installation & service manual paradex® parallel shaft index drives
Contents
1. 8 10 5 11 16 5 1 Typical Output Shaft Torque Limiter 11 12 5 2 FSC Ferguson Slip Clutch 13 16 Maintenance 2 cecnciic dieser deeb tewe oes PEAR hee aaa 17 6 1 Using Correct Lubricants 17 6 2 Changing OW ses se mwr eee RWG Plas Dee ae ae eae ed aes 17 7 Troubleshooting 18 19 8 Repair Replace 20 28 8 1 Repair Replace Cam Followers All Models 24 8 2 Repair and Replace Cam Followers Removal 25 8 3 Repair Replace Oil Seals 26 27 9 Avoid 29 30 REFERENCE Unit configurations Reducer Mtg Positions Hand of Cam Drawing 31 SECTION 1 General Information The Industrial Motion Control IMC Paradex Drives engineered and manufactured to very high tolerances which necessitate careful inspection and maintenance Some users of indexing drives have the facilities and trained personnel to accomplish service repair You must determine the extent to which intricate servicing should be done in your own facility Wh2. RT CLUTCH RANGE SPRING SET NUMBER RT3 6001 1 100 175 RT3 6002 2 175 275 RT3 6003 3 250 350 RT3 6004 4 325 500 RT5 6001 1 500 850 RT5 6002 2 800 1700 RT5 6003 3 1600 3000 RT6 6001 1 1000 2700 RT6 6002 2 2500 5000 RT6 6003 3 4000 8500 RT8 6001 1 4000 9500 RT8 6002 2 6000 15500 CHART 2 SECTION 5 Adjustments continued 5 2 FSC Ferguson Slip Clutch Location Map NOTE Only available with R amp SHV Series Gear Reducers O a 4 5 8 8 3 2 2 lt Thrust Bearing 1 3 4 5 Silicon Spring 6 Adjusting Nut 7 Guide Pin 8 Spool 9 2227227 52 4 SS 11 Setscrew 12 Pipe Plug Housing 22 Body amp Cone Ball Plunger 10 Liner Bushing FIGURE 5 14 SECTION 5 Adjustments continued 5 2 1 5 2 2 Clutch Adjustment Description The clutch must be adjusted to prevent any slippage during normal operation to prevent shock loading It should also not be adjusted so tight as to be able to damage the indexer during a jam or overload However it is best to err on the side of being tighter than required The proper setting for the clutch is determined by gradually tightening the clutch adjusting nut until the clutch no longer slips in either direction during a complete fully loaded index cycle at normal speed Shut off Spool Use amp Adju
3. 8 3 1 8 3 2 8 3 3 8 3 4 8 3 5 8 3 6 8 3 7 8 3 8 8 3 9 8 3 10 Remove oil seals by drilling a number of holes into the case The seal may then be removed with a pointed tool Be sure to remove all metallic chips created during the drilling of removal holes Check dimensions to be sure that shaft and bore diameters match those specified for the seal selected Check seal for damage that have occurred prior to installation A sealing lip that is turned back cut or otherwise damaged should be replaced Check bore to see that the leading edge is deburred a rounded corner or chamfer should be provided Check shaft remove surface nicks burrs and grooves and look for spiral machine marks that can damage the seal lip Check shaft end remove burrs or sharp edges The shaft end should be chamfered Check splines and keyways smooth any sharp edges and when necessary protect the seal lip with an assembly sleeve or shim stock Round the edges of the spline or keyway as much as possible and lubricate with a hard fibrous grease Check seal direction make sure that the new seal faces in the same direction as the original Generally the lip faces the lubricant or fluid to be sealed Pre lubricate the sealing element before installation by wiping with lubricant being retained Use the correct installation tool press fitting tools should have an outside diameter 010 smal
4. C Excessive worm speed Replace Replace inspect holes in roller gear shaft Replace cam followers and fill Flush out when replacing oil Contact Technical Services at 800 645 5207 or 847 459 5200 Contact Technical Services at 800 645 5207 or 847 459 5200 Contact Technical Services at 800 645 5207 or 847 459 5200 Contact Technical Services at 800 645 5207 or 847 459 5200 Reduce worm speed SECTION 7 Troubleshooting continued TROUBLESHOOTING GUIDE Symptom Cause Solution OIL LEAKS AT Seals Worn or damaged seal Replace seal polish shaft and or shaft surface Shims Damaged shim Replace apply Loctite Aviation Grade Sealant to both sides Cap Screws Shim damaged between screw Replace gasket or shim apply Cover joints Oil service pipe fittings hole and interior of housing Holes drilled through Inadequate sealant Not properly sealed Loctite Aviation Grade Sealant to both sides Remove screw apply Loctite Threadlocker and re install Remove clean and reassemble with silicone rubber sealant Remove clean and reinstall with Loctite Teflon Pipe Sealant NOTE In the event that damage is found it is recommended that the unit be returned to the factory for repair or that an Industrial Motion Control representative make or supervise repairs in your plant Proper alignment and adjustment of the components are essential to their performan
