John Deere RG5500 User Manual

REEL MOWER GRINDER

RG5500

SPIN / RELIEF

This book consists of three manual s:

The OPERATO RS MANUAL in ENGLISH w hich contains all the information on operating and do ing routine daily maintenance on this equipment.

The ASSEMBLY and SERVICE MANUAL which is used by the maintainence department to install the equipment and to do all maintenance except routine daily maintenance.

The OPERA TORS MANUAL

(REV. 6/20/201 1)

in FRENCH

which is the same as the English version only translated into

French.

DEALER PREPARATION/INSTALLATION CHECK LIST

Frontier RG5500 Spin/Relief Reel Mower Grinder

THIS CHECKLIST IS TO REMAIN IN OWNER’S MANUAL

It is the r esponsibility of the dealer to complete the procedures listed bel ow , then

review this checklist wi th the customer upon the delivery or the sale of this equipment.The ins tallation

trainin g goes over the basic op erational functi ons of the equipment. To ensure adequate train ing, we require that the following i tems are r eviewed by your John D eere Dealer . Pleas e check off to ensure

that you under stand the follow ing items before the instal lation tr aining i s com plete:

 1. Equipm ent i s c ompl etel y as sem bl ed  2. All s hields ar e in place and i n good condi tion.  3. All decals i n place and r eadable. ( See pages)  4. Overall c ondition good (i .e. paint, wel ds, electr ical)  5. V eri fy there is suffici ent electr ical power to oper ate

the machine.  6. Review Operators, Assembly & Ser v i ce Manuals, and any addi tional tr aining m ateri al if availabl e.

Dealer 's Signature Purchaser's Si gnature

Safety

IMPORT ANT SA FETY MESSA GE FOR OWNERS/OPERAT ORS OF REEL GRINDERS

Safety is a primary concern in the design, manufacture, sale, and use of reel grinders. As manufacturer of reel grinders, we want to confirm to you, our customers, our concern for safety. We also want to remind you about the simple, basic, and common sense rules of safety when using a reel grinder. Failure to follow these rules can result in severe injury or d eath to operators or bystanders.

It is essential that ever yone involved in the assembly, operation, transport, maintenance, and storage of this equipment be aware, concerned, prudent, and properly trained in safety. Always use proper shielding as specified by the manufacturer.

Our current production machines include, as standard equipment, guards or shields for the grinding wheel, safety signs and an operators manual. Never bypass or operate the machine with any of the guards or safety device removed.

Read and fully underst and all t he safety pr acti ces discussed on pages 4 and 5 of this manual. All saf ety r ules must be understood and foll owed by anyone who works wi th r eel grinders.

 7. Review proper posi tioni ng of reel  8. Explain use of reel grinder rel ief mechanis m  9. Review traverse proxi mity switch posi tioni ng  10. Ex plain use of reel grinder ali gnment gage  11. Explain reel gr inder s pin speed vs. quali ty  12. Di s cus s reel gr i nder s et- up char t in manual  13. Review Gener al Mai ntenance

Before operating a reel grinder, an operator must read and und erstand all o f the info rmation in the ow ner’s man ual and in the safety signs attached to the product. A person who has not read or understood the owner’s manual and safety signs is not qualified to operate the unit. Accidents occur often on machines that are used by someone who has not read the owner’s man ual a nd is no t f amiliar with the eq uipm ent . If yo u d o not have an owner’s manual or current production safety signs, contact the manufacturer or your dealer immediately.

Reel grinders are designed for one-man operation. Never operate the grinder with anyone near, or in contact with, any part of the grinder. Be sure no one else, includ ing bystanders, are near you when you operate this product.

Follo wing th ese simple, b asic safety ru les, as well as o thers identified in the owner’s manual and in product safety signs, will help minimize the possibility of accidents and increase your productivity in using this product. Be careful and make sure that everyone who operates the grinder knows and understands that this is a very powerfu l piece of m achinery, and if used improperly, serious injury or death may result. The final responsibility fo r sa fety r ests with the operator of this machin e.

TO THE DEALER:

Assembly and pr oper inst allation of this pr oduct is the responsi bility of the John Deere dealer . R ead manual instructi ons and s afety rules. M ake sur e all i tems on the Pr epar ation Chec k List in the Oper ator’s M anual are complet ed before releasi ng equi pment to the owner.

TO THE OWNER:

Read this manual before operati ng your Fr ontier equipment. Keep this m anual handy for ready reference. Requir e all operators to r ead this manual c arefully and become acquai nted with all adjustments and operating pr ocedures before attem pting to operate the equipment. Replac ement manuals can be obt ained from you sel ling dealer.

The equipmen t you h ave purc hased has been careful ly engi neered and manufacture d to provi de dependable and satisfactory use. Like all mechani cal produc ts, it will requir e cleani ng and upkeep. Lubricate the unit as specified. Pl ease observe al l safety information in this m anual and safety decals on th e equipment.

For servi ce, your authorized John Deer e dealer has trained mechani cs, genuine Fronti er servic e parts, and the necessary tools and equipment to handle all of your servic e needs.

Use only genuine Frontier servic e parts.

SAFETY INSTRUCTIONS

Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards. Whenever you see these symbols, follow their instructions.

The Warning Symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury.

1. KEEP GUARDS IN PLACE and in working order.

2. REMOVE WRENCHES AND OTHER

TOOLS.

3. KEEP WORK AREA CLEAN.

4. DON'T USE IN DANGEROUS ENVIRONMENT. Don't use Grinder in damp or wet locations. Machine is for indoor use onl y. Keep work area well lit.

5. KEEP A LL VISITORS AW AY . All visitors should be kept a s afe distance from w or k ar ea.

6. MAKE WORK ARE A CHILD-PROOF with padlocks or m as ter s wi t ches .

The Cauti on Sym bol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

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

13.MAINTAIN GRINDER WITH CARE . Fo llow instructi ons in Ser vic e M anual for lubr icati on and preventiv e mai ntenance.

14.DISCONNECT PO WER BEFORE SERVICING, or when changing the gr inding w heel.

15.REDUCE T HE RISK OF UNINTENTIONAL STARTING. Make sure all switches are OFF before plugging in the grinder.

16.USE RECOMMENDED ACCESSORIES. Consult the manual for recom mended acces sories . Usi ng improper access ories may cause ris k of personal injury.

7. DON'T FORCE THE GRINDER. It will do the job better and safer if used as specified in this manual.

8. USE THE RIGHT TOOL. Don't force the grinder or an attachm ent to do a j ob for which i t was not designed.

9. WEA R PROPER A PPAREL. Wear no l oos e clothing, gloves, neckti es, or j ewelr y which m ay get caught in moving par ts . Nonslip footwear is recommended. Wear protecti ve hair coveri ng to contain long hai r.

10. ALW AYS USE SA FETY GLASSES.

11. SECURE Y OU R WORK. Make c ertain that the cutting unit is securel y fastened with the clam ps provided before ope rating.

17.CHECK DAMAGED PARTS. A guard or other part that is damaged or will not perform its intended function shoul d be properl y repai red or replaced.

18.KNOW YOU R EQU I PMENT. Read this manual carefully. Learn its applic ation and li mi tations as well as specific potential hazards.

