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OPERATING INSTRUCTIONS (Continued)

1. PARTS LIST 27519 GUARD DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION B190834 10 32 x 1 2 Button Head Socket Cap Screw 1 4 20 x 1 3 4 Socket Head Cap Screw 5 16 18 x 3 4 Button Head Socket Cap Screw 5 16 18x 1 25 Button Head Socket Cap Screw 8 32 Jam Locknut 1 4 20 Locknut 5 16 18 Jam Locknut 10 Flat Washer 5 16 Flat Washer Flat Washer 31 x 88 x 104 Thick Door Frame Bracket Right Hand Door Frame Bracket Left Hand Lower Arm Torque Tube Inside Door Reinforce Right Hand Inside Door Reinforce Left Hand Safety Switch Key Bracket Polycarbonate Door Door Arm Weldment Right Hand Door Arm Weldment Left Hand Safety Switch Straight Key Safety Switch Strain Relief Ball Stud 10MM D Handle 8 32 x 50 Button Head Safety Screw 8 32x 1 50 Button Head Safety Screw Gas Spring Spacer 406 x 875 x 38 Long Handle Ferrule Door Safety Switch Cord Not Shown Foam Strip 25 Thick Not Shown 27541 BEDKNIFE SUPPORT ASSEMLBY EXPLODED VIEW 8 V T PARTS LIST 27541 BEDKNIFE SUPPORT ASSEMLBY DIAGRAM PART NUMBER NUMBER DESCRIPTION 8 32x3 8 Flat Head Cap Screw 10 24x1 2 Flat Head Socket Cap Screw 10 24x1 2 Socket Head Cap Screw 10 24x1 2 Button Head Socket Cap Screw 1 4 20x3 8 Socket Head Cap Screw 1 4 20x1 2 Socket Head Cap Screw 1 4 20x3 4 Socket Head Cap Screw 3 8 16x3 4 Button Head Socket Cap Screw 10 24x1 2 Socket Set Screw Cup P
2. Grinding wheel is glazing too quickly A Wheel needs dressing B Too light a cut when rough grinding C Grinding head is traversing too slow Grinding motor vibrates excessively Grinding wheel is out of balance Carriage traversing varies speed while grinding A Linear bearings in the carriage do not rotate freely B Belt it slipping C Traverse belt tension is too loose REMEDY Dress the wheel before the finish grinding pass on each bedknife See Operators Manual Take off about 002 to 033 05 to 075 mm per pass during rough grind See Operators Manual Speed up traverse Visually check the outside diameter runout while slowly rotating the wheel by hand Also check the motor without a wheel installed Replace the wheel if out of round Adjust bearing for proper tension See adjustments section of this manual Flush linear bearing per lubrication proceedure and replace wipers Or replace three linear bearings and wipers Adjust belt clamping force See adjustment section of manual Adjust traverse belt tension See adjustments section of this manual REASON Wheel will glaze if not dressed often enough If grinding wheel is not extended 1 2 12 mm overbedknife it will glaze more quickly because there is less dressing Too light a grinding cut doesn t permit enough dressing action on the wheel so it glazes Too slow a traverse Speed can cause
3. No DC Voltage from Traverse Drive Control Traverse Motor is bad TSP is not working TSP 10K is bad Worn motor brushes 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 turned full CW to maximum voltage of 90 VDC G Check traverse motor continuity H Check TSP 10K on control panel J Check TSP for 10 000 ohms Remove three wires from TDC red from term 8 white from term 47 black from term 9 Inspect Motor Brushes DISCONNECT POWER FROM MACHINE Check terminals A1 to A2 for 90 Volts DC Yes go to Step G next No go to Step H next Remove motor wires from Terminal Strip 1 terminals 7 amp 8 check for 0 ohms across the black and white wires Yes end troubleshooting No go to Step K next Pin 8 to 7 Pot Full Pot Full CW OVDC 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 Step J next Check for 10 000 ohms red to white wires Full CCW 0 ohms Full CW 10 000 ohms Red to black wires Full CCW 10 000 ohms Full CW 0 ohms Yes replace the TDC No replace TSP Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Traverse Motor NOTE TRAVERSE MOT
4. Possible Cause Defective speed control potentiometer Wiring hookup to potentiometer is improper If components have been replaced Main circuit board dial pot settings not correct If board has not been replaced Checkout Procedure A Check potentiometer on control panel B Check potentiometer for 10 000 ohms Remove three wires from Traverse Drive Control red from term 8 white from term 7 black from term 9 C Check potentiometer wiring for proper hookup See that speed pot is wired per electrical diagram D Check all pot settings on circuit board as shown in wiring diagram See adjustment section Traverse Motor Control Board Settings Traverse Drive Control Pin 8 to 7 Pot full CCW Pot Full CW 0 VDC 9 75 VDC Pin 8 to 9 Pot full CCW 9 75 VDC Yes Pot is OK No Go to Step B next Pot Full CW 0 VDG Check for 10 000 ohms Red to White wires Full CCW 0 ohms Full CW 10 000 ohms Red to Black wires Full CCW 10 000 ohms Full CW 0 ohms Yes Go to Step C next No replace potentiometer Wiper inside of potentiometer controls speed Wiper may be bad and not making contact Wrong wire hookup effects traverse control Reversing red and orange wires to potentiometer to the D C motor will run at zero speed but maximum will be too slow Reversing red and white wires does not affect speed control Check for Proper function Yes end troubleshooting No Go to Step D next
5. 8 screws 20 in lbs 0 23 kg m No 10 screws 32 in lbs 0 37 kg m PACKING LIST Upon arrival make sure that all parts are included shipment Feature Partially Enclosed Cabinet Magnetic Mount for Bed Knife Centers for mounting the Bed Knife Infeed Manual Control Travel Automatic Variable Speed Flood Coolant System Grinding Head Mounted Diamond Dresser Built in Angle Protractor 27550 Operator s Manual Pint Coolant Concentrate Grinding Wheel Wrench 3707393 Transformer Kit for 230 Volts 50 60 Hz Optional Extra Grinding Wheels Optional 6100501 Magnetic Base Dial Indicator Optional If items are MISSING from the shipment notify your distributor who will contact a Service Representative SITE REQUIREMENTS doors Dry Reasonably level Concrete floor Good Lighting 115 Volts 50 60 Hertz 15 Amp outlet Transformer Kit 3707393 available to convert to 230 VAC Adequate access to the front of the machine for the operator ASSEMBLY INSTRUCTIONS Remove the sides front and back of the crate Remove the plastic bag shrink wrap and bubble wrap Remove the metal clips that secure the grinder to the crate base With a fork lift raise the grinder from the wood base and set it in its final position See FIG 38 and 39 Remove shipping al straps THE UNIT WEIGHS 750 LBS 340 kg TO LIFT USE POWER EQUIPMENT FIG 38 POSITION
6. I Check for 120V to MCB Machine works Yes end troubleshooting No go to Step B next Machine works Yes end troubleshooting No go to step C next Machine works Yes end troubleshooting No go to step D next Machine works Yes end troubleshooting No go to step E next Machine works Yes end troubleshooting No but light works in outlet go to Step F next No but light does not work in outlet You must solve your power delivery problem independent of machine FTR Line Terminals for 120 Volts AC Yes Go to Step G next No Replace Power Cord 6059054 FTR Load Terminals for 120 Volts AC Yes Go to Step H next No Replace Filter MCB Bottom Terminal to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step I next No Check wires amp replace if needed MCB Top Terminal to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step J next No Flip Switch on MCB to ON Machine works end trouble shooting Machine does not work replace MCB Possible Causes 120 Volts AC power not delivered to Terminal Strip Grinding Motor Switch GMS not working Bad Emergency Stop Switch ESS Bad System Start Switch SSS Low Voltage Relay REL not operating Bad Main Contactor MAG Checkout Procedure J Check for 120 Volts AC at terminal strip K Check for 120 Volts AC at GMS Terminals 1 M Check voltage after the ESS MAKE SURE SWITCH IS PULLED UP N Hold i
7. Jacobsen Greens King 418 518 422 522 Jacobsen Greens King 426 526 Jacobsen King II IV IV Plus V Jacobsen WHFS HM11 Jacobsen LF100 123 128 3810 Jacobsen Ranger 575111 Jacobsen TF60 Jacobsen Tri King 1671 1672 1684 1900 Jacobsen Trim King Turf King II 76 84 John Deere All Models Lesco All Models National All Models Ransomes G Plex 160 Oto 5 Ransomes Fairway 250 305 405 0 Ransomes Motor 180 3500 T Plex 185 0 GR 500 1000 3000 HTM 175 15 Toro RM 5100 5300 6500 15 Toro RM108 216 2300 3500 4500 15 Toro 5 RM7 PMII Spartan Turf Pro 15 f height of cut is less than 1 2 increase angle up to 30 degrees OPERATING INSTRUCTIONS CONTINUED MOUNTING A GRINDING WHEEL To replace the grinding wheel See FIG 16 1 First turn off the power by pushing in the Emergency Stop button Unscrew the mounting flange that holds the grinding wheel using the grinding wheel wrench supplied with the grinder NOTE The Lock Flange has a left handed thread hold the wheel and turn the wrench clockwise while looking at the Lock Flange Remove the old wheel and install the new one Screw on the flange finger tight then tighten approximately 1 8 turn further with the wrench It will self tighten when motor is turned on IF THE WHEEL FLANGE IS OVERTIGHTENED THE GRINDING WHEEL MAY CRACK AND FLY APART After you install a new or differ
8. TRIP LIGHT INDICATES LOW VOLTAGE DELIVERED f GRINDER 2 OPERATING INSTRUCTIONS OPERATION The Controls for the Model 277 Learn the function of each switch and knob on the control panel As you read and learn about each knob you are encouraged to turn that knob on and view that particular operation See FIG 4 LANT ALWAYS WEAR PROPER SAFETY TRAVERSE WE EYEWEAR WHEN OPERATING SWITCH SWITCH YOUR GRINDER NEVER TURN ON YOUR GRINDER WITHOUT FIRST PUTTING ON SAFETY EMERGENCY EYEWEAR STOP EMERGENCY STOP PUSHBUTTON PUSHBUTTON The red pushbutton is the power off emergercy stop e TRAVERSE switch Pulling out will allow the main power to be turned SPEED on and pushing in will turn all power off The large button CONTROL type design allows a quick stop of all power in an i emergency situation FIG 4 SYSTEM START PUSHBUTTON The green pushbutton is the system start switch Pushing it will engage the magnetic starter and power the control panel The magnetic starter will not engage unless the emergency stop pushbutton is pulled out and the guard door safety switch is engaged GRIND MOTOR SWITCH The grind motor switch turns the Grinding Wheel Motor on and off COOLANT PUMP SWITCH The coolant pump switch turns the coolant pump on and off There is also a valve on the side of the grinding head to control the amount of the flow TRAVERSE POWER SWITCH The travel power switch turns the t
