered condition is not corrected and the reel isnot restored to a true cylinder. The differencebetween the two ends continues to increase, andeventually the taper exceeds the mower’s rangeof adjustment.

A severely cone shaped reel will result in poor qualityof cut, difficulty in adjusting the reel to the bed knife,premature replacement of the reel and bed knife, andin extreme cases, reel bearing failure due tomisalignment.

BACK LAPPING

Back lapping is an important step in maintaining reelmowers. Lapping must be performed after singleblade grinding, to establish a land area and insure aperfect match between the bed knife and reel cuttingedge. Lapping is not intended to be a reconditioningprocess to correct severely nicked or rounded blades.If the edge is not restored after five minutes of lapping,it is time to grind.

FIG. 5

FIG. 6

SINGLE BLADE RELIEF VS. SPIN & RELIEF GRINDING (CONTINUED)

15


GRIND OR BACK LAP

If the edges of the reel blade, and of the bed knife, are only slightly rounded, and have onlyminor nicks, they may be restored to a suitable cutting condition with lapping compound anda back lapper.

When more extremes of wear or damage exist, it is necessary to perform both a grinding andlapping operation.

GRINDING IS NECESSARY IF THE FOLLOWING CONDITIONS EXIST:• Major nicks on the bedknife or reel blades• Uneven wear on either the bedknife or the reel blades• Bent reel blades• Significant roundness to the reel blades or the bedknife• A cone shaped reel.

DRESSING THE GRINDING WHEELDressing is the process of cleaning the surface of the grinding wheel. If the wheel becomesloaded with steel from the grinding process, the steel on the wheel starts to create heat as itcontacts the steel of the reel. Poor quality of grind, slow removal of material from the reel,and excessive heat or a burned surface indicate that it is time to clean the surface of thegrinding wheel. Use the dressing brick #3702508 provided with the machine to clean thesurface of the wheel.

ALWAYS WEAR SAFETY GLASSES OR GOGGLES WHEN DRESSINGTHE WHEEL.

THE DRESSING PROCESS REQUIRES THAT YOU HOLD THE DRESSINGBRICK AGAINST THE WHEEL WHILE IT IS ROTATING AT HIGH SPEED.APPLY ONLY LIGHT PRESSURE BETWEEN THE BRICK AND WHEEL.KEEP FINGERS AWAY FROM THE GRINDING WHEEL. KEEP ALL BODYPARTS, CLOTHING, JEWELRY, AND HAIR AWAY FROM THE ROTATINGPARTS.

16

THE SET UP PROCESS

As with most processes, the beginning and the endare similar. To set up a specific cutting unit for the firsttime, it takes time to determine the specific steps,dimensions, hardware and short cuts that apply to thatcutting unit. If this information is recorded accuratelyso that it may be used to set up the cutting unit thenext time, set up time is reduced to a minimum. Tomake your job easier, record your set ups on the formprovided and label, box and retain special hardware,spacers, etc. that were used to create the set up.Pictures of the completed set up may also helpminimize the time needed to set up the cutting unit.An accurate set up guide enables you, or the personthat has to set up the cutting unit the next time, aconvenient place to start, and to refine the process. Afull size copy of the form below appears later in thissection. Make copies. Fill them out. Use them. Theywill make your job easier.

THE BASIC STEPS ARE....

1. Find the set up guide for that particular reel, referto the information in the following steps.

2. Clean the cutting unit.

3. Remove the Bed Knife.

4. Check for worn reel shaft bearings. If there isplay in the bearings, replace the bearings.

5. Determine which side to set up the spin drive.

6. Move the Grinding Carriage to one side to preventdamage during loading.

7. Move the grinding wheel toward the operator toassure that you can move the grinding wheeltoward the reel during set up.

8. Adjust the V blocks (Or centers).

9. Use the elevator to lift the cutting unit into the Vblocks.

10. Clamp the roller into the V blocks with the rearchain clamp.

11. Check the grinding wheel location according tothe following drawings.

12. Attach the upper support clamps to support thefront of the cutting unit.

13. Use the gauge to fine adjust the vertical andhorizontal location of the reel center shaft.

(111 Model)

14. Use the gauge to fine adjust the vertical andhorizontal location of the reel center shaft.

(181 Model)

15. Check tightness of all clamps and adjustments,the key to a good grind is....Rigidity!! Rigidity!!Rigidity!!!

16. Use the gauge to recheck horizontal and verticaladjustment. If necessary, loosen clampsslightly and readjust the location or the reel.Then retighten and check again.

17. Number the blades with a marker or paint stick.

18. Attach the spin drive to the reel.

19. Adjust the grinding wheel to the reel blade.

20. For the Model 111, single blade relief grind theblades until the relief comes to the front onevery blade, end to end.

21. For the Model 181, spin grind until the desiredcutting edge is achieved on every blade, end toend.

22. For the Model 181, proceed to the relief grindprocess.

23. Record your set up on the form. If you workedfrom a form recorded previously, makecorrections or improvements.

24. Move the grinding wheel back to one end,remove the spin drive connection.

25. Remove the cutting unit from the grinder.

26.Make sure when you set the cutting unit on thefloor that you do not damage the cutting edgesof the reel.

17


1. CHECK THE SET UPGUIDE.Check to see if there is setup information of file.

2. CLEAN THE MOWER ORCUTTING UNIT.Thoroughly clean themower and remove alldried material from the reelblades and the bedknife.

3 REMOVE THE BEDKNIFE.It is possible to spin and relief grind many reelswithout removing the bedknife, however it isrecommended that bed knife is removed andground. Removing the bedknife provides morespace for setting the grinding wheel to the reelblades.

4. INSPECT THE REEL OR CUTTING UNIT.Inspect the back of each reel blade. If there areany irregularities such as weld flashes, thick paintruns, etc., remove them so that the relief guidehas smooth surfaces on which to travel. Checkfor bent reel blades and straighten, if necessary.Inspect welds at spiders. Check the reel andground roller bearings. (In accordance with theinstructions of the mower manufacturer.)Determine that the roller is mounted such that itis parallel too the reel center shaft.

5. DETERMINE WHICH SIDE TO SET UP THESPIN DRIVE.Some cutting units can only be driven from oneside. Determine which side, and that willdetermine the location of the V Blocks in thefollowing steps.

6. POSITION THE GRINDING CARRIAGE TOTHE FAR RIGHT SIDE OF THE MACHINE.Moving the grinding carriage to the end oppositethe elevator will put it out of harms way duringthe loading process.

7. MOVE THE GRINDING WHEEL BACKTOWARD THE OPERATOR.It is frustrating to get all set up, then find out thatthe wheel was adjusted all the way forward, andyou need to relocate the reel so that you canreach it with the grinding wheel.

THE SET UP PROCESS (con’t)

8. ADJUST THE V BLOCKS TO RECEIVE THEREAR ROLLER OF THE CUTTING UNIT.

IT CAN BE DANGEROUS TOADJUST THE V BLOCKSAFTER THE MOWER IS IN

PLACE, OR WHILE IT ISHANGING FROM THEELEVATOR.

9. USE THE ELEVATOR TO LIFT THE CUTTINGUNIT INTO THE V BLOCKS.Place the cutting unit on the floor behind the grinderwith the front of the cutting unit facing towards thefront of the grinder. Securely attach the cutting unitto the hooks of the elevator.

10.CLAMP THE ROLLER TO THE V BLOCKS.

TO PREVENT THE CUTTINGUNIT FROM FALLING OUT OFTHE GRINDER, ALWAYS USETHE VISE GRIP STYLE REARROLLER CLAMP TO HOLDTHE ROLLER IN THE VBLOCKS.

18


KEEP ALL BODY PARTS OUTFROM UNDER THE CUTTINGUNIT WHEN LIFTING IT WITH THEELEVATOR. THE WEIGHT ANDBLADES CAN CAUSE SERIOUSDAMAGE. IF THE CUTTING UNITSHIFTS OR STARTS TO FALL, DONOT TRY TO CATCH IT. MOVEAWAY FROM THE UNIT TOPREVENT INJURY. USING THEWINCH AND THE CAPABILITY OFROTATING THE ELEVATOR,POSITION THE REEL, SO THEREAR ROLLER IS RESTING INTHE “V” BLOCKS. AS AN ADDEDSAFETY MEASURE, IT ISCONSIDERED DESIRABLE TOLEAVE THE ELEVATORATTACHED TO THE MOWER.SOME MOWERS (MOSTNOTABLY GREENS MOWERS)MAY REQUIRE THAT THE UNITBE MOUNTED ON CENTERSTHAT ARE POSITIONED IN THEBEDKNIFE MOUNTING HOLESLOCATED IN THE MOWER SIDEFRAMES.

FIG. 17

19


11. CHECK THE GRINDING WHEEL LOCATION.

A. Position the height of the grinding wheel center so that it is 1/2” to 1" below the reel center. If the reel guide finger interferes, remove it.B. Infeed the grinding wheel until it just makes contact with a reel blade and rotate the reel by hand to make sure the blades clear the stop finger. Now tighten the two locking knobs on the locking arms and the locking knob for the height adjustment screw.

12. ATTACH THE UPPER SUPPORT CLAMPS.Now that grinding wheel is located properly, 1/2” to 1”below the reel, the next step is to adjust the uppermower support arms to hold the reel in the correctposition for spin and relief grinding. There are manyreel designs, all with unique requirements for mount-ing the front of the cutting unit to the grinder. Byloosening the upper mower support arms they canslid side to side for correct alignment to a specificreel. The knob located on the side will allow for in andout as well as rotaional adjustments.

IT IS CRITICAL THAT THE REEL BEHAND ROTATED TO VERIFY STOPFINGER CLEARANCE. FAILURE TODO SO COULD CAUSE SIGNIFICANTDAMAGE TO THE REEL ANDGRINDER AND POTENTIAL INJURYTO THE OPERATOR.

1/2" to 1”

FIG. 19

FIG. 18

Side Lock Knob

20

OPERATING INSTRUCTIONS (CONTINUED)13. USE THE GAUGE TO ADJUST THE VERTICALPOSITION OF THE REEL CENTER SHAFT.(111 Model)Loosen the side lock knob holding the left upper clamp.This will reduce the possibility of pre-loading or binding.(See FIG 19.)

Move the carriage to the right hand side of the reelshaft and position the alignment tool so that the rod(plunger) gently rests on the top or bottom of the reelshaft. Avoid weld areas. (See FIG 20.)

Without disturbing the positioning of the alignment tool,pull the rod to the rear to clear the reel and move thecarriage to the opposite (left) end of the shaft.

Push the rod towards the reel shaft. Loosen the lockhandles and, using the vertical adjustment handwheel,raise or lower the reel until the rod is positioned on thereel shaft as it had been on the right hand side of thereel.

Recheck the measurement on the right hand side.

Repeat as necessary until both sides are at the sameheight. Secure the adjustment with the lock lever.

USE THE GAUGE TO ADJUST THEHORIZONTAL POSITION OF THE REEL CENTERSHAFT (Model 111).Again, loosen the side lock knob holding the left upperclamp. This will reduce the possibility of pre-loading orbinding.

Move the carriage to the right hand side of the grinderand position the alignment tool so that the rod (plunger)gently touches the front of the reel shaft. Avoid weldareas. Tighten the stop block.

