INSTALLATION & SERVICE MANUAL ED & PINNACLE SERIES
Contents
1. 8 2 6 Drain oil and remove front access cover Rotate camshaft so cam follower is directly below access opening Remove and replace followers following procedures outlined in Figures 16 17 or 18 Rotate camshaft until entire set has been changed and continue with step No 4 Scrape old sealant from housing and access cover Apply new silicone rubber sealant and assemble front cover to housing Tighten all screws evenly Refill with oil to level indicated 29 SECTION 8 Repair and Replace continued FOLLOWER NO FM 50 FM 62 FM 75 ROLLER GEAR HUB FOLLOWER NYLON PLUG HEX SOCKET 1 16 THICK N SOCKET HEAD JAM NUT SET SCREW Cup or Dog Point FIGURE 16 DISASSEMBLY Remove jam nut setscrew follower and nylon plug ASSEMBLY Clean the follower stud hole in the hub and inspect for an out of round condition which could cause backlash by failing to support the stud at the top Apply a light coat of assembly grease to a new cam follower and install it firmly against seat loosen and retighten Install new nylon plug and tighten setscrew and jam nut in place 30 SECTION 8 Repair and Replace continued FOLLOWER NO FM 100 amp FS100 FS 400 s FOLLOWER ROLLER GEAR HUB SOCKET HEAD SETSCREW 90 Cone point HEX DRILL SEAT FOR SOCKET SETSCREW DIA SELF LOCKING NUT FIGURE 17 DISASSEMBLY Remove locknut setscrew and follower2. ASSEMBLY Clean the follower and stud hole in the roller gear hub and inspect for elongation which could cause backlash by failing to support the stud at the top Apply a light coat of assembly grease to a new cam follower and install it firmly against seat loosen and retighten Install setscrew tighten sufficiently to mark follower stud with setscrew point and remove setscrew Remove cam follower and drill a setscrew seat at the marked position deeply enough to make seat diameter equal to setscrew diameter Clean cam follower coat with grease and install firmly against seat check that the drilled seat lines up with the setscrew hole Assemble setscrew and locknut and tighten firmly 31 32 SECTION 8 Repair and Replace continued FOLLOWER NO F 50 THROUGH F 400 TAPPED HOLE ROLLER GEAR HUB SOCKET HEAD SEAT FOR SETSCREW SETSCREW Cup Point FIGURE 18 DISASSEMBLY Remove setscrew and pull cam follower from hole using a draw hammer secured in tapped hole ASSEMBLY Clean the follower stud hole in the roller gear hub and inspect for elongation which could cause backlash by failing to support the stud at the top Place a socket head screw in pull hole and strike its head do not strike the follower end cap when installing Apply a light coat of assembly grease to a new cam follower orient so the setscrew and seat are in line and install lightly against shoulder Place a drop of No
3. 10 Bearing cap reducer side 24 Oil site glass 11 Bearing retainer amp seal cap 25 Oil sump vent 12 seal reducer side 26 Bushing 13 Eccentric center tube 27 Cap screws 14 Thrust bearing 28 Cap screws SECTION 2 Overview continued 2 2 ED amp PN Series Location Map FIGURE 2 ED amp PN Series Parts List 1 Housing 15 Cap screws 2 Access cover 16 Pipe plug 3 cover plate 17 Cap screws 4 shaft 18 Bearing clamp 5 Key 19 Cam followers 6 Cam 20 Top seal 7 Locknut 21 Center tube 8 Lockwasher 22 Bearing ring 9 Locknut 23 Output shaft seal 10 Lockwasher 24 Output shaft 11 Timken bearing cup 25 Locking set screw 12 Timken bearing cone 26 Cap screw 13 Cam shaft bearing carrier 27 Cap screw 14 Oil seal SECTION 2 Overview continued 2 3 400 and PN500 Series with Internal Overload Clutch Location Map FIGURE 3 PN400 and PN500 Series with Internal Overload Clutch Parts List Housing Cam Camshaft Camshaft Key Locknuts Timken Cup Timken Cone Bearing Cap Seal 10 Locknut 11 Spacer 12 Tube 13 Housing Cover 14 Cap Screws 15 Center Tube Ring Oo NO gt gt Cap Screws Access Cover Vent Cap Screws Cam Follower Hub Cam Followers Locking Set Screws Thrust Bearing Thrust Bearing Plate Locknut Seal Seal Cap Screws Shim Set Roller Gear Shaft Bearing Plate Cap Screws Detent Seat Ring Dowels