9. excessive heat buildup in the grinding wheel which glazes the wheel A grinding wheel which isn t properly trued up on outside or inside diameters can vibrate excessively and transfer that vibration to the motor When bearing preload is too tight it causes exxcessive loading to drive carriage Grinding grit is getting into the linear bearings and causing excessive driving torque of the carriage If the traverse belt clamp is damaged or not adjusted properly the belt will slip If the belt is too loose it will tend to vibrate or the belt tensioning springs may tend to jump when loaded EXPLODED VIEW 27529 MAIN BASE ASSEMBLY PARTS LIST 27529 MAIN BASE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION B251016 1 4 20 x 5 8 Button Head Socket Cap Screw B251216 1 4 20 x 3 4 Button Head Socket Cap Screw B371616 3 8 16x1 Button Head Socket Cap Screw J257100 1 4 20 Locknut K371501 3 8 Lockwasher 277 Neary Technologies Decal Proximity Switch Traverse LH Proximity Switch Traverse RH Cabinet Weldment Channel Support Bar Strain Relief Strain Relief Wave Spring Washer Flat Washer 75 ID x 1 0 OD x 075 Thick Electrical Warning Decal Pipe Plug 3 4 NPT 1 8 Hex Jam Nut 1 8x 2 Hex Head Cap Screw Full Thread Grinding Motor Cord Not Shown Light Receptacle Cord Not Shown Coolant Receptacle Cord Not Shown 27519 GUARD DOOR ASSEMBLY EXPLODED VIEW
10. go to Step C next Grinding Motor works Yes end troubleshooting No go to Step D next GMS term 5 to Terminal Block 4 Blue for 120 Volts AC Yes go to Step E next No With power off check continuity of wires to GMS With GMS ON check GMS Term 6 to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step F next No replace GMS Check for 120 Volts from 1 to A2 of Grinding motor Relay Yes If Relay does not pull in with click re place Relay if it does Go to Step G next No check continuity of wires to Grinding motor Relay REL Term L1 to Term L2 for 120 Volts AC Yes Go to Step H next No Check wires to REL Term L1 8 L2 Possible Cause Bad Contacts in Grinding motor Relay Bad Circuit Breaker Bad Grinding Motor ELECTRICAL TROUBLESHOOTING Continued Checkout Procedure H Verify power out of Grinding Motor Relay I Verify Power out of Circuit Breaker J Verify Power to Grinding mo tor Cord PROBLEM Coolant Pump not working Possible Cause Coolant Pump Switch CPS is not on Coolant flow valve closed 2 Amp Circuit Breaker CB is tripped 2 Amp Circuit Breaker CB failed Coolant Pump Switch CPS not working Coolant Pump Not Working A Turn switch With relay pulled in click check REL Term T1 to Term T2 for 120 Volts AC Yes Go to Step I next No Replace Gringing Motor Relay Check for 120 Volts AC from ter minals TB2 6
11. MAKE WORK AREA CHILD PROOF with cause risk of personal padlocks or master switches CHECK DAMAGED PARTS A guard or other DON T FORCE THE GRINDER It will do the part that is damaged or will not perform its job better and safer if used as specified in this intended function should be properly repaired or manual replaced USE THE RIGHT TOOL Don t force the Grinder NEVER LEAVE GRINDER RUNNING or an attachment to do a job for which it was not UNATTENDED TURN POWER OFF Do not designed leave grinder until it comes to a complete stop WEAR PROPER APPAREL Wear no loose KNOW YOUR EQUIPMENT Read this manual clothing gloves neckties or jewelry which may carefully Learn its application and limitations as get caught in moving parts Nonslip footwear is well as specific potential hazards recommended Wear protective hair covering to contain long hair KEEP ALL SAFETY DECALS CLEAN AND LEGIBLE If safety decals become damaged or ALWAYS USE SAFETY GLASSES illegible for any reason replace immediately Refer to replacement parts illustrations in this SECURE YOUR WORK Make certain that the Manual for the proper location and part numbers of bedknife is securely fastened with the mounts safety decals provided before operating 21 DO NOT OPERATE THE GRINDER WHEN DON T OVERREACH Keep proper footing and UNDER THE INFLUENCE OF DRUGS balance at all times ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS IMPROPER USE OF GRINDI
12. Minimum and maximum pot settings effect traverse speed ELECTRICAL TROUBLESHOOTING Continued PROBLEM If the carriage traverses to one end of stroke or the other and it stops and does not reverse direction Possible Cause Proximity switch is not working properly or wire connections are loose Remedy First check to see of proximity light comes on When the light is on it means that there is electricity coming to proximity switch Actuate prox switches with steel tool to take measurements Left proximity PROX1 check Traverse drive Control TDC between terminals 14 black wire and 15 brown wire Right proximity PROX check between terminals 13 black wire and 15 brown wire Reason The light coming on shows the prox imity is getting electrical contact Proximity light on 0 Volts DC Proximity light off 12 Volts DC Proximity light on 0 Volts DC Proximity light off 12 Volts DC Replace proximity switch if the volt ages do not read as above PROBLEM Insufficient hesitation at carriage stops prior to reversing traverse The dwell time on the traverse drive control not set properly Reset dwell time as required One increment increases Dwell time by 1 2 second PROBLEM Traverse changes directions erratically while running in traverse cycle Loose wire to proximity switch Check wire connections from the proximity switches and tighten down screws A loose wi
13. Socket Cap Screw 1 4 20 x 1 2 Button Head Socket Cap Screw 1 4 20 x 3 4 Button Head Socket Cap Screw 1 4 20 x 1 Button Head Socket Cap Screw 1 4 20 x 1 1 4 Button Head Socket Cap Screw 3 8 16 x 1 Socket Head Cap Screw 10 24 x 1 2 Socket Set Screw 1 4 20 x 1 4 Socket Set Screw 1 4 20 x 1 2 Socket Set Screw 5 16 18 x 1 4 Socket Set Screw 5 8 18x 5 8 Socket Set Screw 3 8 16 Locknut Jam Nylon No 10 Flat Washer No 10 Lockwasher Split 1 4 Lockwasher Split 3 8 Lockwasher Split Spacer 5 16 Flat Cut Washer Bushing Reducer Grinding Wheel Straight Cup 6 dia x 2 deep Diamond Dresser Clamp Double Tube Shoulder Bolt Spring Compression Adjustable Handle Roller Dual Vee Spring Compression Washer Conical Washer Thrust DIAGRAM PART NUMBER NUMBER PART DESCRIPTION Washer Conical Nylon Ball Indicator Clear Shaft Adjusting Ring Calibrated Handwheel Base Carriage Slide Arm Roller Pivot Bushing V Roller Short Bracket Dresser Lock Guide Feed Screw Motor Assy 3 4 HP Decal Warning Electrical Decal Warning Sharp Decal Warning 3600 RPM Motor Pivot Assy Collar Adjuster Flange Outer Tee Knob Assy Eccentric Pin Assy Dresser Arm Weldment Grinding Wheel Guard Weldment 1 4 20 x3 1 8 Socket Head Cap Screw Handle Hex Jam Nut 1 4 20 1 4 20 Nylok Lock Nut 1 4 x 1 2 Roll Pin Wrench Grinding Wheel 1SI1SLAVd 455 QV3H 6256099 27532 COOLANT ASS
14. Traverse Forward Acceleration Factory set at full CCW 8 30 Do not change this setting Left Traverse Reverse Acceleration Factory set at full CCW 8 30 Do not change this setting DB Dead Band is the potentiometer setting for the 50 or 60 Hz cycle control Factory set to 9 00 works for both 50 and 60 Hz Do not change this setting Calibrating the DWELL TIME rotary DIP switch adjusts the amount of time the process remains in the stop position after a limit switch is actuated The DWELL TIME range is adjustable from O 4 seconds A DIP switch setting of 0 sets the DWELL TIME to 0 seconds while a setting of 8 sets the DWELL TIME to 4 seconds Dwell time is preset to 2 setting for a 1 second dwell time when reversing at each end of stroke Diagnostic LED s indicate the function that is currently being performed indicates that ac power is being applied to the control FORWARD indicates that the process is running in the forward direction traversing left REVERSE indicates that the process is running in the reverse direction traversing right PROX 1 FWD LIMIT lights when the forward limit switch is actuated left prox PROX 2 REV LIMIT lights when the reverse limit switch is actuated right prox DWELL lights when the process remains stopped after a proximity switch is actuated o E z Co c Sa 25 ae eu Sde zem ZB a ig S a 2 98 Potentionmeter Ka is gt Clock Or
15. Wire Harness Assembly 277 Control Not Shown Wire Assembly Not Shown EXPLODED VIEW 27531 CONTROL PANEL ASSEMBLY PARTS LIST 27531 CONTROL PANEL ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 1 4 20 x 1 2 Thread Cutting Screw Hex Head 1 4 Internal Tooth Lock Washer Control Panel Weldment Electrical Panel Sub Assembly See Pages 58 59 Decal Control Panel Strain Relief Yellow E Stop Ring Rocker Switch On Off Rocker Switch On Off 2 Amp Circuit Breaker 10 Amp Circuit Breaker Potentiometer Knob Green Start Pushbutton Normally Open Contact Block Pushbutton Mounting Latch Red Push Pull E Stop Pushbutton Normally Closed Contact Block Decal Safety Symbol 6059054 Main Power Cord Not Shown 3708378 nouis 25 Thick Foam Strip Not Shown 27400 WIRING DIAGRAM 3719 13 t 3081 13 4 S NJ RH LH PRM TRAVERSE qow um WIR RD GR l 27400 WIRING DIAGRAM CBI CIRCUIT BREAKER 1 CB2 CIRCUIT BREAKER 2 DSS OOOR SAFETY SWITCH ESS EMERGENCY STOP SWITCH FTR LINE FILTER MS GRINOLNG NOTOR SWITCH LVR LOW VOLTAGE RELAY MAG MAGNETIC STARTER PXI LEFT PROXINITY SWITCH PX2 RIGHT PROXIMITY SWITCH REL ERINDENG NOTOR RELAY SSS SYSTE
16. it forward Swing the dresser around to the grinding face of the wheel and turn the adjuster ring until the diamond point JUST touches the wheel See FIG 19 When done rotate handle clockwise against the lock bracket before pulling back and replace the dresser movement arm in the holder See FIG 18 If the dresser is adjusted too far into the wheel the area supporting the diamond will be ground and the diamond may come loose Adjust so the diamond tip just touches the wheel NOTE Excessive dressing will shorten the life of the wheel To little dressing will inhibit proper grinding DRESSER Adjusting ring DRESSER MOVEMENT ARM LOCK BRACKET FIG 18 Dresser locked FIG 19 Dresser unlocked Replacing the Wheel A A new vitrified grinding wheel is 2 51 mm deep When II 1 it wears down to a depth of 0 75 19 mm it should be replaced See FIG 20 OPERATING INSTRUCTIONS CONTINUED USING FLOOD COOLANT For quality grinding we highly recommend using flood coolant to prevent heat buildup on the knife edge IF YOU DRY GRIND NEVER ALLOW THE BEDKNIFE EDGE TO CHANGE COLOR OR YOU MAY LOSE THE TEMPER IN THE KNIFE EDGE ALWAYS READ THE MATERIAL SAFETY DATA SHEET MSDS FOR THE COOLANT YOU ARE USING BELOW ARE WARNINGS THAT APPLY TO MOST COOLANTS AVOID CONTACT OF COOLANT WITH EYES IT WILL CAUSE EYE IRRITATION WEAR FACE SHIELD OR GOGGLES WHEN HANDLING CONCENTRATE IN CASE OF CONTACT FLUSH EYES WITH WATER
