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Neary 181 Service Manual

Auto - index spin / relief reel mower grinder
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- ORIGINAL INSTRUCTIONS -
181
AUTO - INDEX
SPIN / RELIEF
REEL MOWER GRINDER
Patent No. 6,010,394
6,290,581 & 6,685,544
SERVICE
MANUAL
YOU MUST THOROUGHLY READ AND UNDERSTAND ALL MANUALS BEFORE
OPERATING THE EQUIPMENT, PAYING PARTICULAR ATTENTION TO THE
WARNING & SAFETY INSTRUCTIONS.
18302 (3-2017)

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Summary of Contents for Neary 181

  • Page 1 - ORIGINAL INSTRUCTIONS - AUTO - INDEX SPIN / RELIEF REEL MOWER GRINDER Patent No. 6,010,394 6,290,581 & 6,685,544 SERVICE MANUAL YOU MUST THOROUGHLY READ AND UNDERSTAND ALL MANUALS BEFORE OPERATING THE EQUIPMENT, PAYING PARTICULAR ATTENTION TO THE WARNING & SAFETY INSTRUCTIONS. 18302 (3-2017)
  • Page 2 - ORIGINAL INSTRUCTIONS - IMPORTANT SAFETY MESSAGE As manufacturers of sharpening equipment, 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 this equipment.
  • Page 3 - ORIGINAL INSTRUCTIONS - TABLE OF CONTENTS Safety Message ......................2 Safety Instructions ....................3 -7 Service Data and Adjustments ................. 8 -17 Trouble Shooting ...................... 18 -35 Parts Diagram ......................36 - 61 Wiring Diagram ......................62 - 63 Wiring Schematic......................
  • Page 4 SAFETY INSTRUCTIONS - ORIGINAL INSTRUCTIONS - TO VOID INJURY, READ AND UNDERSTAND THE SAFETY ITEMS LISTED BELOW. IF YOU DO NOT UNDERSTAND ANY PART OF THIS MANUAL AND NEED ASSISTANCE, CONTACT YOUR LOCAL DEALER. 1. KEEP GUARDS IN PLACE and in working order. 13.
  • Page 5 - ORIGINAL 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".
  • Page 6 SAFETY INSTRUCTIONS - ORIGINAL INSTRUCTIONS - Carefully Read all the instructions below before attempting to operate or service your winch! Failure to comply with instructions could result in personal injury, death and/or property damage! 1. Maximum lifting capacity is 400 pounds (180 kg.) in 15.
  • Page 7 SAFETY INSTRUCTIONS - ORIGINAL INSTRUCTIONS - UNPLUG THE EQUIPMENT PRIOR TO DOING ANY SERVICE ON THIS EQUIPMENT. FAIL- URE TO REMOVE POWER TO THIS EQUIPMENT BEFORE SERVICING MAY RESULT IN INJURY OR DEATH. IF POWER IS REQUIRED FOR TESTING OR TROUBLESHOOTING, THIS SHOULD BE PER- FORMED BY A TRAINED PROFESSIONAL OR LICENSED ELECTRICIAN.
  • Page 8 SERVICE DATA - ORIGINAL INSTRUCTIONS - 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 Spin/Relief Grinder. For those without the background, service can be arranged through your local distributor.
  • Page 9 ADJUSTMENTS - ORIGINAL INSTRUCTIONS - CARRIAGE LINEAR BEARING REPLACEMENT STEP 1--Remove the four screws of one linear bearing and slide the linear bearing off the end of the carriage shaft. STEP 2--Insert a new linear bearing onto the end of the carriage shaft with the tension adjustment screw pointing outward.
  • Page 10 ADJUSTMENTS - ORIGINAL INSTRUCTIONS - SPIN GRINDING ATTACHMENT ADJUSTMENT The tension on the height adjustment screw can be adjusted by turning the adjustment setscrew. See FIG 3. If the screw moves during grinding, increase the tension on the screw with the adjustment setscrew. If there is too much play in the spin drive pivot points, torque down the hex nut until the conical washer is compressed, then back off 1/2 turn.
  • Page 11 ADJUSTMENTS - ORIGINAL INSTRUCTIONS - CROSS SLIDE SHAFT REPLACEMENT If the cross slide shafts become scarred or gnarled, replace them by the following procedure: STEP 1--Loosen the two nuts on the support casting that hold the locking studs and tap with plastic hammer to loosen.
  • Page 12 ADJUSTMENTS - ORIGINAL INSTRUCTIONS - 3/4” TRAVERSE BELT TENSION [19mm] To adjust the tension on the traverse belt tighten the screws and nuts located at the left side of the traverse belt. Tighten nuts until the compression springs measure 3/4" [19 mm]. See FIG. 8. If the springs are not tensioned equally, uneven loading on the traverse system may cause parts to fail.