4. Cap Screw Rollers Retainer Ring O Ring Ring Pressure Switch Springs Spring Adjusting Ring Cap Screws Bearing Clamp O Ring Ring Bearing SECTION 2 Overview continued 2 4 Ferguson Reducer Location Map Ph FIGURE 4 Indexer Input Ferguson R Series Reducer Parts List Housing Ring Gear amp separate hub for some units Pinion Worm Gear Gear Spacer Key for Indexer Shaft Arrestor Washer Lockwasher Cap Screw Keeper Cap Screw for Clamping Hub 10 11 12 13 14 15 16 17 18 19 Closed End Cap Screws Shim Pack Timken Bearing Open End Cap Oil Seal Wear Sleeve Cover Plate Cap Screws Oil Plugs SECTION 3 Specifications a 9 w A D EE 7 5 2 D Qe O 9 TA gt of a 5 n fa 5 gt gt oO te tes Ov m D 8 stil ef S 08 45 5 p BS oa sI 5 2 2 5 g SISS Bs 80 a 55 BR 2 5 5 O gt a or js 36 5 5 5 71 14 PN300 R175 w 1 3HP 1 3HP RT6D N A 1 1 QT 50 NA 65 MDB625 ED200 R200 wi HP 1 2HP DTL10 R2 5 FSC 1 5 15QTS 300 325 MD625 PN400 926CDSS w 1 oHp 1 2HP 4 N A 2 1 5QTS MD625 PN500 930 085 w 1 HP 1 HP
5. appear bronze color when in oil REDUCER Excessive Backlash Overheating in Excess of 210 F Worn damaged followers Bent cam followers Incorrect oil Steel and iron worn from bearing roller ends and cages this is a normal condition A End play in worm shaft B Loose gear on camshaft A Worm shaft bearing preload B Incorrect alignment of worm and gear C Excessive worm speed Replace Replace inspect holes in roller gear shaft Replace cam followers and fill unit with correct oil 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 27 28 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 hole and interior of housing Loctite Aviation Grade Sealant to both sides Holes drilled through Remove screw apply Loctite Threadlocker and re install Cover joints Inadequate sealant Remove clean and Oil service pipe fittings Not properly sealed reas
6. 222 grade Loctite on setscrew install and tighten firmly SECTION 8 Repair and Replace continued 8 3 Oil Seal Replacement 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 Remove oil seals by drilling a number of holes into the seal 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 may 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 wipin
7. 4 N A 3 2 QTS MDB875 ED420 R300 11 1 2 NA R3FSC 5 25QTS 750 789 850 MDB875 ED810 R400 w2HP 2 N A R4FSC 20 1 5GAL 1200 1275 1325 MDB1125 ED1440 R600 w SHP N A N A R6FSC 30 3 7 GAL 3000 3235 3455 ED3240 R700 N A N A N A R7FSC 35 6 5 9500 9780 N A CHART 1 1180 2 Weights are approximate less crating Refer to section on lubrication for specifications of lubricants Amounts are 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 Has optional internal overload clutch SECTION 4 Installation These units are manufactured to meet a specific set of design parameters Any change to the load dials 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 5 and 6 Keyway Shown In Center of Dwell l Additional Flat for F 2 Drive Codes FIGURE 5 PINNACLE SERIES Keyway Shown In Center Of Dwell z a Additional Lobe For xz Drive Codes FIGURE 6 ED SERIES 10 SECTION 4 Installation continued 4 1 2 Mount the Indexer in
8. D lights and then turn approximately 1 4 turn more Rotate the output shaft a full revolution the L E D should always remain on Be sure the end of the prox switch does not contact the detection plate SECTION 5 Adjustments continued 5 2 1 3 Trip the internal clutch the L E D should now go off Repeat this process several times making a full revolution of the output the L E D must go off consistently when the clutch is tripped and light when the clutch is reset NOTE The detection switch set up procedure is appropriate for the Industrial Motion Control Turck part numbers listed below If your equipment has another model number or is from another manufacturer contact the switch manufacturer for set up procedures Industrial Motion Control PN 1000000938 Turck Bi 1 GO8 AN6X Industrial Motion Control PN 1000000939 Turck Bi 2 G12 AN6X Industrial Motion Control PN 1000003115 Turck Bi 1 GO8 AN6X H1 341 21 SECTION 5 Adjustments continued 5 3 FSC Ferguson Slip Clutch Location Map WE Se eS WEE JN 22222000 Dla AY ek A j Sy H FIGURE 14 22 Housing Body amp Cone Thrust Bearing Silicon Spring Adjusting Nut Guide Pin Spool Ball Plunger Liner Bushing Setscrew Pipe Plug SECTION 5 Adjustments continued 5 3 1 5 3 2 Clutch Adjustment Description The clutch must be adjusted to prevent any slippage during normal operation
9. Department at 1 800 645 5207 or 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 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 Tals Warranty Deke pe eee Aaa nd oie aie Wa aren eat 2 18257 MAR EMI LANA EOL aA ge emcee a 2 3 1 3 Operating Environment 3 1 4 Ordering Replacement 5 3 1 5 Requesting ServiCes 63 5 260054 a cite dave ee dda deed 4 1 6 Returning a Unit for Repair erasiak oreraa A rae es 4 2 SOVORVIOW oN nets datan teeth are cee Mow Hae and Sha eth heated 5 8 21 ED200 Series Location Map amp Parts 5 2 2 and PN Series Location Map amp Parts List 6 2 3 PN400 PN500 w Internal Overload Clutch Location Map
