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INDEX DRIVES
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User Manual
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DE-STA-CO INDEX DRIVES User Manual

GENERAL SERVICE MANUAL
INDEX DRIVES
WARNING
Table of Contents
Introduction...........................................................................................................................2
How to Use This Service Manual..........................................................................................2
Warranty...............................................................................................................................2
Warnings and Cautions........................................................................................................3
Interpretation of Index Drive Model Numbers.......................................................................3
Index Drive Basic Service Requirements..............................................................................4
Inspection of Cam Followers................................................................................................4
Index Drive Lubrication Data................................................................................................5
Index Drive Oil Capacities (Approximate).............................................................................6
Oil Seal Installation Recommendations................................................................................6
Gear Reducer Service Data..................................................................................................7
Gear Reducer Lubrication Data............................................................................................8
Overload Clutch....................................................................................................................9
Long Term Reducer/Indexer Storage...................................................................................9
Troubleshooting Guide.......................................................................................................10
Recommended Input Configuration....................................................................................12
Recommended Output Configuration.................................................................................13
Cam & Limit Switch Functions............................................................................................14
How to Order Parts.............................................................................................................15
How to Return Equipment for Repair..................................................................................16
Indexer Weights..................................................................................................................17
Recommended Tightening Torque Values for Cap Screws................................................18
Cam Follower Installation Procedure..................................................................................19
1
Introduction
CAMCO Index Drives are engineered and manufactured to very high tolerances which necessitate careful inspection and maintenance. This manual is a general guide to lubrication, troubleshooting and general information about index drives.
In addition to this General Service Manual, Industrial Motion Control, LLC (IMC) has other service manuals devoted to the specific model CAMCO index drive you are using. The model-specific service manuals cover disassembly and assembly of the major components. They also contain an exploded view drawing of the index drive with a complete bill of materials for identifying and ordering spare or replacement parts.
Some users of index 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 service technicians make the repairs.
How to Use This Service Manual
1. This manual deals covers general service and maintenance subjects. In addition to this manual you should have the model-specific service manual. You may request a copy from your local IMC Sales Representative, directly from IMC (847-459-5200 / camco@destaco.com) or download a copy from the IMC website: www.camcoindex.com.
2. The Model Number Interpretation section will assist you in identifying the model you have and the characteristics of your index drive
3. The Troubleshooting Guide will help you diagnose potential problems.
4. This manual will explain how to order parts or return an Index Drive to IMC for repair. IMPORTANT: The Bill of Materials listed in the model-specific service manual is for a standard unit. If you feel you have a special unit, or are in doubt, please use the procedures outlined in the “How to Order Parts” section.
5. Read all CAUTIONS and WARNINGS prior to service or repair.
6. Read WARRANTY prior to service or repair.
Warranty
IMC 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.
IMC’s 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.
See the "How to Return for Repair" section of this manual.
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Warnings and Cautions
Statements in this manual preceded by the words WARNING or CAUTION and printed in italics are very important. We recommend you take special notice of these during service or repair.
WARNING
Means there is the possibility of personal injury to yourself or others.
CAUTION
Means there is the possibility of damage to the CAMCO unit.
Interpretation of Index Drive Model Numbers
In an effort to better understand the type of Index Drive you have purchased, the complete model number as it appears on the name tag can be divided into five (5) main components.
CAMCO EXAMPLE: 250P4H20-270 250 P 4 H20- 270
(1) (2) (3) (4) (5)
1. The basic CAMCO model series, usually the pitch diameter of the cam follower circle (i.e. 250
means 2.5" diameter).
2. The type of cam and output configuration
P = Parallel cam unit RA = Right angle cam unit RAD = Right angle cam / dial mounting output RD = Roller gear cam / dial mounting output RG = Roller gear cam unit RDM = Roller gear cam / dial mounting output / motorized RNG = Ring index drive E = Heavy duty right angle cam units / dial mounting
3. The number of stops.
Four (4) stops means the output shaft will make four starts and stops during one complete 360 degree revolution. The angle of each segment of output rotation (index distance) is found by dividing 360 by the number of stops.
EXAMPLE: 4 stops = 360/4 = 90° per index
4. Cam follower size in 32nds of an inch.
For example H20 = 20/32 = .625 inch diameter followers H96 = 96/32 = 3.00 inch diameter followers
5. Cam motion in degrees.
The cam is divided into two basic parts, motion and dwell. Motion is the angular segment in which the cam does its work rotating the output shaft one complete index.
