Master C150, C35, C262, C200 Service Manual

MASTER COMBOGEAR RIGHT ANGLE C-FACE REDUCERS
®
SERVICE AND REPAIR
SIZES C150, C200, C262, C350
WARNING: Because of the possible danger to person(s) or property which may result from improper use of products, it is important that correct procedures be followed. Products must be used in accordance with the Engineering information specified in the catalog. Proper installation, operation and maintenance procedures must be observed. The instructions in the instruction manuals must be followed. Inspections should be made as necessary to assure safe operation under prevailing conditions. Proper guards and other suitable safety devices or procedures as may be desirable or as may be specified in safety codes should be provided, and are neither provided by Master Power Transmission nor are the responsibility of Master Power Transmission. This unit and its associated equipment must be installed, adjusted and maintained by qualified personnel who are familiar with the construction and operation of all the equipment in the system and the potential hazards involved. When risk to persons or property may be involved, a failsafe device must be an integral part of the driven equipment beyond the speed reducer output shaft.
3300 Tenth St. / Columbus, IN 47201 / (888) 616-1094 www.master-pt.com
Master ComboGear Right Angle Reducer Instruction Manual 499430
10/2013
INSTRUCTION MANUAL 499430
TABLE OF CONTENTS
GENERAL INFORMATION ....................................................................................................................................3
PRODUCT DESCRIPTION ............................................................................................................
........................ 3
NOMENCLATURE..................................................................................................................................................3
APPLICATION INFORMATION..............................................................................................................................4
WARRANTY ...........................................................................................................................................................4
MOUNTING POSITIONS .......................................................................................................................................4
CHANGING OUTPUT SHAFT FROM K1 TO L1 (AND L1 TO K1).................................................................4
MOTOR INSTALLATION........................................................................................................................................5
COUPLING LOCATION..........................................................................................................................................5
INSTALLATION ......................................................................................................................................................6
TWIN TAPERED BUSHING INSTALLATION ........................................................................................................6
TWIN TAPERED BUSHING REMOVAL ................................................................................................................7
STRAIGHT BORE BUSHING INSTALLATION......................................................................................................7
TORQUE ARM MOUNTING POSITIONS ..............................................................................................................9
INPUT SEALING SYSTEM ....................................................................................................................................9
MAINTENANCE....................................................................................................................................................10
LUBRICATION – GENERAL .........................................................................................................................10
LUBRICATION – OIL FILL LEVELS..............................................................................................................10
LUBRICATION – VERTICAL OU TPUT SHAFT MOUNTING .......................................................................10
STANDARD INPUT SEAL REPLACEMENT.................................................................................................10
OUTPUT SEAL REPLACEMENT........................................................................................................
......... .11
BOLT TYPES AND TORQUES .........................................................................................................
.............12
LONG TERM STORAGE..............................................................................................................
........................ 12
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GENERAL INFORMATION
MASTER Power Transmission manufactures the
the product described in this instruction manual.
PRODUCT DESCRIPTION
The MASTER ComboGear reducer is a double reduction worm-helical speed reducer that utilizes a C-Face motor adapt
er and 3-piece flexible coupling.
This product is available in two basic configurations:
NOMENCLATURE
The part number indicates all the essential characteristics of the MASTER ComboGear.
MASTER ComboGear
MASTER ComboGear
1. Solid Output Shaft: a standard solid output shaft extension that can be specified as left hand, right hand or double shaft configurations. See Mounting Position diagrams.
2. Hollow Output Shaft: uses a hollow through-bore output shaft in either of two configurations: 1) straight bore shaft with locking set screws, or 2) twin tapered bushings. Twin tapered bushing kits are available separately in a range of inch and metric bore sizes.
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APPLICATION INFORMATION
The MASTER ComboGear reducer is designed to operate within the following temperature limits:
Ambient –10 to +165 °F
Oil Sump –10 to +200 °F
Where ambient temperatures exceed 100°F, care should be taken not to exceed 200°F sump temperature during unit operation.
The continuous rated input horsepower shown on the reducer nameplate is for service factor of 1.0 at an input speed of 1750 RPM. Before placing the reducer into service, check the nameplate to confirm that its horsepower rating is consistent with the motor horsepower and the desired service factor. Application versus service factor information and reducer ratings for different speeds can be found in your MASTER Engineering catalogs.
WARNING TO ENSURE THAT DRIVEN EQUIPMENT IS NOT UNEXPECTEDLY STARTED, TURN OFF AND LOCK OUT AND TAG POWER SOURCE BEFORE WORKING NEAR THE EQUIPMENT. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY OR PROPERTY DAMAGE.