10. amp Parts List 7 2 4 Ferguson Reducer Location Map amp Parts List 8 3 Specifications ee niiina iai Mowe oa hea od 9 4 Installation Pe ea RR 10 4 41 Unit Installation 2 Maa Gee Pe ee eee al 10 12 4 2 RT6 D Rite Torq Limiting Clutch Installation 13 18 5 lt 19 25 Bole Internals cats wat tote Beg ees sed Danae een aa nash doers aun a Maks aad 19 5 2 a 20 21 5 3 FSC Ferguson Slip Clutch 22 25 6 Maintenance 26 6 1 Using Correct 1 26 6 2 Changing eee Se Ra ee ee BEER 26 7 Troubleshooting 27 28 8 Repair Replace 29 37 8 1 Follower Replacement Models ED90 ED91 amp ED200 29 8 2 Cam Follower Replacement Models PN300 thru PN500 ED420 thru ED3240 29 8 3 Oil Seal Replacement 33 34 8 4 adds we wed deca 34 37 9 Things to sser reaa ay aa Pew ee Dee ete a aa eee es 38 39 REFERENCE Uni
11. disengagement of the clutch will be up to 30 higher than the set torque initial movement Disassembling clutch for maintenance 4 2 7 1 Remove the dowel between the clutch body and output adapter Do not remove the dowel pins between the output adapter and indexer Do not disassemble the spring adjusting nut from the clutch housing body 4 2 7 2 Carefully unfasten and remove clutch bolts so that the body mounting is released slowly to prevent bodily injury 4 2 7 3 Remove the clutch body assembly from output adapter 4 2 7 4 Clean off any contaminates or residues and inspect all parts for any wear 4 2 7 5 Apply Molykote grease to detent driven plate detent pockets rollers and bearings Reassemble clutch SECTION 5 Adjustments As noted in the introduction the Roller Gear Drive is a solid mechanical backlash free mechanism There no adjustments 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 NOTE Drive should be in center of dwell and dowel pinned to base before installing accessories as previously mentioned in 4 1 1 and 4 1 5 4 5 1 Internal Torque Limiters ED250 PN400 and PN500 NOTE 1 Drive should be in center of dwell and dowel pinned to b
12. shaft Loose 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 1 2 6 Industrial Motion Control does not provide guarding for other moving parts such as dials handwheels switch cams etc Numerous pinch points do exist 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 Conitrol 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 1 4 1 The serial number
13. shown on the nameplate 1 4 2 The part name and or the description listed in the manual 1 4 3 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 always provide the following information 1 5 1 The serial number shown on the nameplate Refer to Inside Front Cover 1 5 2 A clear description of the problem including as much detail as possible of the circumstances leading up to the problem Returning a 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 dec
14. the adjusting nut can be re tightened to its original position c Re tighten setscrew number 11 Figure 14 making sure it engages in adjusting nut number 6 Figure 14 to prevent damage to screw threads NOTE If setscrew number 11 Figure 14 is accidentally tightened on threaded portion of adjusting nut number 6 Figure 14 it will raise a burr Failure to remove this burr will cause shearing of threads and jamming of nut of housing number 1 Figure 14 To remove burr remove setscrew number 11 Figure 14 and rotate adjusting nut counter clockwise until burr is in center of tapped hole in housing number 1 Figure 14 Use a hand electric drill that fits freely into the tapped hole Drill into the adjusting nut number 6 Figure 14 sufficiently to remove the burr There are 2 setscrews number 11 Figure 14 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 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 14 will not rotate with the other parts of the clutch Small amounts of clutch slippage can be diffi
15. 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 Adjustment The shut off spool number 8 Figure 14 is attached to body and cone number 3 Figure 14 by means of shallow round threads in body and cone number 3 Figure 14 and a ball plunger number 9 Figure 14 in spool number 8 Figure 14 When the clutch is operating normally i e not slipping there is no relative movement between spool number 8 Figure 14 and main body number 3 Figure 14 and the remainder of the clutch including the spool number 8 Figure 14 driven by pin number 7 Figure 14 This relative rotation causes the spool to move along the screw threads on the body number 3 Figure 14 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 s
