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Foley 460 Assembly And Service Manual

Automatic rotary blade grinder
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MODEL 460
AUTOMATIC
ROTARY BLADE GRINDER
PATENT NO. 7,329,172
ASSEMBLY
AND
SERVICE
MANUAL
WARNING
You must thoroughly read and understand this
manual before assembling or maintaining the
equipment, paying particular attention to the
Warning & Safety instructions.
1
4607955 (11-11)

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Summary of Contents for Foley 460

  • Page 1 MODEL 460 AUTOMATIC ROTARY BLADE GRINDER PATENT NO. 7,329,172 ASSEMBLY SERVICE MANUAL WARNING You must thoroughly read and understand this manual before assembling or maintaining the equipment, paying particular attention to the Warning & Safety instructions. 4607955 (11-11)

  • Page 2: Safety Instructions

    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 The Caution Symbol identifies special instructions or procedures which, if not strictly observed, could or procedures which, if not correctly followed, could result in damage to or destruction of equipment.
  • Page 3 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".

  • Page 4: Specifications

    This machine is intended for grinding the rotary blades from a rotary type mowing unit 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.

  • Page 5: Torque Requirements

    This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the 460 Rotary Blade Grinder. For those without that background, service can be arranged through a local distributor.
  • Page 6 When both front to back and side to side leveling The 460 Rotary Blade Grinder will require an operating procedures have been completed, thread the hex area of about 75" W x 75" D x 75" H (190 x 190 x 190 cm).

  • Page 7: Apply Power

    4600951, which includes a 230 to 115 Volt Step Down Transformer. See Details on page 8. The grinder is equipped with a high/low voltage IT IS RECOMMENDED THAT THIS 460 ROTARY relay (LVR) which is factory preset at 100 VAC BLADE GRINDER HAS ITS OWN PERMANENT low voltage trip and 140 VAC high voltage trip.

  • Page 8: Important Grounding Instructions

    ASSEMBLY INSTRUCTIONS (Continued) FOR 220-240 V 50 or 60Hz applications Product No. 4600951 should be ordered. 4600951 includes a 2 KVA 220-240 Volt Step Down to 110-120 Volt 50/60 Hz transformer which is prewired. The wiring diagram is shown in FIG. 5. The power cord has no connector.

  • Page 9: Maintenance And Lubrication

    MAINTENANCE & LUBRICATION DAILY MAINTENANCE IS SPECIFIED ON PAGE 6 OF THE OPERATOR'S MANUAL, AND IS TO BE PERFORMED BY THE OPERATOR. LISTED BELOW ARE PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY'S MAINTENANCE DEPARTMENT: 1. Monthly check fan air filter located on the left side panel, inside the grinding enclosure.

  • Page 10: Lubrication Frequency

    MAINTENANCE & LUBRICATION (Continued) LUBRICATION OF LINEAR BEARINGS STEP 1--Thoroughly clean the shafts. STEP 2--Flood spray the four shafts with a spray lubricant (Do not use teflon based lubricant) until the lubricant is dripping off the shafts. See FIG. 6 Then run the carriage back and forth through its full range of travel.
  • Page 11 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.
  • Page 12 ADJUSTMENTS TO REPLACE THE CARRIAGE LINEAR BEARINGS Outer Rail Bearings: 1. To replace the bearing on the top rail or bottom rail See Fig 7, first remove the grinding head. The Grinding head is secured to the Carriage base with 2 shoulder bolts and 2 adjustable handles. Then remove the screws for the bearing.
  • Page 13 ADJUSTMENTS (Continued) SPRING PLUNGER (ANGLE POSITION) Adjust the position of the spring plunger for a positive detent at each position, but still easily moveable. See FIG 8. SPRING PLUNGER FIG. 8...
  • Page 14 ADJUSTMENTS (Continued) PIVOT SHAFT CLAMP BLOCK ADJUSTMENT To adjust the return position of the center support assembly, loosen the clamp shaft nut. See FIG. 10 Disengage the relief release system from bar by rotating it. This will allow the center support assembly to rotate.
  • Page 15 ADJUSTMENTS (Continued) CAM PLATE ALIGNMENT SETSCREW SETSCREW To make adjustments to the cam plate start position loosen the nut located on the position setscrew and adjust the setscrew so that the relief slide bar pin CAM PLATE engages the cam plate smoothly. See FIG 12 After this is adjusted lock the setscrew in place by tightening the nut on the setscrew.
  • Page 16 ADJUSTMENT (Continued) TO ADJUST THE PROXIMITY SWITCHES For the proximity switches to work properly and reverse the direction of the carriage at each end of a traverse, a distance of 3/16 in. +/- 1/32 [4.75 mm +/- 0.75] must be maintained between the top of the switch and the actuator bracket on the bottom of the carriage.
  • Page 17 ADJUSTMENTS (Continued) TO ELIMINATE CARRIAGE INFEED BACKLASH If there is backlash in the carriage infeed system, there are two adjusting points to check: 1.Conical washer and Shaft Backlash nut: A. Remove rubber bellows retainer and pull back Infeed Screw bellows to get access to the Backlash Nut. Block Screws B.
  • Page 18 ADJUSTMENTS (Continued) POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL (TDC) (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. Max. Speed--Set at 2:30 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.