WARRANTY
The MASTER ComboGear Reducer is war­ranted under the MASTER “Standard Terms and Conditions of Sale” to be free of defects in material and workmanship. Warranty claims must be submitted to the company within one (1) year from the date of installation or three (3) years from the date of manufacture, whichever comes first. The warranty is valid providing the product is properly applied, installed, operated and maintained in accordance with our instruction manual. This warranty covers product replacement or repair only and excludes labor, equipment and/or downtime for removal and installation. This warranty shall not apply where equipment is operated above rated load capacity or is subject to accident, alteration, misuse or abuse. This warranty is in lieu of and excludes all other expressed or implied warranties.
NOTE: Service and repair under warranty should be performed only by a MASTER authorized service shop. Contact MASTER Warranty Administration for the nearest location.
MOUNTING POSITIONS
Reducers should always be ordered for the expected mounting position as different oil fill quantities are required and grease fittings are
required on the upper bearings of vertical shaft units. See Lubrication section.
NOTE: The following mounting positions are generic in that many other assemblies of feet and flanges are available. The relationship of the input and output shafts to earth (down) are significant.
CHANGING THE OUTPUT SHAFT FROM K1 TO L1 (AND L1 TO K1)
Units should always be ordered to the required mounting position. However, it is possible to change output shaft location.
1. Drain oil from case. Remove the open bearing housing. Remove the output seal and discard.
2. Lift out the output shaft assembly and the intermediate shaft assembly.
3. Remove the closed bearing housing. Clean machined surfaces.
4. Remove tapered roller bearing cups and shims from each bore in each bearing housing and switch them . (Place cups and shims removed from bores in open bearing housing in closed bearing housing and vice versa.)
5. Apply a 1/16” bead of Loctite 515 or equivalent sealant to the closed bearing housing machined sealing surfaces. The bead of sealant must go completely around all bolt and dowel holes. Install the closed bearing housing. Evenly tighten the housing bolts. Lay the unit on the bench, closed bearing housing down.
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REDUCER
SIZE
MOTOR
FRAME
MOTOR
COUPLING
REDUCER
COUPLING
REDUCER
SIZE
MOTOR
FRAME
MOTOR
COUPLING
REDUCER
COUPLING
C150 56 .090 / (3/32) .00 (EVEN) C200 56 .090 / (3/32) .00 (EVEN)
C150 140 .030 / (1/32) .00 (EVEN) C200 140 .030 / (1/32) .00 (EVEN)
C150 180 N.A. N.A. C200 180 .171 / (11/64) .188 / (3/16)
C150 IEC71 .090 / (3/32) .00 (EVEN) C200 IEC71 .090 / (3/32) .00 (EVEN)
C150 IEC80 .156 / (5/32) .00 (EVEN) C200 IEC80 .156 / (5/32) .00 (EVEN)
C150 IEC90 .141 / (9/64) .00 (EVEN) C200 IEC90 .141 / (9/64) .00 (EVEN)
C262 56 .090 / (3/32) .00 (EVEN) C350 56 .070 / (5/64) .00 (EVEN)
C262 140 .030/ (1/32) .00 (EVEN) C350 140 .125 / (1/8) .00 (EVEN)
C262 180 .090 / (3/32) .00 (EVEN) C350 180 .156 / (5/32) .00 (EVEN)
C262 210 N.A. N.A. C350 210 .090 / (3/32) .00 (EVEN)
C262 IEC71 .141 / (9/64) .250 / (1/4) C350 IEC71 .141 / (9/64) .250 / (1/4)
C262 IEC80 .141 / (9/64) .250 / (1/4) C350 IEC80 .141 / (9/64) .250 / (1/4)
C262 IEC90 .109 / (7/64) .250 / (1/4) C350 IEC90 .109 / (7/64) .250 / (1/4)
C262 IEC100/112 .188 / (3/16) .015 /(1/64) C350 IEC100/112 .188 / (3/16) .015 /(1/64)
C262 IEC132 .047 / (3/64) .00 (EVEN) C350 IEC132 .047 / (3/64) .00 (EVEN)
N.A. (NOT APPLICABLE) NOTE: IEC Motors are B5 flanges.
6. The position of the wormgear must be adjusted so the worm contacts the center of the wormgear teeth. Failure to make this adjustment may cause reduced efficiency and life as well as overheating and tooth breakage.
7. Apply Prussian Blue lightly but evenly to both sides of five adjacent teeth on the bronze wormgear.
8. Install the intermediate shaft assembly into the gearcase so that the intermediate shaft pinion will be on the same side as the output gear when the reducer is reassembled. Install the open bearing housing and secure with two bolts at diagonal corners. The hollow dowel pins must be in place.
