INSTALLATION & SERVICE MANUAL FD & SENTRY® SERIES
Contents
1. 9 4 Installation Oe Eee dale G 10 14 5 222222552 enews cade deine eae See eee 13 22 5 1 Sentry Series Internal Clutch naana aaea 13 14 5 2 Prox Switch Adjustments 15 16 5 3 FSC Ferguson Slip Clutch 17 20 6 2 22 55585444 EAE REESE we Oe Re hee a eg 21 6 1 Using Correct Lubricants 21 6 2 Changing boda ea Gas 21 7 Troubleshooting 22 23 8 Repair Replace 24 35 9 Things to Avoid 36 37 REFERENCE Unit configurations Reducer Mtg Positions Hand of Cam Drawing 38 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 w2. Unmarked Face lt Comparison Dimension 4 Comparison Dimension FIGURE 14 31 32 SECTION 8 Repair and Replace continued 8 5 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 the gear the 15 reflects the reduction ratio In this example the ratio is 15 1 8 5 1 1 Component Removal 8 5 1 1 1 Worm Shaft 8 5 1 1 1 1 Drain oil and remove cover plate 8 5 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 15 8 5 1 1 1 3 Remove screws and worm bearing caps keeping each set of shims with their respective bearing caps 8 5 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 5 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
3. 5 Silicon Spring 6 Adjusting Nut 7 Guide Pin 8 Spool 9 SS FR ii 24 12 Pipe Plug Housing amp Cone FIGURE 8 18 SECTION 5 Adjustments continued 5 3 1 5 3 2 5 3 3 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 Adjustment The shut off spool number 8 Figure 9 is attached to body and cone number 3 Figure 8 by means of shallow round threads in body and cone number 3 Figure 8 and a ball plunger number 9 Figure 8 in spool number 8 Figure 8 When the clutch is operating normally i e not slipping there is no relative movement between spool number 8 Figure 8 and main body number 3 Figure 8 and the remainder of the clutch including the spool number 8 Figure 8 driven by pin number 7 Figure 8 This relative rotation causes the spool to move along the screw threads on the body number 3 Figure 8 The spool will move to the left or
4. SECTION 8 Repair and Replace continued NOTE Worm must be dropped before attempting to remove the gear 8 5 1 1 2 Gear 8 5 1 1 2 1 8 5 1 1 2 2 8 5 1 1 2 3 8 5 1 1 2 4 8 5 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 15 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 8 5 1 1 3 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 5 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 33 34 SECTION 8 Repair and Replace continued 8 5 1 1 3 2 8 5 1 1 3 3 8 5 1 1 3 4 8 5 1 1 3 5 8 5 1 1 3 6 The distance from the finished face of the housing to the unmarked fa
5. lt 5 op lt p a 85 88 2 518 5 5 lt 5 5 512 58 58 gt a a D 828 25 100 Gear HP 702 NA 10 25 Motor 162 20CDSF MDB625 5 5HP YES 0 5 1307 50 110 200 26CDSF 625 5 5HP YES RT5 100 3202 115 170 200 250 30CDSF R3 MDB625 1 1HP YES RT6 1 75 4802 125 195 225 300 6SFM R3 MDB875 1 5 1 5 HP yes 6 Or Ra3FSC 250 2075 300 395 445 With 1 5 HP DTL10 451 R400 C F MDB875 2 15 N A 4 3 00 1 5GAL 560 635 686 501 R500 C F MDB1125 3 N A 5 50 2 5 GAL 900 1035 1255 CHART 1 Requires C face reducer 2180 V DC 3 Weights are approximate less crating Refer to section on lubrication for specifications of lubricants Amounts are approximate only for standard HM 1 position 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 with
6. 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 screw Roller gear hub Clutch detent plate Clutch detent rollers Roller retainer plate Bearing Thrust washer Bearing adapter ring Lockwasher Locknut Cap screw Cap screw Pull dowel Bearing thrust washer Thrust bearing Switch plate Timken bearing Spring Post Compression ring Compression pin Locking nut Set screw Cap screw O ring Set screw SECTION 2 Overview continued 2 3 Ferguson Reducer Location Map Indexer Input FIGURE 3 Ferguson 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 Key for Indexer Shaft 15 Oil Seal 6 Arrestor Washer 16 Wear Sleeve 7 17 Cover Plate 8 Cap Screw deleted keeper 18 Cap Screws 9 Cap Screw for Clamping Hub 19 Oil Plugs SECTION 3 Specifications Unit Weight with Motor Reducer Pkg LBS S 8 E Zj J 5 Cn 5 5 58 814 lt 2 5 2 gt amp 152 gt of 50 5215 B 86 8 128 5 22 3 2 9 gt gal ae CO 9 5 2
7. IMC Technical Services Department 1 800 645 5207 or 847 459 5200 or your local Sales Engineer for assistance when evaluating the above conditions 37 38 UNIT CONFIGURATIONS REDUCER MOUNTING POSITIONS HAND OF Satan n Ibe 5 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 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 0104 REV 7 1 03