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After motion is complete the cam is considered to be in dwell for the reminder of the 360° rotation. During dwell the output of the Index Drive is stationary even though the input shaft continues to rotate.
Example: For a 270° motion, during 270° of input rotation the output shaft makes one index. During the remaining 90° of input rotation the output is stationary.
IMPORTANT NOTE: Some CAMCO units are called "type 2" units. In this case the cam has two motion periods and two dwell periods on the cam.
Example: 250P6H20-270 Type 2 (also shown as Type II)
For 135° on input rotation the output shaft makes one index. During the next 45° of input rotation the output does not move. For the next 135° of input rotation the output makes a second index. During the next 45° of input rotation the output does not move. In summary, two complete cycles of index and dwell are provided for one rotation of the input shaft. Therefore, 50RPM at the input (cam) shaft equals 100 indexes/minute.
Index Drive Basic Service Requirements
1. The Index Drive oil level should be checked monthly and oil added as required to maintain proper level.
2. The oil should be changed as outlined in the lubrication section.
3. All grease fittings should be lubricated with the recommended grease once per month.
4. All index drive mounting bolts should be checked for tightness after three months of service and annually thereafter.
5. Cam followers should be inspected every 8000 hours of operation.
Inspection of Cam Followers
The cam followers should be inspected every 8000 hours of operation. Backlash at any station indicates worn or damaged cam followers. Any binding during rotation of the input shaft could indicate broken cam followers.
To inspect for excessive backlash, place the indexer in a dwell position and check for looseness by physically trying to force the dial or crank arm back and forth. Excessive looseness (.0015” at 6" radius) indicates replacement of the cam followers is required and the Index Drive should be returned to IMC for repair.
Contact your local IMC representative for assistance if necessary.
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Index Drive Lubrication Data
OIL LEVEL
CAMCO Index Drives are furnished with a "bulls-eye" type oil level sight gauge. The oil level should be checked when the unit is stopped at which time the oil level should reach the center of the sight glass (see page 3 for estimated oil capacity). During oil changes this "bulls-eye" can be removed for cleaning.
CAUTION: CAMCO units are shipped without oil. Be sure to fill prior to initial startup.
OIL CHANGE
An oil change is required every 2000 hours of operation, or every six months whichever occurs first. Where operating conditions are severe, such as rapid rise and fall in temperature of the indexer housing (which is accompanied by sweating of the inside walls with a resulting formation of sludge), where operation is in moist and dusty atmospheres, or in the presence of chemical fumes, it may be necessary to change the oil in intervals of one to three months.
NOTE: The magnetic drain plug should be visually inspected at this time for metallic chips that might indicate failure of one of the internal components.
TYPE OF OIL
Lubricating oils should be high quality, well-refined petroleum oils or synthetic lubricants with extreme pressure additives. They may be subjected to high operating temperatures, so they must have good resistance to oxidation.
IMC recommends the following:
• General applications: ISO 220 grade oils with EP additives such as MOBILGEAR 630 (Exxon-Mobil) or OMALA 220 (Shell Oil).
• Severe applications or for longer life: Oil that meets API-GL-5 and Mil Spec 2105D/E parameters such as Mobilube HD Plus 80W90 (conventional) or Mobil Delvac Synthetic Gear Oil 75W90 (synthetic)
• Servo-controlled applications: use Mobil SHC 634 (Exxon-Mobil). NOTE: When the gear reducer and Index Drive have a common oil reservoir (as with the
902RDM Index Drive and the R250 reducer), an AGMA #8 compound is recommended. One such lubricant is Exxon-Mobil's 600 W SUPER CYLINDER OIL.
NOTE: If you cannot locate the oil listed your supplier should be able to cross reference to another brand.
NOTE: For lubricants used in Gear Reducers not sharing common oil with Index Drives see the GEAR REDUCER SERVICE SECTION. DO NOT use oils with EP Additives in Gear Reducers.
