MODEL 300 BACKLAPPER OWNERS MANUAL

MODEL 300 BACKLAPPER OWNERS MANUAL Neary Technologies 1173 Benson Street River Falls, WI 54022 1 Manual No. 30019 (7-07)

SAFETY INSTRUCTIONS Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards. Whenever you see these symbols, follow their instructions. The Warning Symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury. 1. KEEP GUARDS IN PLACE and in working order. 2. REMOVE WRENCHES AND OTHER TOOLS. 3. KEEP WORK AREA CLEAN. The Caution Symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. 13. MAINTAIN BACK LAPPER WITH CARE. Follow instructions in Service Manual for lubrication and preventive maintenance. 14. DISCONNECT POWER BEFORE SERVICING. 4. DON'T USE IN DANGEROUS ENVIRONMENT. Don't use back lapper in damp or wet locations. Machine is for indoor use only. Keep work area well lit. 5. KEEP ALL VISITORS AWAY. All visitors should keep a safe distance from work area. 6. MAKE WORK AREA CHILD-PROOF with padlocks or master switches. 7. DON'T FORCE THE BACK LAPPER. It will do the job better and safer if used as specified in this manual. 8. USE THE RIGHT TOOL. Don't force the back lapper or an attachment to do a job for which it was not designed. 9. 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. 10. ALWAYS USE SAFETY GLASSES. 11. SECURE YOUR WORK. Mount the cutting unit in place before back lapping as prescribed in the operators manual. 12. DO NOT OVERREACH. Keep proper footing and balance at all times. 2 15. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure the switch if OFF before plugging in the back lapper. 16. USE RECOMMENDED ACCESSORIES. Consult the manual for recommended accessories. Using improper accessories may cause risk of personal injury. 17. 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. NEVER LEAVE BACK LAPPER RUNNING UNATTENDED. TURN POWER OFF. Do not leave back lapper until it comes to a complete stop. 19. KNOW YOUR EQUIPMENT. Read this manual carefully. Learn its application and limitations as well as specified potential hazards. 20. 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. 21. DO NOT OPERATE THE BACK LAPPER WHEN UNDER THE influence of drugs, alcohol, or medication.

SAFETY INSTRUCTIONS This machine is intended for back lapping reel mowing 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 manufacturers 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. This machine is for indoor use ONLY. Do NOT power wash machine. SAFETY SYMBOL EXPLAINATIONS Symbols for Read operators manual, wear safety glasses and disconnect power before servicing. Symbol for sharp object which will cause serious injury. Symbol to keep visitors a safe distance away from the grinder. Symbol identifying a panel, cover, or area as having live electrical components within. DAILY MAINTENANCE BY OPERATOR On a daily basis, clean the back lapper by wiping it off. On a daily basis, inspect the back lapper for loose fasteners or components. Contact your company's Maintenance Department if damaged or defective parts are found. 3

MACHINE SPECIFICATIONS The Model 300 Back Lapping machine quickly sharpens the reels and bedknives of your mowers, giving them a fine cutting edge. It connects easily to most reel mowers and to gang mowers while still connected to the frame and tractor. STANDARD FEATURES PHYSICAL SPECIFICATIONS Drive coupler Socket driver assembly Two 6" [15.2 cm] x 6" [15.2 cm] x 15" [38.1 cm] height-adjustable support stands. OPTIONAL EQUIPMENT Trimmer adapter Greenmaster adapter Lapping compound Adapter bushings and Pawl Length Width Height Grinder motor Lapping speed Weight Sound 15" [38.1 cm] 16.5" [41.9 cm] 19" [48.3 cm].50-horsepower, 115/220-volt, 60/50-cycle, single-phase, reversing motor operating at 1725/1425 rpm 140/116 rpm 54 pounds [24.5 kg] Less than 75 Dba when lapping. Drive shaft permits back lapper to be connected to either right or left side of mower unit. T-handle permits drive shaft to be aligned to height of the mower units drive shaft. Height -adjustable support stands Drive Coupler Short bushings (optional) Socket Drive Assembly Pawl (optional) FIG. 1 4

