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

THIS PAGE LEFT INTEN TI ONALLY BLANK FOR NOTE TAKING PORPOSES.

ASSEMBLY

REEL MOWER GRINDER

RG5500

AND

SERVICE MANUAL

SPIN / RELIEF

(REV. 6/20/ 201 1)

DEALER PREPARATION/INSTALLATION CHECK LIST

IS LOCATED IN THE OPERATOR'S MANUAL

SEE OPERA T OR'S M ANUAL F OR INSTALL TION CHEC KLIST

It is the r esponsibility of the dealer to com plete the procedures li sted in the Operators Manual 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 equipm ent. 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:

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 a manufa cturer of reel grinders, we w ant to confirm to you, our customers, our concern for safety . We also want to remind you about the simple, basic, and common sen se rules of safety when using a reel grinder. Failure to follow these rules can result in severe injury or death to o perator s or bys tander s.

It is essential that everyone involved in the assembly , operation, transport, mainte nance, 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 operator's manu al. Never by pass or opera te the m achine with any of the guards or the saf ety devices rem oved.

Read and fully understand all the safety practices discussed on pages 4 and 5 of this manual. All safety rules must be understood and followed by anyone who works with reel grinders.

Before operating a reel grinder, an operator must read and understand all of the information in the operator’s m anual and in the saf ety signs atta ched to the product. A person who has not read or understood the ope rator’s man ual and safety s igns is not qualified to operate the unit. Accidents occur often on machines that are used by someone w ho has not read the operator’s manual and is not familiar with the equipment. If you do not have an operator’s manual or the current production safety signs, contact the manufacturer or your dealer immediately.

Reel grinders are designed for one-m an operation. Never operate the grinder with anyone near, or in cont act wit h, any part of the grinder . B e sure no one else, including bystanders, are near you w hen you operat e this product.

Following these simple, basic safety rules, as well as others identified in the owner’s manual and in the product safety signs, will help minimize the possibility of accidents and increase your productivity in usi ng this product. Be careful and make sure that everyone who operates the grinder knows and understands that this is a very pow erful piece of m achinery , and if used im properly, serious injury or death may result. The final responsibility for safety re sts with the operator of this mach ine.

TO THE DEALER:

TO THE OWNER:

Read the Oper ator's M anual before operati ng your Frontier equipment. Keep this and al l manuals handy for ready reference. R equire all operator s to read the O perator's M anual carefull y and beco me acquainted with all adjust ments and operating procedu res before at tempting to oper ate the equi pment. Repl acement manuals can be obt ained from your selling deal er .

The equipmen t you h ave purc hased has been careful ly engineer ed and m anufacture d to provi de dependable and satisfactor y use. Lik e all mechan ical pr oducts, it w ill require c leaning and upk eep. Lubricate the unit as specified. Please obs erve all s afety information in the Oper ator's M anual and safety decals on the equi pmen t.

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

Use only genuine Frontier servic e parts.

SA FETY I NSTRUC TIONS

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 WOR K AREA CLEAN.

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

5. KEEP A LL VISITORS AWAY . All visitors should be kept a safe dis tance from wor k area.

6. MAKE WORK AREA CHILD-PROOF with padlocks or master switches.

The Caution Sy mbol id entifi es spe cial 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 . Follow instructi ons in Ser vice M anual for lubric ation and

prev entive m aintena nce.

14.DISCONNECT POWER BEFORE SERVICING,

or when changi ng the g rindi ng wheel.

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

16.USE RECOMMENDED ACCESSO RIES. Consult the manual for recom mended accessories. Using improper accessories may cause risk of personal injury .

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

8. USE THE RIGHT TOOL. Don't force the gri nder or an attachment to do a j ob for w hich it was not designed.

9. WEA R PROPER APPA R EL. Wear no loose clothing, gloves, neckti es, or j ewelr y which m ay get caught in moving parts. Nons lip footwear is recommended. Wear protective hair cover ing to contai n long ha ir .

10. ALW AYS USE SAFETY GLASSES.

11. SECURE YOUR WORK. Make certain that the cutting unit is securel y fastened with the clam ps provided before operating.

17.CHECK DAMAGED PARTS. A guard or other part that is damaged or will not perform its intended function shou ld b e proper ly r epaired or replaced.

18.KNOW YOUR EQUIPMENT. Read this manual carefully . Lear n its applicati on and limit ations as well as spec ific potenti al hazar ds.

19.KEEP ALL SAFETY DECALS CLEAN AND LEGIBLE. If safety decals become damaged or illegible for any reason, replace immediately . Refer to replacement parts illustrations in Service Manual for the proper location and part num bers of safety decals.

20.DO NOT OPERATE THE GRINDER WHEN

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

SA FETY I NSTRUC TIONS

IMPROPER USE OF GRINDING WHEEL MA Y CAUSE BREAKAGE AN D SERIOUS INJURY .

Grindi ng is a safe opera tion i f the few bas ic r ules list ed below ar e follow ed. T hese rul es 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 rul es.

1. DO always HANDLE AND STO RE wheels in a careful manner.

2. DO VISUALLY INSPECT all wheels before mounting for p ossible dam age.

3. DO CHECK MACHINE SPEED against the established max imum safe operati ng speed marked on w heel.

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

5. DO USE MOUNTING BLOTTERS when supplied with wheels.

6. DO be sure WORK REST is properly adjusted.

7. DO always USE A SAFETY GUARD C OVER I NG at least one- half of the gr inding wh eel.

DON'T

1. DON'T use a whee that is cracked, HAS BEEN DROPPED, or one that i s 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 established 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 THE WHEEL (see Safety Code B7.2 for excepti on).

7. DON'T start the mac hine until the WH EEL GU A RD

IS IN P LACE.

8. DO allow NEWLY MOUNTED WHEELS to run at operating speed, with guar d in pl ace, for at least one mi nute be fore gri nding.

9. DO always WEAR SAFETY GLASSES or some type of eye p rotec tion when g rindi 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 glass es or face shiel ds, and pr otecti ve clo thing . Prov ide a dequate venti lat ion to eli mina te dust, or to maintain dust level below the Threshold Limit Value for nuisance dust as classified by OSHA.

8. DON'T JAM wor k into the wheel.

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

10. DON'T FORCE GRINDING so that motor slows noticeably or w ork gets hot.

TABLE OF CONTENTS

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

To assure the quality and safety of your machine and to maintain the warranty, you MUST use original equipment manufactur's 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.

Low Voltage Relay

The gri nder is equipped wi th a high- low vol tage rel ay which is factor y preset at 100-140 V AC. If the power supply l ine d oes not deli ver 100- 140 V A C power under load, the relay will open and trip out the star ter . If this occurs, your pow er suppl y l i ne i s i nc or r ect and m us t be correct ed before proceedi ng further with the gr inder .

TABLE OF CONTENTS

Safety Instructi ons ................................................................................................................. Page 2- 6

Dail y M aint enance.................................................................................................................. Page 6

Service Data.......................................................................................................................... Page 7

Assembly Instructions............................................................................................................ Page 8- 12

Maintenance............................................................ .............................................................. Page 13-19

Adjustments........................................................................................................................... Page 20 -25

Electri cal Troubleshooting...................................................................................................... Page 26-41

Mecha nical Tr oubleshooting .................................................................................................. Page 42-43

Exploded Views and parts Lis ts ............................................................................................. Page 44-71

Wiring Diagram & Schematic ................................................................................................ Page 72-74

DAILY MAINTENANCE BY THE OPERATOR

On a daily basis, clean the m achine by w iping 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 mach ine for loose fasten ers or compon ents. Contact you r comp any's Maint enance Depar tment if dam aged or d efective parts ar e found.

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

SERVICE DATA

SKILL AND TRAINING REQUIRED FOR SERVICING

This Servi ce M anual is des igned for techni cians who have the nec essary m echanical and electr ical knowledge and s kills to reliably test and repair the RG5500 S pin/Rel ief Grinder. For those wi thout this background, s ervice can be arra nged through y our loc al dealer .

This sectio n presum es that y ou are alr eady fam ili ar with the norm al operat ion of the gr inder. If no t, you shou ld read t he operator s manual , or do the servi cing in conj uncti on wi th som eone w ho is familiar with its operation.

Persons without the necessar y knowledge and skills should not r emove any panels, shiel ds or attempt any internal tr oubleshootin g, adjustments , or par ts replac ement.

If you have questions not answ ered in this manual, please cont act your deal er .

TORQUE REQUIREMENTS

Throughout this manual we refer to torque requi rement s as "fir mly ti ghten" o r the li ke. For m ore specific torque values, r efer to the information below.

Bolts Going Into a Nut, or Into a Thread Hole in Steel.

Refer to the table at the right.

Bolts G oing Into a Thread Hole In Aluminum

Use the Grade 2 values in the table at the right.

Socket-H ead Screw s Going Into a N u t or St eel

Use the Grade 8 values in the table at the right.

Machi n e Screws

No. 6 screws: 11 i n.- lbs ( 0.125kg - m ) No. 8 screws: 20 in. - lbs ( 0.23 kg - m) No. 10 screws: 32 i n. - l bs ( 0.37 kg - m )

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)

5/16 In. 11 ft-lbs 18 ft-lbs 28 ft-lbs

thread (1.5 kg-m) (2.5 kg-m) (3.9 kg-m) 3/8 In. 19 ft-lbs 31 ft-lbs 46 ft-lbs

thread (2.6 kg-m) (4.3 kg-m) (6.4 kg-m) 7/16 In. 30 ft-lbs 50 ft-lbs 75 ft-lbs

thr ead (4.1 kg-m) (6.9 kg-m) ( 10.4 kg-m) 1/2 In. 45 ft-lbs 75 ft-lbs 115 ft-lbs

thread (6.2 kg-m) (10.4 kg-m) (15.9 kg-m)

A SSEMBLY INST RUCTIONS

Remove the sides , front, and back of the cr ate. Remove the plasti c bag, shrink wrap and bubbl e wrap. Remove the metal cl ips that secure the grinder to the crate bas e. With a fork lift, raise the grinder from the wood base and set it in its final positi on. See FI G. 1 and 2.

THE UNIT WEIGHS 1200 LBS. [544 kg]. TO LIFT, USE POWER EQUIPMENT.

Remove shipping straps and window protective sheets.

R36"

[914cm]

83" [211cm]

OPTIONAL BOOM

71"

[181cm]

41" [104cm]

OPTIONAL PLA TFORM LIFT SYS.

45"

[11 5cm]

POSITION BASE

The RG5500 Spin/Relief Grinder will require an operating area of about 119" W x 127" D x 90" H (302 cm x 323cm x 229 cm ). The m achine oper ator will operate the unit from the front of the m achine. Position the base to allow suffic ient operating room i n front and to the rear of the machine. See FIG . 1 and 2.

The base should be placed on a rel atively lev el concrete floor , with am ple ceili ng height to allow for the installati on of the unit. D o not pl ac e the uni t acr os s tw o conc r ete sl ab seam s or acr os s a large crack.

71"

[181cm]

83"

[21 1cm]

Optional

Boom Kit

[224cm]

FIG. 1

41" [104cm]

FIG. 23

OPTIONAL PLATFORM LIFT

45"

[11 5cm]

70"

[178cm]

FIG. 2

A SSEMBLY INST RUCTIONS (Continued)

Remove the carton and remove the contents from the carton onto a workbench. The carton i ncludes:

Alignment Gage

Mult i posit ion Brac kets

Drive C oupler

Product Packet Assem bly (Operators & Ser vic e M anuals)

Diamond Dresser

Raised Rear Support

Sp anner Wrench

A SSEMBLY INST RUCTIONS (Continued)

LEVEL BASE

Place a level on the top of the table and check the unit for level s ide to side. Adjust the lev eling feet as necessary until the m achine i s level . See FIG. 3 and 4.

Place a level across the table from front to rear. Adjust the leveling feet as n ecessary until the machine is level . See FIG. 3 and 5.

When both front to back and side to side leveling procedures have been completed, thread the hex jam nuts up against the nut that is welded to the bottom of the machine. Be careful not to move the leveling feet during when tightening the jam nut. See FIG. 3. Make certain that all four leveling feet are firmly cont acting the floor.

Recheck that the machine is level after locking the four feet i nto posi tion.

LOOSEN JAM NUT TO

ADJUST FOOT

LEVELING FEET LOCATED

AT CORNERS OF MAHCINE

FIG . 3

FIG . 4

FIG . 5

A SSEMBLY INST RUCTIONS (Continued)

IMPORTANT GROUNDING INSTRUCTIONS

In case of a malfunction or br eakdown, gr ounding reduces the risk of electr ical shock by providing a path of least resistance for electr ical curr ent.

This Gri nder has an elec tric al cor d with an equi pment grounding conductor and a groundi ng plug. The plug must be plugged into a matchi ng outlet that is proper ly instal led and grounded ac cordi ng to all local or other appropriate el ectrical codes and ordinances.

Before plugging in the Grinder , m ake sure it will be connected to a supply circuit pr otected by a properly sized cir cuit breaker or fuse. SEE SER IAL N UM BER PLATE FOR FULL LOAD AM P RATING OF Y OUR MACHINE.

Never modify the plug prov ided wi th the machine- -if it w on't fit the outlet, have a proper outlet and cir cuit installed by a qual ified elec tric ian.

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

A SSEMBL Y INSTRUCT IONS (Continued)

APPLY POWER

BEFORE YOU APPLY POWE R TO THE G RINDER, REFER TO THE "IMPORTANT GROUNDING INSTRUCTIONS" ON PREVIOUS PAGE.

Plug the control box power c ord into a standard 115V AC 20-am p

grounded recept acl e. See FI G. 6.

IT IS RECOMMENDED THAT THIS SPIN/RELIEF GRINDER HAS ITS OWN PERMANENT POWER CONNECTION FROM THE POWER DISTRIBUTION PANEL, W IT H NO O T HE R MAJO R P O WE R D RAW EQUIPMENT ON THE SAME LINE.

IT IS REQUIRED THAT THE POWER DELIVERED TO THIS G R INDE R IS 115 VAC - 20 AMPS. THE TOLERANCE ON THIS POWER REQUIREMENT IS +/5%. THEREFORE THE MINIMUM VOLTAGE REQUIREMENT IS 109VAC WITH 20 AMPS. VOLTAGE MUST BE CHECKED WITH ALL EQUIPMENT UNDER LOAD (OPERATING) ON THE CIRCUIT.

FIG. 6

The grinder i s equipped w ith a highlow voltage rel ay whi ch i s factory preset at 100 -140 V AC . If the power supply l ine doe s not del iver 100-140 V AC power under lo ad, the rela y will open and trip out the star ter . If this occurs, your pow er supply line is incorrec t and m us t be cor r ec t before proceedi ng further with the grin der .

DO NOT OPE RATE T HIS GRINDER WITH AN EXTENSION CORD.