8. 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 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 Serviceman make or supervise repairs in your plant Proper alignment and adjustment of the components are essential to their performance and life 23 24 SECTION 8 Repair Replace 8 1 Cam Follower Replacement Models 162 200 250 451 amp 501 8 1 1 8 1 2 8 1 3 8 1 7 Rotate camshaft to mid dwell position See Figure 4 Drain oil amp remove rear access cover plate Remove cap screws from output shaft bearing cap and remove bearing retaining cap Save all of the shims for re assembly Remove output shaft from housing by driving from rear with a soft mallet Remove outer Timken bearing race from bearing cap and save for re assembly Determine the type of cam
9. 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 222 grade Loctite on setscrew install and tighten firmly SECTION 8 Repair and Replace continued FOLLOWER NO F 38 005 FIGURE 13 DISASSEMBLY Refer to Figure 12 Note there is no draw hammer hole ASSEMBLY Refer to Figure 12 except F 38 has no shoulder Use feeler gauge to set 005 clearance under washer 29 30 SECTION 8 Repair and Replace continued 8 4 Oil Seal Replacement 8 4 1 8 4 2 8 4 3 8 4 4 8 4 5 8 4 6 8 4 7 8 4 8 8 4 9 8 4 10 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
10. 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 8 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 8 making sure it engages in adjusting nut number 6 Figure 8 to prevent damage to screw threads NOTE If setscrew number 11 Figure 8 is accidentally tightened on threaded portion of adjusting nut number 6 Figure 8 it will raise a burr Failure to remove this burr will cause shearing of threads and jamming of nut of housing number 1 Figure 8 To remove burr remove setscrew number 11 Figure 8 and rotate adjusting nut counter clockwise until burr is in center of tapped hole in housing number 1 Figure 8 Use a hand electric drill that fits freely into the tapped hole Drill into the adjusting nut number 6 Figure 8 sufficiently to remove the burr There are 2 setscrews number 11 Figure 8 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 th
11. 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 Resetting Procedure 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 8 on the main body number 3 Figure 8 to the thread engagement closest to the center position on the threaded portion of the body number 3 Figure 8 Check the limit switch circuitry for proper operating conditions The indexer can now be powered up and production resumed SECTION 5 Adjustments continued 5 3 4 Clutch Adjustment Procedure FIGURE 9 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 8 b Insert pins of spanner Figure 9 into holes of adjusting nut number 6 Figure 8 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
12. 45 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 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
13. Automation Robohand FERGUSON CAMEO INSTALLATION amp SERVICE MANUAL FD amp SENTRY 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 Depart
14. CHART 2 21 22 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 Steel and iron worn from bearing roller ends and cages and cams surface this is a normal condition A End play in worm shaft due to improper pre load of shaft bearings B Loose gear on camshaft A Improper pre load on worm shaft bearings 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 Normal 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 Contact Technical Services at 800 645 5207 or 847 459 5200 SECTION 7 Troubleshooting continued TROUBLESHOOTING GUIDE Symptom Cause Solution OIL LEAKS AT Seals Worn or
15. LOWER ROLLER GEAR HUB 242 SOCKET HEAD SETSCREW 90 Cone point HEX DRILL SEAT FOR SOCKET SETSCREW DIA SELF LOCKING NUT FIGURE 11 DISASSEMBLY Remove locknut setscrew and follower 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 27 28 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 12 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
16. USA SECTION 2 Overview The sketches contained in this document are for illustrative purposes only They are intended to than shown depending upon options chosen or the particular configuration of a unit 2 1 FD Series Location Map FIGURE 1 FD Series Parts List 1 Housing 11 Access cover 20 Timken bearing 2 Cover 12 Key 21 Locknut and washer 3 Cover shaft 13 Cam 22 Oil seal 4 Output shaft bearing cap 14 Cam spacer ring 23 Oil seal 5 Bearing clamp not all drives 24 Cap screw 6 Shims 15 Roller gear shaft 25 Cap screw 7 Shims 16 Cam follower 26 Cap screw 8 Open eccentric bushing 17 Set screw 27 Cap screw 9 Eccentric bushing ring 18 Timken bearing 28 Cap screw 10 Shims 19 Timken bearing SECTION 2 Overview continued 2 2 Sentry Series Location Map 38 40 31 16 3940 FIGURE 2 SECTION 2 Overview continued o Pp Pp Pp Pho ND 2 2 S 5 Sentry Series Parts List Housing Cover Cover shaft Output shaft bearing cap Bearing clamp Shims Shims Open eccentric bushing Eccentric bushing ring Shims Access cover Key Cam Cam spacer ring not all drives Roller gear shaft Cam follower Set screw Timken bearing Timken bearing Timken bearing Locknut and washer Oil seal Oil seal Cap screw Cap screw Cap screw Cap screw 28 29 30 31
