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Joyce/Dayton Corp
.
Operation and Maintenance Manual for Joyce/Dayton
Ball Screw ComDRIVE® Actuators
The recommendations in this manual for installation, operation and maintenance must be followed to ensure safe
use. All persons responsible for the installation and use of Joyce ball screw ComDRIVE® actuators must be familiar
with the contents of this manual.
The customer is responsible for travel stops, guards and other protective devices and ensuring that ComDRIVE®
usage conforms with local and national operating and safety codes appropriate to the class of equipment into which
the Ball Screw ComDRIVE® is installed. Series CDB, CDBL, CDHB, and CDHBL ComDRIVEs® are not selflocking. A brake motor or other external locking device must be provided.
Adjustable extending stop collars are included on standard ComDRIVE® actuators. The customer is responsible for
providing travel limits.
©2011 Joyce/Dayton Corp. All rights reserved FB0196-8/11
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Table of Contents
Section I – General Information
1-1 Contact Joyce Dayton Corp...................................................................................................2
1-2 Purpose and Scope.................................................................................................................2
1-3 Receipt of Product...................................................................................................................2
1-4 Warranty....................................................................................................................................2
1-5 Precautions of Use and Installation......................................................................................3
1-6 General Installation Instructions...........................................................................................3
Section II – Maintenance
2-1 Lubrication................................................................................................................................4
2-2 Repair Parts...............................................................................................................................5
2-3 Disassembly of ComDRIVE® jacks.......................................................................................6
2-4 Inspection of Components.....................................................................................................7
2-5 Assembly of ComD Assembly of ComDRIVE® jacks .......................................................8
2-6 Ball Nut disassembly and rebuild .........................................................................................8
Section III – Views &Parts list
3-1 Exploded View ...........................................................................................................................9
3-2 Parts List forTranslating & KFTN ComDRIVEs® .................................................................10
3-3 Maintenance Log and Serial Number.....................................................................................11
Section I
General Information
1-1
Contact Joyce Dayton Corp.
Joyce Dayton Corp.
P.O. Box 1630
Dayton, OH 45401
(800) 523-5204 (US and Canada)
(937) 294-6261 (937) 297-7173 Fax
Email: [email protected]
Website: www.joycedayton.com
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Purpose and Scope
This manual provides installation, operation and maintenance instruction for standard
Joyce/Dayton ball screw ComDRIVE® actuators. Although this manual covers the
standard ball screw ComDRIVE® and most variations of the ball screw ComDRIVE®, there
may be some that vary significantly from this manual. For special units not covered please
contact Joyce/Dayton Corp. for assistance.
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Receipt of Product
All equipment should be immediately inspected upon receipt for any damage and to verify
correct product and quantities. Any problems should be reported to Joyce/Dayton Corp.
and the freight carrier as soon as possible. Products returned without a Return Goods
Authorization (RGA) form will not be accepted.
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Warranty
Seller warrants its products to be free from defects in material and workmanship under
normal and proper use in accordance with instruction of seller for a period of one year
from the date of shipment to buyer. Seller's liability under such warranty or in connection
with any other claim relating to the products shall be limited to the repair, or at seller’s
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option, the replacement or refund of the purchase price, of any products or parts or
components thereof which are returned to seller freight prepaid and which are defective in
material or workmanship. Products or parts or components thereof, which are repaired or
replaced by seller, will be returned to buyer freight collect. This warranty is not intended to
cover consumer products, as defined in the Magnuson-Moss Warranty-Federal Trade
Commission Improvement Act, 15 U. S. C. Sections 2301-12, which are purchased by
buyer for purposes other than resale. If buyer is not intending to resell the products, and if
the products are consumer products as defined in the Magnuson-Moss Act, the foregoing
warranty, but not the limitation of seller's liability, shall be null and void. EXCEPT AS
EXPRESSLY STATED ABOVE, SELLER MAKES NO WARRANTY, EXPRESS OR
IMPLIED, WHETHER OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR
PURPOSE OR USE OR OTHERWISE, ON THE PRODUCTS, OR ON ANY PARTS OR
LABOR FURNISHED DURING THE SALE, DELIVERY OR SERVICING OF THE
PRODUCTS.