GREASE PACKED BEARINGS
Bearings that are accessed by oil in the indexer reservoir require no additional maintenance. Bearings not lubricated by the oil in this way are normally packed with a high quality bearing grease. However, bearings that are not lubricated by the oil reservoir or by grease packing will require periodic greasing. Bearings of this type will be furnished with a grease fitting and should be greased with NGLI #3 bearing grease (such as MOBILGREASE XHP222) at least once per month. Do not over lube since the excess grease will eventually fall into the indexer oil reservoir.
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Index Drive Oil Capacities (Approximate)
For indexers mounted in the normal* position. Consult IMC for units not listed.
Model No. US. Metric Model No. U.S. Metric
(quarts) (liters) (quarts) (liters) 80RDM 601RDM 2 2 50RGD/S 16 oz. 0.5 902RDM 3 3 70RGD/S 20-24 oz. 0.6-0.7 1100RDM 8 8 80RGD/S 30-38 oz. 1-1.1 1305RDM 9 9 110RGD/S C/F C/F 1800RDM 36 34 350RGD/S 1 1.4 425RD 2 2 500RGD/S 5 4.7 800RD 5 5 700RGD/S 10 9.5 1301RD 14 13 1801RD 36 34 1100RNG C/F C/F 1550RNG C/F C/F 250P 1 1 2050RNG C/F C/F 387P 2 2 512P 5 5 750E C/F C/F 662P 10 10 950E 10 gallons 38 900P 20 19 1150E 25 gallons 95 1200P 48 45 1550E 40 gallons 152 1800P 95 90 2050E 45 gallons 171 2750E 75 gallons 285 401RA (C) 1 1 512RA(CC) 2 2 150RPP 2.5 2.4 662RA(CCM) 6 6 300RPP 4 4 663RAD(DR) 4 4 500RPP 10 9 900RAD(GH) 6 6 900RPP 48 45
* Normal indexer mounting position is output vertical over input on all models except the "Parallel series" (P) in which normal mounting is output horizontal, even with input. “Output Vertical” refers to the direction of the center of rotation. For dial-type indexers, this is the position with the dial horizontal. ** “Grease-filled” units are shipped with grease. Grease should only need to be added if the unit is disassembled for rebuild or repair. C/F: Consult IMC for information
Grease filled**
40RGD/S 6 oz. 0.2
Oil Seal Installation Recommendations
IMC recommends that all seals be replaced any time the device is being disassembled regardless of whether they are damaged or not. Most damage to oil seals occurs at assembly when recommended seal installation procedures are not followed.
1. Check dimensions -- to be sure that shaft and bore diameters match those specified for the seal selected.
2. 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.
3. Check bore -- to see that the leading edge is deburred. A rounded corner of chamfer should be provided.
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4. Check shaft -- remove surface nicks, burrs and grooves and look for spiral machine marks that
can damage the seal lip.
5. Check shaft end -- remove burrs or sharp edges. The shaft end should be chamfered.
6. 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.
7. 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.
8. Pre-lubricate the sealing element -- before installation by wiping with lubricant being retained.
9. Use the correct installation tool -- press fitting tools should have outside diameter .010" smaller
than the bore size. If possible, the center of tool should be relieved so pressure is applied only at the outer diameter of the seal.
10. 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.
11. Bottom out the tool or seal -- to avoid cocking of the seal in the bore. This also positions the seal
correctly on the shaft.
12. Check for parts interference -- from other machine parts that might rub against the seal causing
friction and damaging heat.
Gear Reducer Service Data
CAMCO Index Drives use two basic makes of reducers. These are IMC (R180, R225, R260) and Cone (7300C, 7350C, etc.). The service data list below is intended to cover both in a general manner. For other types of reducers, consult the manual supplied with the reducer or contact IMC.
1. For reducers supplied with a sight glass, the oil level should be checked monthly and the
recommended oil added as required to maintain the proper oil level.
2. The oil should be changed as outlined in the lubrication section.
3. All grease fittings should be lubricated with the recommended grease once per month.
4. The reducer, particularly finned areas and fan covers. should be kept clean to allow maximum
heat dissipation. (Excessive accumulation of dirt and grease will effect proper cooling of the unit).
5. All reducer and foundation bolts should be checked for tightness after three months of service
and annually thereafter.
6. A change in sound level or excessive vibration can indicate low oil level, abnormal loading or
worn elements.
7. During operation, a worn gear may run hot. However, unless the temperature exceeds 200° F.
(93° C) there is no cause for alarm.
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