DE-STA-CO PN500 User Manual
The Driving Force in Automation
ED & PINNACLE®SERIES DRIVES
Installation & Service Manual
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
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. Industr ial 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 Depar tment, or the Technical Sales 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 Rep" 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.
INTRODUCTION
1
Table of Contents
Section Page
1. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
1.1. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,3
1.3. Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.4. Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.5. Requesting Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.6. Returning a Unit for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
2.1. ED200 Series Location Map & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2. ED and PN Series Location Map & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.3. PN400/PN500 w/Internal Overload Clutch Location Map & Parts List . . . . . . . .7
2.4. Ferguson Reducer Location Map & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . .8
3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.1. Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12
4.2. RT6-D Rite Torq® Limiting Clutch Installation . . . . . . . . . . . . . . . . . . . . . . .13-18
5. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-25
5.1. Internal Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.2. Prox Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20,21
5.3 FSC…Ferguson Slip Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-25
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.1. Using Correct Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.2. Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27,28
8. Repair and Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29-37
8.1. Cam Follower Replacement - Models ED90, ED91 & ED200 . . . . . . . . . . . . . . . 29
8.2. Cam Follower Replacement - Models PN300 thru PN500, ED420 thru ED3240 . .29
8.3. Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 , 34
8.4. Reducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-37
9. Things to Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38,39
REFERENCE: Unit configurations, Reducer Mtg Positions, Hand of Cam Drawing . . . . . .40
2
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 par ts are returned to our plant within one (1) year after
delivery by us.Wr itten 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 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 Industr ial 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.
3
SECTION 1: General Information (continued)
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 shaft. Loose belts or chains will cause iner tial 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 par t. 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 Control’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).
1.3. 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)
1.4. Ordering Replacement Parts – When ordering parts, always provide the following
information:
1.4.1. The serial number 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.
4
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. 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. Ser ial number (located on name plate)
9. Descr iption 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. 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
5
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
FIGURE 1
Center of dwell
position shown
ED200 Series Parts List
1. Housing
2. Cam
3. Cam shaft
4. Cam shaft key
5. Locknut & washer
6. Tapered roller bearing
7. Shim set
8. Bearing cap
9. Oil seal
10. Bearing cap (reducer side)
11. Bearing retainer & seal cap
12. Oil seal (reducer side)
13. Eccentric center tube
14. Thrust bearing
15. Roller gear shaft
16. Tapered roller bearing
17. Locknut and washer
18. Oil seal
19. Oil seal
20. Cam followers
21. Cone point set screws
22. Locknut and washer
23. Pipe plug
24. Oil site glass
25. Oil sump vent
26. Bushing
27. Cap screws
28. Cap screws
6
SECTION 2: Overview (continued)
2.2. ED & PN Series Location Map
FIGURE 2