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Precautions of Use and Installation
1. Side loading of the lifting screw is not permitted in the dynamic operation of the jack.
A limited side load is allowable in the static condition. Contact Joyce/Dayton for the
allowable side load for a specific application.
2. Extending mechanical stops are provided on the actuator lifting screw. It is the
customer’s responsibility to provide travel limit devices on all ball screw
ComDRIVEs®. The mechanical stop is only an auxiliary device to limit the travel of the
lifting screw. Engaging a mechanical stop during operation can cause damage to the
internal jack mechanism.
3. In most applications, factory or manufacturer-assisted installation is not required.
However, it is necessary that appropriate, qualified personnel perform the installation
of Joyce/Dayton products.
4. Joyce/Dayton ball screw ComDRIVE® actuators are not rated for shock-loading,
extreme vibration or critical speed conditions (high speed or long-length screw.) It is
the responsibility of the user to ensure these conditions are not imposed on the
actuator or the power transmission equipment. Contact Joyce/Dayton for technical
assistance.
5. In the event that service or maintenance is required, the load must be secured or
removed before any work can begin.
6. Ball screw ComDRIVE® actuators can be mounted and operated in any orientation.
When used with the lifting screw in a horizontal position, the worm should be mounted
parallel with the horizon and below the gear to ensure proper lubrication. Standard ball
screw ComDRIVE® actuators are shipped with all holes plugged. The user must insert
the vent in the highest location at final installation.
7. Never allow the actuator to retract beyond the minimum closed position, as damage to
the jack can occur.
8. Boots or protective bellows covers should be used to protect and keep the lifting
screw clean in dusty or abrasive environments.
9. For continuous or high-duty cycles inquire with your local sales representative or
consult Joyce/Dayton Corp. regarding Bevel Ball actuators.
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General Installation instructions
1. Ensure that all personnel who will service or operate equipment are familiar with its
use and limitations.
2. Secure or remove the load before any installation procedures begin.
3. Be certain the rating of the ball screw ComDRIVE® meets or exceeds the load.
4. Ball screw ComDRIVEs® must be mounted on a structure sufficient to support the
maximum possible load. The structure must be rigid. An under-designed structure
could lead to bending of the lifting screw causing premature wear or failure.
5. In a system with shafts, miter boxes, etc., confirm that the shafts and actuators
operate without binding or excessive force before powered drive devices are engaged.
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Drive shaft alignment is critical. Mis-alignment will cause reversing stresses in rotating
members and will lead to fatigue failure. Correct coupling specification is important.
6. When fastening the load to a ball screw actuator, make sure the actuator is in the
retracted position. This positions the load accurately with respect to the lifting screw
centerline. Never pull the screw to one side to make connection with your structure.
Fully extend the actuator to make sure the load is aligned with the lifting screw.
7. All ball screw ComDRIVE® actuators are designed to be mounted with S.A.E. Grade 8
bolts or equivalent.
8. Torque all mounting bolts in a symmetric pattern to avoid damage to the sleeve.
9. Shaft and coupling guards are the responsibility of the user.
10. Optional limit switches furnished with the actuator are NOT preset and require field
adjustment before use.
Section II
Maintenance
2-1
Lubrication
Jacks
1. Ball screw ComDRIVE® actuators are lubricated before leaving the factory.
2. For normal operation, jacks should be greased at least once per month. Under
extended use, grease twice monthly or as conditions dictate. Grease thru the fittings
on the jack with hand or power operated equipment. Grease with No. 1 Consistency
Grease. Do not allow jacks to operate without lubrication. It is the responsibility of the
user to maintain sufficient lubrication of the jack and to the lifting screw.
3. The products listed below are recommended by the lubricant manufacturers to meet
the requirements for normal operation. The listing of brand names is solely for the
convenience of users of Joyce equipment and their lubricant suppliers; it does not
constitute any endorsement. Joyce/Dayton assumes no responsibilities for the quality,
performance or availability of any listed products
COMPANY BRAND NAME
Mobil Grease…………………….XHP 461
Mobil Grease…………………….XHP 221
Mobilith……………….…………..SHC221
Mobilith……………………………SHC 460
4. For operation above 250° F or extreme loading, consult the Engineering Department of
Joyce/Dayton Corp.