5. Michigan USA 248 836 6700 marketing destaco com www destaco com This publication is for information purposes only and should not be considered a binding description of the product except is confirmed in writing by Industrial Motion Control LLC DE STA CO DE STA CO Europe Germany 49 6171 705 0 europe destaco com DE STA CO Asia Thailand 66 2 326 0812 info destaco com DE STA CO South America Brazil 0800 124070 samerica destaco com DE STA CO 2004 2014 All rights reserved Printed in U S A SKU 0107 REV 7 1 03
6. always provide the following information 1 5 1 The serial number shown on the nameplate Refer to Inside Front Cover 1 5 2 clear description of the problem including as much detail as possible of the circumstances leading up to the problem Returning Unit for Repair Please contact the Repair Department in Wheeling Illinois at 847 459 5200 for a Return Material Authorization Number RMA The following information is required of a unit for repair conversion or warranty 1 Purchase order number 2 Customer name 3 Customer billing address 4 Customer shipping address 5 Person to contact upon inspection with delivery and price 6 Telephone number 7 Model number located on name plate 8 Serial number located on name plate 9 Description of defects problems or circumstances The IMC Repair Department will assess repairs by phone and estimate inspection fees or repair costs Non warranty inspection fees will vary depending on the size of the unit and optional equipment mounted These fees apply only if customer decides not to repair or replace subject unit Please return IMC equipment only remove sprockets pulleys etc This will reduce the amount of disassembly time saving customer cost on labor and will provide faster evaluation for quoting price and delivery of repair or conversion Oil must be drained before shipping Package unit to protect it from weather or damage during shipping Place
7. 1 847 459 5200 FAX 1 847 459 3064 or EMAIL techservice camcoindex com If you need to contact a sales representative in your area you can log on to our web site www camcoindex com and go the section labeled Find a local Rep to find the sales office that is nearest to you At Industrial Motion Control it is our policy to provide the highest quality products that meet or exceed our customer s requirements In order to achieve this commitment Industrial Motion Control has documented its policies and procedures to be in compliance with ISO 9001 Table of Contents Section Page 1 2 4 Ei Se eth ee ie ate 2 ta E E Sete tae A 2 3 1 3 Operating Environment 3 1 4 Ordering Replacement 5 3 1 5 Reguesting SEVICE oe nee deed bebe eae ee ee het 4 1 6 Returning a Unit for Repair 4 2 OVERVIEW ie iS Are Been oe we be ee ale Gk PAS 5 6 21 ParaDex Location Map amp Parts 5 2 2 Ferguson Reducer Location Map amp Parts List 6 3 Specifications 7 4 Installation
8. before the worm shaft is installed 8 4 1 1 3 1 The correct relationship of the worm and gear must be maintained when reassembling the components Regardless of the actual position of the reducer unit on the roller gear drive or Intermittor housing you must imagine that the worm is over the gear and that you are viewing the worm from the single extension end the end opposite of the splines on the worm shaft with the unmarked face of the gear to your right Maintain this relationship between components when installing the gear on the roller gear camshaft 25 26 SECTION 8 Repair and Replace continued 8 4 1 1 3 2 8 4 1 1 3 3 8 4 1 1 3 4 8 4 1 1 3 5 8 4 1 1 3 6 The distance from the finished face of the housing to the unmarked face of the gear noted at the time of disassembly must be duplicated either by grinding the adjusting spacer or adding shims see Figure 8 Tighten the clamp screw in the split hub of the gear and assemble the gear retaining screw and washer if such were provided as part of the factory installation Press cones of the tapered bearings onto the worm shaft and insert the worm shaft in the housing Assemble bearing cups shims and caps and establish pre load 2 IN LBS 003 SHIM Adjust shims under bearing cups until the dimension between the worm bearing shoulder and the finished housing bore as recorded at the time of disassembly is duplicated see Figure 8 NOTE Do not disc