Without disturbing the positioning of the alignment tool,pull the rod to the rear to clear the reel and move thecarriage to the opposite (left) end of the grinder.

Push the rod towards the reel shaft. Loosen the locklever and, using the horizontal adjustment handwheel,move the reel back and forth until the rod is touchingthe front of the reel shaft in the same way it touched onthe right hand side of the reel.

Recheck the measurement on the right hand side.

Repeat as necessary until both sides are at the samehorizontal location. Then secure the adjustment withthe lock lever.

VerticalAdjustmentKnob

HorizontalLock Lever

Horizontal AdjustmentKnob

FIG. 20

FIG. 21

Vertical LockLever

21

OPERATING INSTRUCTIONS (Continued)

14. DIAL INDICATOR ALIGNMENT GAGE (181 MODEL)

The dial indicator set up gage is designed to bequickly mounted into position and/or quickly re-moved.

The gage is mounted to the front left corner of thegrinding head assembly.

REEL ALIGNMENT USING THE DIALINDICATOR SET UP GAGE

A. Mount the guage into position on the left frontside of the grinding head assembly.

B. Tighten the clamp located on the fixed end of thetooling bar (right side) and loosen the left sideclamp when aligning the reel. Use the chainvice clamp when using V-bracket mounts.When using the centers do not use the chainvice clamp.

C. Loosen the two locking knobs on the pivotassembly on the left side of the squaretooling bar so that it can be adjusted in boththe vertical and horizontal plane.

ALIGNING REELS IN THE VERTICALPARALLELISM PLANE

A. Move the grinding head assembly until thealignment rod is approximately 1” from theright side of the reel. Lock the Knob A withinapproximately 1/4” of center shaft of the reel.

B. Raise the indicator slide casting on the verticalsupport so that the indicator rod can beextended over or under the center shaft of thereel.

C. Lower the indicator slide by turning the verticalfine adjustment Knob B until the alignmentrod lightly touches the top of the reel centershaft.

D. Pull rod back and lock Knob C. Traverse to theother side of reel, same distance from end.Loosen Knob C and extend alignment rod.

E. Raise or lower the mounting bar and the reel untilthe center shaft of the reel lightly touches theextended indicator rod.

Fig. 22

22

VERTICAL ALIGNMENT (CONTINUED)

F. Take note of the knob so you know where youare starting from. Now turn the verticaladjusting screw 1 more revolution. This 1revolution is to compensate for the fact thatas you adjust the left side, the right side isalso moving at a ratioed amount. Thisshould almost align your reel in the verticalparallelism plane.

G. Move the alignment fixture back to the right handside of the reel and readjust the alignmentrod so that it lightly touches the top orbottom of reel center shaft.

H. Move it back to the left side to make sure thereel is in correct vertical position. If not,move vertical adjustment handle up or downso that it just touches alignment rod on bothsides.

I. Now lock the vertical adjusting screw lockingknob.

NOTE: This alignment is not as critical as thehorizontal plane, but care should be taken on all reelset ups. The accuracy need only be approximately.010”.

CAREFULLY REVIEW THE CORRECTIDENTIFICATION OF THE LOCKINGKNOBS IN FIG 22. MAKE CERTAIN YOUARE LOCKING AND UNLOCKING THECORRECT KNOBS.

ALIGNING REELS IN THE HORIZONTALPARALLELISM

THIS A CRITICAL SET UP AND CARESHOULD BE TAKEN WHEN MAKINGTHESE ADJUSTMENTS. IF REEL ISOUT OF POSITION IN THE HORIZONTALPLANE, IT WILL BE GROUND CONESHAPED.

A. Move set up gauge on the right hand side of reelapproximately 1” from the end.

B. Lower the indicator slide casting on the verticalsupport so the indicator rod can makecontact withe the center of the reel shaftwithin approximately 1/8” and lock Knob A.Center shaft should be clean and free of rustwhere rod makes contact. Now fine adjustusing Knob B until at the center of the centershaft of the reel.

C. Now loosen Knob D on the indicator stop bar.Holding the indicator rod firmly against the reelshaft, move the indicator stop bar back, untilno contact is made with the indicator rodplunger. Now move indicator stop bar forwarduntil 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.

D. 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 whensetting up the other side. Pull back and lockwith Knob C.

E. Move alignment gauge to the left side of the reelcarefully retracting the indicator rod so as notto damage or change setting. Set indicator rodon the same position on the reel as on theother side, that is 1” from the end and centeredon the shaft. Now read the dial indicator todetermine the distance the reel is out of position.

NOTE: Because the set up gauge is mounted to thecarriage, you can unlock the drive system and traversemanually from end to end or you can use the autotraversing drive by setting the pot to a slower speed andpowering from end to end.

T Knob

Indicator Stop Bar

Indicator Rod Plunger

Indicator Rod

1/32" FIG. 23


23


ALIGNING REELS IN THE HORIZONTALPARALLELISM (CONTINUED)

F. To adjust reel position first determine the directionthe reel has to move for alignment. Thedirection that the reel will have to be movedcan be determined by pulling back on the dialindicator stop bar and if the dial moves back tothe “0” position you will have to move the reeltowards you. If that cannot be done the reelwill have to be moved away from you.

There are two adjusting steps for final positioning ofthe reel as follows:

1. With the reel set gauge still in the left hand side ofthe reel, turn the horizontal adjusting screw inthe direction required to match the initialindicator reading on the right hand reel position.

2. Now travel farther by half the amount alreadytraveled.

The reason for this is that the square mounting barpivots on one end and is adjusted on the opposite end.Anytime the adjusting end is moved to change the leftside dimension, the right side dimension is alsochanging at a ratio to the left side. By over compen-sating at the adjusting end you will compensate for thismovement and get the reel aligned much faster.

G. Now move the set up stand back to the right sideof the reel. Set indicator rod on the same spotyou used the first time and reset large dial on“0”. Make sure you read the setting on thesmall scale and note. Repeat the stepsdiscussed above.

IT IS ESSENTIAL THAT CARE IS TAKENWHEN SETTING THE REEL UP IN THEHORIZONTAL POSITIONS IN ORDER TOGRIND IT INTO A CYLINDER SHAPE. ANYMISALIGNMENT WILL CAUSE YOU TOGRIND INTO A CONE.

I. When the horizontal parallelism has been adjustedto within .003” end to end, tighten the horizontaladjustment locking knob and both overheadclamp adjusting knobs. When tightening theknob it is very important that you have the dialindicator at that side of the reel and watch it asyou tighten. It must not move in the tighteningprocess. After both knobs are tight, recheckalignment.

24

CHECKING REEL FOR CONE SHAPE, REELROUNDNESS, AND STRAITNESS OR REELOUTSIDE DIAMETER.

BEFORE GRINDING--A. Before storing the set up gauge, it is very

effective to use it to check the ungroundedreel to determine the amount the reel isconical in shape and which end has thelarger diameter. Start with the set upgauge at the right end of the reel. Loosenthe wing nut on the indicator stop bar,holding the indicator rod firmly against oneblade. Pull the indicator stop bar back untilit clears the plunger then advance ifforward until it contacts the plunger andadvances it 1/2 inch further. Lock in place.This sets the plunger at its midpoint andallows adequate movement in bothdirections. Set outer dial at zero and noteposition of pointer on small dial.

B. Now move it to the left side of reel andindicate the same blade. From thereading determine the amount the reel iscone shaped. This also determines highpoint for grinding. Grinding of a reel mustalways start at the high point.

AFTER GRINDING--A. After grinding a reel, check the roundness on

each end of the reel and center beforeremoving ground reel. Loosen the wing nuton the indicator rod firmly against oneblade. Pull the indicator stop bar back untilthere is a 1/32” gap between it and the setscrew. This is to permit rotation of the reelblades to ride on the domed anvil only. Ateach location (left, right and center) turn thereel by hand and observe the indicatorvariations. All readings should be within.002”.

B. Straitness of reel outside diameter--Takeindicator readings at both ends of reel.Compare readings between each end ofreel for straitness. All reading should bewithin .002”.

C. Carefully remove guage and store in a safeplace.


Cone Shape Cylinder ShapeCORRECT

1/32"

Indicator Rod Plunger

Indicator Stop Bar

Indicator Rod

Wing Screw

Fig. 24

Fig. 25

25


15. NOW TIGHTEN ALL CLAMPS ANDADJUSTMENTS.The key to a good grind is Rigidity! Rigidity!! Rigidity!!!

16. USE THE GAUGE TO RECHECK THEHORIZONTAL AND VERTICAL ADJUSTMENT.Sometimes the reel moves during the tightening process.If necessary, loosen the set up slightly, and readjust.

17. NUMBER THE BLADES WITH A MARKER OR APAINT STICK.This step is helpful in keeping track of which blades havebeen ground and which ones require another pass.

18. ATTACH THE SPIN DRIVE TO THE REEL.(MODEL 181)If not in place already, move the shelf and the back lapperto the side of the machine appropriate to drive the reel.Adjust the lapper front to back on the shelf, and turn theknob on the lapper to adjust the shaft vertically until theshaft is in line with the reel. Using sockets, extensionsand in some cases, special adapters, attach the spin driveto the reel.

Check to assure that the switch on the lapper is set to turnthe reel in the correct direction. With the grinding wheelbacked away from the reel and all body parts and toolsaway from the reel, start the spin drive. The correctdirection is when the reel is turning backwards, the re-verse of the cutting action.

KEEP HANDS, FINGERS, LONGHAIR, AND ALL OTHER BODYPARTS AWAY FROM THE REEL.DO NOT WEAR JEWELRY ORLOOSE CLOTHING.

19. ADJUST THE GRINDING WHEEL TO THEREEL BLADES.If the horizontal and vertical adjustments are accu-rate, and the reel is already a perfect cylinder, theadjustment of the wheel to the reel blades should beuniform end to end. In most cases some additionaladjustments may be made at this time. However, ifthe adjustments are accurate, grinding the reel tomatch the path of the grinding wheel will return thereel to the same diameter on both ends.

FIG. 27

FIG. 26

26

NORMAL HELIX

For a NORMAL HELIX reel, the grinding wheel should bedressed to match the angle of the reel blade. It isrecommended that a slightly larger angle is dressed onthe wheel so the right side of the wheel is contacting theblade prior to the left side as shown. The grinding wheelwill then wear to a match.

If you do not dress the grinding wheelso the right side contacts first you maynot relief grind part of the last 3/8" [10 mm]of the reel blade.

NOTE: The square faced wheel from the factory can beused for normal helix reels with no dressing.

OPERATING INSTRUCTIONS CONT.

20. SINGLE BLADE RELIEF GRINDING WITH THE MODEL 111.

A. Check to see if your mowing unit is a normal or reverse helix. NOTE: As you look into the guide finger in FIG. 28 it shows the normal reel helix. The high point of the finger guide is on the right hand side of the grinding wheel. See FIG. 29 for reverse helix. Most mowing units are normal helix.

The high point of the guide finger mustalways be at the corner of the grindingwheel that is making contact with the reel. (See FIG. 28 and 29)

REVERSE HELIX

For a REVERSE HELIX reel, the grinding wheelshould be dressed to match the angle of the reelblade. It is recommended that a slightly largerangle is dressed on the wheel so the right side ofthe wheel is contacting the blade prior to the lefts i d eas shown. The grinding wheel will then wearto amatch.