16. unit is a RT6 DF the dial mounting instructions shown below do not apply since the dial is installed over the clutch to an external mounting flange The RT6 DF clutch raises the dial mounting height by 1 2 inch and requires a different pilot diameter bolt hole pattern The RT6 D clutches should be protected for use in extremely humid environments or wash down applications WARNING FERGUSON RT6 D AND ALL INDUSTRIAL MOTION CONTROL COMPANY TORQUE LIMITERS ARE ONLY FOR THE PROTECTION OF THE INDEXER THE TORQUE LIMITER IS NOT FOR USE AS A HOLDING OR OVERHAULING FAIL SAFE DEVICE TO PROTECT AGAINST BODILY INJURY 4 2 1 Prepare PN300 Indexer for mounting RT6 D NOTE This step has been finished at factory if the clutch was ordered with the Indexer 312 DIA DRILL 1 25 375 16UNC 2B 1 00 4 PLACES EQ SPACED WIRE BRUSH THIS SURFACE AND DIAMETER 4 3 250 DIA 5 312 DRILL 75 2 PLACES AS SHOWN Le LA PN300 PREPARED FOR RT6 CLUTCH MOUNTING FIGURE 7 13 14 SECTION 4 Installation continued 4 2 2 4 2 1 1 Position Indexer in dwell period of the cam input keyway positioned as in Figure 7 when unit is in center of dwell 4 2 1 2 Drill and tap 4 mounting holes and 2 drilled holes into output of Indexer as shown in Figure 7 4 2 1 3 Rotary wire brush surfaces indicated to burnish in bearing surfaces Mount driven detent plate to dial NOTE If dial has premachined sta
17. A 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 0105 REV 7 1 03
18. Automation Robohand FERGUSON INSTALLATION amp SERVICE MANUAL ED amp PINNACLE SERIES 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 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 which is 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 Illinois 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 Customer Service Department or the Technical Sales
19. H MOUNTING iN S4 TNS IN Ce amp IT CLUTCH HOUSING BODY THIS END OF HOLES MAY BE ENLARGED FOR EASIER ASSEMBLY WW T7 ASSA CLUTCH INTO INDEXER OUTPUT FOR A PRESS Ns DRILL AND REAM THRU 2 FIT WITH 375 DOWEL PINS 2 PLACES SWITCH ACTUATION DOWEL CLUTCH ADAPTER TO PN300 OUTPUT FIGURE 11 Drill and ream through clutch into Indexer output at 2 drilled holes put into Indexer in Step 1b for a press fit with 375 diameter dowel pins 2 places See Figure 11 NOTE Holes in clutch housing body will have one end machined for press fit with dowels for another application End of hole may be enlarged with a clearance drill for easier assembly WARNING IF REQUIRED DISASSEMBLE RT6 D AND CLEAN ALL PARTS TO REMOVE METAL CHIPS AND BURRS CLUTCH IS NOT SEALED AND METAL CHIPS ETC BETWEEN ROTATING PARTS CAN CAUSE CLUTCH TO FAIL CHECK OPERATION OF CLUTCH BY MANUALLY ROTATING THE DIAL TO TRIP THE CLUTCH AND RE ENGAGE IT IN BOTH DIRECTIONS 17 18 SECTION 4 Installation continued 4 2 6 4 2 7 The set or trip torque can be checked by adapting a torque wrench or spring scale to the dial Set torque should be within 15 of the started value NOTE Set torque is defined as the torque which causes the first 001 003 movement of the rollers out of the detent This can be checked with a dial indicator on the switch actuation plate The trip torque to cause a complete
20. ase before installing accessories 2 Customer s dial must have access holes to adjusting screws 3 Torque Limiter comes in three available ranges as shown below Maximum torque for range ordered is stamped on face of output shaft 5 1 1 To adjust clutch to final required setting after installing load turn the 3 torque adjusting screws using a 312 Allen wrench evenly in 3 turn increments Turn clockwise to increase torque and counterclockwise to decrease torque 5 1 2 Clutch proximity switch with 2 meter cable must be adjusted for proper operation FIGURE 12 PN500 INTERNAL CLUTCH TORQUE RANGE OPTIONS HIGH RANGE 7 000 to 14 000 IN LBS approx adjustment range 3 300 IN LBS per turn MED RANGE 5 500 to 11 000 IN LBS approx adjustment range 2 450 IN LBS per turn LOW RANGE 3 600 to 7 350 IN LBS approx adjustment range 1 650 IN LBS per turn 19 SECTION 5 Adjustments continued 5 2 Prox Switch Adjustments Load Resistor 150 Ohm 1 Watt Blue Wire 12 Volt D C Power Supply Brown Wire FIGURE 13 5 2 1 Internal Clutch Trip Detection Prox Switch 5 2 1 1 5 2 1 2 20 Screw the prox switch into the unit until its face just touches the detection plate the angular surface visible through the prox switch hole The L E D on the end of the switch should now be lit Screw the prox switch out until the L E D goes out Next screw the switch in again until the L E
