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SERVICE MANUAL REPAIR PARTS Model 2.5

1. 14 OPERATION aaa aa Section 2 SPECIFICATIONS 2 1 OPERATING 5 6 2 2 OVERHUNG LOAD 2 3 PRESSURE Vs TORQUE CHART Section 3 INSTALLATION 3 1 RECEIVING THE DRIVE 3 2 MOUNTING THE 3 3 WIRING SPECIFICATIONS 3 4 PNEUMATICS 3 5 Section 4 LUBRICATION 4 1 CHECKING THE OIL LEVEL 4 2 CHANGING 0 Section 5 OPERATIONAL CHECKS 5 1 GENERAL SET UP INSTRUCTIONS 5 2 CHECKING CLUTCH AND BRAKE PISTON SEALS AND 5 3 CHECKING CLUTCH AND BRAKE ENGAGEMENT or INPUT SHAFT Vs OUTPUT SHAFT DRIVE MOTORS coris enti 5 5 PNEUMATIC CONTROL Section 6 TROUBLESHOOTING 6 1 TROUBLESHOOTING CHART 6 2 Section 7 DISASSEMBLY 7 1 GENERAL DISASSEMBLY PROCEDURE 7 2 REMOVING C FACE MOUNTED DRIVE MOTORS 7 3 REMOVING FAN SHROUD AND 7 4 SEPARATION AND REMOVAL OF MAJOR SUB ASSEMBLIES FOR ACCESS TO THE CLUTCH AND BRAKE
2. QUANTITY REQUIRED STATIC BRAKING TORQUE Lb Ft QUANTITY REQ D OF DRIVE PLATE 612 38 FORCE CONTROL INDUSTRIES INC CESS IMacGza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com MB 056 MOTOR BRAKE SUB ASSEMBLY 642 Figure 10 5 MB 056 Motor Brake Sub Assembly FORCE CONTROL INDUS TRIES INC 39 INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 SE DIST AUTORIZADO 442 1 95 72 60 ventas industrialmagza com Parts List For Figure 10 6 SECONDARY INPUT amp OUTPUT HOUSING SUB ASSEMBLY Secondary Input amp Output Shaft PART PART REF No PART NAME REF No PART NAME Output Shaft Dowel Pin Bearing Retainer Pipe Plug 1 2 NPT Output Housing Pipe Plug 1 8 NPT Pipe Plug 1 NPT Lockwasher Ball Bearing Lockwasher Pilot Ball Bearing Worm Gear Oil Seal Soc Hd Cap Screw Bearing Retainer Ball Bearing Ball Bearing Breather Sight Gauge Spacer Gasket Bearing Retainer Soc Hd Cap Screw Secondary Input Shaft Soc Hd Cap Screw Lockwasher C Face Adapter eS eS cl cl cl P Indicates parts in Minor Overhaul Kit Indicates parts in Major Overhaul Kit This Major Overhaul Kit also contains all parts that are in the Minor Overhaul Kit AR As Required 40 FORCE CONTROL INDUSTRIES INC CESS mlaazea MEX 55 53 63 23
3. ANI AN eA SECONDARY INPUT SHAFT OPTIONS Male Shaft for Coupling or Belt Drive Shown C Face Adapter 4 1 2 AK with Coupling Quill Shaft for C Face Mtng of Drive Motor 4 1 2 AK FORCE CONTROL INDUSTRIES INC CESS mlaazea MEX 55 53 63 2331 MTY 81 83 54 10 18 227 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com Section 2 SPECIFICATIONS 2 1 OPERATING SPECIFICATIONS PRIMARY CLUTCH TORQUE Lb Ins SA SECONDARY CLUTCH AND BRAKE TORQUE Lb ins 120 104 S 1118 60 966 60 C 25 vzre vsoo o 8 sem 74 of NOTE Cooling water flow requirements GPM equals 10 x calculated thermal horsepower load 2 2 OVERHUNG LOAD CAPACITY Lbs Pull INPUT SHAFT RPM PRIMARY SECONDARY MAX AIR ASSIST STATIC DYNAMIC SPRINGS ONLY psie Psie STATI stanc 1400 60 1554 Q 40 1800 3600 7500 WATER ENGMT HORIZONTAL 0 70 2 00 4 00 VERTICAL 35 1 00 2 00 OUTPUT SHAFT iz 1200 vw no 7000 NOTES Ratings are at midpoint of shaft extension Male Secondary Input Shaft Only 2 3 PRESSURE Vs TORQUE CHART PRIMARY CLUTCH CLUTCH CLUTCH STATIC ACTUATION ENGAGEMENT AIR PR CLUTCH NET TORQUE Lb In PSI PSI NOTE Minimum pres
4. 155 Use Sealant Permatex 3D on the seal bore Clean off any excess Sealant Slide the C Face Adapter 155 carefully over the worm shaft end Do not damage the oil seal lip WORM SHAFT 153 BRAKE END hl DRINE END 0 LIFT UP 1 N Figure 9 5 Installing Quill Worm Shaft 22 INDUSTRIAL ANY MMM NT SN e t TT BIBLIA i PUSH IN FORCE CONTROL INDUSTRIES INC 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com 10 11 Attach the C Face Adapter 155 with 4 Screws 199 and 4 Washers 202 Slide the Collet Spacer 677 and then the Collet 606 over the worm shaft end Place the Hub 602 over the Collet Re install the Hex Hd Cap Screw 651 and Copper Gasket 630 into the Hub and Collet Use Red Loctite 271 on the threads Tighten to 60 Lb Ft Torque Press Oil Seal 631 into the Brake Mounting Plate 678 Use Sealant Permatex 3D the oil seal bore Clean off any excess Sealant Align Gasket 623 on the Brake Mounting Plate 678 Attach Plate 678 to the Housing 9 with 4 Screws 1 99 and 4 Washers 627 Be careful not to damage the lip of the oil seal on the worm shaft 9 7 MB 056 BRAKE SUB ASSEMBLY See Figure 10 1 and 10 5 1 FORCE CONTROL INDUS PRIES INC INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 MSN
5. Place the Brake End Housing 609 in an upright posi tion to facilitate Reassembly as shown in Figure 9 7 If necessary press the Wear Sleeve 676 into housing until it is flush with the Thrust Face Use Red Loctite 271 Drive Pins 657 into housing until they bottom out Use Red Loctite 271 Build up the Brake Stack using Friction Discs 613 and Drive Plates 612 See Page 38 for quantity of Drive Plates 2612 Friction discs 613 and Springs 636 noting the following a Align the Drive Plates 612 so that the Dowel Pins 657 pass through the holes in the Drive Plates b Center Friction Discs 613 on the Drive Plates and align the spline teeth in the discs with each other c Alternate between Drive Plates and Friction Discs starting and ending with a Drive Plate Lubricate the 2 O Rings 640 and install them into the End Housing 609 Install the Teflon Liner 642 into the housing Lubricate the 2 O Rings 639 and place them on the Piston 603 Stretch the Liner 643 over the O Rings on the Piston Lubricate the inside cylinder surface of the Brake End Housing 10 Place Piston Sub Assembly into the housing align ing the 4 holes in the Piston with the 4 Pins 657 in the Brake Stack See Figure 9 7 Be careful not to damage the Teflon Liners in the hous ing or the piston PISTON SUB ASS Y PISTON 603 2 O RINGS 639 e TEFLON LINER 6