19.KEEP ALL SA FETY DECA LS CLEA N AND LEGIBLE. If safety decals become damaged or illegibl e for any reason, r eplace i mmedi ately. Refer to replacement parts illustrations in Service Manual for the proper l ocation and par t number s of safety decals.

20.DO NOT OPERATE THE GRINDER WHEN

UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR MEDICAT ION.

SAFETY INSTRUCTIONS

IMPROPER USE OF GRINDING WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY.

Grindi ng is a safe operat ion if the few basi c rul es l isted bel ow ar e follow ed. Th ese ru les ar e based on mater ial contained in the ANSI B7.1 Safety Code for "Use, Care and Protection of Abras ive Wheels". For your safety , we suggest you benefit from the experi ence of others and follow these r ules.

1. DO always HANDLE AND STORE wheels in a careful manner.

2. DO VISUALL Y INSPECT all w heel s before mounting for poss ible dam age.

3. DO CHECK MACHINE SPEED against the establis hed maxim um safe operating speed marked on wheel .

4. DO CHECK MOUNTING FLANGES for equal and correct di ameter.

5. DO USE MOUNTING BLOTTERS when supplied with w heels.

6. DO be sure WORK REST is properly adjusted.

7. DO always USE A SAFETY GUARD C OVER I NG at least one-half of the grinding wheel.

DON'T

1. DON'T use a c racked wheel or one th at HAS BEEN DROPPED or has become damaged.

2. DON'T FORCE a wheel onto the machine OR ALTER the si ze of the m ounti ng hole- -if w heel w on't

fit the machine, get one that will.

3. DON'T ever EXCEED MAXIMUM OPERATING SPEED establ ished for the wheel.

4. DON'T use mounting flanges on whic h the bear ing surfaces ARE NOT CLEAN, FLAT AND FREE OF

BURRS.

5. DO N' T TI GH TE N t he m ounti ng nut EXCESSIVELY.

6. DON'T grind on the SIDE OF TH E WH EEL (see Safety Code B7.2 for exception).

7. DON'T star t the machine until the WH EEL GU A RD

IS IN P LACE.

8. DO allow NEWLY MOUNTED WHEELS to run at operating speed, with guard i n place, for at least one minute before gr inding.

9. DO always WEAR SA FETY GLA SSES or som e type of eye protection w hen grindi ng.

A VOID INHALATION OF DU ST gener ated by gri nding and cutting oper ations. Exp osure to dust may cause respiratory ailments. Use approved NIOSH or MSHA respirators, safety glasses or face shields, and protec ti ve c lothi ng. Pr ov ide adequate ventil ation to eliminate dust, or to maintain dust level below the Threshold Limit Value for nuisance dust as classi fied by OSHA.

8. DON'T JAM wor k i nto the w heel .

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

10. DON'T FORCE GRINDING so that motor slows noticeably or work get s hot.

TABLE OF CONTENTS

This machine is intended for grinding the reel of reel type mower units ONLY. Any use other than this may cause personal injury and void the warranty.

To assure the quality and safety of your ma chine and to maintain the warranty, you MUST use original equipment manufactures replacement parts and have any repair work done by a qualified professional.

ALL operators of this equi pment mus t be thoroughly trained BEFORE operating the equipment.

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

Low V oltage Relay

The grinder is equi pped with a high-low volt age relay which is factory pr eset at 100-140 V AC. I f the power supply line does not del iver 100-140 VAC power under load, the relay w i ll open and tr i p out the starter. I f this occurs, your pow er suppl y l i ne is i nc or r ect and must be correct before pr oceeding further with the gri nder.

TABLE OF CONTENTS

Safety Instructions ................................................................................................................. Page 4 - 7

Daily M aintenance ................................................................................................................. Page 6

Getting to Know Your Grinder ................................................................................................ Page 8 - 14

Operating Instructions............................................................................................................ Page 15 - 27

Reel Setup Chart ................................................................................................................... Page 28

DAILY MAINTENANCE BY THE OPERATOR

On a daily basis, clean the machine by wiping it off. On a daily basis, remove all grinding grit from the grinding shaft, traverse shafts, and tooling bar area. On a daily basis, inspect the machine for loose fasteners or components. Contact your company's Maintenance Department if damaged or defective parts are found.

DO NOT U SE C OMPRESSED A IR TO CLEAN GRINDING DUST FROM GRINDER.

SAFETY INSTRUCTIONS

PLEASE TAKE SPECIAL NOTE OF THE FOLLOWING WARNING DECALS LOCATED ON THE GRINDER.

GRINDING WHEEL RPM

GENERAL INFORMATION

SHARP OBJECTS

ELECTRICIT Y

Label Sheet (English and S panish) Part Number 5NT155301 (English and French) Part Number 5NT155302

GETTING TO KNOW YOUR GRINDER

SPECIFICATIONS

Tr aversing Sw itches Solid st ate, non-contacting prox imity swi tches. Overall Width 71" [181 cm] Overall Height 69" [175 cm] w i th door cl os ed, 87" [221 c m] w i th door open Overall Depth 42" [107 cm]without wor kst ation, 79" [201 cm] w ith optional wor kst ation Weight 1450 lbs. [658 kg] 1650 lbs shipping weight [748 kg] Base C onstru ction Precision heavy duty reinforced w elded steel bas e Carriage R ails Precision Gr ound, Hardened S teel - 1.000 Di a. [25.4 mm] Grind H ead M otor 1HP AC Motor, 3450 RPM Spin M otor .20 HP Fan C ooled V ari able S peed D C M otor Sound Lev el More than 75 Dba, Less than 95 Dba Auto Tr averse Belt driven with easy to engage clamp system

Control System *Safety grind motor and spin dr ive door interrupt s witc hes

*Reversible S pin drive for variable speed Spin or variable torque relief functions *V ariable s peed traverse contr ol.

Options: *Manual Winch and Boom Kit, Electr ic Winch and Boom Kit or Lift Platform.

GETTING TO KNOW YOUR GRINDER (Continued)

CONTROL PANEL COMPONENT IDENTIFICATION

Review the following c ontrol panel component descr iptions before proc eeding wi th the i nstructi ons

SYSTEM START PUSHBUT TON

The green pushbutton is the system star t swi tch. Pushi ng it will engage the magnetic star ter and power the control panel. The magnetic s tarter will not engage unless the emergency stop pushbutton i s pulled out and the gri nding motor switc h and spi n m otor s wi tc h ar e tur ned off.

GRIND SELECTOR SWITCH

Variable speed spin Switc h m ust be up to perform

s pin gr i ndi ng oper ati ons .

Variable Torq ue Relie f Switc h m ust be down to perform

relief grinding operations .

SPIN DRIVE ROTATION SWITCH

Forward / Off / Reverse This switch reverses the direction of the spin

drive motor. IMPOR T ANT: Because the spin drive motor

c an be flippe d on the hor izontal adj ustm ent arm, the direction m ay be opposite of what is shown on the decal.

SPIN SPEED POTENT IOMETER DIAL RPM

Adjust s the s peed of reel r otation when you

have the grind selector switch set at variable speed spin.

GUARD DOORS MUST BE S HUT FOR SPIN DRIVE TO OPERATE.