DO NOT OPERATE THIS GRINDER ON A GROUND FAULT

A PROPER GROUND IS REQUIRED FOR SAFE OPERATION OF THE EQUIPMENT. VERIFY THAT THE RECEPTACLE GROUND IS A PROPER GROUND BEFORE PLUGGING IN THE MACHINE.

IMPROPER GROUNDING IN YOUR BUILDING MAY RESULT IN A DANGEROUS SHOCK TO THE OPERATOR OR CAUSE THE GRINDER TO MALFUNCTION.

When installi ng the g rinder , t he follow ing guidel ines s hould be us ed to establish the wi re size betw een the power panel in your bui lding and the grinder r eceptacl e. Note that the wir ing i n your buil ding must be per code betw een main pow er panels and sub panels.

FOR 20 AMP RATED LARGE MACHINES

For 0 to 40 Feet (0 to 12 M) from panel to receptac le = Use 12 Ga. (4.0 mm) Wire. For 40 to 60 Feet (12 to 18 M) from panel to receptacl e = Use 10 Ga. (6.0 mm) Wire. For 60 to 100 Feet (18 to 30 M) from panel to receptacle = U se 8 Ga. (10.0 mm ) Wire. For 100 to 160 Feet (30 to 48 M) from panel to receptacle = Use 6 Ga. (16.0 mm) Wire.

PERIODIC MAINTENANCE

DAILY MAINTENANCE IS SPECIFIED ON PAGE 6, AND IS TO BE PERFORMED BY THE OPERATOR.

LISTED BELOW ARE P ERIODI C M AIN TENANCE ITEM S T O BE PERFORMED BY YOUR COMP ANY 'S MAINT ENANCE DEP ART MENT:

1. Cl ean the dust tray l ocated at the low er front of the machine monthly using a vacuum or by removing it. Pull the tray out until the back of the tray is even w ith the front of the frame and vacuum it out. To remove continue to pull straight out unti l the tray is free.

USE CAUTION WHEN PULLING THE TRAY OUT AS THERE IS NO MECHANICAL STOP. WHEN REMOVING TRAY PULL STRAIGHT OUT AND SUPPORT THE TRAY TO PREVENT DUMPING.

2. I nspect t he Poly- V bel t on the grind ing m otor for cracking and make any necessary adjustm ents eve ry three m onths.

3. Wipe off and lubricate with never -sei ze, the horizontal adjus tm ent shafts loc ated on the tooling every six months .

4. Wipe off and lubricate with never -sei ze, the vertical adj ustment shafts every si x months. Run the arms up and down to coat the working areas of the shaft.

5. Inspect the traver se cog belt for cracking and defects every three months. Remove any gr i t or dust that may affect the function of the belt. Adjust tension if necessary per procedures called out in the adjustment secti on. See FI G 9.

6. Clean and lubricate the grinding shaft and traverse shafts every 2 to 4 weeks. Follow the proceedure on the nex t page.

DUST TRAY

VERTICA L ADJUSTMENT SHAFTS LOCATED INSIDE HOUSING - ACCESS THRU SIDE PANELS

HORIZONTAL

ADJUSTMENT

SHAFT

FIG. 7

POLY -V BEL T L OCATED

BEHIND PANEL

FIG. 8

7. Lubricate gr inding shaft bearings with one shot of grease once ever y 2 year s. See FIG 9.

DO NOT GREASE GRINDING SHAFT BEARINGS FOR THE FIRST 2 YEARS. THEY ARE GREASED AT T HE FACTORY. GREASING MAY CAUSE THE BEARINGS TO OVERHEAT AND FAIL PREMATURELY.

LUBRICATION

LUBRICATION OF GRINDING SHAFT AND LINEAR BEARINGS

STEP 1 – Thoroughly c lean all three shafts. STEP 2 – Flood spray all three shafts wi th CRC 3-36 until the lubricant is dripping off the shafts. (Do

not use a Tefl on-based lubri cant) Then run the grinding head ass em bl ies bac k and forth through their full range of travel. This will remove the dust and deposits from inside the wheel flanges. Repeat if necessary until l ubric ation is cl ear of deposits. Cl ean keyw ays l ocated on the gri nding shaft w ith soft brush.

STEP 3 – With a clean rag, wipe off the excess amount of lubricant from the shafts. Run the gr inding assemblies through their range of travel and w ipe the shafts after each traver se. Repeat until the shafts are dry to the feel. This completes the lubri cation pr ocess.

IMPORTANT:

If the unit will be shut down for an extended period of time, more than four w eeks, then the shafts and other appropriate par ts of the unit should be flooded with l ubric ant and that lubri cant left in pl ace until the unit is brought back into serv ice. When the unit is brought back into service the full lubri cation procedure as stated abov e should be repeated.

GRINDING SHAFT

COG BEL T

BEARING

TRAVERSE SHAFTS

GRINDING SHAFT

BEARING

POLY -V BELT

FIG. 9

MAINTENANCE

REPLACEMENT OF G RINDING WHEEL

To replace the wheel fir st rem ove the l eft side cover panel. Now, lower the left side of the gri nding shaft and raise the right side. Next, l oosen the two bolts that hold the bearing brac ket on the rel ief hub so that that bearings pivot aw ay from the wheel and hub ( toward the front of the machine) . See FIG 1 1. Press the index finger down and the wheel and hub assembly should move freely to the right.

Then remove the left side bearing. Fi rst loosen the setscrews on the bearing col lar then r emove the four screws that hol d the bear ing to the left arm .

Slide the grindi ng wheel hub assem bly(s) off the shaft taking note of what side the nut is on. U se the spanner wrench to r emove and repl ace the grindi ng wheel( s).

NOTE: THE RELIEF HAND THR EAD FOR THE NUT. THE SPIN HUB HAS A RIGHT HAND T HREAD.

Place the gri nding wheel hub assem bly( s) back on the grinding shaft. V erify that the spin hub is located between the spin dr ive yoke assem bly and the r elief hub is to the right of the relief drive ass embly before lower ing the grindi ng shaft.

HUB HAS A LEF T

BEARING

RELIEF FLANGE

RELIEF WHEEL

RELIEF NUT

SPIN NUT

SPIN WHEEL

SPIN FLANGE

FIG. 10

MAKE SURE THE WHEEL(S) IS PLACED ON THE SHAFT WITH THE SAME ORIENTATION AS SHOWN. FAILURE TO INSTALL CORRECTLY WILL CAUSE THE WHEEL NUT TO LOOSEN. (THE NUT ON THE RELIEF HUB SHOULD BE TO THE RIGHT & THE NUT O N THE S PIN HUB SHO ULD BE TO THE LEFT.)

Reinstal l the bearin g on the left s ide of the gr inding shaft making sure to fit the pi lot on the bearing into arm. Tighten the four mounting screws, and then tighten the setscrews to the shaft. R einstal l the left side cover panel. Mov e bearing s upport bracket back into place. See rel ief hub bearing adjustm ent to set the bracket correctly .

Loosen bolts and ti p bracket back. Press in the indexing finger and the wheel should slide freel y to the r ight.

FIG. 11

MAINT ENA NCE (Continued)

GRINDING MOTOR BELT REPLACEMENT/ ALIGNMENT

To replace or i nspect the grindi ng motor bel t, remove the right si de cover p anel. To remove the belt, pull down on the tensi oner pul ley .

For the bel t to function properl y the gr indi ng shaft pulley and the gr i ndi ng m otor pul ley m us t be i n l i ne with the tensioner pulley . To adjust the pulley position loosen the s etscrew s on the pulley. Locate the belt in the center of the idler pull ey. Measure from the arm to the edge of the belt at the idler pull ey. Adj us t the tw o other pul l ey's unti l the same measurem ent is achiev ed and tighten the pulley setscrews.

Reinstall the right side cover panel, then r un the grind motor to ass ure that the belt is not m isal igned. The belt will walk off the pulley if the system is not aligned properl y.

TRAVERSE BELT REPL ACEMENT

T o r eplace the traverse belt, r emove the left side cover panel, then loos en the nuts on the left si de pulley that are used to tensi on the belt. Remove the right side c over panel. Loosen the sc rews holding the traverse motor and ti lt the bottom of the motor out releasing any r emaining tensi on on the belt. On the left side r emove the nut from the bottom belt tensioning screw, this will allow the belt to be removed.

Place a new bel t on the l eft pull ey m ak ing s ur e i t i s seated properly in the c ogged teeth and r eplace the locknut. Feed the new belt throught the slot on the right arm and plac e on m otor pul l ey. Use the motor as a lever to apply tensi on to the new belt. Tighten motor scr ews and adjust the tension in the belt as specified in the BELT TENSI ON section. Adjust the height of the motor pulley if necessary so the belt is located in the center of the traverse bel t clam p.

FIG. 12

FIG. 13

Reinstall the left side and right side cover panels, then test the traver se motor.

MAINT ENA NCE (Continued)

TRAVERSE SHAFT/LINEAR BEARING REPLACEMENT

To replace the traver se shafts or the linear bear ings in the Spin or Relief assembly , first remove the left side cover panel.

REMOVE GRINDING SHAFT : Next you will need to remove the grinding shaft. Fi rst move the relief hub away from the rel ief hub assemlby ( see Replacement of Griniding w heel section for details). Then r emove the grinding motor belt and pul ley (see Gr inding M otor Belt Replacement). N ow l oos en the sets cr ew s on the right side bear ing to all ow the grinding shaft to slide out of the beari ng. Next r emove the left side gr indi ng shaft bearing. The grinding shaft is heavy so tak e appropriate measures when lifting or r emoving. To remove the gr inding s haft lift up on the left end and slide the shaft out of the right side bearing. Set the shaft on the floor or bench out of the way .

2. REMOVE REAR PIVOT BOL T

1. REMOVE GRI NDING SHAFT AND TRAV ERSE BEL T

THE GRINDING SHAFT WEIGHS 75LBS [34 Kg] USE APPROPRIATE LIFTING DEVICES TO AVOID INJURY.

REMOVE TH E TRA VER SE BELT: (See Traverse Belt Repl ac ement s ect i on)

REM OVING TH E TRA VER SE SHAFTS: To remove the traverse shaft s use the ver tical adjusters to low er both grindi ng shaft support arm s until they are in there lowes t position. Now r emove the left grindng s haft support arm. To remove the left arm, first rem ove the bolt at the r ear of the machine. (It may be neces sary to c lamp onto the s haft that the bolt is screwed into s o that it does not spin.) After removing the bolt, pull the arm off the rear shaft. Now move the arm toward the r ear of the machine to disengage the front of the arm from the vertical adjuster. Next pull the arm aw ay from the gri nder and off the traverse shafts. ( Note, the shafts may come out of the r ight s i de ar m so support the shafts.)

Slide the Spin and Relief Gr inding Head Assem blies off the traverse shafts.

Replace the s hafts if necessary . REPLACI NG THE TRA VERSE BEARI NG:

T o r eplace the traverse beari ngs, press the bearings out of the bearing housing. Sl ide in the new bearings and secure in place with the seal s. (Two bearings go in the front and 1 bearing the rear of the housing).

3. LIFT ARM OFF REAR PIVOT SHAFT AND SLIDE ARM BAC K THEN OUT.

TO REASSEMBLE: Clean the 2 spher ical beari ngs in the right ar m and place the trav erse shaft into the bear ings. (The shafts should sl ide into the bearings. There is ver y m ini m al c l ear ance s o the shafts need to be preciesly aligned for the shafts to slide into the bearings.) Next slide the gri nding head assemblies ( spin firs t then r elief) onto the traverse shaft s. Now , clean the bear ing in the left arm. Then align the bearings i n the left arm to the two traverse shafts. The shafts should slide into the bearings . Reinstall the left arm into the v ertical adj uster hous ing and onto the rear support s haft. Reinstall the rear pivot bolt and tighten. Continue to instal l the traverse belt, gri nding sh aft, and gri nding m otor bel t. See the sections on Traverse Belt Replac ement, Repl acement of Gr inding Wheel, Grinding Motor Belt Repl acement, T r averse Belt T ens ion, and Rel ief Grind ing Head Beari ng Adjustm ents for addtional detai ls.

Fig. 14

MAINTENANCE (Continued)

CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE

WINDOWS

Cleaning In str uction s

DO NOT USE GASOLINE Adhe r en c e to r e gu la r and pr ope r cleaning procedures is recommen ded to preserve appearance and perform an ce.

Washing to Minimize Scratching

Wash polycarbo nate w indows w ith a mild dish w ashing liquid detergent and lukew arm w ater, using a clean soft spon ge or a sof t c loth. Rinse w ell w ith clean w ater . Dry thorou ghly w ith a m oist c ellulose spo nge to prevent water spots. Do not scrub or use brushes on these windows. Also, do not use butyl cellosolve in direct sunlight. Fresh paint splashes and grease can be removed easily before drying by rubbing lightly with a good grade of VM&P naphtha or isopropyl alcohol. Af terward, a warm final wash should be made, using a mild dish wa shing liquid detergent solution and ending with a thorough rinsing with clean water.

Minimizing Hairline Scratches

Scratc hes and minor abras ions can be minim ized by using a mild autom obile polish. Three such product s that tend to po lish and fill scratches are Johnson pa ste Wax, No vus Plastic P olish #1 and #2, and Mirror Glaze plastic polish (M.G . M10 ). It is suggested that a test be m ade on a corner of the polycarbonate window with the product selected following the polish manufacturer's instructions.

Some Impo rtant "D ON'TS"

♦ DO NOT use abr asive or highly alkaline cleaners on the pol ycarbonat e window s. ♦ Never sc rape polycarbonate w indows wit h squeegees, razor blades or other sharp

instrument s.

♦ Benzene, gasoline, aceton e or c arbon tet rachloride should NEVER be used on polycarbona te

windows.

♦ DO NOT clean polycar bonate windo ws in hot sun or at elevat ed tem pera tures.

Graffit i Removal

• Butyl cellosolve, (for removal of paints, marking pen inks, lipstick, etc.)

• The use of m asking tape, adhesive tape or lint removal tools works well f or lifting off old

weathered paints.

• T o rem ove labels, stickers, etc., the use of kerosene, VM &P naphtha or petroleum spirits is generally effective. When the solvent will not penetrate stickier material, apply heat (hair dryer) to soften the adhesive and promote removal.

GASOLINE SHOULD NOT BE USED!

MAINTENANCE (Continued)

DIGITAL GAGE Impor tant

Do not mar k the scal e unit w i th an elect ric engrav er or scr atch the scale.

Always use an SR44 battery (silver oxide cell)

If the scale will not be used for more than three months, remove the battery and stor e it p rop erly. Otherw ise, leakag e, if any, from the battery m ay damage the unit.

Description of Parts

1. Beam 2. Main Scale

3. Battery com par tm ent 4. Outp Connecti on

5. Display 6. ON/OFF Power

7. ZERO/A BS switch 8. Origin Switch

9. Inch/mm Switch 10. T apped hole

11. Slider

Battery Installation and Origin Setting

Set the origin of the scale after installing the battery. Otherwise, the error s ig n(" E" at the least sig nif icant digi t) m ay ap pear, resulti ng in inc orrect m easur ements.

