INTERMITTOR® ROLLER DIAL INDEX DRIVES Installation & Service Manual The Driving Force in Automation WARNING This is a controlled document. It is your responsibility to deliver this information to the end user of the CAMCO/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 800-645-5207.
INTRODUCTION INTRODUCTION This manual is supplied to aid in the installation and maintenance of your Fergusonbrand 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.
Table of Contents Section 1. 2. Page General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 1.1. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1.2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,3 1.3. Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1: General Information The Industrial Motion Control (IMC) Intermittor is 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.
SECTION 1: General Information (continued) 1.2.4. 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. 1.2.5. When using chain drives, incorporate an idler to eliminate any slack. (Do not use spring-loaded idlers.) As the cam motion stops and starts, any slack in the drive changes sides. It is necessary to maintain a constant speed of the input shaft.
SECTION 1: General Information (continued) 1.5. 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. 1.6.
SECTION 2: Overview The sketches contained in this document are for illustrative purposes only. They are intended to represent standard components and may not be shown to scale. The various models may be different than shown, depending upon options chosen or the particular configuration of a unit. 2.1. Intermittor Location Map FIGURE 1 Intermittor Parts List 1. 2. 3. 4. 5. Housing Cam Roller Gear Hub Roller Gear (Output) Shaft Bearing Ring & Spacer Shims 6. Oil Seal 7. Timken Bearing 8. Cam Followers 9.
SECTION 2: Overview (continued) 2.2. Ferguson Reducer Location Map FIGURE 2 Ferguson “R” Series Reducer Parts List 1. 2. 3. 4. 5. 6. 7. 8. 9. 6 Housing Ring Gear (& separate spider 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.
Output Shaft Torque Limiter Input Shaft Torque Limiter Lubrication Capacity 3 Main Oil Sump (Gallons) Lubrication Capacity 3 Gear Reducer Unit Weight with Reducer (LBS) Unit Weight with Motor/Reducer Pkg. (LBS) 1 HP1 DTL10 R3FSC 4 GAL. 2.5 QTS. 200 250 300 1.5 HP DTL10 R4FSC 4 GAL. 1.5 GAL. 450 550 625 1.5 HP N/A R4FSC 8 GAL. 1.5 GAL. 800 875 975 2.0 HP N/A R5FSC 9 GAL. 2.5 GAL. 1000 1150 1300 N/A N/A R5FSC 14 GAL. 2.5 GAL. 1500 1650 1800 N/A N/A R6FSC 15 GAL.
SECTION 4: Installation These units are manufactured to meet a specific set of design parameters. Any change to the load, size of dial, 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 input shaft so cam is in center of dwell (see Figure 3). FIGURE 3 4.1.2.
SECTION 4: Installation (continued) 4.1.5. 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 holes 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. 4.1.
SECTION 4: Installation (continued) 4.1.7. Check the adjustment of the switch cam if your unit has this option. To insure unit stops in dwell, see Figure 3. 4.1.7.1. A standard roller gear indexer is shown in Figure 3 with a Brake Cam & Limit Switch shown with the keyway in the center of the dwell period.
SECTION 5: Adjustments The Intermittor is a solid mechanical, backlash-free mechanism. There are no adjustments required on the Intermittor during installation unless it is furnished with a torque limiting device or a motor drive package equipped with speed control. After the Intermittor has been installed and set up with the users’ load in place, it will be necessary to check these items for proper adjustment & settings.
SECTION 5: Adjustments (continued) 5.1.1. 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.
SECTION 5: Adjustments (continued) 5.1.4. Clutch Adjustment Procedure CAUTION: OPERATIING THE INDEXER WITH THE CLUTCH NOT ADJUSTED CAN CAUSE IMMEDIATE AND SEVERE DAMAGE TO THE INTERNAL COMPONENTS OF THE INDEXER. a. b. Loosen cone point setscrew (number 11, figure 4). Insert pins of spanner (figure 6) into holes of adjusting nut (number 6, figure 4), and turn nut clockwise one notch in the adjusting nut. This will tighten the clutch.