17. am follower from the following diagrams and replace using the procedure in the diagram Replace the output shaft back into housing and drive outer race of front bearing into housing until it touches rollers of inner race Assemble bearing cap to housing with all of the original shims or a new set with same thickness Tighten all cap screws evenly to pre load bearing NOTE Use Permatex Aviation Form a Gasket 80019 between the housing and the first shim of the output shaft bearing ring NOTE Use Locktite Threadlocker 222 on cap screws Refill oil sump with 7 oz of Mobilgear SHC 680 through oil level plug Use Locktite 592 Teflon Pipe Sealant on pipe plug 25 SECTION 8 Repair and Replace continued FOLLOWER NO FM 50 FM 62 FM 75 ROLLER GEAR HUB 7 FOLLOWER NYLON PLUG HEX SOCKET 1 16 SOCKET HEAD JAM NUT SETSCREW Cup or Dog Point FIGURE 10 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 26 SECTION 8 Repair and Replace continued FOLLOWER NO FM 100 amp FS100 FS400 s FOL
18. cal Service Department at 1 800 645 5207 or 847 459 5200 The indexing unit 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 Industrial Motion Control 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 4 1 10 Check the adjustment of the Switch cam if your unit has this option To insure unit stops in dwell see Figure 4 4 1 10 1 A standard FD indexer is shown in figure 4 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 11 12 SECTION 4 Installation continued 4 1 10 2 If the index
19. ce of the gear noted at the time of disassembly must be duplicated either by grinding the adjusting spacer or adding shims see Figure 15 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 15 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 for quantity and specification SECTION 8 Repair and Replace continued 8 5 2 Winsmith Worm Gear Reducer 8 5 3 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 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 35 36 SECTION 9 THINGS TO AVOID A
20. e screw threads 19 20 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 8 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 8 and along body and cone number 3 Figure 8 If clutch is slipping the line on nut number 6 Figure 8 and body and cone number 3 Figure 8 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 5 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 8 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 2 you have any questions about a particular lubricant feel free to call us at 1 800 6
21. er 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 Controllers 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 FD amp Sentry Drives are solid mechanical backlash free mechanisms There are 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 user s load in place it will be necessary to check these items for proper adjustment and settings NOTE The drive should be in the center of dwell and dowel pi
22. follower from the following diagrams and replace using the procedure in the diagram Replace output shaft back into the housing and drive outer race of front bearing into the housing until it seats against rollers of inner race Assemble bearing cap to housing with all of the original shims or a new set with the same thickness Tighten all cap screws Scrape old sealant from housing and rear access cover Apply new silicone rubber sealant and assemble rear access cover to housing Tighten all screws evenly 8 110 Refill with oil to level indicated 8 2 Cam Follower Replacement Model FD300 8 2 1 8 2 2 8 2 3 8 2 4 8 2 5 8 2 6 Drain oil and remove top access cover Rotate camshaft so cam follower is directly below access opening Determine the type of cam follower from the following diagrams and replace using the procedure in the diagram Scrape old sealant from access cover and housing Apply new silicone rubber sealant and assemble top access cover to housing Tighten all screws evenly Refill with oil to level indicated SECTION 8 Repair and Replace continued 8 3 Cam Follower Replacement Model FD100 8 3 1 8 3 2 8 3 3 Rotate camshaft to mid dwell position See Figure 4 Drain by removing pipe plug in housing Remove cap screws from output shaft bearing cap and remove cap Keep all shims for re assembly Pull output shaft from housing Determine the type of c
23. 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 The 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
24. ment 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 General Information 2 4 Ei Wana ots wet et dee Gig 2 2 3 1 3 Operating Environment 3 1 4 Ordering Replacement Parts naaa aaaea 3 1 5 5 oc nee bebe eae ee 4 1 5 Returning a Unit for Repair 4 2 oe ee OE Pe 5 8 2 1 Series Location Map amp Parts 5 2 2 Sentry Series Location Map amp Parts List 6 7 2 3 Ferguson Reducer Location Map amp Parts List 8 3 Specifications