If you do not dress the grindingwheel so the right side contactsfirst you may not relief grind partof the last 3/8" [10 mm] of the blade.

FIG. 29

FIG. 28

27

B. It is recommended that you practice indexing the blades forrelief grinding prior to actually grinding them. Do this bybacking the grinding wheel away from blade so that virtually nocontact is made with the blade that is resting on the guidefinger. Now, with the grinding wheel NOT turning, manuallytraverse at a uniform speed from right to left on blade 1. Onthe return stroke, always come back on the same blade. Aftertraversing down and returning on a blade, relief grindingrequires the operator to manually index to the next blade. Thisis a critical operation and should be well practiced prior togrinding. When on the practice run you have to hold the reeldown to the finger on the return stroke.

SEE GRINDING WHEEL WARNINGS ONPAGE 3 BEFORE GRINDING.

THE FLANGE AND NUT ON A GRINDINGWHEEL SHOULD BE TIGHTENED TO5 FT.LBS. [.7 KGM]. OVERTIGHTENINGCAN CAUSE WHEEL BREAKAGE.REPLACE ALL CRACKED WHEELSIMMEDIATELY. ALWAYS USE GUARDSAND EYE SHIELDS.

USE ONLY FLANGES FURNISHED WITHTHE GRINDER. THE WHEEL GUARD ISALWAYS TO BE MOUNTED TO COMPLYWITH OSHA REGULATIONS AND FORSAFE OPERATIONS.

C. Turn on the motor and grind across blade #1. Thegrinding should be done with light to moderate cuts asheavy grinding pressure will result in excessive heatingof the blades. Also, the carriage should be traversedmanually in smooth and uniform speed passes acrossthe blade and without stopping. Hold the reel to the guidefinger with your left hand and pull the grinding head assemblywith your right hand. As soon as the grinding wheel contactsthe reel, remove your left hand. The guide finger will keepthe blade in place as the grinding head assembly istraversed across the reel. When it reaches the left sideof the reel, the reel blade comes fully off the grindingwheel and partially off the guide finger. The reel bladewill automatically pick up the same blade on the returnstroke. The blade will be held to the finger in bothdirections by the rotation of the grinding wheel driving theblade downward against the finger. When you reach theright end of the blade let the carriage come off the blade.


28

GRINDING SEQUENCE

1 3 5 7 2 4 6

2 4 6 1 3 5 7

3 5 7 2 4 6 1 OR

1 2 3 4 5 6 7

2 3 4 5 6 7 1

3 4 5 6 7 1 2


FIG. 30

FIG. 31

D. Next manually rotate to blade #2 and grind blade #2 andcontinue to grind all of the blades without changing the

grinding wheel setting. If you have brought all of the blades to a sharp edge, advance the grinding wheel slightly and regrind the blades, in reverse order--

starting with the highest blade number and going down. Example: #5 then 4,3,2,1. The reason for this is to

get a better finish and to compensate for grinding wheel wear on the original grind. If the blade is not ground to

a sharp edge, adjust the horizontal infeed wheel and grindanother cycle. Grind the blades 2-3-4-5-1 as an example

on the second cycle. Listed on FIG. 30 are two optional methods to stagger reel blades during grinding. The reel must be ground until you achieve a sharp edge. See FIG. 31. Again, always reverse order with a slight infeed after achieving a sharp edge.

INFEED AMOUNT:The ring located on the inside of the infeed handle iscalibrated in .002” [.05mm] increments. The maximumdesired infeed is about .015” . Most chose a moreconservative infeed.

IT IS VERY IMPORTANT TO A QUALITYGRIND THAT A STAGGERED GRIND-ING METHOD IS USED.

IT IS NECESSARY TO MANUALLY POSITIONTHE REEL BLADE ON THE GUIDE FINGER. IFYOU OVER-INDEX AND MISS THE FINGER THEGRINDING WHEEL COULD BE JAMMEDBETWEEN TWO BLADES. IF YOU UNDER-INDEX, THE GRINDING WHEEL WILL BEJAMMED AGAINST THE END OF THE BLADEYOU ARE TRYING TO GRIND.

BECAUSE YOU ARE MANUALLY TRAVERSING,BACKING UP AND RESTARTING WITH THEREEL BLADE ON THE GUIDE FINGER IS VERYEASY.

EXTREME CARE MUST BE TAKEN INLEARNING THIS PROCEDURE AS SERIOUSPERSONAL INJURY COULD OCCUR IF THEOPERATOR CONTACTS THE GRINDINGWHEEL OR IS CAUGHT IN A GRINDING WHEELTO REEL JAM. PRACTICE WITHOUT THEGRINDER MOTOR ON UNTIL YOU ARESATISFIED WITH YOUR CAPABILITY.

29

OPERATING INSTRUCTIONS (Continued)SETUP PROCEDURE FOR SPIN DRIVERPM VERSUS TRANSVERSE SPEED

SPIN DRIVE RPM

SPIN DRIVE RPM IS VERY IMPORTANT IN ACHIEVING AQUALITY GRIND. USE CARE IN ESTABLISHING THE SPINDRIVE RPM, PER THE INSTRUCTIONS BELOW.

Generally, the Spin Drive RPM will be between 180 RPM (45%)and 360 RPM (100%). The speed required to spin a specificreel is dependant on reel diameter, the number of reel blades,and reel hardness. For all reels, there is an optimum Spin Speedwhere there is an AGGRESSIVE, yet smooth grind as you spingrind the reel. Your objective is to spin grind the reel as aggres-sively and as fast as possible while maintaining top quality.

It is recommended to start grinding each reel at a Spin Speedof 200 RPM (50%) and evaluate the RPM by adjusting higherand lower to optimize the Spin Speed for that reel. If the SpinSpeed is incorrectly set, you can experience two problems,grinding wheel dressing or grinding wheel resonance. Each ofthese problems is explained below.

On some reels, especially small diameter high blade count reelsif the Spin Speed RPM is set to high, the reel can act as adresser to the grinding wheel. There can develop what ap-pears to be a very aggressive grind (as if the infeed has selfinfed) and then a sudden stop of grinding with no grinding wheelto reel contact. If this occurs, your Spin Speed was set to highand you effectively dressed your grinding wheel.

Some reels have a resonant RPM where the reel goes intoharmonics with the grinding wheel and the resonance vibratesthe grinder and results in a very bad grind. By changing theSpin Speed to a higher or lower RPM you will move out of theresonant range.

After determining the best Spin Speed RPM for a reel, note theRPM on the "Set-up Chart" in the "NOTES" section. See page34. By noting the correct RPM, you will avoid evaluating theSpin Speed the next time you grind the reel.

TRAVERSE DRIVE RPMThe Traverse Speed potentiometer is adjustable from approxi-mately 5 feet per minute [1.5 meters per minute] (20%) to 20feet per minute [6 meters per minute] (100%). It is recom-mended to grind at approximately 15 feet per minute [4.5 metersper minute] (75%).

Grinding at a slower traverse speed, 10 feet per minute[3 meters per minute] (50%) as an example, will give a betterfinish but will extend the grind cycle time. Grind finish versusgrind cycle time is controlled by the choice of the operator.

30


GRINDING REEL INTO A TRUE CYLINDER BYSPIN GRINDING

Spin Grinding removes the conical shape & restoresthe reel back to a cylindrical shape with all reel bladeedges ground to the same distance from the reelshaft.

Remove the Relief Guide from the Grinding WheelGuard.

Using the grinding wheel vertical and horizontaladjustments position the wheel lightly against one ofthe blades. Move end to end and check for alignmentand high blades.

When you are satisfied with the adjustment, positionthe grinding wheel at one end, set the travel speed tozero, and engage the traverse belt.

Locate the travel proximity switches so the grindingwheel can grind off the end of the reel on both sides.With hands away from the reel, turn on the power bypulling out the red power button.

Turn on the spin drive, the grinding wheel, and last thetraverse drive and slowly turn up the travel speed untilthe grinding wheel starts moving across the reel.

Adjust travel speed and infeed as desired.

INFEED AMOUNT:The ring located on the inside of the infeed handle iscalibrated in .002” [.05mm] increments. The maxi-mum desired infeed is about .008” . Most chose amore conservative infeed.

Spin Grind until the grind pattern is uniform from bladeto blade and from end to end.

ALWAYS WEAR PROPERSAFETY EYEWEAR, HEARINGAND RESPIRATORY EQUIP-MENT BEFORE TURNING ONAND OPERATING YOURGRINDER.

VERTICALADJUSTMENT

HORIZONTALADJUSTMENT

It is required to have a sparkout to completegrinding the outside diameter to a true diameter.For sparking out, the process is to infeed thegrinding head for approximately .002 stockremoval and let the grinding wheel sparkout. Forsparking out in grinding process, always traversegrinding head at least 20 passes with no grindinghead infeed. Set traverse at slow speed on dialsetting approximately 30 percent for final grindingsparkout. After sparkout, shut the grinder com-pletely off.

NOTE: This process refers to sparkout, but whatwe are looking for is a near sparkout, approximatelya 99% reduction in grinding sparks from normalgrind. Do not run sparkout until you have nosparks because this could be an extremely ex-tended period.NOTE: Greatest accuracy and best finish isobtained when reel is sparked out.Use your set up gauge, prior to relief grinding tocheck the reels for roundness. This is very impor-tant when first learning the operation of yourmachine.

IT IS VERY IMPORTANT IN SPINGRINDING THAT YOU THOROUGHLYSPARKOUT AT THE END OF THE GRINDCYCLE. THE DIFFERENCE OFACHIEVING .005 OR .003 TOTAL READINGIS ACCOMPLISHED WHEN NOTINFEEDING THE GRINDING WHEEL.

FIG. 33

31


22. FOR THE MODEL 181, PROCEED TO THERELIEF GRIND PROCESS

REEL SPIRALWhen standing behind the mowing unit when themowing unit is sitting in normal position on the ground.If the spiral is such that the right side of the blade cutsbefore the left, it is a right hand lead in or a right handspiral reel. If the spiral is such that the left side of theblade cuts before the right it is a left hand lead in or lefthand spiral reel. Most reels made today are right handspiral.

RELIEF GRINDING TO COMPLETE THEREEL GRINDING PROCESSA. Disconnect the spin drive coupling components

from the reel.B. Check to see if your mowing unit is a left

hand or right hand spiral. See reel spiraldefinition above. NOTE: As you look into theguide finger in FIG. 35 it shows a reel withreverse helix reel spiral. The high point offinger guide is on the right hand side of thegrinding wheel viewed from the fingermounted side. See FIG. 36 for standard helix.Most mowing units are standard helix sotraverse your carriage to the right hand sideof reel for starting position. Traverse carriageuntil there is at least .125 (1/8") clearance tothe guide finger for indexing. See FIG. 37. Setthe right hand traverse stop for this carriagereversing position. Traverse to the other endof the reel blade until the guide finger isbeyond the point of grind by approximately.125 (1/8") to .75 (3/4"). Set the left handtraverse stop for this carriage reversing position.

C. There are two (2) hand knobs to loosen.They are located on the base of the adjustingarms. Raise the grinding wheel up (approximately 7 turns) so the reel blade can rest on thereel guide finger. It will be necessary to infeedthe grinding wheel to accomplish this.See FIG. 34.