1) To ins tall the batter y, remove the c om partm ent l id and install the SR44 battery with its positive side facing up. After the battery i s install ed, set the ori gin.

2) To set the origin, move the slider to an area you wish to set as your origin. Turn the power on. Hold the ORIGIN switch down f or m ore than one second. The " 0.00" di sp lay appear s, indicat ion Orig in setti ng is com plete. The or igin will be retained even if the power i s t ur ned of f.

Incremental (INC) & Absolute (ABS) mode

The LCD will dispay measurements from the origin when turned on (ABS mode) . To s et the ori g i n see above. The display can be set to zero at any desir ed pos i ti on b y p r ess i ng the Z ER O/ ABS s witch. INC indicat or will apper in the displa y (INC mode), permitting measur ements from this zero p oint. To return to the ABS m ode hold the ZERO/ABS button for m m ore than 2 seconds.

Error Symptoms & Remedies

 ERRC and display flickering: Occurs when the scale

surfac e i s s tai ned. Clean the scal e s ur f ac e and c oat a thi n film of low viscosity oil to keep out moisture.

 E in the least significant digit: This occurs when the

slider is m ov ed too q uick ly, but it does not affect t he measurement. If it stays on when the slider stops, the scale surfac e is p rob abl y stained. If this i s the case, t ake remedies a s for ERRC.

 B indication: Bat tery v oltage i s low. Rep lac e the

battery as s oon as possi ble.

Cleaning

Clean gage with CRC 3-36 Cleaning and Lubrication OIl. Wipe off excess after cleaning. If CRC 3-36 is no t a vailable , u se Denatured Alcohol to cl ean, then appl y light oil and wipe of f excess.

ADJUSTMENTS

PROXIMITY SWITCH

For the proximi ty swi tch to per form properly and reverse the direc tion of the grindi ng head as sembl y, the sensor end of the pr ox im i t y s wi t ch m us t face toward the head assembly that is in use and must be mounted such that it is located past the edge of the prox holde r .

NOTE: The light on the pr oxim ity sw itch ac tivates when metal is appr oxim ately 3/16" [4.6 mm] from the front of the proximity switch.

FIG. 15

VERTICAL INFEED SHAFT DRAG

If the grinding shaft tends to wal k duri ng grindi ng, the drag on the vertical adj usters needs to be increased. To increase the drag in the ver tical adjustment shafts, tighten the s etscrew on the back of the vertic al adjustm ent housing.

VERTICAL INFEED SHAFT DRAG SETSCREW LOCATED ON BACK OF EA CH TOWER.

FIG. 16

A DJUSTMENTS (C ontinued)

TRAVERSE BELT T ENSION

To adjust the tension on the tr averse bel t, tighten the screws and nuts located to the l eft side of the traverse belt behi nd the left side c over panel to a minimum of 1.75" [44 m m ]. The tr av er se bel t should be l evel w hen adjusti ng the belt ten sion.

DO NOT OVERTI G HTEN. OV E R T I G HTENING C O UL D DAMAGE THE BELT OR TRAVER SE DRI VE SYSTEM.

FIG. 17

TRAVERSE CLAMP FORCE

If the traverse clam p is sli pping during r egular operation it may become necessar y to adjus t the clamp tip loc ation. To adjust the clamp tip, loosen the jam nut and rotate the clam p tip. The cl amp tip should be adjusted to the dimension s pecified in FIG 18. To measure, move the trav erse belt out of the way . M easur e the clamped di stanc e from the clamp tip to the cl am pi ng bl ock ( shoe) . T o secur e the new position, j am the nut against the clam p being careful not to move the clamp tip.

If there is not enough adjustment i n the clamp tip, the bracket that supports the clam p can also be adjusted. The bracket is sl otted, to adjust loosen the two screws that are hol d the bracket in pl ace and slide the bracket forwar d or back. Then retighten the screw s, make s ure they are ti ght or the bracket will move during clamping. Check the tip distance and make any necess ary adj ustments.

10" [2.5 mm ]

FIG. 18

THE TIP HAS BEEN FACTORY SET SO THAT IT WIL L SLIP IF THE G RINDING HEAD ASSEMBLY COMES IN CONTACT WITH SOMETHING. CAUTION SHOULD BE USE D AS ADJUSTING THE TIP WILL AFFECT THE SLIP LOAD AND COULD DAMAG E THE CLAMP TIP, BELT OR TRAVERSE DRIVE SYSTEM.

A DJUSTMENTS (C ontinued)

SPIN GRINDING HEAD WEAR PADS

The bronze wear pads used to move the spi n wheel will wear and may need to be adjusted or replaced.

When pad wears to within a 1/16" [1.5 mm ] of the screws, the pad will need to be flipped or repl aced. The holes i n the pads are offset sli ghtly, this allow s the pads to be flipped if neccessary to accompl ish the best fit. When installing new pads, flip or rotate the pads until Gap 2 is as small as possible w ithout the pads pinching the wheel.

On the spin grinding head assem bly, the distance from the pad to the wheel can be adjusted i n and out by loosening the scr ews loc ated on the sides of the yokes. Gap 1 shoul d be adjusted to about 1/16" [1.5 mm]. See FI G. 19

SAFETY SWITCH ALIGNMENT/REPLACEMENT

FIG. 19

The safety switch located on the front and rear guard door must line up properl y or the grinder will not function.

The front door switc hes m us t be w ithi n 1/4" [6 m m ] and the targets on the switches m ust li ne up in order for the switch to function proper ly . See FI G. 20 and 21.

The switches and the key are attached to the guarding using a "Torx" style t amper r es i stant screws. A tool for this type of screw i s r equi r ed to m ak e thi s adj ustm ent.

The rear door s witc h may need to be adj usted so that the key sli des smoothl y into the door safety swi tch. I f the switch and key do not al ign, l oosen the scr ews on the switch or key housi ng and adjust until they ar e aligned. Then ti ghten al l scr ews and check the function of the rear door and door switch.

If the door has too much side to si de play, this may cause alignment i ss ues w i th the door sw i tc h. To adjust, loosen the scr ews that hold door s lides . Then push the slides towar d the c enter of the machine to remove any side to side pl ay in the door . Retighten the screws and test then door unti l the key consis tently engages the switch.

FRON T DOOR SWITCH (INSIDE UPPER RIGHT SIDE)

FIG. 20

REAR DOOR SWITCH

DOOR SLIDE SCREWS

(THERE AR E 6 PER SIDE)

FIG. 21

A DJUSTMENTS (C ontinued)

RELIEF GRINDING HEAD BEARING ADJUSTMENT S

It may be necessar y to adjust the guide bear ings on the relief head. To adjust the posi tion of the support bear ings, POSITION THE GRIND ING HEAD A T THE F AR LEFT POSITI ON, loosen the two positi oning bolts located on the side of the support assem bl y. Press on the suppor t ass em bly until the top support bear ing is touc hing the gri nding wheel hub. Hold the suppor t in plac e with the bearing touching the hub and tighten the two positi oning bolts. Check to see that the bearing is touching or has mi nimal clear ance to the hub through the full range of left to right tra vel.

NOTE: EXCESSIVE PRELOAD OF THE BE ARING ASSEMBLIES ON THE HUB CAN CAUSE THE BEARINGS TO WEAR QUICKER AND COULD CAUSE THEM TO FAIL PREMATURELY.

T o p Suppo rt Bear ing Assembly

Bracket Positioning Bolts

FIG. 22

CONTROL BOA RD POTENTIOMETER ADJUSTMENTS

POTENT IOMETER ADJUST MENT S T RAVERSE DRIVE CONTROL (TDC)

Min. Speed- -Factory set at full (CC W) 8:30. D o not chang e this s etti ng . (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 traverse motor may be improved by slight adjustment of the IR COMP pot clockwise from its factory-set position. Overcompensation causes the motor to oscillate or to increase speed when ful ly loaded. If you reach such a p oint, tur n the IR COM P p ot countercloc k wise until the symptom s di sap pear.

Max. Speed--Set at 3:30 for maximum voltage of 90 Volts DC to the traverse motor. When voltage is above 90 volts DC, the traverse motor will start to pulsate and not run sm oot hl y.

(Rig ht Trav erse) For ward Acceler ation--F actory set at ful l (CC W ) 8:30. Do not chang e this setting . (Left Traverse) R evers e Acceleration-- Factory set at f ull ( CCW ) 8:30. Do not chang e this setti ng. (DB) D ead Band is t he p otenti ometer setti ng f or t he 50 or 60 Hz c ycl e contr ol . Factor y set to 9:00, w or k s for both

50 and 60 Hz. D o not change this set ti ng . Calibrating the DWELL TIME rotary DIP switch adjusts the amount of time the process remains in the stop position

after a limit switch is actuated. The DWELL TIME range is adjustable from 0-4 seconds. A DIP switch setting of 0 sets the DWELL TIME to 0 seconds, while a setting of 9 sets the DWELL TIME to 4.5 seconds. Dwell time is preset to #4 setting for a 2 second dwell time when reversing at each end of stroke. A setting of 6, sets the dwell time at 3 seconds, etc.

Diagnostic LED's indicate the function that is currently being performed:

POWER indicates that AC power is being applied to the control. FORWARD indicates t hat the process is runnin g in the forward dir ection

(traversing left).

REVERS E indicates that th e process is r unning in the reve rse direction

(traversing right). PROX 1 FWD LIMIT lights when the forward limit switch is actuated (left prox.). PROX 2 REV LIMIT light s when the reverse limit sw itch is actu ated (right prox.). DWEL L lights w hen the pro cess remains stopped after a proximity switch is

actuated.

Potentiometer Clock Orientation

FIG. 23

CONTROL BOARD POTENTIOMETER ADJUSTMENTS (Continued)

SPIN DRIVE CONTROL BOARD (SDC)

The Spin Drive Control Board has four potentiometers, two switches and one dial as shown on FIG. 24. These potentiometers,swtiches and dial have been set at the factory to the positions shown on FIG . 24.

In the Relief Gr inding Mode--

The T orque Shut Off mode selector allows you to turn on or off the T orque Shut Off feature. When switch 1 is set to ON, the board w ill decrease t he sp in motor torque on ce the shu t time is achieved after leaving the right pro ximity sens or . The amount of ti m e i t takes bef ore t he torque i s decreased is set with t he Torque Shut O ff Del ay di al . The spin m ot or toque will be increased to the higher value once the right proximity switch is activated again. If the T orque Shut Off selector is in the OFF position the torque will rema in co ns tan t du ring relie f grind ing . Th is s hould be set to OFF.

T orque Shut Off Delay dail is used to set the duration of time before the torque is decreased after leaving the right proximity sensor during relief grinding. If the dial is turned clockwise (higher number) the higher torque value will stay on fo r a lon ger period of time.

The Relief Speed (RSP) and the Relief T orq ue Pot (R TP) interact with each ot her . The (RSP) is located on the s pin board as a remote speed preset at 12:00 (20 Volts DC). See FIG. 24. The (RTP) is located on the control panel and is for relief torque adjustment.

Relief S peed Pot (SPEED) when r otated clockwise will in cr eas e s pin d rive speed (the speed at which the reel indexes to the next blade). This speed should never be above the 3:00 setting.

Relief T orque Pot (TORQ) is us ed to vary the reel to finger holding torque for relief grinding. The recommended starting point is 30 in/lbs of torque setting. Never adjust the (RTP) potentiometer dial past the red line marking. Setting the reel to finger torque to high could cause the spin motor system to not operate smoothly.

Relief Idle T orque Pot (ITP) is used to vary the reel to finger holding torque once the shut time is achieved after leaving the right proximity sensor if the Torque Shut Off Selector is set to on.

In the Spin Grinding Mode- - The S pin Torque P otentiometer (STP) and the S pin S peed Pot (SSP) inte ract with ea ch other . The (STP) is located on the sp in board as remote torque pres et at 2:00 for torque s etting. See FIG . 24. T he (SSP) is located on the control pan el and is for sp in speed adjustment.

Spin T orque Pot (STP) controls maximum torque allowable in the spin grinding cycle only. This should never be adjusted past the 3:00 position. If the reel does not turn check that the reel is free turning by hand spinning with the power off and the spin drive disconnected.

The Spin speed Pot (SSP) controls reel spin speed, adjust as required. This controls the spin drive speed for spinning the reel.

IR CO MP Pot --

The IR Compensation is factory set at 9:00. Regulation o f the spin or relief grind s pin motor may be improved by a slight adjustment of the IR COMP p ot clockwis e from its

factory-set position. Overcompensation causes the motor to oscillate or to increase speed when fully loaded. If you reach such a point, turn the IR COMP pot counterclockwise until symptoms just disappear.

RELIEF SPEED POT (SPEED) 12 :00

SPIN TORQUE POT (TORQ) 2:00

IR COMP POT 9:00

DELA Y SET TO 1

SWITCH 1 SET TO OFF

IDLE TORQUE POT (ITP) 10:00

Potentiometer Clock Orientation

FIG . 24

ELECTRIC A L TROU BLESHOOT ING

SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING

This Electr ical Troubleshooting sect ion is designed for techni cians w ho have the nec essar y electr ical knowledge and skills to reliably test and repair the RG5500 electrical system. For those without that background, service c an be arranged thr ough your l ocal dealer.

This section presumes that you are already familiar with the no rmal operation of the Grinder. If not, you should read the Operator's Manual, or do the servicing in conjunction with someone who is familiar with its operation.

Persons without the necessary knowledge and skills should not remove the control panel cover or attempt any internal troubleshoo ting, adjustm ents, or parts repl acement.

If you have any questi on not answered in this m anual, please call your l ocal dealer.

WIRE LABELS

All wir es on the RG5500 have a wi re label at each end for troubleshooti ng. The wi re label has a code which tells yo u wir ing informati on. The wi re l abel has a seven positio n code. The fir st two or three digi ts are the wire number : 01-199. The next three num bers or letter s are the code for the com ponent to which the wir e attaches. Example: TDC for T ravers e Drive Contr ol. The last tw o numbers or letter s are the number of the terminal on the component to which the wi re attaches .

TERMINAL BLOCKS:

T o insert or rem ove a wire from the termi nal block insert a sma ll screw driver into the square hole. Then insert or rem ove wir e from th e round hol e. Rem ove screw driver to lock the wire in place.

Note the squ are hole can also be used when checking for voltages. The probe tip of th e m ultimete r can b e inserted into the square hole to take readings.

TROUBLESHOOTING INDEX

AC Main Power Controls...................................................................................................Page 28-30

Grindi ng M otor Co ntrols ....................................................................................................Page 31

Spin Dr ive Controls ...........................................................................................................Page 32-36

Tr averse Drive C ontrols ....................................................................................................Page 37-41

Mech anical T rou blshooti ng................................................................................................Page 42-43

24 VDC Power

Supply (PWR)

CONTROL PANEL

located on the right side of the machine.