6. When ordering replacement parts please specify all of the following information 1 Drive Model Number On the nameplate 2 Drive Serial Number On the nameplate 3 Part Reference Number On the Exploded View Drawing and the Parts List 4 Part Name On the Parts List 5 Quantity On the Parts List 6 Complete shipping Information Failure to include information for items 1 through 5 will only delay your parts order Unless another method is specified for item 6 parts less than 70 pounds will be shipped United Parcel Service parts over 70 pounds will be shipped motor freight Air freight and other trans portation services are available but only if specified on your order 10 5 NAME PLATE amp MODEL NUMBER MULTI SPEED MSDr DRIVE FORCE CONTROL INDUSTRIES INC Fairfield Hamilton OH USE MOBIL Multi purpose ATF FORCE CONTROL INDUSTRIES INC MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com MULTI SPEED MSDr MODEL NUMBER SIZE 1 2 Size 2 5 PRIMARY INPUT 3 Standard 4 1 2 AK 5 8 U 4 1 2 AK 7 8 U 8 1 2 AK 1 1 8 U 8 1 2 AK 1 3 8 U C Face Piggyback LOGIC 4 A Spring Set Brake 75 25 Spring Set Brake 50 50 C Clutch Only SA Spring Set Brake Air Assist SCP Self Centering Piston Standard Logic e c oom w Standard 4 1
7. have O Ring 839 and Liner 42 in the See Figure 10 2 Piston Retainer 191 1 Press Bearing 38 onto the Input Shaft 2 IMPORTANT 2 Insert the Input Shaft into the Primary Input 17 Attach Brake Assembly with 2 Screws 652 and 2 Washers 627 18 Reinstall any pipe plugs and the Sight Gauge removed during Disassembly 9 8 PISTON RETAINER AND HOUSING SUB ASSEMBLY 5ee Figure 10 4 NOTE Before applying Sealant Loctite 620 to the Bearing 27 and clean it well with cleaning solvent Loctite 755 or equivalent Install the O Rings 39 and the Liners 242 into the Piston Housing 10 and Piston Retainer 191 Lubricate the O Rings before installation Apply Sealant Loctite 620 to the 1 0 of Bearing 27 and press it onto the Thrust Plate 5 Make sure that the bearing is firmly seated on the thrust plate shoulder Apply Sealant Loctite 620 to the O D of Bearing 27 and press the bearing and thrust plate into the Piston 3 Make sure that the bearing is seated firmly against the piston shoulder Housing 8 See Figure 9 8 PRIMARY INPUT HOUSING 8 BEARING 38 4 Repeat steps 2 and 3 for the other Thrust Plate 101 and Bearing 27 Sub Assembly 5 Lubricate the 2 O Rings 40 and install them on the Piston 8 PRIMARY INPUT 6 Heat up the Teflon Liner 43 in an oven to 200 F SHAFT 2 RII pipe OWE te ION UM Figure 9 8 Installing
8. 2 PRIMARY INPUT E ARBOR PRESS BEARING Remove the Piston Sub Assembly which consists of a Thrust Plate 5 b 2 Bearings 27 c B x 0 0 x 7 I D x 3 LG Piston 3 d 2 O Rings 40 e Teflon Liner 43 and f Thrust Plate 101 Figure 7 2 Removing Bearing 38 From Input Shaft FORCE CONTROL INDUS S INC 13 INDUSTRIAL 55 53 632331 MTY 81 83 54 10 18 RE DIST AUTORIZADO 442 1 95 72 60 ventasGindustrialmagza com 2 BEARINGS 27 THRUST PLATE 101 PISTON 3 TEFLON LINER 43 THRUST PLATE 5 Figure 7 3 Piston Sub Assembly 6 The Teflon Liner 43 and 2 O Rings 40 can now be removed for inspection and replacement See Figure 7 3 7 Using the jackscrew holes located in the Thrust Plate 101 thread 3 10 24 UNC x 4 lg Screws into the Thrust Plate and force it out of the Bearing 27 See Figure 7 4 LG THRUST PLATE 101 BEARING 827 PISTON 3 Figure 7 4 Removing Thrust Plate 101 From Piston 8 Press out the remaining Thrust Plate 101 with an Arbor Press 9 Ifthe 2 Bearings 27 are still intact in the Piston 3 insert 1 or 2 steel strips 1 8 x 1 x 3 7 8 between the bearings and use an Arbor Press to press out one of the Bearings See Figure 7 5 The other Bearing 27 can now be easily pushed out of the Piston with an Arbor Press 10 The 2 Teflon Liners 42 and 2 O Rings 3
9. ASSEMBLY WITH MALE INPUT SHAFT See Figure 10 2 1 If the Key 180 is still intact in the Primary Input Shaft 2 remove it at this time 2 Wrap tape around the length of the shaft to protect the oil seal from the keyway IMPORTANT Do not attempt to remove the Primary Input Shaft unless Bearings 26 or 38 has to be replaced 3 Unscrew 6 Screws 100 and remove them Take the Bearing Retainer 7 off over the input shaft being careful not to damage the lip of the Oil Seal 32 Check the Oil Seal 32 and replace if necessary Remove the Locknut 33 from the Input Shaft 2 6 Remove and discard Gasket 55 FORCE CONTROL INDUSTRIES INC 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com 7 7 REMOVING THE MALE PRIMARY INPUT 7 8 PRIMARY INPUT HOUSING SUB SHAFT FROM PRIMARY INPUT HOUSING ASSEMBLY WITH QUILL INPUT SHAFT 1 Use an arbor press to press the Input Shaft out of See Figure 10 2 the Input Housing See Figure 7 1 1 Unscrew 6 Screws 100 and remove them Take the Bearing Retainer 16 off over the input shaft being careful not to damage the lip of the Oil Seal Ny 632 2 Check the Oil Seal 32 and replace if necessary Remove the Locknut 33 from the Input Shaft 2 Remove and discard Gasket 56 Using the same procedure as described in 7 7 remove the Quill Input Shaft 42 from the housi
10. INPUT SHAFT For Coupling or Belt Drive Quill Shaft is available for C Face Mounting ian nt A e ine SS 52 161 sfe 2 PRIMARY INPUT HOUSING 2 si is released Air is applied to port C to release the brake The secondary motor may now be started The second ary clutch must be engaged for the secondary input shaft to drive the output shaft Air is exhausted from port A to disengage the primary clutch and engage the sec ondary F clutch Air is applied to port B to further increase the secondary clutch torque S and SA Logic only The secondary input shaft is now connected to the output shaft A typical application would be to engage the primary clutch to drive a load at high speed Then downshift to the secondary clutch to travel at a low speed The low speed may be to position a load very accurately or a feed speed in a machining operation The secondary motor is turned off and the brake is engaged to stop in the final position PRIMARY CLUTCH PORT s SECONDARY CLUTCH STACK SECONDARY INPUT WORM SHAFT oe RATAST OUTPUT SHAFT wa SECONDARY INPUT AND PISTON RETAINER PISTON HOUSING OUTPUT HOUSING BRAKE STACK MB 056 BRAKE SECONDARY INPUT WORM SHAFT tt one ame 8 0 ee a 4 Jim BRAKE PORT Figure 1 3 Multi Speed Drive Assembly 2 a D E 7 ZN