5. Ball screw and ball nut (on KFTN models) should be lubricated with a spindle or 10weight oil applied to the ball screw.
6. Do not operate jack without lubrication.
7. Total grease capacity by jack type:
Jack
Capacity
2 ton 13 4.5 oz 20 ton 95 33 oz.
5 ton 26 9 oz. 30 ton 135 47 oz.
10 ton 50 17 oz
Number
of Shots
Approximate
Weight
Jack
Capacity
Number
of Shots
Approximate
Weight
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Reducers
1. Standard ball screw ComDRIVE reducers are lubricated before leaving the factory.
The standard lubrication used in the reducers is AGMA 7 Compounded oil (ISO Grade
460).
2. The products listed below are recommended by the lubricant manufacturers to meet
the requirements for normal operation. The listing of brand names is solely for the
convenience of users of Joyce equipment and their lubricant suppliers; it does not
constitute any endorsement. Joyce/Dayton assumes no responsibilities for the
quality, performance or availability of any listed products.
COMPANY BRAND NAME
Mobil Oil. ……………………….Mobil 600W Cylinder Oil
Mobil Oil….………………….….Mobil 85W100
3. Synthetic lubricants are also recommended, especially under severe service. These
lubricants are more viscosity/temperature stable and provide service over a broad
range of temperatures. These lubricants have a longer service life, require fewer oil
changes and increase the life of the gearbox by reducing friction and wear. This
lubricant is also compatible with nitrile seal material and alloy bronze gear material.
COMPANY BRAND NAME
Mobil Oil. ………………………. Mobil SHC 634
4. The oil in the reducer must be maintained at the proper level. The reducer must be at
rest when the oil level is checked.
5. In a new unit, the oil should be changed (or filtered) after four weeks (or 100 hours) of
use. The case should be flushed with light oil to remove any foreign substances.
6. After the initial oil change, the oil should be changed once every 6 months or 2500
hours, whichever occurs first.
7. More frequent oil changes may be necessary when there are severe duty or dirty
conditions present.
8. Special order speed reducers supplied with ComDRIVE® actuators may or may not
be factory lubricated. In this case, a separate O&M can be provided for the special
reducer.
2-2 Repair Parts
Repair parts may be obtained by emailing, [email protected], calling Joyce/Dayton
Customer Service at (800) 523-5204, (937) 294-6261, (937) 297-7371 (facsimile) or
contacting your local sales representative. When ordering repair parts, please supply the
ball screw ComDRIVE serial number, located on the jack nameplate.
The following parts are recommended for repair or rebuild. Exploded View Section 3.1 and
Parts List Section 3.2.
A. (2) Worm shaft bearing and race - Item 11
B. (1) Shim kit - Assortment of item 12
C. (2) Worm shaft seal - Item 15
D. (1) Thrust bearing - Item 2
E. (1) Ball Nut / Wormgear assembly - Item 3
F. (1) Boot (if signs of wear are evident) - Item 34
G. (1) Worm - Item 10
H. (1) Ball screw - Item 7
I. (1) Motor - 25
J. (1) Gear Reducer - Item 20
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2-3 Disassembly of Ball Screw ComDRIVE® Jacks
First remove the motor and reducer from the Ball Screw ComDRIVE®
Remove the four bolts and washers (item 22 and 23) from the adapter/reducer flange (item
17). The reducer and motor can now be removed from the jack. The motor included with
the ball screw ComDRIVE® is not user serviceable, however, it can be replaced. Loosen
bolts (item 26) to separate the motor from the gear reducer.
Disassembling the ball screw jack portion of the ComDRIVE®
Use the appropriate disassembly procedure. If the ball nut (with the re-circulating ball
bearings) is on the screw outside the sleeve, the jack is a Keyed for Traveling Nut (KFTN)
model. This is also called a “rotating screw” jack. If the ball nut is inside the jack sleeve,
the jack is a translating or keyed model. Handle machined parts with care, and maintain
an “order of disassembly” to aid in re-assembly. Remove all couplings, screw support
bearings, etc. before beginning disassembly.