GETTING TO KNOW YOUR GRINDER (Continued)

PUSH-PULL EMERGENCY STOP BUTTON

Push in to cut all pow er to the control panel functions . This removes power from all motors, including the grinding motor, traverse motor, spin motor, etc. To restore power, pull up on button and press the Start button.

SPIN MOT OR SWITCH On / Off

Tur n the S pin M otor on and off.

GUARD DOORS MUST BE SHUT FOR GRIND

MOTOR TO OPER ATE.

RELIEF TORQUE DIAL

Adjust s the Spin Dri ve Motor tor que (the torque holding the reel blade to the relief finger) when Gr ind Selector Switch is set at var iable T orque R elief.

GRINDING WHEEL MOTOR SWITCH On / Off

T urn the Grindi ng Wheel Mo tor on a nd off.

GUARD DOORS MUST BE SHUT FOR GRIND MOTOR TO OPER ATE.

TRAVERSE MOTOR SW ITCH

Tur ns the traver se dri ve motor ON /OFF.

TRAVERSE SPEED POTENTIOMETER DIAL - FT / MIN

Adjust s the speed of the left & rig ht movement of the Grindi ng wheel.

TRAVERSE REVERSE SWITCH

Reverses the di recti on of the grindi ng

head if pushed when the head is moving.

GETTING TO KNOW YOUR GRINDER (Continued)

FRONT AND REAR MOWER MOUNTING

The mow ing uni t s hould b e placed in t he mac hine w ith the rear roller on the table and front roller held in the front tooling. The front tooling can be moved side to side along t he too ling b ar s o they can b e posi tion ed as far ap art as neces sar y to acco mmoda te al l reel wi dths. Decals on the tooling bar make i t easy to position the tooling based on the width of the reel. To move the tooling, loosen the knob located at the front of the tooling base and slide tooling along the tooling bar . The tooling should be located as close to the frame as possible leaving the maximum room to use the position gauge (the gauge will be discussed in the alignment section). The horizontal position is attained by using the hand wheel located at the front of the tooling. If yo u are gri nding a Quick Adjus t mow ing unit (QA7 or QA5), use the decals loc ated on the tooling to quickly position the reel. There are two positions for each reel depending on how the front roller is mounted. See FIG 2.

If you are using the all- pos it ion brac kets , the ver ti cal and horizontal posi ti on c an be adj usted by l ooseni ng the knobs located on the side of the tooling and moving to a new set of pins.

Verify that the reel is positioned properly for the spin wheel and relief wheel by checking the travel limits, both wh ee ls will need to have clearance to come off the reel on both sides. Checking during setup will eliminate the need for major adjustments and alignments when going from spin grinding to relief grinding. W hen the mower is in place lock it into posit ion by tigh tening all kno bs. L ift the rea r r oller onto the angled bracket and clamp the roller firmly by squeezing the clamp handl e.

REEL POSITION

The reel should b e positioned so that it i s at a o ne o’clock or 30° angle position in reference to the grinding wheel. See FIG 3. If the all - pos i ti on br ack ets ar e used tr y to position the unit so that the bottom of the reel is between 1.50-2.00" [38-51MM] off the table. W hen using the roller mount styl e tooling try to maintain the one o’clock positi on and check for clear ance between the reel and grinding wheel. Verify that the proper relief angle can be achieved with this setting and make any adjustments i f necessary.

FIG . 1

QA5 AND QA7 REEL

LOCATION DECAL.

TOOLING POSITION

DECAL

FIG . 2

If you are grindi ng a QA7 or QA5 r eel usi ng the r ol l er style mounts, use the decal s located on the tooli ng to obtain the optimal posi tion to grin d the reel. See fIG 2

FIG . 3

GETTING TO KNOW YOUR GRINDER (Continued)

TRAVERSE ENGAGEMENT AND RELEASE

The belt that drives the relief and spin hubs left and right can b e engaged and r eleased by flipping the c lamp located on the bottom of the grinding head assemblies. Moving the lever t o the left will engage the belt and moving it to the right will disengage the belt. The tip can be adjusted if necessary to i ncrease or decreas e the tension on the belt. See adjustments in the service m anual for m or e detai l s.

THE BELT CLAMP TIP IS ADJUSTED AT THE FACTORY TO ALLOW THE BEL T TO SLIP IF THE HUB COMES IN CONTACT WITH SOME THING. CAUTION SHO ULD BE USED WHEN ADJUSTING THE TIP. IF THE CLAMP IS OVERTIGHTENED, THE BELT WILL NOT SLIP WHICH MAY CAUSE DAMAGE TO THE MACHINE OR REEL.

TRAVERSE BELT ENGAGEMENT

LEVER

CLAMP TIP

TRAVERSE BELT

FIG .4

TRAVERSE PROXIMITY SWITCHES

T wo m ovabl e pr oxi mit y sw itches deter min e the lef t and right lim it s of grinding head assembl y . An LED on the switch li ghts when the grindi ng head gets close to the head of t he pr oxim ity swi tch. The se nsor s ar e m ount ed in the Proximity Brackets located on the traverse shafts. The brackets can easil y be slid along the shafts for quick and easy travel limit adjustments. When switching from the spi n mode to the r elief mo de, the br acket s will need to be lifted off the shafts and snapped back on the shafts in the proper pos ition.

SPIN/RELIEF GRINDING HEAD

This gri nder is equi pped wi th separate spi n and rel ief grinding wheel s. When the setup is done proper ly the reel will be only need to be positioned and aligned once for both cycles. The spin wheel i s located on the ri ght side of the machine and is wider than the relief wheel. Move the wheel that is not being used as far to that side as possible to give the maximum amount of room to setup and operate the machine. The proximity sensors must be moved so that the wheel in use is between the two sensors. Make sure that the wheel that is not in use is not engaged to the drive belt.

TRAVERSE LEFT LI MI T PROXIMITY SENSOR

RELIEF GRINDING WHEEL & HUB

TRAVERSE RIGHT LI MIT PROXIMITY SENSOR

DUST DEFLECTOR

SPIN GRINDING WHEEL & HUB

FIG . 5

GETTING TO KNOW YOUR GRINDER (Continued)

RELIEF ANGLE A DJU STM EN T

Rotating the finger system around the grinding wheel wi ll change the relief angle. By loosening the large ratchet handle the finger system can be rotated to achieve the factory angles, or whateve r angle you select. See FIG. 6. By r otati ng th e finge r for war d the rel ief angle wi ll decr ease and rotating it rearward the relief angle will increase. Retighten the ratchet handle when adjustment i s correct .

RELIEF WHEEL DIAMETER ADJUSTMENT

As the wheel wears, the finger system will need to be adjusted to maintain the correct gap between the f ixed finger and wheel. To move the finger system loosen the small ratchet handle. See FIG. 6. The gap between the fixed finger and the grinding wheel should be between .06" [1.5 m m] and .18" [4.6 mm] dependi ng on the amou nt of existin g relief on the reel . Retighten the rat chet handle after the adjustment i s made.

INDEX FINGER ADJUSTMENTS

The R elief Assemb ly incl udes tw o fing ers. S ee FIG. 6. The Fixed Relief Finger hold the blade in position during the relief grind process. The Movable Index S top Finger moves from the Relief Finger Side (back side) of the reel blade when traversing from right to left, to the grinding wheel side (front s ide) of the reel blade when traver sing from left to right. T he indexing finger all ows the gr inder to index to the next blade automatically during the relief grind. Improper adjustment of the relief f ingers assembly may result in a bad grind or possibly damage to the reel or machine.