11. 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Section 10 ORDERING REPAIR PARTS 10 1 GENERAL INFORMATION This section illustrates lists and describes all available Repair Parts for the Force Control Multi Speed Drive MSDr Exploded views with numbers are used to identify the various parts in the Drive Units These num bers are listed in the parts list along with the part name and quantity used 10 2 FACTORY RE BUILD SERVICE Re conditioning service is offered by Force Control Industries at the factory Before returning a unit for this service be sure to first contact the Force Control Industries Service Sales Dept for authorization and shipping instructions Force Control Industries cannot be responsible for units returned to the factory without prior notice or authorization Care must be given to the packaging of returned drives Always protect mounting feet by attaching to a skid Shipment damaged drives always delay repairs When possible describe the problem experienced on your shipping papers SHIPPING ADDRESS Force Control Industries Inc 3660 Dixie Highway Fairfield Ohio 45014 Telephone 513 868 0900 Fax 513 868 2105 E Mail info forcecontrol com 28 INDUSTRIAL 10 3 DRIVE MOTORS The motors used with these Drive Units are standard and may be repaired or replaced by any qualified motor rebuild facility or supplier 10 4 ORDERING REPAIR PARTS
12. HOLE AND TIGHTEN DRIVE SHEAVE OR PULLEY TAPER LOCK BUSHING STEP 1 REMOVE 2 SET SCREWS Figure 7 7 Removing Input Sheave or Pulley the Brake Side 1 Remove 4 Screws 199 and 4 Lockwashers 627 and take the Bearing Retainer 678 off 2 Check the Oil Seal 631 and if necessary remove it from the Bearing Retainer 678 FORCE CONTROL INDUS PRIES INC INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 MSN 3 Remove and discard Gasket 623 4 Slide the Spacer 677 and the Bearing Spacer 23 off the Worm Shaft 153 the Drive Side 5 the Key 166 from the Worm Shaft 153 Tape the keyway so the oil seal lip will not be damaged when removed C FACE ADAPTER WITH COUPLING 6 If the Coupling 247 is still intact on the Input Shaft loosen the set screw in the coupling and remove it from the shaft Remove 4 Screws 199 and 4 Lockwashers 202 and take the C Face Adapter 155 off Be careful not to damage the Oil Seal 158 STANDARD MALE INPUT SHAFT 6 Remove 4 Screws 199 and 4 Lockwashers 175 and remove Bearing Retainer 155 careful ly so the oil seal lip will not be damaged 7 Check the lip of Oil Seal 158 and remove if necessary 8 Remove Shims 293 and save for Reassembly 9 Slide both Bearing Cups 167 out of the bearing bores 10 With an arbor press press the brake end smaller dia shaft of t
13. Logic S Lockwasher Logic SA Piston Retainer O Ring A and B Logic 5 and Logic KR BAP Indicates parts in Minor Overhaul Kit Indicates parts in Major Overhaul Kit This Major Overhaul Kit also contains all parts that are in the Minor Overhaul Kit 36 FORCE CONTROL INDUSTRIES INC CESS IMacGza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com PISTON RETAINER amp HOUSING SUB ASSEMBLY 191 36 Figure 10 4 Piston Retainer amp Housing Sub Assembly FORCE CONTROL INDUS TRIES INC INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 QA DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com 37 Parts List For Figure 10 5 MB 056 MOTOR BRAKE SUB ASSEMBLY PART PART REF No PART NAME REF No PART NAME 1 1 Liner O D Sealing Breather Sight Gauge End Housing Pipe Plug 1 4 NPT Drive Plate See Chart Below Pipe Plug 1 8 NPT Friction Disc See Chart Below Hex Hd Cap Screw Heli Coil Lockwasher Soc Hd Cap Screw Copper Gasket Washer Dowel Pin Spring See Chart Below Pipe Plug Wear Sleeve Aa NR AH Liner 1 0 Sealing Indicates parts in Minor Overhaul Kit ndicates parts in Major Overhaul Kit This Major Overhaul Kit also contains all parts that are in the Minor Overhaul Kit QUANTITY REQ D OF FRICTION DISC 613
14. Never Seez com pound to the entire inner bore of the Secondary Input Quill Shaft 153 and Primary Input Quill Shaft 2 to prevent Fretting Corrosion within the shafts 2 With an appropriate soft sling and a lifting hook slide the motor shaft into the Quill Input Shaft making sure that the key on the motor shaft aligns with the keyway in the Quill Shaft Attach the Drive Motor with 4 Screws 262 and 4 Lockwashers 265 CAUTION Be very careful not to bump the Input Shaft This could damage the Bearings and Oil Seals 9 15 ATTACHING C FACE MOUNTED SEC ONDARY CLUTCH DRIVE MOTORS WITH COUPLING See Figures 9 11 10 7 1 Install Coupling Hub 247 onto the Secondary Input Shaft 153 and the other Coupling Hub 249 onto the Drive Motor Shaft as shown in Figure 9 11 Tighten with set screws when properly positioned Slip the Coupling Spider 22248 into one of the Couplings Carefully align the two Coupling Hubs together and attach the Drive Motor with 4 Screws 262 and 4 Washers 265 ALIGN END OF SHAFT WITH THIS SURFACE OF COUPLING HUB ALIGN END OF SHAFT WITH THIS SURFACE OF COUPLING HUB SET SCREW SECONDARY INPUT SHAFT 153 C FACE ADAPTER 155 COUPLING HUB 247 KEY 166 COUPLING HUB 249 COUPLING SPIDER 248 Figure 9 11 Installing C Face Motor With Coupling FORCE CONTROL INDUSTRIES INC 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO
15. friction discs The friction discs consist of a resilient paper based friction material bonded to steel discs with oil control grooves machined into the friction surfaces See Figure 1 2 The friction discs have internal teeth which mate with a spline on the output shaft The drive plates are keyed to the input shafts in the clutches and to the housing for the brake The splined sections of the output shaft contains centrifugal impellers to maintain a positive flow of oil between the friction discs and the drive plates maintaining the Oil Shear Principle as described in 1 2 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com 1 4 OPERATION The MSDr Assembly Figure 1 3 shows the drive in the braked or stopped position The spring set MB 056 brake on the secondary input shaft keeps it from rotat ing Springs push the piston in the piston housing against the secondary clutch stack to transmit the brake torque to the output shaft There is an optional air boost Port B using compressed air for increased and adjustable brake torque S and SA Logic only The primary input shaft can run continuously Air is applied to port A to engage the primary clutch The pis ton shifts away from the secondary clutch and engages the primary clutch The primary shaft is now connected to the output shaft The secondary input shaft can only run when the brake SECONDARY CLUTCH PORT PRIMARY CLUTCH STACK MALE PRIMARY