Disassembly Procedure for KFTN (rotating screw) Models: Sections 3-1 & 3-2
1. Tape or otherwise secure the ball nut (item 35) to the ball screw (item 7). Removal of the
ball nut from the screw would allow all of the ball bearings to be released. If the jack is
equipped with boots, remove the boot clamps, collapse boots, and remove them as
needed.
2. On upright jacks loosen the four set screws (item 5) in the sleeve cap assembly, which
includes the sleeve cap (item 4), bushing, and seal. Loosen the sleeve cap assembly by
rotating counter-clockwise (CCW.)
3. On inverted KFTN models remove the sleeve cap (item 4) by loosening the four set
screws (item 5) and rotating CCW. The inverted model has a solid sleeve cap without a
bushing or seal.
4. On upright KFTN models, the ball screw assembly (with the sleeve cap assembly) can
now be removed from the jack sleeve. The ball screw assembly consists of the ball
screw (item 7), the ball nut (item 35), thrust bearings (item 2), key (item 36) and the
wormgear (item 3). Unthread the wormgear from the ball screw and it will slide off the
end of screw with the upper thrust bearing, then the sleeve cap assembly can be
removed from the ball screw.
5. On inverted KFTN models, the ball screw assembly is removed from the bottom of the
sleeve. First, remove the upper thrust bearing (item 2) and the inverted bushing (not
shown). Push the ball screw (item 7) and the key (item 36), out the bottom of the sleeve.
Remove the wormgear (item 3) and the lower thrust bearing (item 2) from the sleeve.
6. It is not recommended to remove the ball nut (item 35) from the ball screw (item 7)
unless it is being replaced. For instructions on removing the ball nut, see Section 2- 6,
Ball Nut Disassembly and Rebuild.
7. Remove three screws (item 16) from the bearing cap (item 13) on one side and three
screws (item 19) from the adapter cap (item 14) on the other side. Remove the caps
and seals (item 15) carefully to avoid damaging seals. Make sure worm shaft keys (item
21) have been removed first.
8. Carefully remove the shims (item 12) from the jack sleeve, bearing cap, or adapter cap.
NOTE: there will not necessarily be an equal quantity of shims per side. Keep track of
the number of shims on each side of the jack.
9. Remove the worm bearings (item 11). The cup may be press-fit. Use a dead-blow,
plastic or other non-marring mallet to remove the worm (item 10).
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Disassembly Procedure for Translating and Keyed Models: Section 3-1 & 3-2
1. If the ball screw ComDRIVE is quipped with a boot, remove the boot clamps, collapse
and remove the boot.
2. On both upright and inverted translating models, loosen the four set screws (item 4)
and loosen the sleeve cap (item 5) by rotating CCW. The ball nut must be removed on
T2 (load pad) and T4 (male clevis) end conditions, otherwise, the sleeve cap will be
captured between the end condition and the ball nut. For these instructions see
Section 2.6 – Ball Nut Disassembly and Rebuild. The inverted model has the protection
tube (item 28) attached to the sleeve cap. Use a strap wrench or similar tool to
unthread the protection tube from the sleeve cap.
3. On upright translating models, the ball screw assembly is removed through the top of
the sleeve. The assembly consists of the ball nut (not shown), thrust bearings (item 2)
and wormgear (item 3).
4. On inverted translating jacks, the ball screw assembly is removed through the top of
the jack for a T1 (plain) or T3 (threaded) end condition. The ball screw assembly
consists of the ball screw (item 7), ball nut (not shown), thrust bearings (item 2) and
wormgear (item 3).
5. NOTE: The wormgear may be unscrewed from the ball nut, but removal will require
heating the thread adhesive to 500° Fahrenheit. If this is necessary, first remove the set
screw. It is not recommended that the ball nut be removed from the ball screw unless it
is being replaced. For ball nut removal, see Section 2.6 – Ball Nut Disassembly and
Rebuild.
