Duff-Norton SK-2389 Installation, Operation & Maintenance Instructions Manual

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Publication Part No. SK-2389

This manual contains important information for the correct installation, operation and maintenance of the

equipment described herein. All persons involved in such installation, operation, and maintenance should be

thoroughly familiar with the contents. To safeguard against the possibility of personal injury or property

damage, follow the recommendations and instructions of this manual and keep it for further reference.

The equipment shown in this manual is intended for industrial use only and should not be used to lift, support, or otherwise transport people.

CAUTION

WARNING

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Contents

Section I General Information................................................................................................................................................ 2

1-1. General .................................................................................................................................................................... 2

1-2. Applications ............................................................................................................................................................ 2

1-3. Specifications .......................................................................................................................................................... 2

1-4 Important Precautions ............................................................................................................................................. 3

1-5. Warranty and Warranty Repair ............................................................................................................................... 4

Section II Maintenance ............................................................................................................................................................ 4

2-1. Lubrication .............................................................................................................................................................. 4

2-2. Rebuild Procedure .................................................................................................................................................. 4

2-3 Required Tools ........................................................................................................................................................ 4

2-4. Disassembly ............................................................................................................................................................ 4

2-5. Cleaning .................................................................................................................................................................. 5

2-6. Inspection ................................................................................................................................................................ 5

2-7. Assembly ................................................................................................................................................................ 5

2-8. Anti-Backlash Nut Function ................................................................................................................................... 6

2-9. Anti-Backlash Nut Adjustment............................................................................................................................... 6

Section III Illustrated Parts List ................................................................................................................................................ 6

3-1. General ................................................................................................................................................................... 6

3-2. Parts List ................................................................................................................................................................. 6

Figure 3-1. Exploded Illustration .............................................................................................................................................. 7

Section I

General Information

1-1. General

This manual contains maintenance instructions for Duff Norton translating machine screw actuators of two ton to 75 ton capacity. It describes and details procedures for installation, disassembly, cleaning, inspection, and assembly of these actuators.

1-2. Applications

Industrial Use Only The actuators described and illustrated in this manual are intended for industrial use only and should not be used to lift, support or otherwise transport people unless you have a written statement from Duff-Norton which authorizes the specific actuator unit, as used in your application, as suitable for moving people.

1-3. Specifications Table 1. 1800 (2000) and 9000 (10000) Series

Standard Actuator Upright 1802 & 9002 9005 9010 9015 9020 9025 9035 1850 & 9050 9075 Model No. Inverted 1801 & 9001 9004 9009 9014 9019 9024 9034 1849 & 9049 9074 Special Actuator Upright 2002 & 1000 Model No. Inverted 2001 & 10001 10004 10009 10014 10019 10024 10034 2049 & 1004 Rated Load (tons) 251015 20 25 35 50 75 Diameter of 11 1/222 1/4 2 1/2 3 3 3/4 4 1/2 5 Lifting Screw (inches) .250 Pitch .375 Pitch .500 Pitch .500 Pitch .500 Pitch .666 Pitch .666 Pitch .666 Pitch .666 Pitch

Closed Height** (inches) 5 1/4 7 7 1/4 8 9 1/4 11 12 13 16 1/2

Base Size (inches)

Worm Gear Ratios Std Ratio 6:1 6:1 8:1 8:1 8:1 10 2/3:1 10 2/3:1 10 2/3:1 10 2/3:1

Turns of Worm Std Ratio 24 16 16 16 16 16 16 16 16 For 1˝ Raise Optional 96 64 48 48 48 48 48 48 48 Maximum H.P. Std Ratio 24555881515 Per Actuator Optional 1/2 3/4 1 1/2 1 1/2 1 1/2 2 1/2 2 1/2 6 6 Torque at Std Ratio 120 450 750 1,430 2,050 2,700 4,000 7,500 12,000 Full Load* (in-lbs) Optional 50 185 400 820 1,170 1,200 2,400 4,200 6,600 Actuator Efficiency Std Ratio 23.2 22.1 23.7 20.2 18.8 18.7 15.8 13.8 12.4 Rating (%) Optional 13.3 12.1 15.1 12.9 12.0 10.5 8.9 8.3 7.5

Weight with Base Raise of 6˝ (lbs)

Weight for Each Additional 1˝ of Raise (lbs)

* For loads from 25% to 100% of actuator load rating. Torque requirements are approximately proportional to the load. ** Closed heights are for standard upright top plate models and may vary with different screw end, inverted models, or when bellows boot is used.