1. Housing
2. Access cover
3. Cam cover plate
4. Cam shaft
5. Key
6. Cam
7. Locknut
8. Lockwasher
9. Locknut
10. Lockwasher
11. Timken bearing cup
12. Timken bearing cone
13. Cam shaft bearing carrier
14. Oil seal
15. Cap screws
16. Pipe plug
17. Cap screws
18. Bearing clamp
19. Cam followers
20. Top seal
21. Center tube
22. Bearing ring
23. Output shaft seal
24. Output shaft
25. Locking set screw
26. Cap screw
27. Cap screw
ED & PN Series Parts List
7
SECTION 2: Overview (continued)
2.3. PN400 and PN500 Series with Internal Overload Clutch Location Map
FIGURE 3
1. Housing
2. Cam
3. Camshaft
4. Camshaft Key
5. Locknuts
6. Timken Cup
7. Timken Cone
8. Bearing Cap
9. Seal
10. Locknut
11. Spacer
12. Tube
13. Housing Cover
14. Cap Screws
15. Center Tube Ring
16. Cap Screws
17. Access Cover
18. Vent
19. Cap Screws
20. Cam Follower Hub
21. Cam Followers
22. Locking Set Screws
23. Thrust Bearing
24. Thrust Bearing Plate
25. Locknut
26. Seal
27. Seal
28. Cap Screws
29. Shim Set
30. Roller Gear Shaft
31. Bearing Plate
32. Cap Screws
33. Detent Seat Ring
34. Dowels
35. Cap Screw
36. Rollers
37. Retainer Ring
38. “O” Ring
39. Ring/Pressure Switch
40. Springs
41. Spring Adjusting Ring
42. Cap Screws
43. Bearing Clamp
44. “O” Ring
45. Ring Bearing
PN400 and PN500 Series with Internal Overload Clutch Parts List
8
SECTION 2: Overview (continued)
2.4. Ferguson Reducer Location Map
FIGURE 4
1. Housing
2. Ring Gear (& separate hub for
some units)
3. Pinion Worm Gear
4. Gear Spacer
5. Key for Indexer Shaft
6. Arrestor Washer
7. Lockwasher
8. Cap Screw Keeper
9. Cap Screw for Clamping Hub
10. Closed End Cap
11. Cap Screws
12. Shim Pack
13. Timken Bearing
14. Open End Cap
15. Oil Seal
16. Wear Sleeve
17. Cover Plate
18. Cap Screws
19. Oil Plugs
Ferguson “R” Series Reducer Parts List
9
SECTION 3: Specifications
IEC71-B14
PN300 R175
w/1/3 HP
1/3 HP RT6D N/A 1 1 QT. 50 N/A 65
MDB625
ED200 R200
w/1 HP
1/2 HP DTL10 R2.5 FSC 1.5 1.5 QTS. 300 N/A 325
MD625
PN400 926CDSS
w/1/2 HP
1/2 HP 4 N/A 2 1.5 QTS.
MD625
PN500 930CDSS
w/1 HP
1 HP 4 N/A 3 2 QTS.
MDB875
ED420 R300
w/2 HP
1-1/2 HP
1
N/A R3FSC 5 2.5 QTS. 750 789 850
MDB875
ED810 R400
w/2 HP
2 HP
1
N/A R4FSC 20 1.5 GAL. 1200 1275 1325
MDB1125
ED1440 R600
w/5HP
N/A N/A R6FSC 30 3.7 GAL. 3000 3235 3455
ED3240 R700 N/A N/A N/A R7FSC 35 6.5 GAL. 9500 9780 N/A
Model
Standard Reducer
Standard AC Motor
With Air Clutch/Brake
Standard 90 V DC
Motor (Max HP)
Output Shaft
Torque Limiter
Input Shaft
Torque Limiter
Lubrication Capacity
Main Oil Sump (Gallons)
3
Lubrication Capacity
Gear Reducer
Unit Weight (LBS)2Unit Weight with Reducer (LBS)
2
Unit Weight with Motor/Reducer Pkg. (LBS)
2
CHART 1
1
180 V.DC.
2
Weights are approximate, less crating.
3
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.
4
Has optional internal overload clutch.
10
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).
FIGURE 5 - PINNACLE SERIES
FIGURE 6 - ED SERIES
11
SECTION 4: Installation (continued)
4.1.2. Mount the Indexer into position on a rigid base and secure with the largest size
bolts that will fit through the mounting holes.
4.1.3. 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.
4.1.4. Tighten all mounting bolts securely and uniformly.
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 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.
4.1.6. Check the oil level of the sump and gear reducer prior to operating the unit.
4.1.6.1. 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. 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 Industrial Motion Control Representative or the
Technical Sales Department at 1-800-645-5207 or 847-459-5200.
4.1.6.2. The unit’s 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).
12
SECTION 4: Installation (continued)
4.1.6.3. 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.)
4.1.6.4. Be sure optional controller is proper ly fused – refer to vendor’s manual.
4.1.7. 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. A standard roller gear indexer shown in Figure 5 with a Brake Cam &
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.
4.1.7.2. 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.
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 & 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.
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