9. the RMA on the outside of the packaging for prompt service Ship Warranty units via surface freight collect Ship Non Warranty units to IMC transportation prepaid IMC will not accept collect shipments on non warranty repairs Ship to Industrial Motion Control LLC 1444 South Wolf Road Wheeling Illinois 60090 USA SECTION 2 Overview The sketches contained in this document are for illustrative purposes only They are intended to shown depending upon options chosen or the particular configuration of a unit 2 1 Location Map FIGURE 1 ParaDex Parts List 1 Housing 6a Cam Follower Bearing 13 Pipe Plug 2 1a Housing Halves 6b Cam Follower Stud 14 Adapter 1b Threaded Inserts Nutsert 7 Double Row Ball Bearing 4 15 90 Street Ell 1c Socket Head Cap Screw 8 Shaft Seals 4 16 Socket Head Cap Screw 5 Long 9 Snap Ring 2 Cam 2 Output Shaft 10 O Ring 2 17 Set Screw 3 Cam Shaft 11 Oil Gage 18 Dowel Pin 4 Cams 12 Vent 19 Threaded Insert Nutsert 5 Eccentric Bushings 2 SECTION 2 Overview continued 2 2 Ferguson Reducer Location Map Indexer Input FIGURE 2 Ferguson R Series Reducer Parts List 1 Housing 10 Closed End Cap 2 Ring Gear amp separate spider 11 Screws for some units 12 Shim Pack 3 Pinion Worm Gear 13 Timken Bearing 4 Gear Spacer 14 Open End Cap 5 for Indexer Shaft 15 Oil Seal 6 Arrestor Washer 16
10. Automation Robohand FERGUSON INSTALLATION amp SERVICE MANUAL PARADEX PARALLEL SHAFT INDEX DRIVES WARNING This is a controlled document It is your responsibility to deliver this information to the end user of the CAMCO or FERGUSON product Failure to deliver this could result in your liability for injury to the user or damage to the machine For copies of this manual call your Customer Service Representative at 800 645 5207 INTRODUCTION This manual is supplied to aid in the installation and maintenance of your Ferguson brand index drive When contacting Industrial Motion Control please have the serial number of your unit available This number can be found on the serial number tag To determine the model number and the ratio of a Ferguson reducer refer to the tag located on the reducer housing If the reducer is by another manufacturer refer to that manufacturer s nametag located on the reducer housing Unit configurations reducer mounting positions and hand of cam nomenclature can be found inside the back cover of this manual These will aid in describing your unit Industrial Motion Control provides factory rebuild or repair services at our centrally located Wheeling IL facility Industrial Motion Control can also provide technicians or engineers for field service calls worldwide If you have any questions or problems please feel free to contact our Technical Service Department at 1 800 645 5207 or
11. Wear Sleeve 7 _ Lockwasher 17 Cover Plate 8 Cap Screw Keeper 18 Cap Screws 9 Cap Screw for Clamping Hub 19 Oil Plugs SECTION 3 Specifications x D x Te 5 5 a e a 2 2 5 a 5 SE IE I IR BE _ 2 Q 2 ZA 5 5 a 56 gt om ay g 0 3 9 8 of 5 B eS jogjog 2 z lt 5 5 2 5 29 e 05 res 4 m 5 8 8 lt o 28 52122 8 as S 2 a5 Sal 5 E gt ns 0 2 gt O D gt D P200 N A N A N A RT3 N A N A N A 20 N A N A MDB625 P325 20CDSF 1 2 HP N A 5 13 60 95 120 with 1 2 HP MDB625 P400 26CDSF 1 2 HP RT5 N A 1 32 85 140 165 with 1 2 HP MDB625 P500 6SF 1 2 RT6 N A 1 2 QTS 110 195 220 with 1 HP MDB875 P600 30SHV 1 5 2 RT6 N A 1 5 2 5 QTS 160 235 295 with 1 5 HP MDB1125 P750 R5 3 HP2 N A R5FSC 3 5 2 5 GAL 500 635 815 with 5 HP P1050 60SHV N A N A 6 5 6 3 7 GAL 750 950 N A P1400 7OSHV N A N A 7 5 13 6 5 GAL 1100 1380 N A P1700 100SHV N A N A N A N A 27 19 GAL 3000 3550 N A CHART 1 Requires face reducer 180 V DC Weights are approximate less crating 4 Refer to section on lubrication for specifications of lubricants Amounts a
12. ack the occurrence of jams and when possible rectify the condition that led to the jam A high jam frequency will shorten indexer life 27 28 SECTION 9 THINGS TO AVOID continued Friction from any source adds to the load of an indexer This can include cam driven mechanisms and or additional ancillary devices driven off the indexer s drive shaft or output Extreme build up of contamination or other sources of interference adds to the frictional load Industrial Motion Control indexers handle frictional loads very well but the loading must be evaluated in terms of the indexer s overall capacity to ensure that the life of the equipment will not be compromised IMPROPER LUBRICATION CAN RESULT IN IMMEDIATE CATASTROPHIC FAILURE OF THE UNIT Contact Industrial Motion Control Technical Sales Department 1 800 645 5207 or 847 459 5200 or your local Sales Engineer for assistance when evaluating the above conditions UNIT CONFIGURATIONS REDUCER MOUNTING POSITIONS HAND OF 5 Right Hand 51741 Left Hamd Cam a Bhat Fanga Sa 29 Aone court Automation Robohand FERGUSON Camco CAMCO amp FERGUSON Products 1444 South Wolf Road Wheeling IL 60090 USA ph 847 459 5200 toll free 800 645 5200 fax 847 459 3064 camco destaco com ISO 9001 2000 Registered DE STA CO Headquarters Auburn Hills