17. straight cupped wheel is used However if the end mounting flanges of the bedknife are more than 2 50 mm high or near the front face of the knife you may need the optional 6 flared cup wheel For Part Numbers and descriptions of all available grinding wheels refer to the Grinding Wheels list on Page 12 FLARED CUP WHEEL FIG 23 ROTATING THE WHEEL GUARD Some bedknives and bedbars have mounting ears so close to the bedknife top face that there is no clearance for the wheel guard For these applications generally a flared cup grinding wheel should be used and the grinding wheel guard can be loosened and rotated so the clearance area of the guard allows the bedknife to be ground without interference When completed ALWAYS reposition the guard to its normal position with the clearance notch down See FIG 23 FOR OPERATOR SAFETY THE GRINDING WHEEL GUARD MUST BE USED WITH THE CLEARANCE AREA UP ONLY WHEN REQUIRED FOR BEDBAR CLEARANCE 15 OPERATING INSTRUCTIONS CONTINUED MOUNTING A BEDKNIFE FOR GRINDING Continued Mount the Bedknife 1 Pull both gage tips forward and rotate the gage into position straight up Loosen the lock knob and on the right side magnet and center assembly See FIG 24 Set the bedknife bedbar assembly to be ground on the magnets Move the right side magnet assembly until the alignment gage tips at both ends of th bedknife then tighten the right side magnet lock knob enough to secure t
18. the shaft slide block See FIG 47 When you turn the handwheel there should not be any free play inthe handwheel before the tooling bar block slide moves Ifthere is free play tighten the set screw that pushes the nylon ball against the acme thread on the adjustment shaft The nylon ball adjusts the freeplay between the adjustment shaft and the Setscrew and tooling bar slide block Apply tension only enough ile to zero the freeplay DO NOT over tension as the adjuster will be difficult to turn 2 Washers behind the handwheel A Loosen about half a turn the setscrew holding the handwheel to the shaft B Tighten the hex lock nut which secures the handwheel to 100 in Ibs 1 15 kg m then back off 1 2 turn C Check for 015 in 04mm gap between the wave washer and the flat washer See FIG 48 Readjust the hex lock nut if necessary D Tighten the setscrew holding the handwheel to the shaft ADJUSTMENTS CONTINUED TO ELIMINATE MOVEMENT IN THE DIAMOND DRESSER ADJUSTMENT COLLAR The adjustment collar on the diamond dresser See FIG 49 has a nylon ball and setscrew to put a holding drag on the diamond dresser shaft Ifthe adjustment collar is moving too freely tighten the setscrew and put more load on the nylon ball If the adjustment collar is very difficult to turn loosen the setscrew and put less load on the nylon ball Setscrew and Nylon Ball ADJUSTMENTS CONTINUED ADJUSTING THE PRELOAD TE
19. 0 degrees clearance angle ground on the front face It will usually be Mounting Surtace measured relative to a line perpendicular to the bedknife mounting surface See FIG 14B BEDKNIFE TERMS Bedknife the stationary blade in a reel mower Bedknife Support or bedbar the bedknife is mounted to this frame member with screws or rivets Top Face the horizontal ground surface of the bedknife Front Relief Angle the angle between vertical and the manufacturer s recommended sharpening angle Top Relief Angle the angle between horizontal and the manufacturer s recommended sharpening angle Recommended Face 8 Top Angles Manufacturers recommend the bedknife relief angles should always be maintained to original manufacturer s specifications Neary Technologies has compiled these angles in a chart below Angles vary depending on the manufacturer and model We have included many of the popular models in the chart If your model is not listed consult your bedknife manufactures manual for the recommended sharpening angles Some units do not have the front face ground For example Some Toro units such as the 70 Pro have a stellite hard coated surface The Toro Turf Pro 84 has a factory ground front face Consult the bedknife manufacturer when in doubt as to grinding the front face Top Angle 9 Front Angle Bed Knife Grind Angles TopAngle Front Angle Jacobsen 19 amp 22 Greens Mower Jacobsen Blitzer F133 Fairway
20. BASE The 277 Bedknife Grinder will require an operating area of about 91 W x 72 D x 87 H 231 x 183 x 221 cm The machine operator will operate the unit from the front of the machine Position the base to allow sufficient operating room in front and right side of the machine See FIG 38 and 39 The base should be placed on a relatively level con crete floor with ample ceiling height to allow for the installation of the unit Do not place the unit across two concrete slab seams or across a large crack FIG 39 25 ASSEMBLY Continued ASSEMBLE THE FLOOD COOLANT SYSTEM 1 The flood coolant system has been fully assembled at the factory The only requirement is to install the coolant Follow the coolant miximg proceedure on page 14 of this manual After the mixed coolant has been added your coolant system is ready to operate When you start the coolant pump for the first time you must adjust the coolant flow using the valve at the grinding head ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT GROUNDING INSTRUCTIONS 115 Volt Model Only Plug the control box power cord into a standard 115V 15 amp grounded receptacle See FIG 41 220 Volt Model Only For 220 Volt Applications order Part No 2770952 which includes a 220 to 110 Volt Step Down Transformer IT IS RECOMMENDED THAT THIS GRINDER HAS ITS OWN PERMANENT POWER CONNE
21. CTION FROM THE POWER DISTRIBUTION PANEL WITH NO OTHER MAJOR POWER DRAW EQUIPMENT ON THE SAME LINE IT IS REQUIRED THAT THE POWER DELIVERED TO THIS GRINDER IS 115 VAC 15 AMPS THE TOLERANCE ON THIS POWER REQUIREMENT IS 5 THEREFORE THE MINIMUM VOLTAGE REQUIREMENT IS 109VAC WITH 15 AMPS VOLTAGE MUST BE CHECKED WITH ALL EQUIPMENT UNDER LOAD OPERATING ON THE CIRCUIT DO NOT OPERATE THIS GRINDER WITH AN EXTENSION CORD grinder is equipped with a low voltage relay which is factory preset at 100 VAC If the power supply line does not deliver 100 VAC power under load the relay will open and trip out the starter If this occurs your power supply line is inadequate and must be correct before proceeding further with the grinder DELIVERED TO GRINDER GROUND IN YOUR BUILDING MUST BE VERIFIED IMPROPER GROUNDING IN YOUR BUILDING MAY o CAUSE THE GRINDER TO MALFUNCTION i PROPER GROUNDING OF THE RECEPTACLE FOR 15 AMP RATED LARGE MACHINES BUILDING WIRING For 0 to 30 Feet 0 to 9 m from panel to receptacle Use 14 Ga 2 5 mm Wire For 30 to 50 Feet 9 to 15 m from panel to receptacle Use 12 Ga 4 0mm Wire For 50 to 80 Feet 15 to 24 m from panel to receptacle Use 10 Ga 6 0 mm Wire For 80 to 140 Feet 24 to 42 m from panel to receptacle Use 8 Ga 10 0 mm Wire ASSEMBLY INSTRUCTIONS Continued FOR 220 V 50 60Hz applications Product No 2770952 should be GREEN GROLNO ordered 2770952 includ
22. EMBLY EXPLODED VIEW PARTS LIST 27532 COOLANT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION B191611 10 24 x 1 Socket Head Cap Screw 161020 8 32 x 5 8 Socket Set Screw 8 32 Jam Lock Nut 10 Flat Washer 10 Lockwasher Split Connector Shut Off Valve Barbed Connector Coolant Pint Barbed Connector Shut Off Valve Coolant Line Assembly Coolant Tube 1 4 ID Cover Coolant Pump Coolant Pump EXPLODED VIEW ASSEMBLY 27535 ELECTRICAL PANEL SUB PARTS LIST 27535 ELECTRICAL PANEL SUB ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 8 x 3 8 Tapping Screw 8 X3 4 Self Tapping Screw 8 External Tooth Lock Washer Terminal Strip Decal 8 Pin Socket Primary Ground Decal Primary Ground Lug Din Rail 14 Power Line Filter Traverse Control Board Magnetic Starter Voltage Sensor Relay End Stop Terminal Block Jumper Adjacent Terminal Block End Plate Terminal Block Terminal Block 2 Conductor Grey Terminal Block 2 Conductor Blue Decal LVR Warning Panel Electrical Circuit Breaker 15 Amp Terminal Strip 19 Pole Straight Double Spade Terminal Single 90 Spade Terminal Double 90 Spade Terminal Cable Tie Mount Not Shown Cable Tie 6 5 Long x 18 Wide Not Shown Cable Tie 4 Long x 10 Wide Not Shown Wire Harness Assembly Common Not Shown Wire Harness Assembly 277 Panel Not Shown
23. FOR 15 MINUTES AND CONTACT A PHYSICIAN AVOID BREATHING MISTS PROVIDE LOCAL VENTILATION KEEP CONCENTRATED BOTTLE CLOSED WHEN NOT IN USE CONTINUED CONTACT OF CONCENTRATE ON SKIN MAY CAUSE IRRITATION WASH WITH SOAP AND WATER AFTER CONTACT DO NOT TAKE INTERNALLY IF INGESTED CONSULT PHYSICIAN AND DO NOT INDUCE VOMITING HAZARD POTENTIAL APPLIES TO CONCENTRATE AND IS LESS AT NORMAL USE DILUTION Mixing the Coolant Mix Part No 80340 Coolant in a separate container at a ratio of 50 parts water to 1 part concentrate Refer also to the label on the Coolant container If the coolant tray is empty this will take about 6 5 gallons of water and one pint of concentrate 24 6 liters of water and 0 5 liter of concentrate THE COOLANT RATIO AS SPECIFIED MUST BE 1 USED HIGH CONCENTRATION OR LOW A CONCENTRATION WILL CAUSE CORROSION AND PERFORMANCE PROBLEMS FIG 22 Using the Coolant Direct the nozzle so the coolant sprays onto the bedknife face being ground FIG 21 or 22 Some coolant will then also be deflected onto the grinding wheel Adjust the flow valve so there is a steady stream of coolant Avoid a stronger flow than needed excessive coolant doesn t cool more and increases splattering Fluid Level in Coolant Tank Check the fluid level in the Coolant tray daily to avoid running out while grinding Keep the coolant level between 25 50 inches 6 12 mm above the top of the coolant sump The pump
24. K START SWITCH BI 1 TERMINAL STRIP 1 TB2 TERMINAL STRIP 2 TB me TERMINAL BLOCK GREY TERMINAL BLOCK WHITE TSP TRAVERSE SPEED POT T TRAVERSE ORIVE CINTRIL JLISSS 4 H 900 Front Angle Bed Knife Grind Angles Top Angle in Front Angle in Degrees Degrees Jacobsen 19 8 22 Greens Mower 8 to 10 Jacobsen Blitzer F133 Fairway 4 to 6 Jacobsen Greens King 418 518 422 522 8 to 10 Jacobsen Greens King 426 526 8 to 10 Jacobsen Greens King II IV IV Plus V 8 to 10 Jacobsen HFS HM11 4 to 6 Jacobsen LF1000 123 128 3810 8 to 10 Jacobsen Ranger ST5111 4 to 6 Jacobsen TF60 8 to 10 Jacobsen Tri King 671 1672 1684 1900 4 to 6 Jacobsen Trim King Turf King II 76 84 4 to 6 John Deere All Models 5 Lesco All Models 6 National All Models 5 Ransomes G Plex 160 8 to 10 Ransomes Fairway 250 305 405 3 Ransomes Motor 180 350D T Plex 185 3 Toro GR500 1000 3000 HTM 175 5 Toro RM5100 5300 6500 5 Toro RM108 216 2300 3500 4500 5 Toro RM5 RM7 RMII Spartan Turf Pro 5 If height of cut is less than 1 2 increase angle up to 30 degrees
25. NG WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY Grinding is a safe operation if the few basic rules listed below are followed These rules are based on material contained in the ANSI B7 1 Safety Code for Use Care and Protection of Abrasive Wheels For your safety we suggest you benefit from the experience of others and carefully follow these rules DO DO always HANDLE AND STORE wheels in a CAREFUL manner DO VISUALLY INSPECT all wheels before mounting for possible damage DO CHECK MACHINE SPEED against the established maximum safe operating speed marked on wheel DO CHECK MOUNTING FLANGES for equal and correct diameter DO USE MOUNTING BLOTTERS when supplied with wheels DO be sure WORK REST is properly adjusted DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding DO always WEAR SAFETY GLASSES or some type of eye protection when grinding DO TURN OFF COOLANT before stopping to avoid creating an out of balance condition DON T DON T use a cracked wheel or one that HAS BEEN DROPPED or has become damaged DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole if wheel won t fit the machine get one that will DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel DON T use mounting flanges on which the bearing
26. NSION ON THE SMALL GRINDING HEAD SLIDE VEE ROLLERS MR The small grinding head slide vee rollers are positioned with two fixed on the left side and one adjustable on the right side To set the correct preload on the right side adjuster tighten the setscrew in FIG 50 until the spring is fully compressed solid then back off 1 2 turn Tension Adjust Setscrew TO ADJUST THE PROXIMITY SWITCHES For the proximity switches to work properly a distance of 3 16 in 1 32 4 75 mm 0 75 must be maintained between the top of the switch and the actuator bracket on the bottom of the carriage See FIG 51 To adjust the clearance loosen one of the hex nut and tighten the other Prox Sensor Prox Prox Bracket 3 16 Nut ADJUSTMENT Continued TRAVERSE BELT TENSION To adjust the tension on the traverse belt tighten the screws and nuts located at the left side of the traverse jj NUN belt Tighten nuts until the comprension springs mea x E31 sure 3 4 See FIG 52 If the springs are not tensioned equally uneven loading on the traverse system may cause parts to fail OVERTIGHTENING COULD DAMAGE THE BELT OR TRAVERSE DO NOT OVERTIGHTEN e DRIVE SYSTEM TRAVERSE CLAMP FORCE If the traverse clamp is slipping during regular operation it may be necessary to tighten the clamp To tighten loosen the jam nut and screw the tip out Move the traverse belt out of the way and verify the clamped distance from the t
27. OR BRUSHES HAVE SHOWN A VERY LONG LIFE THEREFORE IT IS IMPROBABLE THAT MOTOR BRUSHES ARE BAD ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse does not stop to reverse directions when flag goes under the proxim ity switch on the left side or right side of machine Possible Cause Gap between flag and prox is incorrect Proximity Switch is bad Checkout Procedure A Gap between flag and prox should be 3 16 to 1 4 4 6 mm Prox LED does not light when flag is under prox B Proximity switch is not working properly or wire connections are loose If incorrect adjust per adjustment section of manual Yes end troubleshooting No go to Step B next First check to see if proximity light comes on When the light is on it means that there is electricity coming to proximity switch Actuate prox switches with steel tool to take measurements Left proximity PROX 1 check Traverse drive Control TDC between terminals 13 black wire and 15 brown wire Right proximity PROX check 13 black wire and 15 brown wire The light coming on shows the proximity is getting electrical contact Proximity light on 0 Volts DC Proximity light off 12 Volts DC Proximity light on 0 Volts DC Proximity light off 12 Volts DC Replace proximity switch if the voltages do not read as above ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse speed control goes at one speed only
28. Then run the carriage back and forth through its range of travel With a clean rag wipe the excess lubricant from the shafts Run the carriage back and forth through its range of travel and wipe the shafts after each traverse Repeat until the shafts feel dry IMPORTANT If the machine will be shut down for more than one month flood the shafts and other appropriate parts with lubricant as outlined above and leave the lubricant in place until the unit will be used again Then repeat the above lubrication procedure before operating ADJUSTMENTS CARRIAGE LINEAR BEARING REPLACEMENT STEP 1 Remove the four screws of one linear bearing and slide the linear bearing off the end of the carriage shaft LINEAR BEARING STEP 2 Insert a new linear bearing onto the end the carriage shaft with the tension adjustment screw pointing outward See FIG 44 STEP 3 Adjust the tension screw of the linear bearing so when you radially rotate the linear bearing around the carriage shaft there should be no free play between the linear bearing and the carriage shaft NOTE Tension is too tight if you feel a cogging action when you rotate the linear bearing around the shaft This cogging is from the skidding of the bearing on the shaft and indicates the tension screw is to tight Sliding the bearing block back and forth should be a smooth uniform motion TENSION ADJUSTMENT SCREW POSITION FACING 007 FIG 44 Repeat Steps 1 through 3 with th
29. ances and Set Traverse Limits FIG 35 Position the grinding head so that the grinding wheel just touches the top face of the bedknife Check to see if the rim of the grinding wheel is extended 1 2 50mm above the top face of the bedknife If you have previously ground the front face it most often will be correct If not with the vertical cam and lock lever adjust the grinding head See Fig 36 If the shape of the bedbar interferes with the wheel guard or grinding wheel you will need to make adjustments See page 15 Vertical Cam Lever IF THE GRINDING WHEEL RIM DOES NOT EXTEND OVER THE BEDKNIFE FACE IT WILL GRIND UNEVENLY AND CAUSE GROOVES e ACROSS THE SURFACE OF THE BEDKNIFE Check for interference Lock Lever 1 Back out the grinding head so the wheel no longer touches the top face of the bedknife If you have just ground the front face the travel limit should still be correct but you should still verify no interferences as described below If you did not grind the front face follow the full procedure listed below Slide the left and right proximity switches to the far ends of the rail Setthe TRAVERSE speed potentiometer at 10 Set the CARRIAGE TRAVERSE switch ON Traverse the carriage to the left until the contact area of the grinding wheel is about 1 beyond the area to be ground on the bedknife then turn the traverse potentiometer to zero Be prepared to STOP the traverse earlier if there is any interference between th
30. ap Screw 1 4 20 x 1 4 Socket Head Cap Screw Full Thread 1 4 20 x 1 1 2 Socket Head Cap Screw 1 4 20 x 4 Socket Head Cap Screw 3 8 16 x 1 Button Head Socket Cap Screw 1 4 20 Locknut Thin 8 Lockwasher Split 1 4 Lockwasher Split 3 8 Lockwasher Split Support Travel Pulley Channel Machined Guard Travel RH Shaft Travel Pulley Pulley Cog Drive Motor Assembly Travel W34 Guard Traverse Pulley Idler Pulley Assembly Washer Thrust 7510 x 1 2500 Belt Cog Spring Compression Ring Retaining Ext Shaft Carrier Spacer 281 ID x 62 OD x 38 Long EXPLODED VIEW 27543 CARRIAGE ASSEMBLY PARTS LIST 27543 CARRIAGE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION B191213 10 24 x 3 4 Button Head Socket Cap Screw B250816 1 4 20 x 1 2 Button Head Socket Cap Screw B252016 1 4 20 x 1 1 4 Button Head Socket Cap Screw B253216 1 4 20 x 2 Button Head Socket Cap Screw J252000 1 4 20 Hex Jam Nut J627200 5 8 18 Locknut Jam Nylon K251501 1 4 Lockwasher Split Bracket Travel Clamp Block Travel Clamp Spacer Travel Clamp Block Clamp Support Carriage Grinding Head Bracket Rail Wiper Travel Clamp Assembly 275 Tip Belt Clamp Bearing Ball Bushing Wiper Foam 6609529 GRINDING HEAD ASSEMBLY EXPLODED VIEW DIAGRAM PART PART NUMBER NUMBER DESCRIPTION 10 24 x 3 8 Socket Head Cap Screw 10 24 x 3 4 Button Head
31. bout 002 to 003 05 to 075 mm per pass NOTE The horizontal adjustment dial is calibrated in 002 05 mm increments Continue grinding the bedknife in this manner until you are satisfied with the front face grind Dress the wheel when necessary see Dressing the Grinding Wheel on Page 13 6 Dress the wheel before the final spark out grind For spark out procedure see the top of page 22 By partially grinding both surfaces the top face and the front face as shown in FIG 34 you will resharpen a used bedknife with the least metal removal FIG 34 also shows how much stock would be removed if you ground the top face surface until sharp Partially grinding both surfaces is the preferred method for life utilization of the bedknife SHUT OFF THE COOLANT PUMP SWITCH BEFORE YOU SHUT OFF THE GRINDING WHEEL TO ALLOW THE WHEEL TO SPIN DRY IF THE WHEEL RETAINS TOO MUCH COOLANT IT WILL BE UNBALANCED WHEN YOU AGAIN TURN ON THE GRINDING MOTOR OPERATING INSTRUCTIONS Continued GRINDING THE TOP FACE NOTE The following instructions presume that you have already studied all previous sections of this manual Position the Bedknife for Top Face Grinding See FIG 35 When rotating from front face grinding to top face grinding the grinding head must be backed out three full turns Rotate the tooling assembly to the top face position up and set the top face angle to the mower manufacturers factory specifications Check Clear
32. by two magnets and centers The left side magnet and center position is fixed ADJUSTABLE BEDKNIFE SUPPORT FIG 11 The right side magnet and center is adjustable to match bedknife width Right Hand Adjustable Support Lock Knob Locks the right magnet and center assembly in position on the tooling bar slide See FIG 11 Centers Bedknife Gage Lock knob TOOLING ALIGNMENT ADJUSTER FIG 12 Left Hand Adjustment Handwheel Adjusts the left side of the tooling assembly Allowing the tooling assembly and bedknife to be align to the grinding head This ensures maximum life from the bedknifes BEDKNIFE GAGE FIG 10 On the outside of each magnet is a retractable bedknife gage These gages are used to align the bedknife to the grinding wheel carriage travel See page 16 for detailed explanation of use Magnet Center Bedknife Gage FIG 11 Tooling Handle Lever Angle Pointer TOOLING ROTATION FIG 12 To achieve the angles as described on page 10 and 11 the Neary 277 Bedknife grinder has a movable tooling bar with an angle indicator and lock FIG 12 shows the angle pointer and decal The tooling bar is moved from front face to top face with a lever and lock handle on the left inside of the grinder Locking Handle OPERATING INSTRUCTIONS CONTINUED WHEN TO SHARPEN THE BEDKNIFE Dull Reel Blade NOTE To fully sharpen a reel mower you need to grind the reel blades using a Reel Grinder and reshape the cutt
33. dknife OPERATING INSTRUCTIONS Continued BEDKNIFE ALIGNMENT With this alignment you are aligning the bedknife faces to the grinding head by moving the bedknife support GRINDING WHEEL AT RIGHT END OF BEDKNIFE Alignment is accomplished by touching the grinding wheel to the bedknife With the bedknife bedbar assembly mounted per procedure on page 15 16 and in the front face grinding position with the front face angle set to the mower manufacturers factory specification move the grinding head to the right end of the bedknife Now adjust the carriage infeed handwheel until the wheel just touches the bedknife at the end nib of the knife face on a used bedknife or the full knife face on a new bedknife On used bedknives if you do not want to grind back to factory specifications but want to grind to match the worn bedknife then GRINDING WHEEL AT LEFT END OF BEDKNIFE touch the grinding wheel inside the end nib See FIG 29 Next move the grinding head to the left end of the bedknife Now without moving the grinding head infeed adjust the tooling bar left side adjuster until the grinding wheel just touches the bedknife end nib End Nib or the knife face on a used bedknife or the full knife face on a new bedknife Again on a used bedknife if you do not want to grind back to factory specifications but want to grind to match
34. e bedknife With the vertical cam and lock lever adjust the grinding head so the grinding wheel rim extends 1 2 12mm or as much as possible above the front face to be ground See FIG 32 EXTEND OVER THE BEDKNIFE FACE IT WILL GRIND UNEVENLY AND CAUSE GROOVES ACROSS THE SURFACE OF THE BEDKNIFE IF THE GRINDING WHEEL RIM DOES NOT Check for interference Back out the grinding head so the wheel no longer touches the front face of the bedknife Slide the left and right proximity switches to the far ends of the rail Set the TRAVERSE speed potentiometer slow Set the CARRIAGE TRAVERSE switch ON Traverse the carriage to the left until the contact area of the grinding wheel is about 1 beyond the area to be vertical cam lever ground on the bedknife then turn the traverse lock lever potentiometer to zero Be prepared to STOP the traverse earlier if there is any interference between the grinding wheel and the bedbar With the carriage still in the position determined in Step 3 above slide the left proximity switch in until its LED lights Traverse back to the right until the grinding wheel reaches the point where it covers the entire area to be ground and goes past that point by 1 25 mm or more if possible Then set the right proximity switch in the same manner NOTE The area of the grinding wheel which contacts the bedknife is on the left side of the wheel When grinding the left end of the bedknife the area of the whee
35. e grinding wheel and the bedbar With the carriage still in the position determined in Step 3 above slide the left proximity switch in until its LED lights OPERATING INSTRUCTIONS Continued GRINDING THE TOP FACE Continued Traverse back to the right until the grinding wheel reaches the point where it covers the entire area to be ground and goes past that point by 1 25 mm or more if possible Then set the right proximity switch in the same manner NOTE The area of the grinding wheel which contacts the bedknife is on the left side of the wheel When grinding the left end of the bedknife the area of the wheel which doesn t contact the bedknife will still be over the bedknife See FIG 37 When you go to the right end of the Grinder the wheel traverses completely off the bedknife Infeed the grinding wheel until it very lightly touches the bedknife on the left side Now traverse to the right end of the bedknife to assure that the right side is not closer to the grinding wheel Back the wheel out if necessary until you can traverse full length with a very light touch at the closest point Grind the Bedknife Align the bedknife per the procedure on Page 17 NOTE Top face alignment is fully independent of the front face alignment and MUST be done When you are satisfied with the grinding head travel and alignment begin grinding ZN REFER ALSO TO THE SAFETY RULES WHEN GRINDING ON PAGE 3 NOTE Atthis point you won t know
36. e other two linear bearings BEARINGS WHICH ARE TOO TIGHT OR TOO LOOSE WILL CAUSE POOR GRIND QUALITY ALSO BEARINGS WHICH ARE TOO TIGHT WILL HAVE SUBSTANTIALLY SHORTER LIVES AND MAY DAMAGE THE SHAFT SETTING THE BEARING TENSION CORRECTLY IS CRITICAL TO PROPER GRINDING STEP 4 Slide linear bearing under carriage and attach with the four screws STEP 5 After allthree linear bearings are secured to the carriage check for correct bearing tension The bearing tension is correct when you try to lift the carriage and can feel no carriage movement If there is movement this means there is up and down free play The most dependable method of checking free play is to use a magnetic base dial indicator attached to the traverse frame weldment and reading the vertical movement above each bearing This movement should be within 001 03 mm When pulling the carriage in the traversing direction there should be only approximately a three lbs force with the belt clamp disengaged To double check the assembly slide the carriage from end of travel to end of travel it should have very uniform resistance through its full range ADJUSTMENTS Continued TO ELIMINATE INFEED HANDWHEEL BACKLASH If there is backlash in the Grinder Head Infeed handwheel FIG 45 there are two adjustment points on each to check 1 Washers behind the handwheel A Loosen about half a turn the setscrew holding the handwheel to the shaft This setscrew i
37. e to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause Traverse Motor Switch TMS is not on Traverse Speed Pot TSP set to zero Fuse Traverse Drive Control has failed Traverse Drive Control is bad Bad Traverse Motor Switch TMS Checkout Procedure A Turn on TMS B Set TSP to 35 on the control panel C Check fuse and replace if failed See Page 23 Too heavy a grind causes grinding head traverse motor to overload and blow the fuse NOTE Fuse can not be checked visually Use Ohm test to check fuse Fuse must be replaced with a slo blo fuse D Check for 120 Volts AC incoming to TDC E Check for 120 Volts AC at TMS Make certain TMS is on Traverse works Yes end troubleshooting No got to Step B next Traverse works Yes end troubleshooting No go to Step C next Traverse works Yes end troubleshooting No go to Step D next On TDC Terminal L1 to L2 for 120 Volts AC Yes Go to Step F No Go to Step E next Measure 120 volts AC from TMS Termi nal 5 to Term Block 4 Blue Yes Verify wiring to TDC No Flip Switch and check again Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch ELECTRICAL TROUBLESHOOTING Continued Possible Cause
38. eed handwheel see Page 31 Slow down the traversing speed Direct coolant into the grinding wheel at the point of the grind See Operators Manual Take off about 002 to 003 05 to 075mm per pass during rough grind See Operators Manual Dress the wheel before the finish grinding pass on each bedknife See Operators Manual REASON A loaded wheel creates undue pressure on the surface being ground Both ends of bedknife move because of this pressure allowing bedknife to rock on the middle support For precise grinding spark ing out process is critical It eliminates excessive final grinding pressure on centers and middle support which helps maintain grinding straightness Looseness in roller causes erratic grind When the rim doesn t extend over the top face it wears unevenly and causes grooves across the bedknife Looseness in rollers causes erratic grind Backlash allows grinding wheel to move under load Traversing speed controls the grinding surface texture A slower traverse produces grind marks closer together When the front face of the bedknife gets too hot the steel loses its temper softens Too much stock removal in one pass creates too much heat and softens the steel Wheel will glaze if not dressed often enough Also as a general rule use a higher traverse speed for the heavy grind MECHANICAL TROUBLESHOOTING Continued PROBLEM POSSIBLE CAUSE
39. ent wheel it is recommended that you dress it before grinding Dressing trues the grinding surface of the wheel and removes the hard glaze sometime remaining from the manufacturing process This dressing properly prepares the wheel for grinding See Page 13 GRINDING WHEELS AVAILABLE FOR 277 BEDKNIFE GRINDER WHEEL PART NO COLOR DESCRIPTION SIZE 3700060 White red ruby flare cup wheel 6 3 1 4 x 2 0 627 inch bore vitrified ruby 3700062 White flare cup wheel 6 3 1 4 x 2 0 627 inch bore vitrified 3700268 White red ruby straight cup wheel 6 x 2 x 0 627 inch bore vitrified ruby 3700411 White straight cup wheel Standard Grinding 6 x 2 x 1 25 inch bore vitrified Wheel 3700670 Borazon straight cup wheel For normal or extra 6 x 1 1 2 x 0 625 inch bore hardened bedknife 3700696 Borazon straight cup wheel For normal or extra 6 x 1 1 2 x 0 625 inch bore hardened bedknife OPERATING INSTRUCTIONS CONTINUED DRESSING THE GRINDING WHEEL Dress the grinding wheel whenever there is any glazing Glazing is the buildup of stone dust grinding grit and coolant on the face of the wheel For best results also dress the wheel before making the final grind REFER ALSO TO THE SAFETY RULES WHEN GRINDING ON PAGE 3 For dressing always move the grinding head to the right hand side of the machine fig 17 so you are clear of the FIG 17 bedknife With the wheel turning lift the dresser movement arm off its holder and push
40. er Controls Page 38 40 Grinding Motor Controls Page 41 42 Coolant Pump Controls Traverse Drive Controls w prox Page 43 47 ELECTRICAL TROUBLESHOOTING Continued PROBLEM AC Main Power Controls no electrical power to control panel Verify all wires shown on the wiring diagram on pages 68 69 are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If problem persists test as listed below Possible Cause Emergency Stop Botton ESS is Depressed You must push the System Start Switch SSS to get power to control Panel Main Power Cord is not plugged in Guard doors must be closed and ALL Switches MUST be turned OFF for contactor to pull in Main 15 amp outlet circuit breaker has tripped No 120 Volts AC power to Filter FTR No 120 Volts AC power out of Filter No 120 Volts AC power to Main Circuit Breaker MCB No 120 Volts AC power from Main Circuit Breaker MCB Checkout Procedure A Pull Up on ESS Button B Listen for the Magnetic Starter MAG contacts to pull in with a clunk C Plug in main power cord D Close guard doors and turn off all switches E Check circuit breaker in your building and reset if necessary Check wall outlet with a light to make sure it works Check for 120V at Cord into FTR Power Cord 32 G Check for 120V out of FTR H Check for 120V to MCB
41. er washer to clean the machine SPECIFICATIONS POWER REQUIREMENT 115 Volts 50 60 Hz 15 Amps DIMENSIONS 61 155 cm wide x 32 82 cm deep x 81 206 cm high 750 Ibs 340 kg SHIPPING DIMENSIONS 74 188 cm wide x 41 104 cm deep x 68 173 cm high 935 Ibs 424 kg 119 4 cubic feet 3 4 cubic meters The Model 277 Model Features Feature Partially Enclosed Cabinet Magnetic Mount for Bed Knife Centers for Mounting Bed Knife Infeed Manual Control Travel Automatic Variable Speed Flood Coolant System Grinding carriage Mounted Diamond Dresser Transformer for 220 Volts 50 60 Hz Optional GETTING TO KNOW YOUR GRINDER Continued Symbols for Read operators manual wear safety glasses and disconnect power before servicing Symbols for sharp object which will cause serious injury and symbol for keep visitors a safe distance away from machine Symbols for caution relating to RPM of motor and minimum safe rated RPM of the grinding wheel Symbol identifying a panel cover or area as having live electrical components within Low Voltage Relay The grinder is equipped with a low voltage relay which is factory preset at 100 VAC If the power supply line does not deliver 100 VAC power under load the relay will open and trip out the starter If this occurs your power supply line is inadequate and must be correct before proceeding further with the grinder 222222 2
42. es a 2 KVA 220 Volt Step Down to 110 volt 50 60 Hz POWER Y transformer which is prewired AL ACK The wiring diagram is shown in NHITE NEUTRAL WHITE NEUTRAL FIG 42 The power cord has no connector A A connector which is appropriate for your locality and 220 volt 8 amp application should be installed X X2 X amp HIOHS HI HB INDIVIDUALLY WIRE MUT TRANSFORMER LEADS Ht H7 HA AND H9 USE ONLY A QUALIFIED INSTALL THE GREEN FIRE SUPPLIED INTO THE TERKINAL BLOCK JN THE HILE ELECTRICIAN TO FPOSITE WIRE Xj AS SHOWN TO INSTALL THE WIRE INSERT A SMALL COMPLETE THE SCREWORTVER INTO THE CAVITY MARKED A TO OPEN THE WIRE HOLE INSTALLATION ATTACH THE OTHER END DF THE GREEN YIRE SUPPLIED 10 THE LFOLND STUD ON THE TRANSFORMER IMPORTANT GROUNDING INSTRUCTIONS In case of a malfunction or breakdown grounding reduces the risk of electrical shock by providing a path of least resistance for electrical current This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded according to all local or other appropriate electrical codes and ordinances Before plugging in the Grinder make sure it will be connected to a supply circuit protected by a properly sized circuit breaker or fuse Never modify the plug provided with the machine If it won t fit the outlet have a proper out
43. he magnet When tightening make certain the mount is tight to the tooling bar at top and front 2 Position the bedknife so the unworn tips on a used bedknives or the ends of a new bedknife are on the gage tips See FIG 25 Pull the bedknife forward firmly Make sure tight against the gage tips Install the centers by loosening Fiahitland top and front the arms lock handles only enough to slide the arms 19 an and loosening the center lock knobs Position the center Adjustable support into a bedknife hole and tighten the center lock knob Lock Knob and the arm lock handle on both sides See FIG 25 amp 26 Turn down and park both alignment gage tips direction and should be tightened into the 1 The center should not load the bedbar any bedbar only enough to hold the bedbar rigid BEDKNIVES WITH DUAL CUTTING EDGES Some mowing unit manufacturers and some after market bedknife manufacturers make a bedknife with Dual Cutting Edges as shown in FIG 28 Because of the two radiused surfaces that these bedknives present to the magnets there is minimal holding force Therefore to achieve a solid hold with the magnets you must file the bottom side of the bedknife with a flat bastard file as shown in Fig 27 You must file with a uniform stroke across both radius File until you have developed flats on the radius that are a minimum of 3 32 09 2 3mm wide and uniform in width for the length of the magnet on each end of the be
44. ientation zh dB 5 o m 36 ELECTRICAL TROUBLESHOOTING SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING This Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowledge and skills to reliably test and repair the electrical system For those without that background service can be arranged through your local distributor This manual presumes that you are already familiar with the normal operation of the Grinder If not you should read the operators section or do the servicing in conjunction with someone who is familiar with its operation Persons without the necessary knowledge and skills should not remove the control box cover or attempt any internal troubleshooting adjustments or parts replacement If you have any question not answered in this manual please call your distributor They will contact the manufacturer if necessary WIRE LABELS All wires have a wire label at each end for troubleshooting The wire label has a code which tells you wiring information The wire label has a seven or eight position code The first two or three digits are the wire number 01 99 or 123 The next three numbers or letters are the code for the component to which the wire attaches Example GMC for Grind Motor Control The last two numbers or letters the number of the terminal on the component to which the wire attaches ELECTRICAL TROUBLESHOOTING INDEX AC Main Pow
45. ing edge of the bedknife using the Neary 277 Bedknife Grinder i NOTE New bedknives should be ground before being put into use New bedknives deform and move to match the shape of the bedbar at the time of installation and therefore MUST be ground to a straight surface after installation Sharp Reel Blade When the grass is not being cut cleanly or the cut and Bedknife ends of the grass appear torn or ragged the edges of the reel blade and bedknife have become rounded and need sharpening See FIG 13A The purpose of sharpening is to restore the sharp edges to the reel and bedknife as well as to return the mowing unit to the manufacturers recommended configuration See page 64 for manufactures specifications Top Face Angle BEDKNIFE GRINDING ANGLES The bedknife has two faces that normally need to be 4 TO 10 ground the top face and the front face on some yo Z a models the front face may be curved and not need mma y grinding Mounting Surface This line is arallel to proper grinding angles for the two faces will vary BEDKNIFE A depending on the reel manufacturer Always follow surface the manufacturer s recommended specifications for bedknife angles Typically however This line is There will be 4 to 10 degrees clearance Front Face Angle Bene angle ground on the top face It will usually mounting be measured relative to the bedknife surface mounting surface See FIG 14A P R There will be a 0 3
46. ing to MAG T3 Disconnect Wire to MAG L3 and Measure 120 Volts AC from MAG term to Term Block 4 Blue Press and hold Green Start button to hold in MAG contacts while checking Yes Verify continuity of wiring from MAG L3 No Replace MAG ELECTRICAL TROUBLESHOOTING Continued PROBLEM Grinding motor not working Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram on pages 68 69 are correct and pull on wire terminals with approximately 3lbs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause Grinding Motor Switch GMS is not on Guard door is not closed 10 Amp Circuit Breaker CB is trioped Grind Motor Switch GMS not working Grinding Motor Relay not working No Power to Relay Contacts A Turn switch on B Close Front guard doors and rear ramp lift option C Check 10 amp CB on front of Control panel Press in if tripped D Check for power to GMS E Check for power from GMS F Check for power to relay Coil Relay should click when GMS is turned on G Verify Power to Relay Contacts Grinding Motor works Yes end troubleshooting No go to Step B next Grinding Motor works Yes end troubleshooting No
47. inlet must always be completely submerged in water Never add plain water to the coolant when the level is low Always add water and concentrate in the correct proportions It is recommended to pre mix coolant and water in a separate container for this purpose OPERATING INSTRUCTIONS CONTINUED MOUNTING A BEDKNIFE FOR GRINDING Inspect and Clean the Bedknife Inspect the bedknife for damage cracks warping bushing wear excessive bedknife wear Replace or repair if necessary see the mowing unit manufacturers manual Thoroughly clean the bedknife especially on the bottom where the magnets will attach It is recommended that you thoroughly wire brush the bottom of the bedknife before mounting Prepare the Machine for Mounting the Bedknife Pivot the tooling assembly to the horizontal position Front face grinding position and set the bedknife angle to 0 front face angle Position the grinding head all the way to the right then crank the carriage back away from the magnets to gain clearance for the bedknife Always wipe any grindings dirt etc from the magnets and the tooling bar right side slide area before mounting the bedknife USING A FLARE CUP WHEEL WHEEL GUARD LOCK KNOB FOR ADDED CLEARANCE The shape of some bed bars requires using an optional flare cup grinding wheel to clear the end supports See FIG 23 Flare cup wheels can be ordered in several 6 150 mm diameter versions For most applications the 6 vitrified
48. ip to the clamping block shoe See FIG 53 Lock in place by tightening the jam nut against the clamp being careful not to move the tip Do not set the adjustment at less than 10 The 10 setting allows slippage in a jam situation and damage can occur if this adjustment is set to narrow CAUTION SHOULD BE USED AS ADJUSTING THE TIP WILL AFFECT THE SLIP LOAD AND COULD DAMAGE THE CLAMP TIP BELT OR TRAVERSE DRIVE SYSTEM ADJUSTMENTS Continued POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL TDC Min Speed Factory set at full CCW 8 30 Do not change this setting Right Traverse Forward Torque Factory set at full CW 4 30 Do not change this setting Left Traverse Reverse Torque Factory set at full 4 30 Do not change this setting IR COMP Factory set to 9 00 IR COMP is current 1 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 trim pot clockwise from its factory set position Overcompensation causes the motor to oscillate or to increase speed when fully loaded If you reach such a point turn the IR COMP trim pot counterclockwise until the symptoms disappear Max Speed Set at 3 30 for maximum voltage of 90 Volts DC to the traverse motor When voltage is above 90 volts DC the traverse motor will start to pulsate and not run smoothly Right
49. l which doesn t contact the bedknife will still be over the bedknife See FIG 33 When you go to the right end of the Grinder the wheel traverses completely off the bedknife Infeed the grinding wheel until it very lightly touches the bedknife on the left side Now traverse to the right end of the bedknife to assure that the right side is not closer to the grinding wheel Back the wheel out if necessary until you can traverse full length with a very light touch at the closest point OPERATING INSTRUCTIONS Continued GRINDING THE FRONT FACE Continued Grind the Bedknife When you are satisfied with the grinder head travel begin grinding ZN REFER TO THE SAFETY RULES WHEN GRINDING ON PAGE 3 NOTE During the grinding process watch the spark pattern for the full length of grind the sparks should look equal for the full length of grind Set the GRINDING WHEEL switch to ON Set the COOLANT PUMP switch to ON Check the nozzle is directing coolant onto the bedknife FIG 22 Set the TRAVERSE speed Potentiometer at about 15 to 20 NOTE If an excessive amount of metal stock will have to be removed on one end of the bedknife recheck your setup first and then the straightness of the bedknife If it is bowed or twisted replace it Set the carriage traverse switch ON With the horizontal infeed handwheel crank the grinding head in clockwise until the wheel is removing metal lightly from the bedknife It is recommended to take off a
50. let and circuit installed by a qualified electrician ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOUR MACHINE AN IMPROPER CONNECTION CAN CAUSE A DANGEROUS ELECTRICAL SHOCK IF YOU ARE UNSURE OF THE PROPER ELECTRICAL GROUNDING PROCEDURE CONTACT A QUALIFIED ELECTRICIAN 28 DAILY MAINTENANCE On a daily basis clean the grinder by wiping all areas down On a daily basis check coolant tray fluid level On a daily basis inspect the grinder for loose fasteners or components and tighten Contact your company s Maintenance Department if damaged or defective parts are found DO NOT USE COMPRESSED AIR TO CLEAN GRINDING DUST FROM THE GRINDER PERIODIC MAINTENANCE 1 Clean the Traverse Rails by wiping down with WD 40 or equivalent on a weekly basis Replace the four foam rail wipers FIG 43 every 6 months of operation Clean the interior of the Coolant Tray as necessary and at least every 6 months Check the brushes on the auto traverse drive motor once every 36 months Replace as necessary LUBRICATION Linear Bearings Do the following at least every six months 1 Thoroughly clean the carriage rails and shaft seals Wipe the shafts and seals thoroughly with a clean rag While cleaning traverse the carriage several times to clean the full length of the rails Flood spray shafts with WD 40 or an equivalent lubricant do not use a Teflon based lubricant until lubricant drips off the shafts
51. ly test and repair the 277 Bedknife Grinder For those without the background service can be arranged through your local distributor This section presumes that you are already familiar with the normal operation of the Grinder If not you should read the front of this manual or do the servicing in conjunction with someone who is familiar with its operation Persons without the necessary knowledge and skills should not remove the control box cover or attempt any internal troubleshooting adjustments or parts replacement If you have questions not answered in this manual please call your distributor They will contact the manufacturer if necessary TORQUE REQUIREMENTS Throughout this manual we refer to torque requirements as firmly tighten or the like For more specific torque values refer to the information below GRADE 2 GRADE 5 GRADE 8 Bolts Going Into a Nut or Into a Thread Hole in SMOOTH HEAD Steel Refer to the table at the right thread 0 8 kg m 1 25 kg m 1 8 kg m Bolts Going Into a Thread Hole In Aluminum Use the Grade 2 values in the table at the right thread 1 5 kg m BRO 3 9 kg m Socket Head Screws Going Into a Nut or Steel thread 2 6 kg m 4 3 kg m 6 4 kg m Use the Grade 8 values in the table at the right EJ ft lbs EH ft Ibs thread 4 1 kg m EJ EH Machine Screws 1 2 In 45 ft lbs 75 ft lbs 115 ft lbs 6 screws 11 in lbs 0 125kg m thread 19 9 kg m No
52. n SSS and Check voltage after the SSS O Hold in SSS and Check voltage at LVR LVR must be installed in 8 pin socket P Hold in SSS and Check voltage at MAGA1 amp A2 ELECTRICAL TROUBLESHOOTING Continued Terminal 11 on Terminal Strip 2 07TB2 11 to Terminal Block 4 Blue for 120 Volts AC Yes Go to Step K next No Check wires 7 8 3 Check Jumper on Terminal Blocks 1 3 Measure 120 volts AC from GMS Terminal 1 to Term Block 4 Blue Yes Go to Step M next No Flip Switch and check again Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch Measure 120 Volts AC from ESS term 2 to Term Block 4 Blue Yes Go to Step N next No Check wire for continuity then verify switch continuity If bad replace ESS contactor NC Measure 120 Volts AC from SSS term 3 to Term Block 4 Blue Yes Go to Step O next No Check wire for continuity then verify switch continuity If bad replace SSS contactor NO Measure 120 Volts AC from LVR term 8 to Term Block 4 Blue Yes Go to Step P next No Check for 120 Volts AC from LVR term 6 to term 7 Yes Verify Continuity of term 1 to term 8 on LVR Replace LVR if bad No Verify Continuity of Wires Measure 120 Volts AC from MAG Term A1 to Term A2 Yes MAG Should pull in with clunck if not replace MAG No Verify Continuity of Wires ELECTRICAL TROUBLESHOOTING Continued PROBLEM Machine Shuts off when you tur
53. n on Grind motor switch Possible Cause Guard Door is open Low Voltage Relay is tripping Door Safety Switch is not aligned Door Safety Switch is not working properly Checkout Procedure A Close the guard doors B Power delivered to the grinder is inadequate Verify that adequate power is delivered to the grinder See page xx of the manual Fix the problem with building power C Check Alignment of Door Safety Switch on guard door D Verify Door Swith is Working PROBLEM MAG turns only with System Start Switch held in Possible Cause No Power to MAG holding Contact MAG holding contact has failed Checkout Procedure A Check voltage to MAG holding contact in B Verify the magnetic starter MAG holding contact is working Machine works Yes end troubleshooting No go to Step B next Machine works Yes end troubleshooting No go to Step C next Check aligment of door switch Yes end troubleshooting No Go to Step D next Disconnect door safety switch cord at terminal 14 and 15 on Terminal Strip 1 Verify Conituity of switch with door closed Yes Reconnect Terminals and verify continuity of wires No Verify continuity of cord and replace cord or switch Measure 120 Volts AC at MAG term T3 to Term Block 4 Blue with E Stop Pulled out do NOT press start button while checking Yes Go to Step D next No Verify continuity of wir
54. on Page 34 COOLANT SYSTEM FIG 7 Coolant Nozzle Directs a stream of coolant onto the bedknife and grinding wheel For precise aiming the nozzle and connecting tubing are completely flexible NOTE The connecting tube can be shortened by removing segments as desired Coolant Flow Valve Controls the volume of coolant flowing to the nozzle Use only enough flow to cool the bedknife Excess flow will cause excess splashing and won t improve performance Flexible tube amp Flow valve Nozzle OPERATING INSTRUCTIONS CONTINUED GRINDING HEAD FIG 8 AND FIG 9 Wheel Guard Lock Screw Vertical Cam Lever Vertical Eccentric Adjustment and Lock Moves the grinding head up and down Horizontal Handwheel Moves the grinding head infeed in and out Horizontal Adjustment Scale Calibrated in 002 in 05mm increments so you can accurately move the grinding wheel in for each pass across the face of the bedknife Wheel Guard Lock Screws T knob holds the guard in position Loosen it to pivot the guard when the guard interferes with the bedbar 5 Lock Lever f Diamond Wheel Dresser Diamond Dresser Allows you to dress the grinding wheel Cleaning and dressing the grinding wheel improves the quality of the grind See Page 13 for more information Handwheel Horizontal Adjustment Horizontal Adjustment Scale OPERATING INSTRUCTIONS CONTINUED FIXED BEDKNIFE SUPPORT FIG 10 The bedknife and bedbar is held in position
55. raverse motor on and off It controlls the side to side movement of the carriage and grinding head TRAVERSE SPEED CONTROL POTENTIOMETER This control knob sets the speed of traverse for the grinding carriage When turned on to minimum the carriage will stop When turned to the maximum the carriage moves back and forth at full speed When learning to use this machine it is a good idea to set this speed at minimum start the other functions then slowly increase the speed to observe that your operation and set up are correct OPERATING INSTRUCTIONS CONTINUED TRAVERSE ENGACEMENT LEVER TRAVEL MECHANISM RELEASE FIG 5 ENGAGED POSITION To move the grinding head from side to side manually there is a release located on the front bottom of the TRAVERSE TIP carriage To disengage the carriage drive system l PIKINITY SWITCH rotate the red handle engagement lever to the down TRAVERSE LIMIT TTA position To engage the carriage drive system rotate the red handle engagement lever to the up position See FIG 5 TRAVERSE BELT TRAVERSE ENGAGENENT LEVER DISENGAGED POSITION PROXIMITY SWITCHES FIG 6 Two movable switches determine the left and right limits of carriage traverse An LED on the switch lights when the switch actuator bracket on the bottom of the carriage gets close to the head of the switch Note there should be a 3 16 gap between the proximity switch head and the traverse actuator bracket See FIG 51
56. re connection will give intermittent electrical contact MECHANICAL TROUBLESHOOTING PROBLEM Top face of bedknife is ground in a convex shape high in the center or concave shape low in the center The top face of the bedknife is ground unevenly across the width Too coarse a grind on bedknife The top face of the bedknife shows burn marks from being too hot POSSIBLE CAUSE A Grinding wheel is loading up with grinding grit B Too heavy a grind on the final grinding pass C Small Grinding Head Slide Vee Roller loose A Grinding wheel rim is not completely over the top face being ground B Small grinding Head Slide Vee Roller loose C Backlash in infeed handwheel Grinding head is traversing too fast A Coolant not directed onto the bedknife and grinding wheel B Too heavy stock removal during grinding C Grinding wheel is glazing REMEDY Dress the wheel prescribed in the Operators Manual Follow the procedures in the Operators Manual On the final pass infeed only about 001 025 mm Let the wheel spark out for 10 20 passes at about slow speed with no additional infeed Adjust Vee Rollers per procedure on Page 34 The wheel rim must extend over the bedknife top face by 1 2 13 mm whenever possible See Operators Manual If not possible dress the wheel more often Adjust Vee rollers per procedure on Page 34 Eliminate backlash in inf