OPERATING INSTRUCTIONS MOUNT THE MOWING UNIT ONTO THE SUPPORTS NOTE: For the mower units with drive wheels, lock out the pinion gear using the procedures appropriate for the mower. To stabilize the mowing unit while it is being sharpened, mount it onto the supports: 1. Adjust the height of the support stands so that the reel will be clear of the floor or bench. 2. Depending on the type of mower, place the heightadjustable support stands under either the front tie bar or the mower frame; the stands should be placed as far apart as possible. 3. For optimum performance of your back lapper, the front edge of your bedknife should be lower than the back of your bedknife. This is a better setup than is shown in FIG. 2. 4. If necessary, readjust the height of the support stands. Rear roller Drive shaft of back lapper Front roller While reel is turning, apply lapping compund with paint brush FIG. 2 5

OPERATING INSTRUCTIONS (Continued) CONNECT THE BACK LAPPER TO THE MOWER UNIT Before starting to connect the back lapper to the mower unit, please note the following points: * To connect the back lapper, it is necessary to have access to the reel drive of the mower unit. The procedure to gain access to the reel drive depends upon the individual mower unit; refer to the mower unit's service manual for the correct instructions. * To easily accommodate a wide variety of mower units, the back lapper can connect to either the right or left side of the mower unit, as indicated in FIG. 2. After obtaining access to the reel drive, use the following procedures to connect the back lapper to the mower unit: 1. Slowly spin the mower unit's reel by hand to make sure it spins freely. There should be no contact with the bedknife. If there is any contact, make the necessary adjustments, according to the mower unit's operating instructions. 2. Align the back lapper to the mower unit. First position the back lapper about 9" [22.9 cm] from the mower unit. Then loosen the T-handle and align the height of the lapper's power drive shaft to the height of the mower unit's reel drive. 3. Connect the drive coupler, socket drive assembly, and any other drive sockets or special adapters necessary to drive the mower reel, according to the order shown in FIG. 3. Note that there are several different connection combinations, depending upon the size of the reel drive of the mower unit. Use the following information to determine the appropriate combination for your mower: * If the reel drive of the mower unit is too small to fill the hole of the drive coupler of the back lapper, install an OPTIONAL short bushing into the reel shaft. OPTIONALLY available bushings include 1/2" (12.7 mm], 9/16" [14.3 mm]. and 5/8" [15.9 mm] bushings inside diameter.* If the mower unit's drive shaft has a slot at the end of the shaft, the OPTIONAL pawl is required. * The majority of mower unit manufacturers supply a hex drive for back lapping the mower. In addition, the manufacturer of the Model 300 Back Lapper also offers special adapters for certain mower units. They are available as optional parts and are included in the parts list in the Service Manual. Use the appropriate components for your mower unit. 4. Make a final adjustment of the height and distance alignment of the back lapper to make sure it is square to the reel drive of the mower unit. Use the T-handle to adjust the height of the lapper. Move the lapper closer to the mower unit to adjust the distance. 5. Connect the back lapper to the reel shaft of the mower unit. *Optional FIG. 3 NOTE: The coupler combination depends upon the mower unit. Use the appropriate combination for your mower. 6 * Short Bushings--Optional