Optional 24:1 24:1 24:1 24:1 24:1 32:1 32:1 32:1 32:1

Acme Acme Acme Acme Acme Acme Acme Square Square

3 1/2 x 7

4 1/8 x 6 1/4

17 35 52 66 93 160 240 410 650

.33 .85 1.4 1.5 2.6 2.5 3.7 5.5 6.5

10005 10010 10015 10020 10025 10035 2050 & 1005010075

6 x 87 1/2 x 8 3/4 7 3/4 x 9 1/4 8 1/4 x 11

These actuators are intended for a clean, non- corrosive environment with ambient temperatures ranging from -20 to 200 ° F. If your environment is dirty and/or contains abrasive particles it is impor- tant to protect the screw with a boot. If your atmo- sphere is corrosive it is important to specify a non- corrosive material or finish. Duff-Norton can provide stainless steel, nickel plated or epoxy coated actua- tors. If your duty is high or your use severe, more frequent lubrication should be employed. Duff- Norton publishes a Mechanical Actuator Design Guide, Catalog No. 2003, which you may find helpful in the selection and application of mechanical actuators. If you need additional help, please con- tact Duff-Norton at (800) 477-5002.

10074

10 1/4 x

13 3/4

10 1/4 x

15 1/2

9 3/4 x 19 3/4

10 1/2 x 21 3/4

14 x 23

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Table 2. 4800 and 9400 Series

Standard Actuator Upright 4802 & 9402 9405 9410 9415 9420 9425 9435 4850 & 9450 9475 Model No. Inverted 4801 & 9401 9404 9409 9414 9419 9424 9434 4849 & 9449 9474 Special Actuator Upright 5802 & 1040 Model No. Inverted 5801 & 10401 10404 10409 10414 10419 10424 10434 5849 & 1044 Rated Load (tons) 251015 20 25 35 50 75 Torque at Std Ratio 135 500 1045 1573 2255 1320 4400 4620 13200 Full Load* (in-lbs) Optional 55 205 905 1290 1320 1320 2640 4620 7260 Actuator Efficiency Std Ratio 19.6 19.9 19.8 18.0 17.6 13.4 13.7 12.4 11.3 Rating (%) Optional 11.9 10.9 12.6 11.0 10.8 8.3 7.7 7.3 6.8 Closed Height (in)** 5 1/4 7 7 1/4 8 9 1/2 1 2 1 3 14 18 1/2 Weight with Base Raise of 6˝ (lbs)

18 37 55 70 101 197 250 440 700

10405 10410 10415 10420 10425 10435 5850 & 1045010475

10474

Note: Additional specifications are same as for Series 1800 and 9000. See Table 1.

Table 3. Decimal Ratios

Standard Actuator Upright 1802 & 9002 9005 9010 9015 9020 9025 Model No. Inverted 1801 & 9001 9004 9009 9014 9019 9024 Special Actuator Upright 2002 & 1000 Model No. Inverted 2001 & 10001 10004 10009 10014 10019 10024 Rated Load (tons) 251015 20 25

1˝ Dia. 1 1/2˝ Dia. 2˝ Dia. 2 1/4˝ Dia. 2 1/2˝ Dia. 3˝ Dia.

Lifting Screw (inches) .250 Pitch .250 Pitch .250 Pitch .250 Pitch .250 Pitch .320 Pitch

Acme Acme Acme Acme Acme Square

Worm Gear Ratios 25:1 25:1 25:1 25:1 25:1 32:1 Turns of Worm For 1˝ Raise 100 100 100 100 100 100 Torque at Full Load (in-lbs) 48 175 370 640 925 1500 Actuator Efficiency Rating (%) 13.2 9.1 8.6 7.5 6.9 5.3 Maximum H.P. Per Actuator 1/2 3/4 1 1/2 1 1/2 1 1/2 2 1/2

Note: All other data for these models same as shown in Table 1.