  • Page 19: Electrical Troubleshooting

    WIRE LABELS All wires on the 460 Rotary Blade Grindier 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: 01-118.
  • Page 20 460 MANUAL CONTROL PANEL IDENTIFICATION Relay Block 1-5 Traverse Drive (RB5) Control Board (RB1) (TDC) 3 Tier Terminal Block (TTB) 24 VDC Power Supply (PW1) for PLC Magnetic Contactor Programable (MAG) Logic Controller (PLC) Low Voltage Relay (LVR) Stepper Infeed...

  • Page 21: Electric Schematic

    ELECTRIC SCHEMATIC 4604511-1...
  • Page 22 ELECTRIC SCHEMATIC 4604511-1...
  • Page 23 ELECTRIC SCHEMATIC 4604511-1...

  • Page 24: Electric Diagram

    ELECTRIC DIAGRAM 4604522 ASB - AUTOMATIC START BUTTON CB1 - CIRCUIT BREAKER 1 ESS - EMERGENCY STOP SWITCH SIC - STEPPER INFEED CONTROLLER FTR - FILTER SSS - SYSTEM START SWITCH GMS - GRIND MOTOR SWITCH TBB - TERMINAL BLOCK BLUE GND - GROUND TERMINAL BLOCK TBG - TERMINAL BLOCK GREY IJS - INFFED JOG SWITCH...
  • Page 25 ELECTRIC DIAGRAM 4604522...
  • Page 26 THIS PAGE INTENTIONALLY BLANK FOR NOTE TAKING PURPOSES...
  • Page 27 ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--AC Main Power Controls: no electrical power to control panel. Verify all wires shown on the wiring diagram on pages 88 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 wire and terminal.
  • Page 28 ELECTRICAL TROUBLESHOOTING (Continued) Possible Causes Checkout Procedure No 120 Volts AC power L. Check for 120V from MCB MCB right terminal (03MCB--) to Neutral (Blue) from Main Circuit Breaker Terminal on FTR for 120 Volts AC (MCB) Yes--Go to Step M. next. No--Flip Switch on MCB to "ON"...
  • Page 29 ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Machine Shuts off 2 seconds after you turn on Grind Motor Switch. Possible Cause Checkout Procedure -Light on top should be steady red. Indicates A. Remove electrical box cover and Low Voltage Relay is energized. If the light turns off then watch LVR light on top of LVR comes back green then red this means the sensor has detected a trip mode and restarted.
  • Page 30 ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM-- Grinding Motors Don't turn on when GMS is switched to On. Possible Cause Checkout Procedure Machine works Guard Doors are A. Close the front doors Yes--end troubleshooting Open No--go to Step B. next Check alignment of door switch. Make Door Safety B.
  • Page 31 ELECTRICAL TROUBLESHOOTING (Continued) Possible Cause Checkout Procedure Measure 120 volts AC from RB1 terminal 11 J. Check voltage into RB1 and RB2 to terminal 21 and RB2 terminals 11 to 21 Yes--Go to Step K. next. No--Check wiring/Verify Continuity or wires to RB1 11 &...
  • Page 32 ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Traverse Drive not working in (manual) jog mode Assuming 115 Volts AC to control panel and all other manual mode functions are working. Possible Cause Checkout Procedure Traverse works Traverse Speed Pot (TSP) A. Set (TSP) to 35 on the control set to zero Yes--end troubleshooting panel...
  • Page 33 ELECTRICAL TROUBLESHOOTING (Continued) Possible Cause Checkout Procedure Bad Relay Block Relay L. Remove wires at RB4 & RB5 and Continuity when light is on verify continuity from terminal 11 to Yes--Reinstall wires, go to step M. next term 14 when Relay Block light is on. No-- Replace removable relay (TSP) (10K) is bad M.
  • Page 34 ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Traverse Proximity Switches not working in (manual) jog mode Assuming 115 Volts AC to control panel and all other manual mode functions are working. Possible Cause Checkout Procedure If incorrect, adjust per adjustment Gap between flag and prox A.
  • Page 35 ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Machine exhaust fan does not come on. (Machine must be on) Possible Cause Checkout Procedure Measure 120 volt AC across terminals at Bad Fan cord A. Remove cord at fan. Check cord plug. voltage across terminals. Yes-- Replace Fan No-- Go to step B.
  • Page 36 ELECTRICAL TROUBLESHOOTING (Continued) PROBLEM--Both Stepper Infeed not working in (manual) jog mode. Assuming 115 Volts AC to control panel and all other manual (jog) mode functions are working. Possible Cause Checkout Procedure Stepper motor works: Infeed Jog Switch is not A.
  • Page 37 Possible Cause Checkout Procedure Continuity from Terminal 5 to Terminal 6: J. Remove wire #70 on Terminal 5 Yes-Reinstall wires. Check continuity of and Wire #71 on Terminal 6. Press Wire #71, TTB10 and PLC inputs and hold IJS "In" button and check Cable.