INDEX FINGER STOP POSITION KNOB

W HEEL DIAMETER ADJUSTMENT

HANDLE

RELIEF ANGLE ADJUSTMENT HANDLE

FIXED FINGER

INDEX STOP PIN

MOVABLE INDEXI NG FINGER

FIG . 6

The Index Finger Stop Position Knob adjusts where the Index finger stops when the reel blade indexes. See FIG . 6. Proper positi on of this st op is cr itica l to allow the reel blade to smoothly transition from the Index Finger to the Fixed Finger.

IMPORTANT! After adjusting the Index Finger Stop Position Knob there should be 1/32" [0.8 mm] clearance between the index finger and the reel blade when you push on the index finger . This will allow the Fixed Relief Finger to guide the reel blade during the relief grind cycle. The Reel blade should never be riding on the Index Finger when grinding.

The Index Stop Pin is height adjustable. It should be adjusted to catch the reel blade and still leave enough clearanc e to the reel spider after the r elief i s gr ound to the depth required.

There is a forward position stop on the Finger system located near the pivot poi nt of the I ndex Finger . T his w ill only need to be adjusted if there is a clearance issue with the finger when it travels forward. See FIG 7.

INDEX FINGER FORWARD STOP POSITION SETSCREW

FIG . 7

GETTING TO KNOW YOUR GRINDER (Continued)

ALIGNMENT GAUGE

A properly ground reel should be cylindrical. All taper must be ground out of the reel. To ensure the reel will be ground correct ly it MUST be aligned pr ecisely prior to grinding. The digital alignment gauge is used for accurate reel setup. The gauge is used for setting the horizontal alignment and checking for taper within thousands of an inch. The digi tal gauge al l ows y ou to measure o ne end of the reel by extending the slide rai l until you make c ontact w ith the cen ter shaft of the reel. See FIG . 8. By measuring at the far left and the far right on the center shaft you can adjust the horizontal alignment using the front tooling adjustment knobs until the alignment is w ithin .005 i nches [.13mm ].

When this is completed, you can then res et the gauge to zero on the center shaft, retract the gauge slide and measure the outer surface of a reel blade. By comparing the readings on the left side of the reel to the right side of the reel, you can determine exactly how much taper you have in the reel. Compensating for taper will be explained later in the grindin g proced ure.

INDICATOR SLIDE RAIL

IN / mm

REEL CENTER SHAFT

ZERO RESET

ON/OFF

FIG. 8

NOTE: The gauge can be set for both inch and metr ic readout.

OPERATING INSTRUCTIONS

PREPARE MOWING UNIT FOR SHARPENING

Always follow the procedures specified in the cutting unit manual w hen pr epar i ng the uni t for shar peni ng. It is recommended that the reel to be sharpened is thoroughl y cl eaned . Remo ve the whee ls an d bed bar, if possible, from the reel. The bedknives should be sharpened when the reel is sharpened. Inspect, adjust and/or r epl ac e any w or n or dam aged bear i ngs. Mak e sure the ree l beari ngs are in go od wor king con dition and adjusted properly so the reel turns easily by hand.

Becaus e thi s gri nder m ounts the r eel u sing the reel rear roller and front roller if applicable, the bearings in the rollers must be in good repair with no free play. The

front and rear rollers must be properly aligned parallel to the reel prior to grinding.

REELS WITH EXCESS TENSION ON THE BEARIN GS WILL BE EXTREMELY DIFFICULT TO SPIN GRIND AND COULD CAUSE DA MAGE TO THE REEL OR THE SPI N D RI VE MECHANISM ON YOUR GRINDER. NO MORE THAN 25. IN. LBS MAXIMUM TORQUE

LOAD TO ROTATE THE REEL IS ALLOWED OR DAMAGE TO THE SP IN DRIVE COULD OCCUR.

FIG. 9

LIFTING REEL INTO POSITION

The RG5500 grinder does not com e standar d wi th a l ift device. If the facility does not have a lift, it is r ecommended that the winch and b oom ki t or R ear Li ft Platform is us ed. .

WINCH & BOOM KIT The Winch & Boom kit mounts to the back right side of the cabinet. When using the W inch & Boom, position the cutting unit behind the machine and secure the spreader bar to the cutti ng unit. Use the winc h to li ft the unit and swing the reel into the working area of the machine. (Refer to m anual in kit for further i nstructions.) See FIG. 9 - Av ailable wi th a Manual or El ectric w inch.

REAR LIF T PLA TFOR M The Rear Lift T able is a portable platform that can be used to raise the r eel up l evel to the gr i nder. The r eel can be rolled onto the platform with the front of the reel facing the front of the grinder. With rear roll er cl am p r em oved the reel can be roll ed fr om t he pla tform int o th e ma chin e from the rear. The Workstation uses a 12V rechargeable system to power the platform and can be moved around the facility on the 4 caster wheels . See FIG . 10

FIG. 10

OPERATING INSTRUCTIONS (Continued)

INSTA LL REEL

Move the r eel to the appr oxim ate position having the r ear roller on the tabletop, and front roller on the front roller Mounts.

MAKE SURE THE GRINDING WHEEL IS LOW ENOUGH TO CLEAR THE REEL. YOU CAN LOWER THE GRINDING WHEEL BY TURNING BOTH HANDWHEELS

Position front r eel in the center of the machine. Move the roll er m ounts as far o ut as poss ible to the e nds of the fro nt roller. (See FIG 11). Us e the dec al s on the tool i ng bar to aid in the positioning of the front tooling. Check for clearance to the tooling, front rol l er and fram e w i th both the spin and relief wheels. This will ensure that yo u will not have to move the reel between the spin and relief grinding. NOTE: On large reels it may be necessary to offset the r eel s light ly fro m cente r t o allow the s pin driv e to be mounted on the app ropriate s ide of the cuttin g unit.

COUNTERCLOCKWISE.

FIG. 11

Place the rear roller onto the rear roller clamp. (See FIG 12).

If using the all- position brac kets, set the vertical height of the clamps so that the bottom of the reel i s 1.5-2. 0 inches [38-51mm] above the table. It is also recommended to mount the support ar m with as l ittle extensi on from the all position bracket as possible leaving just enough clearance for mounting the reel in the “V” of the support arm.

Position the reel in and out by adjusting the front handwheels. The reel should be positioned so that the reel shaft is located at a 1 o’clock or 30° position to the grinding wheel. See figure 13. If there are clearance issues the reel can be moved forward or backward to resolve this is sue. If y ou are gr indi ng a QA5 or QA7 r eel use the decals located on the tool ing to quic kly l ocate the reel in the optimal position. See FIG 2. After the reel is positioned corr ectly lock dow n the front roller and tighten the rear clamp. Make sure all knobs are tight before grinding.

FIG. 12

30° angle or

FIRMLY TIGHTEN ALL LOCKING KNOBS BEFORE GRINDING. ANY LOO SE KNOBS, CLAMPS OR BEARINGS WILL ADVERSELY AFFECT THE GRIND QUALITY.

FIG. 13

OPERATING INSTRUCTIONS (Continued)

AL I GN TH E REEL IMPORTANT: When measuring to the reel center shaft

always mak e sur e you are contacti ng an area free of dirt and grass.