10005 10010 10015 10020 10025

1-4 Important Precautions

In order to ensure that Duff-Norton actuators provide good service over a period of years the following precautions should be taken:

1. Select an actuator that has a load rating greater

than the maximum load that may be imposed on

it.

2. The structure on which the actuator is mounted

should have ample strength to carry the maxi-

mum load, and should be rigid enough to pre-

vent undue deflection or distortion of the actua-

tor supporting members.

3. It is essential that the actuator be carefully

aligned during installation so that the lifting

screws are perfectly plumb and the connecting

shafts are exactly in line with the worm shafts.

After the actuators, shafting, gear boxes, etc.,

are coupled together, it should be possible to

turn the main drive shaft by hand. If there are no

signs of binding or misalignment, that actuator

system is then ready for normal operation.

4. Actuators should have a greater raise than is

needed in the actual application. Should it be

necessary to operate the actuator at the ex-

treme limits of travel, it should be done cau-

tiously.

CAUTION

Do not allow actuator travel to go beyond

specified (catalog) closed height, or serious damage to internal mechanism may result. Refer to table of specifications (par. 1-3) for closed heights of respective units.

5. The worm shaft speed for these actuators should not exceed 500 RPM for heavy loads, 1200 RPM for light loads of one-fourth (or less) of the actuators load rating.

6. The lifting screw should not be permitted to accumulate dust and grit on the threads. If possible, lifting screws should be returned to closed position when not in use.

CAUTION

Where lifting screws are not protected from airborne dirt, dust, etc., bellows boots should be used. Inspect frequently at regular internals to be certain that a lubricating film is present. Lifting screws should never be run dry.

7. When using an 1800 (2000) or 9000 (10000) Series Actuator, a periodic check of backlash of the lifting screw thread is recommended to check wear of the worm gear internal threads. The normal backlash on a new unit of this type is approximately .010 inch. Backlash of 50% or more of the thread thickness indicates the need to replace the worm gear.

The 4800 and 9400 Series Anti-backlash Actua-

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tors are designed to be adjusted for minimum backlash, approximately .002 inch. The worm gear and anti-backlash nut are manufactured to have a clearance between their surfaces of 1/2 the thread thickness. When adjustments have been made to the point where all this clearance is gone, 50% of the thread thickness is gone and replacement is necessary. (See paragraph 2-8 for a detailed explanation of how the anti- backlash nut functions.)

Note

For loads of from 25% to 100% of actuator capacity, torque requirements are approximately proportioned to the load.

8. The lubrication procedures for normal and severe service conditions, as described in Section II, paragraph 2-1, should be closely followed.

1-5. Warranty and Warranty Repair

Subject to the conditions stated herein, Duff-

Norton will repair or replace, without charge, any parts proven to Duff-Norton's satisfaction to have

been defective in material or workmanship. Claims must be made within one year after date of ship- ment. Duff-Norton will not repair or replace any parts that become inoperative because of improper maintenance, eccentric loading, overloading, chemi- cal or abrasive action, excessive wear, or other abuse.

Equipment and accessories not of Duff-Norton's manufacture are warranted only to the extent that they are warranted by the manufacturer, and only if the claimed defect arose during normal use, appli- cations and service. Equipment which has been altered or modified by anyone without Duff-Norton's authorization is not warranted by Duff-Norton. EXCEPT AS STATED HEREIN, DUFF-NORTON MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MER- CHANTABILITY AND FITNESS FOR A PARTICU- LAR PURPOSE.

If you have any questions concerning warranty repair, please contact Duff-Norton. Authorization for return must be received from Duff-Norton before returning any equipment for inspection or warranty repair.

Section II

Maintenance

2-1. Lubrication

Unless otherwise specified, actuators are shipped packed with grease which should be suffi- cient for one month of normal operation. For normal operation, the actuator should be lubricated once a month using Extreme Pressure grease Shell Oil Co. Albida LC EP #2 (Shell Product Code 70311).

This grease has been thoroughly evaluated in Duff-Norton actuators and has demonstrated supe- rior lubricating properties affecting both wear life and maximum duty cycle. Duff-Norton is not aware of an equivalent grease. If this grease is not available in your area please contact your local supplier for their recommendations. Greases con- taining molybdenum disulfide should never be used.