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 (number 3, Figure 4) will not rotate with the other parts of the clutch. Small amounts of clutch slippage can be difficult to determine.
SECTION 6: Maintenance 6.1. 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 1-800-422-8936. 6.2. 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 & fill plug.
SECTION 7: Troubleshooting TROUBLESHOOTING GUIDE Symptom Solution Backlash at output shaft (in dwell) Worn/damaged followers Replace Tight Stations (torque required to rotate cam shaft through tight station is more than 1 1/2 times the loose station) Bent cam followers Replace; inspect holes in roller gear shaft Pitting of cam follower outer race/cam track surface Incorrect oil Replace cam followers and fill unit with correct oil Fine magnetic metallic particles in oil; appear bronze color when i
SECTION 7: Troubleshooting (continued) TROUBLESHOOTING GUIDE Symptom OIL LEAKS AT: Seals Cause Solution Worn or damaged seal and/or shaft surface Replace seal; polish shaft Shims Damaged shim Replace; apply “Loctite Aviation Grade Sealant” to both sides Cap Screws Shim damaged between screw hole and interior of housing Replace gasket or shim; apply “Loctite Aviation Grade Sealant” to both sides Holes drilled through Remove screw, apply “Loctite Threadlocker” and re-install Cover joints Inadequ
SECTION 8: Repair and Replace 8.1 Cam Follower Replacement 8.1.1. Rotate camshaft to mid-dwell position. (See Figure 3) 8.1.2. Drain oil and remove front access cover. 8.1.3. Stand unit on end and remove bottom access cover to expose cam follower stud locking fastener. 8.1.4. Determine cam follower design for your unit, and refer to the following instructions (Figures 6 through 9). Then continue with step #8.1.5. below. 8.1.5. Clean sealant from access cover(s) and surfaces on housing. 8.1.6.
SECTION 8: Repair and Replace (continued) FOLLOWER NO. F-50 THROUGH F-400 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.
SECTION 8: Repair and Replace (continued) FOLLOWER NO. FM-100 & FS100 - FS-400 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.
SECTION 8: Repair and Replace (continued) 8.2. Oil Seal Replacement 8.2.1. 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. 8.2.2. Check dimensions – to be sure that shaft and bore diameters match those specified for the seal selected. 8.2.3. Check seal – for damage that may have occurred prior to installation.
SECTION 8: Repair and Replace (continued) 8.2.12. Bottom out the tool or seal – to avoid cocking of the seal in the bore. This also positions the seal correctly on the shaft. 8.2.13. Check for parts interference – from other machine parts that might rub against the seal causing friction and damaging heat. 8.3.
SECTION 8: Repair and Replace (continued) 8.3.1. “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 IMC’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).
SECTION 8: Repair and Replace (continued) NOTE: Worm must be dropped before attempting to remove the gear. 8.3.1.1.2. Gear 8.3.1.1.2.1. Remove the worm as described above. 8.3.1.1.2.2. Record the distance from the finished face of the housing to the unmarked face of the gear (see Figure 10). 8.3.1.1.2.3. Remove screw and washer retaining gear, if applicable. 8.3.1.1.2.4. Loosen the screw clamp on the split hub side of the gear. 8.3.1.1.2.5. Remove the gear.
SECTION 8: Repair and Replace (continued) 8.3.1.1.3.2. 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 10). 8.3.1.1.3.3. 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. 8.3.1.1.3.4.
SECTION 9: THINGS TO AVOID An 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.
UNIT CONFIGURATIONS, REDUCER MOUNTING POSITIONS, HAND OF CAM 27
Industrial Motion Control, LLC www.camcoindex.com Michigan Office 550 Forest Avenue Unit #14 Plymouth, Ml 48170 USA ph: 734-459-8080 fax: 734-459-8110 1444 S.