The di gital gauge hor izonta l extens ion bra cket i s ver tical ly adjustable to allow the digital gauge to be positioned to avoi d any reel fr ame mem ber . In ad ditio n, the mo unting of the vertical slide to the horizontal weldment has three positions . Rem oved the kno b on the si de to adju st the til t of the vertical slide if necessary to avoid a reel frame member. Se e FI G . 14.

Before aligning the cutting unit, loosen the horizontal locki ng knobs on the too ling, to all ow the cutti ng unit to be adjusted i n the hor izont al pl ane. See F IG. 14.

T o alig n the cut ting unit, m ove the digi tal gauge as sembly as far as possible to the left side of the reel. Extend the digita l gauge maki ng sur e the t ip of t he gaug e is c enter ed on the reel center shaft. See FIG 15. With the gauge pressed against the reel center shaft, set the gauge to zero. R etract the gauge and move to the r ight si de of the reel and measure to the center of the reel shaft. Do not rotate the reel shaft ex cept for a mini mum amoun t if ther e are clearance issues to the reel blades. With the gauge against the center s haft, adjust the horizon tal handw heel until the gauge reads zero. Repeat adjustments going from one side to the opposite side until the alignment is within .005" [.13 mm ].

GAUGE ANGLE ADJUSTMENT T-KNOB

FORWARD AND BACKWARD MOUNTI NG HOL ES

TOOLING BA R POSITION KNOB

HORIZONTAL LOCKING T-KNOB

GAUGE VERTI CAL ADJUST MENT T-KNOB

HORIZONTAL ADJUSTMENT HANDWHEEL

GAUGE BASE

FIG. 14

CHECKING FOR TAPER

First, m easure the left si de of the reel as far to the left as possible wi th the di gital ali gnment gauge, make sur e the tip of the gauge is centered on the reel center shaft. Set the gauge to zero, then measure to the edge of one blade. Remember or write thi s number down. Mov e to opposite side and do the same thi ng. Compar e the tw o numbers ; the difference is the amount of taper in the radius of the wheel.

NOTE: TO OBT A IN A CORRECT TA PER REA DING TO BE USED WITH THE TAPER CHART LATER, THE READING MUST BE TAKEN AS CLOSE TO THE ENDS OF THE REEL AS POSSIBLE GIVING THE MAXIMUM DISTANCE BETWEEN READINGS.

T o r emove the taper in the reel , the side of the reel that i s larger will need to be infed heavier to remove this extra material.

Remove the gau ge and st ore the di gital gauge on the pin located on the front r ight si de of the machine. The ga uge base can be placed ins ide the mac hine out of the way.

FIG. 15

FIG. 16

OPERATING INSTRUCTIONS (Continued)

ALIGNMENT OF GRINDING SHAFT T O REEL

T o ali gn the grin ding s haft t o the reel bri ng the sh aft up so th at the spin wheel is about ¼ inch [6 mm] from the reel blades. Move the spin wheel to one side of the reel and raise the grinding shaft until the wheel just touches the blade. Move the wheel to the other side of the reel and bring the shaft up until the wheel jus t touches . Recheck from s i de to si de and make minor adjustments until the wheel touches the same on both ends of the reel. The grind shaft is now aligned verti cal ly to the r eels ou ter diam eter. Ze ro the ga uges loc ated on the vertical adjustm ent housing. Check for high spots in the reel by moving the wheel the length of the reel while spinning the reel. If there are high spots lower the shaft equally on both ends and zero out the gauges again.

FIG. 17

SETT ING T HE T RAVERSE L IMITS

Move the grinding wheel to the right until the wheel has cleared the reel by approximately ¼ inch [6 mm] (if clearance to the frame allows). Disengage both the relief and Spin grinding assemblies from traverse belt. Turn the Traverse speed potentiometer to zero and turn on the Traverse Motor Switch. This will activate the proximity sensors. Mov e the right T rav erse Tr avel Li mit s witch in until the light on the proximity sensor illuminates. Move the wheel to the opposite end, clearing the reel as mentioned above, and set the left Traverse Travel Limit Switch. (Fig 17) Engage the trave rse bel t and sl ow ly tu rn the Tr aver se S peed up. Allow the wheel to traver se from end to end to verify the switches stop and reverse the direction of the grinding wheel. V erify t hat t he grindi ng wheel travel s fully of f the reel at each end. Note: If the reel will hit the f rame , then adjust travel sensors so the w heel does not contac t the fram e.

ATTACHING THE VARIABLE SPEED SPIN DRIVE UNIT TO T HE REEL

IF THE REEL FRAME EXTENDS BELOW THE REEL ITSELF, MAKE SURE THE STOP IS SET SO THAT THE GRINDING WHEEL DOES NOT RUN INTO THE FRAME WHILE

GRINDING.

FIG. 18

The spin driv e unit attaches to the end of the reel shaft or a drive system compo nent. Consult the cutti ng unit m anual for proper spin drive placem ent and attachment. Determi ne which side to mount the spin drive. This will generally be the same drive system component used for backlapping. See FI G . 18.

IMPORTANT: When spin grinding, the reel should turn in the same directi on as the grindi ng wheel. See FI G . 19.

Befo re po sitio n ing th e sp in u nit let us f a miliariz e o urs elve s with the availabl e adj ustments and coupler /dri ve assembl ies. See FI G . 20.

FIG.19

OPERATING INSTRUCTIONS (Continued)

Knob A—

Allows the spi n unit to be loosened and moved in and out.

Knob B-

Allows the spi n unit to be loosened and moved up and down.

Knob C –

Allow s t he spi n ass embly t o be loosen ed from the to oling b ar and moved sid e-to-si de.

When positioning the spin unit it may be necessar y to complete several of the above adjustm ents to proper ly al ign the spi n unit to the reel .

THE COUPLER ASSEMBLY INCLUDES: RUBBER SLEEVE COU PLER: This is placed in the

corresponding flange c oupler already mounted in the s pin drive shaft. See FIG. 21. DRIVE COUPLER ADAPTER ASSEMBLY: This is mounted to the rubber coupler . Note: If the Drive Coupler Adapter is removed, there is a short square drive shaft attached to the Adapter Sleeve. This can be used with a socket if there is li mited space. AD APTER SLEEVE: Connects the rubber coupler to the square dri ve adapter . SQUA RE DRIVE A DAPTER: This is inser ted into t he drive coupler adapter. The square drive adapter has approximately 2" [51 mm] of movement. It will be necessary to move this when attaching reel to spin drive unit. This adapter shaft has a groove machined into it on the opposite end of the snap ring. This groove is there to advise that you have reached the maximum extension of the square drive shaft. If you cannot connect the reel without extending past this groove, then the spin unit must be repositioned on the tooling bar (Knob C). A 1/2" [12.7 mm] sq uare driv e socket or reel drive a dapter is u sed to connect the square dr ive adapter to the reel.

NOTE: The 1/2" [12.7 mm] square drive socket or adapter that is plac ed on the reel w hen spin grindi ng is NOT with the grinder. See next page for details

included

FIG.20

FIG. 21

DO NOT EXTEND SQUARE SHAFT PAST GROOVE, INSTEAD REPOSITION SPIN UNIT.