Door Safety Sw itch M onitor

(SSM)

Low Voltage Relay

(L VR)

T er minal S trip #2

(TB2)

Magnetic

Contactor

(MAG)

Blue Terminal Blocks (TBB)

Grey Terminal

Blocks (TBG)

Secondary

Circui t Breaker

(SCB)

Main Circuit

Breaker (M CB)

Grinding Motor

Relay (REL)

Tr averse Dr ive

Control Board

FUSES

3A Slow Blow

Tr averse Dr ive

Control Board

(TDC)

Spin Drive

Control Board

(SDC)

T ermial Strip #1

(TB1)

Main Ground Lug

AC Filter

(FTR)

ELECTRICAL TROUBLESHOOT ING (Continued)

PROBLEM--AC Main Power Controls: no electrical power to control panel. Veri fy all w ires show n on t he wiri ng diagram are correct and pull on w ire termi nals wi th approximately 3 lbs f o rce to verify there are n o l o o s e terminal connecti o n s an d/ or no loose crimps between t he wire and the terminal. If problem persists, test as listed below.

Possible Cause Checkout Procedure

Emergency S top Botton(ESS) is Depressed

You must push the System St ar t Sw it ch (SSS) to get power to control Panel

Main Power Cord is not plugged in

Guard doors m us t be closed and ALL Sw itches MUST be turned OFF for contactor to pull in.

Main 20 am p outlet circuit breaker h as tri pped

A. Pull Up on ESS Button

B. Listen for the M agnetic S tarter

(MAG) contacts to pull in with a clunk

C. Plug in main power c or d

D. Clos e guard doors and tur n off

all switche s.

E. Check c irc uit breaker in your building and reset if necessary. (Check wal l outlet with a light to make sure it works)

Machine works Y e s-- end tr ouble shooti ng No--go to S tep B. next

Machine works Y e s-- end tr ouble shooti ng No--go to step C. next.

Machine works Y e s-- end tr ouble shooti ng No--go to step D. next.

Machine works Y e s-- end tr ouble shooti ng No--go to step E. nex t.

Machine works Y e s-- end tr ouble shooti ng No--but li ght works in outlet- -go to S tep F. next. No--and light does not work i n outlet. Y ou m ust solve your power del ivery problem independent of machi ne.

No 120 V olts AC pow er to Filter (FTR)

No 120 V olts AC power out of Filt er

No 120 V olts AC pow er to Main Ci rcuit Breaker ( MC B)

No 120 Vol ts AC power from Main Ci rcuit Breaker ( MC B)

F. Check for 120V at Cord into FTR (Power Cord #32) [Blue wire to Brown wir e]

G. Check for 120V out of FTR [Blue wire to Brown wir e]

H. Check for 120V to MC B

I. Check for 120V to MCB

FTR "Li ne" Terminal s for 120 Volts AC Y es--Go to Step G. next. No--Repl ace Cor d - ( 5NT6059054)

FTR "Load" Termi nals for 120 V ol ts AC Yes--Go to S tep H. next. No--R eplace F ilter

Measur e 120 V AC from M CB Terminal (01MCB--) to Terminal Block 4 (02TBW-4) blue ( use square hol e) Y es- -Go to S tep I. next. No--Chec k wi res & repl ace i f needed.

Measur e 120 V AC from M CB Terminal (03MCB--) to Termi nal Bloc k 4 blue (02TBW-4) Y es- -Go to S tep J. next. No--Flip Switch on MCB to "ON" Machin e works -- en d trouble sh ooting Machine does not work -- check MC B

ELECTRICAL TROUBLESHOOT ING (Continued)

Possible Causes

No 120 V ol ts AC power to Secondar y Circuit Br eaker (SCB) 6 Amp.

No 120 V ol ts AC power from Secondary Cir cuit Breaker (SC B) 6 Amp.

120 V olts AC power not deli vered to T erminal S trip

Grinding Motor Switch (GMS) not working

Checkout Procedure

J. Check for 120V to SCB

K. Check for 120V from SC B

L. Check for 120 Volts AC at

terminal s tri p.

M. Check for 120 Volts AC at GMS Termin als 1 (swi tch must be in the off posi tion)

Measure 120 VAC from SCB (03SCB--) to nuetral (blue) terminal out of FTR ( 02FTRBU ) Y es- -Go to Step K. next. No--Chec k wi res & repl ace i f needed.

Measure 120 VAC fromSCB (67SCB--) to nuetral (blue) terminal out of FTR ( 02FTRBU ) Y es-- Go to Step L. next. No--Flip Switch on SCB to "ON"-Machine works--end of troubleshooting. M achine does not work --check SC B

Measure 120 VAC from Terminal "11" on Terminal Strip 2 "07TB2-1 1" to nuetr al (blue) terminal out of FTR (02FTR BU) Yes--Go to S tep M. next. No--Chec k continuity of wi res #07 and #03, ver ify terminal block Jumper are installed on Grey Blocks 1-3.

Measur e 120 VAC from GMS Termi nal 1 to nuetral ( bl ue) terminal out of FTR (02FT RBU) Yes--Go to S tep N. next. No--Fl i p Swi t ch and c heck again- Works-- Sw itc h i s upside down. S till no 120V AC- - Check wi ring/V er ify Continuity/ R eplace Swi tch

Spin Motor Switch (SMS) not working

Bad Emergency Stop Swi tc h (ESS)

Bad System S tart Switch (SSS)

Low Voltage Relay (REL) not operating

N. Check for 120 Volts AC at SMS Terminal s 1 (sw itch must be in the off posi tion)

O. Check voltage after the (ESS) MAKE SURE SWITCH IS PULLED UP!

P. Hold in SSS and Check voltage after the (SSS)

Q. Hold in SSS and Check voltage at LVR. LVR must be installed i n 8- pin socket.

Measure 120 volts AC from SM S T ermi nal 1 to nuetral (blue) terminal out of FTR (02FT RBU) Y es- -Go to Step O. next. No--Fl i p Swi t ch and c heck again- Works-- Sw itc h i s upside down. S till no 120VAC -- Check Wiring/ V erify Continuity/ R eplace Swi tch

Measure 120 Volts AC from (ESS) terminal 2 to nuetral (blue) term inal out of FTR (02FTR BU) Y es- -Go to S tep P. next No--Check wir e for continuity, then verify swi tch continuity . I f bad replace ESS contactor ( NC)

Measur e 120 Volt s AC from (SSS) term 3 to nuetral (bl ue) terminal out of FTR (02FT RBU) Y es- -Go to Step Q. next No--Check wir e for continuity, then verify swi tch continuity . I f bad replace SSS contactor (N O)

Measure 120 Volts AC from LVR term 8 to nuetral (blue) terminal out of FTR (02FT RBU) Y es- -Go to Step R. next No--Chec k for 120 V olt s AC from LVR term 6 to term 7. Y es- -Verify Continuity from term 1 to term 8 on L VR. Replace LVR if bad. No--V erify Continuity of LVR Wires.

Bad Mai n Contac tor (MAG)

R. Hold i n SSS and Check voltage at MAG A1 & A2.

Measure 120 V olt s AC from M AG Term A1 to Term A2 Y es- -M AG Should pul l in with clunck, if not repl ace M AG. No-- V erify Continu ity of Wires to M AG A1 and A2

ELECTRICAL TROUBLESHOOT ING (Continued)

PROBLEM--Machine Shuts off when you turn on Grind motor switch or Spin Motor Switch.

Possible Cause

Checkout Pro cedure

Guard Doors ar e Open

Door Safety Switches ar e not work ing proper ly

No 24 Volts DC to Safety Monitor (SSM)

No Power into 24 Volt DC Power Supply (PWR)

No Power Out to Door Switches

A. Close the front doors and rear door

B. Check Alignm ent of Door Safety Switches on front doors and rear door

C. Check SSM for 24 Volts DC. (Turn switches off and press start switch to pull in MAG before testin g voltag es)

D. Check PWR for 120 Volts AC. (Turn switches off and press start switch to pull in MAG before testin g voltag es)

E. Verify 24Volts DC out to Door Switches.

Machine works Y e s-- end tr ouble shooti ng No--go to S tep B. next

See Alignm ent sect ion of thi s Man ual. Machine works Y e s-- end tr ouble shooti ng No--go to S tep C. next

Measur e 24 volts D C from SSM Terminal A1+ to T erm inal A2Y es- -Go to S tep E. next. No--Go to S tep D. next.

Meas ure 1 20 vol ts AC from PWR Termi nal L to T er mi nal N Yes--V eri fy 24 VDC out of PWR (V+ to V-). Replace if no V oltage out; or Chec k Wiring & V erify Continuity to SSM if there is 24 VD C. No--V er ify Wiring and Conti nuity from PWR to terminal blocks (16T BW-12 and 24TBG-8)

Measur e approximatel y 24 volts DC from T er minal S tr ip 1 Terminal 17 (56TB1- 17) to T er minal S trip 2 Terminal 3 (29TB2-3) Y es--Go to Step F. next. No--V e rify Conti nuity of Wires to Termi nal strip, Repl ace SSM i f wi res check OK.

Rear Door Switch or Rear Ramp Switch is Bad

Front Door Switch is Bad

PROBLEM--(MAG) turns on only with System Start Switch held in.

Possible Cause

(MAG) holding contact has failed

F. W ith Rear Door closed or Rear Ramp Closed Verify 24Volts DC back form rear Door Switc h.

G. W ith Front doors Closed Verify 24Volts DC back form Front Door

Switch.

Checkout Procedure

A. Check wiring to and from MAG holding c ontact in. Verify the magnetic starter holding contact is working.

Measur e approximatel y 24 volts DC from T er minal S trip 2 Terminal 3 (29TB2-3) to Terminal S tri p 1 Terminals 14 and 15. Y es--Go to Step G. next. No--Chec k Al ingment of Rear door switch. I f no V oltage to Term14 or 15 then replace r ear switch. If still not working replace cord.

Measur e approximatel y 24 volts DC from T er minal S tr ip 1 Terminal 17 (56TB1- 17) to Terminal S tr ip 2 Terminals 2 and 4. Y es- -Replac e SSM No--Chec k Alingment of Front door sw itch. If no V oltage to Term2 or 4 after alignment then replace front swi tch.

Measure 120 Volts AC at MAG term L3 to Term Block 4(Bl ue) after SSS i s pushed. Y es- -V erify Wiring to L VR No--M easure 120 V ol ts AC at MAG ter m T 3 to Term Bl ock 4( Bl ue) after SSS is pushed. If 120 V ol ts AC Rep lace M AG. I f no 120 V ol ts AC verify wiring to T3.

ELECTRICA L TROUBLESHOOTING (Continued)

PROBLEM-- Gr indin g motor not work ing.

Assuming (SSS) Syste m Start Switch i s o n with 120 volts AC to control panel and all other functions are working.

V erify all wires show n on the w iri ng di agram are correct an d pul l on wir e term inal s wi th appr oxim atel y 3lbs force to verify there are no loose terminal connections and/or no loose crimps between the wire and the terminal. If problem persists, test as listed below.

Possible Cause

Grinding Motor Switch (GMS) is not on

Guard doors are not closed

15 Amp Circuit Breaker (CB) is tripped

GMS no t worki ng

Checkout Procedure A. T urn switch on

B. Close front and rear guard

doors

C. C heck 15 amp CB on the side of the grinder above the control cover . Press in if tripped.

D. Check for pow er to GM S

E. Check for power from GM S

Grindi ng M otor wo rks Y e s-- end tr ouble shooti ng No--go to S tep B. next

Grindi ng M otor wo rks Y e s-- end tr ouble shooti ng No--go to S tep C. next

Grindi ng M otor wo rks Y e s-- end tr ouble shooti ng No--go to S tep D. next

Meas ure 120 volts AC from T er minal strip 2 termi nal #15 to nuetral ( blue) ter minal out of FTR (02FT RBU) Y es- -go to Step E. next No-- check continuity of wires to GMS.

Meas ure 120 volt s AC fr omT erm inal str ip 2 term inal #14 to nuetral ( blue) ter minal out of FTR (02FT RBU) Y es- -Go to S tep F. next No--replace GMS

Grinding Motor Relay not working

No Power to Relay Contacts

Bad Contacts in Grindi ng motor R elay

Bad Circuit Breaker / Bad Gri nding M otor

F. Check for power to relay Coil (Rel ay should c lick w hen GMS i s turned on .)

G. Verify Power to Relay Contacts

H. Verify power out of Grinding

Motor Relay.

I. V eri fy Power to Grin ding motor Cord.

Check for 120 V olts (AC) from A1 to A2 of Gri nding motor Relay (REL) Y es- -Go to S tep G. next No-- check wires to Gr inding m otor Relay A1 & A2.

(REL) Terminal s L1 to L2 for 120 Vol ts (AC) Yes--Go to S tep H. next No--Check wires to REL Term L1 & L2

(REL) Terminals T1 to T2 for 120 Vol ts (AC ) Y es- -Go to S tep I. next No-- Replace Grin ging M otor Relay

V erify wiring at terminals 1, 2 & 3 on T er minal Strip 1. Check 42TB1-1 to 64TB1- 2 for 120 Volts (AC). Yes-- Check motor cord ter minal s. Replac e motor. No-- Chec k c ontinuity of cir cuit break er. Replace.

ELECTRICAL TROUBLESHOOT ING (Continued)

PROBLEM--S PIN DRIV E NOT WORKING IN SPI N MODE .

Assuming (SSS) System Start Switch is on with 120 volts AC to control panel and all other functions are working.

Veri fy all wi res show n on the wiring di agram are correct and pull on wire t erminals w ith approximately 3 lbs fo rce to v eri fy there are n o loo se t erm in al connect i ons and/o r no l oos e cri mp s b etween the w ire and the terminal. If problem persists, test as listed below.

Possible Cause

Spin Speed Pot (SSP) set to zero

Spin Motor Switch (SMS) is not on

Circuit Breaker is Tripped (4 AM P)

Spin Drive Control (SDC) is not working

Checkout Procedure

A. Set (SSP) to 200 on the contr ol panel .

B. Turn (SMS) switch on

C. Reset Circiut Breaker on

right side of machine by above the Control Panel. Push in if tripped.

D. Check (SDS) L1 to L2 for 120 V olt s AC

E. With the Selector switch in spin and the spin pot set to 400RPM Check (SDC) A1 and A2 for 90-120 Vol ts D C

Spin Motor works Y e s-- end tr ouble shooti ng No--go to S tep B next

Spin Motor works Y e s-- end tr ouble shooti ng No--go to S tep C. next

Spin Motor works Y e s-- end tr ouble shooti ng No--go to S tep D. next

(SDC) Remove wires to Terminals L1and L2 and test betwen wires for 120V AC. Yes--reconnect wires to board then go to Step E. next No--V erify Power to C ircuit Breaker and SM S and continuity of wires. Replace CB or SMS if needed.