D. Now you can adjust the back angle you wish toput on the reel blade. (The averagerecommended manufacturer's angle is 15degrees. When in doubt, check with eachreel manufacturer as to the exact anglerequired.) By looking down the reel from theoperator's position you can see the reel andits relative position to the grinding wheel. Byraising the grinding wheel you will decreasethe back angle and conversely by loweringthe grinding wheel you will increase the backrelief angle. Traverse the grinding wheelassembly to the right side of the reel.Retighten the two hand knobs.

15° Relief Grind

Corner of WheelDoing Grinding

Left HandReel Spiral

High Point ofFinger Guide

Right HandReel Spiral

Corner of WheelDoing Grinding

SIDE VIEW OFGRINDING WHEEL

LOOKING FROMTHE REELLOADING POSITION

Grinding Wheel

Mower UnitEnd Frame

Guide Finger

Reel

1/8" [1.25] Clearancefor Blade Indexing

Over .75 Dimension uselarge finger guide. For .75to .50 Dimension usesmall finger guide, and.375 wide grinding wheel

FIG. 34

FIG. 35

FIG. 36

FIG. 37

32


REEL SPIRAL (CONTINUED)

E. It is recommended that you practice indexingthe blades for relief grinding prior to actuallygrinding them. Do this by backing the grindingwheel away from the blade so that virtuallyno contact is made with the blade that isresting fully on the guide finger. Now with thegrinding wheel NOT turning, turn on traversemotor and set speed at 9 or 10 o’clockposition and let grinding assembly traversedown. On the return stroke, always comeback on the same blade. After traversingdown and returning on a blade, reliefgrinding requires the operator to manuallyindex to the next blade. This is a criticaloperation and should be well practice priorto grinding. When on the practice run youhave to hold the reel down to the finger onthe return stroke.

THE HIGH POINT OF THE GUIDEFINGER MUST ALWAYS BE ATTHE CORNER OF THE GRINDINGWHEEL THAT IS MAKINGCONTACT WITH THE REEL.SEE FIG. 35 & 36.

ROTATE FINGER GUIDE ENDFOR END WHEN REEL SPIRALIS IN THE OPPOSITE DIRECTIONAS SHOWN IN FIG. 35 & 36.

IT IS NECESSARY TO MANUALLYPOSITION THE REEL BLADE ON THEGUIDE FINGER. IF YOU OVER-INDEX ANDMISS THE FINGER THE GRINDING WHEELWILL BE JAMMED BETWEEN TWOBLADES. IF YOU UNDER-INDEX THEGRINDING WHEEL WILL BE JAMMEDAGAINST THE BLADE YOU ARE TRYINGTO GRIND.

EXTREME CARE MUST BE TAKEN INLEARNING THIS PROCEDURE AS SERIOUSPERSONAL INJURY COULD OCCUR IF THEOPERATOR CONTACTS THE GRINDINGWHEEL OR IS CAUGHT IN A GRINDINGWHEEL TO REEL JAM. PRACTICE UNTILYOU ARE SATISFIED WITH YOURCAPABILITY.

When you are comfortable with this procedure,continue with the next step in actually grinding.

NOTE: At each end of the stroke when reversing,there must be a 1-second or longer pause. Thiscan be increased. The 1-second hesitation at theend of the stroke permits time to manually indexthe reel.

F. It is recommended that when the reliefgrinding is completed that 60% of the reelblade be removed. This will generally takeup to three passes across each blade. Atthis time infeed the grinding wheel to take1/3 to 1/2 relief grind. This amount will varydepending on the condition of the reel.

G. Mark the first blade with an "X" using a feltmarker and with this reel blade resting onthe finger guide but not making reel contactwith the grinding wheel, set the traversedial to "0", turn on the grinding wheel motorand traversing motor.

H. Hold the reel to the guide finger with yourleft hand and turn the traverse speed at 9or 10 o’clock. As soon as the grindingwheel contacts the reel, remove you hand.The guide finger will keep the blade in placeas the grinding assembly traverses acrossthe reel. When it reaches the left side ofthe reel the reel blade leaves the guidefinger and then traverse switches reversecarriage to the opposite direction. Theguide finger will automatically pick up thesame reel blade and will be held down tothe guide finger with the rotation of thegrinding wheel driving force downward.

I. Now continue grinding each blade byindexing them as practiced in procedure "E"until you have ground each blade down andback. When each blade has been groundinspect to see if proper relief has beenattained. If not, reset wheel and regrind asbefore. Continue until you achieve the 60%relief.

33


REEL BLADE GRINDING WITHCLOSELY SPACED BLADES

A. If the reel blades are too close together or theclearance between mower unit is too narrowand will not permit you to use the large reelfinger guide, it will be necessary to use thealternate stamped finger guide and a 3/8"wide grinding wheel (Part No. 3700363).NOTE: This wheel is not includedwith the grinder. In order to use this guideyou will be required to dress the grindingwheel as follows: Place the guide finger on thegrinding motor assembly and position about1/16" away from the grinding wheel. On thenormal helix reels, no dressing is required.See FIG. 38. On the reverse helix reels. SeeFIG. 39. With the grinding wheel assembly in aposition where you can reach it with thedressing stick, turn on the grinding wheel anddress the portion of the wheel atapproximately 10 degrees. See FIG. 39.

B. The grinding procedures for using this fingerwill be the same as when using the largerguide finger, but because of its relative smallsize it is recommended that you index fromblade to blade in the following manner: Whengrinding wheel assembly makes contact withthe right traversing stop and pauses beforereversing direction. Turn the traversingspeed dial to "0" this will stop the grindinghead carriage. Now index the next blade andslowly dial to move the grinding wheel into thereel while you position the blade onto theguide finger. Once finger is in place andgrinding has started turn the speed dial upand continue to grind as before. This procedurewill be necessary for every blade.

IT IS NECESSARY TO MANUALLY POSITION THEREEL BLADE ON THE GUIDE FINGER. IF YOUOVER-INDEX AND MISS THE FINGER THE GRIND-ING WHEEL WILL BE JAMMED BETWEEN TWOBLADES. IF YOU UNDER-INDEX THE GRINDINGWHEEL WILL BE JAMMED AGAINST THE BLADE YOUARE TRYING TO GRIND. EXTREME CAR MUST BETAKEN IN LEARNING THIS PROCEDURE AS SERI-OUS PERSONAL INJURY COULD OCCUR IF THEOPERATOR CONTACTS THE GRINDING WHEEL ORIS CAUGHT IN A GRINDING WHEEL TO REEL JAM.PRACTICE UNTIL YOU ARE SATISFIED WITH YOURCAPABILITY.

Left Hand Spiral

High Point of FingerGuide

NO SPECIAL WHEELDRESSING REQUIRED

Point of GrindingWheel Contact

High Point ofFinger Guide

10 °

Point of GrindingWheel Contact

Right Hand Spiral

Hand Dressto a Point

FIG. 39

FIG. 38

34


NEARY MODEL 111 & 181 SET UP GUIDE

MOWER TYPE:

MAKE:MODEL:

Notes on pre-grind prep:

CONNECTING THE REEL TO THESPIN MOTOR

From Left From Right

Notes on Spin Set-up:

LOWER MOWER SUPPORT SET-UPV-ROLLER SUPPORT

CENTER SUPPORT

Completed By Date

UPPER MOWER SUPPORT SET-UP

Notes:

Spin Speed:

Orientation: ( front of machine)

Small Clamp

Large Clamp

No Clamp, 90° & bolt

Low Holes Middle holes High Holes

35

23. RECORD YOUR SET UP ON THE FORM, THESET UP GUIDE.We recommend recording the setups. This will makeyour job easier, and will make it much easier to showsomeone else how to use the machine in the future.Make copies of page 34 and record the set ups for eachtype of cutting unit.

24. MOVE THE GRINDING WHEEL BACK TO ONEEND.

25. CAREFULLY REMOVE THE CUTTING UNITFROM THE GRINDER.Keep hands and feet and other body parts out fromunder the cutting unit.

26. DO NOT DAMAGE THE CUTTING EDGES OFTHE BLADES MOVING THE CUTTING UNIT AWAYFROM THE GRINDER.The reel or cutting unit is now sharp and ready for reas-sembly and adjustment.

BACK LAPPING

Many turf professionals feel that it is necessary to backlap reels and bed knives after grinding . This assures aproper match between the bed knife and the reel cuttingedges. It also establishes a “land” area on the reelblades. The Model 18556 Lapping Machine used for thespin drive on the Model 181 may be removed from theshelf and used as a back lapper on the floor.


36

SERVICE DATA

SKILL AND TRAINING REQUIRED FOR SERVICING

This Service Section of this manual is designed for technicians who have the necessary mechanical andelectrical knowledge and skills to reliably test and repair the 111/181 Reel Grinder. For those without thebackground, service can be arranged through your local distributor.

This section presumes that you are already familiar with the normal operation of the Grinder. If not, youshould read the front of this manual, or do the servicing in conjunction with someone who is familiar with itsoperation.

Persons without the necessary knowledge and skills should not remove the control box cover or attempt anyinternal troubleshooting, adjustments, or parts replacement.

If you have questions not answered in this manual, please call your distributor. They will contact the manu-facturer if necessary.

Throughout this manual we refer to torquerequirements as "firmly tighten" or the like. For morespecific torque values, refer to the informationbelow.

Bolts Going Into a Nut, or Into a Thread Hole inSteel.Refer to the table at the right.

Bolts Going Into a Thread Hole In AluminumUse the Grade 2 values in the table at the right.

Socket-Head Screws Going Into a Nut or SteelUse the Grade 8 values in the table at the right.

Machine ScrewsNo. 6 screws: 11 in.- lbs (0.125kg - m)No. 8 screws: 20 in. - lbs (0.23 kg - m)No. 10 screws: 32 in. - lbs (0.37 kg - m)

TORQUE REQUIREMENTS

GRADE 2 GRADE 5 GRADE 8

SMOOTH 3 MARKS 6 MARKS HEAD on HEAD on HEAD

1/4 In. 6 ft-lbs 9 ft-lbs 13 ft-lbs thread (0.8 kg-m) (1.25 kg-m) (1.8 kg-m)





37

MAINTENANCE

DAILY MAINTENANCE IS TO BE PERFORMEDBY THE OPERATOR. PERIODIC MAINTENANCEITEMS ARE TO BE PERFORMED BY YOURCOMPANY'S MAINTENANCE DEPARTMENT :

DAILY MAINTENANCE

On a daily basis, clean the grinder by wiping all areasdown.

On a daily basis, inspect the grinder for loose fastenersor components and tighten.

Contact your company's Maintenance Department ifdamaged or defective parts are found.

DO NOT USE COMPRESSEDAIR TO CLEAN GRINDINGDUST FROM THE GRINDER.

PERIODIC MAINTENANCE

1. Check gib plate adjustment in the grinder carriagebase monthly. See Troublshooting Section forAdjustment.

2. Check the free play in the grinding wheel shaftbearings once a year. Replace if excessive playexists.

3. Replace the four foam rail wipers (FIG. 40) every 6months of operation.

4. Check the brushes on the auto traverse drive motoronce every 24 months. Replace as necessary.

5. Lubricate the shafts and bearings at least everythree to six months. Follow the lubrication procedurelocated on page 38.

6. On a monthly basis spray a lubricant onto the verticaland horizontal screws and also the motorhead infeedand height adjustment screws.