13. ard any of the shims Make adjustments in pre load by shifting shims from one bearing cup to the other Replace cover plate and refill with oil Refer to Chart 1 amp 3 for quantity and specification 8 3 2 Winsmith Worm Gear Reducer 8 3 3 NOTE Due to its modular and hollow shaft design it is not considered economical to replace componenis only in these reducers Except for seal or other oil leak problems replacement of entire reducer is recommended Brison Gear Motor NOTE May come with 1 11 HP or 1 4 HP motor depending on reducer ratio It is not considered economical to repair or replace components only Replacement of the entire product is recommended SECTION 9 THINGS TO AVOID An Indusirial Motion Control Indexer is a relatively simple mechanism using an input shaft mounted cam to drive roller followers on the output hub While simple in concept the precision nature of the indexer requires that it must be used within design constraints The indexer is after all just a mechanical device In this regard there are several situations which should be avoided to protect your warranty and maximize indexer life Off center loading such as might be seen when a large press is used in conjunction with an indexer requires a back up support anvil under the dial The bearings of an indexer are very heavy duty but their life will be shortened dramatically by unsupported asymmetrical loading The support anvil is typically desig
14. cations grease fittings are not supplied since oil splash supplies the lubrication Should grease be specified use Lithium No 2 Indexer Oil Use SAE 90 EP Gear oil or equivalent meeting MIL PRF 2105E and API Service Classification GL5 or GL6 For example Mobilube HD 80W 90 Capacity See specifications in Chart 1 for your model Gear Oil Bronze Gear Reducer oil requires SAE 140 Steam Cylinder Oil meeting AGMA 8 Compound MIL SPEC MIL L 15016A symbol 3150 Or manufacturer s specified oil if a Industrial Motion Control manufactured reducer Capacity See specifications in Chart 1 for your model CHART 3 17 18 SECTION 7 Troubleshooting TROUBLESHOOTING GUIDE Symptom Cause Solution Backlash at output shaft in dwell Tight Stations torque required to rotate cam shaft through tight station is more than 1 1 2 times the loose station Pitting of cam follower outer race cam track surface Fine magnetic metallic particles in oil appear bronze color when in oil REDUCER Excessive Backlash Overheating in Excess of 210 F Worn damaged followers Bent cam followers Incorrect oil unit with correct oil Steel and iron worn from bearing roller ends and cages and cams surface this is a normal condition A End play in worm shaft B Loose gear on camshaft A Improper preload on worm shaft bearings B Incorrect alignment of worm and gear
15. ce and life 19 20 SECTION 8 Repair and Replace 8 1 Cam Follower Replacement All Models 8 1 1 Drain oil amp rotate the input shaft so that indexing cam is approximately in center of dwell position See Figure 3 Set unit on side opposite cap screw heads of screws holding the two housing halves together Remove cap screws and tap top half of housing to break sealant loose and remove top of housing Follow steps in Figure 7 to remove cam followers from hub assembly After changing cam follower set remove all sealant from housing halves Apply new silicone rubber sealant bead up to the seals and assemble two housing halves with cap screws removed in 8 1 3 Tighten all screws evenly Refill with oil to level indicated SECTION 8 Repair and Replace 8 1 Cam Follower Removal Procedure 8 2 1 Rotate input shaft until farthest cam follower stud is clear of housing 8 2 2 Remove locking set screw from hub plate 8 2 3 With soft punch drive follower stud by going through open hole in hub plate 8 2 4 Remove and discard old cam follower and inspect stud for wear 8 2 5 Reverse procedure to install new bearing 8 2 6 Rotate camshaft until complete follower set has been changed 8 2 7 Continue with step 8 1 5 0 1222 22 FIGURE 7 TIE 21 22 SECTION 8 Repair and Replace continued 8 3 Oil Seal Replacement