OPERATING INSTRUCTIONS (Continued) SHARPEN THE MOWING UNIT KEEP HANDS AND LOOSE CLOTHING CLEAR OF THE MOWING EQUIPMENT AND WEAR SAFETY GLASSES WHEN THE BACK LAPPER IS OPERATING. 1. Select the appropriate lapping compound. The lapping compounds provided by the back lapper's manufacturer are 100% biodegradable. They are available in a wide variety of grits, so that every sharpening requirement can be met. 60 grit Fast metal removal for fairway mowers. 80 grit Regular maintenance of fairway and greens mowers and finish lapping. 120 grit Extra fine finish lapping of greens and tee mowers. 150 grit Ultra fine finish lapping of greens and tee mowers. 2. Plug the back lapper into the proper electrical circuit. Note the following information on grounding: The back lapper is equipped with an electrical cord having an equipment grounding conductor and a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded. If unsure of the proper electrical grounding, contact the electrical service technician within your company. DO NOT MODIFY THE PLUG PROVIDED; IF IT WILL NOT FIT THE OUTLET, HAVE THE PROPER OUTLET AND CIRCUIT INSTALLED BY A QUALIFIED ELECTRICIAN. 3. Turn on the back lapper so that the mower unit's reel turns backward from its normal cutting direction, as shown in FIG. 4. KEEP ALL VISITORS A SAFE DISTANCE FROM THE REEL AND LAPPER. Reel It is important to note that the "CW ROTATION" and "CCW ROTATION" labels on the toggle switch indicate the direction of the back lapper's motor; they do not indicate the lapping direction of the mower unit. 4. Using a long handled paint brush, apply the appropriate lapping compound to the rotating blades until the blade runs free. Then, adjust the mechanism that aligns the reel and bedknife. Continue applying the lapping compound and adjusting the reel to the bedknife until the radiused edges of the reel blades are reasonably square, as shown in FIG. 4. While adjusting the alignment of the mower unit's reel to the bedknife, make certain that the bedknife-to-reel adjustment is uniform across the entire width of the mower unit. Refer to the mower unit's operating instructions for the adjustment procedures. 5. Turn off the back lapper. 6. Uncouple the back lapper and mower unit. 7. Check the sharpness of the mower unit in three locations -- the left side, the center, and the right side. Use two thicknesses of newspaper approximately 1" wide. To be sufficiently sharpened, the mower unit must cut at least one thickness of the paper. It is important to use newspaper, not another type of paper, for verifying the sharpness because newspaper has a consistent thickness and indicates best how grass will cut. 8. Thoroughly rinse off all of the lapping compound from the mower unit, using a garden hose or water under medium pressure. BEFORE AFTER Back lapping direction Moving direction Bedknife Continue lapping until the radius edges of the reel and bedknife are reasonably square. 7 FIG. 4

GROUNDING AND MAINTENANCE INSTRUCTIONS UNPACK THE CARTONS Use care when unpacking. The back lapper is delivered assembled, ready to use. Miscellaneous parts are wrapped separately. Verify that they are in the shipping carton so that they are not discarded by mistake. Inspect all items for shipping damage as they are removed from the shipping containers. If you find any damage, notify the carrier's claims agent and do not proceed with unpacking until the damage has been inspected by the agent. Refer also to the "Shipping and Receiving Instructions" packed with the unit. 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 back lapper 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 back lapper, make sure it will be connected to a supply circuit protected by a properly-sized circuit breaker or fuse. 15 amp minimum for 115V applications. DO NOT MODIFY THE PLUG PROVIDED; IF IT WILL NOT FIT THE OUTLET, HAVE THE PROPER OUTLET AND CIRCUIT INSTALLED BY A QUALIFIED ELECTRICIAN. 115 VOLT MODEL ONLY. Plug the power cord into standard grounded receptacle as shown: 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. PERIODIC MAINTENANCE Monthly Quarterly - Inspect the unit for loose, worn or damaged components. Repair or replace any found. - Inspect belts for proper tension and cracks. Adjust or replace as required. 8

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ELECTRICAL INFORMATION 120 VOLT AC - AS BUILT Your machine has been built to operate on 120 volt AC power in the United States and other countries. NOTE: The back lapper has the three-position toggle switch for CW rotation, off, and CCW rotation. Note that the "CW ROTATION" and "CCW ROTATION" labels on the switch decal indicate the operating direction of the back lapper's motor; they do not indicate the lapping direction of the mower unit. 10