FIG. 40

Wiper

CHANGING THE GRINDING WHEEL #3700090:When installing a new grinding wheel, it is important tofollow the instructions provided by the grinding wheelmanufacturer. These instructions are detailed onpage 3 of the manual.

BEFORE PERFORMING ANYMAINTENANCE PROCEDUREUNPLUG THE UNIT FROMITS POWER SOURCE.

38

MAINTENANCE (Continued)

LUBRICATION

Linear BearingsDo the following at least every six months:

1. Thoroughly clean the carriage rails and shaft seals. Wipethe shafts and seals thoroughly with a clean rag.

While cleaning, traverse the carriage several times toclean the full length of the rails.

2. Flood-spray shafts with WD-40 or an equivalentlubricant (do not use a Teflon-based lubricant) untillubricant drips off the shafts. Then run the carriage backand forth through its range of travel.

3. With a clean rag, wipe the excess lubricant from theshafts. Run the carriage back and forth through itsrange of travel, and wipe the shafts after eachtraverse. Repeat until the shafts feel dry.

IMPORTANT: If the machine will be shut down for more thanone month, flood the shafts and other appropriate parts withlubricant as outlined above, and leave the lubricant in placeuntil the unit will be used again. Then repeat the abovelubrication procedure before operating.

39

CARRIAGE LINEAR BEARING REPLACEMENT

STEP 1--Remove the four screws of one linear bearing and slidethe linear bearing off the end of the carriage shaft.STEP 2--Insert a new linear bearing onto the end of the carriageshaft with the tension adjustment screw pointing outward. SeeFIG. 41. Adjust the tension screw of the linear bearing so whenyou radially rotate the linear bearing around the carriage shaft thereshould be no free play between the linear bearing and the carriageshaft.NOTE: Tension is too tight if you feel a cogging action when yourotate linear bearing around the shaft. This cogging is from theskidding of the bearing on the shaft and indicates tension screw istoo tight.

Finally, sliding the bearing block back and forth should be a smoothuniform motion.

SETTING THE BEARING TENSIONCORRECTLY IS CRITICAL TO PROPERGRINDING. BEARINGS WHICH ARE TOOTIGHT OR TOO LOOSE WILL CAUSE POORGRIND QUALITY. ALSO, BEARINGS WHICHARE TOO TIGHT WILL HAVE SUBSTANTIALLYSHORTER LIVES AND MAY DAMAGE THESHAFT.

STEP 3--Slide linear bearing under carriage and attach with thefour screws.NOTE: Repeat Steps 1 thru 3 with the other two linear bearings.STEP 4--After all three linear bearings are reattached to the carriagecheck for correct bearing tension. The bearing tension is correctwhen you try to lift the carriage and can feel no carriage movement,which is free play up and down. The most dependable method ofchecking free play is to use a magnetic base dial indicator attached tothe traverse frame weldment and reading the vertical movementabove each bearing. This movement should be within .001" [.03 mm]Also, when pulling the carriage in the traversing direction, thereshould be only approximately a 3 lb force, with the belt clampdisengaged. To double check the assembly, slide the carriageassembly from "end of travel" to "end of travel", it should have veryuniform resistance through the full range of travel.

ADJUSTMENTS

FIG. 41

40

ADJUSTMENT (Continued)

TRAVERSE BELT TENSION

To adjust the tension on the traverse belt tighten the screwsand nuts located at the left side of the traverse belt. Tightenuntil the springs are fully compressed then back off 1-turn.If the springs are not tensioned equally, uneven loading onthe traverse system may cause parts to fail.

DO NOT OVERTIGHTEN.OVERTIGHTENING COULDDAMAGE THE BELT OR TRAVERSEDRIVE SYSTEM.

TRAVERSE CLAMP FORCE

If the traverse clamp is slipping during regular operationit may be necessary to tighten the clamp. To tighten,loosen the jam nut and screw the tip out. Move thetraverse belt out of the way and verify the clampeddistance from the tip to the clamping block (shoe). Lockin place by tightening the jam nut against the clampbeing careful not to move the tip.

CAUTION SHOULD BE USED ASADJUSTING THE TIP WILL AFFECTTHE SLIP LOAD AND COULD DAM-AGE THE CLAMP TIP, BELT ORTRAVERSE DRIVE SYSTEM.

GRIND MOTOR BELT TENSION

The belt must be tensioned so when the lock handleis locked the maximum belt deflection is .12 at a10lb./load.

FIG. 42

FIG. 43

41

TO ADJUST THE CARRIAGE GIB PLATE

The gib plate must be readjusted occasionally toeliminate free play. Otherwise, the grinding headcan move from side to side, and the reel may beground unevenly.

The gib must allow the carriage to be crankedfreely forward and back without any side play.See FIG. 44.

To adjust:

1. Crank the carriage all the way forward(toward the operator position).

2. Tighten the front gib screw until the carriagehas no side play but the horizontalhandwheel can still be cranked.

3. Crank the carriage gradually back (awayfrom the operator position), and adjust theremaining gib screws as you go.

FREQUENT OVERLOADING ANDCIRCUIT TRIPPING

The magnetic starter is factory set at a 12 AMPrating. If your motor is frequently shutting down,consult the factory. The main control powersource is for a 15 AMP supply circuit. Seemachine set up for explanation.

ADJUSTMENTS (Continued)

FIG. 44

Manual/AutoSelector

Manual Reset

Overload Sensor

FIG. 45

42


PROXIMITY SWITCH

For the proximity switch to perform properly and reversethe direction of the carriage at each end of the rails, adistance of 4 mm [.156”] to 6mm [.234”] needs to bemaintained between the proximity sensing bracket andthe proximity switch.

NOTE: Light on proximity activates when metal crossesover the switch.

ALIGNMENT FIXTURE ADJUSTMENT

The body of the dial indicator should be flush with thecasting it is mounted in. The anvil should be able to bedepressed fully without touching the casting. To adjustproperly, loosen the set screw in the indicator mountingcasting and adjust accordingly. See FIG. 47.

Tighten dial indicator set screw enough to lightly hold theindicator in place. Never overtighten so plunger does nothave free travel.

SET UP GAUGE ADJUSTMENT

There should be no backlash in the fine adjustmentscrew on the set up gauge slide. See FIG. 48. Adjusthex nut tight so conical washer is completely com-pressed then back off 1/2 turn.

Make sure the set screw is compressing the nylon plugtightly on the vertical adjusting screw.

FIG. 46

FIG. 48

FIG. 47

43


TO ELIMINATE CARRIAGE INFEED BACKLASHIf there is backlash in the carriage infeed handwheel (SeeFIG. 49), there are two adjusting points to check:

1. Conical washers behind the shaft adjusting nut:A. Unscrew the shoulder bolt.B. Hold the horizontal handwheel, and turn the shaft

adjusting nut counterclockwise until the conicalwashers are touching each other. Continueturning the nut counterclockwise until the nextnotch is centered over the shoulder-bolt hole.Then turn the nut one notch (40 degrees) further.

C. Reinstall the shoulder bolt to lock the nut in position.

2. Washers behind the handwheel:A. Loosen (about one-half turn) the set screw holding

the handwheel to the shaft.B. Tighten the hex nut which secures the handwheel

to 100 in.-lbs [1.15 kg-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. 50.Reajust the hex nut if necessary.

D. Tighten the set screw holding the handwheel to theshaft.

FIG. 50

Shoulder Bolt & Brass Nut

FIG. 49Carriage Infeed Handwheel

44


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 (R) compensation (COMP).IR COMP adjusts the output voltage of the drive which balances load to motor RPM. Regulation of a traversemotor may be improved by slight adjustment of the IR COMP trim pot clockwise from its factory-set position.Overcompensation causes the motor to oscillate or to increase speed when fully loaded. If you reach such apoint, 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 90volts 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 forboth 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 stopposition after a limit switch is actuated. The DWELL TIME range is adjustable from 0 - 4 seconds. A DIPswitch setting of 0 sets the DWELL TIME to 0 seconds, while a setting of 8 sets the DWELL TIME to 4 sec-onds. Dwell time is preset to #2 setting for a 1 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 LIMIT 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.

3:00

12:0

0

6:00

9:00

PotentionmeterClock Orientation

45

TROUBLE SHOOTING

Troubleshooting:1. Ask Questions???2. Double check the easy things first.3. Establish a sequence.4. Use common sense.5. Use the manual.6. Safety First!!!

Ask Questions???

What does it do right? What does it do wrong?What won’t it do? Did it fail gradually?Did it fail suddenly? Did it ever work right?What does the failure look like?Did it smoke? Was there a smell?Were there any different sounds?

Electrical Control Boxes:

Double check the following to assure that something assimple as a loose connection is not the source of theproblem. When a grind motor starts, it draws up to 55amps for a very brief period of time. A loose connectioncannot carry enough current to start the motors.

1. Double check the easy things first!!!2. Tighten all screws (wire connections).3. With the power off, push all buttons (on contactors,

motor starters and relays) .4. With the power off, push on all relays (to assure they

are seated in their sockets).5. Reset all circuit breakers.

Then try again...

46

TROUBLE SHOOTING ELECTRICAL

--POSSIBLE CAUSE-- --REMEDY-- --REASON----PROBLEM--

A--System start Switch (SSS)is not on

B--Main power source breakeris tripped, power source switchis off, or grinder is not pluggedin.

C--Machine circuit breakers arenot switched to the on position.

D--Power not getting throughthe motor contactor

E--Burned out motor

A-- Low voltage coming intomachine and tripping the lowvoltage relay (LVR)

A-- Direction switch on back ofSpin drive in not selected, orspeed pot is at zero.

B-- Spin drive is defective orplug on electrical panel hasmalfunctioned.

A-- Speed pot is turned downlow, carriage not engaged tobelt

B-- DC motor drive board hasmalfunctioning.

A-- Travel limit proximity switchnot set at proper height.

B-- The two travel limit proxim-ity switch positions are re-versed.

Grinding motordoes not function(no apparentpower to ma-chine)

Turn on grindingmotor and itimmediatelyshuts off.

Spin drive/Backlapper willnot run.

Grinding carriagedoes not traverse

Carriage doesnot changedirection

115 volt single phase ACpower source required

This machine is equippedwith a LVR. If voltage is toolow at the outlet, or anextension cord is used, themachine will turn itself off.

A DC motor control boardcontrols the traverse system.Part number 3707550.

There is a designated lefthand a right hand proximityswitch

Pull Emergency stop switchout to turn on the grinder.

Reset breaker, turn switch on,or plug machine in.

Set circuit breakers to the onposition.

With a voltmeter set to ACvoltage, check terminals 1 and2 for 115 Volt AC. If no voltagereplace contactor

Replace Motor. Part #3707991

Check power source to see ifadequate. Don’t use anextension cord.

Check the direction switch onthe back of the spin drive. Itmust be up or down for the spindrive to operate. Turn the potlocated on the spin driveclockwise.

Plug spin drive into a 120 V15amp outlet to verify it isworking. With voltmeter checkreceptacle in the back of theelectrical box.

Engage the traverse clamp andturn speed pot clockwise untilyou can see movement

Check the traverse board fuse.Check all traverse board pot areset too the proper settings.Check wiring for looseness.

Make sure there is about 3/16clearance between the top ofthe proximity switch and thetravel flag.

Reverse the placement of thetwo switches and rechecktravel position.