16. cuitry for proper operating conditions The indexer can now be powered up and production resumed SECTION FIGURE 6 5 Adjustments continued 5 2 3 Clutch Adjustment Procedure CAUTION OPERATIING THE INDEXER WITH THE CLUTCH NOT ADJUSTED CAN CAUSE IMMEDIATE AND SEVERE DAMAGE THE INTERNAL COMPONENTS OF THE INDEXER a Loosen cone point setscrew number 11 Figure 5 b Insert pins of spanner Figure 6 into holes of adjusting nut number 6 Figure 5 and turn nut clockwise one notch in the adjusting nut This will tighten the clutch NOTE For heavy indexing loads or clutches on large units it may be necessary to increase the length of the spanner wrench to gain more leverage If clutch has not been adjusted for a long period of time it may be necessary to turn the nut counter clockwise several turns and tap the face of housing number 1 Figure 5 towards the indexer with a rubber mallet to separate loosen the tapers Take note of the number of loosening turns so the adjusting nut can be re tightened to its original position Re tighten setscrew number 11 Figure 5 making sure it engages in adjusting nut number 6 Figure 5 to prevent damage to screw threads NOTE If setscrew number 11 Figure 5 is accidentally tightened on threaded portion of adjusting nut number 6 Figure 5 it will raise a burr Failure to remove this burr will cause shearing of threads and jamming of nut of housing number 1 Figure 5 T
17. en in doubt IMC recommends that IMC trained servicemen make the repairs 1 1 Warranty Products are warranted as follows 1 1 1 Our products are warranted for one 1 year from the date of shipment to be free from defects in workmanship and materials The foregoing warranty is exclusive and in lieu of all other warranties whether written or orally expressed or implied and there are no warranties of merchantability or fitness for particular use Our obligation under the foregoing is limited to replace free of charge including the lowest transportation cost but not including installation or any other charges any part that our inspection shows to be defective provided that the part was properly installed suitably maintained and not subject to misuse or abuse and further provided that the defective parts are returned to our plant within one 1 year after delivery by us Written permission for such return must first be obtained from IMC A complete explanation is required of the alleged defects and circumstances 1 2 Safety Read and follow all Warnings and Cautions prior to any service or repair 12 1 1 2 2 1 2 3 1 2 1 Indexing Drives should not be started and stopped at high speed during the transfer phase of the cams This can cause serious damage to the Indexer and reduce the cam follower life For cycling during setup or jog mode speed must be reduced to 25 of the normal operating speed The use of an E stop for
18. epeat steps a through d until there is positively no clutch slippage 5 2 4 Lubrication a Clutches are grease packed at the factory and should not require additional lubrication clutch is subject to consistent slippage and heating remove pipe plug number 9 Figure 5 and insert your standard grease fitting lubricate with Lithium EP grease Do not use air pressure gun SECTION 6 Maintenance 6 1 6 2 Correct Lubricants For the protection of the unit use only lubricants meeting the specifications shown below in Chart 3 If you have any questions about a particular lubricant feel free to call us at 1 800 645 5207 or 847 459 5200 Changing Oil 6 2 1 All parts are oil splash lubricated except for isolated areas where grease fittings will be supplied 6 2 2 Maintain oil to the midpoint of the sight gauge or oil level amp fill plug NOTE The orientation of your unit will determine the exact quantity of oil required 6 2 3 Drain flush and fill the unit in intervals of 2400 hours or at least yearly If drive operates at speeds above 300 RPM or at temperatures above 140 degrees F increase oil change frequency to 6 months or 1200 hour intervals NOTE When draining the oil observe for metal particles This is an indication of excessive wear and the source of this wear must be determined 6 2 4 Service all grease fittings on 1 month intervals or every 200 hours of operation NOTE In the majority of the appli
19. ghly cleaned and re filled with oil See Chart 1 in Section 3 for capacities NOTE If shot pins or guide pins in dies are used the unit should have been manufactured with a dwell relief in the cam Tangential loads may require the use of a shot pin or dial clamp If vertical loads exist an anvil may be required For further information consult your Industrial Motion Control Representative or the Technical Sales Department at 1 800 645 5207 or 847 459 5200 The unit s sump must be filled with SAE 90 EP Gear oil or equivalent meeting MIL PRF 2105E and API Service Classification GL5 or GL6 before operation see Chart 1 in Section 3 for capacities An example of this oil is Mobilube HD 80W 90 For extreme applications use Mobilube HD 85W 140 consult your local representative to determine if your application is extreme Bronze Gear Reducer oil must be SAE140 Steam Cylinder Oil meeting AGMA 8 Compound MIL SPEC MIL L 15016A symbol 3150 see Chart 1 in Section 3 for capacities Or manufacturer s specified oil if not a Ferguson manufactured reducer Be sure optional controller is properly fused refer to vendor s manual which is included under separate cover for information on installation set up adjustment and maintenance Check the adjustment of the Switch cam if your unit has this option To insure unit stops in dwell see Figure 3 4 1 10 1 A standard Parallel Shaft indexer is shown in Figure 3 with a Brake Cam amp Li