(SDC) Remove wires, test Terminals A 1 to A2 on the board for appr ox 90- 120 V DC Yes--reconnect w ires and go to S tep F. next No--go to Step G.

Spin Drive motor is bad

Spin drive control in T or que m ode

F. Check spin motor continuity

DISCONNECT POWER FROM MACHINE !

G. Check continuity of mode

selector switch.

Remove wir es at Terminal Strip 1, Term 4 & 5 check 0 ohms ac ross the black and white wires from the motor. Reading 0 Ohms Y es --en d troubl eshooti ng, sp in dr ive sho uld run, if not, replace motor . No--go to S tep J.

Light on SDC next to SP should be ON. If not, remove wires 41SDCMOD and 44SDCCOM from SDC control board. Check continui ty of wires, should read 0 ohms. Light next to SP is on? No--Check continuity of STS switch, replace if bad. (Machine was in Torque mode) Yes-- Light next to SP is on but machine does not work. Rei nstall wir es, Go to Step H. next

ELECTRICAL TROUBLESH OOTING (Continue d)

Possible Cause Checkout Procedure

Spin T orque Pot (TORQ) is not set correctly

(SSP) is not work ing

Worn Motor Brushes

H. Check remote torque pot (TORQ) on the (SDC) board.

I. (SSP) (10K) Remove 3 Remote S peed wires. Red wire to term 2 White wire to term 1 Black wire to term 3

DISCONNECT POWER FROM MACHINE !

J. Inspect Motor Brushes

(TORQ) on (SDC) board, should be set as labled on page 25. Adjust if incorrec t and check Spin Drive Function. All Potentiometers are set correctly Y es- -Go to S tep I. next No--Retes t after adjustments.

Check for 10,000 ohm Red wire to white wire Full CCW--0 o hms Full CW-10,000 ohms Red wire to bl ac k w i r e Full CCW--10,000 ohms Full CW--0 ohms Yes--replace (SDC) No--repl ace (SSP)

Remove the brushes one at a time and maintain ori entation for rei nsertion. See if brush is worn s hort 3/8" ( 10 mm) minim um length. Yes--replace motor brushes No-- replace Spin Dr ive M otor

ELECTRICA L TROUBLESHOOTING (Continued)

PROBLEM--Spin Drive not working in relief mode.

As suming (SSS) System St art Switch is on w ith 120 volts A C t o co n tr ol panel and all other functions are working.

Verify all wires shown on the wiring diagram are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose terminal connections and/or no loose crimps between the wire and the terminal. If problem persists, test as listed below.

Possible Cause

Reli ef T orque Pot (RTP) set to zero .

Spin Motor Switch (SMS) is not on.

Circuit Breaker is Tripped (4 AM P)

Spin Drive Control (SDC) is not workin g

CB or S pin M otor Switch (SMS) is bad

Checkout Procedure

A. Set (RTP) to 20 on the

contr ol panel .

B. Turn (SMS) switch on.

C. Reset Circiut Breaker on

the right side of the machine. Push in if tri pped.

D. Check (SDC) L1 to L2 for 120 V olt s AC

E. Check power into (SMS) terminal 6 for 120 V olt s AC

Spin Motor works. Y e s-- end tr ouble shooti ng No--go to S tep B. next

Spin Motor works. Y e s-- end tr ouble shooti ng No--go to S tep C. next

Spin Motor works. Y e s-- end tr ouble shooti ng No--go to step D. next

(SDC) Remove wires to Terminals L1and L2 and test betwen wires for 120V AC. Yes--reconnect wires, go to Step F. No--Go t o S tep E. next

Remove Wire to SMS Terminal 6 "89SMS -6" and chec k between the wi re and nuetral (blue) terminal out of (FTR) (02FTRBU ) for 120 VAC Yes--Check sw itch continui ty, replace No--Chec k CB conti nuity , replac e.

Spin Drive motor is bad

Worn Motor Brushes

F. Check (SDC) A1 & A2 for approx. 20 Volts DC (Have Reli ef T orque set to maximum torque - full cl ockwi se.

G. Check spin motor continuity

DISCONNECT POWER FROM THE MACHINE

H. Inspect Motor Br ushes

DISCONNECT POWER FROM MACHINE !

Check for approx. 20 VDC from Terminal Strip 1 Terminal 4 ( 48T B1- 4) to T er minal 5 (49T B1-5) Y es- -go to Step G. next No--Go to Step I.

Remove motor wires at T erminal Strip 1 (left side lower strip), Term 4 & 5 and check 0 ohms across the black and white motor wires Y es--end troubleshooting motor should work (i f it does not, replace motor) No--go to S tep H. next

Remove the brushes one at a time and maintain ori entation for reinsertion. See if brush is worn short 3/8" (10 mm) minimum l ength Yes--replace motor brushes No-- replace Spin Dr ive M otor

ELECTRICA L TROUBLESHOOTING (Continued)

Possible Cause Checkout Procedure

Board is i n s pi n m ode.

Relief Speed Pot (RSP) is not set correctly.

(RTP) is not working

I. Spin Torque Selector not working

J. Check (RSP) remot e speed (10k) on ( SD C) boar d

K. (RTP) (10 K) R emo ve 3 Remote Torque Wires red wire to term 2 white wire to term 1. black wir e to ter m 3.

Light next to TQ on SDC boar d should be ON. If not remove wires 41SDCMOD and 44SDCCOM from SDC control board. Machi ne work s. Yes--Machine was in spin mode. Check continui ty of STS switch. Replace i f bad. No-- Light next to TQ is ON but machine does not work, go to st ep J.

V erify (SPEED) pot setting on the ( SDC) board. Should be set as specified on pages 24 and 25. Adjust if incorrect and check Reli ef Torque function. Works Y es- -end of troubl eshooti ng No--go to S tep K. next

Check for 10,000 ohms Red wire to white wire Full CCW--0 o hms Full CW--10,000 ohms Red wire to bl ac k w i r e Full CCW--10,0000 ohms Full CW--0 ohms Yes--go to St ep L. nest No--r epl ace ( R T P)

Switches on SDC incorrect

L. V erify postion of all pots and switch on S DC

Verify postion of 4 pots on board. Should be set as specified on pages 24 and 25. Verify that the Troque reduction feature is in the OFF position. (pushed toward the pots on boar d). Motor works Y es- -end of troubl eshooti ng No--r eplac e SD C .

ELECTRICAL TROUBLESHOOT ING (Continued)

PROBLEM : Spin drive speed goes at one speed only.

Possible Cause

Wiring hookup to potentiometer is improper. (If components have been replaced)

Defective spin speed control (SSP) potentiometer.

Main circuit board dial pot settings not correct. (If board has been replaced

Remedy

A. Ch eck po tent iome ter wir ing for

proper hookup. See that speed pot is wired per electrical diagram

B. (SSP) 10K Remove 3 rem ote speed wires . red wire to term 2 white wire to term 1 black wire to term 3

C. Check all pot settings on both boards as of the (SDC) shown on Pages 25. (See Adjustment Section Spin Drive Control [SDC] Board Set ting).

If wiring is wrong, correct and test. Y es- -end of troubl eshooting No--Go to S tep B. next

Check for 10,000 ohms Red wire to white wire Full CCW--0 o hms Full CW--10,000 ohms Red wire to bl ac k w i r e Full CCW--10,000 ohms Full CW--0 ohms Yes-- Go to S tep C. nex t No--Repl ac e ( SSP)

Y es- - end of troubl eshooting No--replace (SDC)

PROBLEM : Spin driv e m otor speed varies.

IR Comp trim pot not adjusted properly.

Torque to rotate the reel too high.

Check all ter minal connec tions for tightness.

A. See adjustment section for trim pot setting on Page 25.

B. Readjust bearing preload for the reel. Maximum torque load 25 in./lb to rotate r eel.

C. When .250 female spade terminals are not tight, remove and crimp sli ghtly together . When reinstalling, push on pressure should have increased for good contact.

Original adjustment was not set properly

T oo much load on drive motor will cause motor to hunt and vary speed.

When connections are not tight the control board varies voltage to the DC motor which then varies speed.

ELECTRICAL TROUBLESH OOTING (Continue d)

PROBLEM--Traverse Drive not working.

Assuming (SSS) System Start Switch is on with 120 volts AC to co ntrol panel and all other functions ar e working.

Verify all wires shown on the wiring diagram are corre ct and pull on wire terminals with approximately 3 lbs force to verify there are no loose terminal connections and/or no loose crimps between the wire and the terminal. If problem persists, test as listed below.

Possible Cause

Traverse Motor Switch (TMS) is not on

Traverse Speed Pot (TSP) set to zero

Fuse on Tr avers e Drive Control (TDC) has failed

Checkout Procedure

A. Turn on (TMS)

B. Set (TSP) to 35 on th e control

panel

C. Check fuse and replace if faile d. See Pag e 24. T oo he avy a grind causes grinding head traverse motor to overload and blow the fuse. NOTE: The Fuse can not be checked visually. Remove fuse and use Ohm test to check fuse. If the fuse needs replacing you MUST use a 3 amp slo-bl o fuse. Part Num ber 5NT 3707546.

Traverse works Y e s-- end tr ouble shooti ng No--got to S tep B. next

Traverse works Y e s-- end tr ouble shooti ng No--go to S tep C. next

Traverse works Y e s-- end tr ouble shooti ng No--go to S tep D. next

Check power to the Traverse Drive Control (TDC)

Bad Traverse Motor Switch (TMS)

D. Check for 120 Volts (AC) incoming to (TDC) with machine on and TMS set to on.

E. Check for 120 Volts AC at (TMS). (Make certain (TMS) is on)

On (TDC) check Terminal L1 to L2 for 120 V olt s AC Y es- -Go to S tep F. next No--Go to Step E. next

Measure 120 volts AC from TMS Terminal 5 to nuetral ( blue) ter minal out of FTR (02FTRBU) Yes--Check conti nuity of wir es from Switch to Contr ol. Replace w ir es . No--Fl ip Switc h and check againWorks--Switch is upside down. Does not work-- Check wiri ng/V erify Continuity/ R eplace Swi tch

ELECTRICAL TROUBLESHOOT ING (Continued)

Possible Cause

No DC Voltage from (TDC) Traverse Drive Control

Tr averse M otor is bad

(TSP) is not working

Checkout Procedure

F. Check for 90 Volts DC across

(TDC) terminals #A1 to #A2 this voltage drives the DC traverse motor. NOTE: Traverse must be on and have (TSP) tur ned full C W to maximum voltage of 90 VDC

G. Check traverse motor continuity

DISCONNECT POWER FROM MACHINE

H. Check (TSP) (10K) on control

panel

Check (TDC) terminals #A1 to #A2 for 90 Volts DC Y es- -go to Step G. next No--go to S tep H. next

Remove motor wires from T erminal Strip 1 termi nals # 7 & #8 c heck for 0 ohms acr oss the black and w hite wi res

Yes--end troubleshooting, motor should work (i f it does not, replace motor) No-- go to S tep J. next

(TDC) Pi n #8 to #7 Pot Full CCW Pot Full CW 0VDC 9.75 VDC Pin #8 to 9 Pot Full CCW Pot Full CW

9.75 VDC 0 VDC Yes--replace the (TDC) No--go to S tep I. next

(TSP) (10K) is bad

Worn motor brushes

I. Check (TSP) for 10,000 ohms. Remove th ree wires from (TDC) red from term #8 white from term #7 black from ter m #9

J. Inspect Motor Brushes

DISCONNECT POWER FROM MACHINE

Check for 10,000 ohms red to white wires Full CCW --0 o hms Full CW--10,000 ohms Red to black wi r es Full CC W--10,000 ohms Full CW --0 oh ms Yes--replace the (TDC) No--repl ace (T SP)

Remove the brushes one at a time and maintain orientation for reinsertion. See if brush is w orn shor t, 3/8" (10 mm ) mi nim um length. Yes--replace motor brushes No-- replace T rav erse Motor

ELECTRICAL TROUBLESH OOTING (Continue d)

PROBLEM--Traverse does not stop to reverse directions when flag goes under the proximity switch on the left side or right side of machine.

Gap between flag and prox is incorrect.

Proximity Switch is bad.

A. Gap between flag and prox should be 3/16 to 1/4" (4-6 mm). Prox LED does not light when flag is u nder prox.

B. Proximity switch is not working properly or wire connections are loose.

If inc or rect, adj ust per ad just ment section of manual. Y e s-- end tr oubles hooti ng No--go to Step B. next

First check to see if proximity light comes on. When the light is on, it means that there is electricity coming to proximity switch. Actuate prox switches with steel tool to take measur ements.

Left proximity (PROX 1) check Traverse drive Control (TDC) between terminals #13 (black wire) and #15 (br own wi re) .

Right proximity (PROX) check #14 (black wi r e) and #15 (br ow n wire).

The light coming on shows the proxim i t y i s getting el ectri cal contact.

Proximity light on 0 Volts DC Proximity light off 12 Volts DC

Replace proxi mity switch i f the vol tages do not read as above.

ELECTRICAL TROUBLESHOOT ING (Continued)

PROBLEM--Traverse speed control goes at one speed only.

Possible Cause

Defective speed c ontrol potentiometer

Checkout Procedure

A. Check potentiometer (Pot) on

contr ol panel .

B. Check potenti ometer for 10,000 ohms. Remove three wires from Tr averse Dr ive Contr ol red from term #8 white from term #7 black from ter m #9

Tr avers e Dri ve Control Pin #8 to 7 Pot full CCW Pot Full CW 0 VDC 9.75 VDC Pin #8 to 9 Pot full CCW Pot Full CW

9.75 VDC 0 VDC Yes --Po t is O K No--Go to S tep B. next

Check for 10,000 ohms Red to White wires Full CCW - 0 ohms Full CW - 10,000 ohms Red to Black wires Full CC W - 10,000 ohms Full CW - 0 ohms Y es- -Go to Step C. next No--replace potentiometer . Wiper inside of potentiometer controls speed. Wiper may be bad and not making contact.

Wiring hookup to potentiometer is improper. (If components have been repl aced.)

Main circuit board dial pot settings not correct. (If board has not been replaced.)

C. Check potentiometer wiring for proper hookup. See that speed pot is wir ed per el ectr i c al diagr am

D. Check all pot settings on circuit board as shown in wiring diagram. (See adjustment section Traverse Motor Co ntrol Board Settings.)

Verify potentiomter White wire to terminal 7, Red wire to terminal 8 and Black wire to terminal 9, i f not, correct. Check for Pr oper function. Y e s-- end tr ouble shooti ng No--Go to S tep D. next

Mini mum and m axim um pot settings effect travers e speed.

ELECTRICA L TROUBLESHOOTING (Continued)

PROBLEM--If the carriage traverses to one end of stroke or the other and it stops and does not reverse direction.