21. ch 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 The lobes on the Brake Cam of PN series indexers are formed by removing material from a shaft collar rather than a protruding lobe This will make a difference in the setup of the limit switch and the control NOTE Controllers are normally shipped loose and brake cam limit switches are mounted to the unit However neither are set or adjusted at the factory Limit switch and cam must be set to initiate the stopping cycle Controller must be set for the load amp speed of the application per instruction in the vendor s manual NOTE The switch and brake cam commonly provided to initiate the stop cycle cannot be used to indicate on station A second switch and brake cam should be ordered for this purpose SECTION 4 Installation continued 4 2 RT6 D Rite Torq Limiting Clutch NOTE The RT6 D is designed to be used with only the Ferguson PN300 Indexer and maintains the same dial height Other Torque Limiters are available for various applications Call Industrial Motion Control Technical Support at 1 800 645 5207 or 847 459 5200 for assistance If the clutch on the PN300
22. cult 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 14 and along body number 3 Figure 14 If clutch is slipping the line on nut number 6 Figure 14 and body number 3 Figure 14 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 Repeat steps a through d until there is positively no clutch slippage 5 3 4 Lubrication a Clutches are grease packed at the factory and should not require additional lubrication If clutch is subject to consistent slippage and heating remove pipe plug number 9 Figure 14 and insert your standard grease fitting lubricate with Lithium EP grease Do not use air pressure gun 25 26 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 2 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
23. d defects and circumstances 1 2 Safety Read and follow all Warnings and Cautions prior to any service or repair 1 2 1 Roller Gear 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 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 1 2 2 Always disconnect power and lockout the source before working on these units 1 2 3 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 SECTION 1 General Information continued 1 3 1 4 1 2 4 Reducers should be of minimum backlash variety and directly coupled with backlash free connection If line shafts are used they must be sized for severe reversing loads 1 2 5 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 chain changes sides It is necessary to maintain a constant speed of the input
24. designed 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
25. 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 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 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 19 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
26. g with lubricant being retained 8 3 10 Use the correct installation tool press fitting tools should have an outside diameter 010 smaller 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 33 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 TYPICAL FERGUSON R SERIES REDUCER Splined end of shaft 2 AA A AIA A A Extended Shaft a 24 Unmarked Face Comparison gt lt gt Comparison Dimension Dimension FIGURE 19 34 SECTION 8 Repair and Replace continued 8 4 1 R Series Ferguson Reducers NOTE The 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 numbe
27. ides 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 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 not intended to accurately represent the components and therefore are not to scale The various models may be different than shown depending upon options chosen or the particular configuration of a unit 2 1 ED200 Series only Location Map Center of dwell position shown FIGURE 1 ED200 Series Parts List 1 Housing 15 Roller gear shaft 2 Cam 16 Tapered roller bearing 3 Cam shaft 17 Locknut and washer 4 Cam shaft key 18 Oil seal 5 Locknut amp washer 19 Oil seal 6 Tapered roller bearing 20 Cam followers 7 Shim set 21 Cone point set screws 8 Bearing cap 22 Locknut and washer 9 Oil seal 23 Pipe plug
28. 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 hours 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 applications 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 not a Industrial Motion Control manufactured reducer Capacity See specifications in Chart 1 for your model CHART 2 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