16. 16 to the Housing 8 with 6 Screws 100 Be careful not to damage the lip of the Oil Seal 32 9 f the C Face Adapter 200 was removed remount it back on the housing with 6 Screws 201 and 6 Washers 230 10 Install Key 180 back into the Input Shaft 9 11 INSTALLING WATER COOLED HEAT EXCHANGER See Figure 10 3 1 Guide the Heat Exchanger 48 into the Primary Input Housing making sure that the tube ends proj ect out the 2 holes in the back of the housing Attach with 2 Screws 56 2 Mark the tubing approximately 1 16 beyond the face of the housing See Figure 9 10 HEAT EXCHANGER 48 2 FERRULES INLET amp OUTLET APPROX 1 16 puc 7 MARK amp CUT F TUBING OFF PRIMARY INPUT HOUSING Figure 9 10 Installing Heat Exchanger 3 Remove the Heat Exchanger from the Housing and cutoff the tubes on the 1 16 marks IMPORTANT The ends of the tubes must be square and free of all burrs before reassembly 4 Reinstall the Heat Exchanger back into the Housing and place the 2 Compression Fittings 71 with ferrules on the tubing ends 5 Add Pipe Coupling 177 Pipe Nipple 178 Pipe Tee 242 and the Zinc Anode 176 to the Inlet Fitting 71 9 12 REATTACHING MAJOR SUB ASSEMBLIES AND CLUTCH STACKS See Figure 10 1 1 Place the Output Housing so that the key end of the Output Shaft is down and the Housing is on a sta ble flat surfac
17. 4 NPT C Port 1 8 NPT PRIMARY NPUT gl 1 2 e OUTPUT 402 5 MSDr UNIT PNEUMATIC CONTROL VALVE FUNCTION STATION 1 STATION 2 PRESSURE PRIMARY SECONDARY SOLENOID A SOLENOID A TO PORT CLUTCH CLUTCH 2 Insert Diagnostic Pressure Gauges in the air supply between the control valves and the drive See Figure 5 2 3 Activate Solenoid Control Valves for desired function See Logic Diagrams below in Figure 5 2 a Primary Clutch b Secondary Clutch c Brake 4 Check air pressure with installed diagnostic pressure gauges for each function 5 Check all electrical connections and solenoid opera tions per manufacturer s specifications STATION 1 STATION 2 EXHAUST FILTER EXHAUST Optional SHOP LUBRICATOR AIR BRAKE REGULATOR 40 to 80 PSI PRIMARY CLUTCH REGULATOR 60 PSI Max S and C Logic 80 PSI Max SA A and B Logic NOTE Top porting and bottom porting are both sup plied The use of bottom porting is recom mended to purge contaminents out of the cylinders when they are exhausted The use of top porting will not purge the cylinders BRAKE Spring Set Air Release Not Used on C Logic Posidyne MULTI SPEED DRIVE BRAKE HIGH SPEED OFF or A or ENGAGED DISENGAGED ENGAGED or ON A and C ENGAGED DISENGAGED DISENGAGED LOW SPEED OFF Secondary motor must be off whenever brake is engage
18. Primary Input Shaft 7 Replace Springs 36 back into the appropriate holes in the Piston Retainer 191 Grease may be 3 Set the Primary Input Shaft and Housing into an used to hold the springs in their holes during Arbor Press See Figure 9 9 Using an appropriate reassembly sized tube press Bearing 26 onto the Input Shaft 8 Inspect the Piston Sub Assembly for an etched until it bottoms out Make sure the Loading Slots are marking OP This designates the side of the towards the input end Piston that should be placed down into the Piston IMPORTANT Housing Insert the Piston Sub Assembly into the DO NOT press on the bearing cage or Piston Housing 10 Be careful not to damage the the outer race Only press on the inner Liners 42 and 43 in the Piston Housing and race of Bearing 26 Piston Screw Locknut 33 onto the Input Shaft 2 Use 9 Align the Gasket 51 on the Piston Housing using Red Loctite 271 on threads 10 24 the Dowel Pins 68 for proper positioning Assemble the Piston Retainer 191 to the Piston Housing 3 with 4 Screws 62 and 4 Washers 1 27 INDUSTRIAL Apply a thin coat of Sealant Permatex 3D to the oil seal bore in the Bearing Retainer 7 and press Oil Seal 32 into the Retainer Place tape over the keyway and then slide the Bearing Retainer 7 over the shaft being careful FORCE CONTROL INDUSTRIES INC 55 53 63 23 31 MTY 81 83 54 10 18 DIST
19. This Major Overhaul Kit also contains all parts that are in the Minor Overhaul Kit AR As Required 42 FORCE CONTROL INDUSTRIES INC CESS mlaazea MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com SECONDARY INPUT amp OUTPUT HOUSING SUB ASSEMBLY Male Secondary Input Worm Shaft REF HOUSING 9 L 199 C LOGIC ONLY 262 WITH COUPLING REF HOUSING 9 7 lt gt SK 157 677 265 913 159 C LOGIC ONLY Figure 10 7 Secondary Input amp Output Housing Sub Assembly Secondary Input Worm Shaft FORCE CONTROL INDUS PRIES INC 43 INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Manual Revision amp Printing History 2 5 Posidyne Multi Speed Drive MSDr REVISION REVISION PRINTING NUMBER REVISION ACTION DESCRIPTION Created complete digital file to create a PDF file for the web 502 MT MS 01 8 03 Updated manual format New cover and back Added Warranty information Removed Detroit info Added Revision Histor y INDUSTRIAL MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com REVISION REVISION INITIATED BY Name Brooks Brooks FORCE CONTROL INDUSTRIES INC Worldwide Leader in Oil Shear Technology Providing today s industrie
20. not attempt to reuse any Gaskets removed during Disassembly They must be replaced with new ones at Reassembly FORCE CONTROL INDUS PRIES INC 11 INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com 3 When removing the Clutch Stacks always keep the Drive Plates 13 and Friction Discs 12 in the same order as they were removed 4 Also when removing the Brake Stack keep the Drive Plates 612 and Friction Discs 613 in the same order as they were removed PRIMARY CLUTCH STACK 1 Remove 4 Screws 61 and 4 Lockwashers 126 from the input end of the Primary Input Housing SubAssembly 2 Remove 8 Screws 69 and 8 Lockwashers 126 from the output end of the Output Housing SubAssembly 3 Using jackscrews separate and lift the Primary Input Housing Sub Assembly away from the Drive Unit Remove and discard Gasket 53 The Primary Clutch Stack can now be removed from the Output Shaft Spline SECONDARY CLUTCH STACK 1 Using jackscrews separate and remove the Piston Retainer and Housing Sub Assembly away from the Secondary Input Output Housing Sub Assembly Remove and discard Gasket 53 The Secondary Clutch Stack can now be removed from the Output Shaft Spline BRAKE STACK 1 Remove 2 Screws 652 and 2 Lockwashers 627 from the front of the Brake Unit 2 Slide the Brake Unit away