Possible Cause

Proximity switch is not working pr oper ly or wi r e connections are loose

Remedy

First check to see of proximity light comes on. When the light is on, it means that there is electric it y c omi ng to proximity switch. Actuate proximity switches with steel tool to take meas urements.

Left proximity (PROX1) check Traverse drive Control (TDC) between terminals #14 (black wire) and #15 (brown wire ).

Right proximity (PROX) check (TDC) between terminals #13 (black wir e) and #15 (brown wi re) .

Reason

The light coming on shows the proximi ty is getting electri cal contact.

Proximity light on 0 Volts DC Proximity light off 12 Volts DC

Replace proximity switch if the voltages do not read as abov e.

PROBLEM--Insufficient hesitation at carriage stops prior to reversing traverse.

The dwell time on the traverse drive control not set properly .

PROBLEM--Traverse changes directions erratically while running in traverse cycle.

Loose wire to proximity switch.

Reset dwell time as required. One increment increases Dwell time by 1/2 second.

Check wire connections from the proximity switches and tighten down screws.

A loose wire connection will give intermittent el ectrical contac t.

MECHANICA L T ROUBLESHOOTING

PROBLEM-- Excessive noise or vibration on one end of the machine.

Possible Cause

Set screws on bear ings ar e not tight on grinding shaft.

PROBLEM--Grinding wheel traverse binding.

Possible Cause

Shafts are dirty.

Grinding shaft is at a severe angle.

PROBLEM-- Handwheel or vertical indicator gage "walks" during grinding.

Possible Cause

Checkout Procedure

Ti ghten set scr ews located on bear ings

Checkout Procedure

Clean the shafts as s pecified in the mai ntenance section of this manual.

Raise or lower one end of the shaft until approximatel y level. Thi s grinder i s not desi gned to operate at a severe angle. Adjus t reel or setup until the sh aft is approxim ately le vel.

Checkout Procedure

Bracket connecting gage to v ertic al adjuster is loose.

Plug and set screw loos e.

PROBLEM--Reels ground have high/low bl ades

Possible Cause

Traverse Speed set too fast.

Push lightly up and down on the digital gage to see if it is l oose. Tighten the screws on the bracket to the vertical adjuster or remove the gage and tighten the scr ews from the br acket to the gage.

Ti ghten the drag on the verti cal shaft s by tightening the setscr ew located on the back of the verti cal adjus ter husin g. (See Vertical I nfeed Shaft Drag in the adjustm ent section.)

Checkout Procedure

Check roun dness using the digital gage. Tr averse speed shoul d be set approx imately 12 ft/ min. (4 meter s/m i n.) i f roundness i s var yi ng.

MECHA NICA L TROUBLESHOOT ING (Continued)

PROBLEM - - Uneven traverse sp eed o r g rinding stock removal from reel is irregular.

Possible Cause

Linear bearings ar e damaged or hav e gr it bui ldup causing uneven traver sing load.

Grinding shaft or wheel s have gr it buil dup causi ng uneven load ing.

Left side traverse pulley i s full of grit causing the pulley not to turn freely on s haft.

PROBLEM--Traverse Belt Slips

Possible Cause

Clamping ti p is not adjusted pr operly .

Checkout Procedure

Clean shafts and bearings accordi ng to the lubr icati on of Grinding Shaft and Linear Bearings instructions in the Maintanc e Secti on of the manual. If problem persists replac e linear bear ings ac cording to the replacement of l inear beari ngs instr uctions.

Clean the w heel flanges and shaft ( see Lubricati on of Grinding Shaft). Replace flanges or shaft if necessary.

Clean and l ubricate the shaf t and pull ey .

Checkout Procedure

Adjust the clamping ti p as specified in the T raverse Clamp For ce sect ion of this manual.

Too heavy a gr ind for traver se speed.

PROBLEM-- Too heavy a burr on cutting edge of reel blades.

Possible Cause

Travers e speed set too high causing a heav y burr on the reel blade when s pin gri nding.

PROBLEM--Cone shaped reel after grinding.

Possible Cause

Grinding head travel not paral lel to the reel c enter shaft.

PROBLEM--Relief grind on the reel blades do not go the full length of the reel.

Slow the traver se speed or back off on the amount that is being i nfed.

Checkout Procedure

Travers e speed should be s et lower approxi mately 12 ft./min (4 meters/min.) for a smaller burr on the cutting edge.

Checkout Procedure

Grinding head travel was not setup parall el to the reel center shaft in verti cal and horiz ontal planes. See Align the Reel Sec tion.

Possible Cause

Need to adjust the finger stop. Need to dress the Wheel to the corr ect angle

Checkout Procedure

Adjust finger s top and check for c ontact full length. Dress the wheel (F or more detai l, see r elief gri nding

section in oper ating instruc tions of the manual.)

EXPLODED VIEW: CA BINET A ND DOOR A SSEMBL Y

P A RTS LIST: CA BINET AND DOO R ASSEMBL Y

DIAGRAM NUMBER

1 .............................................. 5NTRG5509504 ........... Cab ine t Weldme nt

2 .............................................. 5NT B 191 0 1 3................ 10 -24 x 5/8 Butto n He ad Sock et Cap Scre w

3 .............................................. 5NT B 2 50 8 1 6................ 1/4-20 x 1/2 Button Head Socket Cap Screw

4 .............................................. 5NT B 3 71 2 0 1................ 3/8-16 x 3/4 He x head Cap Screw

5 .............................................. 5N TJ 1 9 7 0 0 0................. 10-24 L ockn ut Ja m Nylon Ins ert

6 .............................................. 5NT K 2 51 5 0 1................ 1/4 Lockw as her S plit

7 .............................................. 5NT K 370 0 0 1................ 3/8 SAE Flat Wash er

8 .............................................. 5NT K 3 71 5 0 1................ 3/8 Lockw as her S plit

9 .............................................. 5NT09891 .................... Grab Ha ndl e En clo su re

10 ............................................ 5NT55279 .................... T ap er Ch ar t De ca l

11............................................. 5NTRG5509001 ........... Side C over Pan el - Rig ht Ha nd

12 ............................................ 5NTRG5509002 ........... Side C over Pa nel - L eft Han d

13 ............................................ 5NTRG5509003 ........... Elect rica l Cover Pane l

14 ............................................ 5NT155301 .................. Fro ntier De cal - La rge (p art of Lab el Shee t)

15 ............................................ 5NT155301 .................. RG 5500 De cal ( par t of La be l She et)

16 ............................................ 5NT155301 .................. Tooling Bar Pos ition D eca l (p art o f Labe l She et)

17 ............................................ 5NT55490 .................... Door Shi pping Brack et

18 ............................................ 5NT80413 .................... Patent D eca l

19 ............................................ 5NT 3 7 0 8 37 8 ................ Foa m Str ip .25 Thi ck (Sold per F oot)

PART NUMBER

DESCRIPTION

20 ................................................................................. Whee l RPM C auti on De cal (se e pa ge 7 of Op erators Manual)

21 ................................................................................. Sharp C autio n De cal (s ee pag e 7 o f Oper ators Manual)

22 ................................................................................. Electrical Warning D ecal (se e pa ge 7 of Op erators Manu al)

23 ................................................................................. Machine Ca ution Dec al (s ee pag e 7 of Ope rato rs Manual)

................................................ 5NT155301 .................. T o oling Lo catio n De cal ( Not Sho wn- p art o f Lab el Sh eet)

EXPLODED VIEW: CA BINET A ND DOOR A SSEMBL Y

P A RTS L IST : CA BINET A ND DO OR A SSEMBL Y

DIAGRAM NUMBER

1 .............................................. 5NT B 191 0 1 3................ 10 -24 x 5/8 Butto n He ad Sock et Cap Scre w

2 .............................................. 5NT B 2 50 8 0 1................ 1/4-20 x 1/2 He x Hea d Cap Screw

3 .............................................. 5NT B 3 71 6 1 6................ 3/8-16 x 1.0 Button Head Socket Cap Screw

4 .............................................. 5NT B 3 73 2 1 6................ 3/8-16 x 2 Button Head Socket Cap Screw

5 .............................................. 5NT 3 70 9 37 2 ................ H ole Plu g .50 Dia meter

6 .............................................. 5N TJ 1 9 7 0 0 0................. 10-24 L ockn ut Ja m Nylon Ins ert

7 .............................................. 5N TJ 31100 0................. 5/16- 18H ex Full N ut

8 .............................................. 5N TJ 3 1 7 0 0 0................. 5/16 Lockn ut Ja m Nylon In s ert

9 .............................................. 5N TJ 3 7 7 1 0 0................. 3/8-16 Loc knu t Full Ny lon In ser t

10 ............................................ 5N TJ 5 0 70 0 0................. 1/2-1 3 Lo ckn ut Ja m Nylon Ins ert

11............................................. 5NT K2 5 1 5 0 1................ 1/4 Lockw as her S plit

12 ............................................ 5NT K3 7 0 1 0 1................ Flat Wash er 3 /8 H ea vy

13 ............................................ 5N TR00 0 453................ 5/16 ID x 7/8 OD x 1/8 Thick Wash er

14 ............................................ 5NT09891 .................... Grab H an dle E nc los ure

15 ............................................ 5NT50234 .................... T ool ing B ar- Mac hine d

16 ............................................ 5NT80421 .................... Retaini ng C lip - Ga s S p ring

17 ............................................ 5N TH 2 5 1 2 0 2................ .25 Diameter x 3/4" lon g R oll-Pin

18 ............................................ 5NT55713 .................... Doo r Weldme nt

19 ............................................ 5NT55430 .................... Arm Weld ment - Sho rt

PART NUMBER

DESCRIPTION

20 ............................................ 5NT55431 .................... Arm Weldment - Lon g R ight H and

21 ............................................ 5NT55433 .................... Arm Weldment - Lon g L eft Ha nd

22 ............................................ 5NT 6 5 0 9 18 2 ................ Windo w R etai ning Brac ket - Me dium

23 ............................................ 5NT 6 5 0 9 1 1 0................. Window R eta ining Brac ket - Lo ng

24 ............................................ 5NT55465 .................... Polyca rbo na te Wind ow - Fo rmed

25 ............................................ 5NT80416 .................... Air S pr ing

26 ............................................ 5NT80418 .................... Air Sp ring S tud

27 ............................................ 5NT 3 7 0 6 07 5 ................ S pirol Pin .25 Dia. x 1.0 Lon g

28 ............................................ 5NT 3 7 0 8 37 8 ................ Foa m Str ip .25 Thi ck (Sold per F oot)

29 ............................................ 5NT 3 7 0 8 88 9 ................ Foam Seal .5 0 Hig h (Sold per Foot)

30 ............................................ 5NT 3 7 0 8 89 0 ................ S to ra ge H oo k

31 ............................................ 5NT 3 7 0 6 04 4 ................ Ga ge M oun tin g Pin

32 ............................................ 5NT 6 3 0 9 1 11 ................. Up/D ow n De cal

P A RTS LIST: REAR DOOR A SSEMBL Y

P A RTS LIST: REA R DO OR A SSEMBLY

DIAGRAM NUMBER

1 ..................................5NT B 1 90 6 1 3 .............................Button Head Socket Cap Screw 10-24 x 3/8 Long

2 ..................................5NT B 2 51 0 1 6 .............................Button Head Socket Cap Screw 1/4-20 x 5/8 Long

3 ..................................5NT B 2 50 8 1 6 .............................Button Head Socket Cap Screw 1/4-20 x 1/2 Long

4 ..................................5NT B 3 72 0 1 6 .............................Button Head Socket Cap Screw 3/8-16 x 1-1/4 Long

5 ..................................5NT B 3 72 4 1 6 .............................Button Head Socket Cap Screw 3/8-16 x 1-1/2 Long

6 ..................................5N TJ 1 6 7 0 0 0 ..............................8-32 Lock N ut Ja m

7 ..................................5N TJ 1 9 7 0 0 0 ..............................10-2 4 Loc k Nu t Jam

8 ..................................5N TJ 25 7 10 0 ..............................1/4-20 Lock Nut

9 ..................................5N TJ 3 7 7 0 0 0 ..............................3/8-1 6 Lo ck Nu t Jam

10 ................................5NT K3 7 0 0 0 1 .............................3/8 Flat Wash er

11.................................5NT K3 7 1 5 0 1 .............................3/8 Loc k Washer

12 ................................5NT K1 6 0 0 0 1 .............................No. 8 Flat Wash er

13 ................................5NT 6 32 91 3 5..............................Rea r Doo r Slid e

14 ................................5NT 6 3 2 9 55 1..............................Slide Up R ear Do or Weldmen t

15 ................................5NT 6 3 2 9 13 6..............................Rear Sl ide S p ace r Pla te

16 ................................5NT K2 5 1 5 0 1 .............................1/4 Loc k Washer

17 ................................5NT 3 7 0 8 81 9..............................8-32 x .75 Butto n Hea d Safety Sc rew

18 ................................5NT 3 70 89 9 2..............................Fold ing H an dle

19 ................................5NT 3 7 0 8 99 7..............................Compres sion S pring .24 OD x 1.5 Long

20 ................................5NT 3 7 0 8 99 8..............................Wave S p ring .3 5 ID

PART NUMBER

DESCRIPTION

21 ................................5NT 6 2 0 9 16 5..............................Low er Guid e B ar

22 ................................5NT 6 32 90 2 9..............................Hing ed Walke r Pan el

23 ................................5NT 3 70 88 6 9..............................Sp rin g H inge

24 ................................5NT 6 3 2 9 12 7..............................Door Safety Switch Key

25 ................................5NT 6 3 2 9 12 8..............................Door K ey H ous ing

26 ................................5NT6329131 ..............................Catch

27 ................................5NT 6 32 91 3 2..............................Catch Bra cket

28 ................................5NT 6 3 2 9 13 3..............................Catch Pin

29 ................................5NT 6 3 2 9 13 4..............................Catch S p acer Plate

EXPLODED VIEW: GRINDING HEAD A SSEMBL Y

P ARTS LIST : GRINDING HEAD A SSEMBL Y

DIAGRAM NUMBER

1 .............. .......................................... 5 NT B 19 1 0 11.....................10-24 X 5/8 So ck et Head C ap Sc rew

2 ........................................................ 5NT3708848.....................1 /4-2 8 x 1/2 S ock et Head Cap Sc rew w/ patc h

3 .............. .......................................... 5 NT B 25 1 2 11.....................1/4-20 x 3/4 S oc ket Head Cap S crew

4 .............. .......................................... 5 NT B 25 0 8 1 6 ....................1 /4-2 0 x 1/2 B utton H ead So ck et Cap Sc rew

5 .............. .......................................... 5 NT B 37 1 2 1 6 ....................3 /8-1 6 x 3/4 B utton H ead So ck et Cap Sc rew