  • Page 38: Parts List

    PARTS LIST 4609516 GUARD DOOR ASSEMBLY...
  • Page 39 PARTS LIST (Continued) 4609516 GUARD DOOR ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 ......... B160807 ....8-32 x 1/2" Long Button Head Socket Cap Screw 2 ......... B190813 ....10-24 x 1/2" Long Button Head Socket Cap Screw 3 ......... B250816 ....1/4-20 x 1/2" Long Button Head Socket Cap Screw 4 .........
  • Page 40 PARTS LIST (Continued) 4609515 CABINET ASSEMBLY...
  • Page 41 27 ........... 3708448 ..... Electrical Warning Decal 28 ........... 3709563 ..... Adjustable Leveling Bolt 29 ........... 3709613 ..... Star Knob 5/16-18 Female Threaded 30 ........... 3709926 ..... Foley United Decal 31 ........... 3889068 ..... Anchor Strap 32 ........... 4609056 ..... Frame Top Panel 33 ...........
  • Page 42 PARTS LIST (Continued) 4609514 TRAVERSE ASSEMBLY...
  • Page 43 PARTS LIST (Continued) 4609514 TRAVERSE ASSEMBLY PART DIAGRAM DESCRIPTION NUMBER NUMBER 1 ..........B190613 ....... 10-24 x 3/8" Long Button Head Socket Cap Screw 2 ..........B190811 ......10-24 x 1/2" Long Socket Head Cap Screw 3 ..........B191031 ....... 10-32 x 5/8" Long Socket Head Cap Screw 4 ..........
  • Page 44 PARTS LIST (Continued) 4609514 TRAVERSE ASSEMBLY...
  • Page 45 PARTS LIST (Continued) 4609514 TRAVERSE ASSEMBLY PART DIAGRAM DESCRIPTION NUMBER NUMBER 60 ..........4609118 ......Dust Shield 61 ..........B250616 ....... 1/4-20 x 3/8 Button Head Socket Cap Screw 62 ..........3708419 ......Wave Spring 63 ..........3706025 ......Eyebolt 64 ..........
  • Page 46 PARTS LIST (Continued) 4650520 GRINDING HEAD ASSEMBLY...
  • Page 47 37 ............. 3709809 ......Shoulder Bolt 3/8 Dia. x 3/8 Long 38 ............. 4609011 ......Roller Pivot Arm 39 ............. 4609013 ......Angle Clamp Plate 40 ............. 4609015 ......460 Boot 41 ............. 4609016 ......Infeed Screw Block 42 ............. 4609033 ......Boot Retainer 43 .............
  • Page 48 PARTS LIST (Continued) 4609550 CENTER SUPPORT ASSEMBLY...
  • Page 49 PARTS LIST (Continued) 4609550 CENTER SUPPORT ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 ............B190602 ......10-24 x 3/8" Round Head Machine Screw 2 ............B251011 ......1/4-20 x 5/8" Long Socket Head Cap Screw 3 ............B252011 ......1/4-20 x 1 1/4" Long Socket Head Cap Screw 4 ............
  • Page 50 PARTS LIST (Continued) 4609511 CONTOL PANEL ASSEMBLY...
  • Page 51 PARTS LIST (Continued) 4609511 CONTOL PANEL ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 ......... B250800 ....1/4-20 x 1/2" Long Thread Cutting Screw 2 ......... R000536 ....1/4 Lock Washer 3 ......... 80367 ...... 3 Position Selector Switch 4 ......... 3707009 ....Liquid Tight Strain Relief (for Wire Dia. .27 - .47) 5 .........
  • Page 52 PARTS LIST (Continued) 4609522 CONTOL PANEL SUB-ASSEMBLY...
  • Page 53 PARTS LIST (Continued) 4609522 CONTOL PANEL SUB-ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER NUMBER 1 ......... D160666 ....#8 x 3/8" Long Phillips Pan Head Self Tapping Screw 2 ......... R000480 ....#8 Lock Washer 3 ......... 3707163 ....Primary Ground Decal 4 .........