  • Page 13 ADJUSTMENTS - ORIGINAL INSTRUCTIONS - BELT TENSION BELT DEFLECTION .12" The belt must be tensioned so when the lock handle is [3mm] WITH 10 LBS locked the maximum belt deflection is .12 [3 mm] at a [4.5 Kg] LOAD 10lb [4.5 Kg] load. FIG.
  • Page 14 ADJUSTMENTS - ORIGINAL INSTRUCTIONS - ALIGNMENT FIXTURE ADJUSTMENT The body of the dial indicator should be flush with the casting it is mounted in. The anvil should be able to be depressed fully without touching the casting. To adjust properly, loosen the set screw in the indicator mounting casting and adjust accordingly.
  • Page 15 ADJUSTMENTS - ORIGINAL INSTRUCTIONS - TO ELIMINATE CARRIAGE INFEED BACKLASH SHOULDER BOLT & BRASS NUT If there is backlash in the carriage infeed handwheel (See FIG. 14), there are two adjusting points to check: 1.Conical washers behind the shaft adjusting nut: A.
  • Page 16 ADJUSTMENTS - ORIGINAL INSTRUCTIONS - POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL (TDC) Min. Speed--Factory set at full (CCW) 8:30. Do not change this setting. (Right Traverse) Forward Torque--Factory set at full (CW) 4:30. Do not change this setting. (Left Traverse) Reverse Torque--Factory set at full (CW) 4:30. Do not change this setting. IR COMP--Factory set to 9:00.
  • Page 17 ADJUSTMENTS - ORIGINAL INSTRUCTIONS - SPIN DRIVE CONTROL BOARD (SDC) The Spin Drive Control Board has four potentiometers, two switches and one dial. These potentiometers,swtiches and dial have been set at the factory to the positions shown on Figure 17. In the Relief Grinding Mode-- The Torque Shut Off mode selector allows you to turn on or off the Torque Shut Off feature.
  • Page 18 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - CONTROL PANEL located on the right side of the machine. Traverse Drive Low Voltage Relay Control Board (LVR) FUSES 3A Slow Blow Terminal Strip #2 (TB2) Magnetic Traverse Drive Contactor Control Board (MAG) (TDC) Blue Terminal Blocks (TBB) Grey Terminal...
  • Page 19 SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING This Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowledge and skills to reliably test and repair the 181 electrical system. For those without that background, service can be arranged through your local distributor.
  • Page 20 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - - ORIGINAL INSTRUCTIONS - 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 lbs force to verify there are no loose terminal connections and/or no loose crimps between the wire and the terminal.
  • Page 21 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - Possible Causes Checkout Procedure No 120 Volts AC J. Check for 120V to SCB SCB (03SCB--) to nuetral (blue) terminal out of FTR for power to Secondary 120VAC Circuit Breaker (SCB) Yes--Go to Step K. next. 6 Amp.
  • Page 22 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM--(MAG) turns on only with System Start Switch held in. Possible Cause Checkout Procedure Measure 120 Volts AC at MAG term T3 to No Power to A. Check voltage to MAG holding Term Block 4(Blue) with E-Stop Pulled out. MAG holding contact in.
  • Page 23 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - Possible Cause Checkout Procedure F. Check spin motor Remove wires at Terminal Strip 1, Term 4 Spin Drive motor is continuity & 5 check 0 ohms across the black and white wires DISCONNECT POWER Yes--end troubleshooting, spin drive FROM MACHINE ! should run, if not, replace motor.
  • Page 24 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - 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 lbs force to verify there are no loose terminal connections and/or no loose crimps between the wire and the terminal.
  • Page 25 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - Possible Cause Checkout Procedure Board is in spin mode. J. Spin Torque Selector not work- Light next to TQ on SDC board should be ON. If not remove wires 41SDCMOD and 44SDCCOM from SDC control board. Ma- chine works.
  • Page 26 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM : Spin drive speed goes at one speed only. Possible Cause Remedy If wiring is wrong, correct and test. A. Check potentiometer wiring for Wiring hookup to potentiometer Yes--end of troubleshooting proper hookup. See that speed pot is improper.
  • Page 27 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM-- Machine will go to E-stop when the Grinding motor or Spin motor is turned on. Assuming (SSS) System Start Switch is on with 120 volts AC to control panel and all other functions are working.
  • Page 28 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - 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 3 lbs force to verify there are no loose terminal connections and/or no loose crimps between the wire and the terminal.