6 .............. .......................................... 5 NT B 25 1 2 1 6 ....................1 /4-2 0 x 3/4 B utton H ead So ck et Cap Sc rew

7 .............. .......................................... 5 NT B 25 3 2 11.....................1/4-20 x 2.00 So cket Head C ap S crew

8 .............. .......................................... 5 N TH 2 5 08 0 2 ....................Roll Pin .25D x .50 Lg

9 .............. .......................................... 5NT J 25 200 0 .....................1/4 -20 Hex J am Nut

10 ...................................................... 5 NT J62 720 0 .....................5/8-18 Lockn ut Jam Nylon

11 ...................................................... 5NT3708854..................... 1 /4-20 K nob Assembly

12 ...................................................... 5 NT K25 000 1 .................... Flat W asher 1/4

13 ...................................................... 5 NTK 251 501 .................... 1/ 4 Lock washer Split

14 ...................................................... 5NT3709852..................... 1 /8" Diameter N ylon Ball

15 ...................................................... 5NT 05720 .........................Grind ing Wh eel 6 x 2.75B x 1.5W 46G

16 ...................................................... 5NT 05731 .........................Grind ing Wh eel 6 x 2.75B x .38W 24G Type 1

17 ...................................................... 5NT3708839.....................3/8-16 x 1/2 Sc rew w/lock ing Flange

18 ...................................................... 5 NT5 003 7 ......................... Spin Flange Nut

19 ...................................................... 5 NT50 039 ......................... Spin W heel Flange

20 ...................................................... 5 NT 5 007 3 .........................W ear Pad

21 ...................................................... 5 NT5 520 0 ......................... Re lief W heel F lange

22 ...................................................... 5 NT55 201 ......................... Relief Flange Nut

23 ...................................................... 5 NT 502 04 ......................... Spin Yoke

24 ...................................................... 5 NT5 529 8 ......................... Bearing Support Bracket

25 ...................................................... 5NT3708846.....................Ball Bearing .25 ID x .625 OD

26 ...................................................... 5 NT J37 700 0 .....................3/8-16 Lockn ut Jam Nylon

27 ...................................................... 5 NT5 029 7 ......................... Tr averse Sho e

28 ...................................................... 5 NT5 029 8 ......................... Tr averse Clamp B rack et

29 ...................................................... 5 NT55 296 ......................... Single Bearing Asse mbly

30 ...................................................... 5 NT50 310 ......................... Belt Clamp T ip

31 ...................................................... 5 NT5 032 0 ......................... Tr averse Guard

32 ...................................................... 5 NT 503 21 ......................... S hield Mount Bracket

33 ...................................................... 5 NT5 032 4 ......................... Spark Shield

34 ...................................................... 5 NT5 032 9 ......................... Spin Support

35 ...................................................... 5 NT55 582 ......................... Bearing Housin g Ass embly

36 ...................................................... 5 NT09 404 ......................... Lin ear Bearin g

37 ...................................................... 5NT3709209.....................Oil Seal 1"ID x 1.57"OD x .18 7

38 ...................................................... 5NT3708561..................... A djustable Handle 3/8-16 x 1.56 Long

39 ...................................................... 5NT3708835..................... A djustable Handle 1/4-20 x 1.25 Long

40 ...................................................... 5NT 27115 .........................Spacer - .386 ID x .50 OD x .75 Long

41 ...................................................... 5 NT80 335 ......................... Desta co 602 Clamp

42 ...................................................... 5 NT 8 033 7 .........................T-knob As semb ly

43 ...................................................... 5NT3589106.....................Washer

44 ...................................................... 5 N T B 19 1 0 3 1 ....................1 0-3 2 x 5/8 Soc ket Head C ap S crew

45 ...................................................... 5NT55297 .........................Finger Rotate Base

46 ...................................................... 5NT6009057.....................Spacer .265 ID x .438 OD x .50 L

47 ...................................................... 5NT3708999.....................Flat W asher .3 8 ID x .56 ID x .03Th ick

48 ...................................................... 5NT3708036.....................Bearing

49 ...................................................... 5 NT55 11 2 ......................... Cam Plate

50 ...................................................... 5 NT8 039 2 ......................... Cam Follower - 1 /2" Diameter

51 ...................................................... 5 NT5 5113 ......................... Fin ger Slid e

52 ...................................................... 5 NT5 5117 ......................... Fixed Finger

53 ...................................................... 5 N T B 19 0 6 3 4 ....................1 0-3 2 x 3/8" B utton H ead So cket C ap Sc rew

54 ...................................................... 5NT3249153.....................Flat W asher .25 ID x .38 OD x .02 Th ick

55 ...................................................... 5 NT 5 528 1 .........................Index Finger Stop Block

56 ...................................................... 5 N TH 18 12 02 ....................3/16 x 3/4" long Roll Pin

57 ...................................................... 5 NT55 579 ......................... Locking Plate Weldment

58 ...................................................... 5NT3708833.....................Spacer - .252 ID x .50 OD x .125 Long

59 ...................................................... 5 N T C 1 9 04 6 7 ....................10-32 x 1/4" S oc ket H ead Set screw

60 ...................................................... 5 NT 551 27 ......................... 3 /16 Diameter Index Stop Pin

61 ...................................................... 5 NT55 501 ......................... Indexing Fing er A ssembly

62 ...................................................... 5NT3708107..................... Comp ressio n Spr ing

63 ...................................................... 5 N T C 1 9 03 6 0 ....................10-32 x 3/8" S oc ket H ead Set screw

PART NUMBER

DESCRIPTION

P ARTS LIST : PIVOT ARM A ND GRINDING SHAFT ASSY 1 of 2

P AR TS LIST : PIVOT ARM A ND GRINDING SHA FT A SSY 1 of 2

DIAGRAM NUMBE R

1 .............................................. 5NT B 3 13 6 0 1................ 5/16-1 8 x 2-1 /4 H ex Head Cap Scre w

2 .............................................. 5NT B 3 71 6 11 ................ 3/8-16 x 1 Socke t Head Ca p Screw

3 .............................................. 5NT B 3 72 4 11 ................ 3/8-16 x 1-1/2 Soc ket Hea d Cap Screw

4 .............................................. 5NT B 3 73 6 0 1................ 3/8-16 x 2-1/4 Hex H ead C ap S crew

5 .............................................. 5NT B 7 52 0 0 1................ 3/4-10 x 1 .25 He x Head C ap Screw

6 .............................................. 5N TC25 0 820................ 1/4 -20 x 1/2 Cu p Po int S et Scr ew

7 .............................................. 5N TJ 3 1 7 0 0 0................. 5/16-1 8 L ockn ut N ylon J am

8 .............................................. 5N TJ 3 7 7 1 0 0................. 3/8-16 L ocknu t Hex Ny lok Full

9 .............................................. 5NT K 3 71 5 0 1................ 3/8 Lo ckwa she r S plit

10 ............................................ 5N TR00 0 453................ Flat Washer .3 1 x .88 x .104T

11............................................. 5NT 3 7 0 7 69 0 ................ Mo to r 1H P

12 ............................................ 5NT50235 .................... Tra ver s e S ha ft

13 ............................................ 5NT50236 .................... Pulley 2.45 D iameter Po ly V

14 ............................................ 5NT50237 .................... Pulley 3.72 D iameter Po ly V

15 ............................................ 5NT50256 .................... Grin ding Wheel Shaft

16 ............................................ 5NT50279 .................... T en sio ner Bar

17 ............................................ 5NT50280 .................... T en si one r Pivot Shaf t

18 ............................................ 5NT50281 .................... T en sion er Pu lley Sha ft

19 ............................................ 5NT50282 .................... Pivot Su pp ort Sh aft

20 ............................................ 5N T5 0 3 11 .................... Pro x Sw itch Ho lder R.H.

21 ............................................ 5NT50318 .................... Prox Sw itch Ho lder L.H.

22 ............................................ 5NT55404 .................... Arm Asse mbly R.H.

23 ............................................ 5NT55407 .................... Arm Asse mbly L.H.

24 ............................................ 5N TC19 0 420................ 10-24 x 1/4 C up Point Se t Scre w

25 ............................................ 5NT09680 .................... T o rrin gto n Be ari ng

26 ............................................ 5NT80336 .................... Pilote d Bea ring Fl ange

27 ............................................ 5NT80338 .................... Key .25 s q x 1.25 L g

28 ............................................ 5NT80342 .................... T or sio n S pr ing

29 ............................................ 5NT80343 .................... Conical Wash er .53 9 x .862 x .014T

PART NUMBE R

DESCRIPTION

30 ............................................ 5NT80349 .................... Idler P ulle y 4. 0 D iamete r

31 ............................................ 5NT80350 .................... Poly V Belt

32 ............................................ 5NT80351 .................... Conical Wash er 1.4 0 x 2.03 x .024T

33 ............................................ 5NT 3 7 0 8 42 5 ................ Sh oulde r Bolt .313 D x .375 L

34 ............................................ 5NT 3 7 0 9 01 9 ................ Th rust Wash er .500 x .93 7 x .032 T

35 ............................................ 5NT 3 7 0 9 88 6 ................ Flat Wash er .81 2 x 2.25 x.135 T

36 ............................................ 5NT80126 .................... Key 3/10 sq x 1.00 Lg

EXPLOD ED VIEW: PIVOT A RM & GRINDIN G SHA FT A SSY 2 of 2

P A RTS LIST: PIVOT A RM & GRIND ING SHA FT A SSY 2 of 2

DIAGRAM NUMBE R

1 .............................................. 5NT B 1 20 3 11 ................ 5-40 X .1 88 Lg Socket H ead Cap Screw

2 .............................................. 5NT B 130 6 0 5................ 6-3 2 x 3 /8 Flat He ad Sock et Cap Scre w

3 .............................................. 5NT B 1 60 4 11 ................ 8-32 x 1/4 Socket Head Cap Scre w

4 .............................................. 5NT B 1 90 6 11 ................ 10-24 x 3/8 Sock et Head C ap Scre w

5 .............................................. 5NT B 1 90 8 3 1................ 10-24 x 1/2 So cket Head Cap S crew

6 .............................................. 5N TC37 0 820................ 3/8-1 6 x 1 /2 C up P oint Set S crew

7 .............................................. 5N TJ 5 0 2 0 0 0................. 1/2-13 H ex Ja m Nu t

8 .............................................. 5N TJ 5 0 7 1 0 0................. 1/2-13 Lo cknu t Full N ylon

9 .............................................. 5NT K 1 61 5 0 1................ #8 Lockw as her S plit

10 ............................................ 5NT K1 9 1 5 0 1................ #10 Lock w ash er S p lit

11............................................. 5NT80428 .................... Washe r Con ical .53 x 1.13 x .06T

12 ............................................ 5NT09299 .................... 1/2-13 x 2.5 Lg Butto n Hea d Socket C ap Screw

13 ............................................ 5NT09707 .................... Digital Scale, 6" Mitutoyo #572

14 ............................................ 5NT50095 .................... Mountin g Bloc k

15 ............................................ 5NT50283 .................... Gage Mou nting Bracke t

16 ............................................ 5NT55472 .................... Hand w he el 1/ 2-1 3 ID

17 ............................................ 5NT50325 .................... Arm Sup por t Pivot

18 ............................................ 5NT50348 .................... Vertic al Adjustment Shaft

19 ............................................ 5NT50573 .................... Vertica l Adjuster Asse mbly

20 ............................................ 5NT50591 .................... Cap As sembly

21 ............................................ 5NT80344 .................... Hex Aco rn N ut 1 /2-1 3

22 ............................................ 5NT 3 7 0 9 04 2 ................ Ba ll Bea ring Thr us t Nic e #6 03 -1/4

23 ............................................ 5NT 7 4 6 9 14 9 ................ Ny lon P lug 5 /16 Dia meter

24 ............................................ 5NT K1 2 1 5 0 1................ # 5 Split Lockw as her

PART NUMBE R

DESCRIPTION

EXPLODED VIEW: TRAVERSE DRIVE A SSEMBL Y

P A RTS LIST : T RAVERSE DRIVE ASSEMBL Y

DIAGRAM NUMBER

1 .............................................. 5NT B 2 51 0 11 ................ 1/4-20 X 5/8 S ocke t Head Cap Screw

2 .............................................. 5NT B 2 57 2 11 ................ 1/4-20 x 4.5 Sock et Hea d Cap Scre w

3 .............................................. 5N TJ 2 5 7 0 0 0................. 1/4-20 L ock nut Th in

4 .............................................. 5NT K 2 50 0 0 1................ Flat Washer 1 /4

5 .............................................. 5NT K 2 51 5 0 1................ 1/4 Lo ckwa she r S plit

6 .............................................. 5NT50309 .................... Traver se Pull ey Sh aft

7 .............................................. 5NT 3 70 6 05 6 ................ Cog P ulle y Dr ive

8 .............................................. 5NT 60 59 06 2 ................ Motor A ssem bly Tra v W16

9 .............................................. 5NT50363 .................... Traver se Pul ley Gua rd

10 ............................................ 5NT55553 .................... Cog P ulley Dri ven .37 5 P .5 0W

11............................................. 5NT80353 .................... Die Sp ring .34 ID x 2.0 Lg

12 ............................................ 5NT80354 .................... Cog Be lt

13 ............................................ 5NT80355 .................... Thrust Was her .7 5 ID x 1.2 5 OD

14 ............................................ 5NT 3 70 93 3 1 ................ Retain ing Ring

15 ............................................ 5N TC25 0 460................ 1/4-28 x 1/4 Soc ket H ead Set Screw

16 ............................................ 5NT80126 .................... 3/16 SQ x 1.00 Key

17 ............................................ 5NT 3 7 0 8 41 9 ................ Wa ve S prin g .7 8 ID x 1.00 OD

PART NUMBER

DESCRIPTION

EXPLODED VIEW: MOWER SUPPORT ASSEMBL Y

P ARTS LIST : MOWER SUPPORT A SSEMBL Y

DIAGRAM NUMBER

1 .............................................. 5NT B 2 51 0 1 6................ 1/4-20 X 5/8 Butto n Hea d C ap S crew

2 .............................................. 5NT B 2 51 2 1 6................ 1/4-20 x 3/4 Bu tton Head Cap Screw

3 .............................................. 5N TC25 0 420................ 1/4-2 0 x 1 /4 C up P oint Set S crew

4 .............................................. 5N TJ 3 7 7 0 0 0................. 3/8-16 L ockn ut Ja m Nylo n

5 .............................................. 5N TJ 5 0 2 0 0 0................. 1/2-13 H ex Ja m Nu t

6 .............................................. 5NT K 2 51 5 0 1................ 1/4 Lockw as her S plit

7 .............................................. 5NT09853 .................... Knob 4 p ron g 1/2- 13 F

8 .............................................. 5N T1 7 119 .................... Thread ed S tu d 1/ 2-1 3 x 65 Lg

9 .............................................. 5NT50242 .................... Ro ller Clamp Weldmen t

10 ............................................ 5NT50288 .................... T oo ling Bl ock Ad jus tment

11............................................. 5NT50290 .................... Front C lamp Plate

12 ............................................ 5NT50291 .................... Clamp Bloc k

13 ............................................ 5NT55449 .................... T oo ling Ba se Pl ate

14 ............................................ 5NT55376 .................... T oo ling S p ace r

15 ............................................ 5NT55374 .................... Acme Shaft L .H. Tooling

16 ............................................ 5NT50568 .................... V Roller Weldment L. H.