47

TROUBLESHOOTING (Continued) TRA VERSING

--POSSIBLE CAUSE-- --REMEDY-- --REASON----PROBLEM--C--Damage proximity switch orloose wire

A--Carriage is binding on rails.There is an obstruction. Travelpulleys are misaligning.

B--Settings of the pots on theDC traverse drive board are notcorrect.

C--Travel speed set too low.

The lights coming on shows theproximity switch is gettingelectrical contact.

Check for looseness in thewire. Check for any damage toswitch or wire. Check functionof proximity switch by passinga metal object over the sensorand verify sensor lights turn on.

Clear any obstruction in thepath of the carriage travel.Check and align carriage onlinear guides. Check thetraverse pulley alignment.

Check setting by referring toPotentiometer adjustmentsection.

Turn up the travel speed.

Carriage move-ment not smoothor is erratic

48



A--Blown fuse.

B--No voltage going to motor.

C--Bad traverse motor.

Traverse motordoes not work.

Extremely heavy grindingcuts cause excessiveloading of the motor.

Worn and binding actuatorscauses heavy loading tomotor.

Grinding grit over a period oftime does get into the linealbearings and causesexcessive drive torque ofcarriage.

This checks to see thatvoltage is getting to thecontrol board.

A short brush does notmake an adequate electricalconnection to run theelectrical motor. NOTE:Brushes are long lived andseldom need replacing.

Replace the 3 amp slo-blo fuseon the control board anddecrease stock removal rate.

Replace actuator bearings ifthey are worn and do not rotatefreely. (For more detail, seeactuator maintenance in theadjustment section of themanual.)

Replace the lineal bearings inthe main carriage. Carriageshould traverse freely with a 3lb. maximum loading. Alsocheck for excessive bearingpreload. (For more detail seecarriage bearing replacement inthe adjustment section of themanual.)

Check for 90 volt DC at thecircuit board leads going to themotor. Across terminals A1and A2, check reading with avoltage meter. When there isvoltage from the circuit boardbut DC motor does not run,check wiring and connections.The voltage reading varies withspeed pot setting.NOTE: Make sure speed potsetting is towards the maxi-mum dial reading for 90 volts.Check for incoming voltage atL1 to L2 for at least 105 VoltsAC Red power light is on.

Remove the brushes one at atime and maintain orientationfor reinsertion. See if brush isworn short 3/8" [9.5 mm]minimum length, and look atwear pattern on commutatorfor arcing. Replace brushes ifnecessary. Replace motor ifbrushes are good.Remove wires from A1 to A2from the spin motor. Checkwith the ohm meter for "0"ohms across the white andblack wires.

49


--POSSIBLE CAUSE-- --REMEDY-- --REASON----PROBLEM--A--Wiring hookup to potentiom-eter is improper. (If compo-nents have been replaced.)

B--Defective speed controlpotentiometer.

C--Main circuit board dial potsettings not correct. (If boardhas been replaced.)

Traverse speedcontrol goes atone speed only.

Wrong wire hookup effectstraverse control. Reversing redand black wires topotentiometer the DC motor willrun at zero speed but maximumwill be too slow. Reversing redand white wires does not affectspeed control.

Traverse Drive ControlPin #8 to 7Pot Full CCW Pot Full CW

0 VDC 9.75 VDCPin #8 to 9Pot Full CCW Pot Full CW 9.75 VDC 0 VDCIf Yes, pot is O.K.If No, go to step below

Check for 10,000 ohmsred to white wiresFull CCW--10,000 ohmsFull CW--0 ohmsRed to black wiresFull CCW--0 ohmsFull CW--10,000 ohmsIf Yes, pot is O.K.If No, replace potentiometer.Wiper inside of potentiometercontrols speed. Wiper may bebad and not making contact.

Minimum and maximum potsettings effect traverse speed.

Check potentiometer wiring forproper hookup. See that speedpot is wired per electricaldiagram.

Check Potentiometer on controlpanel.

Check Petentiometer for 10,000ohms.Remove three wires fromTraverse Drive Controlred from term #8white from term #7black from term #9

Check all pot settings on circuitboard as shown in wiringdiagram. (See adjustmentsection Traverse Motor ControlBoard Settings.)

50

Driving torque is lostbecause the belt is slipping.

Grinding grit over a period oftime does get into the linealbearings and causeexcessive drive torque ofcarriage. Abrasive noise isdetectable when excessivegrit is in the lineal bearings.

When bearing preload is tootight, it causes excessiveloading to drive the carriage.When lineal actuator isdisengaged, the propertraverse load 2 to 3 lb. Usea tension scale to check.(A general guide only.)

NOTE: Check with linearactuator released.



A--Traverse belt is slipping.

B--Lineal bearings in carriagedo not rotate freely.

A--Lineal bearings in thecarriage are set too tight.

Carriagetraversing (variesspeed) whilegrinding.

Traverse speed istoo slow.

Adjust clamping tip belttension. See Traverse clampforce in Adjustments Section.

Replace the lineal bearings inthe main carriage. (For moredetail, see lineal bearingreplacement in the adjustmentsection of the manual.)

Readjust bearings for propertension. (For more detail seelineal bearing replacement inthe adjustment section of themanual.)

--MECHANICAL--

51

TROUBLESHOOTING (Continued) STRAIGHTNESS OF GROUND REEL

--PROBLEM--

Reel ground in a concave, convex shape or irregularshape.There are two methods of checking reel outside diameterstraightness. One method is by using a precision straight edgeand the second method is using the reel set up gauge.

1. Inspect the reel by using a precision straight edge to checkstraightness (use a .002 maximum shim). Use a .002 shim stockand check full length between straight edge and reel.2. Inspect the reel by using the set up gauge while mower unitis in the spin grinder (see reel set up gauge instructions inoperating instruction section).


A--Too heavy a grind on thefinal grinding pass.

B--Overhead clamps and fixtureclamps are not holding mowerunit tight.

C--Square tubing tooling bar forfixture holding is not rigid.

See Above. For close tolerance inroundness the sparking outprocess is critical on finalgrinding of a reel.

To eliminate reel movementduring grinding.

To eliminate reel movementduring grinding.

Infeed the grinding head for onlyapproximately .002 stockremoval in final two passes andlet the grinding wheel sparkout. For sparking out ingrinding process alwaystraverse grinding head 20passes with no grinding headinfeed. Set traverse at slowspeed on dial setting approxi-mately 25 percent for finalgrinding sparkout. NOTE: Thisprocess refers to sparkout, butwhat we are looking for is anear spark out, approximately a99% reduction in grinding sparkfrom normal grind. Do not runsparkout until you have nosparks because this could bean extremely extended period.

Tighten down eight lockinghand knobs. Four hand knobsfor the square tube top andbottom clamps, two knobs forthe mower holding clamps, andtwo knobs for the mower clampswivel. Check alignment ofoverhead clamp so there is nobinding before locking down ofhand knobs.

The pivot end is bolted station-ary and must be tight. Onadjustable end, tighten slideend locking handles one forvertical and one for horizontallocking.

52



D--Grinding wheel head moving.

E--Gibs loose on carriage.

F--Tooling bar support bracketsare loose.

Reel ground in aconcave , convexshape or irregu-lar shape.

To prevent grinding head frommoving.

The two adjusting arm lockswill not hold the motor baserigid when locked downtightly.

To prevent grinding head frommoving during grinding.

When the supports are notheld tight to the square tube,the reel can move duringgrinding.

Loose centers effect grindingaccuracy.

Clamps must be tight toprevent movement duringgrinding.

Tighten up two head mountingbolts, torque screws to 19 ft. lbs.

There are two adjusting handlesto tighten. They are locatedon the slots on the adjustingarm. There is also one setscrew with a nylon plug fortension for grinding wheelvertical height adjustmentlocking screw.

Tighten gib screws to preventmovement.

Crank the motor slide baseforward and adjust the gibscrews. Then crank the motorslide base all the way back toadjust the final gib screws.

All reels are mounted with twoV-support brackets or two centersupport brackets. Be sure theyare tight to the square toolingsupport tube in horizontal andvertical plane. Tighten thehorizontal locking screws firstfirmly pull over to the side of thetooling support tube. Thentighten the vertical lockinghandle to pull down the supportsto the top of the tooling supporttube. Last, retighten the verticallocking hand knob.

When using center supports,check to see if the fixed center isscrewed in tight using a wrench.The adjustable center is to belocked tight with locking knobs.

Vise chain clamps are to havesufficient tension.

53



H--Carriage has varying load ineither direction from grindinggrit buildup inside of linearbearings.

I--Rails not straight. Check railtowards the reel side forstraightness in the horizontalplane.

J--Rails not straight verticalplane straightness of rails.

Reel ground in aconcave , convexshape or irregu-lar shape.

With grit buildup unevenloading to linear bearingscan effect the straightness ofgrinding.

Linear bearings needreplacement caused fromexcessive grinding gritbuildup. Grinding grit buildupin the linear bearings cancause uneven carriagemovement. With enough gritbuildup over a period of time,bearings may be noisy.

Rail straightness directlyeffects grind straightness ofoutside diameter of the reelin the horizontal plane.

This plane is not as criticalfor reel grinding accuracy,but still must be held totolerance listed to hold grindstraightness of outsidediameter of the reel.

With belt clamp released fromthe traverse belt, check for a 2to 3 lb. traversing load in bothdirections.

When there is a varying load orexcessive noisy bearings, havelinear bearings replaced. (Formore detail, see replacingcarriage linear bearing in theadjustment section.)

Use a three foot long precisionstraight edge, and using afeeler gage, check for amaximum of .002 in straight-ness at the front edge of thefront rail. (Consult factory.)

Use a three foot long precisionstraight edge, and using afeeler gage, check for amaximum of .003 in straight-ness at the top edge of thefront rail. (Consult factory.)

54


--PROBLEM--

Roundness of reel varies: Reel blades are high or low.(Use set up gage to check roundness; see set up gage instruc-tions in manual.) The high and low indicator readings on the reeloutside diameter should not vary over .001.


Did not sparkout properly onfinal grinding pass.

A--Gibs loose on carriage.

B--Grinding wheel head moving.

See Above.

Grinding stockremoval fromreel irregularwhen reversingdirections ofgrind.

For close tolerance inroundness the sparking outprocess is critical on finalgrinding of a reel.

NOTE: For other trouble-shooting, see B thru K insection: Problem--Reelground in a concave,convex or irregular shape.

The rule of thumb is ahigher spin drive RPM anda slower traverse speedgives a higher quality offinish required in the finalgrind.

To prevent grinding headfrom moving during grinding.

To prevent grinding headfrom moving or pivotingduring grinding.

When motor base and slidebase mounting surface arenot aligned to each other,the two adjusting arm lockswill not hold the motor baserigid.

Infeed approximately .002 (onthe infeed dial) in final passand let the grinding wheel sparkout. For sparking out ingrinding process alwaystraverse grinding head 20passes with no grinding headinfeed. Set traverse at slowspeed on dial setting approxi-mately 25 percent for finalgrinding sparkout. The spindrive to be towards the higherRPM. (See chart in OperatingInstruction Section of themanual.) NOTE: This processrefers to sparkout, but what weare looking for is a near sparkout, approximately a 99%reduction in grinding spark fromnormal grind. Do not runsparkout until you have nosparks because this could bean extremely extended period.