ELECTRICAL INFORMATION NOTE: This motor will correctly operate on 60 Hz or 50 Hz. 220 VOLT AC CONVERSION To convert this unit to 220 Volt 1 Phase, cut the plug off from cord and replace it with the appropriate plug for your locality. For plug and circuit breaker sizing, see motor nameplate rating. NOTE: Circuit should have breaker or fuse rated at 5 amp minimum for 220V application. Use only a qualified electrician. Rewire the unit as below: 220 VOLT: To convert the unit from 120 volt to 220 volt: 1. Remove Brown Jumper 3707669 and Light Blue Jumper 3707673. 2. Connect Brown L1 and Light Blue L2 Power cord wires to switch as shown. 3. Connect the black jumper wire 3707664 to the toggle switch terminals as shown above. 4. Cut the female terminals off the orange and white wires. Strip these wires.50" and connect to the black jumper wire 3707665, with a blue wire nut 3707077. 5. Connect the black jumper wire 3707665 to the toggle switch terminal as shown above. 6. Connect all other wires to the toggle switch terminals as shown above. 11

PARTS LIST MODEL 300 BACK LAPPER 30 29 12

PARTS LIST (Continued) DIA. NO. PART NUMBER DESCRIPTION MODEL 300 BACK LAPPER 1... 3649038... Adjusting Arm 2... 3649237... Handle 3... 6009535... T-Handle 4... 3659002... Drive Coupler 5... *3659003... Pawl 6... *3659006... 1/2" Bushing 7... *3659007... 9/16" Bushing 8... *3659008... 5/8" Bushing 9... 3659054... Drive Shaft 10... 3708440... Sheave with Set Screw - 7" 11... 3659039... Sheave with Set Screw 12... 3659047... Reduction Shaft 13... 3659010... Base 14... 3659542... Support Arm and Bearing Assembly 15... 3659543... Support Arm Assembly 16... 3659545... Shaft Housing Assembly 17... 3659546... Shaft Housing & Bearing Assembly 18... 3659550... Socket Drive Assembly 20... 3659553... Support Stand 21... 33008... Clamp Weldment 23... 3709088... Bronze Flange Bearing 25... 3707770... Electric Motor 1/2 HP -- Dual Voltage 26... 3659592... Motor Assy Dual Voltage Includes: 25, 41, 46, 47, 48, 49, 50, 51, 59, 62, 63, 64 27... 3709650... "V" Belt 28... 3709767... Rubber Support 29... 80398... Knob - T 5/16-18 x.79 Long 30... [Part of T Knob Item 29 above] 31... 3709875... Set Collar with Set Screw 32... 3708465....188 Dia. Blind Rivet 33... B310801... Hex Head Cap Screw 5/16"-18 x 1/2" Long 35... B311201... Hex Head Cap Screw 5/16"-18 x 3/4" Long 37... J317000... 5/16-18 Nylok Hex Locknut 38... R000551... 5/16-18 Kep Locknut 39... K310001... 5/16 Flat Washer 41... R000444... 7/8 Internal Tooth Lockwasher 42... *3659904... Trimmer Adapte 44... *3659906... Greenmaster Adapter 45... H251609... Drive Lock Pin 1/4 x 1 Long 46... 3659178... Electrical Box 47... 3707976... Conduit Connector 48... 3659177... Cover with Screws 49... 3707151... Box Connector... 3707152... Locknut - Conduit 1/2 [For item 49 above] (Not Shown) 50... 3707039... Cord Set 51... 3707668... Switch 52... 30032... Front Sheave Guard 53... 30033... Back Sheave Guard 54... 30034... Door 55... B250601... Hex Head Cap Screw 1/4-20 x 3/8" Long 56... D190660... Hex Head Sheet Metal Screw #10 x 3/8" 57... K250001... 1/4 Plain Washer 58... B311601... Hex Head Cap Screw 5/16-18 x 1" Long 59... 3708448... Warning Decal 60... 3659083... Bumper 61... 09366... Decal - Caution 62... 3707669... Wire Assembly - 2 loop Brown 63... 3707673... Wire Assembly - 2 loop Light Blue 64... 3659015... Switch Box Decal 65... 80151... Warning Decal 67... 3589106... Flat Washer.39" ID x 1.38" OD... *80166... Goggles Safety (not shown) *Optional Equipment 13