20. he gear the 15 reflects the reduction ratio In this example the ratio is 15 1 8 4 1 1 Component Removal 8 4 1 1 1 Worm Shaft 8 4 1 1 1 1 Drain oil and remove cover plate 8 4 1 1 1 2 Record the distance between the worm bearing shoulder on the splined end of the shaft opposite the single extension end of the shaft to the finished bore on the cover side see Figure 8 8 4 1 1 1 3 Remove screws and worm bearing caps keeping each set of shims with their respective bearing caps 8 4 1 1 1 4 Tap the worm shaft back and forth axially to move the outer race of the supporting bearings out of position 8 4 1 1 1 5 Shaft the worm to the side of the housing clear of the gear Remove the worm through the bearing bore in the housing SECTION 8 Repair and Replace continued NOTE Worm must be dropped down before attempting to remove the gear 8 3 1 1 2 8 4 1 1 3 Gear 8 4 1 1 2 1 8 4 1 1 2 2 8 4 1 1 2 3 8 4 1 1 2 4 8 4 1 1 2 5 Remove the worm as described above Record the distance from the finished face of the housing to the unmarked face of the gear see Figure 8 Remove screw and washer retaining gear if applicable Loosen the screw clamp on the split hub side of the gear Remove the gear Tapped holes in the end of the gear hub may be utilized in conjunction with a puller Component Replacement NOTE If both worm and gear were removed from the housing the gear must be replaced
21. ler than the bore size If possible the center of tool should be relieved so that pressure is applied only at the O D 8 3 11 Use proper driving force where possible an arbor press otherwise a dead blow hammer to avoid popping the spring out of the seal NEVER HAMMER DIRECTLY ON THE SURFACE OF THE SEAL SECTION 8 Repair and Replace continued 8 3 12 Bottom out the tool or seal to avoid cocking of the seal in the bore This also positions the seal correctly on the shaft 8 3 13 Check for parts interference from other machine parts that might rub against the seal causing friction and damaging heat 8 4 Reducers Splined end of shaft ASA DAIA A A Single Extended Shaft Unmaked Face lt Comparison Dimension Comparison gt Dimension Typical Ferguson R Series Reducer FIGURE 8 23 24 SECTION 8 Repair and Replace continued 8 4 1 R Series Ferguson Reducers NOTE The R Series reducer is a double enveloping worm gear type with components manufactured to Industrial Motion Control s specifications by selected vendors The worm and gear are provided in matched sets with minimal backlash and installed in housings of Industrial Motion Control s design The identifying number of a reducer consists of the letter R followed by a number and a two digit number i e R4 15 The 4 indicates the center to center distance between the worm and t
22. mit Switch shown with the keyway in the center of the dwell period It is necessary to phase the Brake Cam such that the input shaft of the indexer stops during the dwell period of the index cycle while leaving enough of the dwell period for the input shaft to accelerate to full speed before leaving the dwell period SECTION 4 Installation continued 10 4 1 10 2 If the indexer has a drive code which causes multiple indexes per camshaft revolution i e X2 X3 etc drive codes additional lobe s on the Brake Cam are required The lobes will be equally spaced Therefore phasing the one lobe of the Brake Cam to one dwell period on the indexing cam will in most cases cause the other lobes to be correctly phased with the other dwell periods NOTE Conirollers are normally shipped loose and brake cam limit switches are mounted to the unit However neither are set or adjusted at the factory Controller must be set for load amp speed of the application per instruction in the vendor s manual The limit switch and brake cam must be set so as to initiate the stopping cycle and result in an on station stop somewhere in the cam s dwell period NOTE The switch and brake cam commonly provided to initiate the stop cycle can not be used to indicate on station A second switch and brake cam should be ordered for this purpose SECTION 5 Adjustments The ParaDex is a solid mechanical backlash free mechanism There are no adju