  • Page 29 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM--Traverse Drive not working. Assuming (SSS) System Start Switch is on with 120 volts AC to control panel and all other functions are working. Verify all wires shown on the wiring diagram are correct and pull on wire terminals with ap- proximately 3 lbs force to verify there are no loose terminal connections and/or no loose crimps between the wire and the terminal.
  • Page 30 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - Possible Cause Checkout Procedure Check (TDC) terminals #A1 to #A2 for 90 Volts No DC Voltage from (TDC) F. Check for 90 Volts DC across (TDC) Traverse Drive Control terminals #A1 to #A2 this voltage Yes--go to Step G.
  • Page 31 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM--Traverse does not stop to reverse directions when flag goes under the proximity switch on the left side or right side of machine. If incorrect, adjust per adjustment Gap between flag A. Gap between flag and section of manual.
  • Page 32 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM--Traverse speed control goes at one speed only. Possible Cause Checkout Procedure A. Check potentiometer on control Defective speed control Traverse Drive Control Pin #8 to 7 potentiometer panel. Pot full CCW Pot Full CW 0 VDC 9.75 VDC Pin #8 to 9...
  • Page 33 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM--If the carriage traverses to one end of stroke or the other and it stops and does not reverse direction. Possible Cause Remedy Reason Proximity switch is not First check to see of proximity light comes The light coming on shows the working properly or wire on.
  • Page 34 ELECTRICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM-- Power goes off when Grinding Motor or Spin Motor is turned on - Door Switch . Verify all wires shown on the wiring diagram are correct and pull on wire terminals with approximately 3 lbs force to verify there are no loose terminal connections and/or no loose crimps between the wire and the terminal.
  • Page 35 MECHANICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM--Reel ground concave, convex or with irregular shape. Possible Cause Checkout Procedure Too heavy a grind on the final grinding passes. Grind out reel using correct sparkout procedure as specified in the Operators Manual. Overhead clamps and tooling bar clamps not tight.
  • Page 36 MECHANICAL TROUBLESHOOTING - ORIGINAL INSTRUCTIONS - PROBLEM--Relief grind on the reel blades does not go full length. Checkout Procedure Possible Cause The right hand side of the grinding wheel is not in full The right side corner of the grinding wheel is contact for relief grinding.
  • Page 37 - ORIGINAL INSTRUCTIONS -...
  • Page 38 PARTS LIST 18527 CABINET ASSEMBLY - ORIGINAL INSTRUCTIONS - 16 18...
  • Page 39 PARTS LIST CABINET ASSEMBLY 18527 - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1 ....... B190809......10-24 x 1/2 Round Head Machine Screw 2 ....... B251016......Button Head Socket Cap Screw 1/4-20 x 5/8 Long 3 ....... B251216......Button HeadSocket Cap Screw 1/4-20 x 3/4 Long 4 .......
  • Page 40 PARTS LIST 18543 DOOR ASSEMBLY - ORIGINAL INSTRUCTIONS -...
  • Page 41 PARTS LIST 18543 DOOR ASSEMBLY - ORIGINAL INSTRUCTIONS - DIAGRAM PART DESCRIPTION NUMBER NUMBER 1....... B311013 ....... 5/16-18 x 5/8 Button Head Socket Cap Screw 2....... J161000 ......#8-32 Hex Nut 3....... J167000 ......#8-32 Locknut Thin 4....... J317000 ......5/16-18 Locknut Thin 5.......
  • Page 42 PARTS LIST 18518 CROSS SLIDE ASSEMBLY - ORIGINAL INSTRUCTIONS -...
  • Page 43 PARTS LIST 18518 - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1 ....... C250420 ......1/4-20 x 1/4" Long Socket Set Screw 2 ....... C311220 ......5/16-18 x 3/4" Long Socket Set Screw 3 ....... J371000 ......3/8-16 Hex Nut 4 .......
  • Page 44 PARTS LIST 27554 CHANNEL & TRAVEL - ORIGINAL INSTRUCTIONS -...
  • Page 45 PARTS LIST 27554 CHANNEL & TRAVEL - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1....... B160607 ....... 8-32 x 3/8 Button Head Socket Cap Screw 2....... B251211 ....... 1/4-20 x 3/4 Socket Head Cap Screw 3....... B252016 ....... 1/4-20 x 1-1/4 Button Head Socket Cap Screw 4.......
  • Page 46 PARTS LIST 18504 CARRIAGE ASSEMBLY - ORIGINAL INSTRUCTIONS -...