For severe service conditions, the actuators should be lubricated more frequently using the above grease (daily to weekly depending upon the conditions). If duty is heavy, an automatic lubrication system is strongly recommended.

CAUTION

Where lifting screws are not protected from airborne, dirt, dust, etc., bellows boots should be used. Inspect frequently at regular intervals to be certain that a lubricating film is present. Lifting screws should never be run dry.

2-2. Rebuild Procedure

Duff-Norton recommends the following proce-

dures for assembly and disassembly of actuators.

1. Tag critical parts to facilitate reassembly.

2. Mark mating surfaces to ensure proper meshing.

3. Clean and lubricate all parts as required.

4. All seals must be replaced when rebuilding.

5. All screws, washers and other small common parts must be replaced if damaged in any way.

6. Replace damaged or frozen lubrication fittings with new ones.

2-3 Required Tools

A bearing puller or press, and common hand

tools are necessary for proper assembly and disas- sembly.

2-4. Disassembly (Refer to Figure 3-1)

1. Remove lifting screw (5) from actuator.

2. Remove bottom pipe (4) from shell (3) (upright models) or shell cap (2) (inverted models) or base plate as applicable.

3. Loosen and remove set screws (1) in cap (2) and remove cap from shell (3).

Note

It may be necessary to break shell cap or base plate loose with a hammer.

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4. Remove gear (6A) or worm gear and nut assem- bly (6B) from shell (3).

Note

To facilitate removal of the gear from the shell on models with 50- ton or higher load ratings, partially reassembly the lifting screw into the worm gear (or worm gear and nut assembly) and use a hoist or pulley block to lift on the screw.

5. Remove top load bearing (7) which may be attached to either shell cap (2) or worm gear (6A) or anti-backlash nut.

Note

Use only a soft face hammer to tap bearings loose.

6. Remove bottom load bearing (8) which may be attached to either the shell (3) base plate or worm gear (6A).

7. Remove four cap screws (9) from each of the two worm flanges (11) and remove flanges.

Note

Be careful not to lose flange shims (12).

8. Press oil seal (13) out of flange (11).

9. Remove worm (14) and worm bearings (15) from shell (3) by striking one end of worm with a soft face hammer.

10. Remove worm bearings (15) from worm (14) with bearing puller or press. (Note: This step will not be necessary if worm or worm bearings are not damaged.

11. If actuator is keyed, remove screw in shell cap and tap key out of keyway.

2-6. Inspection (Refer to Figure 3-1)

Inspect actuator parts as follows:

1. Make a visual inspection of shell (3) for broken, cracked or distorted areas. Check threads of all bores for burrs or broken threads.

2. Check shell cap (2), base plate, bottom pipe (4), lifting screw (5), worm gear (6A) or worm gear and nut assembly (6B) for burrs or scratches on their working or mating surfaces.

3. Check fit between lifting screw thread and internal thread in worm gear. If fit is excessively loose, replace worm gear or lifting screw as required. Replace worm gear and nut assembly as a set [4800 (5800) and 9400 (10400) Series].

4. Check small common components (screws, etc.) and replace as required.

5. Check bearings (7), (8) and (15) for seizure, galling or play and replace as required.

2-7. Assembly (Refer to Figure 3-1)

1. Press worm bearings (15) onto worm shaft (14), making sure that bearings are seated properly against shoulder.

Note

When tapered roller bearings are used, the small end of the cone should point to the worm end.

2. Position worm shaft end (14) in shell (3).

Note

If tapered roller bearings are used, tap worm bearing cups into place in the shell.

3. Press oil seals (13) into worm flange (11).

2-5. Cleaning

1. Use degreasing solvent to remove grease or oil from all parts.

Note

Remove grease from unit and do not reuse old grease.

WARNING

Provide adequate ventilation during the use of cleaning agents; avoid prolonged breath- ing of fumes and contact with skin. Read & follow manufacturer's instructions.

2. Use clean hot water or a soap solution for general cleaning of painted surfaces.

3. Dry parts thoroughly after cleaning.

Note

Before installing new parts, remove any rust preventive, protection grease, etc.

Note

The sealing element should point inward.