17 ............................................ 5NT50570 .................... T-Kno b Ass embly 3 /8-16 x .75 Do g Po int

18 ............................................ 5NT80396 .................... Knob A ss e mbly 1/4- 20 x 1.0 L g

19 ............................................ 5NT55506 .................... V Roller Weldment R.H.

20 ............................................ 5NT50254 .................... Rear Ro ller C lamp Weldm ent

21 ............................................ 5NT70512 .................... Roller Ro ller Br acke t Weldment

22 ............................................ 5NT80346 .................... Bolt T Slot 3/8-1 6 x 2.0 L g

23 ............................................ 5NT 3 7 0 8 24 5 ................ Kno b T 23 5 3 /8-1 6 F

24 ............................................ 5NT 3 7 0 8 39 3 ................ H and w he el 3 . 50 Dia mete r

25 ............................................ 5NT 3 7 0 9 06 2 ................ Con ical Washer .38 2 x .75 x .035 T

26 ............................................ 5NT 3 8 8 9 04 5 ................ S pa cer .40 6 ID x .88 OD x .38Long

PART NUMBER

DESCRIPTION

EXPLODED VIEW:VERTICA L MOWER SUPPORT A SSEMBL Y

P A RTS LIST : VERTICA L MOWER SUPPORT A SSEMBL Y

DIAGRAM NUMBER

1 .............................................. 5NT B 3 71 6 0 1................ 3/8-16 X 1 He x Hea d Ca p Sc rew

2 .............................................. 5N TC 2 5 0 4 2 0................ 1/4-20 x 1/4 C up Point C ap Scre w

3 .............................................. 5N TJ 3 7 7 0 0 0................. 3/8-16 Loc knut Jam Ny lon

4 .............................................. 5NT K 3 71 5 0 1................ 3/8 Lo ckwa she r S plit

5 .............................................. 5NT17519 .................... Kn ob T As s embly 1/2 -13 x 6.5"

6 .............................................. 5NT50288 .................... Too ling Bl ock Ad jus tment

7 .............................................. 5NT55376 .................... Tooling Sp ace r

8 .............................................. 5NT55374 .................... Acm e Shaf t L.H . Tooling

9 .............................................. 5NT50592 .................... Kn ob T 3/8 -16 x 1.0 Lg

10 ............................................ 5NT55282 .................... Hange r " V"

11............................................. 5NT55343 .................... Clamp Weld ment La rge L .H.

12 ............................................ 5NT55358 .................... Clamp Weldment La rge R.H.

13 ............................................ 5N T5 5 5 11 .................... Tooling P ost Ass embly L.H .

14 ............................................ 5NT55512 .................... T oo ling Pos t A ss embly R.H.

15 ............................................ 5NT 3 7 0 8 39 3 ................ H an dw he el 3 .5 0 D ia.

16 ............................................ 5NT 3 7 0 9 06 2 ................ C onical Washe r .382 Id x .75 OD x .035 Thick

PART NUMBER

DESCRIPTION

EXPLODED VIEW: CA RTON A SSEMBL Y

WHEEL DRESSER

ASSEMBLY

P ART S LIST : CA RTON ASSEMBL Y

DIAGRAM NUMBER

1 .............................................. 5NT50014 .................... S pa nne r Wre nch

2 .............................................. 5NTC190320................ #10-24 x 3/16 Socket Head Setscrew

3 .............................................. 5N TH25 0 802................ 1/4" x 1/2" R oll Pin

4 .............................................. 5NT09394 .................... 1/4 -20 2-p rong Kno b

5 .............................................. 5NT55122 .................... Dres s er Support Block

6 .............................................. 5NT55461 .................... Dr es ser Su pp ort Weld ment

7 .............................................. 5NT 3 7 0 8 84 5 ................ 3/4 Wide x 1/4 Thick Diamond D res se r

8 .............................................. 5NT 65 095 88 ................ T-K nob As sembly

9 .............................................. 5N TR0003 77 ................ Sq K e y 3 /1 6 x .75

10 ............................................ 5NT 3 70 90 7 3 ................ R eta inin g Rin g

11............................................. 5NT 3 7 0 9 58 4 ................ Flan ge C oup ler .62 5 Bore

12 ............................................ 5NT 60 09 05 1 ................ Dri ve A dapter 1/2 sq 3.5 Lg

13 ............................................ 5NT6009052 ................ Adapter

14 ............................................ 5NT 6 00 92 1 7 ................ D rive r Co up le r Adapter

15 ............................................ 5NT 37 09 58 5 ................ S lee ve Co upl er

................................................ 5NT55022 .................... Compen sa tio n for Taper C ha rt ( No t Sh ow n)

PART NUMBER

DESCRIPTION

EXPLODED VIEW: ALIGNMENT GAGE ASSEMBL Y

P A RTS L IST : AL IGNMENT GA GE AS SEMBL Y

DIAGRAM NUMBER

1 .............................................. 5NT B 1 20 6 11 ................ 5-40 x .38 Socke t Head Ca p Screw

2 .............................................. 5NT B 1 61 0 11 ................ 8-32 x 5/8 Socke t Head Ca p Screw

3 .............................................. 5NT B 2 51 0 1 6................ 1/4-20 x 5/8 Bu tton Head Socke t Cap Scre w

4 .............................................. 5NT B 2 51 2 1 6................ 1/4-20 x 3/4 Bu tton Head Socke t Cap Scre w

5 .............................................. 5NT6609501 ................ Knob Assembly T 1/4-20 x 1.31 Long

6 .............................................. 5N TJ 1 6 1 0 0 0................. 8-32 H ex nu t

7 .............................................. 5NT K 1 21 5 0 1................ #5 Lo ckw ash er S plit

8 .............................................. 5NT K 1 61 5 0 1................ #8 Lo ckwa she r S plit

9 .............................................. 5NT K 2 51 5 0 1................ 1/4 Lo ckwa she r S plit

10 ............................................ 5NT50290 .................... Fron t Clamp Pla te

11............................................. 5NT50291 .................... Clamp Blo ck

12 ............................................ 5NT50570 .................... T-Kno b As sembl y 3/8-1 6 x .75 Dog Point

13 ............................................ 5NT50586 .................... Gage Ba se Weldme nt

14 ............................................ 5NT50597 .................... Gage Bar Asse mbly Ver tical

15 ............................................ 5NT 352 9 0 69 ................ S p a cer .25 ID x .375 OD x .69 Long

16 ............................................ 5NT 6 5 0 9 41 8 ................ P ivot P late Mac hin ed

17 ............................................ 5NT 6 50 93 4 9 ................ Retain er Pla te

18 ............................................ 5NT 3 7 0 8 09 4 ................ Ad jus tab le Handle 5/1 6-18 x 1.25 Long

19 ............................................ 5NT 6 5 0 9 35 9 ................ D igit al G age Ma ch ined

20 ............................................ 5N TH 0 6 0 3 0 2................ Roll Pin .063 D x .188 Long

21 ............................................ 5NT80396 .................... Knob T 1 /4-2 0 x 1.18 Lon g

22 ............................................ 5NT 6 32 95 5 6 ................ Gage Bas e Weldment

PART NUMBER

DESCRIPTION

EXPLODED VIEW: SPIN DRIVE ASSEMBL Y

P A RTS LIST: SPIN DRIVE A SSEMBL Y

DIAGRAM NUMBER

1 .............................................. 5NT B 2 51 0 1 6................ 1/4-20 x 5/8 Bu tton Head Socket Cap Screw

2 .............................................. 5NT B 2 51 2 11 ................ 1/4-20 x 3/4 Sock et Hea d Cap Scre w

3 .............................................. 5NT B 2 51 2 1 6................ 1/4-20 x 3/4 Bu tton Head Socket Cap Screw

5 .............................................. 5NT K 2 50 0 0 1................ Flat Washer 1 /4

6 .............................................. 5NT K 2 51 5 0 1................ 1/4 Lo ckwa she r S plit

7 .............................................. 5N TR0003 76 ................ Sq Key 1/8 x .75

8 .............................................. 5NT50290 .................... Front C lamp P late

9 .............................................. 5NT50291 .................... C lamp B lock

10 ............................................ 5NT 6 32 91 6 0 ................ Motor Spin Ass embly Sp in

................................................ 5NT 3 7 0 7 62 3 ................ D C Mo tor B rus h (fo r Ser vice - no t sh ow n)

11............................................. 5NT50570 .................... T-Kno b As sembl y 3/8-1 6 x .75 Dog Point

12 ............................................ 5NT50585 .................... Sp in Mo unt We ldment V ertic al

13 ............................................ 5NT55437 .................... Sp in Mo un t Weld ment

14 ............................................ 5NT55442 .................... Sp in Arm Weldmen t Ho rizont al

16 ............................................ 5NT 3 70 95 8 6 ................ Flange Co up ler .50 Bo re

17 ............................................ 5NT6509588 ................ Knob Assembly T 2.5 3/8-16 x 1.00L

18 ............................................ 5NT 6 3 2 9 07 2 ................ D ecal - Sca le

PART NUMBER

DESCRIPTION

EXPLODED VIEW: CONTROLS ASSEMBL Y

P ARTS LIST : CONTROLS ASSEMBL Y

DIAGRAM NUMBER

1 .............................................. 5N TD 1 6 0 6 0 8................ Thrd Cutting Screw 8- 32 x 3/8 " F T ype"

2 .............................................. 5N TD 2 5 0 8 0 0................ Thrd Cutting Screw 1/4- 20 x 1/2 "F T ype " Hex Hd

3 .............................................. 5NT 3 7 0 7 82 6 ................ Pus h Butto n Squ are Gr een

4 .............................................. 5N TJ 1 6 7 0 0 0................. 8-32 Nylon In se rt Loc k Nu t Jam

5 .............................................. 5N TR 0 0 0 5 3 6................ Lockwa s her 1/4" Inte rnal Teeth

6 .............................................. 5N T5 57 11 .................... Co ntro l Panel Deca l

7 .............................................. 5NT 3 7 0 7 72 8 ................ Do or Sa fety S witc h

8 .............................................. 5NT55422 .................... Co ntr ol Se rvice Pane l

9 .............................................. (see ne xt pa ge)............ Control P ane l Sub -As se mbly

10 ............................................ 5NT 3 7 0 7 59 5 ................ Hole Plug - 7/8

11............................................. 5NT 3 7 0 7 56 3 ................ S tra in Re lief - L iquid T ig ht .27 -.46 Wire Dia .

12 ............................................ 5N TJ 2 5 70 0 0................. 1/4-2 0 Lo ckn ut - Ja m

13 ............................................ 5NT80419 .................... Potentiometer Asse mbly - 10K

14 ............................................ 5NT55476 .................... Door Swit ch Bra cket

15 ............................................ 5NT 3 7 0 7 00 9 ................ S tra in Re lief - L iquid T ig ht .27 -.47 Wire Dia .

16 ............................................ 5NT 3 7 0 7 02 9 ................ S tra in Re lief - L iquid T ig ht .19 -.30 Wire Dia .

17 ............................................ 5NT 3 7 0 7 65 8 ................ S tra in Re lief - L iquid T ig ht .54 -.71 Wire Dia .

18 ................................................................................. Electrical Warnin g De cal (s ee p ag e 7 Op erato rs Manual)

19 ............................................ 5NT 3 7 0 7 09 3 ................ S tra in Re lief - L iquid T ig ht .55 -.71 Wire Dia .

20 ............................................ 5NT 3 7 0 7 71 5 ................ C ord Cla mp - D oub le

21 ............................................ 5NT 3 7 0 8 81 9 ................ 8-3 2 x .75 Butto n Head Safety Screw

22 ............................................ 5NT 3 7 0 8 86 5 ................ 8-3 2 x 1.50 Bu tton Head Safety Scre w

23 ............................................ 5NT 3 7 0 7 34 2 ................ Yellow E-S to p Ri ng

24 ............................................ 5NT 3 7 0 7 36 7 ................ Roc ker S witch

25 ............................................ 5NT 3 7 0 7 42 9 ................ Roc ker S witch

26 ............................................ 5NT 3 7 0 7 44 6 ................ Po ten tiom eter Kn ob

27 ............................................ 5NT 3 70 75 6 4 ................ Gr een P ush butt on

28 ............................................ 5NT 3 7 0 7 56 5 ................ Con tact B lock - N ormally Op en

29 ............................................ 5NT 3 7 0 7 56 6 ................ Sw itch Mo unting Latc h

PART NUMBER

DESCRIPTION

30 ............................................ 5NT 3 7 0 7 56 7 ................ Red S top P ush /Pull Pus hbu tton

31 ............................................ 5NT 3 7 0 7 56 8 ................ Con tact B lock - No rmally Clos ed

32 ............................................ 5NT 3 7 0 7 64 7 ................ Do or Safe ty C od ed M agn et

33 ............................................ 5NT 3 7 0 7 76 1 ................ Circ uit Brea ker - 20 Amp

34 ............................................ 5NT 3 7 0 7 65 3 ................ Circu it Brea ker - 4 Amp

35 ............................................ 5NT 6 0 5 9 02 1 ................ Doo r Safety Sw itch As sembly - Fr ont

36 ............................................ 5NT B2 5 1 0 1 6................ 1/4-20 x 5/8 Button Head So cket Cap S crew

37 ............................................ 5NT 3 7 0 8 82 0 ................ 8-3 2 x .50 Butto n Head Safety Screw

................................................ 5NT27169 .................... Travers e Pr oximity S w itch Cor d- Righ t H an d (N ot Sho w n)

................................................ 5NT 6 0 5 9 07 8 ................ Tra vers e Pr oximity Swi tch C ord - L eft H and (N ot Sh ow n )

................................................ 5NT 3 7 0 7 60 1 ................ Pro ximity Sen sor

................................................ 5NT55717 .................... Contro l Pan el Cord ( Not Sh ow n)

................................................ 5NT55491 .................... Rear D oor Safety Swi tch C ord (No t Sho w n)

................................................ 5NT 6 0 5 9 08 3 ................ Lig ht R ece ptac le C ord (No t S how n)

................................................ 5NT 6 32 90 7 8 ................ Ma in Pow er Co rd (No t Show n)

................................................ 5NT 3 7 0 8 37 8 ................ Foam S trip - .25 Thick {S old by the foo t]

EXPLODED VIEW: ELECTRIC P A NEL SUB ASSEMBL Y

John Deere RG5500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual