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ELECTRICAL TROUBLESHOOTING (Continued)

1. ado 41782 4 41182 2 UP 41182 1 14400084 140782 12 oma 115 VAC NEUTRAL LINE FILTER CB1 CIRCUIT BREAKER 1 CB2 CIRCUIT BREAKER 2 ESS EMERGENCY STOP SWITCH FTR LINE FILTER GMS GRINDING MOTOR SWITCH LVR LOW VOLTAGE RELAY MAG MAGNETIC STARTER MCB MAIN CIRCUIT BREAKER PWR DC POWER SUPPLY START REL GRINDING MOTOR RELAY gt gt RTP RELIEFTORQUE POT La RSS REVERSE SELECTOR SWITCH SCB SECONDARY CIRCUIT BREAKER SDC SPIN DRIVE CONTROL SMS SPINMOTOR SWITCH SRS SPIN ROTATION SWITCH SSM SAFETY SWITCH MONITOR SSP SPIN SPEED POT SSS SYSTEM START SWITCH STS SPIN TORQUE SELCTOR SWITCH TB1 TERMINAL STRIP 1 TB2 TERMINAL STRIP 2 TBG TERMINAL BLOCK GREY TBW TERMINAL BLOCK BLUE TMS TRAVERSE MOTOR SWITCH TSP TRAVERSE
2. y 1991 XI73H 384338 104 X113H 3543A34 OPERATING INSTRUCTIONS Continued RELIEF GRINDING CONTINUED Reset the Traverse Limit Proximity Switch so the grinding wheel clears the reel at both ends by approximately 1 16 1 5 Set Grind Selector switch to variable torque 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 looking at the right side NOTE Relief torque reel rotation is always opposite spin rotation DO NOT TURN ON THE 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 the blade Turn the traverse speed potentiometer to zero then turn the traverse drive motor on With the belt drive disengaged manually move the Relief Grinding Assembly to the left until the reel blade is on the fixed relief finger At this point if necessary you can adjust the relief 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 de crease the relief angle Adjusting the relief angle or index finger stop position i
3. 437 Se 0 palajal OSje 51991 EWJON 991 y 0 pue 51991 ewou Jo pasn aq ued ay paseyolnd se s enbs 941 310 Ope q 891 jo a Bue yojeu PInoys Buipuu ay 1981 XITIH IVINHON 104 XITAH JUIO y Peluog Buipung enjoy 1514 1261000 Isnyy 1994 M 10 apis a Buy Buiyoyeyy OPERATING INSTRUCTIONS Continued uo sod y JO 149 y 0 55216 SMOJY SI991MOAUY Y97 10 Apis 55216 ay BUMOOT 991 1514 Bund OPIS Se 0 S 991 XIJ Y SI991 98 9491 JOPULH pue aq Alje 9ua ueo ewou e yojeu sey ey y ILON ay yo O1 8 2 1521 ay Jo Wed punub Jou NO 511 51281402 p s ay os ay 5 10 e Jeam ay 5 SE apIs ya 941 0 apejq ay s y JO ay os au 5 a Bue 19618 e yey s jes 99 yojeu passalp aq pinoys
4. mecanizado El mecanizado debe Ubicarse tan cerca nenn a ge del marco como sea posible al dejar el m ximo espacio para utilizar el calibre de posici n el calibre se explicar in of en la secci n de alineaci n La posici n horizontal se PEER obtiene al utilizar la manivela ubicada en la parte frontal PERILLAS DE DE POSICIONAMIENTO spr POSICIONAMIENTO perf MULTIPLE del mecanizado Si debe rectificar una unidad segadora ajuste r pido QA7 5 utilice las calcomanias ubicadas en el mecanizado para posicionar r pidamente el carrete Hay dos posiciones para cada carrete seg n c mo se monte el rodillo frontal Vea la Fig 2 Si utiliza soportes para todas las posiciones las posiciones vertical y horizontal pueden ajustarse al aflojar las perillas ubicadas en el lateral del mecanizado y mover a un nuevo conjunto de clavijas Verifique que el carrete est ubicado adecuadamente para la rueda de rotaci n y la rueda de alivio al comprobar los l mites de carrera ambas ruedas deber n contar con un margen para soltarse en ambos laterales La verificaci n durante la configuraci n eliminar la necesidad de ajustes y alineaciones importantes CALCOMANIA DE cuando pase del rectificado por rotaci n al rectificado tog Yen UBICACION DE LOS de alivio Cuando la segadora est en su lugar bloquee P CARRETES QAS Y QA7 la posici n al ajustar todas las perillas Levante el rodillo
5. posterior sobre el soporte angulado sujete el rodillo firmemente al apretar la manivela de la abrazadera 4 CALCOMAN A DE LA POSICI N DEL CARRETE POSICION DEL El carrete debe posicionarse de manera que est en la MECANIZADO posici n de ngulo de la una en punto o a 30 en FIG 2 referencia a la rueda abrasiva Vea la Fig 3 Si se utilizan 1 EN PUNTO los soportes para todas las posiciones intente ubicar p p p la unidad de manera que la parte inferior del carrete 90 est alejada entre 1 50 2 00 38 y 51 mm de la mesa Cuando utilice el mecanizado del tipo de montaje por rodillo intente mantener la posici n de la una en punto y compruebe que haya un margen entre el carrete y la rueda abrasiva Verifique que se pueda lograr el ngulo de alivio adecuado con esta configuraci n y realice cualquier ajuste de ser necesario Si rectifica un carrete QA7 o QA5 con montajes por rodillo utilice las calcoman as ubicadas en el mecanizado para obtener la posici n ptima para rectificar el carrete Vea la Fig 2 CONOZCA SU RECTIFICADORA Continuaci n ACOPLE Y DESACOPLE LONGITUDINAL La correa que impulsa el alivio y los centros de giro hacia la derecha y hacia la izquierda puede acoplarse y desacoplarse al volcar la abrazadera ubicada en la parte inferior de los montajes del cabezal de rectificado Al mover la manecilla hacia la izquierda acoplar la correa y al moverla a la derecha desacopla
6. 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 1 DON T DON T use 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 fitthe machine get one that will DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURRS DON T TIGHTEN the mounting nut EXCESSIVELY DON T grind on the SIDE OF THE WHEEL see Safety Code B7 2 for exception DON T start the machine until the WHEEL 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 or to maintain dust level belo
7. DRAG SETSCREW LOCATED ON BACK OF EACH TOWER ADJUSTMENTS Continued TRAVERSE BELT TENSION To adjust the tension on the traverse belt tighten the screws and nuts located to the left side ofthe traverse belt behind the left side cover panelto a minimum of 1 75 44 mm The traverse belt should be level when adjusting the belt tension DO NOT OVERTIGHTEN OVERTIGHTENING COULD DAMAGE THE BELT OR TRAVERSE DRIVE SYSTEM TRAVERSE CLAMP FORCE If the traverse clamp is slipping during regular operation it may become necessary to adjust the clamp tip location To adjust the clamp tip loosen the jam nut and rotate the clamp tip The clamp tip should be adjusted to the dimension specified in FIG 18 To measure move the traverse belt out of the way Measure the clamped distance from the clamp tip to the clamping block shoe To secure the new position jam the nut against clamp BRACKET SCREWS y being careful not to move the clamp tip A CLAMP CLAMPTNG BLOCK If there is not enough adjustment in the clamp tip BRALKET SHE the bracket that supports the clamp can also be JAM NIT MINIMUM GAP DISTANCE adjusted The bracket is slotted to adjust loosen TIP 10 2 5 mm the two screws that are hold the bracket in place and slide the bracket forward or back Then FIG 18 retighten the screws make sure they are tight or the bracket will move during clamping Check the tip distance and make any necessary adjustments TH
8. ERRC and display flickering Occurs when the scale surface is stained Clean the scale surface and coat a thin film of low viscosity oil to keep out moisture E in the least significant digit This occurs when the slider is moved too quickly but it does not affect the measurement If it stays on when the slider stops the scale surface is probably stained If this is the case take remedies as for ERRC B indication Battery voltage is low Replace the battery as soon as possible Cleaning Clean gage with CRC 3 36 Cleaning and Lubrication Oll Wipe off excess after cleaning If CRC 3 36 is not available use Denatured Alcohol to clean then apply light oil and wipe off excess ADJUSTMENTS PROXIMITY SWITCH For the proximity switch to perform properly and reverse the direction of the grinding head assembly PRIX GRINDING HEAD the sensor end of the proximity switch must face LIGHT END toward the head assembly that is in use and must be mounted such that it is located past the edge of the prox holder NOTE The light on the proximity switch activates when metal is approximately 3 16 4 6 mm from the HE PAST HOLDER PROX SENSOR END VERTICAL INFEED SHAFT DRAG If the grinding shaft tends to walk during grinding the drag on the vertical adjusters needs to be increased To increase the drag in the vertical adjustment shafts tighten the setscrew on the back of the vertical adjustment housing
9. WEAR PROPER APPAREL Wear no loose clothing gloves neckties or jewelry which may 19 KEEP ALL SAFETY DECALS CLEAN AND get caught in moving parts Nonslip footwear is LEGIBLE If safety decals become damaged or recommended Wear protective hair covering to illegible for any reason replace immediately contain long hair Refer to replacement parts illustrations in Service Manual for the proper location and part numbers ALWAYS USE SAFETY GLASSES of safety decals SECURE YOUR WORK Make certain that the 20 NOT OPERATE THE GRINDER WHEN cutting unit is securely fastened with the clamps UNDER THE INFLUENCE OF DRUGS provided before operating ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS BREAKAGE AND SERIOUS INJURY IMPROPER USE OF GRINDING WHEEL MAY CAUSE Grinding is a safe operation if the few basic rules listed below are followed These rules are based on material contained 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 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
10. La rueda abrasiva y los motores de giro no funcionar n a menos que las tapas est n cerradas Ubique el interruptor selector de giro alivio en la posici n de giro Encienda el motor de rectificado y el interruptor del motor del impulsor de rotaci n Configure la velocidad de rotaci n en aproximadamente 200 rpm consulte las RPM del impulsor de rotaci n de la p gina anterior Aseg rese de que la rotaci n sea la misma que la de la rueda abrasiva en sentido de las agujas del reloj CW vi ndolo desde el extremo derecho Vea la Fig 22 IMPORTANTE Cuando el carrete gira en la misma direcci n de rotaci n que la rueda abrasiva el punto de contacto donde se encuentran est en direcciones opuestas Encienda el interruptor del motor del impulsor longitudinal y gire el indicador de velocidad para aumentarla hasta aproximadamente 15 y 20 IMPORTANTE Si el rectificado comienza a ponerse pesado ajuste el cabezal de rectificado hacia abajo hasta que pueda recorrer todo el largo del carrete sin experimentar un rectificado pesado Cuando rectifique avance la rueda aproximadamente 0 005 0 13 mm por vez Permita que la rueda abrasiva se deslice de un lado a otro a trav s del carrete 2 a 3 veces antes de avanzar El rectificado de giro estar completo cuando haya contacto completo a lo largo de todo el carrete y cuando todo el largo de sus l minas y el carrete est n afilados El ltimo paso debe ser un rectificado de avance normal
11. ON OFF FIG 8 OPERATING INSTRUCTIONS PREPARE MOWING UNIT FOR SHARPENING Always follow the procedures specified in the cutting unit manual when preparing the unit for sharpening It is recommended that the reel to be sharpened is thoroughly cleaned Remove the wheels and bed bar if possible from the reel The bedknives should be sharpened when the reel is sharpened Inspect adjust and or replace any worn or damaged bearings Make sure the reel bearings are in good working condi tion and adjusted properly so the reel turns easily by hand Because this grinder mounts the reel using 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 BEARINGS WILL BE EXTREMELY DIFFICULT TO SPIN GRIND AND COULD CAUSE DAMAGE TO THE REEL OR THE SPIN DRIVE MECHANISM ON YOUR GRINDER NO MORE THAN 25 IN LBS MAXIMUM TORQUE LOAD TO ROTATE THE REEL IS ALLOWED OR DAMAGE TO THE SPIN DRIVE COULD OCCUR LIFTING REEL INTO POSITION The RG5500 grinder does not come standard with a lift device If the facility does not have lift it is recommende thatthe winch and boom kit or Rear Lift Platform is usec WINCH BOOM KIT The Winch amp Boom kit mounts to the back right side c the cabinet When using the Winch amp Boom positio the cutting unit behi
12. RIEL DE DESLIZAMIENTO INDICADOR REINICIO EN CERO ENCENDIDO APAGADO FIG 8 INSTRUCCIONES DE OPERACI N PREPARACI N DE LA UNIDAD SEGADORA PARA VOLVER A AFILAR Siempre siga el procedimiento especificado en el manual de la unidad de corte cuando prepare la unidad para volver a afilar Es recomendable que el carrete que se debe volver a afilar se limpie en profundidad De ser posible quite las ruedas y la mordaza de bancada del carrete Deben volver a afilarse las cuchillas cuando se vuelva a afilar el carrete Inspeccione ajuste y o reemplace cualquier rodamiento desgastado o da ado Aseg rese de que los rodamientos del carrete est n en buenas condiciones de trabajo y ajustados adecuadamente de manera que el carrete pueda girarse f cilmente con la mano Puesto que esta rectificadora monta el carrete al utilizar el rodillo posterior y el rodillo frontal del carrete si corresponde los rodamientos de los rodillos deben estar en buen estado sin holgura Los rodillos frontal y posterior deben estar adecuadamente alineados en paralelo con el carrete antes del rectificado SER MUY DIFICULTOSO EL RECTIFICADO DI GIRO SOBRE LOS CARRETES CON EXCESO DI TENSI N EN LOS RODAMIENTOS Y ES POSIBLI QUE CAUSE DA OS AL CARRETE O AL MECANISMO IMPULSOR DE ROTACI N DE SU RECTIFICADORA SE PERMITE UNA CARGA M XIMA DEL MOMENTO DE TORSI N DE NO M S DE 25 PULGADAS LIBRA O PUEDE DA ARSE EL IMPULSOR DE ROTACI N C MO LEVANTAR EL
13. Note the square hole can also be used when checking for voltages The probe tip of the multimeter can be inserted into the square hole to take readings TROUBLESHOOTING INDEX AC Main Power Controls Page 28 30 Grinding Motor Controls Spin Drive Controls Page 32 36 Traverse Drive Controls Page 37 41 Mechanical Troublshooting Page 42 43 24 VDC Power Supply PWR Low Voltage Relay LVR Terminal Strip 2 TB2 Magnetic Contactor MAG Blue Terminal Blocks TBB Grey Terminal Blocks TBG Secondary Circuit Breaker SCB Main Circuit Breaker MCB Grinding Motor Relay REL Termial Strip 1 TB1 Main Ground Lug AC Filter FTR CONTROL PANEL located on the right side of the machine Door Safety Switch Monitor SSM Traverse Drive Control Board FUSES 3A Slow Blow Traverse Drive Control Board TDC Spin Drive Control Board SDC ELECTRICAL TROUBLESHOOTING Continued PROBLEM AC Main Power Controls no electrical power to control panel Verify all wires shown on the wiring diagram 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 the wire and the 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
14. Works Switch is upside down Does not work Check wiring Verify Continuity Replace Switch ELECTRICAL TROUBLESHOOTING Continued Possible Cause No DC Voltage from TDC 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 DISCONNECT POWER FROM MACHINE H Check TSP 10K on control panel Check TSP for 10 000 ohms Remove three wires from TDC red from term 8 white from term 7 black from term 9 J Inspect Motor Brushes DISCONNECT POWER FROM MACHINE Check TDC terminals A1 to A2 for 90 Volts DC Yes go to Step G next No go to Step H next Remove motor wires from Terminal Strip 1 terminals 7 amp 8 check for 0 ohms across the black and white wires Yes end troubleshooting motor should work if it does not replace motor No go to Step J next TDC Pin 8 to 7 Pot Full CCW Pot Full CW 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 I next Check for 10 000 ohms red to white wires Full CCW 0 ohms Full CW 10 000 ohms Red to black wires Full CCW 10 000 ohms Full CW 0 ohms Yes replace the TDC
15. de alto bajo voltaje cuyo ajuste predeterminado de f brica es 100 140 V CA Si la l nea de suministro el ctrico no entrega 100 140 V CA bajo carga el rel se abrir y desenganchar el arrancador Si esto sucede la l nea de suministro el ctrico es incorrecta y debe corregirse antes de continuar trabajando con la rectificadora 7 Y YA Y INDICE DE CONTENIDOS Instrucciones de seguridad P gina 4 7 Mantenimiento diario P gina 6 Conozca su rectificadora P gina 8 14 Instrucciones de operaci n P gina 15 27 Gr fico de configuraci n del carrete P gina 28 MANTENIMIENTO DIARIO POR EL OPERADOR Diariamente limpie la m quina con un trapo Diariamente quite toda la arenilla del eje de rectificado de los ejes longitudinales y del rea de la barra de mecanizado Diariamente inspeccione la m quina en busca de sujetadores o componentes sueltos P ngase en contacto con el Departamento de mantenimiento de su compa a si encuentra piezas da adas o defectuosas NO UTILICE AIRE COMPRIMIDO PARA LIMPIAR EL POLVO DE LA RECTIFICADORA INSTRUCCIONES DE SEGURIDAD PRESTE ESPECIAL ATENCION ALAS CALCOMANIAS DE ADVERTENCIA QUE APARECEN A CONTINUACION Y QUE ESTAN UBICADAS EN LA RECTIFICADORA CONSULTE EL MANUAL DE SERVICIO PARA OBTENER LOS NUMEROS DE PIEZA DE REPUESTO INFORMACION GENERAL RPMDE LA RUEDA ABRASIVA A CAUTION ATENCI N ER To Avoid Injury Para
16. 063 D x 188 Long 5NT80396 Knob 1 4 20 x 1 18 Long 5NT6329556 Gage Base Weldment EXPLODED VIEW SPIN DRIVE ASSEMBLY PARTS LIST SPIN DRIVE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB251016 1 4 20 x 5 8 Button Head Socket Cap Screw 5NTB251211 1 4 20 x 3 4 Socket Head Cap Screw 5NTB251216 1 4 20 x 3 4 Button Head Socket Cap Screw 5NTK250001 Flat Washer 1 4 5NTK251501 1 4 Lockwasher Split 5NTR000376 Sq Key 1 8 x 75 5NT50290 Front Clamp Plate 5NT50291 Clamp Block Motor Spin Assembly Spin DC Motor Brush for Service not shown T Knob Assembly 3 8 16 x 75 Dog Point Spin Mount Weldment Vertical Spin Mount Weldment Spin Arm Weldment Horizontal Flange Coupler 50 Bore Knob Assembly T 2 5 3 8 16 x 1 00L Decal Scale EXPLODED VIEW CONTROLS ASSEMBLY PARTS LIST CONTROLS ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTD160608 Thrd Cutting Screw 8 32 x 3 8 F Type 5NTD250800 Thrd Cutting Screw 1 4 20 x 1 2 F Type Hex Hd 5NT3707826 Push Button Square Green 5NTJ167000 8 32 Nylon Insert Lock Nut Jam 5NTRO00536 Lockwasher 1 4 Internal Teeth 5NT55711 Control Panel Decal 5NT 155504 Door Safety Switch Bracket Weldment 5NT55422 Control Service Panel see next page Control Panel Sub Assembly 5NT3707595 Hole Plug 7 8 1 4 20 Locknut Jam Potentiometer Assembly 10K Door Switch Bracket Strain Relief Liquid Tight 27
17. 4 AMP CB 2 e i q LAVIS 1755308 SSS 94015 SS S WWLIL S SWIOL a ES 50 SWI El c8leb 28109 4 80 91 20119 11 81 81 281 128109 D D 554 21214 4 08 9I 2BLEL 11 08101 BI ALIL 61 2810 ewe SE Darm 1 3006 SE Ii SW dsl El 11 BISIC LL AENA EUA OI CB1 CIRCUIT BREAKER 1 A 0801 CB2 CIRCUIT BREAKER 2 ESS EMERGENCY STOP SWITCH FTR LINE FILTER GMS GRINDING MOTOR SWITCH LVR LOW VOLTAGE RELAY MAG MAGNETIC STARTER MCB MAIN CIRCUIT BREAKER PWR DC POWER SUPPLY REL GRINDING MOTOR RELAY RTP RELIEF TORQUE POT RSS REVERSE SELECTOR SWITCH SCB SECONDARY CIRCUIT BREAKER SDC SPIN DRIVE CONTROL it io a 1887 AA LODE ROS TED HS OD ur Rn 5310 15 331017 S410L 18 D 43 4 30 AENA SMS SPIN MOTOR SWITCH SRS SPIN ROTATION SWITCH SSM SAFETY SWITCH MONITOR SSP SPIN SPEED POT SSS SYSTEM START SWITCH STS SPIN TORQUE SELCTOR SWITCH TB1 TERMINAL STRIP 1 TB2 TERMINAL STRIP 2 TBG TERMINAL BLOCK GREY TBW TERMINAL BLOCK BLUE TMS TRAVERSE MOTOR SWITCH TSP TRAVERSE SPEEDPOT TDC TRAVERSE DRIVE CONTROL
18. Continued PROBLEM Traverse speed control goes at one speed only Possible Cause Defective speed control potentiometer Checkout Procedure A Check potentiometer Pot 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 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 VDC 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 Verify potentiomter White wire to terminal 7 Red wire to terminal 8 and Black wire to terminal 9 if not correct Check for Proper function Yes end troubleshooting No Go to Step D next Wiring hookup to potentiometer is improper If components have been replaced C Check potentiometer wiring for proper hookup See that speed pot is wired per electrical diagram Minimum and maximum pot settings effect traverse speed Main circuit board dial pot settings not correct If board has not been replaced D Check all pot settings on circuit board as shown in wiring diagram See adjustment section Traverse Motor Con
19. 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 ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse does not stop to reverse directions when flag goes under the proximity switch on the left side or right side of machine Gap between flag and prox is incorrect Proximity Switch is bad A Gap between flag and prox should be 3 16 to 1 4 4 6 mm Prox LED does not light when flag is under prox B Proximity switch is not working properly or wire connections are loose 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 lightis 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 14 black wire and 15 brown wire The light coming on shows the proximity is getting electrical contact Proximity light on 0 Volts DC Proximity light off 12 Volts DC Proximity light on 0 Volts DC Proximity light off 12 Volts DC Replace proximity switch ifthe voltages do notread as above ELECTRICAL TROUBLESHOOTING
20. Read manual instructions and safety rules Make sure all items on the Preparation Check List in the Operator s Manual are completed before releasing equipment to the owner TO THE OWNER Read the Operator s Manual before operating your Frontier equipment Keep this and all manuals handy for ready reference Require all operators to read the Operator s Manual carefully and become acquainted with all adjustments and operating procedures before attempting to operate the equipment Replacement manuals can be obtained from your selling dealer The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactory use Like all mechanical products it will require cleaning and upkeep Lubricate the unit as specified Please observe all safety information in the Operator s Manual and safety decals on the equipment For service your authorized John Deere dealer has trained mechanics genuine Frontier service parts and the necessary tools and equipment to handle all of your service needs Use only genuine Frontier service 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 The Caution Symbol identifies special special instructions or procedures instructions or procedures which if not which if not correctly followed could strictly obse
21. See FIG 6 IT IS RECOMMENDED THAT THIS SPIN RELIEF The grinder is equipped with a high GRINDER HAS ITS OWN PERMANENT POWER low voltage relay which is factory CONNECTION FROM THE POWER DISTRIBUTION preset at 100 140 VAC If the power PANEL WITH NO OTHER MAJOR POWER DRAW supply line does not deliver 100 140 EQUIPMENT ON THE SAME LINE VAC power under load the relay will open and trip out the starter Ifthis IT IS REQUIRED THAT THE POWER DELIVERED TO occurs your power supply line is THIS GRINDER IS 115 VAC 20 AMPS THE incorrect and must be correct before TOLERANCE ON THIS POWER REQUIREMENT IS proceeding further with the grinder 5 THEREFORE THE MINIMUM VOLTAGE REQUIRE MENT IS 109VAC WITH 20 AMPS VOLTAGE MUST BE CHECKED WITH ALL EQUIPMENT UNDER LOAD OPERATING ON THE CIRCUIT DO NOT OPERATE THIS GRINDER WITH AN y FACTORY PRESET EXTENSION CORD FLASHING GREEN LIGHT DO NOT OPERATE THIS GRINDER ON A GROUND FAULT INDICATES LOW VOLTAGE FLASHING A PROPER GROUND IS REQUIRED FOR SAFE an OPERATION OF THE EQUIPMENT VERIFY THAT THE Y HIGH VOLTAGE RECEPTACLE GROUND IS A PROPER GROUND Y DELIVERED BEFORE PLUGGING IN THE MACHINE TO GRINDE IMPROPER GROUNDING IN YOUR BUILDING MAY RESULT IN A DANGEROUS SHOCK TO THE OPERATOR OR CAUSE THE GRINDER TO MALFUNCTION When installing the grinder the following guidelines should be used to establish the wire size between the power panel in your building and the
22. 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 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 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 power washer to clean the machine Low Voltage Relay FACTORY PRESET The grinder is equipped with a high low voltage relay FLASHING which is factory preset at 100 140 VAC Ifthe power supply line does not deliver 100 140 power under LOW VOLTAGE load the relay will open and trip out the starter If this FLASHING occurs your power supply line is incorrect and must be RED LIGHT corrected before proceeding further with the grinder 4 INDICATES HIGH VOLTAGE DELIVERED TABLE OF CONTENTS Safety Instructions Daily Maintenance Service Data Assembly Instructions Page 8 12 Maintenance Page 13 19 Adjustments Page 20 25 Electrical Troubleshooting Page 26 41 Mechanical Troubleshooting Page 42 43 Exploded Views and parts Lists Page 44 73 Wiring Diagram amp Schematic Page 74 76 DAILY MAINTE
23. n a una entrada cuadrada macho de 1 2 Para operar la rectificadora se necesita un adaptador de la entrada cuadrada macho de 1 2 al eje del carrete Estos adaptadores NO est n incluidos con esta rectificadora En los ltimos a os la mayor a de las unidades de corte cuenta con una ranura macho o hembra en el extremo del eje del carrete que se conecta con un eje de motor hidr ulico o el ctrico Si tiene un eje de carrete que tiene un extremo de interior roscado al que tiene acceso instale un perno de cabeza hexagonal o un tornillo de cabeza cil ndrica ranurada del tama o de esa rosca con una contratuerca de manera que est bien ajustado para que no se suelte durante el rectificado de giro y luego atornille con un manguito del impulsor de 1 2 para la forma hexagonal o el tama o de una llave hexagonal CARRETES JOHN DEERE ACOPLADOR Los ejes de exterior ranurado utilizan un acoplador hembra ranurado entre el eje del carrete y el eje macho ranurado del motor hidr ulico La ranura es una ranura dentada de 8 9 u 11 Nuestra recomendaci n es que adquiera un acoplador ranurado hembra de John Deere y lo suelde a una extensi n de manguito corta y cuadrada de 1 2 Nota El adaptador ranurado de 8 dientes puede utilizarse con un adaptador del impulsor de manguito cuadrado de macho cuadrado de 3 8 a hembra cuadrado de 1 2 sin soldadura DIAM DEL TIPODE CARRETE CARRETE Recomendaci n 5 G M Cuenta con un eje externo de 8 dientes Utili
24. n posible del soporte para todas las posiciones al dejar solo el margen suficiente como para montar el carrete en la V del brazo de soporte Ubique el carrete adentro y afuera al ajustar las manivelas frontales El carrete debe ubicarse de manera que el eje del carrete est orientado en la posici n de la una en punto 30 grados de la rueda de rectificado Vea la figura 13 Angulo de Si experimenta problemas con el margen el carrete puede 30 0 moverse hacia adelante o hacia atr s para resolver este problema Si rectifica un carrete QA5 o QA7 utilice las calcoman as ubicadas en el mecanizado para ubicar r pidamente el carrete en la posici n ptima Vea la Fig 2 Luego de posicionar el carrete bloquee correctamente el rodillo frontal y ajuste la abrazadera posterior Aseg rese de que todas las perillas est n ajustadas antes de comenzar el rectificado AJUSTE FIRMEMENTE TODAS LAS PERILLAS DE BLOQUEO ANTES DE COMENZAR EL RECTIFICADO CUALQUIER PERILLA ABRAZADERA O RODAMIENTO SUELTO TENDR UN EFECTO ADVERSO EN LA CALIDAD DEL RECTIFICADO INSTRUCCIONES DE OPERACI N Continuaci n ALINEACI N DEL CARRETE PERILLA DE AJUSTE IMPORTANTE Cuando mida el eje central del carrete NGULO DEL CALIBRE VERTICAL ENFORMA DET siempre aseg rese de que est poniendo en contacto un PERILLADE AJUSTE EN DEL CALIBRE rea libre de suciedad y de grama FORMADET MANIVELA DE nr ORIFICIOS DE MONTAJE AJUSTE HO
25. 005 13 mm CHECKING FOR TAPER First measure the left side of the reel as far to the left as possible with the digital alignment gauge make sure 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 this number down Move to opposite side and do the same thing Compare the two numbers the difference is the amount of taper in the radius of the wheel NOTE TO OBTAIN A CORRECT TAPER READING 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 To remove the taper in the reel the side of the reel that is larger will need to be infed heavier to remove this extra material Remove the gauge and store the digital gauge on the pin located on the front right side of the machine The gauge base can be placed inside the machine out of the way OPERATING INSTRUCTIONS Continued ALIGNMENT OF GRINDING SHAFT TO REEL To align the grinding shaft to the reel bring the shaft up so that the spin wheel is about 1 4 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 just touches Recheck from side to side and make minor adjustments until the wheel touches the same on both ends of t
26. 47 Wire Dia Strain Relief Liquid Tight 19 30 Wire Dia Strain Relief Liquid Tight 54 71 Wire Dia Electrical Warning Decal see page 7 Operators Manual 5NT3707093 Strain Relief Liquid Tight 55 71 Wire Dia 5NT3707715 Cord Clamp Double 5NT3708820 8 32 x 50 Button Head Safety Screw 5NT3707342 Yellow E Stop Ring 5NT3707367 Rocker Switch 5NT3707429 Rocker Switch 5NT3707446 Potentiometer Knob 5NT3707564 Green Pushbutton 5NT3707565 Contact Block Normally Open 5NT3707566 Switch Mounting Latch 5NT3707567 Red Stop Push Pull Pushbutton 5NT3707568 Contact Block Normally Closed 5NT3707647 Door Safety Coded Magnet 5NT3707761 Circuit Breaker 20 Amp 5NT3707653 Circuit Breaker 4 Amp 5NT6059021 Door Safety Switch Assembly Front 5NTB251016 1 4 20 x 5 8 Button Head Socket Cap Screw 5NT27169 Traverse Proximity Switch Cord Right Hand Not Shown 5NT6059078 Traverse Proximity Switch Cord Left Hand Not Shown 5NT3707601 Proximity Sensor 5NT55780 Control Panel Cord Not Shown 5NT6329078 Main Power Cord Not Shown 5NT3708378 Foam Strip 25 Thick Sold by the foot EXPLODED VIEW ELECTRIC PANEL SUB ASSEMBLY PARTS LIST ELECTRIC PANEL SUB ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTD160666 No 8 x 3 8 Pan Head Self Tapping Screw 5NTD161266 No 8 x 3 4 Pan Head Self Tapping Screw 5NTRO00480 Lockwasher No 8 External Teeth 5NT3706079 19 Pole
27. 5 check 0 ohms across the black and white wires from the motor Reading 0 Ohms Yes end troubleshooting spin drive should run if not replace motor No go to Step J Light on SDC next to SP should be ON If not remove wires 41SDCMOD and 44SDCCOM from SDC control board Check continuity 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 Reinstall wires Go to Step H next ELECTRICAL TROUBLESHOOTING Continued Possible Cause Checkout Procedure Spin Torque Pot TORQ H Check remote torque pot is not set correctly TORQ on the SDC board SSP is not working SSP 10K Remove 3 Remote Speed wires Red wire to term 2 White wire to term 1 Black wire to term 3 DISCONNECT POWER FROM MACHINE Worn Motor Brushes J Inspect Motor Brushes TORQ on SDC board should be set as labled on page 25 Adjust if incorrect and check Spin Drive Function All Potentiometers are set correctly Yes Go to Step I next No Retest after adjustments Check for 10 000 ohm Red wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Red wire to black wire Full CCW 10 000 ohms Full CW 0 ohms Yes replace SDC No replace SSP Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace m
28. 5NTK161501 8 Lockwasher Split 10 Lockwasher Split Washer Conical 53 x 1 13 x 06T 1 2 13 x 2 5 Lg Button Head Socket Cap Screw Digital Scale 6 Mitutoyo 572 Mounting Block Gage Mounting Bracket Handwheel 1 2 13 ID Arm Support Pivot Vertical Adjustment Shaft Vertical Adjuster Assembly Cap Assembly Hex Acorn Nut 1 2 13 Ball Bearing Thrust Nice 603 1 4 Nylon Plug 5 16 Diameter 5 Split Lockwasher EXPLODED VIEW TRAVERSE DRIVE ASSEMBLY PARTS LIST TRAVERSE DRIVE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB251011 1 4 20 X 5 8 Socket Head Cap Screw 5NTB257211 1 4 20 x 4 5 Socket Head Cap Screw 5NTJ257000 1 4 20 Locknut Thin 5NTK250001 Flat Washer 1 4 5NTK251501 1 4 Lockwasher Split 5NT50309 Traverse Pulley Shaft 5NT3706056 Cog Pulley Drive 5NT6059062 Motor Assembly W16 5NT50363 Traverse Pulley Guard Cog Pulley Driven 375 50W Die Spring 34 1D x 2 0 Lg Thrust Washer 75 ID x 1 25 OD Retaining Ring 1 4 28 x 1 4 Socket Head Set Screw 3 16 SQ x 1 00 Key Wave Spring 78 ID x 1 00 OD EXPLODED VIEW MOWER SUPPORT ASSEMBLY a Q THERE ARE 2 BASE ASSY PER MACHINE PARTS LIST MOWER SUPPORT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB251016 1 4 20 X 5 8 Button Head Cap Screw 5NTB251216 1 4 20 x 3 4 Button Head Cap Screw 5NTC250420 1 4 20 x 1 4 Cup Point Set Screw 5NTJ377000 3 8 16 Locknut Jam Nylon 5NTJ502000 1 2 13
29. Decal TB2 5NT3707073 8 Pin Socket 5NT3707163 Primary Ground Decal 5NT3707164 Primary Ground Lug 5NT3707378 Din Rail 14 Long 5NT3707764 Power Line Filter 5NT3707850 Traverse Control Board 5NT3707556 Magnetic Starter 1 HP 5NT3707688 Voltage Sensor Relay 5NT3707625 Terminal Block End Stop 5NT3707626 Terminal Block Jumper 5NT3707627 Terminal Block End Plate 5NT3707628 2 Conductor Geey Terminal Block 5NT3707629 2 Conductor Blue Terminal Block 5NT3706078 19 Pole Decal TB1 5NT6009270 Electrical Panel 5NT80259 Circuit Breaker 20 Amp 5NT3707778 Terminal Strip 2 Row 19 Pole 5NT3707707 Terminal Strip Double Flat Spade 5NT3707709 Terminal Strip Single 90 Spade 5NT3707708 Terminal Strip Double 90 Spade 5NT3707779 6 amp Circuit Breaker 5NT3707624 Ground Terminal Block 5NT3707328 Door Safety Switch Monitor 5NT3707333 Power Supply 24 VDC 0 3 Amp 5NT3707830 Spin Control Board 5NT3707224 Cable Tie Mount Not Shown 5NT3707225 Cable Tie 6 5 x 18 Wide Not Shown 5NT3707631 Terminal Block Tag 1 10 Not Shown 5NT3707632 Terminal Block Tag 11 20 Not Shown WIRING DIAGRAM 9 5 568 S SHSEL 50 ly SWS 1 SHSI6 IM dSS HAZ 5 HINHSSUZ ES 2054 4 52 5530 51 514 2855 51 522 25 5 JCB 1 20 AMP gE E SNSER ge ESIST8 Er SAS SIS ge IM did andre 01 0512 STSSH S2 14 5855 52 522 50550 52 532 SBSSM S2 C
30. Guard doors must be closed and ALL Switches MUST be turned OFF for contactor to pull in Main 20 amp outlet circuit breaker has tripped 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 F Check for 120V at Cord into FTR Power Cord 32 Blue wire to Brown wire G Check for 120V outof FTR Blue wire to Brown wire H Check for 120V to MCB Check for 120V to 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 and 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 Cord 5NT6059054 FTR Load Terminals for 120 Volt
31. HANDLE INDEX FINGER ADJUSTMENTS The Relief Assembly includes two fingers See FIG 6 The Fixed Relief Finger hold the blade in position during the relief grind process The Movable Index Stop 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 side of the reel blade when traversing from left to right The indexing finger allows the grinder to index to the next blade automatically during the relief grind Improper adjustment of the relief fingers assembly may result in a bad grind or possibly damage to the reel or machine The Index Finger Stop Position Knob adjusts where the Index finger stops when the reel blade indexes See FIG 6 Proper position of this stop is critical 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 clearance to the reel spider after the relief is ground to the NDEXENGER depth required FORWARD STOP POSITION There is a f
32. IS VERY IMPORTANT IN ACHIEVING A QUALITY GRIND USE CARE IN ESTABLISHING THE SPIN DRIVE RPM PER THE INSTRUCTIONS BELOW Generally the Spin Drive RPM will be between 180 RPM 45 and 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 is an optimum Spin Speed where there is an AGGRESSIVE yet smooth grind as you spin grind the reel Your objective is to spin grind the reel as aggressively and as fast as possible while maintaining top quality It is recommended to start grinding each reel at a Spin Speed of 200 RPM 50 and evaluate the RPM by adjusting higher and lower to optimize the Spin Speed for that reel If the Spin Speed is incorrectly set you can experience two problems grinding wheel dressing or grinding wheel resonance Each of these problems is explained below On some reels especially small diameter high blade count reels if the Spin Soeed RPM is set too high the reel can act as a dresser to the grinding wheel There can develop what appears to be a very aggressive grind as if the infeed has self infed and then a sudden stop of grinding with no grinding wheel to reel contact If this occurs your Spin Speed was set too high and you effectively dressed your grinding wheel Some reels have a resonant RPM where the reel goes into harmonics with the grinding wheel and the resonance vibrates the grinder and results in
33. SPEED POT TDC TRAVERSE DRIVE CONTROL TMS 5 TSP 35 10K OHM TRAV PROX LH REVERSE TRAV PROX RSS PX2 RAH No Lc RTP 38 REMOTE 10K OHM TORGUE TORQUE SSP 39 gt REMOTE 10K OHM SPEED VELOCITY FJRONTIER Manual del operador NUMERO DE SERIE DESDE 1XFRG55XPD0000025 RECTIHCADORA DESEGADORA DE CARRETEDEG RO AUMO 5 FJRONTIER REV 5 8 2013 LISTADE COMPROBACI N DE PREPARACI N INSTALACI N DEL DISTRIBUIDOR Rectificadora de segadora de carrete de giro alivio Frontier RG5500 ESTA LISTA DE COMPROBACI N DEBE PERMANECER EL MANUAL DEL USUARIO El distribuidor tiene la responsabilidad de realizar los procedimientos que se enumeran a continuaci n y luego revisar la lista de comprobaci n con el cliente en el momento de la entrega o venta de este equipo La capacitaci n sobre la instalaci n cubre las funciones operativas b sicas del equipo Para garantizar una capacitaci n apropiada establecemos como requisito que su distribuidor de John Deere revise los puntos a continuaci n Marque para asegurarse de comprender los puntos a continuaci n antes de comp
34. Support 5NT55582 Bearing Housing Assembly 5NT09404 Linear Bearing 5NT3709209 Oil Seal 1 ID x 1 57 OD x 187 5NT3708561 Adjustable Handle 3 8 16 x 1 56 Long 5NT3708835 Adjustable Handle 1 4 20 x 1 25 Long 5NT27115 Spacer 386 ID x 50 OD x 75 Long 5NT80335 Destaco 602 Clamp 5NT80337 T knob Assembly 5NT3589106 5NTB191031 10 32 x 5 8 Socket Head Cap Screw 5NT55297 Finger Rotate Base 5NT6009057 Spacer 265 ID 438 OD x 50 L 5NT3708999 Flat Washer 38 ID x 56 ID x 03Thick 5NT3708036 Bearing 5NT55112 Cam Plate 5NT80392 Cam Follower 1 2 Diameter 5NT55113 Finger Slide 5NT55117 Fixed Finger 5NTB190634 10 32 x 3 8 Button Head Socket Cap Screw 5NT3249153 Flat Washer 25 ID x 38 OD x 02 Thick 5NT55281 Index Finger Stop Block 5NTH181202 3 16 x 3 4 long Roll Pin 5NT55579 Locking Plate Weldment 5NT3708833 Spacer 252 ID x 50 OD x 125 Long 5NTC190467 10 32 x 1 4 Socket Head Set screw 5NT55127 3 16 Diameter Index Stop Pin 5NT55501 Indexing Finger Assembly 5NT3708107 Compression Spring 5NTC190360 10 32 x 3 8 Socket Head Set screw PARTS LIST PIVOT ARM AND GRINDING SHAFT ASSY 1 of 2 PARTS LIST PIVOT ARM AND GRINDING SHAFT ASSY 1 of 2 DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB313601 5 16 18 x 2 1 4 Hex Head Cap Screw 5NTB371611 3 8 16 x 1 Socket Head Cap Screw 5NTB372411 3 8 16 x 1 1 2 Socket Head Cap Screw 5NTB373601 3 8 16 x 2 1 4 Hex Head Cap Screw 5NTB752001 3 4 10 x 1 25 Hex Head Cap Screw 5NTC250820 1 4 20 x 1 2
35. an adapter Our recommendation is to purchase adapter Toro tool part numberTOR 4074 available from K Line Industries Inc 315 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 assembly 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 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 Square 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 RECOMENDATION FOR SPIN DRIVE RPM AND TRANSVERSE SPEED WHEN GRINDING SPIN DRIVE RPM SPIN DRIVE RPM
36. de 0 005 0 13 mm a una velocidad longitudinal lenta aprox 8 pies por minuto 2 5 metros por minuto o m s lenta Luego del ltimo paso apague la rectificadora Nota Debido a que se configur el carrete en la posici n de la una en punto avanzar la rueda 0 015 pulgadas 0 38 mm quitar 0 010 pulgadas de material INSTRUCCIONES DE OPERACI N Continuaci n RECTIFICADO DE ALIVIO Para cambiar al rectificado de alivio desacople el montaje del centro de la rueda abrasiva de giro y estaci nelo lo m s a la derecha posible Traiga el montaje del centro de alivio por sobre el carrete para el rectificado de alivio Esto necesitar que vuelva a posicionar los soportes del interruptor de proximidad de recorrido Nota A medida que el di metro del carrete disminuye y el n mero de l minas aumenta el di metro de la rueda abrasiva de alivio trabaja mejor cuando es m s peque o Por ejemplo un carrete de cortadora de c sped de 5 127 mm de di metro con 11 l minas logra un mayor ngulo de alivio con una rueda abrasiva m s peque a ESPIRAL DEL CARRETE Verifique si su unidad segadora cuenta con una h lice normal o de contramarcha NOTA Mientras estudia el dedo de retenci n gu a EN LA P GINA A CONTINUACI N SE MUESTRA UNA H LICE DE CARRETE NORMAL Mientras estudia el dedo de retenci n gu a EN LA P GINA SIGUIENTE SE MUESTRA UNA H LICE DE CARRETE DE CONTRAMARCHA El punto alto del dedo de retenci n de alivi
37. grinder receptacle Note that the wiring in your building must be per code between main power panels and sub panels FOR 20 AMP RATED LARGE MACHINES For 0 to 40 Feet 0 to 12 M from panel to receptacle Use 12 Ga 4 0 mm Wire For 40 to 60 Feet 12 to 18 M from panel to receptacle Use 10 Ga 6 0 mm Wire For 60 to 100 Feet 18 to 30 M from panel to receptacle Use 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 PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY S MAINTENANCE DEPARTMENT 1 Clean the dust tray located at the lower front of the machine monthly using a vacuum or by removing it Pullthe tray out until the back of the tray is even with the front of the frame and vacuum it out To remove continue to pull straight out until 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 Inspect the Poly V belt on the grinding motor for cracking and make any necessary adjustments every three months Wipe off and lubricate with never seize the horizontal adjustment shafts located on the tooling every six months Wipe off and lubricate with never seize the vertical adjustment shafts every six months Run the ar
38. in the front tooling The front tooling can be moved side to side along the tooling bar so they can be positioned as far apart as necessary to accommodate all reel widths Decals on the tooling bar make it 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 you are grinding a Quick Adjust mowing unit or QA5 use the decals located 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 position brackets the vertical and horizontal position can be adjusted by loosening 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 wheels 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 When the mower is in place lock it into position by tightening all knobs Lift
39. line with the tensioner pulley To adjust the pulley position loosen the setscrews on the pulley 7 a Locate the belt in the center of the idler pulley Measure from the arm to the edge of the belt at the idler pulley Adjust the two other pulley s until the same measurement is achieved and tighten the pulley setscrews Reinstall the right side cover panel then run the grind motor to assure that the belt is not misaligned The belt will walk off the pulley if the system is not aligned properly ENSIDNER PULLEY GRIND MOTOR PULLEY TRAVERSE BELT REPLACEMENT To replace the traverse belt remove the left side TRAVERSE MOTOR cover panel then loosen the nuts on the left side pulley that are used to tension the belt Remove the right side cover panel Loosen the screws holding the traverse motor and tilt the bottom of the motor out releasing any remaining tension on the belt On the left side remove the nut from the bottom belt tensioning screw this will allow the belt to be removed WA TRAVERSE BELT Place a new belt on the left pulley making sure it is TRAVERSE TENSIINER seated properly in the cogged teeth and replace the PULLEY locknut Feed the new belt throught the slot on the right arm and place on motor pulley Use the motor TENSION SPRINGS as a lever to apply tension to the new belt Tighten motor screws and adjust the tension in the belt as spec
40. n de parada del dedo de retenci n indice ajusta donde se detiene el dedo de retenci n ndice cuando se indexa la l mina del carrete Vea la Fig 6 Una posici n correcta de este punto de parada es crucial para permitir que la l mina del carrete se traslade sin obst culos desde el dedo de retenci n ndice al dedo de retenci n fijo IMPORTANTE Luego de ajustar la perilla de posici n de parada del dedo de retenci n ndice debe haber un margen de 1 32 0 8 mm entre el dedo de retenci n ndice y la l mina del carrete cuando empuje el dedo de retenci n ndice Esto permitir que el dedo de retenci n de alivio fijo gu e la l mina del carrete durante el ciclo de rectificado de alivio La l mina del carrete nunca debe recorrer el dedo de retenci n ndice durante el rectificado Se puede ajustar la altura de la clavija de parada ndice Se debe ajustar para agarrar la l mina del carrete y que aun deje suficiente margen al centrador del carrete luego de rectificar el alivio a la profundidad necesaria ins TORNILLO DE Hay una parada de la posici n de avance en el sistema de FIJACI N DE LA dedos de retenci n ubicada cerca del punto de giro del dedo POSICI N DE de retenci n ndice Esta solo se deber ajustar si hay un PARADA DEL problema de m rgenes con el dedo de retenci n cuando se AVANCE DEL l DEDODE traslada hacia adelante Vea la Fig 7 RETENCI N NDICE CONOZCA SU RECTIFICADORA Continua
41. 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 CLAMP TIP TRAVERSE BELT ENGAGEMENT LEVER TRAVERSE LEFT LIMIT PROXIMITY SENSOR TRAVERSE BELT TRAVERSE RIGHT LIMIT PROXIMITY SENSOR DUST DEFLECTOR RELIEF GRINDING WHEEL amp HUB SPIN GRINDING WHEEL amp HUB GETTING TO KNOW YOUR GRINDER Continued RELIEF ANGLE ADJUSTMENT Rotating the finger system around the grinding wheel will change the relief angle By loosening the large ratchet FIXED FINGE handle the finger system can be rotated to achieve the MOVABLE factory angles or whatever angle you select See FIG 6 Ve INDEXING By rotating the finger forward the relief angle will decrease Fr and rotating it rearward the relief angle will increase NDEXFINGER Retighten the ratchet handle when adjustment is correct INDEX STOP RELIEF WHEEL DIAMETER ADJUSTMENT As the wheel wears the finger system will need to be adjusted to maintain the correct gap between the fixed finger and wheel To move the finger system loosen the small ratchet handle See FIG 6 The gap between the ADJUSTMENT n fixed finger and the grinding wheel should be between HANDLE 06 1 5 mm and 18 4 6 mm depending on the amount of existing relief on the reel Retighten the ratchet handle after the adjustment is made RELIEF ANGLE ADJUSTMENT
42. que el motor del impulsor de rotaci n puede volcarse sobre el brazo de ajuste horizontal es posible que la direcci n sea la opuesta a la que muestra la calcoman a RPM DEL INDICADOR DEL POTENCI METRO DE VELOCIDAD DE ROTACION Ajuste la velocidad de rotaci n del carrete cuando el interruptor de selecci n de rectificado est configurado en velocidad de rotaci n variable LOS PROTECTORES DE LAS TAPAS DEBEN ESTAR CERRADOS PARA QUE EL IMPULSOR DE ROTACI N PUEDA OPERAR CONOZCA SU RECTIFICADORA Continuaci n BOT N DE PARADA DE EMERGENCIA DE EMPUJE TIRO Presione para detener todo suministro el ctrico a las 9 funciones del panel de control Esto detiene el suministro el ctrico a todos los motores lo que incluye el motor de la rectificadora el motor longitudinal el motor de DETENCI N rotaci n etc Para reanudar el suministro el ctrico tire del bot n y presione el bot n Start Inicio INTERRUPTOR DE ENCENDIDO APAGADO DEL MOTOR DE ROTACION Enciende y apaga el motor de rotaci n LOS PROTECTORES DE LAS TAPAS DEBEN ESTAR CERRADOS PARA QUE EL MOTOR DE LA RECTIFICADORA PUEDA OPERAR INDICADOR DE MOMENTO DE TORSI N DE ALIVIO Ajusta el momento de torsi n del motor del impulsor de rotaci n la torsi n que sostiene la l mina del carrete al dedo de retenci n de alivio cuando el interruptor del selector de rectificado se configura en alivio de momento de torsi n variable INTERRUPTOR DE ENCENDIDO APA
43. remove the traverse shafts use the vertical adjusters to lower both grinding shaft support arms until they are in there lowest position Now remove the left grindng shaft support arm To remove the left TO REASSEMBLE arm first remove the bolt at the rear of the machine Clean the 2 spherical bearings in the right arm It may be necessary to clamp onto the shaft that the and place the traverse shaft into the bearings bolt is screwed into so that it does not spin After The shafts should slide into the bearings removing the bolt pull the arm off the rear shaft Now There is very minimal clearance so the shafts move the arm toward the rear of the machine to need to be preciesly aligned for the shafts to disengage the front of the arm from the vertical slide into the bearings Next slide the grinding adjuster Next pull the arm away from the grinder head assemblies spin first then relief onto the and off the traverse shafts Note the shafts may traverse shafts Now clean the bearing in the come out of the right side arm so support the shafts left arm Then align the bearings in the left arm to the two traverse shafts The shafts should Slide the Spin and Relief Grinding Head Assemblies slide into the bearings Reinstall the left arm off the traverse shafts into the vertical adjuster housing and onto the rear support shaft Reinstall the rear pivot bolt Replace the shafts if necessary and tighten Continue to install the traverse
44. s Signature Safety is 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 death to operators or bystanders It is essential that everyone 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 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 4 Overall condition good i e paint welds electrical 5 Verify there is sufficient electrical power to operate 6 Review Operators Assembly amp Service Manuals 7 Review proper positioning of reel 8 Explain use of reel grinder relief mechanism 9 Review traverse proximity switch positioning 10 Explain use of reel grinder alignment gage 11 Explain reel grinder spin speed v
45. the rear roller onto the angled bracket and clamp the roller firmly by squeezing the clamp handle REEL POSITION The reel should be positioned so thatit is at a one o clock or 30 angle position in reference to the grinding wheel See FIG 3 If the all position brackets are used try to position the unit so that the bottom of the reel is between 1 50 2 00 38 51MM off the table When using the roller mount style tooling try to maintain the one o clock position and check for clearance between the reel and grinding wheel Verify that the proper relief angle can be achieved with this setting and make any adjustments if necessary If you are grinding a or 5 reel using the roller style mounts use the decals located on the tooling to obtain the optimal position to grind the reel See fIG 2 ROLLER CLAMPING ROLLER MOUNT STYLE FRONT CLAMPS TOOLBAR POSITIONING LOK FINE ADJUSTMENT HANOWHEEL ALL PLSITEN STYLE FRINT CLAMPS REAR ROLLER CLAMP HORIZONTAL POSITION LOCKING T KNIB POSITIONING KNOBS CLAMP T KNIBS CLAMP POSITION QA5 AND REEL LOCATION DECAL TOOLING POSITION lt 1 DIK GETTING TO KNOW YOUR GRINDER Continued TRAVERSE ENGAGEMENT AND RELEASE The belt that drives the relief and spin hubs left and right can be engaged and released by flipping the clamp located on the bottom of the grinding head assemblies Moving the lever to the left will engage the belt and
46. 0 Door Stop Block 5NT6329181 Hinged Walker Panel 5NT6329182 Door Stop Spacer Plate 5NT6329183 Door Catch Bracket 5NT6329184 Door Switch Assembly EXPLODED VIEW GRINDING HEAD ASSEMBLY PARTS LIST GRINDING HEAD ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB191011 10 24 X 5 8 Socket Head Cap Screw 5NT3708848 1 4 28 x 1 2 Socket Head Cap Screw w patch 5NTB251211 1 4 20 x 3 4 Socket Head Cap Screw 5NTB250816 1 4 20 x 1 2 Button Head Socket Cap Screw 5NTB371216 3 8 16 x 3 4 Button Head Socket Cap Screw 5NTB251216 1 4 20 x 3 4 Button Head Socket Cap Screw 5NTB253211 1 4 20 x 2 00 Socket Head Cap Screw 5NTH250802 Roll Pin 25D x 50 Lg 5NTJ252000 1 4 20 Hex Jam Nut 5NTJ627200 5 8 18 Locknut Jam Nylon 5NT3708854 1 4 20 Knob Assembly 5NTK250001 Flat Washer 1 4 5NTK251501 1 4 Lockwasher Split 5NT3709852 1 8 Diameter Nylon Ball 05720 Grinding Wheel 6 x 2 75B x 1 5W 46G 5NT05731 Grinding Wheel 6 x 2 75B x 38W 24G Type 1 5NT3708839 3 8 16 x 1 2 Screw w locking Flange 5NT50037 Spin Flange Nut 5NT50039 Spin Wheel Flange 5NT50073 Wear Pad 5NT55200 Relief Wheel Flange 5NT55201 Relief Flange Nut 5NT50204 Spin Yoke 5NT55298 Bearing Support Bracket 5NT3708846 Ball Bearing 25 ID x 625 OD 5NTJ377000 3 8 16 Locknut Jam Nylon 5NT50297 Traverse Shoe 5NT50298 Traverse Clamp Bracket 5NT55296 Single Bearing Assembly 5NT50310 Belt Clamp Tip 5NT50320 Traverse Guard 5NT50321 Shield Mount Bracket 5NT50324 Spark Shield 5NT50329 Spin
47. 256 0 238 0 100 0 665 0 576 0 508 0 455 0 412 0 376 0 346 0 320 0 298 Small side of reel downward adjustment SPIN GRINDING After the reel has been aligned and the taper has been adjusted for you are now ready to spin grind the reel Close the front and rear guard doors The grinding wheel and spin motors will not work unless the doors are closed Position the spin relief selector switch to the spin position Turn on the Grinding Motor and the Spin Drive Motor switch Set the spin speed at approximately 200 rpm Refer to Spin Drive RPM pervious page Make sure spin rotation is the same as the grinding wheel clockwise CW looking from right end See FIG 22 IMPORTANT When the reel turns in the same rotation as the grinding wheel the point of contact where they meet is in opposite directions Turn on the traverse drive motor switch and turn the speed dial up to approximately 15 20 IMPORTANT If the grind starts getting heavier adjust the grinding head down until you can travel the full length of the reel without heavy grinding 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 length of the reel the entire width of all blades and the reel is sharp The last passes should be a normal 005 13 mm infeed grind at a slow travers
48. 3 Patent Decal 5NT3708378 Foam Strip 25 Thick Sold per Foot Wheel RPM Caution Decal see page 7 of Operators Manual Sharp Caution Decal see page 7 of Operators Manual Electrical Warning Decal see page 7 of Operators Manual Machine Caution Decal see page 7 of Operators Manual EXPLODED VIEW CABINET AND DOOR ASSEMBLY PARTS LIST CABINET AND DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB191013 10 24 x 5 8 Button Head Socket Cap Screw 5NTB250801 1 4 20 x 1 2 Hex Head Cap Screw 5NTB371616 3 8 16 x 1 0 Button Head Socket Cap Screw 5NTB373216 3 8 16 x 2 Button Head Socket Cap Screw 5NTJ167000 8 32 Nylon Insert Locknut Jam 5NTJ197000 10 24 Locknut Jam Nylon Insert 5NTJ311000 5 16 18Hex Full Nut 5NTJ317000 5 16 Locknut Jam Nylon Insert 5NTJ377100 3 8 16 Locknut Full Nylon Insert 5NTJ507000 1 2 13 Locknut Jam Nylon Insert 5NTK251501 1 4 Lockwasher Split 5NTK370101 Flat Washer 3 8 Heavy 5NTRO00453 5 16 ID x 7 8 OD x 1 8 Thick Washer 5NTO9891 Grab Handle Enclosure 5NT50234 Tooling Bar Machined 5NT80421 Retaining Clip Gas Spring 5NTH251202 25 Diameter x 3 4 long Roll Pin 5NT55713 Door Weldment Arm Weldment Short Arm Weldment Long Right Hand Arm Weldment Long Left Hand Window Retaining Bracket Medium Window Retaining Bracket Long Polycarbonate Window Formed Air Spring Air Spring Stud Spirol Pin 25
49. 4 y 6 metros por minuto El rectificado a una velocidad longitudinal menor por ejemplo 10 pies por minuto 3 metros por minuto dar un acabado mejor pero dilatar el per odo del ciclo de rectificado La elecci n del operador controla el acabado del rectificado versus el per odo del ciclo de rectificado COMO COMPENSAR EL AHUSAMIENTO Para mantener la mejor calidad de corte debe eliminarse el ahusamiento de un carrete para devolverle la forma cil ndrica al carrete Para eliminar el ahusamiento que se midi con el calibre como se explic anteriormente en la Secci n C mo comprobar el ahusamiento en primer lugar alinee el carrete al eje por el m todo de toque como se explic anteriormente Luego deje que el lado del eje de la rectificadora que est alto el lado m s peque o del carrete descienda la cantidad sugerida en el gr fico Consulte el gr fico de la p gina a continuaci n o el Gr fico C mo compensar el ahusamiento ubicado en la maquina Ejemplo Para un carrete de 22 pulgadas 56 cm de largo con un ahusamiento medido de 0 12 3 mm el dispositivo de ajuste del lado m s peque o deber a descender para que haya una lectura de 0 546 13 9 mm Esto llevar el eje de la rectificadora a una posici n paralela al eje central Configure en cero los calibres ubicados en las torres de ajuste vertical y avance ambos lados de manera equidistante hasta que la rueda apenas toque el lado m s grand
50. CARRETE EN POSICI N La rectificadora RG5500 en su versi n est ndar no cuenta con un dispositivo de elevaci n Si el establecimiento no cuenta con un elevador es recomendable que se utilicen el kit de cabrestante y brazo o la plataforma de elevaci n posterior KIT DE CABRESTANTE BRAZO El kit de cabrestante y brazo se monta en la parte posterior derecha del gabinete Cuando utilice el cabrestante y brazo posicione la unidad de corte por detr s de la m quina y asegure la barra esplegadora a la unidad de corte Utilice el cabrestante para elevar la unidad y virar el carrete al rea de trabajo de la m quina Consulte el manual del kit para obtener instrucciones adicionales Vea la Fig 9 Disponible con el cabrestante manual o el ctrico PLATAFORMA DE ELEVACI N POSTERIOR La mesa de elevaci n posterior es una plataforma port til que puede utilizarse para elevar el nivel superior del carrete a la rectificadora El carrete se puede hacer rodar sobre la plataforma con la parte frontal del carrete de cara a la parte frontal de la rectificadora Una vez quitada la abrazadera del rodillo se puede hacer rodar el carrete de la plataforma a la m quina desde la parte trasera La estaci n de trabajo utiliza un sistema recargable de 12 V para impulsar la plataforma y puede moverse alrededor del establecimiento sobre las 4 ruedas de la roldana Vea la Fig 10 INSTRUCCIONES DE OPERACI N Continuaci n INSTALACI N DEL CARRETE Mu
51. Cup Point Set Screw 5NTJ317000 5 16 18 Locknut Nylon Jam 5NTJ377100 3 8 16 Locknut Hex Nylok Full 5NTK371501 3 8 Lockwasher Split 5NTRO00453 Flat Washer 31 x 88 104T 5NT3707690 Motor 1HP 5NT50235 Traverse Shaft 5NT50236 Pulley 2 45 Diameter Poly V 5NT50237 Pulley 3 72 Diameter Poly V 5NT50256 Grinding Wheel Shaft 5NT50279 Tensioner Bar 5NT50280 Tensioner Pivot Shaft 5NT50281 Tensioner Pulley Shaft 5NT50282 Pivot Support Shaft Prox Switch Holder R H Prox Switch Holder L H Arm Assembly R H Arm Assembly L H 10 24 x 1 4 Cup Point Set Screw Torrington Bearing Piloted Bearing Flange Key 25 sq x 1 25Lg Torsion Spring Conical Washer 539 x 862 x 014T 5NT80349 Idler Pulley 4 0 Diameter 5NT80350 Poly V Belt 5NT80351 Conical Washer 1 40 x 2 03 x 024T 5NT3708425 Shoulder Bolt 313 375 L 5NT3709019 Thrust Washer 500 937 x 032 T 5NT3709886 Flat Washer 812x 2 25 135 5NT80126 Key 3 10 sq x 1 00 Lg EXPLODED VIEW PIVOT ARM amp GRINDING SHAFT ASSY 2 of 2 PARTS LIST PIVOT ARM amp GRINDING SHAFT ASSY 2 of 2 DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB120311 5 40 X 188 Lg Socket Head Cap Screw 5NTB130605 6 32 x 3 8 Flat Head Socket Cap Screw 5NTB160411 8 32 x 1 4 Socket Head Cap Screw 5NTB190611 10 24 x 3 8 Socket Head Cap Screw 5NTB190831 10 24 x 1 2 Socket Head Cap Screw 5NTC370820 3 8 16 x 1 2 Cup Point Set Screw 5NTJ502000 1 2 13 Hex Jam Nut 5NTJ507100 1 2 13 Locknut Full Nylon
52. Dia x 1 0 Long Foam Strip 25 Thick Sold per Foot Foam Seal 50 High Sold per Foot Storage Hook 5NT3706044 Gage Mounting Pin 5NT6309111 Up Down Decal PARTS LIST REAR DOOR ASSEMBLY PARTS LIST REAR DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB190411 Socket Head Cap Screw 10 24 x 1 4 Long 5NTB190613 Button Head Socket Cap Screw 10 24 x 3 8 Long 5NTB250816 Button Head Socket Cap Screw 1 4 20 x 1 2 Long 5NTB251016 Button Head Socket Cap Screw 1 4 20 x 5 8 Long 5NTB251216 Button Head Socket Cap Screw 1 4 20 x 3 4 Long 5NTB310813 Button Head Socket Cap Screw 5 16 18 x 1 2 Long 5NTB370801 Hex Head Cap Screw 3 8 16 x 1 2 Long 5NTB370816 Button Head Socket Cap Screw 3 8 16 x 1 2 Long 5NTB372001 Hex Head Cap Screw 3 8 16 x 1 1 4 Long 5NTB372016 Button Head Socket Cap Screw 3 8 16 x 1 1 4 Long 5NTB372401 Hex Head Cap Screw 3 8 16 x 1 1 2 Long 5NTB372416 Button Head Socket Cap Screw 3 8 16 x 1 1 2 Long 5NTH371202 3 8 Diameter Roll Pin x 3 4 Long 5NTJ167000 8 32 Jam Locknut 5NTJ191000 10 24 Jam Locknut 5NTJ252000 1 4 20 Hex Jam Nut 5NTJ257000 1 4 20Jam Locknut 5NTJ257100 1 4 20 Locknut Full 5NTJ371000 3 8 16 Hex Nut 5NTJ377000 3 8 16 Jam Locknut 5NTJ627100 5 8 11 Locknut 5NTK190001 10 Flat Washer 5NTK191501 10 Lock Washer 5NTK250001 1 4 Flat Washer 5NTK251501 1 4 Lock Washer 5NTK370001 3 8 Fla
53. E TIP HAS BEEN FACTORY SET SO THAT IT WILL SLIP IF THE GRINDING HEAD ASSEMBLY COMES IN CONTACT WITH SOMETHING 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 SPIN GRINDING HEAD WEAR PADS The bronze wear pads used to move the spin wheel will wear and may need 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 replaced The holes in the pads are offset slightly this allows the pads to be flipped if neccessary to accomplish the best fit When installing new pads flip or rotate the pads until Gap 2 is as small as possible without the pads pinching the wheel On the spin grinding head assembly the distance from the pad to the wheel can be adjusted in and out by loosening the screws located on the sides of the LIP 2 yokes Gap 1 should be adjusted to about 1 16 1 5 mm See FIG 19 FIG 19 6MM 25 MAXIMUM DISTANCE SAFETY SWITCH ALIGNMENT REPLACEMENT The safety switch located on the front and rear guard door must line up properly or the grinder will not function The front and rear door switches must be within 6mm 25 and the targets on the switches must line up in order for the switch to function properly See FIG 20 5 21 FRONT DOOR SWI
54. ECTRICIDAD 4 CAUTION To Avoid Injury Make sure all electrical power to this machine has been disconnected before removing any electrical panels or covers for maintenance 4 ATENCION Asegurese d h que se ectado por OBJETOS CORTANTES ACAUTION AATENCION To Avoid Injury Para evitar Keep hands lesiones away from Mantenga las rotating objects manos alejadas de los objetos giratorios CALCOMANIA DE HOJA ENGLISH ESPANOL 5NT155301 CONOZCA SU RECTIFICADORA Interruptores longitudinales Ancho total Altura total Profundidad total Peso Estructura de la base Rieles del carro Motor del cabezal de rectificado Motor de rotaci n Nivel de sonido Desplazamiento autom tico Sistema de control Opciones ESPECIFICACIONES Interruptores de proximidad sin contacto de estado s lido 71 181 cm 69 175 cm con la tapa cerrada 87 221 cm con la tapa abierta 42 107 cm sin la estaci n de trabajo 79 201 cm con la estaci n de trabajo opcional 1450 Ibs 658 kg peso de embarque 1650 Ibs 748 kg Base de acero reforzado soldado para trabajo pesado y de precisi n Acero endurecido con rectificado de precisi n 1 000 di m 25 4 mm Motor de 1 HP CA 3450 RPM Motor de CC de velocidad variable y refrigeraci n por ventilador de 0 20 HP M s de 75 dBA menos de 95 dBA Accionada por correa con un sistema de abrazaderas de f cil enganche Motor de la rectificadora de s
55. EED SPIN DRIVE UNIT TO THE REEL The spin drive unit attaches to the end of the reel shaft or a drive system component Consult the cutting unit manual for proper spin drive placement and attachment Determine which side to mount the spin drive This will generally be the same drive system component used for backlapping See FIG 18 IMPORTANT When spin grinding the reel should turn in the same direction as the grinding wheel See FIG 19 Before positioning the spin unit let us familiarize ourselves with the available adjustments and coupler drive assemblies See FIG 20 OPERATING INSTRUCTIONS Continued Knob A Allows the spin unit to be loosened and moved in and out Knob B Allows the spin unit to be loosened and moved and down Knob Allows the spin assembly to be loosened from the tooling bar and moved side to side KNOB B 3 When positioning the spin unit it may be necessary to complete x several of the above adjustments to properly align the spin unit to the reel THE COUPLER ASSEMBLY INCLUDES RUBBER SLEEVE COUPLER This is placed in the corresponding flange coupler already mounted in the spin 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 limited space ADAPTER SLEEVE Connects th
56. GADO DEL MOTOR DE LA RUEDA ABRASIVA Enciende y apaga el motor de la rueda abrasiva LOS PROTECTORES DE LAS TAPAS DEBEN ESTAR CERRADOS PARA QUE EL MOTOR DE LA RECTIFICADORA PUEDA OPERAR INTERRUPTOR DEL MOTOR LONGITUDINAL ENCIENDE APAGA el motor del impulsor longitudinal INDICADOR DEL POTENCI METRO DE VELOCIDAD LONGITUDINAL FT MIN Ajuste la velocidad de los movimientos hacia la izquierda y hacia la derecha de la rueda abrasiva INTERRUPTOR DEL MOTOR DE CONTRAMARCHA Invierte la direcci n del cabezal de rectificado si se presiona mientras el cabezal est en movimiento CONOZCA SU RECTIFICADORA Continuaci n MONTAJE FRONTAL Y POSTERIOR DE LA SEGADORA EL CARRETE LA RUEDA gt PERILLA DE SUJECI N La unidad segadora debe ubicarse en la m quina con RECTIFICADORA DEBEN DESLIZABLE a 5 GIRAR EN LA MISMA el rodillo posterior sobre la mesa y el rodillo frontal pirecci n sostenido en el mecanizado frontal El mecanizado puede moverse de lado a lado a lo largo de la barra de ABRAZADERA E En mecanizado de manera que pueda ubicarse tan alejado AGAR MONTAJE como sea necesario para que puedan respetarse todos los anchos del carrete Las calcoman as de la barra de mecanizado facilitan el posicionamiento del mecanizado pERILLA EN T DE sobre el ancho del carrete Para mover el mecanizado AL suelte la perilla ubicada en el frente de la base de mecanizado y desl celo a lo largo de la barra de permaen r
57. Hex Jam Nut 5NTK251501 1 4 Lockwasher Split 5NT09853 Knob 4 prong 1 2 13 F 5NT17119 Threaded Stud 1 2 13 x 65 Lg 5NT50242 Roller Clamp Weldment Tooling Block Adjustment Front Clamp Plate Clamp Block Tooling Base Plate Tooling Spacer Acme Shaft L H Tooling V Roller Weldment L H T Knob Assembly 3 8 16 x 75 Dog Point Knob Assembly 1 4 20 x 1 0 Lg V Roller Weldment R H 5NT50254 Rear Roller Clamp Weldment 5NT70512 Roller Roller Bracket Weldment 5NT80346 Bolt T Slot 3 8 16 x 2 0 Lg 5NT3708245 Knob T 235 3 8 16 F 5NT3708393 Handwheel 3 50 Diameter 5NT3709062 Conical Washer 382 x 75 x 035 T 5NT3889045 Spacer 406 ID x 88 OD x 38Long EXPLODED VIEW VERTICAL MOWER SUPPORT ASSEMBLY PARTS LIST VERTICAL MOWER SUPPORT ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB371601 3 8 16 X 1 Hex Head Cap Screw 5NTC250420 1 4 20 x 1 4 Cup Point Cap Screw 5NTJ377000 3 8 16 Locknut Jam Nylon 5NTK371501 3 8 Lockwasher Split 5NT17519 Knob T Assembly 1 2 13 x 6 5 5NT50288 Tooling Block Adjustment 5NT55773 Tooling Spacer 5NT55774 Acme Shaft L H Tooling 5NT50592 Knob 3 8 16 x 1 0 Lg 5NT55282 Hanger V 5NT55343 Clamp Weldment Large L H 5NT55358 Clamp Weldment Large R H 5NT55511 Tooling Post Assembly L H 5NT55512 Tooling Post Assembly R H 5NT3708393 Handwheel 3 50 Dia 5NT3709062 Conical Washer 382 ld x 75 OD x 035 Thick EXPLODED VIEW CARTON ASSEMBLY ASSEMBLY PARTS LIST CARTON ASSEMB
58. IN PLACE and in working order REMOVE WRENCHES AND OTHER TOOLS KEEP WORK AREA CLEAN DON T USE IN DANGEROUS ENVIRONMENT Don t use Grinder in damp or wet locations Machine is for indoor use only Keep work area well lit KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area MAKE WORK AREA CHILD PROOF with padlocks or master switches DON T FORCE THE GRINDER It will do the job better and safer if used as specified in this manual USE THE RIGHT TOOL Don t force the grinder or an attachment to do a job for which it was not designed WEAR PROPER APPAREL Wear no loose clothing gloves neckties or jewelry which may get caught in moving parts Nonslip footwear is recommended Wear protective hair covering to contain long hair ALWAYS USE SAFETY GLASSES SECURE YOUR WORK Make certain that the cutting unit is securely fastened with the clamps provided before operating The Caution Symbol 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 Follow instructions in Service Manual for lubrication and preventive maintenance DISCONNECT POWER BEFORE SERVICING or when changing the grinding wheel REDUCE THE RISK OF UNINTENTIONAL STARTING Make sure all switches are OFF before plugging in t
59. IVIO Como la rueda se desgasta el sistema de dedos de retenci n ENTER deber ajustarse para mantener un espacio correcto entre el pEAJUSTE dedo de retenci n fijo y la rueda Para mover el sistema de dedos de retenci n afloje la manivela del ret n peque o Vea DI METRO _ la Fig 6 El espacio entre el dedo de retenci n fijo la rueda PELA abrasiva debe estar entre las 0 06 1 5 mm y 0 18 4 6 mm RUEDA seg n la cantidad de alivio existente en el carrete Vuelva a ajustar la manivela del ret n luego de realizar el ajuste MANIVELA AJUSTES DE LOS DEDOS DE RETENCI N NDICE DEAJUSTE El montaje de alivio incluye dos dedos de retenci n Vea la DEL NGULO Fig 6 El dedo de retenci n de alivio fijo sostiene la l mina en PFALIVIO posici n durante el proceso de rectificado de alivio El dedo de retenci n ndice m vil de parada se mueve del lateral del dedo de retenci n de alivio lado posterior de la l mina del carrete cuando se traslada de derecha a izquierda al lateral de la rueda abrasiva lado frontal de la l mina del carrete cuando se traslada de izquierda a derecha El dedo de retenci n ndice permite que la rectificadora indexe a la pr xima l mina en forma autom tica durante el rectificado de alivio Un ajuste incorrecto del montaje de los dedos de retenci n de alivio puede dar como resultado un rectificado defectuoso o posiblemente da ar el carrete o la m quina La perilla de posici
60. L SERVICING This Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowledge and skills to reliably test and repair the RG5500 electrical system For those without that background service can be arranged through your local dealer This section presumes that you are already familiar with the normal 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 troubleshooting adjustments or parts replacement If you have any question not answered in this manual please call your local dealer WIRE LABELS All wires on the RG5500 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 position code The first two or three digits are the wire number 01 199 The next three numbers or letters are the code for the component to which the wire attaches Example TDC for Traverse Drive Control The last two numbers or letters are the number of the terminal on the component to which the wire attaches TERMINAL BLOCKS To insert or remove a wire from the terminal block insert a small screw driver into the square hole Then insert or remove wire from the round hole Remove screwdriver to lock the wire in place
61. LY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NT50014 Spanner Wrench 5NTC190320 10 24 x 3 16 Socket Head Setscrew 5NTH250802 1 4 x 1 2 Roll Pin 5NT09394 1 4 20 2 prong Knob 5NT55122 Dresser Support Block Dresser Support Weldment 5NT3708845 3 4 Wide x 1 4 Thick Diamond Dresser 5NT6509588 T Knob Assembly 5NTR000377 Sq Key 3 16 x 75 5NT3709073 Retaining Ring 5NT3709584 Flange Coupler 625 Bore 5NT6009051 Drive Adapter 1 2 sq 3 5 Lg 5NT6009052 5NT6009217 Driver Coupler Adapter 5NT3709585 Sleeve Coupler 5NT55022 Compensation for Taper Chart Not Shown EXPLODED VIEW ALIGNMENT GAGE ASSEMBLY PARTS LIST ALIGNMENT GAGE ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NTB120611 5 40 x 38 Socket Head Cap Screw 5NTB161011 8 32 x 5 8 Socket Head Cap Screw 5NTB251016 1 4 20 x 5 8 Button Head Socket Cap Screw 5NTB251216 1 4 20 x 3 4 Button Head Socket Cap Screw 5NT6609501 Knob Assembly T 1 4 20 x 1 31 Long 5NTJ161000 8 32 Hex nut 5NTK121501 5 Lockwasher Split 5NTK161501 8 Lockwasher Split 5NTK251501 1 4 Lockwasher Split 5NT50290 Front Clamp Plate 5NT50291 Clamp Block 5NT50570 T Knob Assembly 3 8 16 x 75 Dog Point 5NT50586 Gage Base Weldment 5NT50597 Gage Bar Assembly Vertical 5NT3529069 Spacer 25 ID x 375 OD x 69 Long 5NT6509418 Pivot Plate Machined 5NT6509349 Retainer Plate 5NT3708094 Adjustable Handle 5 16 18 x 1 25 Long 5NT6509359 Digital Gage Machined 5NTH060302 Roll Pin
62. NANCE 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 1 DO NOT USE COMPRESSED AIR CLEAN GRINDING DUST FROM GRINDER O SERVICE DATA SKILL AND TRAINING REQUIRED FOR SERVICING This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the RG5500 Spin Relief Grinder For those without this background service can be arranged through your local dealer This section presumes that you are already familiar with the normal operation of the grinder If not you should read the operators 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 any panels shields or attempt any internal troubleshooting adjustments or parts replacement If you have questions not answered in this manual please contact your dealer 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 SMOOTH 3 MARKS 6 MARKS Bolts Going Into a Nut or Into a Thread Ho
63. OPERATOR S MANUAL FOR SERIALNUMBERS 1XFRG55XPD0000025 AND UP SPIN REEF GRINDER 500 FJRONTIER This book consists of three manuals The OPERATORS MANUAL in ENGLISH which contains all the information on operating and doing 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 Translated OPERATORS MANUAL which is the same as the English version only translated into another language REV 5 8 2013 DEALER PREPARATION INSTALLATION CHECK LIST Frontier RG5500 Spin Relief Reel Mower Grinder THIS CHECKLIST IS TO REMAIN INOWNER S MANUAL Itis the responsibility of the dealer to complete the procedures listed below then review this checklist with the customer upon the delivery or the sale of this equipment The installation training goes over the basic operational functions of the equipment To ensure adequate training we require that the following items are reviewed by your John Deere Dealer Please check off to ensure that you understand the following items before the installation training is complete 1 Equipment is completely assembled 2 All shields are in place and in good condition 3 All decals in place and readable See pages the machine 00000 and any additional training material if available Dealer s Signature Purchaser
64. OYISJAP US 8109 soj 95 U9IQUIB ap soj y ap soj esed ewou 391 94 eun uoo anb esed epelse sap opis ey anb epan eun YLON el OL 8 sewiyn sej sed usa 1 anb jq sod sa s ope anb eed eniselqe epan e e1qe IS IIPIOUIOD EISEU as epan e BIISONW as op s nbz e1a e uoo anb sa Ue uoo as epan e anb ej 5 o nSue un es anb 53 8 8 1189 op eulue e a esed 5 epan el YHOHVWVHLNOD un eed INSTRUCCIONES DE OPERACI N Continuaci n RECTIFICADO DE ALIVIO CONTINUACI N Reinicie el interruptor de proximidad del l mite longitudinal de manera que la rueda abrasiva se aleje del carrete en ambos extremos alrededor de 1 16 1 5 mm Configure el interruptor del selector de rectif
65. RIZONTAL El soporte de extensi n horizontal del calibre digital puede DE AVANCE Y Z ajustarse verticalmente para permitir que el calibre digital RETROCESO h 1 SNe eae se ubique de manera que no se ponga en contacto con PERILLADEPOSICI N Y SARA CALIBRE ning n miembro del marco del carrete Adem s el montaje DELABARRA DE lk gt de la gu a de desplazamiento vertical en el conjunto MECANIZADO horizontal de piezas soldadas tiene tres posiciones Quite la perilla del lateral para ajustar la inclinaci n de la gu a de desplazamiento vertical de ser necesario para que no se ponga en contacto con ning n miembro del marco del carrete Vea la Fig 14 PERILLA DE BLOQUEO Antes de alinear la unidad de corte afloje las perillas de HORIZONTAL bloqueo horizontal sobre el mecanizado para permitir que EN FORMA se ajuste la unidad de corte en el plano horizontal Vea la Fig 14 Para alinear la unidad de corte mueva el montaje del calibre digital hacia el lateral izquierdo del carrete tanto como sea posible Extienda el calibre digital mientras se asegura de que la punta del calibre est centrada con el eje central del carrete Vea la Fig 15 Con el calibre presionado contra el eje central del carrete configure el calibre en cero Retraiga el calibre mu valo a la derecha del carrete y midalo con el centro del eje del carrete No gire el eje del carrete con excepci n de una cantidad minima si hay problemas de margenes c
66. Run the grinding assemblies through their range of travel and wipe the shafts after each traverse Repeat until the shafts are dry to the feel This completes the lubrication process IMPORTANT If the unit will be shut down for an extended period of time more than four weeks then the shafts and other appropriate parts of the unit should be flooded with lubricant and that lubricant left in place until the unit is brought back into service When the unit is brought back into service the full lubrication procedure as stated above should be repeated GRINDING SHAFT GRINDING SHAFT GRINDING SHAFT COG BELT TRAVERSE SHAFTS MAINTENANCE REPLACEMENT OF GRINDING WHEEL To replace the wheel first remove the left side cover BEARING panel Now lower the left side of the grinding shaft and RELIEF FLANGE raise the right side Next loosen the two bolts that hold ed the bearing bracket on the relief hub so that that NO _ PELENU bearings pivot away from the wheel and hub toward the front of the machine See 11 Press the index finger down and the wheel and hub assembly should move freely to the right SPINNUT a Then remove the left side bearing First loosen the SPIN WHEEL r setscrews on the bearing collar then remove the four SPIN FLANGE screws that hold the bearing to the left arm Slide the grinding wheel hub assembly s off the shaft taking note of what side the nut is on Use the spanner wrench t
67. T SAFETY MESSAGE FOR OWNERS OPERATORS OF REEL GRINDERS Before operating a reel grinder an operator must read and understand all of the information in the operator s manual and in the safety signs attached to the product A person who has not read or understood the operator 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 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 man operation Never operate the grinder with anyone near or in contact with any part of the grinder Be sure no one else including bystanders are near you when you operate 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 using this product Be careful and make sure that everyone who operates the grinder knows and understands that this is a very powerful piece of machinery and if used improperly serious injury or death may result The final responsibility for safety rests with the operator of this machine TO THE DEALER Assembly and proper installation of this product is the responsibility of the John Deere dealer
68. TCH The switches are attached to the guarding using a INSIDE UPPER RIGHT SIDE Torx style tamper resistant screws Atool for this type of screw is required to make this adjustment 6MM 25 MAXIMUM DISTANCE REAR DOOR SIWTCH ADJUSTMENTS Continued RELIEF GRINDING HEAD BEARING ADJUSTMENTS Top Support Bearing It may be necessary to adjust the guide bearings on the relief Assembly head To adjust the position of the support bearings POSITION THE GRINDING HEAD AT THE FAR LEFT POSITION loosen the two positioning bolts located on the side of the support assembly Press on the support assembly until the top support bearing is touching the grinding wheel hub Hold the support in place with the bearing touching the hub and tighten the two positioning bolts Check to see that the bearing is touching or has minimal clearance to the hub through the full range of left to right travel NOTE EXCESSIVE PRELOAD OF THE BEARING ASSEMBLIES ON THE HUB CAN CAUSE THE BEARINGS TO WEAR QUICKER AND COULD CAUSE THEM TO FAIL o PREMATURELY Bracket Positioning Bolts CONTROL BOARD POTENTIOMETER ADJUSTMENTS POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL TDC Min Speed Factory set at full CCW 8 30 Do not change this setting Right Traverse Forward Torque Factory set at full CW 4 30 Do not change this setting Left Traverse Reverse Torque Factory set at full CW 4 30 Do not change this setting IR COMP Factory s
69. TIFICADO RPM DEL IMPULSOR DE GIRO LAS RPM DEL IMPULSOR DE ROTACI N SON MUY IMPORTANTES PARA LOGRAR UNA BUENA CALIDAD EN EL RECTIFICADO TENGA LA PRECAUCI N DE ESTABLECER LAS RPM DEL IMPULSOR DE ROTACI N SEG N LAS INSTRUCCIONES A CONTINUACI N Por lo general las RPM del impulsor de rotaci n estar n entre 180 RPM 45 y 380 RPM 100 La velocidad necesaria para girar un carrete espec fico depende del di metro del carrete el n mero de l minas del carrete y la dureza de este Para todos los carretes hay una velocidad de rotaci n ptima en la que se realiza un rectificado AGRESIVO pero al mismo tiempo de un acabado fino a medida que rectifica el carrete Su objetivo es rectificar por giro el carrete tan agresiva y r pidamente como sea posible mientras mantiene la mejor calidad Se recomienda que comience a rectificar cada carrete auna velocidad de giro de 200 RPM 50 y que eval e las RPM al ajustarlas m s alto o m s bajo para optimizar la velocidad de rotaci n para ese carrete Si la velocidad de rotaci n no est configurada correctamente puede experimentar dos problemas labrado de la rueda abrasiva o resonancia en esta Cada uno de estos problemas se explica a continuaci n En algunos carretes especialmente aquellos con gran cantidad de l minas y de di metro peque o si se configura una velocidad de rotaci n muy alta el carrete puede actuar como un reavivador de la rueda abrasiva Puede desarrolla
70. Yes end troubleshooting No go to step D next SDC Remove wires to Terminals Liand L2 and test betwen wires for 120VAC Yes reconnect wires go to Step F No Go to Step E next Remove Wire to SMS Terminal 6 895 5 6 and check between the wire and nuetral blue terminal out of FTR 02FTRBU 120 Yes Check switch continuity replace No Check CB continuity replace Check for approx 20 VDC from Terminal Strip 1 Terminal 4 48TB1 4 to Terminal 5 49TB1 5 Yes go to Step G next No Go to Step l Remove motor wires at Terminal Strip 1 left side lower strip Term 4 amp 5 and check 0 ohms across the black and white motor wires Yes end troubleshooting motor should work if it does not replace motor No go to Step H next 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 Spin Drive Motor ELECTRICAL TROUBLESHOOTING Continued Possible Cause Board is in spin mode Relief Speed Pot RSP is not set correctly RTP is not working Switches on SDC incorrect Checkout Procedure Spin Torque Selector not working J Check RSP remote speed 10k on SDC board K RTP 10K Remove 3 Remote Torque Wires red wire to term 2 white wire to term 1 black wire to term 3 L Verify postion of all pots and switch on SDC Light next to on SDC board
71. a CABEZAL DE RECTIFICADO DE GIRO ALIVIO La rectificadora est equipada con ruedas abrasivas de giro y alivio separadas Cuando se realiza la configuraci n adecuadamente solo se debe posicionar y alinear el carrete una vez para ambos ciclos La rueda de giro est ubicada en el lateral derecho de la m quina y es m s ancha que la rueda de alivio Mueva la rueda que no se utiliza al extremo tanto como sea posible de manera de darle la mayor cantidad de espacio para configurar y operar la m quina Los sensores de proximidad deben moverse para que la rueda que se utilice est entre los dos sensores Aseg rese de que la rueda que no est en uso no est enganchada a la correa impulsora CONOZCA SU RECTIFICADORA Continuaci n AJUSTE DEL NGULO DE ALIVIO Se modificar el ngulo de alivio al rotar el sistema de dedos y CLAVIJA NDICE de retenci n alrededor de la rueda abrasiva Al soltar la DEDO DERETENCIONFNO DEPARADA manivela del ret n grande se puede rotar el sistema de dedos DEDODE de retenci n para lograr los ngulos de f brica o cualquier AG oe 2 PERILLA DE A A ngulo que seleccione Vea la Fig 6 Al rotar el dedo de osici nne INDEXADO retenci n hacia adelante el ngulo de alivio disminuir y al PARADA DEL x rotarlo hacia atr s el ngulo aumentar Vuelva a ajustar DEDODE manivela del ret n cuando el ajuste sea correcto RETENCION NDICE AJUSTE DEL DI METRO DE LA RUEDA DE AL
72. a very bad grind By changing the Spin Speed to a higher or lower RPM you will move out of the resonant range TRAVERSE DRIVE RPM The Traverse Speed potentiometer is adjustable 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 minute Grinding at a slower traverse speed 10 feet per minute 3 meters per minute as an example will give a better finish but will extend the grind cycle time Grind finish versus grind cycle time is controlled by the choice of the operator 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 To remove the taper that was measured with the gauge as discussed previously in Checking For Taper Section first align the reel to the shaft by the touch method as discussed previously Then drop the side of the grinding shaft that is high the smaller side of the reel the amount suggested in the chart See chart on next page or Compensation for Taper Chart located on the machine Example For a reel that is 22 inches 56 cm long with a measured taper of 12 3 mm the adjuster on the smaller side of the reel would be dropped to read 546 13 9 mm This will bring the grinding shaft parallel to the reel center shaft Zero out the digital gauges located on the vertical adjustment towers an
73. acia arriba disminuir el ngulo de alivio Ajustar el ngulo de alivio o la posici n de parada del dedo de retenci n ndice es m s sencillo con el cabezal de alivio del lado izquierdo del carrete Una vez que tenga el cabezal de rectificado en posici n con la l mina del carrete sobre el punto alto del dedo de retenci n de alivio fijo ajuste el punto de parada del dedo de retenci n ndice Debe haber alrededor de entre 1 32 0 8 mm y 1 16 1 5 mm de holgura entre el dedo de retenci n ndice y la parte posterior de la l mina El dedo de retenci n ndice es accionado por resorte a la posici n hacia arriba o contra la parte posterior de la l mina del carrete Para verificar si hay holgura presione el dedo de retenci n ndice Vea la Fig 24 Si no hay holgura en el dedo de retenci n ndice es recomendable que gire la perilla ajustable de posici n de parada del dedo de retenci n ndice en sentido contrario a las agujas del reloj Si hay m s de 1 16 1 5 mm de holgura es recomendable que gire la perilla ajustable de posici n de parada del dedo de retenci n ndice en sentido de las agujas del reloj IMPORTANTE La posici n del dedo de retenci n indice debe configurarse para detener la l mina del carrete y permitir que se desplace a la izquierda sin que la l mina golpee el lateral del dedo de retenci n de alivio Esta posici n tambi n debe permitir que haya aproximadamente 1 32 0 8 mm de holgura del dedo
74. all four leveling feet are firmly contacting the floor Recheck that the machine is level after locking the four feet into position ASSEMBLY INSTRUCTIONS Continued 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 SEE SERIAL NUMBER PLATE FOR FULL LOAD AMP RATING OF YOUR MACHINE Never modify the plug provided with the machine if it won t fit the outlet have a proper outlet and circuit installed by a qualified electrician ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOUR MACHINE AN IMPROPER CONNECTION CAN CAUSE A DANGEROUS ELECTRICAL SHOCK IF YOU ARE UNSURE OF THE PROPER ELECTRICAL GROUNDING PROCEDURE CONTACT A QUALIFIED ELECTRICIAN ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT GROUNDING INSTRUCTIONS ON PREVIOUS PAGE FIG 6 Plug the control box power into a standard 115V 20 grounded receptacle
75. als 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 Traverse Drive Control TDC has failed Check power to the Traverse Drive Control TDC 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 24 Too heavy 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 Ohmtestto check fuse If the fuse needs replacing you MUST use a 3 amp slo blo fuse Part Number 5NT3707546 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 Traverse works Yes end troubleshooting No gotto 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 check Terminal L1 to L2 for 120 Volts AC Yes Go to Step F next No Go to Step E next Measure 120 volts AC from TMS Terminal 5 to nuetral blue terminal out of FTR 02FTRBU Yes Check continuity of wires from Switch to Control Replace wires No Flip Switch and check again
76. ar los sensores de proximidad Mueva el interruptor de l mite de recorrido longitudinal hacia adentro hasta que la luz del sensor de proximidad se ilumine Mueva la rueda al extremo opuesto al alejar el carrete como se menciona anteriormente y configure el interruptor de l mite de recorrido longitudinal izquierdo Fig 17 Acople la correa longitudinal y lentamente aumente la velocidad longitudinal Permita que la rueda se desplace de un extremo a otro para comprobar que los interruptores se detengan y reviertan la direcci n de la rueda abrasiva Verifique que la rueda abrasiva sobresalga en cada extremo durante su recorrido Nota Si el carrete golpea el marco ajuste los sensores de recorrido de manera que la rueda no se ponga en contacto con el marco C MO ACOPLAR LA UNIDAD DEL IMPULSOR DE ROTACION DE VELOCIDAD VARIABLE AL CARRETE La unidad del impulsor de rotaci n se acopla al extremo del eje del carrete o a un componente del sistema de impulsi n Consulte el manual de la unidad de corte para obtener la ubicaci n y el acoplamiento correctos del impulsor de rotaci n Determine de qu lado montar el impulsor de rotaci n Por lo general ser el mismo componente del sistema del impulsor de rotaci n utilizado para el esmerilado Vea la Fig 18 IMPORTANTE Cuando realice rectificado de giro el carrete debe girar en la misma direcci n que la rueda abrasiva Vea la Fig 19 Antes de ubicar la unidad de giro fam
77. 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 Spin Speed Pot SSP set to zero Spin Motor Switch SMS is not on Circuit Breaker is Tripped 4 AMP Spin Drive Control SDC is not working Spin Drive motor is bad Checkout Procedure A Set SSP to 200 on the control 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 Volts AC E With the Selector switch in spin and the spin pot set to 400RPM Check SDC A1 and A2 for 90 120 Volts DC F Check spin motor continuity DISCONNECT POWER FROM MACHINE Spin drive control in Torque mode G Check continuity of mode selector switch Spin Motor works Yes end troubleshooting No go to Step B next Spin Motor works Yes end troubleshooting No go to Step C next Spin Motor works Yes end troubleshooting No go to Step D next 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 Verify Power to Circuit Breaker and SMS and continuity of wires Replace CB or SMS if needed SDC Remove wires test Terminals A1 to A2 on the board for approx 90 120 V DC Yes reconnect wires and go to Step F next No go to Step G Remove wires at Terminal Strip 1 Term 4 8
78. 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 USE COMPRESSED AIR TO CLEAN GRINDING DUST FROM GRINDER SAFETY INSTRUCTIONS PLEASE TAKE SPECIAL NOTE OF THE FOLLOWING WARNING DECALS LOCATED ON THE GRINDER GENERAL INFORMATION GRINDING WHEEL RPM CAUTION A CAUTION ATENCI N dh SE Avoid Injury Para evitar lesiones equipment Follow all safety rules and instructions Manuals are Do not exceed grinding No exceda la velocidad de avallable from your selling dealer wheel maximum operating funcionamiento m xima de Keep bystanders away from equipment during operation Keep 4 all shields in place and in good condition speed of 3600 revolutions 3600 revoluciones por minuto Wear all of the appropriate safety equipment specified in the per minute de la rueda rectificadora Operator s Manual while operating this machine Always make sure machine is off and all machine movement has stopped before leaving machine Never allow children or untrained persons to operate equipment 4 ATENCI N Para evitar lesiones Lea el manual del operador antes de la puesta en funcionamiento del mantenimiento o de la reparaci n del equipo Siga todas las reglas e Instrucciones de seguridad Los manuales se encue
79. belt grinding shaft and grinding motor belt REPLACING THE TRAVERSE BEARING See the sections on Traverse Belt Replace To replace the traverse bearings press the bearings ment Replacement of Grinding Wheel Grind out of the bearing housing Slide in the new bearings ing Motor Belt Replacement Traverse Belt and secure in place with the seals Two bearings go Tension and Relief Grinding Head Bearing in the front and 1 bearing the rear of the housing Adjustments for addtional details MAINTENANCE Continued CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE WINDOWS Cleaning Instructions DO NOT USE GASOLINE Adherence to regular and proper cleaning procedures is recommended to preserve appearance and performance Washing to Minimize Scratching Wash polycarbonate windows with a mild dish washing liquid detergent and lukewarm water using a clean soft sponge or a soft cloth Rinse well with clean water Dry thoroughly with a moist cellulose sponge 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 amp P naphtha or isopropyl alcohol Afterward a warm final wash should be made using a mild dish washing liquid detergent solution and ending with a thorough rinsing with clean water Minimizing Hairline Scratches Scratches and minor abrasions ca
80. checklist with the customer upon the delivery or the sale of this equipment The installation training goes overthe basic operational functions of the equipment To ensure adequate training we require that the following items are reviewed by your John Deere Dealer Please check off to ensure that you understand the following items before the installation training is complete Safety is a primary concern the design manufacture sale and use of reel grinders As a 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 death to operators or bystanders Itis essential that everyone 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 operator s manual Never bypass or operate the machine with any of the guards or the safety devices removed 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 Safety IMPORTAN
81. ci n CALIBRE DE ALINEACI N Una rueda adecuadamente rectificada debe ser cil ndrica Se debe rectificar hasta eliminar todo el ahusamiento del carrete Para asegurarse de que el carrete sea correctamente rectificado DEBE alinearse con precisi n antes del rectificado El calibre de alineaci n digital se utiliza para lograr una configuraci n precisa del carrete El calibre se utiliza para configurar la alineaci n horizontal y comprobar el ahusamiento en mil simas de pulgada El calibre digital le permite medir un extremo del carrete al extender el riel de deslizamiento hasta que haga contacto con el eje central del carrete Vea la Fig 8 Al realizar las mediciones en los extremos izquierdo y derecho del eje central puede ajustar la alineaci n horizontal al utilizar las perillas de ajuste frontales del mecanizado hasta que la alineaci n se encuentre dentro de las 0 005 in 0 13 mm Cuando est finalizada puede luego reiniciar el calibre en cero en el eje central retraer la gu a de deslizamiento del calibre y medir la superficie externa de la l mina del carrete Al comparar las lecturas del lateral izquierdo del carrete con las del lateral derecho puede determinar exactamente cu nto ahusamiento tiene el carrete Se explicar m s adelante en el procedimiento de rectificado c mo compensar el ahusamiento NOTA El calibre puede configurarse para lecturas tanto en pulgadas como en sistema m trico EJE CENTRAL DEL CARRETE
82. coman as est n da adas o legibles por alguna raz n reempl celas inmediatamente Tome como referencia las ilustraciones de las piezas de repuesto que contiene el Manual de servicio para ubicarlas adecuadamente y obtener los n meros de pieza de las calcoman as de seguridad NO PONGA EN FUNCIONAMIENTO LA RECTIFICADORA BAJO LA INFLUENCIA DE DROGAS ALCOHOL O MEDICAMENTOS INSTRUCCIONES DE SEGURIDAD UN USO INADECUADO DE LA RUEDA ABRASIVA PUEDE CAUSAR DANO O UNA LESION GRAVE El rectificado es una operaci n segura si se siguen las pocas reglas enumeradas a continuaci n Estas reglas se basan en el material incluido en el C digo de seguridad ANSI B7 1 para el Uso cuidado y protecci n de ruedas abrasivas Para su seguridad le sugerimos que aproveche los beneficios de la experiencia de otros y siga estas reglas LO QUE DEBE HACER Siempre MANIPULE Y ALMACENE las ruedas con cuidado INSPECCIONE VISUALMENTE todas las ruedas en busca de da os posibles antes de montarlas VERIFIQUE LA VELOCIDAD DE LA M QUINA comparaci n con la velocidad operativa de seguridad m xima establecida marcada en la rueda CONTROLE LAS BRIDAS DE MONTAJE a fin de que tengan el mismo di metro y que sea el correcto UTILICE SECADORES DE MONTAJE cuando se le suministren las ruedas ASEG RESE de que el PORTAPIEZAS est ajustado adecuadamente SIEMPRE utilice una CUBIERTA PROTECTORA DE SEGURIDAD que cubra por lo menos la
83. cto Una persona que no haya le do o comprendido el manual del usuario y las se ales de seguridad no est calificada para poner en funcionamiento la unidad A menudo ocurren accidentes en m quinas que son utilizadas por una persona que no ley el manual del usuario y no se familiariz con el equipo Si no cuenta con un manual del usuario o con las se ales de producci n actualizadas p ngase en contacto con el fabricante o con su distribuidor de inmediato Las rectificadoras de carrete est n dise adas para ser operadas por una sola persona Nunca ponga en funcionamiento la rectificadora cuando alguien est cerca de alguna parte de la rectificadora o est en contacto con esta Aseg rese de que nadie m s lo que incluye cualquier persona cercana al rea est cerca de usted cuando ponga en funcionamiento este producto Seguir estas reglas de seguridad simples y b sicas as como tambi n otras especificadas en el manual del usuario y en las se ales de seguridad del producto ayudar a minimizar la posibilidad de accidentes y aumentar su productividad al utilizar este producto Tenga la precauci n y aseg rese de que toda persona que ponga en funcionamiento la rectificadora sepa y comprenda que es una m quina muy poderosa y que de ser utilizada indebidamente puede causar lesiones graves e incluso la muerte La responsabilidad final sobre la seguridad recae en el operador de esta m quina PARAEL DISTRIBUIDOR El montaj
84. d infeed both side equally until the wheel just touches the large side of the reel Zero the gauges again you are now ready to grind 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 Grind until full contact is made across the entire length of the reel and the reel is sharp the entire width of all blades AMOUNT OF AMOUNT TAPER IN REEL OF TAPER IN SHAFT After determining the best Spin Speed 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 this manual By noting the correct RPM you will avoid evaluating the Spin Speed the next time you 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 OPERATING INSTRUCTIONS Continued TAPER ADJUSTMENT SETUP CHART REEL WIDTH 1 16 18 20 22 24 26 28 30 32 0 033 0 029 0 025 0 023 0 021 0 019 0 017 0 016 0 015 0 100 0 086 0 076 0 068 0 062 0 056 0 052 0 048 0 045 0 166 0 144 0 127 0 114 0 103 0 094 0 086 0 080 0 075 0 233 0 202 0 178 0 159 0 144 0 132 0 121 0 112 0 104 0 299 0 259 0 229 0 205 0 185 0 169 0 156 0 144 0 134 0 060 0 399 0 346 0 305 0 273 0 247 0 225 0 207 0 192 0 179 MEASURED TAPER 0 080 0 532 0 461 0 407 0 364 0 329 0 301 0 277 0
85. d store it properly Otherwise leakage if any from the battery may damage the unit Description of Parts 1 Beam 2 Main Scale 3 Battery compartment 4 Outp Connection 5 Display 6 ON OFF Power 7 ZERO ABS switch 8 Origin Switch 9 Inch mm Switch 10 Tapped hole 11 Slider gt ABSOLUTE 0 A Battery Installation and Origin Setting Set the origin of the scale after installing the battery Otherwise the error sign E at the least significant digit may appear resulting in incorrect measurements 1 To install the battery remove the compartment lid and install the SR44 battery with its positive side facing up After the battery is installed set the origin 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 for more than one second The 0 00 display appears indication Origin setting is complete The origin will be retained even if the power is turned off Incremental INC amp Absolute ABS mode The LCD will dispay measurements from the origin when turned on ABS mode To set the origin see above The display can be set to zero at any desired position by pressing the ZERO ABS switch INC indicator will apper in the display INC mode permitting measurements from this zero point To return to the ABS mode ABS 2145 hold ZERO ABS button form more than 2 seconds L gt Error Symptoms amp Remedies
86. das Si est quitando una gran cantidad de material en los avances posteriores es posible que sea necesario configurar velocidades longitudinales m s lentas Luego de que el rectificado de alivio est finalizado apague todos los interruptores tambi n es una buena pr ctica presionar el bot n de parada de emergencia y luego quite la unidad de corte de la m quina Tenga precauci n puesto que las l minas del carrete estar n afiladas r 7 GRAFICO DE CONFIGURACION DEL CARRETE 31344V9 PI ano NOIOVLOH 10a 04 1 OUVZINVIAN arv non rv now 13031409 NOIOV LOH 134 130 NOIDISOd 13avunL v v 3a NOISYOLV13A v130 YOSINdWI 35 SVLON 130 NOIDISOd arv non VIONVLSIO oavz nvoan OOVZINVIAN VIHVIN ap e OJOS 50159 919 B 8100 LINY 313449 130 9 9 189 UDIDISOd ej 52153 BION NOIOVINDIANOS OIJ VD ESTA P GINA EST EN BLANCO INTENCIONALMENTE CON EL OBJETIVO DE TOMAR NOTAS PART NUMBER NUMERO DE PIEZA 5NTRG5507951 FJRONTIER
87. de retenci n ndice cuando la l mina est sobre el punto alto del dedo de retenci n de alivio Vea la Fig 24 Avance la rueda abrasiva hacia arriba hasta que haya un margen m nimo entre la l mina del carrete y la rueda abrasiva CLAVIJA DEDODE INDICEDE RETENCI N PARADA DEDODE RETENCI N Z M VILDE I INDEXADO PERILLA DE y x POSICI N DE gt PARADA DEL DEDODE RETENCI N NDICE MANIVELADE AS 62 AJUSTE DEL SS DIAMETRO DELA 7 5 RUEDA AL MANIVELA DE AJUSTE DEL ANGULO DE ALIVIO TORNILLO DE FIJACI N DE LA POSICI N DE PARADA DELAVANCE DEL DEDO DE RETENCI N NDICE INSTRUCCIONES DE OPERACI N Continuaci n RECTIFICADO DE ALIVIO CONTINUACI N Cierre las tapas frontal y posterior Encienda el interruptor del motor de giro NOTA El impulsor de rotaci n aplicar una carga de torsi n contra los dedos de retenci n Configure el potenci metro de torsi n de alivio en aproximadamente 15 IMPORTANTE Es posible que los carretes de giro libre necesiten un valor menor a 15 y los carretes r gidos o los carretes con un tren impulsor una torsi n mayor a 15 Acople la correa longitudinal y desplace hasta el extremo izquierdo controlando que haya un margen adecuado entre la rueda abrasiva y la l mina Compruebe que haya un margen adecuado entre el dedo de retenci n ndice luego de desacoplar de la l mina en la posici n extrema izquierda y el lado frontal de la l mina
88. e Adjust the clamping tip as specified in the Traverse Clamp Force section of this manual Slow the traverse speed or back off on the amount that is being infed Checkout Procedure Traverse speed should be set lower approximately 12 ft min 4 meters min for a smaller burr on the cutting edge Checkout Procedure Grinding head travel was not setup parallel to the reel center shaft in vertical and horizontal planes See Align the Reel Section Checkout Procedure Adjust finger stop and check for contact full length Dress the wheel For more detail see relief grinding section in operating instructions of the manual EXPLODED VIEW CABINET AND DOOR ASSEMBLY DIAGRAM NUMBER NUMBER DESCRIPTION 5NTB191013 10 24 x 5 8 Button Head Socket Cap Screw 5NTB250816 1 4 20 x 1 2 Button Head Socket Cap Screw 5NTB371201 3 8 16 x 3 4 Hex head Cap Screw 5NTJ197000 10 24 Locknut Jam Nylon Insert 5NTK251501 1 4 Lockwasher Split 5NTK370001 3 8 SAE Flat Washer 5NTK371501 3 8 Lockwasher Split 5 09891 Grab Handle Enclosure 5NT55279 Taper Chart Decal 5NTRG5509001 Side Cover Panel Right Hand 5NTRG5509002 Side Cover Panel Left Hand 5NTRG5509003 Electrical Cover Panel Frontier Decal Large see page 7 of Operators Manual RG5500 Decal see page 7 of Operators Manual Tooling Bar Position Decal see page 7 of Operators Manual 5NT55490 Door Shipping Bracket 5NT8041
89. e STP is located on the spin board as remote torque preset at 2 00 for torque setting See FIG 24 The SSP is located on the control panel and is for spin speed adjustment Spin Torque Pot STP controls maximum torque allowable in the spin grinding cycle only This should never be adjusted past the 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 COMP Pot The IR Compensation is factory set at 9 00 Regulation of the spin or relief grind spin motor may be improved by a slight adjustment of the IR COMP pot clockwise from its factory set position Overcompensation causes the motor to oscillate or to increase speed when fully loaded If you reach such a point turn the IR COMP pot counterclockwise until symptoms just disappear DELAY SET RELIEF SPEED SPEED 12 00 SPIN TORQUE POT TORQ 2 00 TQ SHUT SWITCH 1 SET TO OFF moo Sun Potentiometer Clock IRCOMP A IDLETORQUE Orientation 5 POT 9 00 53 52 51 13 12 OR ON NIC ON DH EX 10 00 FIG 24 ELECTRICAL TROUBLESHOOTING SKILL AND TRAINING REQUIRED FOR ELECTRICA
90. e del carrete Configure en cero los calibres nuevamente Ahora est listo para comenzar con el rectificado y quitar el ahusamiento Cuando realice el rectificado la rueda solo har contacto con el lado m s grande del carrete y gradualmente rectificar m s a medida que las reas m s grandes se rectifiquen El bot n de contramarcha puede utilizarse para agilizar este proceso Rectifique hasta que haya contacto completo a lo largo de todo el carrete y que todo el largo de sus l minas est afilado CANTIDAD DE AHUSAMIENTO DELCARRETE CANTIDAD DE INSTRUCCIONES DE OPERACION Continuaci n CARRETE GR FICO DE CONFIGURACION DE MEDIDO AHUSAMIENTO ANCHO eo 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 0 015 0 100 0 088 0 076 0 068 0 062 0 056 0 052 0 048 0 025 0 166 0 144 0 127 0 114 0 103 0 094 0 086 0 080 0 075 0 035 0 233 0 202 0 178 0 159 0 144 0 132 0 121 0 112 0 104 0 299 0 259 0 229 0 205 0 185 0 169 0 156 0 060 0 399 0 346 0 305 0 273 0 247 0 225 0 207 0 192 0 179 AJUSTE DE AHUSAMIENTO 0 080 0 532 0 461 0 407 0 364 0 329 0 301 0 277 0 256 0 238 0 100 0 665 0 576 0 508 0 455 0 412 0 376 0 346 0 320 0 298 Ajuste hacia abajo del lado peque o del carrete RECTIFICADO DE GIRO Luego de que el carrete se haya alineado y se haya ajustado el ahusamiento est ahora listo para el rectificado de giro del carrete Cierre las tapas de los protectores frontal y posterior
91. e proper 1 2 12 7 mm square drive socket or adapter on the reel drive nut and then insert the square drive shaft into the socket Place the adapter sleeve over the drive shaft and insert the drive coupler adapter assembly into it Finally place the rubber coupler onto the drive coupler adapter See FIG 21 By holding the square drive shaft firmly into position with your left hand you will be able to move the other components to the right and insert the rubber coupler into the flange on the spin drive unit When this is done tighten the T Knob on the adapter sleeve to hold all parts in place 5 Finally readjust the spin drive unit if it is not in alignment NOTE It is not necessary to have perfect alignment but it must be close enough so that the coupler remains engaged and that excess torque is not applied to the reel OPERATING INSTRUCTIONS Continued REEL DRIVE ADAPTERS This grinder is equipped with an adapter that transfers the rotation from the spin drive gear box coupling to a 1 2 male square To operate the grinder you need an adapter from this 1 2 male square to the reel shaft These adapters are NOT included with this grinder Most cutting units In recent years have a male or female spline on the end of the reel shaft that connects to a hydraulic or electric motor shaft If you have a reel shaft that has an internal threaded end which you can access install a hex head bolt or socket head screw of that thread size with a ja
92. e rubber coupler tothe opaco steve square drive adapter SQUARE DRIVE ADAPTER This is inserted into the 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 ADAPTER SLEEVE DRIVE COUPLER ADAPTER unit This adapter shaft has a groove machined into it on Be SBUARE DRIVE ADAPTER 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 lf 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 square drive socket or reel drive adapter is used DO NOT EXTEND SQUARE SOCKET NOT INCLUDED to connect the square drive adapter to the reel NOTE The 1 2 12 7 mm square drive socket or adapter that is placed on the reel when spin grinding is NOT included with the grinder See next page for details SHAFT PAST GROOVE INSTEAD REPOSITION SPIN UNIT The following procedures will make setting up the spin drive unit easier 1 Move spin drive unit close to the reel Align the shaft on the spin drive with the nut on reel by completing the necessary adjustments discussed above Now slide the spin drive unit approximately 7 18 cm from the reel drive coupling point and securely fasten to the tooling bar tightening the locking knob Knob C Place th
93. e speed approx 8 feet per minute 2 5 meters per minute or slower After the last pass turn the grinder off Note Dueto the positioning of the reel to the 1 o clock position infeeding the wheel 015 inches 38 mm will remove 010 inches of material OPERATING INSTRUCTIONS Continued RELIEF GRIND To change over to the relief grind disengage the spin grinding wheel hub assembly and park it as far to the right as possible Bring the relief hub assembly over to the reel for relief grinding This will require repositioning the travel proximity switch brackets Note As the reel diameter gets smaller and the number of blades increases the relief grinding wheel diameter works better when smaller For example a 5 127 mm diameter greensmower reels with 11 blades achieve a greater relief angle with a smaller grinding wheel REEL SPIRAL Check to see if your mowing unit is normal or reverse helix NOTE As you look into the guide finger on THE NEXT PAGE IT SHOWS THE NORMAL REEL HELIX As you look into the guide finger on the FOLLOW PAGE IT SHOWS THE REVERSE REEL HELIX The high point of the relief finger is on the right hand side of the grinding wheel Most mowing units are normal helix 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 a THE GRINDING WHEEL THE HIGH POINT OF THE RELIEF FINGER MUST WHEEL DRESSING If the gri
94. e y la instalaci n adecuada de este producto son responsabilidad del distribuidor de John Deere Lea las instrucciones del manual y las reglas de seguridad Aseg rese de que se hayan realizado todos los puntos de la Lista de comprobaci n de preparaci n del Manual del usuario antes de entregar el equipo al propietario PARA EL PROPIETARIO Lea este manual antes de poner en funcionamiento su equipo Frontier Conserve este manual al alcance de su mano para tener una referencia r pida Solicite a todos los operadores que lean este manual con detenimiento y se familiaricen con todos los ajustes y procedimientos operativos antes de intentar poner en funcionamiento el equipo Puede obtener los manuales de repuesto de su distribuidor El equipo que adquiri ha sido dise ado y fabricado cuidadosamente para brindar un uso confiable y satisfactorio Como todos los productos mec nicos requerir limpieza y mantenimiento Lubrique la unidad como se especifica Tenga en cuenta toda la informaci n de seguridad que incluye este manual y las calcoman as de seguridad sobre el equipo Para obtener servicio su distribuidor autorizado John Deere cuenta con mec nicos capacitados piezas de repuesto Frontier genuinas y las herramientas y los equipos necesarios para dar respuesta a todas sus necesidades de servicio Utilice solo piezas de servicio Frontier genuinas INSTRUCCIONES DE SEGURIDAD Los Simbolos de seguridad est n incluidos en este manual pa
95. ed Yes Verify Wiring to LVR No Measure 120 Volts AC at MAG term T3 to Term Block 4 Blue after SSS is pushed If 120 Volts AC Replace MAG If no 120 Volts AC verify wiring to T3 contact has failed holding contactin Verify the magnetic starter holding contact is working 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 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 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 not working Grinding Motor Relay not working No Power to Relay Contacts Bad Contacts in Grinding motor Relay Bad Circuit Breaker Bad Grinding Motor Checkout Procedure A Turn switch on B Close front and rear guard doors C Check 15 amp CB on the side of the grinder above the control cover 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 Powerto Relay Contacts H Verify power out of Grinding Motor Relay Verify Power to Grind
96. eg rese de que la unidad de corte est trabada en forma segura con las abrazaderas que se brindan antes de poner en funcionamiento 12 13 17 El S mbolo de precauci n identifica instrucciones o procedimientos especiales que si se obedecen estrictamente pueden resultar en da os al equipo e incluso su destrucci n NO ADOPTE POSTURAS FORZADAS Mantenga una posici n firme y equilibrada en todo momento REALICE EL MANTENIMIENTO DE LA RECTIFICADORA CON CUIDADO Siga las instrucciones del Manual de servicio para la lubricaci n y el mantenimiento preventivos DESCONECTE LA ALIMENTACI N EL CTRICA ANTES DE REALIZAR EL SERVICIO o cuando cambie la rueda abrasiva REDUZCA EL RIESGO DE UN ARRANQUE INVOLUNTARIO Aseg rese de que todos los interruptores est n en OFF Apagado antes de conectar la rectificadora UTILICE LOS ACCESORIOS RECOMENDADOS Consulte el manual para obtener informaci n acerca de los accesorios recomendados Utilizar accesorios inadecuados puede aumentar el riesgo de lesiones personales VERIFIQUE LAS PIEZAS DA ADAS Un protector u otra pieza que est n da ados o no cumplan con la funci n que deben realizar deben repararse o reemplazarse adecuadamente CONOZCA SU EQUIPO Lea este manual con atenci n Conozca sus aplicaciones y limitaciones as tambi n como los peligros potenciales espec ficos CONSERVE TODAS LAS CALCOMAN AS DE SEGURIDAD LIMPIAS Y LEGIBLES Si las cal
97. eguridad Tambi n deseamos recordarles las reglas simples b sicas y de sentido com n acerca de la seguridad cuando utilicen la rectificadora de carrete No seguir estas reglas puede resultar en lesiones graves para el operador o las personas cercanas al rea e incluso la muerte Es esencial que toda persona involucrada en el montaje la operaci n el transporte el mantenimiento y el almacenamiento de este equipo sea consciente y se preocupe por la seguridad sea prudente y cuente con la capacitaci n adecuada sobre seguridad Siempre utilice la protecci n adecuada como lo especifica el fabricante Nuestras m quinas de producci n actuales incluyen como equipamiento est ndar protectores o protecciones para la rueda abrasiva se ales de seguridad y un manual del operador Nunca pase por alto o ponga en funcionamiento la m quina sin alguno de los protectores o alguno de los dispositivos de seguridad Lea y comprenda completamente todas las pr cticas de seguridad que se especifican en las p ginas 4 y 5 de este manual Toda persona que trabaje con las rectificadoras de carrete debe comprender y seguir todas las reglas de seguridad MENSAJE DE SEGURIDAD IMPORTANTE PARA LOS PROPIETARIOS OPERADORES DE LAS RECTIFICADORAS DE CARRETE Antes de poner en funcionamiento la rectificadora de carrete un operador debe leer y comprender toda la informaci n en el manual del usuario y en las se ales de seguridad que aparecen adjuntas al produ
98. eguridad e interruptores de corte en la tapa del impulsor de rotaci n Impulsor de rotaci n reversible para una velocidad de giro variable o para funciones de alivio de momento de torsi n variable Control longitudinal de velocidad variable de cabrestante y brazo manual kit de cabrestante y brazo el ctrico o plataforma de elevaci n CONOZCA SU RECTIFICADORA Continuaci n IDENTIFICACI N DE LOS COMPONENTES DEL PANEL DE CONTROL Revise las descripciones de los componentes del panel de control a continuaci n antes de proceder con las instrucciones PULSADOR DE INICIO DEL SISTEMA El pulsador verde es el interruptor de arranque del sistema Al presionarlo pondr en funcionamiento el arrancador magn tico y suministrar electricidad al panel de control El arrancador magn tico no se pondr en funcionamiento a menos que se tire del pulsador de parada de emergencia y los interruptores del motor de la rectificadora del motor de rotaci n est n apagados INTERRUPTOR DEL SELECTOR DE LA RECTIFICADORA Velocidad de rotaci n variable El interruptor debe estar levantado para realizar las operaciones de rectificado de giro Alivio de momento de torsi n variable El interruptor debe estar bajo para realizar las operaciones de rectificado de alivio INTERRUPTOR DE GIRO DEL IMPULSOR DE ROTACION Marcha Apagado Contramarcha Este interruptor invierte la direcci n del motor del impulsor de rotaci n IMPORTANTE Puesto
99. et to 9 00 IR COMP is current 1 resistance compensation COMP IR COMP adjusts the output voltage of the drive which balances load to motor RPM Regulation of a traverse motor may be improved by slight adjustment of the IR COMP 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 pot counterclockwise until the symptoms disappear Max Speed Set at 3 30 for maximum voltage of 90 Volts DC to the traverse motor When voltage is above 90 volts DC the traverse motor will start to pulsate and not run smoothly Right Traverse Forward Acceleration Factory set at full CCW 8 30 Do not change this setting Left Traverse Reverse Acceleration Factory set at full CCW 8 30 Do not change this setting DB Dead Band is the potentiometer setting for the 50 or 60 Hz cycle control Factory set to 9 00 works for both 50 and 60 Hz Do not change this setting Calibrating the DWELL TIME rotary DIP switch adjusts the amount of time the process remains in the stop position after a limit switch is actuated The DWELL TIME range is adjustable from 0 4 seconds A DIP switch setting of O 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 seconas etc Diagn
100. eva el carrete a la posici n aproximada al mantener el rodillo posterior sobre la parte superior de la mesa y el rodillo frontal en los montajes del rodillo frontal ASEG RESE DE QUE LA RUEDA ABRASIVA EST LO SUFICIENTEMENTE BAJA COMO PARA DEJAR UN ESPACIO PARA EL CARRETE PUEDE BAJAR LA RUEDA ABRASIVA AL GIRAR AMBAS MANIVELAS EN SENTIDO CONTRARIO ALAS AGUJAS DEL RELOJ Ubique el carrete frontal en el centro de la m quina Mueva los montajes del rodillo hacia afuera tanto como sea posible en direcci n a los extremos del rodillo frontal Vea la Fig 11 Utilice las calcoman as sobre la barra de mecanizado para ayudarse con el posicionamiento del mecanizado frontal Compruebe que haya un margen entre el mecanizado el rodillo frontal y el marco con ambas ruedas de giro y alivio Esto asegurar que no tenga que mover el carrete entre el rectificado de giro y el de alivio NOTA En los carretes m s grandes es posible que sea necesario desviar ligeramente el carrete del centro para permitir que se monte el impulsor de rotaci n sobre el lateral adecuado de la unidad de corte Ubique el rodillo posterior sobre la abrazadera del rodillo posterior Vea la Fig 12 Si utiliza los soportes para todas las posiciones configure la altura vertical de estos de manera que la parte inferior del carrete est entre 1 5 y 2 0 in 38 y 51 mm por encima de la mesa Es recomendable tambi n que se monte el brazo de soporte con la menor extensi
101. evitar lesiones equipment Follow al safety rules and Instructions Manuals Do not exceed grinding No exceda la velocidad de avallable from your selling dealer wheel maximum operating funcionamiento maxima de Keep bystanders away from equipment during operation Keep all shields in place and in good condition speed of 3600 revolutions 3600 revoluciones por minuto Wear all of the appropriate safety equipment specified in the per minute de la rueda rectificadora Operator s Manual while operating this machine Always make sure machine is off and all machine movement has stopped before leaving machine Never allow children or untrained persons to operate equipment 4 ATENCI N Para evitar lesiones Lea el manual del operador antes de la puesta en funcionamiento del mantenimiento o de la reparaci n del equipo Siga todas las reglas e instrucciones de seguridad Los manuales se encuentran disponibles a trav s de su distribuidor Mantenga al personal ajeno alejado del equipo durante el funcionamiento Mantenga todos los protectores en su lugar y en buenas condiciones Durante el funcionamiento de esta m quina utilice todos los equipos de seguridad correspondientes especificados en el manual del operador Aseg rese siempre de que la m quina se encuentre apagada haya dejado de moverse antes de abandonarla Nunca permita que un ni o o una persona sin capacitaci n pongan la m quina en funcionamiento EL
102. he grinder USE RECOMMENDED ACCESSORIES Consult the manual for recommended accessories Using improper accessories may cause risk of personal injury CHECK DAMAGED PARTS A guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced 18 KNOW YOUR EQUIPMENT Read this manual carefully Learn its application and limitations as well as specific potential hazards 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 numbers of safety decals 20 DO NOT OPERATE THE GRINDER WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS IMPROPER USE OF GRINDING WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY Grinding is a safe operation if the few basic rules listed below are followed These rules 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 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
103. he reel The grind shaft is now aligned vertically to the reels outer diameter Zero the gauges located on the vertical adjustment 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 SETTING THE TRAVERSE LIMITS Move the grinding wheel to the right until the wheel has IF THE REEL FRAME EXTENDS cleared the reel by approximately inch 6 mm if BELOW THE REEL ITSELF MAKE clearance to the frame allows Disengage both the relief SURE THE STOP IS SET SO THAT and Spin grinding assemblies from traverse belt Turn the THE GRINDING WHEEL DOES NOT Traverse speed potentiometer to zero and turn on the RUN INTO THE FRAME WHILE Traverse Motor Switch This will activate the proximity GRINDING sensors Move the right Traverse Travel Limit switch 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 traverse belt and slowly turn the Traverse Speed up Allow the wheel to traverse from end to end to verify the switches stop and reverse the direction of the grinding wheel Verify that the grinding wheel travels fully off the reel at each end Note If the reel will hit the frame then adjust travel sensors so the wheel does not contact the frame ATTACHING THE VARIABLE SP
104. icado en alivio de torsi n variable IMPORTANTE El interruptor de giro del impulsor de rotaci n debe estar en la posici n de OFF Apagado cuando cambie el interruptor del selector de rectificado Configure el interruptor de giro del impulsor de rotaci n para que gire el carrete al interior del dedo de retenci n en sentido contrario a las agujas del reloj CCW cuando est de cara al lado derecho NOTA La rotaci n del carrete de torsi n de alivio es siempre una rotaci n opuesta NO ENCIENDA EL INTERRUPTOR DEL MOTOR DE ROTACION Con el desplazamiento en la posici n de inicio sensor de proximidad longitudinal del lateral derecho iluminado avance la rueda abrasiva de alivio hacia arriba mientras manualmente gira el carrete hasta que el dedo de retenci n toque la l mina Gire el potenci metro de velocidad longitudinal a cero y luego encienda el motor del impulsor longitudinal Con el impulsor de la correa desacoplado mueva manualmente el montaje de rectificado de alivio hacia la izquierda hasta que la l mina del carrete se encuentre sobre el dedo de retenci n de alivio fijo En esta instancia de ser necesario puede ajustar el ngulo de alivio al ajustar la posici n del dedo de retenci n de alivio Para realizar este ajuste suelte la manivela de ajuste del ngulo de alivio Vea la Fig 24 Rotar el sistema de dedos de retenci n hacia abajo aumentar el ngulo de alivio y rotar el sistema de dedos de retenci n h
105. ified in the BELT TENSION section Adjust the height of the motor pulley if necessary so the belt is located in the center of the traverse belt clamp Reinstall the left side and right side cover panels then testthe traverse motor MAINTENANCE Continued TRAVERSE SHAFT LINEAR BEARING REPLACEMENT 2 REMOVE REAR PIVOT BOLT To replace the traverse shafts or the linear bearings in the Spin or Relief assembly first remove the left side 5 T RENOVE GENDING IS TRAVERSE BELT REMOVE GRINDING SHAFT Next you will need to remove the grinding shaft First move the relief hub away from the relief hub assemlby see Replacement of Griniding wheel section for details Then remove the grinding motor belt and pulley see Grinding Motor Belt Replacement Now loosen the setscrews on the right side bearing to allow the grinding shaft to slide out of the bearing Next remove the left side grinding shaft bearing The grinding shaft is heavy so take appropriate measures when lifting or removing To remove the grinding shaft 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 THE GRINDING 5 WEIGHS 75LBS ES 7 34 Kg USE APPROPRIATE LIFTING DEVICES TO AVOID INJURY 3 LIFT ARM OFF REAR PIVOT SHAFT AND SLIDE REMOVE THE TRAVERSE BELT ARM BACK THEN OUT See Traverse Belt Replacement section REMOVING THE TRAVERSE SHAFTS To
106. iliaric monos con los ajustes disponibles y los montajes de acoplador impulsor Vea la Fig 20 INSTRUCCIONES DE OPERACI N Continuaci n Perilla A Permite que la unidad de giro se desacople y se mueva hacia adentro y hacia afuera Perilla B Permite que la unidad de giro se desacople y se mueva hacia arriba y hacia abajo Perilla C Permite que el montaje de giro se desacople de la barra de mecanizado y se mueva de un extremo a otro _4 PERILLA A Al momento de ubicar la unidad de giro es posible que sea necesario completar varios de los ajustes antes mencionados para alinear adecuadamente la unidad de giro con el carrete EL MONTAJE DE ACOPLADOR INCLUYE ACOPLADOR DE MANGO DE CAUCHO Este se ubica en el acoplador de la brida correspondiente que ya est montado en el eje del impulsor de rotaci n Vea la Fig 21 MONTAJE DEL ADAPTADOR DEL ACOPLADOR DEL IMPULSOR Este se monta al acoplador de caucho Nota Si se quita el adaptador del acoplador del impulsor hay un eje del impulsor corto y cuadrado acoplado al mango del adaptador Se puede utilizar con un manguito si el espacio es limitado MANGO DEL ADAPTADOR Conecta el acoplador de caucho PERILLAB 6 2 lt S con el adaptador cuadrado del impulsor ADAPTADOR CUADRADO DEL IMPULSOR Se coloca dentro del adaptador del acoplador del impulsor El adaptador cuadrado del impulsor tiene un movimiento de aproximadamente 2 51 mm Ser necesario m
107. ing motor Cord Grinding Motor works Yes end troubleshooting No go to Step B next Grinding Motor works Yes end troubleshooting No go to Step C next Grinding Motor works Yes end troubleshooting No go to Step D next Measure 120 volts AC from Terminal strip 2 terminal 15 to nuetral blue terminal out of FTR O2FTRBU Yes go to Step E next No check continuity of wires to GMS Measure 120 volts AC fromT erminal strip 2 terminal 14 to nuetral blue terminal out of FTR O2FTRBU Yes Go to Step F next No replace GMS Check for 120 Volts AC from 1 to 2 of Grinding motor Relay REL Yes Go to Step G next No check wires to Grinding motor Relay A1 amp A2 REL Terminals L1 to L2 for 120 Volts AC Yes Go to Step H next No Check wires to REL Term L1 amp L2 REL Terminals T1 to T2 for 120 Volts AC Yes Go to Step I next No Replace Gringing Motor Relay Verify wiring at terminals 1 2 amp on Terminal Strip 1 Check 42TB1 1 to 64TB1 2 for 120 Volts AC Yes Check motor cord terminals Replace motor No Check continuity of circuit breaker Replace ELECTRICAL TROUBLESHOOTING Continued PROBLEM SPIN DRIVE NOT WORKING IN SPIN MODE Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram are correct and pull on wire terminals with approximately 3 105 force to verify there
108. ittent electrical contact MECHANICAL TROUBLESHOOTING PROBLEM Excessive noise or vibration on one end ofthe machine Possible Cause Set screws on bearings are not tight on grinding shaft PROBLEM Grinding wheel traverse binding Possible Cause Shafts are dirty Grinding shaft is ata severe angle PROBLEM Handwheel or vertical indicator gage walks during grinding Possible Cause Bracket connecting gage to vertical adjuster is loose Plug and set screw loose PROBLEM Reels ground have high low blades Possible Cause Traverse Speed set too fast Checkout Procedure Tighten set screws located on bearings Checkout Procedure Clean the shafts as specified in the maintenance section of this manual Raise or lower one end of the shaft until approximately level This grinder is not designed to operate at a severe angle Adjust reel or setup until the shaft is approximately level Checkout Procedure Push lightly up and down on the digital gage to see if it is loose Tighten the screws on the bracket to the vertical adjuster or remove the gage and tighten the screws from the bracket to the gage Tighten the drag on the vertical shafts by tightening the setscrew located on the back of the vertical adjuster husing See Vertical Infeed Shaft Drag in the adjustment section Checkout Procedure Check roundness using the digital gage Traverse speed should be set approximately 12 ft min 4 meter
109. je de la rectificadora con el carrete eleve el eje de manera que la rueda de giro est alrededor de in 6 mm de las l minas del carrete Mueva la rueda de giro a un lado del carrete y eleve el eje de la rectificadora hasta que la rueda apenas toque la l mina Mueva la rueda al otro lado del carrete y eleve el eje hasta que la rueda apenas toque Vuelva a verificar en cada lado y realice ajustes en espejo hasta que la rueda toque lo mismo en ambos extremos del carrete El eje de la rectificadora est ahora alineado verticalmente con el di metro exterior del carrete Configure en cero los calibres ubicados en la carcasa de ajuste vertical Compruebe que no haya puntos elevados en el carrete al mover la rueda a lo largo del carrete mientras lo gira Si hay puntos elevados baje el eje de manera equidistante en ambos extremos y configure en cero los calibres nuevamente SIEL MARCO DEL CARRETE SE COMO CONFIGURAR LOS LIMITES EXTIENDE POR DEBAJO DEL LONGITUDINALES CARRETE MISMO ASEG RESE DE Mueva la rueda abrasiva a la derecha hasta que se haya QUE LA PARADA ESTE alejado del carrete aproximadamente 1 4 in 6 si el margen CONFIGURADA DE MANERA QUE LA con el marco lo permite Desacople ambos montajes de RUEDA ABRASIVA NO SE rectificado de giro y alivio de la correa longitudinal Gire el ENCUENTRE CON EL MARCO potenci metro de velocidad longitudinal a cero y encienda el DURANTE EL RECTIFICADO interruptor del motor longitudinal Esto activ
110. l NIOSH Instituto nacional para la seguridad y salud ocupacional y la MSHA Administraci n para la seguridad y salud de los mineros Propicie una ventilaci n adecuada para eliminar el polvo o para mantener el nivel de polvo por debajo del Valor m nimo de polvo perjudicial seg n lo clasifica la OSHA Administraci n para la seguridad y salud ocupacional INDICE DE CONTENIDOS Esta m quina fue disenada SOLO para rectificar el carrete de los tipos de unidades segadoras de carrete Cualquier uso diferente a este puede causar lesiones personales y anular la garantia Para asegurar la calidad y seguridad de su m quina y para mantener la garantia usted DEBE utilizar piezas de repuesto del fabricante del equipo original y encargar cualquier trabajo de reparaci n a un profesional calificado TODOS los operadores de este equipo deben estar debidamente capacitados ANTES de poner en funcionamiento el equipo No utilice aire comprimido para limpiar de la m quina el polvo generado por el rectificado Este polvo puede causar lesiones personales as como tambi n da os a la rectificadora La m quina es solo para uso en interiores No utilice una hidrolavadora para limpiar la m quina ADVERTENCIA N Q PREAJUSTE DE Rele de bajo voltaje A F BRICA LA LUZ VERDE A INTERMITENTE INDICA BAJO 4 VOLTAJE LA LUZ ROJA A INTERMITENTE INDICA QUE LA 4 RECTIFICADORA SS La rectificadora est equipada con un rel
111. le in HEAD onHEAD HEAD Steel 1 4In 6 ft lbs 9 ft lbs 13 ft Ibs Refer to the table at the right as Bolts Going Into a Thread Hole In Aluminum 527 Es en Use the Grade 2 values in the table at the right thread 2 6 kg 4 3 kg 6 4 kg Socket Head Screws Going Into a Nut or Steel del 7 16 In 30 ft lbs 50 ft lbs 75 ft lbs Use the Grade 8 values in the table at the right 29 Machine Screws 1 2 In 45 ft lbs 75 ft lbs 115 ft lbs hread 6 2 kg 4 kg 9 kg No 6 screws 11 in lbs 0 125kg m Md A No 8 screws 20 in lbs 0 23 kg m No 10 screws 32 in lbs 0 37 kg m 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 1 and 2 THE UNIT WEIGHS _ 83 211cm 1200 LBS 544 USE POWER Remove shipping straps and window protective sheets 71 181cm POSITION BASE FIG 1 RG5500 Spin Relief Grinder will require an operating area of about 119 W x 127 D x 90 302 cm x 323cm x 229 cm The machine operator will operate the unit from the front ofthe machine Positi
112. letar la capacitaci n sobre la instalaci n O 1 El equipo est completamente montado 2 Todas las protecciones est n en su lugar y en buenas condiciones O 3 Todas las calcoman as est n en su lugar y son legibles Ver p ginas O 4 Se encuentra en buenas condiciones generales es decir pintura soldaduras instalaciones el ctricas O 5 Verifique que haya suficiente suministro el ctrico para poner la m quina en funcionamiento O 6 Revise los manuales del operador montaje y servicio y cualquier material de capacitaci n adicional que tenga a disposici n O 7 Revise la posici n adecuada del carrete Firma del distribuidor Firma del comprador O 8 Explique la utilizaci n del mecanismo de alivio de la rectificadora de carrete O 9 Revise la posici n del interruptor de proximidad longitudinal O 10 Explique la utilizaci n del mecanismo de alivio de la rectificadora de carrete O 11 Explique la velocidad de giro de la rectificadora de carrete vs la calidad O 12 Converse acerca del gr fico de configuraci n de la rectificadora de carrete que se encuentra en el manual O 13 Revise el mantenimiento general Seguridad La seguridad es una de las preocupaciones principales para el dise o la fabricaci n la venta y la operaci n de las rectificadoras de carrete Como fabricantes de rectificadoras de carrete deseamos confirmarles a ustedes nuestros clientes nuestra preocupaci n por la s
113. ll the blades before infeeding further NOTE Traverse speed should be set to approximately 15 fom 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 After the relief grind is complete remove turn all switches to off it is also good practice to push in the E stop button then remove cutting unit from the machine Use caution as the reel blades will be sharp REEL SETUP CHART NOLLISOd ONILL3S SNILL3S ONILLAS INNON INNOMN 30 LHDI3H a33dS 310801 NOILISOd SONVLSIG DNIMTOOL DNITOOL SALON 3S4Y3AVHL 5 5 SNITOOL INOY3 LNOUY4 NVI 1334 AjUO e se sanjea asey asp 018 UOIISOd no Jo erp jee LYVHD 0135 1334 ul INP SUOISUSUWIP 95941 910N THIS PAGE LEFT INTENTIONALLY BLANK FOR NOTE TAKING PORPOSES FJRONTIER ASSEMBLY ano SERVICE MANUAL FOR SERIALNUMBERS 1XFRG55XPD0000025 AND UP SPIN REEF GRINDER 500 FJRONTIER REV 5 8 13 DEALER PREPARATION INSTALLATION CHECK LIST IS LOCATED IN THE OPERATOR S MANUAL SEE OPERATOR S MANUAL FOR INSTALLTION CHECKLIST Itis the responsibility of the dealerto complete the procedures listed in the Operators Manual then review this
114. m nut very tight so it does not loosen while spin grinding and then drive with a 1 2 drive socket for that hex or hex key size JOHN DEERE REELS COUPLERS The external spline shafts use a female splined coupler between the reel shaft and the male splined hydraulic motor shaft The spline is either an 8 9 or 11 toothed spline Our recommendation is to purchase the female splined coupler from John Deere and weld itto a short 1 2 square socket extension Note The 8 tooth spline adapter can be used with a Square Socket Drive Adapter 3 8 square male to 1 2 square female without welding REEL DIA REEL TYPE Recomendation 5 G M Has an 8 T External shaft Use coupler AET11038 Ti H Has an 11 T External shaft Use coupler TCA12581 NOTE THIS CAN ALSO BE DRIVEN WITH A 1 25 HEX SOCKET 7 Has a 9 T External shaft Use coupler AET11310 NOTE THIS CAN ALSO BE DRIVEN WITH A 1 25 HEX SOCKET 8 Has a M16 X 2 External shaft Use nut A31869 and drive with a 24mm Hex Socket 5 Use 3 8 24 UNF Bolt and drive with a 9 16 Hex Socket Has an 8 T Internal Spline shaft Use part AMT3022 to make an adapter Has an 11 T Internal Spline shaft Use a 1 25 Hex Socket or make and adapter from part TCA18958 TORO EQUIPMENT Toro uses an 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
115. mitad de la rueda abrasiva PERMITA que las RUEDAS RECI N MONTADAS giren a la velocidad operativa con el protector colocado en su lugar durante por lo menos un minuto antes de comenzar a rectificar SIEMPRE USE GAFAS DE SEGURIDAD o alg n tipo de protecci n ocular cuando rectifique LO QUE NO DEBE HACER NO utilice una rueda agrietada ni una que SE HAYA CAIDO o que est da ada NO FUERCE una rueda a la m quina NI ALTERE el tama o del orificio de montaje Si la rueda no encaja en la m quina busque una que s NUNCA EXCEDA LA VELOCIDAD OPERATIVA MAXIMA establecida para la rueda NO utilice bridas de montaje en las que las superficies de rodamiento NO ESTEN LIMPIAS PLANAS Y LIBRES DE QUEMADURAS NO AJUSTE EXCESIVAMENTE la tuerca de montaje NO rectifique con el LATERAL DE LA RUEDA consulte el C digo de seguridad B7 2 para conocer las excepciones NO encienda la m quina hasta que el PROTECTOR DE LA RUEDA ESTE EN SU LUGAR NO ATASQUE la pieza de trabajo en la rueda NO SE PARE DIRECTAMENTE DELANTE de la rueda abrasiva cada vez que se encienda una rectificadora NO FUERCE EL RECTIFICADO de modo que el motor disminuya notablemente la velocidad o la pieza de trabajo se caliente EVITE INHALAR EL POLVO generado por las operaciones de rectificado y corte La exposici n al polvo puede causar problemas respiratorios Utilice respiradores gafas de seguridad o m scaras e indumentaria protectora aprobados por e
116. moving it to the right will disengage the belt The tip can be adjusted if necessary to increase or decrease the tension on the belt See adjustments in the service manual for more details THE BELT CLAMP TIP IS ADJUSTED AT THE FACTORY TO ALLOW THE BELT TO SLIP IF THE HUB COMES IN CONTACT WITH SOMETHING CAUTION SHOULD BE USED WHEN ADJUSTING THE TIP IF THE CLAMP IS OVER TIGHTENED THE BELT WILL NOT SLIP WHICH MAY CAUSE DAMAGE TO THE MACHINE OR REEL TRAVERSE PROXIMITY SWITCHES Two movable proximity switches determine the left and right limits of grinding head assembly An LED on the switch lights when the grinding head gets close to the head of the proximity switch The sensors are mounted in the Proximity Brackets located on the traverse shafts The brackets can easily be slid along the shafts for quick and easy travel limit adjustments When switching from the spin mode to the relief mode the brackets will need to be lifted off the shafts and snapped back on the shafts in the proper position SPIN RELIEF GRINDING HEAD This grinder is equipped with separate spin and relief grinding wheels When the setup is done properly the reel will be only need to be positioned and aligned once for both cycles The spin wheel is located on the right 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
117. ms up and down to coat the working areas of the shaft Inspect the traverse cog belt for cracking and defects every three months Remove any grit or dust that may affect the function of the belt Adjust tension if necessary per procedures called out in the adjustment section See FIG 9 Clean and lubricate the grinding shaft and traverse shafts every 2 to 4 weeks Follow the proceedure on the next page Lubricate grinding shaft bearings with one shot of grease once every 2 years See FIG9 DO NOT GREASE GRINDING SHAFT DUSTTRAY VERTICALADJUSTMENT SHAFTS LOCATED INSIDE HOUSING ACCESS THRU SIDE PANELS FIG 7 POLY V BELT LOCATED BEHIND PANEL HORIZONTAL ADJUSTMENT BEARINGS FOR THE FIRST 2 YEARS THEY ARE GREASED AT THE FACTORY GREASING MAY CAUSE THE BEARINGS TO OVERHEAT AND FAIL PREMATURELY LUBRICATION LUBRICATION OF GRINDING SHAFT AND LINEAR BEARINGS STEP 1 Thoroughly clean all three shafts STEP 2 Flood spray all three shafts with CRC 3 36 until the lubricant is dripping off the shafts Do not use a Teflon based lubricant Then run the grinding head assemblies back and forth through their full range of travel This will remove the dust and deposits from inside the wheel flanges Repeat if necessary until lubrication is clear of deposits Clean keyways located on the grinding shaft with soft brush STEP 3 With a clean rag wipe off the excess amount of lubricant from the shafts
118. n be minimized by using a mild automobile polish Three such products that tend to polish and fill scratches are Johnson paste Wax Novus Plastic Polish 1 and 2 and Mirror Glaze plastic polish M G M10 Itis suggested that a test be made on a corner of the polycarbonate window with the product selected following the polish manufacturer s instructions Some Important DON TS DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows Never scrape polycarbonate windows with squeegees razor blades or other sharp instruments Benzene gasoline acetone or carbon tetrachloride should NEVER be used on polycarbonate windows DO NOT clean polycarbonate windows in hot sun or at elevated temperatures Graffiti Removal Butyl cellosolve for removal of paints marking pen inks lipstick etc The use of masking tape adhesive tape or lint removal tools works well for lifting off old weathered paints To remove labels stickers etc the use of kerosene VM amp 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 Important Do not mark the scale unit with an electric engraver or scratch 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 an
119. n perno de 3 8 en el extremo del eje del carrete con una contratuerca de manera que quede bien ajustada para que no se suelte durante el rectificado Utilice un manguito de 9 16 para atornillar Tambi n pueden atornillarse desde el extremo del motor hidr ulico al presionar el adaptador del impulsor de manguito cuadrado de macho cuadrado de 3 8 a hembra cuadrado de 1 2 dentro del acoplador de carrete ranurado Jacobsen n mero de pieza 337370 y utilizar este montaje presionado como adaptador las unidades de carrete de 7 pueden atornillarse desde cualquier extremo La unidad de carrete cuenta con un acoplador adjunto al eje del carrete en ambos extremos Adquiera la pieza Jacobsen n mero 4102440 el eje del motor del carrete suelde el eje del motor hidr ulico desde el kit al manguito de 1 2 y utilice esta soldadura como adaptador las unidades de carrete Tri King pueden atornillarse en unidades de impulsor de polea m s antiguas con un manguito de 9 16 sobre el perno de 3 8 que sostiene la polea En unidades ranuradas m s nuevas adquiera el acoplador del carrete ranurado Jacobsen n mero de pieza 132002 y presione un adaptador al adaptador del impulsor de manguito cuadrado de macho cuadrado de 3 8 a hembra cuadrado de 1 2 dentro del acoplador de carrete ranurado y utilice este montaje como INSTRUCCIONES DE OPERACI N Continuaci n RECOMENDACI N PARA LAS RPM DEL IMPULSOR DE GIRO Y LA VELOCIDAD LONGITUDINAL DURANTE EL REC
120. n the OFF position the torque will remain constant during relief grinding This should be setto OFF Torque Shut Off Delay dail is used to 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 for a longer period of time The Relief Speed RSP and the Relief Torque Pot RTP interact with each other The RSP is located on the spin 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 Speed Pot SPEED when rotated clockwise will increase spin drive speed the speed at which the reel indexes to the next blade This speed should never be above the 3 00 setting Relief Torque Pot TORQ is used 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 Torque 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 Spin Torque Potentiometer STP and the Spin Speed Pot SSP interact with each other Th
121. n the Spin Motor Switch on NOTE The spin drive will apply torque load against the fingers Set the Relief Torque Potentiometer at approximately 15 IMPORTANT Free turning reels may need a lower value than 15 and stiff reels or reels with a drive train may need a higher torque than 15 Engage the traverse belt and traverse all the way 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 blade at far left position and the front side of the blade on the return trip to the home position Also verify clearance to the reel blade support spiders If necessary the forward stop can be adjusted See FIG 25 Stop the traverse in home position and check for a proper blade index The traverse drive control is factory set with a two second dwell time before it reverses the carriage travel This is to allow time for the reel to rotate and the index finger to catch the next blade If necessary the dwell time can be adjusted refer to Control Board Potentiometer Adjustments section in the Assembly and Service Manual Turn on the Spin Drive Motor should already be on and the Grinding Wheel Motor switch Turn the traverse speed potentiometer to proper grinding speed Slowly infeed the grinding wheel until you are able to grind the full length of the reel evenly A typical infeed is between 010 to 020 25 50 mm Be sure you have ground a
122. nd the machine and secure th spreader bar to the cutting unit Use the winch to lift th unit and swing the reel into the working area of th machine Refer to manual in kit for further instructions See FIG 9 Available with a Manual or Electric winch REAR LIFT PLATFORM The Rear Lift Table is a portable platform that can be use to raise the reel up level to the grinder The reel can b rolled onto the platform with the front of the reel facing th front of the grinder With rear roller clamp removed th reel can be rolled from the platform into the machine fror the rear The Platform Lift uses a 12V rechargeabl system to power the platform and can be moved aroun the facility on the 4 caster wheels See FIG 10 OPERATING INSTRUCTIONS Continued INSTALL REEL Move the reel to the approximate position having the rear 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 COUNTERCLOCKWISE Position front reel in the center of the machine Move the roller mounts as far out as possible to the ends of the front roller See FIG 11 Use the decals on the tooling bar to aid in the positioning of the front tooling Check for clearance to the tooling front roller and frame with both the spin and relief wheels This will ensure that you will not have to move the reel between the spin and relief gri
123. nding NOTE On large reels it may be necessary to offset the reel slightly from center to allow the spin drive to be mounted on the appropriate side of the cutting unit Place the rear roller onto the rear roller clamp See FIG 12 If using the all position brackets set the vertical height of the clamps so that the bottom of the reel is 1 5 2 0 inches 38 51mm above the table It is also recommended to mount the support arm with as little extension 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 30 angle or issues the reel can be moved forward or backward to resolve this issue If you are grinding a QA5 or reel use the decals located on the tooling to quickly locate the reel in the optimal position See FIG 2 After the reel is positioned correctly lock down the front roller and tighten the rear clamp Make sure all knobs are tight before grinding BEFORE GRINDING ANY LOOSE KNOBS CLAMPS OR BEARINGS WILL ADVERSELY AFFECT THE GRIND QUALITY FIRMLY TIGHTEN ALL LOCKING KNOBS OPERATING INSTRUCTIONS Continued ALIGN THE REEL rn GAUGE VERTICAL ADJUST GAUGEANGLE MENT T KNOB IMPORTANT When measuring to the reel cen
124. nding 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 is nearly touching the dresser For dressing the spin grinding wheel put the dresser in the straight position Close the doors and infeed the spin grinding wheel into the dresser and then move the grinding wheel side to side against the dresser which will dress the full face of the wheel Typically only infeed 002 05 mm per pass Infeeding too heavy can damage the dresser or the wheel Continue dressing until the wheel looks new or the proper shape is achieved For dressing the relief wheel put the dresser at the correct 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 side to side OPERATING INSTRUCTIONS Continued JUIO y 08009 enjoy 1514 1261000 Isnyy 1994 M 10 a Buy BulyoJeln uonisod jo 1 6 ay sses6 smoJy 14614 10 uonisod 65616 001 1514
125. ntran disponibles a trav s de su distribuidor Mantenga al personal ajeno alejado del equipo durante el funcionamiento Mantenga todos los protectores en su lugar y en buenas condiciones Durante el funcionamiento de esta m quina utilice todos los equipos de seguridad correspondientes especificados en el manual del operador Aseg rese siempre de que la m quina se encuentre apagada y haya dejado de moverse antes de abandonarla Nunca permita que un ni o o una persona sin capacitaci n pongan la m quina en funcionamiento ELECTRICITY 4 CAUTION gt Avoid Injury Make sure all electrical E power to this machine E U 0 BE 1 1 r pe before removing any electrical panels or covers for maintenance RG5500 4 ATENCION SHARP OBJECTS ACAUTION AATENCI N To Avoid Injury Para evitar Keep hands lesiones away from Mantenga las rotating objects manos alejadas de los objetos giratorios Label Sheet English and Spanish Part Number 5NT155301 English and French Part Number 5NT155302 Traversing Switches Overall Width Overall Height Overall Depth Weight Base Construction Carriage Rails Grind Head Motor Spin Motor Sound Level Auto Traverse Control System Options GETTING TO KNOW YOUR GRINDER SPECIFICATIONS Solid state non contacting proximity switches 71 181 cm 69 175 cm with door closed 87 221 cm with door open 42 107 cm without workstation 79 201 cm with op
126. o est del lado derecho de la rueda abrasiva La mayor a de las unidades segadoras cuenta con una h lice normal EL PUNTO ALTO DEL DEDO DE RETENCI N DE ALIVIO DEBE ESTAR SIEMPRE EN EL V RTICE DE LA RUEDAABRASIVA QUE HACE CONTACTO CON EL CARRETE EN ESTA RECTIFICADORA ES SIEMPRE EL LADO DERECHO DE LA RUEDA ABRASIVA LABRADO DE LA RUEDA Si la rueda abrasiva se carga con material es posible que sea necesario labrar la rueda El modelo RG5500 se distribuye con un reavivador de punta de diamante Para utilizarlo coloque el reavivador sobre el brazo horizontal del impulsor de rotaci n en el rea donde la rueda debe ser labrada Ajuste el reavivador en la posici n y ngulo adecuados Levante la rueda abrasiva de manera que apenas toque el reavivador Para labrar la rueda abrasiva de giro disponga el reavivador en posici n derecha Cierre las tapas y avance la rueda abrasiva de giro dentro del reavivador y luego mueva la rueda abrasiva de lado a lado contra el reavivador que labrar la cara completa de la rueda Normalmente solo avance 0 002 0 05 mm por paso Un avance demasiado profundo puede da ar el reavivador o la rueda Contin e el labrado hasta que la rueda se vea como nueva o se haya logrado la forma adecuada Para labrar la rueda de alivio disponga el reavivador en el ngulo correcto para un carrete de h lice normal y de h lice de contramarcha Cierre las tapas y avance la rueda abrasiva de alivio hacia el rea
127. o remove and replace the grinding wheel s NOTE THE RELIEF HUB HAS A LEFT HAND THREAD FOR THE NUT THE SPIN HUB HAS A RIGHT HAND THREAD Place the grinding wheel hub assembly s back on the grinding shaft Verify that the spin hub is located between the spin drive yoke assembly and the relief hub is to the right of the relief drive assembly before lowering the grinding shaft MAKE SURE THE WHEEL S IS PLACED ON THE SHAFT WITH THE SAME ORIENTATION AS SHOWN FAILURE TO INSTALL lt CORRECTLY WILL CAUSE THE WHEEL NUT Lie TO LOOSEN THE NUT ON THE RELIEF Loosen bolts and tip bracket HUB SHOULD BE TO THE RIGHT amp THE back Press in the indexing NUT ON THE SPIN HUB SHOULD BE TO finger and the wheel should THE LEFT slide freely to the right FIG 11 Reinstall the bearing on the left side of the grinding shaft making sure to fit the pilot on the bearing into arm Tighten the four mounting screws and then tighten the setscrews to the shaft Reinstall the left side cover panel Move bearing support bracket back into place See relief hub bearing adjustment to set the bracket correctly MAINTENANCE Continued GRIND SHAFT PULLEY GRINDING MOTOR BELT REPLACEMENT ALIGNMENT CRIND MOTOR BELT To replace or inspect the grinding motor belt remove the right side cover panel To remove the belt pull down on the tensioner pulley For the belt to function properly the grinding shaft pulley and the grinding motor pulley must be in
128. on las laminas del carrete Con el calibre presionado contra el eje central ajuste la manivela horizontal hasta que el calibre indique cero Repita los ajustes de un lado al opuesto hasta que la alineaci n est dentro de las 0 005 0 13 mm COMO COMPROBAR EL AHUSAMIENTO Primero mida el lateral izquierdo del carrete tan a la izquierda como sea posible con el calibre de alineaci n digital asegurese de que la punta del calibre est centrada con el eje central del carrete Configure el calibre en cero y luego midalo contra el filo de una lamina Recuerde o tome nota de este numero Mu vase al lateral opuesto y realice la misma medici n Compare los dos numeros La diferencia es la cantidad de ahusamiento en el radio de la rueda NOTA PARA OBTENER UNA LECTURA DE AHUSAMIENTO CORRECTA PARA QUE PUEDA UTILIZARSE LUEGO CON EL GRAFICO DE AHUSAMIENTO LA LECTURA DEBE TOMARSE TAN CERCA DE LOS EXTREMOS DEL CARRETE COMO SEA POSIBLE LO QUE DARA LA MAYOR DISTANCIA ENTRE LAS LECTURAS Para quitar el ahusamiento de la rueda deber avanzarse m s el lateral del carrete que sea m s grande para quitar el material extra Quite el calibre y almacene el calibre digital en la clavija ubicada en el lateral frontal derecho de la m quina La base del calibre puede ubicarse en el interior de la m quina para que no moleste INSTRUCCIONES DE OPERACION Continuaci n ALINEACI N DEL EJE DE LA RECTIFICADORA CON EL CARRETE Para alinear el e
129. on the base to allow sufficient operating room in front and to the rear ofthe machine See FIG 1 and 2 The base should be placed on a relatively level concrete 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 71 181cm 83 211cm Optional Boom Kit 41 104cm 45 OPTIONAL PLATFORM LIFT 115cm 70 178cm ASSEMBLY INSTRUCTIONS Continued Remove the carton and remove the contents from the carton onto a workbench The carton includes Alignment Gage 2 Diamond Dresser Spanner Wrench Product Packet Assembly Operators amp Service Manuals ASSEMBLY INSTRUCTIONS Continued LEVEL BASE Place a level on the top of the table and check the unit for level side to side Adjustthe leveling feet as necessary until the machine is level See FIG 3 and 4 Place a level across the table from front to rear Adjust the leveling feet as necessary until the machine is level See FIG 3 and 5 LOOSEN JAM NUT TO ADJUST FOOT LEVELING FEET LOCATED Pa AT CORNERS OF MAHCINE When both front to back and side to side leveling procedures have been completed thread the hex FIG 3 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
130. orward position stop on the Finger system SETSCREW located near the pivot point of the Index Finger This will only need to be adjusted if there is a clearance issue with the finger when it travels forward See 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 correctly it MUST be aligned precisely 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 digital gauge allows you to measure one end of the reel by extending the slide rail until you make contact with the center 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 within 005 inches 13 When this is completed you can then reset 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 grinding procedure NOTE The gauge can be set for both inch and metric readout REEL CENTER SHAFT ZERO RESET
131. ostic LED s indicate the function that is currently being performed POWER indicates that AC power is being applied to the control FORWARD indicates that the process is running in the forward direction traversing left REVERSE indicates that the process is running in the reverse direction traversing right PROX 1 FWD LIMIT lights when the forward limit switch is actuated left prox PROX 2 REV LIMIT lights when the reverse limit switch is actuated right prox DWELL lights when the process remains stopped after a proximity switch is actuated PROX 1 LIMIT REVERSE O e gt O Potentiometer Clock Orientation 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 atthe factory to the positions shown on FIG 24 In the Relief Grinding Mode The Torque Shut Off mode selector allows you to turn on or off the Torque Shut Off feature When switch 1 is setto ON the board will decrease the spin motor torque once the shut time is achieved after leaving the right proximity sensor The amount of time it takes before the torque is decreased is set with the Torque Shut Off Delay dial The spin motor toque will be increased to the higher value once the right proximity switch is activated again If the Torque Shut Off selector is i
132. otor brushes No replace Spin Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Spin Drive not working in relief mode Assuming SSS System Start Switch is on with 120 volts AC to control panel and all other functions are working Verify all wires shown on the wiring diagram 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 the wire and the terminal If problem persists test as listed below Possible Cause Relief Torque Pot RTP set to zero Spin Motor Switch SMS is not on Circuit Breaker is Tripped 4 AMP Spin Drive Control SDC is not working CB or Spin Motor Switch SMS is bad Spin Drive motor is bad Worn Motor Brushes Checkout Procedure A Set RTP to 20 on the control panel B Turn SMS switch on C Reset Circiut Breaker on the right side of the machine Push in if tripped D Check SDC L1 to L2 for 120 Volts AC E Check power into SMS terminal 6 for 120 Volts AC F Check SDC A1 amp A2 for approx 20 Volts DC Have Relief Torque set to maximum torque full clockwise G Check spin motor continuity DISCONNECT POWER FROM THE MACHINE H Inspect Motor Brushes DISCONNECT POWER ZN FROM MACHINE Spin Motor works Yes end troubleshooting No go to Step B next Spin Motor works Yes end troubleshooting No go to Step C next Spin Motor works
133. overlo cuando acople el carrete a la unidad del impulsor de rotaci n Este eje del adaptador cuenta con una estr a maquinada en el extremo opuesto del aro a presi n Esta estr a est all para advertirle que se alcanz la extensi n m xima del eje cuadrado del impulsor ACOPLADOR DE MANGO DE CAUCHO MANGO DEL ADAPTADOR ADAPTADOR DEL ACOPLADOR KK x DEL IMPULSOR ADAPTADOR CUADRADO NL DEL IMPULSO gt MANGUITO NO INCLUIDO FIG 21 NO TRASPASE LAESTRIADEL EJE CUADRADO EN SU LUGAR VUELVA A UBICAR LA UNIDAD DE GIRO Si no puede conectar el carrete sin extenderse m s all de esta estr a entonces debe volver a ubicar la unidad de giro sobre la barra de mecanizado Perilla C Un manguito cuadrado del impulsor o un adaptador del impulsor de carrete de 1 2 12 7 mm se utiliza para conectar el adaptador cuadrado del impulsor al carrete NOTA El manguito cuadrado o adaptador del impulsor de 1 2 12 7 mm que se ubica en el carrete en el rectificado de giro NO se incluye con la rectificadora Consulte la p gina siguiente para m s detalles Los procedimientos a continuaci n facilitar n la configuraci n de la unidad del impulsor de rotaci n Mueva la unidad del impulsor de rotaci n cerca del carrete Alinee el eje en el impulsor de rotaci n con la tuerca del carrete al completar los ajustes necesarios que se explicaron anteriormente Ahora deslice la unidad del impulsor de rotaci n apr
134. oximadamente unas 7 18 cm desde el punto de acoplamiento del impulsor del carrete y f jela en forma segura a la barra de mecanizado al ajustar la perilla de bloqueo Perilla C Ubique el manguito o adaptador cuadrado del impulsor de 1 2 12 7 mm adecuado sobre la tuerca del impulsor del carrete y luego coloque el eje cuadrado del impulsor en el manguito Ubique el mango del adaptador por sobre el eje del impulsor y coloque el montaje del adaptador del acoplador del impulsor dentro de este Finalmente ubique el adaptador de caucho sobre el adaptador del acoplador del impulsor Vea la Fig 21 Al sostener el eje cuadrado del impulsor firmemente en posici n con su mano izquierda podr mover los componentes a la derecha y colocar el acoplador de caucho dentro de la brida sobre la unidad del impulsor de rotaci n Cuando esto est hecho ajuste la perilla en forma de T sobre el mango del adaptador para sostener todas las piezas en su lugar 5 Finalmente vuelva a ajustar la unidad del impulsor de rotaci n si no est alineada NOTA No es necesario contar con una alineaci n perfecta pero debe acercar lo suficiente de manera que el acoplador se mantenga acoplado y que no se aplique un exceso de torsi n al carrete INSTRUCCIONES DE OPERACI N Continuaci n ADAPTADORES DEL IMPULSOR DEL CARRETE Esta rectificadora est equipada con un adaptador que transfiere la rotaci n del acoplador de la caja de engranajes del impulsor de rotaci
135. pot settings on both boards as of the SDC shown on Pages 25 See Adjustment Section Spin Drive Control SDC Board Setting PROBLEM Spin drive motor speed varies IR Comp trim pot not adjusted properly Torque to rotate the reel too high Check all terminal connections for tightness A See adjustment section for trim pot setting on Page 25 B Readjust bearing preload for the reel Maximum torque load 25 in lb to rotate reel C When 250 female spade terminals are not tight remove and crimp slightly together When reinstalling push on pressure should have increased for good contact If wiring is wrong correct and test Yes end of troubleshooting No Go to Step B next Check for 10 000 ohms Red wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Red wire to black wire Full CCW 10 000 ohms Full CW 0 ohms Yes Go to Step C next No Replace SSP Yes end of troubleshooting No replace SDC Original adjustment was not set properly Too much load on drive motor will cause motor to hunt and vary speed When connections are not tight the control board varies voltage to the DC motor which then varies speed PROBLEN Traverse Drive not working ELECTRICAL TROUBLESHOOTING Continued Assuming SSS System Start Switch is on with 120 volts AC to control panel and allother functions are working Verify all wires shown on the wiring diagram are correct and pull on wire termin
136. properly adjusted DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding DO always WEAR SAFETY GLASSES or some type of eye protection when grinding DON T DON T use a whee that is cracked HAS BEEN DROPPED or one that is damaged DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole if wheel won t fitthe machine get one that will DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURRS DON T TIGHTEN the mounting nut EXCESSIVELY DON T grind on the SIDE OF THE WHEEL see Safety Code B7 2 for exception DON T start the machine until the WHEEL 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 or to maintain dust level below the Threshold Limit Value for nuisance dust as classified by OSHA TABLE OF CONTENTS
137. r la correa La punta puede ajustarse de ser necesario para aumentar o disminuir la tensi n sobre la correa Consulte los ajustes en el manual de servicio para obtener m s detalles LAPUNTADE LAABRAZADERADE LA CORREASE AJUSTA EN LA F BRICA PARA PERMITIR QUE LACORREASE DESLICE SI EL CENTRO SE PONE EN UN ADELA CONTACTO CON ALGO SE DEBE MANECILLA DE ABRAZADERA TENER PRECAUCI N AL AJUSTAR ACOPLE DELA CORREA LONGITUDINAL LA PUNTA SI LA ABRAZADERA SE 2 en AJUSTA EN EXCESO LA CORREA NO SE DESLIZAR LO QUE PUEDE CAUSAR DA O ALA M QUINA O AL CARRETE INTERRUPTORES DE PROXIMIDAD LONGITUDINALES A an Dos interruptores de proximidad m viles determinan los DEL LIMITE l mites izquierdo y derecho del montaje del cabezal de pe Lime gt DERECHO rectificado Se enciende un LED sobre el interruptor DB 428 LONGITUDINAL cuando el cabezal de rectificado se acerca al cabezal SL DESVIADOR del interruptor de proximidad Los sensores se montan mi gt TR RB DEL POLVO en los soportes de proximidad ubicados en los ejes CENTRO Y RUEDA a longitudinales Los soportes pueden desplazarse ABRASIVADE ALIVIO f cilmente a lo largo de los ejes para realizar ajustes en los l mites de recorrido en forma r pida y f cil Cuando CENTRO Y cambie del modo de giro al modo de alivio deber n RUEDAABRASIVA levantarse los soportes de los ejes y volver a colocarse DE GIRO sobre los ejes en la posici n adecuad
138. r lo que parece ser un rectificado muy agresivo como si el avance tuviese un avance propio y luego una parada repentina del rectificado sin una rueda abrasiva que se ponga en contacto con el carrete Si esto ocurre la velocidad de rotaci n se configur demasiado alta y en efecto labr su rueda abrasiva Algunos carretes cuentan con un nivel de RPM de resonancia en el que el carrete se armoniza con la rueda abrasiva y la resonancia hace que la rectificadora vibre y d como resultado un rectificado de mala calidad Al cambiar la velocidad de rotaci n a un mayor o menor nivel de RPM saldr del rango de resonancia Luego de determinar la mejor velocidad en RPM para un carrete tome nota de las RPM en el Gr fico de configuraci n en la secci n NOTAS El Gr fico de configuraci n se encuentra al final de este manual Al tomar nota de las RPM correctas evitar tener que evaluar la velocidad de rotaci n la pr xima vez que rectifique el carrete Tambi n tome nota de la posici n del impulsor de rotaci n al utilizar las calcoman as de posici n sobre el montaje de rotaci n y documentar la posici n en el Gr fico de configuraci n AHUSAMIENTO RPM DEL IMPULSOR LONGITUDINAL El potenci metro de velocidad longitudinal puede ajustarse desde aproximadamente 5 pies por minuto 1 5 metros por minuto hasta 20 pies por minuto 6 metros por minuto Es recomendable que rectifique entre 15 y 20 pies por minuto
139. ra que este alerta de los posibles peligros de seguridad Siempre que vea estos simbolos siga sus instrucciones El S mbolo de advertencia identifica instrucciones o procedimientos especiales que si no se siguen correctamente pueden resultar en lesiones personales CONSERVE LOS PROTECTORES EN SU LUGAR y en buenas condiciones de operaci n QUITE LAS LLAVES Y OTRAS HERRAMIENTAS CONSERVE EL REA DE TRABAJO LIMPIA NO UTILICE EN ENTORNOS PELIGROSOS No utilice la rectificadora en zonas h medas o mojadas La m quina es solo para uso en interiores Conserve el rea de trabajo bien iluminada TODOS LOS VISITANTES DEBEN MANTENER DISTANCIA Todos los visitantes deben mantenerse a una distancia segura del rea de trabajo ACONDICIONE EL REA DETRABAJO PARAQUE SEA A PRUEBA DE NINOS con candados e interruptores principales NO FUERCE LA RECTIFICADORA Realizar un trabajo mejor y m s seguro si se utiliza seg n las especificaciones de este manual UTILICE LA HERRAMIENTA CORRECTA No fuerce la rectificadora ni ninguna pieza adjunta a que realicen un trabajo para el que no fueron dise adas UTILICE LA VESTIMENTA ADECUADA No vista indumentaria suelta guantes corbatas ni alhajas que puedan atascarse en las piezas en movimiento Se recomienda el uso de calzado antideslizante Utilice una redecilla protectora del cabello para contener el cabello largo SIEMPRE UTILICE GAFAS DE SEGURIDAD ASEGURE SU TRABAJO As
140. rection may be opposite of what is shown on the decal SPIN SPEED POTENTIOMETER DIAL RPM Adjusts the speed of reel rotation when you have the grind selector switch set at variable speed spin GUARD DOORS MUST BE SHUT FOR SPIN DRIVE TO OPERATE GETTING TO KNOW YOUR GRINDER Continued PUSH PULL EMERGENCY STOP BUTTON Push in to cut all power 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 MOTOR SWITCH On Off Turn the Spin Motor on and off GUARD DOORS MUST BE SHUT FOR GRIND MOTOR TO OPERATE RELIEF TORQUE DIAL Adjusts the Spin Drive Motor torque the torque holding the reel blade to the relief finger when Grind Selector Switch is set at variable Torque Relief GRINDING WHEEL MOTOR SWITCH On Off Turn the Grinding Wheel Motor on and off GUARD DOORS MUST BE SHUT FOR GRIND MOTOR TO OPERATE TRAVERSE MOTOR SWITCH Turns the traverse drive motor ON OFF TRAVERSE SPEED POTENTIOMETER DIAL FT MIN Adjusts the speed of the left amp right movement of the Grinding wheel TRAVERSE REVERSE SWITCH Reverses the direction of the grinding head if pushed when the head is moving GETTING TO KNOW YOUR GRINDER Continued FRONT AND REAR MOWER MOUNTING The mowing unit should be placed in the machine with the rear roller on the table and front roller held
141. roper installation of this product is the responsibility of the John Deere dealer Read manual instructions and safety rules Make sure all items on the Preparation Check List in the Operator s Manual are completed before releasing equipment to the owner TO THE OWNER Read this manual before operating your Frontier equipment Keep this manual handy for ready reference Require all operators to read this manual carefully and become acquainted with all adjustments and operating procedures before attempting to operate the equipment Replacement manuals can be obtained from you selling dealer The equipment you have purchased has been carefully engineered and manufactured to provide dependable and satisfactory use Like all mechanical products it will require cleaning and upkeep Lubricate the unit as specified Please observe all safety information in this manual and safety decals on the equipment For service your authorized John Deere dealer has trained mechanics genuine Frontier service parts and the necessary tools and equipment to handle all of your service needs Use only genuine Frontier service 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
142. rved could result in damage to result in personal injury or destruction of equipment KEEP GUARDS IN PLACE and in working 12 DON T OVERREACH Keep proper footing and order balance at all times REMOVE WRENCHES AND OTHER 13 MAINTAIN GRINDER WITH CARE Follow TOOLS instructions in Service Manual for lubrication and preventive maintenance KEEP WORK AREA CLEAN 14 DISCONNECT POWER BEFORE SERVICING DON T USE IN DANGEROUS ENVIRONMENT or when changing the grinding wheel Don t use Grinder in damp or wet locations Machine is for indoor use only Keep work area 15 REDUCE THE RISK OF UNINTENTIONAL well lit STARTING Make sure all switches are OFF before plugging in the grinder KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area 16 USE RECOMMENDED ACCESSORIES Consult the manual for recommended MAKE WORK AREA CHILD PROOF with accessories Using improper accessories may padlocks or master switches cause risk of personal injury DON T FORCE THE GRINDER It will do the job 17 CHECK DAMAGED PARTS A guard or other better and safer if used as specified in this part that is damaged or will not perform its manual intended function should be properly repaired or replaced USE THE RIGHT TOOL Don t force the grinder or an attachment to do a job for which itwas 18 KNOW YOUR EQUIPMENT Read this manual designed carefully Learn its application and limitations as well as specific potential hazards
143. s quality 12 Discuss reel grinder set up chart in manual 13 Review General Maintenance Safety IMPORTANT SAFETY MESSAGE FOR OWNERS OPERATORS OF REEL GRINDERS A Before operating a reel grinder an operator must read and understand all of the information in the owner s manual 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 manual and is not familiar with the equipment If you do 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 including bystanders are near you when you operate this product Following these simple basic safety rules as well as others 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 powerful piece of machinery and if used improperly serious injury or death may result The final responsibility for safety rests with the operator of this machine TO THE DEALER Assembly and p
144. s AC Yes Go to Step H next No Replace Filter Measure 120 VAC from MCB Terminal 01 MCB to Terminal Block 4 02TBW 4 blue use square hole Yes Go to Step I next No Check wires amp replace if needed Measure 120 VAC from MCB Terminal 03MCB to Terminal Block 4 blue O2TBW 4 Yes Go to Step J next No Flip Switch on MCB to ON Machine works end trouble shooting Machine does not work check MCB ELECTRICAL TROUBLESHOOTING Continued Possible Causes No 120 Volts AC power to Secondary Circuit Breaker SCB 6 Amp No 120 Volts AC power from Secondary Circuit Breaker SCB 6 Amp 120 Volts AC power not delivered to Terminal Strip Grinding Motor Switch GMS not working Spin Motor Switch SMS not working Bad Emergency Stop Switch ESS Bad System Start Switch SSS Low Voltage Relay REL not operating Bad Main Contactor MAG Checkout Procedure J Check for 120V to SCB K Check for 120V from SCB L Check for 120 Volts AC at terminal strip M Check for 120 Volts AC at GMS Terminals 1 switch must be in the off position N Check for 120 Volts AC at SMS Terminals 1 switch must be in the off position 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 in 8 pin socket R Hold in SSS and Check voltage at MAGA1 amp A2 Mea
145. s easiest with the relief head at the left side of the reel Once you have the Grinding Head positioned with a reel blade resting on the Fixed Relief Finger high point adjust the indexing finger stop There should be about 1 32 8mm to 1 16 1 5mm free play of the Index Finger to the back of the blade The Index Finger is spring loaded to the up position or against the back of the reel blade To check free play push down on the Index Finger See 24 If there is no free play of the Index Finger you want to rotate the Adjustable Index Finger Stop Position Knob counter clockwise If there is more 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 reel blade and allow traversing to the left without the blade hitting the side of the relief finger This position must also allow approximately 1 32 8 mm free play of the index finger when the blade is resting on the high point of the relief finger See FIG 24 Infeed the grinding wheel up until there is minimal clearance between the reel blade and the grinding wheel MOVABLE INDEXING INDEX FINGER STOP POSITION KNOB WHEELDIAMETER gt ADJUSTMENT ___ HANDLE RELIEF ANGLE ADJUSTMENT HANDLE INDEX FINGER FORWARD STOP POSITION SETSCREW OPERATING INSTRUCTIONS Continued RELIEF GRINDING CONTINUED Close the front and rear doors Tur
146. s min if roundness is varying MECHANICAL TROUBLESHOOTING Continued PROBLEM Uneven traverse speed or grinding stock removal from reel is irregular Possible Cause Linear bearings are damaged or have grit buildup causing uneven traversing load Grinding shaft or wheels have grit buildup causing uneven loading Left side traverse pulley is full of grit causing the pulley not to turn freely on shaft PROBLEM Traverse Belt Slips Possible Cause Clamping tip is not adjusted properly Too heavy a grind for traverse speed PROBLEM Too heavy a burr on cutting edge of reel blades Possible Cause Traverse speed set too high causing a heavy burr on the reel blade when spin grinding PROBLEM Cone shaped reel after grinding Possible Cause Grinding head travel not parallel to the reel center shaft PROBLEM Relief grind on the reel blades do not go the full length of the reel Possible Cause Need to adjust the finger stop Need to dress the Wheel to the correct angle Checkout Procedure Clean shafts and bearings according to the lubrication of Grinding Shaft and Linear Bearings instructions in the Maintance Section of the manual If problem persists replace linear bearings according to the replacement of linear bearings instructions Clean the wheel flanges and shaft see Lubrication of Grinding Shaft Replace flanges or shaft if necessary Clean and lubricate the shaft and pulley Checkout Procedur
147. should be ON If not remove wires 41SDCMOD and 44SDCCOM from SDC control board Machine works Yes Machine was in spin mode Check continuity of STS switch Replace if bad No Light next to TQ is ON but machine does not work go to step J Verify SPEED pot setting on the SDC board Should be set as specified on pages 24 and 25 Adjust if incorrect and check Relief Torque function Works Yes end of troubleshooting No go to Step K next Check for 10 000 ohms Red wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Red wire to black wire Full CCW 10 0000 ohms Full CW 0 ohms Yes go to Step L nest No replace RTP 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 board Motor works Yes end of troubleshooting No replace SDC ELECTRICAL TROUBLESHOOTING 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 Check potentiometer wiring for proper hookup See that speed pot is wired per electrical diagram B SSP 10K Remove 3 remote speed wires red wire to term 2 white wire to term 1 black wire to term 3 C Check all
148. sobre el dispositivo interruptor de regreso a la posici n de inicio Tambi n verifique el margen a los centradores de soporte de la l mina del carrete De ser necesario la parada de avance puede ajustarse Vea la Fig 25 Detenga el desplazamiento en la posici n de inicio y verifique que haya una indexaci n correcta de la l mina El control del impulsor longitudinal est configurado de f brica con un tiempo de permanencia de dos segundos antes de revertir el recorrido del carro Esto es para permitir que el carrete gire y el dedo de retenci n ndice sujete la l mina siguiente De ser necesario el tiempo de permanencia puede ajustarse consulte la secci n Ajustes del potenci metro del tablero de control en el Manual de montaje y servicio Encienda el motor del impulsor de rotaci n ya deber a estar encendido y el interruptor del motor de la rueda abrasiva Gire el potenci metro de velocidad longitudinal hasta la velocidad de rectificado adecuada Lentamente avance la rueda abrasiva hasta que sea capaz de rectificar la longitud total del carrete de manera uniforme Un avance t pico est entre 0 010 y 0 020 0 25 y 0 50 mm Aseg rese de haber rectificado todas las l minas antes de avanzar m s NOTA La velocidad longitudinal debe configurarse en aproximadamente 15 pies por minuto Si est quitando una peque a cantidad de material en los avances iniciales se sugiere configurar en velocidades longitudinales m s r pi
149. sure 120 from SCB 03SCB to nuetral blue terminal out of FTR O2FTRBU Yes Go to Step K next No Check wires amp replace if needed Measure 120 VAC fromSCB 67SCB to nuetral blue terminal out of FTR 02FTRBU Yes Go to Step L next No Flip Switch on SCB to ON Machine works end of troubleshooting Machine does not work check SCB Measure 120 VAC from Terminal 11 on Terminal Strip 2 07TB2 11 to nuetral blue terminal out of FTR O2FTRBU Yes Go to Step M next No Check continuity of wires 07 and 03 verify terminal block Jumper are installed on Grey Blocks 1 3 Measure 120 VAC from GMS Terminal 1 to nuetral blue terminal out of FTR 02FTRBU Yes Go to Step N next No Flip Switch and check again Works Switch is upside down Still no 120VAC Check wiring Verify Continuity Replace Switch Measure 120 volts AC from SMS Terminal 1 to nuetral blue terminal out of FTR 02FTRBU Yes Go to Step O next No Flip Switch and check again Works Switch is upside down Still no 120 Check Wiring Verify Continuity Replace Switch Measure 120 Volts AC from ESS terminal 2 to nuetral blue terminal out of FTR 02FTRBU Yes Go to Step P 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 nuetral blue terminal out of FTR 02FTRBU Yes Go to Step next No Check wire for continuity
150. t Washer 5NTK371501 3 8 Lock Washer 5 09054 Flat Washer 63 OD x 39 ID 5NT55492 Door Switch Spacer 5NT80406 Flat Washer 5 OD x 27 ID 5NT80418 Gas Spring Stud 5NT80421 Retaining Clip for Gas Spring 5NT3249153 Flat Washer 38 OD x 25 ID 5NT3706032 Ball Bearing R10 5NT3706097 Pulley 1 75 OD x 37 ID 5NT3706098 Pulley 1 50 OD x 25 ID 5NT3706099 Clevis Rod End 5NT3706100 Gas Spring 3 9 Stroke 5NT3706101 Cable Assembly 5NT3707029 Strain Relief Liquid Tight 19 30 Wire Dia 5NT3707647 Coded Door Magnet 5NT3708820 8 32 x 1 2 Long Button Head Safety Screw 5NT3708869 Spring Hinge 5NT3708998 Wave Spring 5NT3709597 Ball Bearing R4 5NT62091 65 Lower Guide Bar 5NT6329131 5NT6329133 Catch Pin 5NT6329136 Rear Slide Spacer Plate PARTS LIST REAR DOOR ASSEMBLY ZN W ISA gt PANA VAYA MANN A AA KS V 5 Ni REAL A ee AN DE 90 PARTS LIST REAR DOOR ASSEMBLY DIAGRAM PART NUMBER NUMBER DESCRIPTION 5NT6329163 Rear Door Arm 5NT63291 64 Pulley Block 5NT6329165 Door Switch Bracket Rear Door 5NT6329166 Cable Guide 5NT6329167 Bearing Block 5NT6329172 Rear Door Inner Slide 5NT6329173 Cable Bracket Door 5NT6329174 Rear Door Lift Handle 5NT6329175 Rear Door Stiffener 5NT6329177 Rear Door Sliding 5NT6329179 Rear Door Outer Plate 5NT632918
151. ter shaft ADJUSTMENT __ i i HORIZONTAL always make sure you are contacting an area free of dirt T KNOB 2 FORWARD AND HANDWHEEL and grass BACKWARD The digital gauge horizontal extension bracket is vertically MOUNTING HOLES adjustable to allow the digital gauge to be positioned to TOOLING BAR avoid any reel frame member In addition the mounting of POSITION the vertical slide to the horizontal weldment has three positions Removed the knob on the side to adjust the tilt of the vertical slide if necessary to avoid a reel frame member See FIG 14 HORIZONTAL Before aligning the cutting unit loosen the horizontal LOCKING T KNOB locking knobs on the tooling to allow the cutting unit to be adjusted in the horizontal plane See FIG 14 To align the cutting unit move the digital gauge assembly as far as possible to the left side of the reel Extend the digital gauge making sure the tip of the gauge is centered on the reel center shaft See FIG 15 With the gauge pressed against the reel center shaft set the gauge to zero Retract the gauge and move to the right side of the reel and measure to the center of the reel shaft Do not rotate the reel shaft except for a minimum amount if there are clearance issues to the reel blades With the gauge against the center shaft adjust the horizontal handwheel until the gauge reads zero Repeat adjustments going from one side to the opposite side until the alignment is within
152. then verify switch continuity If bad replace SSS contactor NO Measure 120 Volts AC from LVR term 8 to nuetral blue terminal out of FTR 02FTRBU Yes Go to Step R next No Check for 120 Volts AC from LVR term 6 to term 7 Yes Verify Continuity from term 1 to term 8 on LVR Replace LVR if bad No Verify Continuity of LVR Wires Measure 120 Volts AC from MAG Term 1 to Term 2 Yes MAG Should pull in with clunck if not replace MAG No Verify Continuity of Wires to MAGA1 and 2 ELECTRICAL TROUBLESHOOTING Continued PROBLEM Machine Shuts off when you turn on Grind motor switch or Spin Motor Switch Possible Cause Guard Doors are Open Door Safety Switches are not working properly No 24 Volts DC to Safety Monitor SSM No Power into 24 Volt DC Power Supply PWR No Power Out to Door Switches Rear Door Switch is Bad Front Door Switch is Bad Checkout Procedure A Close the front doors and rear door B Check alignment 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 testing voltages D Check PWR for 120 Volts AC Turn switches off and press start switch to pull in MAG before testing voltages E Verify 24 Volts DC out to door switches F With rear door closed verify 24Volts DC back from rear door switch G With front doors closed verify 24Volts DC back from front door s
153. tional workstation 1450 lbs 658 kg 1650 Ibs shipping weight 748 kg Precision heavy duty reinforced welded steel base Precision Ground Hardened Steel 1 000 Dia 25 4 mm 1HP AC Motor 3450 RPM 20 HP Fan Cooled Variable Speed DC Motor More than 75 Dba Less than 95 Dba Belt driven with easy to engage clamp system Safety grind motor and spin drive door interrupt switches Reversible Spin drive for variable speed Spin or variable torque relief functions Variable speed traverse control Manual Winch and Boom Kit Electric Winch and Boom Kit or Lift Platform GETTING TO KNOW YOUR GRINDER Continued CONTROL PANEL COMPONENT IDENTIFICATION Review the following control panel component descriptions before proceeding with the instructions 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 grinding motor switch and spin motor switch are turned off GRIND SELECTOR SWITCH Variable speed spin Switch must be up to perform spin grinding operations Variable Torque Relief Switch must be down to perform relief grinding operations SPIN DRIVE ROTATION SWITCH Forward Off Reverse This switch reverses the direction ofthe spin drive motor IMPORTANT Because the spin drive motor can be flipped on the horizontal adjustment arm the di
154. trol Board Settings 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 proximity 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 TDC between terminals 13 black wire and 15 brown wire Reason 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 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 Check wire connections from the switch proximity switches and tighten down screws A loose wire connection will give interm
155. vivador NO mueva la rueda abrasiva de lado a lado r INSTRUCCIONES DE OPERACION Cont i n 0 9e uo9 jee en seige epany s uod aqaq epan e oy9aJap e1a e7 ugioisod ej eey ej eloue ap e ols n ua BOO ap SO 95 U9IQUIB 3919y S9 911EI 50 y 98 1189 a919y e UOD JIPIOUIOD eied 5 s A SO esed aueln ap 27 8181169 euwe ey esed asjejsebsep en selge IVINION 9129 un 3093H r INSTRUCCIONES DE OPERACION Cont i n 0 02 U09 Jeo en seige epany s uod aqaq epan e oy9aJap e1a e7 ope odo jap UgIdISOd e ep s nbz ewelb ej eloue op s nbz O UOIDISOd ajuaJ O SIA
156. w the Threshold Limit Value for nuisance dust as classified by OSHA 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 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 power washer to clean the machine PASTOR Low Voltage Relay an The grinder is equipped with a high low voltage relay GREEN LIGHT which is factory preset at 100 140 VAC Ifthe power INDIGATES supply line does not deliver 100 140 VAC power under LOW VOLTAGE J load the relay will open and trip out the starter If this ee ene occurs your power supply line is incorrect and must be INDICATES correct before proceeding further with the grinder HIGH VOLTAGE DELIVERED GR o 02222 TABLE OF CONTENTS Safety Instructions Daily Maintenance Getting to Know Your Grinder Operating Instructions Reel Setup Chart DAILY MAINTENANCE BY THE OPERATOR On a daily basis clean the machine by wiping it off On a daily
157. witch PROBLEM MAG turns on only with System Start Switch held in Possible Cause MAG holding Checkout Procedure A Check wiring to and from MAG Machine works Yes end troubleshooting No go to Step B next See Alignment section of this Manual Machine works Yes end troubleshooting No go to Step C next Measure 24 volts DC from SSM Terminal A1 to Terminal A2 Yes Go to Step E next No Go to Step D next Measure 120 volts AC from PWR Terminal L to Terminal N Yes Verify 24 VDC out of PWR V to V Replace if no voltage out or check wiring amp verify continuity to SSM if there is 24 VDC No Verify wiring and continuity from PWR to terminal blocks Measure approximately 24 volts DC from Terminal Strip 1 Terminal 17 to Terminal Strip 2 Terminal 3 Yes Go to Step F next No Verify continuity of wires to Terminal strip Replace SSM if wires check OK Measure approximately 24 volts DC from Terminal Strip 2 Terminal 3 to Terminal Strip 1 Terminals 14 and 15 Yes Go to Step G next No Check Alignment of Rear door switch If no aa to Term14 or 15 then replace rear switch Measure approximately 24 volts DC from Terminal Strip 1 Terminal 17 to Terminal Strip 2 Terminals 2 and 4 Yes Replace SSM No Check alignment of front door switch If no voltage to Term2 or 4 after alignment then replace front switch Measure 120 Volts AC at MAG term L3 to Term Block 4 Blue after SSS is push
158. za el acoplador AET11038 H Cuenta con un eje externo de 11 dientes Utiliza el acoplador TCA12581 NOTA TAMBIEN PUEDE ATORNILLARSE CON UN MANGUITO HEXAGONAL DE 1 25 Cuenta con un eje externo de 9 dientes Utilice el acoplador AET11310 NOTA TAMBIEN PUEDE ATORNILLARSE CON UN MANGUITO HEXAGONAL DE 1 25 Cuenta con un eje externo de M16 X 2 Utilice una tuerca A31869 y atornille con un manguito hexagonal de 24 mm Utilice un perno UNF de 3 8 24 y atornille con un manguito hexagonal de 9 16 Cuenta con un eje de ranurado interno de 8 dientes Utilice la pieza AMT3022 para producir un adaptador Cuenta con un eje de ranurado interno de 11 dientes Utilice un manguito hexago nal de 1 25 o produzca un adaptador a partir de la pieza TCA18958 EQUIPAMIENTO TORO Toro utiliza una ranura hembra de 8 o 9 dientes sobre los carretes El ranurado hembra de 8 dientes puede atornillarse eficazmente con un adaptador del impulsor de manguito cuadrado de macho cuadrado de 3 8 a hembra cuadrado de 1 2 La ranura de 9 dientes requiere de un adaptador Nuestra recomendaci n es adquirir una herramienta Toro para adaptador n mero de pieza TOR 4074 disponible en K Line Industries Inc 315 Garden Ave Holland MI 49424 EQUIPAMIENTO JACOBSEN A continuaci n hay una lista de sistemas de atornillado sobre la base de las unidades de corte las unidades de carrete de 5 pueden atornillarse desde el extremo del motor no hidr ulico del carrete Instale u

ELECTRICAL TROUBLESHOOTING (Continued)

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