29. l detent plate assembly See Figure 9 4 2 3 2 Rotate dial while applying downward pressure to level out excess grease 4 2 3 3 Measure the height difference between the top of the detent driven plate and the top of the clutch adapter Install shims as required to raise adapter surface 001 003 above top of detent driven plate This will ensure that the dial will rotate freely with minimum clearance 4 2 3 4 Coat top of detent driven plate and detent pockets with Molykote Grease 15 SECTION 4 Installation continued 4 2 4 Clutch Assembly DIAL THRUST BEARING SPRING go S 1 375 DOWEL PRESS FIT IN ADAPTER PLATE DETENT PLATE ROLLER PRESSURE PLATE RT6 D CLUTCH MOUNTED TO OUTPUT OF PN300 FIGURE 10 4 2 4 1 Assemble remaining RT6 D clutch parts to PN300 unit as shown in Figure 11 being careful to correctly align mounting holes in adjacent parts and rotating dial to cause all rollers to seat into a detent pocket Coat thrust bearing and rollers with grease See Figure 10 NOTE Some parts have additional holes for use on other applications If dial plate has station holes verify correct location at this point 4 2 4 2 Lightly snug 4 3 8 clutch mounting bolts Install 1 375 dowel into pre machined hole to align clutch parts Tighten clutch bolts securely SECTION 4 Installation continued 4 2 5 Dowel Clutch Adapter to PN300 Output 4 2 5 1 TIGHTEN CLUTC
30. r 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 the 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 19 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 35 36 SECTION 8 Repair and Replace continued NOTE Worm must be dropped before attempting to remove the gear 8 4 1 1 2 8 4 1 1 3 Gear 8 4 1 1 2 1 Remove the worm as described above 8 4 1 1 2 2 Record the distance from the finished face of the housing to the unmarked face of the gear see Figure 19 8 4 1 1 2 3 Remove screw and washer retaining gear if applicable 8 4 1 1 2 4 Loosen the screw clamp on the split hub side of the gear 8 4 1 1 2 5 Remove the gear Tapped holes in the
31. semble 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 Serviceman make or supervise repairs in your plant Proper alignment and adjustment of the components are essential to their performance and life SECTION 8 Repair and Replace 8 1 8 2 Cam Follower Replacement Models ED90 ED91 amp ED200 8 1 1 Drain oil amp rotate the input shaft so that indexing cam is approximately in center of dwell position See Figures 5 and 6 Remove locknut on bottom of output center shaft except ED91 Remove roller gear hub shaft and center shaft as an assembly from housing Remove and replace followers following procedures outlined in Figures 16 17 or 18 and continue with step 5 Install roller gear hub shaft and center shaft assembly into housing Care must be taken to insure proper alignment with locating pin Apply an anaerobic type sealer between flange on center shaft and housing to form an oil tight seal Install locknut and tighten securely except ED91 Install new oil seal on outer flange of roller gear shaft if necessary Refill with oil to level indicated Cam Follower Replacement Models PN300 PN400 PN500 ED420 ED810 ED1440 amp ED3240 8 2 1 8 2 2 8 2 3 8 2 4 8 2 5
32. strial Motion Control Representative or the Technical Sales Department at 1 800 645 5207 or 847 459 5200 4 1 6 2 The units 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 11 12 SECTION 4 Installation continued 4 1 6 3 4 1 6 4 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 an Industrial Motion Control manufactured reducer Be sure optional controller is properly fused refer to vendor s manual Check the adjustment of the Switch cam if your unit has this option To insure unit stops in dwell see Figures 5 and 6 4 1 7 1 4 1 7 2 A standard roller gear indexer shown in Figure 5 with a Brake Cam amp Limit 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 If the indexer has a drive code whi
33. t configurations Reducer Mtg Positions Hand of Cam Drawing 40 SECTION 1 General Information Industrial Motion Control IMC Index Drives are 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 When 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 1 1 2 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 allege