57. s accessed by removing the calibration ring setscrew and rotating the calibration ring to access the handwheel setscrew Setscrew with nylon ball B Tighten the hex lock nutwhich secures the handwheel to 100 in Ibs 1 15 kg m then back off 1 2 turn Infeed Handwheel C Check for 015 in 04mm gap between the wave washer and the flat washer See FIG 46 Re adjust the hex lock nut if necessary D Tighten the setscrew holding the handwheel to the shaft Install and tighten the calibration ring setscrew 2 Check the nylon ball tension on the flat washers adjustment shaftthreads atthe grinding head slide See FIG 45 When you turn the handwheel there should be no free play inthe handwheel before the grinding head slide moves Ifthere is free play tighten the setscrew that pushes the nylon ball against the acme thread of the adjustment shaft The nylon ball preloads the free play out of the threaded joint between the adjustment shaft and the tooling bar slide block Apply tension only enough to zero the free play DO NOT over tension the setscrew as the adjuster will be difficult to turn ADJUSTMENTS Continued TO ELIMINATE ALIGNMENT ADJUSTMENT BACKLASH If there is backlash in the alignment adjustment handwheels FIG 47 there are two adjustment points to check 1 Check the nylon ball tension On the tooling bar adjustment block there is a nylon ball setscrew combination used to set the tension on
58. sparking out always traverse the grinding head 10 to 20 passes without cranking the grinding head in further To get the finest top face grind set the TRAVERSE knob at slow speed for this final grinding sparkout This process improves the surface finish of the grind and improves the grind quality NOTE What you are looking for is a near sparkout about a 99 reduction in grinding spark from a normal grind Don t continue sparking out until you have no sparks because this could be an extremely long time SHUT OFF THE COOLANT PUMP SWITCH BEFORE YOU SHUT OFF THE GRINDING WHEEL THIS WILL ALLOW THE WHEEL TO SPIN DRY IF THE WHEEL RETAINS TOO MUCH COOLANT IT WILL BE UNBALANCED WHEN YOU TURN ON THE GRINDING MOTOR AGAIN REMOVING THE BEDKNIFE To remove the bedknife rotate the tooling assembly to the front face grinding position down Remove the right hand center from the bedbar by backing the center back as far as necessary DO NOT loosen the arm lock grasp the bedknife and pull it off the magnets If the next bedknife to be ground is the same type and size as the previous simply mount it and proceed with verifying mounting and proceed with new alignment Ifthe next bedknife to be ground is a different type or size follow the full installation procedure SERVICE DATA SKILL AND TRAINING REQUIRED FOR SERVICING This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliab
59. surfaces ARE NOT CLEAN FLAT AND FREE OF BURNS 6 T 8 9 10 DON T TIGHTEN the mounting nut excessively DON T grind on the SIDE OF THE WHEEL see Safety Code B7 2 for exception DON T start the machine until the WHEEL GUARD IS IN PLACE DON T JAM work into the wheel DON T STAND DIRECTLY IN FRONT of a grinding wheel whenever a grinder is started DON T FORCE GRINDING so that motor slows noticeably or work gets hot AVOID INHALATION OF DUST generated by grinding and cutting operations Exposure to dust may cause respiratory ailments Use approved NIOSH or MSHA respirators safety glasses or face shields and protective clothing Provide adequate ventilation to eliminate dust orto maintain dust level below the Threshold Limit Value for nuisance dust as classified by OSHA GETTING TO KNOW YOUR GRINDER This machine is intended for reel mower bedknife grinding ONLY Any use other than this may cause personal injury and void the warranty To assure the quality and safety of your machine and to maintain the warranty you MUST use original equipment manufactures replacement parts and have any repair work done by a qualified professional ALL operators of this equipment must be thoroughly trained BEFORE 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 pow
60. t 5 16 18x1 4 Socket Set Screw Cup Pt 5 16 18x1 2 Socket Set Screw Cup Pt 1 4 dia x 1 2 Long Roll Pin 1 4 dia x 2 Long Roll Pin 3 8 16 Jam Locknut 1 4 Lockwasher 3 8 Flat Washer 3 8 Lockwasher Rubber Tip Tooling Bar Center Assy RH Tooling Pivot Block LH Tooling Slide Bar Tooling Adj Block Bracket Tooling pointer Decal Protractor Spacer 3910 x 750D x 311 Long Spacer 2510 x 375D x 69Long Nylon Plug 3 16 Dia Washer Flat 39 x 1 38 x 125 Handwheel 4 5Dia 38 Bore Knob T 1 5 1 2 13 Knob 2 5 3 8 16x1 5 Long Handle Adj 3 8 16 x 1 97 Washer Conical 1 2 x 1 83 x 024 Spring Compressed 600D x 531ID x 2 5Long Washer Conical 382 x 75 x 035 Washer Thrust 375 x 812 x 032 Shaft Adjusting Acme LH Lock Bar LH Adjuster Lock Bar Threaded LH Adjuster Base Gage Short C bore Block Slide RH Shaft Gage Arm Center Adjust Screw Gage Lock Strap Slide RH Bar Lock Slide RH Knob Assy T 2 5 1 4 20 x 1 31Long Mount Weldment LH Slide Weldment RH Tip Gage 3 8 16 Hex Jam Nut Thin Spacer 386 IDx 50 ODx 75 Long 3 8 16 x3 62 LG Thread Stud Bracket Rotation Decal 1 4 20 x 1 2 Socket Head Cap Screw EXPLODED VIEW 27544 CHANNEL 8 TRAVEL ASSEMBLY PARTS LIST 27544 CHANNEL 8 TRAVEL ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 8 32 x 3 8 Button Head Socket Cap Screw 1 4 20 x 3 4 Socket Head C
61. the condition of the grinding wheel after the previous job Always dress the wheel before grinding See Page 13 1 Set the GRINDING WHEEL switch to ON 2 Setthe COOLANT PUMP switch at ON and check that the nozzle is directing coolant onto the bedknife See FIG 37 Set the TRAVERSE speed potentiometer at about 15 to 20 NOTE If an excessive amount of metal stock will have to be removed on one end recheck your setup first and then check the straightness of the bedknife If it is bowed or twisted replace it Set the carriage traverse switch at on With the horizontal infeed handwheel crank the head in clockwise until the grinding wheel is removing metal lightly from the bedknife It is recommended to take off about 002 to 003 05 to 075 mm per pass during the rough grind NOTE The horizontal adjustment dial is calibrated in 002 05 mm increments Continue grinding the bedknife in this manner until you are satisfied with the top face grind Dress the wheel when necessary See dressing the Grinding Wheel on page 13 During the grinding process watch the spark pattern for the full length of grind the sparks should look equal for the full length of grind Dress the wheel before making the final spark out grind OPERATING INSTRUCTIONS Continued GRINDING THE TOP FACE Continued On the spark out passes crank the grinding head in clockwise only about 001 025 mm and then let the grinding wheel spark out For
62. the won bedknife touch the grinding wheel inside the end nib See FIG 30 Because when you adjust the left side the right side also moves a small amount you should go to the right and left sides several times to verify that you just contact the knife at both ends This can be done while grinding the knife NOTE These adjustments are done at the side handwheel NOT at the infeed handwheel on the grinding head Grind the front face per the instructions on Page 18 and 19 Then rotate the tooling bar to the Top Face position and repeat the above procedure to grind the Top Face Grind the top face per the instructions on Page 20 22 OPERATING INSTRUCTIONS Continued GRINDING THE FRONT FACE NOTE The following instructions presume that you have already studied all previous sections of this manual NOTE On some mower bedknives the front face is curved and therefore may not have to be sharpened Position the Bedknife for Front Face Grinding See FIG 31 Loosen the left side tooling rotate lock handle Rotate the tooling assembly to the front face position down and set the front face angle to the mower manufacturers factory specification Tighten the tooling rotate lock handle Check Clearances and Set Traverse Limits Position the grinding head so that the grinding wheel just touches the front face of th
63. to Terminal Block 4 Blue Yes Go to Step J next No Check circuit breaker for con tinuity Verify wiring and replace if needed Verify wiring at terminals 1 2 amp 3 on Terminal Strip 1 Check TB1 1 to TB1 2 for 120 Volts AC Yes Check terminals on motor cord If tight replace motor No Check wires from Grinding Motor Relay and Circuit Breaker to Terminal Strip 1 Coolant Pump works Yes end troubleshooting No go to Step B next B Open coolant flow valve Coolant Pump works Yes end troubleshooting No go to Step C next C Check 2 amp CB on front of Control panel Press in if trioped D Check power from CB Coolant Pump works Yes end troubleshooting No go to Step D next Measure 120 volt AC from both sides of 2 amp CB to Terminal Block 4 Blue Yes go to Step E next No With power off check continuity of CB amp wires to CB Replace CB E Check for power from CPS Term 5 to Terminal Block 4 Blue for CPS 120 Volts AC Yes Go to Step F next No replace CPS F Check for power from Measure 120 volt AC from TB1 4 to TB1 5 CPS Yes Replace Coolant Pump ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse Drive not working Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram on pages 68 69 are correct and pull on wire terminals with approximately 3lbs forc
64. zzneary TECHNOLOGIES MODEL 277 Bed Knife Grinder OWNERS MANUAL WARNING You must thoroughly read and understand this manual before operating the equipment paying particular attention to the Warning 8 Safety instructions 27550 8 04 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 Caution Symbol identifies special instructions procedures which if not correctly followed could result or procedures which if not strictly observed could in personal injury result in damage to or destruction of equipment KEEP GUARDS IN PLACE and in working order 13 MAINTAIN GRINDER WITH CARE Follow instructions in service section of the Manual for REMOVE WRENCHES AND OTHER TOOLS lubrication and preventive maintenance KEEP WORK AREA CLEAN DISCONNECT POWER BEFORE SERVICING or when changing the grinding wheel DON T USE IN DANGEROUS ENVIRONMENT Don t use Grinder in damp or wet locations REDUCE THE RISK OF UNINTENTIONAL Machine is for indoor use only Keep work area STARTING Make sure all switches are OFF well lit before plugging in the Grinder KEEP ALL VISITORS AWAY All visitors should USE RECOMMENDED ACCESSORIES be kept a safe distance from work area Consult the manual for recommended accessories Using improper accessories may

OPERATING INSTRUCTIONS (Continued)

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