21. of the Drive Motors Force Control furnishes all Drive Motor Mounting Parts and required Belt Guard s Drive belts and sheaves are provided as an option as per cus tomer s requirements If the motor mounting parts are not furnished by Force Control then the customer must supply and install all appropriate Safety Guards for all exposed drive rotating parts as required 6 Air Breathers 45 and 645 are removed before shipment and pipe plugs are put in their place In most cases this will be a red plastic plug This is to prevent oil spillage during shipment These plugs must be removed and both Breathers 45 and 645 installed to prevent damage to the drive Both Breathers are taped to the drive for shipment CAUTION Failure to install both Air Breathers will result overheating which will cause the brake and clutch components to malfunction FORCE CONTROL INDUSTRIES INC MEX 55 5 63 2331 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com After the drive has been in operation for a few hours make sure that all mounting bolts are tight and re check alignment of all driving components After 40 hours of operation check mounting bolts and tighten if necessary 3 3 WIRING SPECIFICATIONS See Motor Plate for Wiring Specifications 3 4 PNEUMATICS Note the following when planning and installing the Pneumatic System See Figure 3 1 1 A and B Ports 1
22. reducers and other component parts may be provided by their respective manufactures Any legal action for breach of any Force Control warranty must be commenced within one year of the date on which the breach is or should have been discovered A Return Goods Authorization RGA number must be obtained from the factory and clear ly marked on the outside of the package before any equipment will be accepted for war ranty work Force Control will pay the shipping costs of returning the owner parts that are covered by warranty Force Control believes that the information in this document is accurate The document has been carefully reviewed for technical accuracy In the event that technical or typo graphical errors exist Force Control reserves the right to make changes to subsequent editions of this document without prior notice to holders of this edition The reader should consult Force Control if errors are suspected In no event shall Force Control be liable for any damages arising out of or related to this document or the information contained in it FORCE CONTROL INDUSTRIES INC CESS mlaazea MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Table Of Contents Section 1 DESCRIPTION and OPERATION 1 1 UNIT DESCRIPTION 0 1 2 THE OIL SHEAR 1 3 DESCRIPTION OF CLUTCH AND BRAKE
23. slide it onto the Worm Shaft 153 4 Slide both Bearing Cups 167 into the bearing bores 5 Place Bearing Spacer 23 over the shaft end up against the Bearing Cup 167 on the brake side AN A ENS 6 Slide the Collet Spacer 677 over the brake end of MARES the Worm Shatt 153 Then slide the Collet 606 onto the worm shaft BEARING 41 CAUTION DO NOT USE MOLYBDENUM DISULFIDE MOLYKOTE OR ANY OTHER SIMILAR LUBRICANT ON THE e Figure 9 3 Determining Thickness of Shim 292 a Using a depth micrometer take a reading from sur SHAFT The collet hub locking element face A to surface B This is dimension is keyless and depends on friction to b With the depth micrometer take a reading from surface OM Ane Drake Ode to bearing surface This is dimension aii 66 77 66 55 ki 77 66 77 66 27 66 m 77 7 Install the Hub 602 Over the Collet 606 c Subtract a from b to get c a b c c 9 J ki Reinstall the Hex Cap Screw 651 and d Amount of shims required Copper Gasket 630 Use Red Loctite 4271 on 7 Align the Shims 292 onto the Housing the threads Tighten to 60 Lb Ft torque 8 Attach Bearing Retainer 162 with 6 Screws 8 Press Oil Seal 631 into Brake Mounting Plate 159 and 6 Washers 128 678 Use Sealant Permatex 3D in the seal bore 9 Align Gasket 623 on
24. the Brake Mounting Plate 9 5 SECONDARY INPUT HOUSING SUB 678 ASSEMBLY See Figure 10 5 and 10 7 10 Attach the Brake Mounting Plate 678 to the Secondary Input Housing 9 with 4 Screws WITH MALE INPUT WORM SHAFT 199 and 4 Washers 627 Be careful not to 1 Press the Bearing Cone 168 onto the drive end damage the oil seal lip on the hub spline of the Worm Shaft 153 11 On the Drive Side press Oil Seal 158 into Brg 2 Insert the Worm Shaft and the Bearing Cone 168 Retainer or C Face Adapter 155 Use Sealant into the bearing bore of the Secondary Input Permatex 3D on the seal bore Housing 9 SECONDARY INPUT WORM GEAR 154 WORM SHAFT 153 BRAKE END P DRIVE END 1 NN e Bak 2 25 UE PUSH IN Ot N O Figure 9 4 Installing Male Worm Shaft FORCE CONTROL INDUS TRIES INC 21 INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Sr LIFT UP 12 13 14 15 16 17 18 Slide the Retainer or Adapter 155 over the Worm Shaft 153 being careful not to damage the lip of Oil Seal 158 Use 4 Screws 199 and 4 Washers 175 or 202 to attach to the housing Use a Feeler Gauge to check the gap between the Brg Retainer or Adapter and the Housing Determine the thickness of Shims 293 required by using the