6. On inverted translating jacks, the ball screw is removed through the bottom of the jack
for T2 (load pad) or T4 (male-clevis) end condition. Loosen the set screw in the ball nut
(not shown) and unscrew the ball nut from the wormgear (item 3.) Removal will require
heating the thread adhesive to 500° Fahrenheit, then remove the ball nut from the ball
screw; see Section 2.6 – Ball Nut Disassembly and Rebuild. Remove the ball screw
from the bottom of the sleeve and the thrust bearings (item 2) and wormgear (item 3)
from the top of the sleeve.
7. NOTE: the bearing races may remain pressed into the sleeve cap (upper bearing race)
and the sleeve (lower bearing race). These should not be removed unless they are
being replaced. Always replace bearings in sets.
8. Upright translating and have a protection tube (item 28) in the bottom of the jack
sleeve. It is threaded into the sleeve and may be removed if required. Inverted jacks
have a protection tube in the sleeve cap and they also include a bushing.
9. Remove three screws (item 16) from the bearing cap (item 13) on one side and three
screws (item 19) from the adapter cap (item 14) on the other side. Remove the caps
and seals (item 15) carefully to avoid damaging seals. Make sure worm shaft keys
(item 21) have been removed first
10. Carefully remove the shims (item 12) from the jack sleeve, bearing cap, or adapter cap.
NOTE: there will not necessarily be an equal quantity of shims per side. Keep track of
the number of shims on each side of the jack.
11. Remove the worm shaft bearings (item 11). The cup may be press-fit. Use a dead-blow,
plastic or other non-marring mallet to remove the worm (item 10).
2-4 Inspection of Components
1. Before any inspection, it will be necessary to clean all parts of the jack thoroughly.
Use caution with any machined or fragile part.
2. Inspect the cleaned sleeve (item 1) and sleeve cap (item 4) for any signs of stress or
facture, especially around the mounting bolt locations.
3. Inspect the worm (item 10) and thrust bearings (item 2) for any signs of Brinelling,
abrasive wear or spalling. Test for smooth, quiet operation of bearings.
4. Inspect bearing cap and adapter cap (items 13 & 14) for any signs of stress.
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5. Inspect the keyway on the worm (item 10) and roll worm on a flat surface to look for
wobble in the shaft. Threads on worm should not show a heavy buildup of bronze gear
material.
6. Replace all seals when a complete disassembly is done.
7. Inspect Aluminum-Bronze wormgear (item 3) for signs of excessive wear.
8. Check boots for wear or cracks
9. Check ball screw (item 7) for straightness or excess wear in ball threads.
2-5 Assembly of Ball Screw jacks
1. Assure that all bearings are packed with grease. Coat seals with light oil and put
masking tape on keyway and other sharp surfaces to avoid seal damage.
2. Assembly of jack is reverse of the disassembly procedure. Make sure all bearings and
seals seat properly. The bearing cap screws and sleeve cap should only be hand
tightened initially. Some jacks may require the wormgear and thrust bearing be
installed first, as they will not pass the worm, if already installed.
3. Tighten bearing cap and adapter cap bolts. Check the input shaft for excessive axial or
lateral movement. If the input shaft feels loose remove shims, if it feels tight, add
shims. Give the input shaft a solid blow on each end (in axial direction) with a soft
mallet and re-check the feel. If it feels OK, continue to next step, otherwise continue
adding (if tight) or removing (if loose) shims. This is a trial and error operation. The
correct set-up has a solid feel without play (axial or lateral) and the input shaft rotates
with an even, smooth but snug feel.
4. When jack is re-assembled, the thrust bearing pre-load needs to be set. Check by
rotating the input shaft, while tightening the sleeve cap. Continue to check the rotation
of the input shaft as sleeve cap is tightened. Use a dead-blow hammer on top of sleeve
cap to help it seat. Tighten sleeve cap until it will not tighten further by hand.
2-6 Ball Nut Disassembly and Rebuild
1. This requires the use of an arbor. An arbor can be acquired from Joyce/Dayton, or it
can be manufactured. The arbor is usually a tube or bar that can be made out of
plastic, stiff cardboard or steel and should be at least 4 inches longer than the ball nut.