Tighten gib screws to preventmovement. Crank the motorslide base forward and adjustthe gib screws. Then crank themotor slide base all the wayback to adjust the final gibscrews.

Tighten up head mounting boltsthat holds the head in a verticallocked position, torque screwto 19 ft. lbs.

There are two hand adjustingknobs to tighten. They are locatedon the slots of the adjusting arm.Also, the set screw with a nyonplug located on the verticaladjustment shaft should be tight.

55



C--Carriage has varying load ineither direction from grindinggrit buildup inside of linearbearings.

D--Carriage has vertical move-ment.

Too heavy a grind on finalgrinding pass.

Reel position not parallel tocarriage travel.

Grinding stockremoval fromreel irregularwhen reversingdirections ofgrind.

Too heavy a burron cutting edgeof reel blades.

Cone shape ofreel.

With grit buildup unevenloading to linear bearingscan effect the straightness ofgrinding.

Linear bearings needreplacement caused fromexcessive grinding gritbuildup. Grinding grit buildupin the linear bearings cancause uneven carriagemovement. With enough gritbuildup over a period of time,bearings may be noisy.

Proper linear bearing adjust-ment is needed to eliminatezero vertical movement.

Light grinds in final passescreate less of a burr andwould remove some ofprevious burrs from heavygrind passes.

Reel hub has to be parallelto carriage traverse rails soreel is not cone shaped.

With belt clamp released fromthe traverse belt, check for a 2to 3 lb. traversing load in bothdirection. When there is avarying load or excessive noisybearings, have linear bearingsreplaced. (For more detail, seereplace carriage linear bearingsin the adjustment section.)

Adjust linear bearings. (Formore detail, see adjustmentsection for proper adjustment.

Make two infeeds of .002 (onthe infeed dial) each for grind-ing, then let the grindersparkout. For sparking out ingrinding always traversegrinding head with no infeed forfinal 20 passes. Use a hard-wood board or a deburring toolis desired for complete burrremoval. The spin drive to betowards the higher RPM. (Seechart in Operating InstructionSection of the manual.) NOTE:This process refers to sparkout,but what we are looking for is anear sparkout, approximately a99% reduction in grinding sparkfrom normal grind. Do not runsparkout until you have nosparks, because this could bean extremely extended period.

Use reel setup gage proceduretouching off on reel hub to zeroout the reel position from eachend. (For more detail, see reelsetup gage procedure inmanual.)

56



Large finger guide is mountedon backwards.

Large finger guide is too wide.

Relief grind onthe reel bladesdo not go fulllength.

The relief will be ground fulllength on the reel at the oneend but on the opposite endit will drop off too soon andleave a band 3/4" [.75] long.NOTE: 3/4" is the samewidth of the grinding wheel.

Smaller finger will allowtraversing complete length ofreel.

Mount the large finger guideso that the corner of thewheel doing the grinding andthe high point of fingerguides are in the samelocation. (For more detail,see relief grinding section inoperating instructions of themanual.)

Use smaller finger.

57

58

PARTS LIST 18561 REEL SET UP GAUGE ASSEMBLY

59

PARTS LIST 18561 REEL SET UP GAUGE ASSEMBLY

DIAGRAM NO. PART NO. DESCRIPTION

1 .................... 6009089 ....................Slide, Setup Gage2 .................... 18003 ........................Tube, Gage Slide3 .................... 6009599 ....................Tee Knob Assembly 1.75 lg.4 .................... 6009049 ....................Block, Adjust Slide5 .................... K250001 ....................1/4 Flat SAE Washer6 .................... 7469533 ....................T-Knob Assembly .88 Long7 .................... J257100.....................Locknut--Nylon 1/4-20 Full8 .................... 3579123 ....................Dial Indicator9 .................... C250420 ....................SKSS, CP-PT, 1/4-20 x 1/4"10 .................. 6009054 ....................Bar, Indicator Stop11 .................. 3709278 ....................Spring--Compression12 .................. 3969109 ....................Spring Guide Rod13 .................. 3709336 ....................Push on Ring14 .................. 3109022 ....................Saddle Stop15 .................. 6009598 ....................Tee Knob Assembly16 .................. 6009055 ....................Rod, Gage Alignment17 .................. 3708540 ....................Domed Anvil 3/818 .................. C251220 ....................SKSS, CP-PT, 1/4-20 x 3/4"19 .................. J252000.....................1/4-20 Jam Nut20 .................. 6009050 ....................Clamp, Spring Loaded21 .................. C310420 ....................SSS 5/16-18 x 1/4" CP-PT22 .................. 3579109 ....................Nylon Plug23 .................. 3708453 ....................Shoulder Bolt 1/4" D x 3/4"24 .................. 3708175 ....................Spring25 .................. 3708674 ....................Set Collar 1/4 with SSS26 .................. 6009057 ....................Square27 .................. 6009597 ....................Tee Knob Assembly 2.25 Lg.28 .................. 3708154 ....................Plug--Spacer29 .................. 6009596 ....................Tee Knob Assembly, Nylon

60

18503 GRINDING HEAD ASSEMBLY EXPLODED VIEW

61

PARTS LIST 18503 GRINDING HEAD ASSEMBLY

1 ..... B190831 .....10-32x1/2 Socket Head Cap Screw2 ..... B191233 .....10-32x3/4 Pan Head Machine Screw3 ..... B250816 .....1/4-20x1/2 Button Head Cap Screw4 ..... B250819 .....1/4-20x1/2 Truss Head Machine Screw5 ..... B251616 .....1/4-20x1 Button Head Cap Screw6 ..... B255011 .....1/4-20x3-1/8 Socket Head Cap Screw7 ..... B310811 .....5/16-18x1/2 Socket Head Cap Screw8 ..... B311001 .....5/16-18x5/8 Hex Head Cap Screw9 ..... B311401 .....5/16-18x7/8 Hex Head Cap Screw10 ... C250420 .....1/4-20x1/4 Socket Setscrew Cup Pt.11 ... C251020 .....1/4-20x5/8 Socket Setscrew Cup Pt.12 ... C252420 .....1/4-20x1-1/2 Socket Setscrew Cup Pt.13 ... C310420 .....5/16-18x1/4 Socket Setscrew Cup Pt.14 ... C372020 .....3/8-16x1-1/4 Socket Setscrew Cup Pt.15 ... H252802 ..... .25 Dia x 1.75Lg Roll Pin16 ... H311602 ..... .31 Dia x 1 Lg Roll Pin17 ... H372002 ..... .38 Dia x 1.25 Lg Roll Pin18 ... H502001 ..... .50 Dia x 1.25 Lg Dowel Pin19 ... J251000 ......1/4-20 Hex Nut20 ... J252000 ......1/4-20 Hex Jam Nut21 ... J257000 ......1/4-20 Thin Locknut22 ... J371100 ......3/8-24 Hex Nut23 ... J377000 ......3/8-16 Locknut Jam Nylon24 ... J377100 ......3/8-16 Locknut Hex Nylok Full25 ... J502100 ......1/2-20 Hex Jam Nut26 ... J627200 ......5/8-18 Locknut Jam Nylon27 ... K190001 .....#10 Flat Washer28 ... K250001 .....1/4 Flat Washer29 ... K251501 .....1/4 Split Lock Washer30 ... K310001 .....5/16 Flat Washer31 ... K311501 .....5/16 Split Lock Washer32 ... K370001 .....3/8 Flat Washer33 ... K371501 .....3/8 Split Lock Washer34 ... 18067 .........Traverse Clamp Bracket35 ... 80335 .........Destaco Clamp36 ... 3579109 ......Nylon Plug 3/16 Dia.37 ... 3589081 ......Spacer .191 ID x .438 OD x .43 Lg38 ... 3649018 ......Outer Flange39 ... 3700090 ......Grinding Wheel 6” Dia x .75” Wide40 ... 3707935 ......Cord Clip41 ... 3708148 ......Handwheel 4.5 Dia42 ... 3708213 ...... .24 OD x .62 Lg Comp. Spring43 ... 3708458 ......Sharp Warning Decal44 ... 3708461 ......RPM Warning Decal45 ... 3708561 ......3/8-16x1.56Lg Adj. Handle46 ... 3709062 ......Conical Washer47 ... 3709304 ......Thrust Washer

DIA. PART PARTNO. NO. NAME

48 ... 3709370 ......Handle49 ... 3709437 ......3/8-16 Adj Handle50 ... 3709463 ......Rod End Bearing51 ... 3709620 ......Conical Washer52 ... 3709764 ......V-Belt53 ... 3709809 ...... .375 Dia x .38 Lg Shoulder Bolt54 ... 3809047 ......Clear Indicator55 ... 3889059 ......1.13 OD 2.0 Lg Compr. Spring56 ... 3889088 ...... .62 Bore Pulley57 ... 3889509 ......Belt Guard Weldment58 ... 3969027 ......Adjusting Arm59 ... 3969057 ......Reel Guide Finger60 ... 3969058 ......Guide Finger Support61 ... 3969065 ...... .406ID x 1Lg Steel Spacer62 ... 4509385 ......Rotation Decal63 ... 6009024 ......1/2-10 ACME Backlash Nut64 ... 6009025 ......Gib Plate65 ... 6009026 ......Tapped Pivot Sleeve66 ... 6009027 ......ACME Adjusting Shaft67 ... 6009029 ......Keeper Plate68 ... 6009030 ......Shaft Locking Stud69 ... 6009031 ...... .386 ID x .56Lg Steel Spacer70 ... 6009034 ......Calibrated Ring71 ... 6009037 ......Wheel Guard72 ... 6009041 ......Angle Locking Pin73 ... 6009044 ......4.50 Dia Modified Handwheel74 ... 6009083 ......Grinding Head Slide Base75 ... 6009084 ......Grinding Head Pivot Base76 ... 6009088 ......Grinding Head Swivel Base77 ... 6009136 ......Feed Screw Guide78 ... 6009216 ......Rear Belt Guard79 ... 6009218 ......ACME Adjusting Shaft80 ... 6009535 ......Tee Handle Assembly81 ... 6009587 ......Grinding Head Arbor Assembly82 ... 6009598 ......1/4-20 x .5Lg Tee Knob Assy.83 ... 3708448 ......Electrical Warning Decal84 ... 3707155 ......Black Wire Nut w/Setscrew85 ... 6009195 ......Grind Motor Cord86 ... 3707976 ......3/8 Cable Connector87 ... 3709372 ...... .50 Dia Hole Plug88 ... 3707991 ......3/4 HP Motor

DIA. PART PARTNO. NO. NAME

62

18504 CARRIAGE ASSEMBLY EXPLODED VIEW

63

PARTS LIST 18504 CARRIAGE ASSEMBLY


1 .................... B191011 ....................#10-24x5/8 Socket Head Cap Screw2 .................... B250601 ....................1/4-20x3/8 Hex Head Cap Screw3 .................... B252016 ....................1/4-20x1-1/4 Button Head Socket Cap Screw4 .................... B253216 ....................1/4-20x2 Button Head Socket Cap Screw5 .................... J252000.....................1/4-20 Hex Jam Nut6 .................... K251501 ....................1/4 Split Lockwasher7 .................... 18065 ........................Carriage Base8 .................... 18571 ........................Traverse Clamp Assembly9 .................... 28187 ........................Traverse Clamp Block10 .................. 28188 ........................Traverse Clamp Spacer11 .................. 28189 ........................Clamp Support Block12 .................. 3709044 ....................Ball Bushing Bearing13 .................. 3969063 ....................Sponge Wiper Holder14 .................. 3969064 ....................Foam Wiper15 .................. 50310 ........................Belt Clamp Tip