25. will give additional life to the drive A new drive will produce an abundance of torque until it has burnished in Initial regulator settings should be set at about 80 of charted ratings See Section 2 TORQUE Vs ACTUATION PRES SURE After using the drive for a few weeks the acceleration time may increase Increasing the air pressure will restore the acceleration Secondary motor must be off whenever the brake is engaged Station 2 solenoid A is commonly con nected to an auxiliary contactor on the secondary motor starter to prevent this problem 3 5 START UP 1 STATION 1 Lock out machine and air pressure Verify that the Electrical Power is to avoid personal injury Recheck Air Connections for tightness to see if they are correct as shown in the Pneumatic Schema tic Figure 3 1 Set Air Regulators to 8096 required air pressure As charted in Section 2 TORQUE Vs ACTUATION PRESSURE Unlock Main Disconnect Check out Secondary Drive Speed mode for proper rotation and adjust all limit switches as needed Check operation of Primary Motor Drive STATION 2 EXHAUST FILTER QY EXHAUST Optional SHOP LUBRICATOR N AIR BRAKE REGULATOR 40 to 80 PSI PRIMARY CLUTCH REGULATOR 60 PSI Max S and C Logic 80 PSI Max SA Logic NOTE Top porting and bottom porting are both sup plied The use of bottom porting is recom mended to purge c
26. 2 AK 5 8 U 4 1 2 AK 7 8 U 8 1 2 AK 1 1 8 U 8 1 2 AK 1 3 8 U Piggyback amp 8 1 2 AK 1 3 8 U C Face 1 2 3 4 5 6 7 8 9 REVISION 9 By Force Control SECONDARY INPUT 8 Standard 4 1 2 AK 5 8 U 4 1 2 AK 7 8 U 8 1 2 AK 1 1 8 U c D E 8 12 AK 1 3 8 U F G H C Face with Quill Shaft 4 1 2 AK 5 8 U C Face with 4 1 2 AK 7 8 U Coupling Piggyback COOLING 7 1 Std Radiant 2 Water 5 Fan 7 Fan Split Shroud RATIO 6 A 61 30 1 12 40 1 15 1 48 1 E 20 1 J 60 1 24 1 96 1 U Motor Shaft Diameter 2 AK Motor Register Pilot Dia FORCE CONTROL INDUS TRIES INC 29 INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Parts List For Figure 10 1 MAJOR SUB ASSEMBLIES amp CLUTCH STACKS PART PART REF No PART NAME La REF No PART NAME B Friction Disc Lockwasher Drive Plate Lockwasher Soc Hd Cap Screw Soc Cap Screw Soc Hd Cap Screw Indicates parts in Minor Overhaul Kit 30 FORCE CONTROL INDUSTRIES INC CESS IMacGza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com MAJOR SUB ASSEMBLIES amp CLUTCH STACKS 2 126 PRIMARY INPUT HOUSING SUB ASSEBLY See Figure 10 2 See Figur
27. 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com SECONDARY INPUT amp OUTPUT HOUSING SUB ASSEMBLY Secondary Input Shaft amp Output Shaft 162 159 Oy 182 N NW s EN NS 192 NS 27 M 14 45 79 S 72 PR EN AZ 7 gt lt C FACE ADAPTER Figure 10 6 Secondary Input 8 Output Housing Sub Assembly Secondary Input Shaft 8 Output Shaft FORCE CONTROL INDUS TRIES INC 41 INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Parts List For Figure 10 7 SECONDARY INPUT amp OUTPUT HOUSING SUB ASSEMBLY Secondary Input Worm Shaft PART PART REF No PART NAME 2 REF No PART NAME Bearing Spacer Coupling 1 Bore Worm Shaft Coupling Spider Bearing Retainer Coupling 875 Bore Extended C Face Adapter With Coupling Hex Hd Cap Screw Bearing Retainer With C Logic Lockwasher Ball Bearing Shim Male Input Shaft Only Gasket Male Input Shaft Quill Input Shaft Roller Bearing Cup Lockwasher Roller Bearing Cone Oil Seal Lockwasher Heli Coil Insert C Logic Only No Brake With Brake Soc Hd Cap Screw Lockwasher 2 Screw With Logic Key N HH HS Adapter Plate Gasket C Logic Only lt a NR AP A Indicates parts in Minor Overhaul Kit Indicates parts in Major Overhaul Kit
28. 4 NPT C Port 1 8 PRIMARY INPUT Use direct acting solenoid air valves or pilot operat ed valves to give the response speed required Locate the valves as close as possible to the air inlets on the drive The valves may be installed directly on the drive if they are supported Be sure to use valves with a minimum Cv factor of 8 Cv of 1 5 works well in most cases Lubricators are not necessary for the MSDr but they may be used if needed for air valve operation The optional accumulator should be used for quick response particularly if the air line loss and the nature of the air supply is such that recovery is slow Size the accumulator to be at least ten 10 times the air required per engagement See Section 2 SPECIFICATIONS The accumulator would be installed between the filter and the air valve or lubricator if used SECONDARY CLUTCH REGULATOR 60 PSI Max S and C Logic 40 PSI Max SA Logic SECONDARY INPUT Opposite Side AND MB 056 BRAKE UNIT PRIMARY CLUTCH en T pem e X tl KO Ilo pod Qr eT fa EES SECONDARY CLUTCH S SA amp C Logic Only e output ELT EH 402 5 MSDr UNIT Figure 3 1 Typical Pneumatic Schematic FORCE CONTROL INDUS PRIES INC INDUSTRIAL MEX 55 53 63 2331 MTY 81 83 54 10 18 MSN Pressure is proportional to torque Use only the pressure necessary to operate the drive This
29. 4 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasQindustrialmagza com Remove and discard Gasket 622 Remove Springs 636 The quantity of springs are predetermined at the factory for your Brake Torque requirements When removing these springs if all of the holes are not used it would be helpful for you to make a freehand sketch locating the position of the springs This will help at Reassembly 7 Remove the Brake Piston Sub Assembly Inject compressed air into the actuation port if necessary to pop out the piston This Piston Sub Assembly consists of a Piston 603 b Liner 643 and 2 O Rings 639 8 The Teflon Liner 643 and 2 O Rings 639 can now be removed from the Piston for inspection and replacement 9 Remove the Teflon Liner 642 and 2 O Rings 640 from the End Housing 609 10 There is a Wear Sleeve 676 located in the End Housing 609 This sleeve is used to aid in prop er oil distribution through the Brake Stack Check the Sleeve for damage and if replacement is necessary use a small chisel to remove it from the End Housing 7 11 SECONDARY INPUT AND OUTPUT HOUSING SUB ASSEMBLY See Figure 10 7 WITH MALE INPUT WORM SHAFT Remove any remaining belt guards belts sheaves or pulleys connected to the Secondary Input Worm Shaft or the Output Shaft See Figure 7 7 for removal of Input Sheave or Pulley TO REMOVE TAPER LOCK BUSHING PLACE 1 SET SCREW IN JACK SCREW