  • Page 47 PARTS LIST 18504 CARRIAGE ASSEMBLY - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1 ....... B191011......#10-24x5/8 Socket Head Cap Screw 2 ....... B250601......1/4-20x3/8 Hex Head Cap Screw 3 ....... B252016......1/4-20x1-1/4 Button Head Socket Cap Screw 4 ....... B253216......1/4-20x2 Button Head Socket Cap Screw 5 .......
  • Page 48 PARTS LIST 18520 GRINDING HEAD - ORIGINAL INSTRUCTIONS -...
  • Page 49 PARTS LIST 18520 GRINDING HEAD - ORIGINAL INSTRUCTIONS - DIA. PART PART DIA. PART PART NAME NAME 43 ..3709437 ... 3/8-16 Adj Handle 1 ..B191233 ..10-32 x 3/4 Pan Head Machine Screw 44 ..3709463 ... Rod End Bearing 2 ..
  • Page 50 PARTS LIST 6059550 INDEX FINGER ASSEMBLY - ORIGINAL INSTRUCTIONS -...
  • Page 51 PARTS LIST 6059550 INDEX FINGER ASSEMBLY - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1 ....... B190634......10-32 x 3/8 Long Button Head Socket Cap Screw 2 ....... B191031......10-32 x 5/8 Long Socket Head Cap Screw 3 ....... C190467 ......10-32 x 1/4 Long Socket Setscrew Nylock Cup Point 4 .......
  • Page 52 PARTS LIST 6009523 SPIN DRIVE - ORIGINAL INSTRUCTIONS -...
  • Page 53 PARTS LIST (continued) 6009523 SPIN DRIVE ASSEMBLY - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1 ....... 6329160 ......Motor Assembly , Electric 90 VDC .25 HP 2 ....... 3709586 ......Flange Coupler .50 3 ....... R000376......Square Key 1/8 x 1/8 x 3/4 4 .......
  • Page 54 PARTS LIST 6009527 REEL SET UP GAUGE ASSEMBLY - ORIGINAL INSTRUCTIONS -...
  • Page 55 PARTS LIST 6009527 REEL SET UP GAUGE ASSEMBLY - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1 ....... 6009089 ......Slide, Setup Gage 2 ....... 18003 ......Tube, Gage Slide 3 ....... 6009597 ......Tee Knob Assembly 2.25 lg. 4 .......
  • Page 56 PARTS LIST 18535 CONTROL PANEL ASSEMBLY - ORIGINAL INSTRUCTIONS -...
  • Page 57 PARTS LIST 18535 CONTROL PANEL ASSEMBLY - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1 ....... D250800 ....... 1/4-20 x 1/2" Long Thread Cutting Screw 2 ....... R000536......1/4 Internal Teeth Lock Washer 3 ....... see next page ....Control Panel Sub-Assembly 4 .......
  • Page 58 PARTS LIST 18534 ELECTRICAL PANEL SUB-ASSEMBLY - ORIGINAL INSTRUCTIONS -...
  • Page 59 PARTS LIST 18534 ELECTRICAL PANEL SUB-ASSEMBLY - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1 ....... D160666 ....... #8 x 3/8" Long Pan Head Tapping Screw 2 ....... D161266 ....... #8 x 3/4" Long Pan Head Tapping Screw 3 ....... R000480......#8 Lock Washer - External Teeth 4 .......
  • Page 60 PARTS LIST 18536 CARTON ASSEMBLY - ORIGINAL INSTRUCTIONS -...
  • Page 61 48 ..... B190614 41 ..... 6009052 ......Adapter 49 ..... 3709304 42 ..... 6009217 ......Drive Coupling Adapter 50 ..... 3709158 43 ..... 3709585 ......Sleeve Coupler 51 ..... 3706130 ......3730117 ......CD - Neary Training 181 52 ..... 3708025...
  • Page 62 PARTS LIST 18558 WINCH & BOOM - ORIGINAL INSTRUCTIONS -...
  • Page 63 PARTS LIST 18558 WINCH & BOOM - ORIGINAL INSTRUCTIONS - DIAGRAM NO. PART NO. DESCRIPTION 1 ....... B372801......3/8-16X1-3/4 Hex Head Cap Screw 2 ....... J371000 ......3/8-16 Hex Nut 3 ....... 3708647 ......7" Winch Handle 4 ....... J377100 ......3/8-16 Locknut Nylon Full 5 .......
  • Page 64 18437 WIRING DIAGRAM - ORIGINAL INSTRUCTIONS -...
  • Page 65 - ORIGINAL INSTRUCTIONS -...
  • Page 66 WIRING SCHEMATIC - ORIGINAL INSTRUCTIONS -...