23. ned with 001 of clearance under the dial and is strong enough to carry the full load of the asymmetrical load Consult Industrial Motion Control Technical Sales Department at 1 800 645 5207 or 847 459 5200 for assistance in all asymmetrical load situations E Stop Usage should be limited to emergency situations only E Stops should not be used to jog an indexer The E Stop function causes extreme load conditions inside the indexer by virtue of the instantaneous stopping of significant weights This is not unlike driving a car into a brick wall Excessive use of the E Stop will significantly shorten the life of the indexer Starting and Stopping while in the motion profile of the cam will also put high loading on the indexer s internal components Should it be necessary to stop start the indexer in any position other than the dwell of the cam it is best to reduce motor speed to avoid overloading the unit Shock Loading may also lead to problems Shock loading typically occurs when there is looseness in the input drive train or where the output load is not stable This condition will eventually damage either the indexer s followers or cam Overload devices that are not set correctly are sometimes a source of this condition Chain drives or loose timing belt drives are also potentials Machine Jams like E Stops put excessive loading on an indexer While the impact of jams is minimized by the use of overload devices it is always best to tr
24. o remove burr remove setscrew number 11 Figure 5 and rotate adjusting nut counter clockwise until burr is in center of tapped hole in housing number 1 Figure 5 Use a hand electric drill that fits freely into the tapped hole Drill into the adjusting nut number 6 Figure 5 sufficiently to remove the burr There are 2 setscrews number 11 Figure 5 They are positioned so one screw is half way between the slots in the nut when the other screw engages the slot in the nut This is to allow for fine adjustment of the clutch DO NOT use both screws at the same time as one screw will not be over a slot and will cause damage to the screw threads 15 16 SECTION 5 Adjustments continued d Apply power to the unit and check for clutch slippage NOTE When clutch is not slipping entire clutch will rotate as a single unit When clutch is slipping body and cone number 3 Figure 5 will not rotate with the other parts of the clutch Small amounts of clutch slippage can be difficult to determine To aid in providing if the clutch is slipping use a grease pencil or felt tip marker and draw a line across face of nut number 6 Figure 5 and along body and cone number 3 Figure 5 If clutch is slipping the line on nut number 6 Figure 5 and body and cone number 3 Figure 5 will move relative to each other DO NOT LET CLUTCH SLIP ANY LONGER THAN NECESSARY OR CLUTCH MAY HEAT UP RESULTING IN UNPREDICTABLE OPERATION AFTER IT COOLS R
25. purposes other than emergencies is not recommended A cycle stop button should be incorporated into the system controls Please consult Industrial Motion Control s Wheeling factory for additional information Always disconnect power and lockout the source before working on these units All input and output connections should be backlash free Use friction lock type shaft couplings such as taper lock bushings split and clamped hubs etc in the input and output drive train There should be no loose keys set screws etc as this may cause sheared keys and shaft damage SECTION 1 General Information continued 1 3 1 4 1 2 4 Reducers should be of minimum backlash variety and directly coupled with a 1 2 5 1 2 6 1 4 1 1 4 2 1 4 3 backlash free connection If line shafts are used they must be sized for severe reversing loads When using chain or belt drives incorporate an idler to eliminate any slack Do not use spring loaded idlers As the cam motion stops and starts any slack in the drive changes sides It is necessary to maintain a constant speed of the input shaft Loose V belts or chains will cause inertial over run causing distorted acceleration and deceleration characteristics which may cause damage to the unit Belts and chains must be sized for severe reversing loads Ferguson does not provide guarding for other moving parts such as pulleys handwheels switch cams etc Numerous pinch points do exis
26. re approximate for standard HM 1 position only Actual capacities may vary by other mounting positions or drive codes Always check oil level site glass or plugs before topping off or refilling SECTION 4 Installation These units are manufactured to meet a specific set of design parameters Any change to the load on the output shaft or speed of the camshaft may require a size change No change can be made without affecting other performance characteristics of the unit and therefore should not be done without consulting the factory 4 1 To install the unit 4 1 1 Rotate camshaft so cam is in center of dwell see Figure 3 Keyway Shown In Additional Lobe For Center Of Dwell x2 Drive Codes FIGURE 3 4 1 2 Mount the Indexer into position on a rigid base and secure with the proper size fastener 4 1 3 Align the Indexer with respect to the station positions before tightening fasteners Use a dial indicator or other appropriate tools to insure alignment 4 1 4 Tighten all mounting bolts securely and uniformly SECTION 4 Installation continued 4 1 5 4 1 6 4 1 10 Check the oil level of the sump and gear reducer prior to operating the unit Pay particular attention if the oil level is too high If a unit has been idle for some time since its manufacture condensation may be present If condensation is noticed the oil should be drained the unit thorou
