When you need to see the parts moving to find the problem, get a helper to turn the flywheel, very gently, until it stops. Then have your helper turn the flywheel backwards until the knotter begins turning, then turn it forward again until it hits the obstruction. Repeat this over and over while looking at every moving part. Sometimes you can hear it when two parts make contact that are not supposed to. Since the clutch will not turn the knotter shaft backwards, you will need to clamp a pair of vise-grips somewhere on the shaft so you can turn the shaft backwards as your assistant turns the flywheel. My first thought was the plunger lock, but you specifically said knotter shear pin; but the plunger would have locked long before the needles got that high in the chamber. Also bothers me its doing the same thing after changing the knotter assembly. Without being there to see it we are kind of shooting in the dark, but I think rocking it back and forth against the obstruction you will eventually find out what is hitting.
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Today's Featured Article - Seeing an Old Friend - by Joe Evans. Dad had a concrete contracting business starting in 1960. One of his first pieces of equipment was a Ferguson TO-35 with a Davis loader. Dad replaced the TO-35 with a MF 202 Workbull, essentially an industrialized Ferguson 35 I am told. Dad bought the 202 new in 1962, and I recall quite clearly going to the dealer with him to sign for it.
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