4. Position worm flanges (11) with shims (12) and bolt in place.

5. Position bottom load bearing (8) or bearing cup in shell (3).

5a. On 5-ton, 35-ton and 75-ton models, press load

bearing cones onto worm gear (6A) or worm gear and nut assembly (6B).

6. Install worm gear (6A) or worm gear and nut assembly (6B) in shell (3).

Note

Strike each end of worm shaft sharply with a soft face hammer to seat bearing properly. Recheck flange bolts for tightness. Worm should turn freely with minimum drag and end play. If too much end play is present, remove shims as required. If worm does not turn freely, add shims

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as required.

7. Install top load bearing (7) or bearing cup on worm gear (6A) or worm gear and nut assembly (6B).

8. Fill housing fully with grease.

9. Install shell cap (2) and screw down until tight.

Note

Shell cap flange does not necessarily have to bear against top of shell, there will usually be a gap. This will put a slight drag on the worm. If worm is hard to turn, back off slightly on the shell cap.

10. Lock base plate in place with set screws.

Note

If new parts have been installed, it may be necessary to respot holes for these screws.

11. Screw bottom pipe (4) into shell (3) (upright models) or into shell cap (2) (inverted models).

12. Brush lifting screw (5) with a light film of grease and install in actuator. On inverted models, install guide bushing (16) and then install lifting screw (5).

engage the threads of the lifting screw (1). Adjust- ment of backlash is made by running down on the shell cap of the actuator. This forces the anti-back- lash nut threads into closer contact, reducing clear- ance and thus reducing backlash.

2-9. Anti-Backlash Nut Adjustment

1. To minimize backlash remove the two set screws (4) and tighten down on shell cap until the desired backlash is obtained. Spot drill top of shell through set screw holes, then replace set screws and tighten to prevent shell cap backing off.

2. To avoid binding and excessive wear, do not adjust lifting screw backlash to less than 0.002 inch.

3. The clearance (A) designed into the worm gear and anti-backlash nut set is one-half the thread thickness. When adjustments have been made to use all this clearance replace the worm gear and anti-backlash nut as a set.

13. If actuator is keyed, install key in shell cap (2) and bolt in place.

14. Operate unit to ensure proper functioning of all components prior to reinstallation.

2-8. Anti-Backlash Nut Function

As shown in Figure 2-1, the worm gear (2) and

anti-backlash nut (3) are pinned together with guide pins. The threads in the anti-backlash nut work in opposition to the threads in the worm gear as they

Figure 2-1. Anti-Backlash Nut Adjustment

Section III

Illustrated Parts List

3-1. General

This section contains an exploded illustration of the

1800, 9000, 4800 and 9400 Series translating machine screw actuators. The number adjacent to each part on the illustration is the index number. Keyed to this index

3-2. Parts List For 1800 (2000), 9000 (10000), 4800 (5800) and 9400 (10400) Series Translating Machine Screw Actuators.

ndex Qty. Index Qty.

No. Part Name

1 Screw, Set 1 9 Screw, Cap 1 2 2 Cap, Shell 1 1 0 Washer, Lock 12 3 Shell, Actuator 1 11 Flange, Worm 2 4 Pipe, Bottom 1 12 Shim, Flange 2 5 Screw Assembly, Lifting 1 13 Seal, Oil 2

6A Worm Gear 1 14 Worm 1

Worm Gear and Anti-backlash Nut

Assembly (Mfg’d and sold in sets

onl 7 Bearing, Top Load 1 16 Bushin 8 Bearin

, Bottom Load 118Nameplate 1

eq. No. Part Name

number on the parts list is the part name.

When ordering parts be sure to include:

1. The nameplate model of your unit.

2. Index number and name of part.

15 Bearin

, Worm 2

, Guide (inverted model o 1

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Figure 3-1. Exploded Illustration 1800 (2000), 9000 (10000), 4800 (5800) and 9400 (10400)

Series Translating Machine Screw Actuators

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P.O. Box 7010 Charlotte, NC 28241-7010

General Office (704) 588-0510 Customer Service (800) 477-5002 Customer Service (704) 588-4610 FAX (704) 588-1994 Email: duf[email protected]

www.duffnorton.com

SK-2389

2M/1002