FD & SENTRY® SERIES 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 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.
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 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.
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 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.
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. FD Series Location Map FIGURE 1 FD Series Parts List 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
SECTION 2: Overview (continued) 2.2.
SECTION 2: Overview (continued) Sentry Series Parts List 1. Housing 28. Cap screw 2. Cover 29. Roller gear hub 3. Cover shaft 30. Clutch detent plate 4. Output shaft bearing cap 31. Clutch detent rollers 5. Bearing clamp 32. Roller retainer plate 6. Shims 33. Bearing 7. Shims 34. Thrust washer 8. Open eccentric bushing 35. Bearing adapter ring 9. Eccentric bushing ring 36. Lockwasher 10. Shims 37. Locknut 11. Access cover 38. Cap screw 12. Key 39. Cap screw 13. Cam 40.
SECTION 2: Overview (continued) 2.3. Ferguson Reducer Location Map FIGURE 3 Ferguson Reducer Parts List 1. 2. 3. 4. 5. 6. 7. 8. 9. 8 Housing Ring Gear (& separate spider for some units) Pinion Worm Gear Gear Spacer Key for Indexer Shaft Arrestor Washer Lockwasher Cap Screw - deleted "keeper" Cap Screw for Clamping Hub 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
External Output Shaft Torque Limiter Input Shaft Overload – Available on Ferguson R Series Reducers Only Lubrication Capacity 4 Main Oil Sump (Gallons) Lubrication Capacity Gear Reducer 4 Unit Weight (LBS) Unit Weight with Reducer (LBS) Unit Weight with Motor/Reducer Pkg. (LBS) YES RT3 N/A 7 OZ. N/A 10 N/A 25 162 20CDSF N/A MDB625 (.5) .5 HP YES RT5 N/A 0.5 13 OZ 50 N/A 110 200 26CDSF N/A MDB625 (.5) .5 HP YES RT5 N/A 1.
SECTION 4: Installation These units are manufactured to meet a specific set of design parameters. Any change to the load on the output shaft, or speed of the camshaft may require a size change. No change can be made without affecting other performance characteristics of the unit and, therefore, should not be done without consulting the factory. 4.1. To install the unit: 4.1.1. Rotate camshaft so cam is in center of dwell (see figure 4). FIGURE 4 4.1.2.
SECTION 4: Installation (continued) 4.1.5. Check the oil level of the sump and gear reducer prior to operating the unit. 4.1.6. 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).
SECTION 4: Installation (continued) 4.1.10.2. If the indexer has a drive code which causes multiple indexes per camshaft revolution (i.e. X2, X3, etc… drive codes), additional lobe(s) on the Brake Cam are required. The lobes will be equally spaced. Therefore, phasing the one lobe of the Brake Cam to one dwell period on the indexing cam will, in most cases, cause the other lobes to be correctly phased with the other dwell periods.
SECTION 5: Adjustments The FD & 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.
SECTION 5: Adjustments (continued) 5.1.2. S/SM162 - S/SM300A FIGURE 6 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.
SECTION 5: Adjustments (continued) 5.2. Prox Switch Adjustments 12 Volt D.C. Power Supply FIGURE 7 5.2.1. Internal 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.
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.
SECTION 5: Adjustments (continued) 5.3. FSC… Ferguson Slip Clutch Location Map 1. Housing 3. Body & Cone 4. Thrust Bearing 5. Silicon Spring 6. Adjusting Nut 7. Guide Pin 8. Spool 9. Ball Plunger 10. Liner Bushing 11. Setscrew 12.
SECTION 5: Adjustments (continued) 5.3.1. 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) 5.3.4. 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 8). 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.
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.
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 1-800-645-5207 or 847-459-5200. 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 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 Inadequat
SECTION 8: Repair and Replace 8.1 Cam Follower Replacement – Models 162, 200, 250, 451, & 501. 8.1.1. Rotate camshaft to mid-dwell position. (See Figure 4) 8.1.2. Drain oil & remove rear access cover plate. 8.1.3. Remove cap screws from output shaft bearing cap and remove bearing retaining cap. Save all of the shims for re-assembly. 8.1.4. Remove output shaft from housing by driving from rear with a soft mallet. 8.1.5. Remove outer Timken bearing race from bearing cap and save for re-assembly. 8.1.6.
SECTION 8: Repair and Replace (continued) 8.3. Cam Follower Replacement – Model FD100 8.3.1. Rotate camshaft to mid-dwell position. (See Figure 4) 8.3.2. Drain by removing pipe plug in housing. 8.3.3. Remove cap screws from output shaft bearing cap and remove cap. Keep all shims for re-assembly. 8.3.4. Pull output shaft from housing. 8.3.5. Determine the type of cam follower from the following diagrams, and replace using the procedure in the diagram. 8.3.6.
SECTION 8: Repair and Replace (continued) FOLLOWER NO. FM-50; FM-62; FM-75 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.
SECTION 8: Repair and Replace (continued) FOLLOWER NO. FM-100 & FS100 - FS400 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.
SECTION 8: Repair and Replace (continued) FOLLOWER NO. F-50 THROUGH F-400 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 head - do not strike the follower end cap when installing.
SECTION 8: Repair and Replace (continued) FOLLOWER NO. F-38 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.
SECTION 8: Repair and Replace (continued) 8.4. Oil Seal Replacement 8.4.1. 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. 8.4.2. Check dimensions – to be sure that shaft and bore diameters match those specified for the seal selected. 8.4.3. Check seal – for damage that may have occurred prior to installation.
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.
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).
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. Remove the worm as described above. 8.5.1.1.2.2. Record the distance from the finished face of the housing to the unmarked face of the gear (see Figure 15). 8.5.1.1.2.3. Remove screw and washer retaining gear, if applicable. 8.5.1.1.2.4. Loosen the screw clamp on the split hub side of the gear. 8.5.1.1.2.5. Remove the gear.
SECTION 8: Repair and Replace (continued) 8.5.1.1.3.2. 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 15). 8.5.1.1.3.3. 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. 8.5.1.1.3.4.
SECTION 8: Repair and Replace (continued) 8.5.2. 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. 8.5.3. Brison Gear Motor NOTE: May come with 1/11 HP or 1/4 HP motor depending on reducer ratio. It is not considered economical to repair or replace components only. Replacement of the entire product is recommended.
SECTION 9: THINGS TO AVOID An 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.
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. 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.
UNIT CONFIGURATIONS, REDUCER MOUNTING POSITIONS, HAND OF CAM 38
NOTES
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.