The followi ng procedur es will make setting up the spin drive unit easier .

Move spin dri ve unit cl ose to the reel. Ali gn the shaft on the spin drive wi th the nut on reel by completing the necessary adjus tm ents disc uss ed above.

Now sl ide the spin drive uni t appr oxim ately 7 " [18 cm ] from the ree l dri ve co upling poi nt and secu rely fasten to the tooling bar tighte ning the l ocking knob. (Kn ob C)

Place the proper 1/2 " [12.7 mm ] square dr ive soc ket or adapt er on the reel driv e nut and then ins ert the squar e drive shaft into the socket. Place the adapter sleeve over the drive shaft and insert the dri ve coupler adapter assembly into it. Final ly pl ace the rubber coupler onto the drive coupl er adapter. See FIG. 21.

By holding the square drive shaft firmly into position with your left hand you will be able to move the oth e r components to the right and inser t the rub ber coupler i nto the flange on the spin driv e unit. When this is done tighten the T - Knob on the adapter sleeve to hol d all part s in plac e. Finally r eadjust the spin dr ive unit if it i s not in alignm ent.

NOTE: It i s not necess ar y to have perfect alignment but it must be cl os e enough so that the coupler remains engaged and that excess tor que is not appli ed to the reel.

OPERATING INSTRUCTIONS (Continued)

REEL DRIVE ADAPTERS

his grinder is equipped wi th an adapter that transfers the rotation from the spi n drive gear box coupling to a 1/2" male square. To operate the grinder you need an adapter from this 1/2" male squar e to the reel shaft. These adapters are NOT

Most cutti ng units In recent y ears have a mal e or female spl ine on the end of the reel shaft that c onnects to a hydraulic or elec tric motor shaft.

If you have a reel shaft that has an internal threaded end whi ch you can access, instal l a hex head bolt or socket head screw of that thread size w ith a jam nut ver y tight so i t does not loos en whil e spin gr inding and then drive with a 1/2" driv e socket for that hex or hex key size.

JOHN DEERE REELS

COUPLERS- T he external spline shafts use a female splined coupler between the reel shaft and the male splined hydraul ic m otor shaft. The spli ne is either an 8,9 or 11 toothed spline. Our r ecomm endation is to purchase the female s plined coupler from John Deer e and w eld it to a shor t 1/2" square socket extens ion. Note: The 8 tooth spline adapter can be used with a Square Socket Dri ve Adapter [3/8" s quare male to 1/2" square female] without w elding.

included w ith this grinder.

REEL DIA

REEL TYPE Recomendation

5 " G, M Has an 8-T, Extern a l shaft. U se co upler AET11038 7 " H Has an 11-T, External sha ft. Us e coupler TCA12581

(NOTE: THIS CAN ALSO BE DRIVEN WITH A 1.25 HEX SOCKET)

7 " 26H Has a 9-T, Extern al sh aft. U se co upler AET11310

(NOTE: THIS CAN ALSO BE DRIVEN WITH A 1.25 HEX SOCKET)

8 " ESP Has a M16 X 2, Externa l sha ft. Use nut A31869 and dr ive with

a 24mm Hex Socket.

5 " WB G M Use a 3/ 8"-24 UNF B olt, and d rive with a 9/ 16 Hex So cket

5" QA5 Has an 8-T, Internal Spline shaft. Use part AMT3022, to make

an adapter.

7" QA 7 Has an 11-T, Internal Spline shaft. Use a 1.25 Hex Socket or

make and a dapter from pa rt TCA18958.

TORO EQUIPMENT : T oro uses a n 8 tooth female spline or a 9 tooth female spline on their reels. The 8 tooth female spline can be affectively driven with a Square Socket Drive Adapter [3/8"square male to 1/2" square female]. The 9 tooth spline requires an adapter . Our r ecommendation is to p urchas e ada pter Toro too l part nu mberTOR-4074 available from K-Line Industries, Inc. 31 5 Garden Ave. Holland, MI 49424.

JACOBSEN EQUIPMENT : Below is a list of drive systems based on the cutting units: * 5" reel units can be driven from the non hydraulic motor end of the reel. Install a 3/8" bolt in the end of the reel shaft with a jam nut very tight so it does not loosen while spinning. Use a 9/16" socket to drive. They can also be driven from the hydraulic motor end by pressing a Square Socket Drive Adapter [3/8" square male to 1/2" square female] into the splined reel coupling Jacobsen part number 337370 and use this pressed as sembly as the adapter. * 7" reel units can be driven from either end. The reel unit has a coupler attached to the reel shaft a both ends. Purchase Jacoben part number 4102440 Reel Motor Shaft and weld the hydraulic motor shaft form the kit to a 1/2" socket and use this weldment as the adapter. * Tri-King reel units can be driven on older pulley drive units with a 9/16" socket on the 3/8" bolt that holds the pulley. On newer splined units, purchase the splined reel coupling Jacobsen part number 132002 and press a S quare Socket Drive Adater [3/8" square male to 1/2"square female] into the splined reel coupling and use this assembly as the adapter.

OPERATING INSTRUCTIONS (Continued)

RECOMEN DA TION FOR SPI N DRIVE RPM A ND TRANSVERSE SPEED WHEN GRINDING

SPIN DRIVE RPM

SPIN DRIVE RPM IS VERY IMPORTANT IN ACHIEVING A QUALITY GR IND. USE C ARE IN ESTABLISHING THE SPIN DRIVE RPM, PER THE INSTRUCTIONS BELO W.

Generally, the Spin Drive RPM will be be tween 180 RPM (45%) and 380 RPM (100%). The speed required to spin a specific reel is dependant on reel diameter, the number of reel blades, and reel hardness. For all reels, there i s an opti m um Spin Speed where ther e i s an AGGRESSIVE, yet smooth grind as you spin gri nd the reel. Your objective is to spin grind the reel as aggressi vely and as fast as pos sibl e w hile m aint aining top quality .

It is r ecommen ded to star t grinding eac h reel at a S pin Speed of 200 RPM (50%) and evaluate the RPM by adjusting hi gher and lower to opt imiz e the S pin S peed for that reel. If the Spin Speed is incorrectly set, you can experience two problems, grinding wheel dressing or grinding w heel resonance. Each of these problems is explained below .

On some reels, especially small diameter high blade count reels if the Spi n S peed RPM is s et too high, the reel can act as a dr esser to the grinding w heel. T here can develop what appears to be a very aggressive grind (as if the infeed has self infed) and then a sudden stop of grinding with no grinding wheel to reel contact. If this occurs, your Spi n Speed was set too high and you effectiv ely dressed y our g rinding w heel.

Some ree ls have a res onant R PM w here the reel goes into harmonics with the grinding wheel and the resonance vibrates the grinder and results in a very bad grind. By changing the Spin S peed to a higher or lower RPM you will move out of the resonant range.

After determini ng the best S pin S peed RPM for a reel, note the RPM on the "Set-up Chart" in the "NOTES" section. (Set-up chart is located at the back of th is manu al) By no ting th e correct RPM, you will a void evaluating the Spin S peed the next time y ou grind the reel. Also note the spin drive position using the position decals on the spin mounting and documenting the position on the "Set-up Chart".