64

27544 CHANNEL & TRAVEL ASSEMBLY EXPLODED VIEW

65

1 ........................................... B160607 ................... 8-32 x 3/8 Button Head Socket Cap Screw2 ........................................... B251211 ................... 1/4-20 x 3/4 Socket Head Cap Screw3 ........................................... B251611 ................... 1/4-20 x 1/4 Socket Head Cap Screw Full Thread4 ........................................... B252411 ................... 1/4-20 x 1-1/2 Socket Head Cap Screw5 ........................................... B256411 ................... 1/4-20 x 4 Socket Head Cap Screw6 ........................................... B371616 ................... 3/8 - 16 x 1 Button Head Socket Cap Screw7 ........................................... J257000 ................... 1/4-20 Locknut Thin8 ........................................... K161501 ................... #8 Lockwasher Split9 ........................................... K251501 ................... 1/4 Lockwasher Split10 ......................................... K371501 ................... 3/8 Lockwasher Split11 ......................................... 28192 ....................... Support - Travel Pulley12 ......................................... 28195 ....................... Channel - Machined13 ......................................... 28197 ....................... Guard - Travel RH14 ......................................... 50309 ....................... Shaft- Travel Pulley15 ......................................... 50354 ....................... Pulley - Cog Drive16 ......................................... 50361 ....................... Motor Assembly - Travel W3417 ......................................... 50363 ....................... Guard - Traverse Pulley18 ......................................... 55553 ....................... Idler Pulley Assembly19 ......................................... 80355 ....................... Washer - Thrust .75ID x 1.25OD20 ......................................... 80375 ....................... Belt -Cog21 ......................................... 3708658 ................... Spring - Compr Danly22 ......................................... 3709331 ................... Ring - Retaining Ext23 ......................................... 6509063 ................... Shaft - Carrier

PARTS LIST 27544 CHANNEL & TRAVEL ASSEMBLY


66

18506 MOWER SUPPORT ASSEMBLY EXPLODED VIEW

67

PARTS LIST 18506 MOWER SUPPORT ASSEMBLY


1 .................... A313601 ....................5/16-18x2-1/4 Hex Head Cap Screw Full2 .................... C250420 ....................1/4-20 x 1/4 Long Socket Set Screw3 .................... B371201 ....................3/8-16x3/4 Hex Head Cap Screw4 .................... B371616 ....................3/8-16x1 Button Head Socket Cap Screw5 .................... C311220 ....................5/16-18x3/4 Socket Setscrew Cup Pt.6 .................... H371602 .................... .375 Dia. x 1 Lg Roll Pin7 .................... J371000 .....................3/8-16 Hex Nut8 .................... J377000 .....................3/8-16 Locknut Jam Nylon10 .................. K371501 ....................3/8 Split Lockwasher11 .................. 18573 ........................Tooling Bar Weldment12 .................. 3109026 .................... .406 ID x .75Lg Steel Spacer13 .................. 3579109 ....................3/16 Dia. Nylon Plug14 .................. 3589106 ....................Flat Washer15 .................. 3708262 ....................5/16-18 T-Knob16 .................. 3708393 ....................3.50 Dia Handwheel17 .................. 3709062 ....................Conical Washer18 .................. 3709258 ....................Bumper19 .................. 3709304 ....................Thrust Washer20 .................. 3709437 ....................3/8-16 Adj. Handle21 .................. 3709808 ....................Flat Washer22 .................. 3889066 ....................Center Stand Lock24 .................. 3969094 ....................Top Clamp25 .................. 3969095 ....................Bottom Clamp26 .................. 3969096 ....................Clamp Bar27 .................. 3969160 ....................Shaft Locking Stud28 .................. 3969162 ....................Clamp Lip29 .................. 3969547 ....................Mower Clamp Weldment30 .................. 6009020 ....................Adjustable Center31 .................. 6009027 ....................ACME Adjusting Shaft32 .................. 6009035 ....................Shaft Locking Stud33 .................. 6009221 ....................Adjustable Center Stand34 .................. 6009222 ....................Center Stand - Fixed35 .................. 6009081 ....................Cross Slide36 .................. 6009082 ....................Cross Slide Support37 .................. 6009095 ....................Slide Shaft38 .................. 6009517 ....................Fixed Center Assembly39 .................. 6009555 ....................3/8-16x1.5Lg T-Knob40 .................. 6009566 ....................3/8-16x3.25Lg T-Knob41 .................. 6009577 ....................3/8-16x2.25Lg T-Knob

68

18505 MAIN BASE ASSEMBLY EXPLODED VIEW

69

PARTS LIST 18505 MAIN BASE ASSEMBLY


1 .................... B190811 ....................10-24X1/2 Socket Head Cap Screw2 .................... B371616 ....................3/8-16x1 Button Head Socket Cap Screw3 .................... B502401 ....................1/2-13x1-1/2 Hex Head Cap Screw4 .................... J191000 .....................10-24 Hex Nut5 .................... K191501 ....................#10 Split Lockwasher6 .................... K370001 ....................3/8 Flat Washer7 .................... K371501 ....................3/8 Split Lockwasher8 .................... 18074 ........................181SR Neary Decal9 .................... 18502 ........................Frame Weldment10 .................. 18565 ........................Lapper Shelf Weldment11 .................. 28182 ........................Channel Support Bar12 .................. 80186 ........................Control Box Bracket13 .................. 3708419 ....................Wave Spring14 .................. 3708421 ....................Flat Washer15 .................. 3708662 ....................3/8-16 T-Knob16 .................. 27107 ........................RH Proximity Switch17 .................. 27106 ........................LH Proximity Switch

70

18507 CARTON ASSEMBLY EXPLODED VIEW

71

PARTS LIST 18507 CARTON ASSEMBLY

DIAGRAM NO. PART NO. DESCRIPTION1 .................... A313601 ....................5/16-18x2-1/4 Hex Head Cap Screw Full2 .................... 3649078 ....................Clamp Tip3 .................... B370801 ....................3/8-16x1/2 Hex Head Cap Screw4 .................... K371501 ....................3/8 Split Lockwasher5 .................... 18004 ........................Lapper Bracker Weldment8 .................... 3969017 ....................Mower Support9 .................... 3889066 ....................Center Stand Lock10 .................. 6009555 ....................3/8-16x1.5Lg T-Knob11 .................. 18100 ........................Manual12 .................. 3702508 ....................Dressing Stick13 .................. 3709298 ....................Vise Grip Chain Clamp14 .................. 6009133 ....................Guide Finger15 .................. B371601 ....................3/8-16x1 Hex Head Cap Screw16 .................. J317100 .....................5/16-18 Locknut Nylon Full17 .................. J377100 .....................3/8-16 Locknut Nylon Full18 .................. R000454 ....................Flat Washer19 .................. 3649005 ....................Chain20 .................. 3709316 ....................5/16-18x3Lg U-Bolt21 .................. 6009011 .....................Spreader Bar22 .................. 6009102 ....................Grab Hook23 .................. R000377 ....................3/16 x 3/4Lg Square Key24 .................. C250620 ....................1/4-20x3/8 Socket Setscrew Cup Pt.25 .................. 3709073 ....................Retaining Ring26 .................. 3709584 ....................Flange Coupler27 .................. 6009051 ....................1/2 Square x 3.5Lg Drive Adapter28 .................. 6009052 ....................Adapter29 .................. 6009217 ....................Drive Coupler Adapter30 .................. 6009598 ....................1/4-20x.50Lg T-Knob31 .................. 3709585 ....................Sleeve Coupler32 .................. 18053 ........................1/2 Square x 6.0Lg Drive Adapter

72

18558 WINCH & BOOM ASSEMBLY EXPLODED VIEW

73

PARTS LIST 18558 WINCH & BOOM ASSEMBLY


1 .................... B372801 .................... 3/8-16X1-3/4 Hex Head Cap Screw2 .................... B375601 .................... 3/8-16x3-1/2 Hex Head Cap Screw3 .................... J371000.....................3/8-16x Hex Nut4 .................... J377100.....................3/8-16 Locknut Nylon Full5 .................... K370001 .................... 3/8 Flat Washer6 .................... K371501 .................... 3/8 Split Lockwasher7 .................... 3708645 ....................Winch with 11’ Handle8 .................... 18566 ........................Boom Weldment9 .................... 3708456 ....................Boom Capacity Warning Decal10 .................. 3709407 ....................Hook & Cable Assembly11 .................. 3709795 ....................Pulley12 .................. 6309036 ....................Boom Capacity Warning Decal13 .................. 6309037 ....................Winch Warning Decal

74

27509 CONTROL BOX COMPONENTS EXPLODED VIEW

75

PARTS LIST 27509 CONTROL BOX COMPONENTS

DIAGRAMNUMBER

PARTNUMBER DESCRIPTION

1 ........................................... 27112 ....................... Mini Contactor2 ........................................... 50938 ....................... Relay base3 ........................................... 50937 ....................... Relay4 ........................................... 3707558 ................... Undervoltage Relay5 ........................................... 80384 ....................... 4 Amp Circuit Breaker6 ........................................... 80383 ....................... 20 Amp Circuit Breaker7 ........................................... 6009199 ................... Potentiometer8 ........................................... 80388 ....................... Contact Block - NO9 ........................................... 80386 ....................... Switch10 ......................................... 80385 ....................... Emergency Stop Switch11 ......................................... 80387 ....................... Collar - Switch12 ......................................... 3707073 ................... Undervolt Relay Base13 ......................................... 27110 ....................... Terminal Strip Assembly14 ......................................... 3707163 ................... Ground Decal15 ......................................... 3707164 ................... Ground Lug16 ......................................... 3707550 ................... Traverse Board17 ......................................... 80389 ....................... Contact Block - NC

76

27542 CONTROL BOX ASSEMBLY EXPLODED VIEW

77

DIAGRAMNUMBER

PARTNUMBER DESCRIPTION

PARTS LIST 27542 CONTROL BOX ASSEMBLY

1 ........................................... 3708448 ................... Electrical Warning Decal2 ........................................... 27509 ....................... Control Box Assembly (See Pages 58-59)3 ........................................... 17093 ....................... Decal Control Box4 ........................................... 3707446 ................... Knob with pointer5 ........................................... 3707049 ................... Wire Strain Relief6 ........................................... 27109 ....................... Cord Grinding Motor7 ........................................... 27107 ....................... Proximity Switch RH8 ........................................... 27106 ....................... Proximity Switch LH9 ........................................... 6009215 ................... Electrical Warning Tag10 ......................................... 3707029 ................... Cord Strain Relief11 ......................................... J251000 ................... 1/4-20 Hex Jam Nut Thin12 ......................................... K252501 ................... 1/4 Split Lock Washer13 ......................................... B250816 ................... 1/4-20 x.50 BHSCS14 ......................................... 80327 ....................... Male Bracket Hanger15 ......................................... 3708683 ................... Decal Undervoltage Relay (not shown)

78

Documents

MODEL 111 & 181 REEL GRINDER OWNER’S MANUAL · MODEL 111 & 181 REEL GRINDER WARNING You must thoroughly read and understand this manual before ... Don't use Grinder in damp or wet