9. Rotate the input shaft so the “blued” wormgear teeth are rotated through the gear mesh. Then rotate in the opposite direction. Marks of contact will be made by the worm in the bluing on the wormgear teeth.
10. Remove the open bearing housing and intermediate shaft assembly. Examine the contact pattern on the wormgear teeth. The ideal pattern is centered in the wormgear teeth.
11. If the pattern is not centered, the intermediate shaft must be moved in the direction where the contact shows the heaviest. Remove a thin shim from the bearing cup on the side that the contact is heaviest and install it under the cup on the opposite side. Shims may be moved from one side to the other but the total number of shims must not be changed, as this controls the endplay of the bearings.
COUPLING LOCATION
The motor and reducer coupling halves must be properly located before assembly to prevent bearing and coupling failure. Refer to the following chart and reference diagram for proper locations.
MOTOR INSTALLATION
The MASTER ComboGear uses a standard NEMA C­face motor with a 3-piece flexible coupling. IEC motor adapters and couplings are available.
12. Repeat the above steps, cleaning, rebluing and inspecting each time, until the contact pattern is centered on the wormgear.
13. Install the intermediate and output shaft assemblies. Apply sealant to the gearcase machined sealing surfaces. Install the open bearing housing and tighten all bolts. Be sure all parts rotate freely.
14. Lubricate the shaft seal surface and seal bore liberally with SHC 634. Install a new seal, taking care not to cut or roll the lip or dislodge the seal garter spring. Seat the seal flush with the outside of the bearing housing. The use of a driver is recommended.
15. Fill unit with proper amount of lubricant. See charts. Use sealant on plug threads. Test unit.
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INSTALLATION
IMPORTANT!
While the basic MASTER ComboGear reducer is suitable for any approved mounting position, different oil levels are required for mounting positions other than K1/L1/S1. You must add the required amount of oil for the desired operating position.
IMPORTANT: RIGID MOUNTING OF THE REDUCER IS NOT RECOMMENDED.
System alignment problems indicate that rigid mounting of a reducer in a rigid system may cause “binding”, leading to premature bearing, shaft or reducer failure. A system must have some flexible element that allows it to self-align during operation.
The ideal mounting for a hollow shaft reducer is to use a torque arm design. If a reducer uses a flange/bracket mounting concept, it is highly recommended that the reducer be mounted on the conveyor head shaft using the conveyor pillow block on the opposite side of the conveyor as a support bearing. A system with a rigidly mounted bearing close to a rigidly mounted reducer will probably be impossible to align and maintain.
Units are shipped from the factory with the reducer half of the input coupling installed.
1. Drive key into motor shaft. Slide the input coupling half onto the motor shaft. Position the coupling half on the motor shaft as shown in the preceding chart. Tighten setscrews.
2. Insert the elastomer coupling element into the reducer-side coupling half. Visually align the openings in the coupling half with the ears on the motor side coupling half. Slip the motor straight into the motor adapter, insuring that the coupling engages properly. Once the coupling engages, slide the motor tenon into the motor adapter. Install and tighten four motor bolts.
WARNING: Keep fingers clear of mating flanges of motor and reducer to prevent pinching injury.
3. Insure that there is no binding or excess clearance between the coupling halves. The motor-side coupling half may be loosened with a hex wrench inserted through the adapter access hole; then use a screwdriver to gently pry the motor coupling half toward the reducer. The metal ears should not touch the face of the opposite coupling hub and should have no more than 1/32” clearance. Tighten setscrews securely.
4. Install the plastic safety cap into the adapter access hole.
TWIN TAPERED BUSHING INSTALLATION
WARNING: The output shaft bushings must be shielded to prevent contact, which may result in injury. Fabricate or contact MASTER for shields.
1. One bushing assembly is required to mount the reducer onto the driven shaft. One assembly consists of two tapered bushings, six bushing screws, bushing keys and a shaft key.
2. The driven shaft must extend through the full length of the reducer. The reducer should be mounted the recommended minimum distance from the shaft bearing (shown as dimension “A” in Fig. 2 and table. Dimension “A” is required for bolt clearance/jackscrew removal.)
3. Place one bushing on the shaft and position per dimension “A”. If the reducer is positioned closer to the bearing than “A”, place the screws (with lockwasher) in the unthreaded holes in the bushing before positioning the bushing on the shaft. Allow a minimum of 1/8” between the screw heads and the bearing. Do not grease the bushings.
4. Insert the output key in the shaft and bushing.
5. Place the reducer in position on the shaft aligning the hub keyway with the shaft key.
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