The outer diameter is approximately equal to the minor diameter of the ball screw
thread. Its purpose is to prevent the ball bearings from falling out of the ball nut.
Place the arbor at the end of the screw and carefully un-thread the ball nut onto the
arbor. After the ball nut is transferred to the arbor, secure it in place with tape or a
clamp.
2. Remove the return tubes, one at a time and empty ball bearings from return tube and
internal ball nut path in ball nut into a container.
3. Continue to remove ball return tubes and empty all ball bearings. There could be up to
three return tubes and ball bearing paths.
4. Discard the return tubes and used ball bearings (if ball nut is being rebuilt.)
5. Flush all components with a clean degreasing solvent.
6. Check ball nut threads for damage and replace if necessary.
7. Check retaining wire location. Some are free to rotate to other part of nut when the
return tubes are removed.
8. Lightly oil (Spindle or 10 weight) all components to aid in re-assembly.
9. Thread ball nut onto ball screw or arbor.
10. Begin re-filling ball bearing paths and return tubes. After the return tube is filled, a
small dab of grease will hold the balls in the tube during assembly. Remove one or
two balls (for clearance) and assemble return tube and ball nut.
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3-1 Exploded View
Section III
Views & Parts List
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3-2 Parts List – Translating and KFTN Ball Screw ComDRIVEs®
Table 3-2 Parts list
Item
1 Sleeve 1 Sleeve
2 Thrust Bearing 2 Thrust Bearing
3 Nut (Wormgear) 3 Nut (Wormgear)
4 Sleeve Cap 4 Sleeve Cap
5 Sleeve cap set screw (4) 5 Sleeve cap set screw (4)
6 Grease Fitting 6 Grease Fitting
7 Ball Screw 7 Ball Screw
8 Screw Stop 8 ----------------------------------------------
9 Pin or Set Screw 9 ---------------------------------------------10 Worm (Input Shaft) 10 Worm (Input Shaft)
11 Worm Shaft Bearing (2) 11 Worm Shaft Bearing (2)
12 Shims 12 Shims
13 Bearing Cap 13 Bearing Cap
14 Adapter Cap 14 Adapter Cap
15 Worm Shaft Seal (2) 15 Worm Shaft Seals (2)
16 Bearing Cap Screw (3-4) 16 Bearing Cap Screw (3-4)
17 Adapter 17 Adapter
18 Lock Washer (6-8) 18 Lock Washer (6-8)
19 Adapter Cap Screw (3-4) 19 Adapter Cap Screw (3-4)
20 Gear Reducer 20 Gear Reducer
21 Woodruff Key 21 Woodruff Key
22 Hex Head Cap Screws (3-4) 22 Hex Head Cap Screws (3-4)
23 Lock Washers (3-4) 23 Lock Washers (3-4)
24 Key – Motor Key 24 Key – Motor Key
25 Electric Motor 25 Electric Motor
26 Hex Head Cap Screws (3-4) 26 Hex Head Cap Screws (3-4)
27 Lock Washers (3-4) 27 Lock Washers (3-4)
28 Protection Tube 28 ------------------------------------29 Screw Stop (1) extending 29 Screw Stop (1) (extending)
30 Pin or Set Screw 30 ------------------------------------31 Key – keyed jacks 31 ------------------------------------32 Key Screw – keyed jacks 32 ------------------------------------33 Boot Clamp 33 Boot Clamp
34 Bellows Boot 34 Bellows Boot
35 ------------------------------------------------ 35 Traveling Nut
36 ------------------------------------------------- 36 Key - KFTN
Translating Item
KFTN- Keyed For Traveling Nut
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3-3 Maintenance Log and Serial Number
Date Maintenance Performed Initials
Serial #_______________________________________________
Contact Joyce/Dayton Corp. and provide the serial number to obtain product
information needed for maintenance, repair and reorder.
Joyce/Dayton Corp
P.O. Box 1630
Dayton, Ohio 45401
Phone (800) 523-5204 (U.S. & Canada); (937) 294-6261 Fax (937) 297-7173
www.joycedayton.com E-mail: [email protected]
FB0196 – 8/11
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