34. the dimension between the worm bearing shoulder and the finished housing bore as recorded at the time of disassembly is duplicated see Figure 19 NOTE Do not discard 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 4 2 Winsmith Worm Gear Reducer NOTE Due to its modular and hollow shaft design it is not considered economical to replace components only in these reducers Except for seal or other oil leak problems replacement of entire reducer is recommended 37 38 SECTION 9 THINGS TO AVOID An Indusirial Motion Control Indexer is a relatively simple mechanism using an input shaft mounted tapered ribbed barrel cam to drive roller followers on the output hub While simple in concept the precision nature of the indexer s manufacture indicates that they must be used within their 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
35. tion holes which must hold a relationship to Indexer verify position before following these steps DETENT DRIVEN PLATE USE FINISHED HOLE IN DRIVEN PLATE AS REAMER JIG FOR DOWEL HOLES IN DIAL 2 PLACES THESE DIAMETERS MUST BE CONCENTRIC WITHIN 001 T I R NOTE MOUNTING HARDWARE MUST EXTEND BEYOND SURFACES DEBURR ALL HOLES AND EDGES STONE BOTTOM OF DIAL TO REMOVE ANY BURRS MOUNT DETENT DRIVE PLATE TO DIAL FIGURE 8 4 2 2 1 Mount the driven detent plate of the clutch to the dial and transfer the four 3 8 capscrew holes and two 375 diameter dowel holes See Figure 8 4 2 2 2 Maintain a concentricity of 001 TIR as indicated between the bores in both pieces SECTION 4 Installation continued 4 2 2 3 Ream the dowel pin holes for a press fit using the hardened detent plate as a guide for the reamer 4 2 2 4 Assemble the driven detent plate to the dial with four 3 8 16 capscrews and two 375 diameter dowel pins Check that the fasteners do not protrude on either side of the assembly Apply Loctite 242 Threadlocker to capscrews 4 2 3 Shimming RT6 D TOP OF DETENT DRIVE PLATE LUBRICANT THIS SURFACE AND DETENT POCKETS INSTALL SHIMS UNTIL THIS LUBRICATE THIS SURFACE AND PILOT DIAMETERS BEFORE MOUNTING DIAL SHIM FOR RT6 CLUTCH MOUNTING FIGURE 9 4 2 3 1 Coat the Indexer dial mounting surface and pilot with Molykote Grease and mount the clutch adapter and dia
36. to position on a rigid base and secure with the largest size bolts that will fit through the mounting holes Align the Indexer with respect to the station positions before tightening bolts and doweling Use a dial indicator or other appropriate tool to insure alignment Tighten all mounting bolts securely and uniformly Install dowels 4 1 5 1 Use a commercially available straight dowel of the appropriate size 4 1 5 2 Drill a hole into the base to a depth of at least 1 1 2 times the diameter of the dowel Use a drill the same size as the pilot hole in the Indexer housing 4 1 5 3 Line ream housing and base for press fit with dowel pin 4 1 5 4 Install dowel pins into position Leave some material exposed to facilitate removal in the future or use threaded dowel pins Check the oil level of the sump and gear reducer prior to operating the unit 4 1 6 1 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 thoroughly 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 If severe vertical loads exist an anvil may be required Tangential loads may require the use of a shot pin or dial clamp For further information consult your local Indu
37. to track the occurrence of jams and when possible rectify the condition that led to the jam A high jam frequency will shorten indexer life 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 39 UNIT CONFIGURATIONS REDUCER MOUNTING POSITIONS HAND OF CAM Hen Daten 5 Right Hamd St d Di Fiance hal Left Hang Cam 40 NOTES 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 Michigan US
38. ufficiently 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 14 on the main body number 3 Figure 14 to the thread engagement which is closest to the center position on the threaded portion of the body number 3 Figure 14 Check the limit switch circuitry for proper operating conditions The indexer can now be powered up and production resumed 23 24 SECTION 5 Adjustments continued 5 3 3 Clutch Adjustment Procedure FIGURE 15 CAUTION OPERATIING THE INDEXER WITH THE CLUTCH NOT ADJUSTED CAN CAUSE IMMEDIATE AND SEVERE DAMAGE TO THE INTERNAL COMPONENTS OF THE INDEXER a Loosen cone point setscrew number 11 Figure 14 b Insert pins of spanner figure 15 into holes of adjusting nut number 6 Figure 14 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 14 towards the indexer with a rubber mallet to separate loosen the tapers Take note of the number of loosening turns so
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