TRAVERSE DRIVE RPM

The T raver se Speed potentiom eter is adjust able from approximately 5 feet per minute [1.5 meters per minute] to 20 feet per minute (6 meters per minute). It is recommended to grind between 15 and 20 feet per minute (4 and 6 meters per mi nute).

Gri nding a t a slow er tr aver se spee d, 10 feet p er min ute (3 meters per minute) as an example, will give a better finish but will extend the gri nd cycle ti me. Grind finish versus grind cycle time is controlled by the choice of the operator .

COMPENSATING FOR TAPER.

To maintain the best quality of cut, the taper in a reel must be removed returning the reel to a true cylinder. T o re move the t aper that w as measur ed with the gauge (as discussed previously in Checking For T aper Section) first align the reel to the shaft by the touch m ethod (as discussed previously). Then drop the side of the grinding shaft that is hi gh (the sm all er side of the reel ) the amount suggested in the chart [See char t on next page or Compensation for

Taper Chart located on the machine].

Example: For a r eel that is 22 i nches [56 c m ] long

with a measur ed t aper of .12" [3 m m ], the adjuster on the smaller side of the reel would be dropped to read-.546 [13.9 m m].

This will bring the grinding shaft parallel to the reel center shaft. Z er o out the di gi tal g auges loc ated on the vert ical adj ustme nt tower s and infeed both side equal ly until the wheel just touches the large side of the reel. Zero the gau ges again, you are now rea dy to grin d and remove the taper. When grinding, the wheel will only make contact with the larger side of the reel and will gradually grind more as the larger areas are ground away. The reverse button may be used to help speed of this process . Gri nd until full c ontact is made acros s the entire length of the reel, and the reel is sharp the entire width of all blades .

AMOUNT OF

AMOUNT

OF TAPER

IN SHAFT

TAPE R IN REEL

OPERATING INSTRUCTIONS (Continued)

TAPER A DJUSTMENT SETUP C HART

REEL WIDTH

16 18 20 22 24 26 28 30 32

0.005 0.033 0.029 0.025 0.023 0.021 0.019 0.017 0.016 0.015

0.010 0.066 0.058 0.051 0.045 0.041 0.038 0.035 0.032 0.030

0.015 0.100 0.086 0.076 0.068 0.062 0.056 0.052 0.048 0.045

0.020 0.133 0.115 0.102 0.091 0.082 0.075 0.069 0.064 0.060

0.025 0.166 0.144 0.127 0.114 0.103 0.094 0.086 0.080 0.075

0.030 0.199 0.173 0.153 0.136 0.123 0.113 0.104 0.096 0.089

0.035 0.233 0.202 0.178 0.159 0.144 0.132 0.121 0.112 0.104

0.040 0.266 0.231 0.203 0.182 0.165 0.150 0.138 0.128 0.119

0.045 0.299 0.259 0.229 0.205 0.185 0.169 0.156 0.144 0.134

0.050 0.332 0.288 0.254 0.227 0.206 0.188 0.173 0.160 0.149

0.060 0.399 0.346 0.305 0.273 0.247 0.225 0.207 0.192 0.179

MEASURED T APER

SPIN GRINDING

After the reel has been aligned and the taper has been adjusted for , you ar e now ready to spin grind the r eel. Cl ose the front and r ear guar d doors. (The g rinding w heel and spin motors will not work unle ss th e doors are closed.) Position the spin/relief selector switch to the spin position. Tu rn on the Grinding M otor and the S pi n Dri ve M otor swi tch. Set the spin speed at approximately 200 rpm (Refer to Spin Drive RPM on per vious page) . M ake s ure spin r otation i s the same as the grinding wheel – clockwise (CW) looking from right end. See FI G 22.

0.070 0.465 0.403 0.356 0.318 0.288 0.263 0.242 0.224 0.209

0.080 0.532 0.461 0.407 0.364 0.329 0.301 0.277 0.256 0.238

0.090 0.598 0.519 0.458 0.409 0.370 0.338 0.311 0.288 0.268

0.100 0.665 0.576 0.508 0.455 0.412 0.376 0.346 0.320 0.298

0.120 0.798 0.692 0.610 0.546 0.494 0.451 0.415 0.384 0.358

Small side of reel downward adjustment.

IM PORTANT: When the reel turns i n the sam e rot ation as the grinding wheel , the point of contact where they meet is in opposit e direc tions.

Tur n on the tr averse dr ive m otor sw itch and turn the speed dial up to approxi matel y 15- 20.

IM PORTANT: If the gri nd st arts get ting heav ier , adjust the grindi ng head down u ntil yo u can tr avel th e full length of the reel w ithout heav y grindin g.

When grinding, infeed the wheel approximately .005” [.13 mm] at a time. Allow the grinding wheel to travel back and forth across the reel 2 to 3 times before infeeding. The spin grinding is completed when full contact is made across the entire le ngth of the reel, the entire width of all bl ades and the reel is s harp. The l ast pas ses shoul d be a norm al .005 [.13 mm] infeed gri nd at a slow trav erse speed (appr ox. 8 feet per minute [2.5 meters per minute] or slo wer). Aft er the l ast pass turn the grin der off. (Note: Due to the positioning of the reel to the 1 o’ clock posi tion, infeeding the wheel .015 inches [.38 mm] will remove .010 inches of material. )

FIG.22

OPERATING INSTRUCTIONS (Continued)

RELIEF GRIND

T o change over to the relief grind, disengage the spin grinding wheel hub assembly and par k i t as far to the ri ght as possibl e. Bring the relief hub assembly over to the reel for relief grinding. This will require repos itioning the tr avel pr oximity switch br ackets.

Note: As the reel diameter get s sm aller and the num ber of blades increases the relief grinding wheel diameter works better when smaller. For exampl e a 5" [127 mm] diameter greensm ower r eels with 1 1 bl ades ach ieve a greater rel ief angle wi th a sma ller gr inding wheel.

REEL SPIRAL

Check to see if your mow ing unit is nor mal or reverse hel ix.

NOTE: As you look into the gui de finger on TH E NEXT PAGE, IT SHOWS TH E NORM AL REEL HELIX. As you l ook into the guide finger on the FOLLOW PAGE, IT SHOWS THE REVERSE REEL HELIX. The high po int of the reli ef finger is on th e right h and

side of the grinding wheel . Most m owing units ar e nor mal hel ix.

THE HIGH POINT OF THE RELIEF FINGER MUST ALWAYS BE AT THE CORNER OF THE GRINDING WHEEL THAT IS MAKING CONTACT WITH THE REEL. ON THIS GRINDER THAT IS ALWAYS THE RIGHT HAND SIDE OF

WHEEL DRESSING

If the grinding wheel becomes loaded with material it may be necessary to dress the wheel. The RG5500 is supplied with a diamond dresser. To use, place the dresser on the spin drive horizontal arm in the area where the wheel is to be dressed. Adjust the dresser to the appropriate position and angle. Raise the grinding wheel so it i s nearly touching the dress er .

For dressing the spin grinding wheel, put the dresser in the straight position. Close the door s and infeed the spin grinding wheel into the dresser and then move the gr inding wheel side to side agai nst the dresser which will dress the full face of the wheel.

THE GRINDING WHEEL.