25. mponents 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 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 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 Ferguson 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 the
26. n Industrial 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 designed with 001 of clearance under the dial and is strong enough to carry the full load of the asymmetrical load Consult the IMC 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 co
27. nned to the base before installing accessories as previously mentioned in 4 1 1 amp 4 1 5 4 5 1 Internal Torque Limiters S Series only 5 1 1 S SM100 Unit Output FIGURE 5 Industrial Motion Control s S SM100 is the same as the previously offered FD100 with the internal clutch That means that this unit has a non adjustable internal clutch Also this unit unlike the other Sentry units has a junction box on the unit to mount the proximity switch 13 SECTION 5 Adjustments continued 5 1 2 S SM162 S SM300A FIGURE 6 PROX SWITCH FLANGE STYLE OUTPUT SHAFT STYLE OUTPUT ADJUST ING SCREWS Industrial Motion Control s S SM162 S SM300A has an adjustable internal clutch The torque setting is adjusted by tightening 3 or 4 depending upon unit size independent screws clockwise rotation increases the torque setting The screws should be run all the way in then adjusted equivalent amounts in 1 4 turn increments from that point The adjusting screws are retained and sealed by a vibration resistant thread coating This coating could over a number of adjustments wear out Reapplication of this coating will return screws to manufacturers specifications 14 SECTION 5 Adjustments continued 5 2 Prox Switch Adjustments Load Resistor l 150 Ohm 1 Watt Black Wire x L E D 12 Volt D C Brown Wire Power Supply FIGURE 7 5 2 1 I
28. ntact 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 a dirty environment periodic cleaning must be practiced 1 3 1 1 4 1 1 4 2 1 4 3 and careful inspection of seals and accessories is necessary 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 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
29. nternal Clutch Trip Detection Prox Switch 5 2 1 1 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 5 2 1 2 Screw the prox switch out until the L E D goes out Next screw the switch in again until the L E 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 15 16 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 IMC part numbers listed below If your equipment has another model number or is from another manufacturer contact the switch manufacturer for set up procedures IMC Part Number 1000000938 Turck 1 GO8 AN6X IMC Part Number 1000000939 Turck Bi 2 G12 AN6X IMC Part Number 1000003115 Turck Bi 1 G08 AN6X H1341 SECTION 5 Adjustments continued 5 3 FSC Ferguson Slip Clutch Location Map O 0 4 5 8 3 Thrust Bearing 1 3
30. orkmanship 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 alleged 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 cam This can cause serious damage to the Indexer and reduce the cam follower life For cycling during setup of 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 so
31. out 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 4 Keyway Shown In Additional Lobe For Center Of Dwell x2 Drive Codes FIGURE 4 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 10 SECTION 4 Installation continued 4 1 5 4 1 6 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 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 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 local Industrial Motion Control Representative or the Techni
32. 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 smaller than the bore size If possible the center of tool should be relieved so that pressure is applied only at the O D SECTION 8 Repair and Replace continued 8 4 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 8 4 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 4 13 Check for parts interference from other machine parts that might rub against the seal causing friction and damaging heat 8 5 Reducers Typical Ferguson R Series Reducer Splined end of shaft ASA DA AIA A BF AA 7 3 A 42 Extended Shaft
33. urce 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 1 2 5 1 2 6 Reducers should be of minimum backlash variety and directly coupled with a 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 chain changes sides It is necessary to maintain a constant speed of the input shaft Loose belts or chains will allow inertial over run that may cause damage to the cam followers Belts and chains must be sized for severe reversing loads Industrial Motion Control does not provide guarding for other moving parts such as sprockets 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 co
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