#202, 8704 – 51 Avenue Edmonton, Alberta Canada T6E 5E8 Turf Technologies
greensIRON 3000 DRIVE ROLLER INSTRUCTIONS FOR REAPPLYING COVER
1. Before You Start You have your materials and you have read these instructions, but there is no better instructor than experience. We recommend that you do a “practice” run – wrap the belting without the adhesive – as once the material is glued to the roller, it cannot be removed and re-applied. If this is your first time replacing the roll covering, we also recommend that you call our Plant Manager, John Gross, to address any questions you may have prior to application. He is located in Manitoba, Canada, which is in the Central Time Zone and can be reached at 204-746-6728. 2. Cement (Adhesive) The cement is a two-part material. You have received either 2 cans labeled SC2000 with 40g of hardener or 1 can of SC 4000 with 30g hardener. Each GreensIron 3000 drive roller will require 1 kilogram of cement and the applicable hardener. It should be mixed by pouring the hardener into the adhesive can and stirred with steel rod - wood is not recommended. The appropriate quantities can then be poured into a plastic pail for brushing onto the roller and the belting. Any excess must be kept sealed in the can between coats so that it will not set prematurely.
3. Roller Covering Material The roller covering material is identified by the manufacturer as "Pebble Top Roll Cover" and can be purchased in 4" (102 mm) strip widths. If you cannot find a local supplier, contact Wood Bay Turf Technologies to purchase. The length needed is 18'6" however we recommend you a 20' length (6 metres).
4. Preparation of the Roller After removing the drive roller from the GreensIron 3000, set it up on a stand (two saw horses will do) where it can be rotated as needed. The work area should be very clean. Manually remove whatever remains of the old cover and scrape off as much of the old cement as possible. The roller surface must be cleaned down to bare metal and therefore must be sand blasted to remove the balance of any old material and any grease or other contaminating materials on the surface. After blasting it must be kept very clean and handled only while wearing rubber gloves. This is to prevent oil from your hands getting on the roller surface.
Turf Maintenance Equipment Specialists Web Site: www.greensiron.com E-mail: woodbay@greensiron.com
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5. Procedure for Covering the Roller It is imperative that the work area is very clean. The belting material will have to be laid out on a long table, a clean floor section or a sheet of plywood (in this latter case it will have to be snaked around flat on the board). Place it with the fabric side up. Please refer to Picture #1. If you purchased the covering material from Wood Bay Turf Technologies, both ends will be cut at an angle – see Picture #1. If you purchased the material from an outside source, you will have to cut off a section at an angle on the starting end. Lay the belting out on the floor with the fabric side up (rubber down). Looking over the roller with the belting stretched behind you, measure up the belting on the right edge for about 22" (560 mm) - the circumference of the roller. Using a straight edge and a sharp utility knife cut off a triangular piece running from the left corner at the end of the belting to the mark you placed on the right edge. When you get to the point of winding the belting onto the drive roller you will have to line the angled cut edge up with the right hand end of the drive roller so it will wrap all the way around with about 1/8" (3 mm) sticking out beyond the end of the roller. Multiple coats of the adhesive must be applied to both the drive roller and the cover material before wrapping it on. The following sequence is recommended: •
Using a brush, apply the first coat of cement evenly on the drive roller and on the fabric side of the cover and allow it to dry completely. See pictures #2 through #5 – note drive roller in picture has been coated with primer – this is not necessary or recommended. Drying time at 66° to 70° F (19° to 21° C) at average humidity is 5 to 10 minutes. High humidity will increase drying time to about 30 minutes, and colder temperatures will further extend the drying time.
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Apply a second coat of cement to the cover material only and let it dry completely.
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Apply a second coat of cement on the drive roller (Picture #6) and a third coat of cement on the cover material and allow it to dry only until it is tacky. To test this wear rubber cloves and try touching a knuckle to the roller. It is ready when the cement is still sticky but does not come off on the knuckle. If a small bit of adhesive does come off when you first do the knuckle test, do not be concerned; it won’t affect the final result.
When the adhesive is tacky, bring the covering material up to the drive roller. Start wrapping with the end as show in Picture #7. The covering material is applied from right to left. Leave about 1/8” (3mm) of covering extending over the right side of the roller when you begin to wrap as shown in Picture #8. Rotate the roller as the material is guided straight onto it along the angled cut edge. Care must be taken while the covering is being wound on to roller to get a good spiral winding, to ensure that the material is uniformly tight (but not stretched), to avoid getting wrinkles in it, and to ensure that the edges are kept tight together (no gaps or overlapping). Please refer to Pictures #9 though #11. Never pull the cover material back from the adhesive to try and correct for gaps and overlaps—this will pull chunks of adhesive off the drive roller - you have only one opportunity to do it right.
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When the roller is completely covered, roughly trim the long piece of surplus belting off the finishing end. Fine trimming can be done later. As soon as the cover material has been applied to the roller, thoroughly peen it all over with a rubber-ended dead blow hammer or a very heavy rubber mallet. Start by spinning the roller slowly and peening between the seams. Then rotate the roller and peen along the seams. It is necessary to peen the entire surface to get a smooth finish and to get all of the air out from under the covering material. Please see Picture #12. After the peening, allow the drive roller covering to sit for at least 12 hours (24 hours is preferable) before further handling. Then use a sharp utility knife to carefully trim the excess materials away around both ends of the drive roller (refer to Picture #13). This is necessary to ensure no material will stick out to catch on anything or dig into the turf when using the roller. The drive roller is now ready to be installed back on the GreensIron 3000. Questions or Comments? We trust that these instructions have enabled you to apply the new cover on the drive roller of your greensIRON 3000 turf roller with a minimum of difficulties. If you have questions or comments, please let us know by telephone at 1-800-661-4942, e-mail at info@woodbayturftech.com or fax at 780-468-0059. We appreciate your assistance and thank you for choosing our products.
For further information call 1-800-661-4942 or 1-780-468-4378.
July 2006
#1 Layout Material – fabric side up
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#2 Adhesive on cover – 1 coat
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#3 Adhesive on cover – 1 coat
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#4 Adhesive on roller 1 coat
#5 Adhesive on roller – 1 coat
#6 Roller ready – 2 coats of adhesive
#7 Start wrapping from this end
#8 Apply from right to left – extend 1/8” over edge
#9 Wrapping
#10 Wrapping
#11 Wrapping
#12 Peening
#13 Trimming
#14 Final Product