FIG.23

T ypic ally onl y infeed .002 " [.05 mm] per pas s. Infeeding too heavy can dam age the dresse r or the w heel. Contin ue dres sing unti l the wheel looks new or the proper shape is achieved.

For dressi ng the rel ief w heel, put the dr esser at the corr ect angle for normal helix reel or reverse helix reel. Close the doors and infeed the relief grinding wheel into the dresser. Do NOT move the grinding wheel from s ide to side.

OPERATING INSTRUCTIONS (Continued)

Matching Angle

Actual Grindi ng Wheel

Contac t Point

Prefered Dres sing

New S traight Wheel

Right Side of Wheel

Must Contact First

NORMAL HELIX

For a N ORMA L HELI X re el, the gr inding w heel

should wear to match the angle of the reel

blade.

NOTE: The square faced grinding wheel as

purchased from the factory can be used for

normal helix reels and will wear to match the

reel blade helix.

Normal helix reels are also refered to as Left

Hand Side Cutting First (Looking from front -

grass entry position.) or Right Throw reels

(Throws grass to the right of operator

position.)

OPERATING INSTRUCTIONS (Continued)

Matching Angle

Actual Grinding Wheel

Contac t Point

Prefered Dressi ng

Right Sid e of Wheel

Must Contact First

For a REVERSE HELIX reel, the grinding wheel should

be dressed to match the angle of the reel blade. It is

recomm ended that a slightly larger angle is dressed on

the wheel so the right side of the wheel is contacting the

blade prior to the left side as shown. The grinding w heel

will then wear to a match.

REVERSE HELIX

If you do not dress the grinding wheel so the right side

contacts first you may not relief grind part of the last 3/8"

[10 mm] of the blade.

NOTE: A wheel that has been worn to match a norm al hel ix

can generally be rem oved and rev ersed to grinder rever se

helix. reels.

Reverse helix ree ls are also refered to as Right Side

Cutting First reels (Looking from the front - grass entry

side) or Left Throw reels (Throws grass to the left of the

operat or position .)

OPERA TING INSTRUCTIONS (Continued)

RELIE F GRINDING CONTINUED

Reset the Traverse Limit Pr oxi m i ty Sw i tc h so the grinding wheel clears the reel at both ends by approximately 1/16" [1.5 mm].

Set Grind Selector s witch to variable tor que relief. (IMPORTANT: The Spin Drive Rotation switch must be in the OFF position when changing the Grind Selector switch.) Set the Spin Drive Rotation switch to rotate the reel into the stop finger, counterclockwise (CCW) when look ing at the r ight s ide . NOTE: Relie f tor que r eel rotati on is al ways opposi te spin r otati on. DO NOT T URN ON T HE SPIN MOTOR SWITCH.

With the traverse in the home

position (right side traverse proximity sensor lit), infeed the grinding relief wheel up while manually rotating the reel until the index finger touches t he blade.

Tur n the travers e speed potentiometer to zero, then turn the traver se drive motor on. With the bel t drive dis engaged, manually move the Relief Grinding Assembly to the left until the r eel bl ade is on the fixed r elief finger.

INDEX FINGER STOP POSITION KNOB

WHEEL DIA METER ADJUSTMENT

HANDLE

RELIEF ANGLE ADJUSTMENT HANDLE

FIXED FINGER

INDEX STOP PIN

MOVABLE INDEXI NG FINGER

At this point, i f necessary , you can adj ust the rel ief angle by adjusting the relief finger position. To make this adjustment loosen the Relief Angle Adjustment handle. See FIG 24. Rotating the finger system down will increase the relief angle and rotating the finger system up will decrea se the reli ef angle. Adju sting the r elief angl e or index finger stop position is easiest with the relief head at the left side o f the reel.

Once you have the Grinding Head pos itioned with a reel blade r esti ng on the F ixed R eli ef Fin ger high point , adju st the indexing finger stop. There should be about 1/32" [.8mm] to 1/16" [1.5m m ] free pl ay of the I ndex F i nger to the back of the blade. The Inde x Finge r i s spri ng loaded to the up posi tion or again st the back o f the r eel bl ade. To check free play, push down on the Index Finger. See FIG 24. If there is no free play of the Index Finger you want to rotate the Adj ust able Index F inger S top Posi tion Knob counter clockw i se. If there is m or e than 1/16" [1.5 mm] free play you want to rotate the Index Finger Stop Position Knob clockwise.

IMPORTANT: The Index Finger position must be set to stop the r eel blad e and al low tr aversi ng to the le ft witho ut the blade hitti ng the side of the r elief finger . Thi s position must also allow approxi mately 1/32" [.8 m m] free play of the index finger when the blade is resting on the high point of the relief finge r . See FIG . 24.

Infeed the grinding wheel up until there is minimal clearance between the reel blade and the grinding wheel.

INDEX FINGER FORWARD STOP POSITION SETSCREW

FIG 24.

FIG 25.

OPERA TING INSTRUCTIONS (Continued)

RELIE F GRINDING CONTINUED

Close the front and rear doors. Tur n the Spin Motor Switch on. NOTE: The spin drive will apply torque load against

the finger s. Set the Rel ief Torque Potentiom eter at appr oximate ly

15. IMPORTANT: Free turning reels may need a lower value than 15 and sti ff reels or r eels with a drive tr ain may need a higher torque than 15.

Engage the traverse belt and tr av er se al l the w ay to the left watching for proper clearance between the grinding wheel and the blade. Check for proper clearance between the index finger (after releasing from bl ade at far left posi tion) a nd the front side of the blade on the return trip to the home clearance to the reel blade support spiders. If necessary the forward stop can be adjusted. See FI G 25.

position. Also ver ify

Stop the traverse in home proper blade index. The traverse drive control is factory set with a two second dwell time before it reverses the carri age tr avel . This i s to al l ow tim e for the reel to rotate and the index finger to catch the next blade. If necessary the dwell time can be adjusted (refer to Control Board Potentiometer Adjustments section in the Ass embly and Serv ice M anual).

Tur n on the Spin Drive Motor (should already be on) and the Grinding Wheel Motor s witc h.

Turn the traverse speed potentiometer to proper grind ing sp eed. Sl owly infe ed the grin ding w heel until you are able to grind the full length of the reel evenly. A typical infeed is b etween .010" to .020" [.25-.50 mm]. Be sure you have ground all the blades before infeeding further.

NOT E : Traverse speed should be set to approximately 15 fpm. If you are removing a small amount of stock on initial infeeds, faster traverse speeds are suggested. If you are removing a large amount of stock on later infeeds, slower traverse speed may be required.

position and check for a

After the relief grind is complete remove turn all switches to off (it i s als o good practic e to push i n the E-stop button) then remove cutting unit from the machine. Use caution as the reel blades will be sharp.

REEL SETUP CHART

NOTES

E S

V A

T E

R T

SPIN

TORQUE

SETTING

frame, reel dia., height of cut, roller position, etc.

Note: These dimensions will vary due to reel position in

SPIN

SPEED

SETTING

E V

I R

I P

Use these values as a guide only.

SPIN DRIVE

MOUNTING

SIDE R OR L

TOOLING

DISTANCE

APART

FRONT

TOOLING

MOUNT

POSITION

REEL SETUP CHART

FRONT

TOOLING

MOUNT

TYPE

REEL MAKE,

MODEL &

HEIG HT OF

CUT

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