27. stment The shut off spool number 8 Figure 5 is attached to body and cone number 3 Figure 5 by means of shallow round threads in body and cone number 3 Figure 5 and a ball plunger number 9 Figure 5 in spool number 8 Figure 5 When the clutch is operating normally i e not slipping there is no relative movement between spool number 8 Figure 5 and main body number 3 Figure 5 and the remainder of the clutch including the spool number 8 Figure 5 driven by pin number 7 Figure 5 This relative rotation causes the spool to move along the screw threads on the body number 3 Figure 5 The spool will move to the left or to the right depending on the rotation of the clutch This lateral movement of the spool is intended to activate a limit switch arm located in the center groove in the spool The tripped limit switch should be electrically connected to the controls to stop the operation of the motor driving the indexer To recover from a jam or overload in which the clutch has slipped sufficiently to displace the shut off spool Manually disconnect the power to the drive motor to prevent an accidental start up use O S H A approved lockout procedures clear the cause for the overload Then simply push or pull the spool number 8 Figure 5 on the main body number 3 Figure 5 to the thread engagement which is closest to the center position on the threaded portion of the body number 3 Figure 5 Check the limit switch cir
28. stments required on the Indexer during installation unless it is furnished with a torque limiting device or a motor drive package equipped with speed control After the Indexer has been installed and set up with the users load in place it will be necessary to check these items for proper adjustment amp settings 51 Typical Output Shaft Torque Limiter TORQUE ADJUST ING SHOWN AT MAX CLUTCH OUTPUT FLANGE TENNA TINA GS kal CLUTCH INPUT BORE fj LOCKING SET SCREW FIGURE 4 11 12 SECTION 5 Adjustments continued 5 1 1 To adjust trip torque remove locking setscrew Use spanner wrench to adjust nut position Turn clockwise to increase torque or counterclockwise to decrease See Chart 2 for torque adjustment values 5 1 2 Replace locking set screw after achieving required torque NOTE 1 Total torque range in the different models is achieved by a combination of different spring groups and applied pressure through the adjusting nut Chart 2 below shows the different torque ranges available for each spring group When reordering specify model number e g RT3 6001 etc for your required spring range 2 If a tamper proof setting is desired apply a permanent adhesive such as Loctite 680 to the setscrew after achieving the required trip torque value 5 1 3 Spring Sets for RT Clutches
29. t on this equipment and the possibility exists of being struck by a moving part Since this product is expected to become part of a further developed machine it is the customer s responsibility to add safety fencing guarding light curtains or other protection devices as necessary to protect personnel and property NOTE In the event the unit is damaged contact Industrial Motion Conirol s Wheeling factory or your local representative for proper reconditioning or repair see sections 1 5 Requesting Service or 1 6 Returning a Unit for Repair Operating Environment This machine is intended to operate in a clean environment Excessive coolant chips dust dirt or debris can adversely affect its performance and life If this machine does operate in a dirty environment periodic cleaning must be practiced and careful inspection of seals and accessories is necessary 1 3 1 For extended storage remove vents and fill with proper oil Refer to section 6 Ordering Replacement Parts When ordering parts always provide the following information The serial number shown on the nameplate The part name and or the description listed in the manual The part numbers shown on the bill of material or assembly drawings SECTION 1 General Information continued 1 5 1 6 Requesting Service Call our Technical Service Department in Wheeling IL at 1 800 645 5207 or 847 459 5200 between 8 00AM and 4 00PM CST When requesting service
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