30. 43 SPRING 636 BRAKE SUB ASS Y HOUSING 609 e 2 O RINGS 8640 TEFLON LINER 642 BRAKE STACK Figure 9 7 Installing Piston Into Brake 11 12 13 14 15 16 Replace Springs 636 back into the proper holes in the Piston 603 Place Gasket 2622 on the End Housing 609 Use Sealant Permatex 30 Set the Adapter Plate 679 onto the Brake Sub Assembly Attach with 2 Screws 655 and 2 Washers 628 Evenly tighten down these screws to compress the springs correctly Apply 60 P S I air pressure to the Brake Port This port is labeled Brake Port Listen for air leaks and Observe to see if the Brake Stack releases While air pressure is still applied to the Brake check and align the Friction Disc spline teeth with each other Remove the air pressure Slide the Brake Assembly over the Hub 602 IMPORTANT Do not force the Friction Discs over the hub It may be necessary to realign them so the spline teeth are all in line with each other The Brake will then slip on with ease 23 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com IMPORTANT When placing the Piston Retainer over the Piston be careful not to damage the Teflon Liner 42 in the Retainer Tighten down Screws 62 in an even manner to compress the springs correctly 9 9 PRIMARY INPUT HOUSING SUB Drive Units with A or B Logic will not ASSEMBLY WITH MALE INPUT SHAFT
31. 442 1 95 72 60 ventasQindustrialmagza com NOTE The Coupling Hubs 247 and 249 may have to be heated up to slip them on the appropriate shaft Do not drive them onto the shafts The Bearings could be dam aged 9 16 INSTALLING BELT DRIVEN SHEAVE OR PULLEY Male Input Shaft Only 1 Install guard back plate if necessary 2 Assemble the Taper Lock Bushing and the Drive Sheave or Pulley with the 2 Set Screws placed in the locking holes 3 Place assembled Sheave or Pulley onto the Male Input Shaft as close as possible to the unit to mini mize overhang shaft deflection Tighten the 2 Set screws to lock it on the shaft See Figure 9 12 DRIVE SHEAVE OR PULLEY STEP 1 REMOVE SET SCREW FROM JACK SCREW HOLE TAPER LOCK BUSHING STEP 2 INSTALL 2 SET SCREWS AND TIGHTEN TO LOCK ON SHAFT TORQUE TO 200 In Lbs Figure 9 12 Installing Sheave or Pulley 9 17 FINAL REASSEMBLY 1 Replace all pipe plugs and fittings removed for inspection or disassembly 2 Fill the Drive Unit with Mobil Multi Purpose ATF Automatic Transmission Fluid as indicated in Section 4 LUBRICATION 3 Replace all external motor drive parts safety guards sheaves pulleys belts and couplings on belt drive units 4 Before replacing the Drive Unit back into service completely check out the Operation as described in Section 5 OPERATIONAL CHECKS FORCE CONTROL INDUS PRIES INC 27 INDUSTRIAL 55 53 63 23 31 MTY 81
32. 502 MT MS 01 SERVICE MANUAL AND REPAIR PARTS FOR Model 2 5 Posidyne MULTI SPEED DRIVE WARNING Read this manual before any installation maintenance and operation FORCE MANUFACTURERS OF MECHANICAL AND FORCE CONTROL INDUSTRIES ELECTRICAL POWER TRANSMISSION EQUIPMENT CESS mlaazea MEX 55 53 63 2331 MTY 81 83 54 10 18 QRO 442 1 95 tas i QTE DIST AUTORIZADO QR 7260 ventasGindustrialmagza com LIMITED WARRANTY SPECIAL 24 MONTH WARRANTY Upon written approval of the application by Force Control Industries Inc the Standard Warranty period will be extended to 24 months Force Control Industries Inc Force Control warrants its products to be free from defects in material and workmanship under normal and proper use for a period of one year from the date of shipment Any products purchased from Force Control that upon inspec tion at Force Control s factory prove to be defective as a result of normal use during the one year period will be repaired or replaced at Force Controls option without any charge for parts or labor This limited warranty shall be void in regard to 1 any product or part thereof which has been altered or repaired by a buyer without Force Control s previous written consent or 2 any product or part thereof that has been subjected to unusual elec trical physical or mechanical stress or upon which the original identification marks have been removed or altered Tr
33. 7 13 SECONDARY INPUT SHAFT SUB ASSEMBLY see Figure 10 6 1 Unscrew Screws 159 and 6 Lockwashers 1 28 and remove the Bearing Retainer 162 Remove Shims 292 and save for Reassembly 3 Slide the Secondary Input Sub Assembly out of the housing over the Output Shaft See Figure 7 12 4 Place the Secondary Input Shaft into an Arbor Press and press Bearings 27 and 41 Spacer 49 and Worm Gear 154 off of the Secondary Input Shaft 192 See Figure 7 13 5 Take the Key 182 out of the Secondary Input Shaft 1 92 FORCE CONTROL INDUS TRIES INC 17 INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com 7 14 REMOVING THE OUTPUT SHAFT FROM THE OUTPUT HOUSING 1 If the Key 181 is still intact in the Output Shaft 1 remove it at this time and place tape over the keyway 2 Remove 6 Screws 63 and 6 Washers 126 and carefully remove the Bearing Retainer 7 so the oil seal lip is not damaged 3 Check the Oil Seal 32 and replace if necessary Remove and discard Gasket 55 Using a rubber mallet tap on the back of the Output Shaft 1 until the Bearing 35 comes out of the BEARING 35 bearing bore Pull the Output Shaft 1 and the Bearings 28 and 35 out of the front of the hous OUTPUT SHAFT 1 ing See Figure 7 14 Figure 7 14 Removing The Output Shaft Remove Locknut 34 fro
34. 9 can now be removed from the Piston Retainer and Housing and replaced if necessary 14 INDUSTRIAL ARBOR PRESS INSERT 1 OR 2 1 8 x 1 x 3 7 8 LG STEEL STRIPS TO PRESS BOTTOM BEARING 427 QUT OF PISTON TOP BEARING 27 PISTON 3 SPACER BOTTOM BEARING 27 Figure 7 5 Pressing Out Bearing 27 7 10 BRAKE SUB ASSEMBLY See Figures 10 1 and 10 5 1 Remove 2 Screws 652 and 2 Lockwashers 627 from the front of the Brake Unit and slide the Brake Unit off of the Hub 602 Remove and discard Gasket 622 Take the Hex Hd Cap Screw 651 and Seal Washer 630 out of the end of the Hub 602 Screw a 3 8 16 UNC x 1 2 Lg Soc Set Screw into the Collet 606 Then screw a 1 2 13 UNC x 1 1 2 Lg Hex Hd Cap Screw into the Hub until it contacts the Set Screw continue turning the Hex Hd Screw until the Hub 602 is forced off of the Collet 606 See Figure 7 6 1 2 13 UNC x 1 1 2 LG HEX HD CAP SCREW TS Mi dat ds m 3 8 16 UNC x 1 2 LG x SOC HD SET SCREW HUB 4602 N z Figure 7 6 Brake Collet amp Hub Disassembly 4 With care remove 2 Screws 655 and 2 Lockwashers 628 from the Adapter Plate 679 CAUTION The Brake Sub Assembly is under spring pressure so care must be taken to avoid personal injury when removing Screws 655 FORCE CONTROL INDUSTRIES INC MEX 55 53 63 23 31 MTY 81 83 5
35. AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com not to damage the lip of the Oil Seal 32 Attach with 4 Screws 100 ARBOR PRESS PRIMARY INPUT SHAFT 2 TUBE LOADING SLOTS PRIMARY INPUT HOUSING 8 BEARING 26 2 NNNNNNNNNNNNSNSNNSNNNNANANAN AX JT AALL JF AL y PE AMRANNNNA NS N Figure 9 9 Pressing Bearing 26 On Primary Input Shaft 9 10 PRIMARY INPUT HOUSING SUB ASSEMBLY WITH QUILL INPUT SHAFT See Figure 10 2 1 Press the Bearing 38 onto the Input Shaft 2 2 Lubricate and place the O Ring 104 into the input shaft bore Press the Freeze Plug 99 into the bore 3 Insert the Quill Primary Input Shaft 2 into the Primary Input Housing 8 See Figure 9 8 4 Set the Primary Input Shaft and Housing into an arbor press Using an appropriate sized tube press Bearing 26 onto the Input Shaft until it bottoms out Make sure the Loading Slots are towards the input end See Figure 9 9 IMPORTANT DO NOT press on the bearing cage or the outer race Only press on the inner race of Bearing 26 5 Screw Locknut 33 onto the Input Shaft 2 Use Red Loctite 271 on threads 6 Apply a thin coat of Sealant Permatex 3D to the oil seal bore in the Bearing Retainer 16 and press Oil Seal 32 into the Retainer Clean off any excess sealant Align Gasket 56 onto the Bearing Retainer 16 Attach Bearing Retainer
36. C Face Adapter 180 Figure 10 2 Primary Input Housing Sub Assembly FORCE CONTROL INDUS TRIES INC 39 INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Parts List For Figure 10 3 FAN COOLING AND WATER COOLING PART PART REF No PART NAME Eat REF No PART NAME Compression Fitting Self Tapping Screw Zinc Anode Pipe Coupling Heat Exchanger Machine Screw Pipe Nipple Soc Hd Cap Screw Access Cover Set Screw Pipe Tee Indicates parts in Minor Overhaul Kit 34 FORCE CONTROL INDUSTRIES INC CESS mlaazea MEX 55 53 63 2331 MTY 81 83 54 10 18 SE DIST AUTORIZADO 442 1 95 72 60 ventas industrialmagza com FAN COOLING With Male Input Shaft REF PRIMARY INPUT HOUSING SUB ASSY REF PRIMARY INPUT HOUSING SUB ASSY 56 Figure 10 3 Fan Cooling and Water Cooling FORCE CONTROL INDUS TRIES INC 35 INDUS 55 53 63 28 31 81 83 54 10 18 tasQindustrialmagz TRIAL DIST AUTORIZADO 442 1 95 72 60 ventas Imagza com Parts List For Figure 10 4 PISTON RETAINER amp HOUSING SUB ASSEMBLY PART PART REF No PART NAME La REF No PART NAME Clutch Thrust Plate Liner Sealing Piston Housing A and B Logic Ball Bearing 5 and Logic Spring Soc Hd Cap Screw Logic A Liner O D Sealing Logic B Logic C Clutch Thrust Plate
37. O FILL BRAKE PRIMARY HOUSINGS AIR BREATHER 45 PIPE PLUG 14 REMOVE TO FILL PRIMARY HOUSINGS BRAKE SIGHT GAUGE 646 BRAKE FLUID LEVEL OUTPUT SIGHT GAUGE 46 PRIMARY HOUSINGS FLUID LEVEL PIPE PLUG 73 REMOVE TO DRAIN PRIMARY HOUSINGS PIPE PLUG 674 REMOVE TO DRAIN BRAKE Figure 4 1 Lubrication 6 FORCE CONTROL INDUSTRIES INC INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 RE DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 5 OPERATIONAL CHECKS These Operational Checks are to be made when the Drive Unit is removed from service for repair Provisions for manually controlled 60 to 80 PSI air pressure must be made for these Operational Checks 9 1 GENERAL SET UP INSTRUCTIONS The set up shown in Figure 5 1 is only an example The basic requirement is that the air supply have a quick act ing shut off action Install the 60 to 80 PSI air supply to the drive and remove the 2 Inspection Plugs and the Brake Breather CAUTION Do not remove these Inspection Plugs or Breather while the drive is running 3 MANUAL QUICK DISCONNECT FITTINGS INSPECTION SECONDARY INPUT SHAFT BREATHER 1 4 NPT PORTS A PRIMARY CLUTCH B SECONDARY CLUTCH 1 8 NPT PORT C BRAKE Figure 5 1 Set Up For Operational Checks 5 2 CHECKING CLUTCH AND BRAKE PISTON SEALS AND MOVEMENT 1 Manually apply air to the Primary Clutch port A With the aid of
38. SEMBLY 9 8 PISTON RETAINER AND HOUSING SUB ASSEMBLY 9 9 PRIMARY INPUT HOUSING SUB ASSEMBLY WITH MALE INPUT 5 9 10 PRIMARY INPUT HOUSING SUB ASSEMBLY WITH QUILL INPUT 9 11 INSTALLING WATER COOLED HEAT EXCHANGER 9 12 REASSEMBLY OF MAJOR SUB ASSEMBLIES AND CLUTCH 9 13 AND FAN SHROUD INSTALLATION 9 14 ATTACHING C FACE MOUNTED DRIVE MOTORS WITH QUILL INPUT 9 15 ATTACHING C FACE MOUNTED SECONDARY CLUTCH DRIVE MOTOR WITH COUPLING 9 16 INSTALLING BELT DRIVEN SHEAVE OR PULLEY 9 17 FINAL REASSEMBLY Section 10 ORDERING REPAIR PARTS 10 1 GENERAL INFORMATION 10 2 FACTORY RE BUILD SERVICE MOTORS Dua tuta ente db Sot 10 4 ORDERING REPAIR 10 5 NAME PLATE AND MODEL NUMBER MULTI SPEED MSDr MODEL NUMBER INFORMATION MAJOR SUB ASSEMBLIES amp CLUTCH STACKS Figure 10 1 PRIMARY INPUT HOUSING SUB ASSEMBLY Figure 10 2 FAN COOLING and WATER COOLING Figure 10 3 PISTON RETAINER and HOUSINGS SUB ASSEMBLY Figure 10 4 MB 056 MOTOR BRAKE SUB ASSEMBLY Figure 10 5 SECONDARY INPUT and O
39. STACKS 7 5 REMOVAL OF HEAT DISASSEMBLY MAJOR SUB ASSEMBLIES 7 6 PRIMARY INPUT HOUSING SUB ASSEMBLY WITH MALE INPUT 5 7 7 REMOVING THE MALE PRIMARY INPUT SHAFT FROM THE PRIMARY INPUT HOUSING 7 8 PRIMARY INPUT HOUSING SUB ASSEMBLY WITH QUILL INPUT 5 7 9 PRIMARY PISTON RETAINER AND HOUSING SUB ASSEMBLY ARRA 7 10 BRAKE 50 7 11 SECONDARY INPUT HOUSING SUB ASSEMBLY WITH MALE INPUT SHAFT 7 12 SECONDARY INPUT HOUSING SUB ASSEMBLY WITH QUILL INPUT SHAFT 7 13 SECONDARY INPUT SHAFT SUB ASSEMBLY 7 14 REMOVING THE OUTPUT SHAFT FROM THE OUTPUT HOUSING DIST AUTORIZADO Section 8 CLEANING and INSPECTION 8 1 CLEANING AND INSPECTION 8 2 REPAIR AND REPLACEMENT Section 9 REASSEMBLY 9 1 GENERAL REASSEMBLY INSTRUCTIONS REASSEMBLY MAJOR SUB ASSEMBLIES 9 2 INSTALLING BEARINGS ON OUTPUT SHAFT 9 3 OUTPUT HOUSING SUB ASSEMBLY 9 4 WORM GEAR 5 55 9 5 SECONDARY INPUT HOUSING SUB ASSEMBLY WITH MALE INPUT WORM 9 6 SECONDARY INPUT HOUSING SUB ASSEMBLY WITH QUILL INPUT WORM 9 7 MB 056 BRAKE SUB AS
40. UTPUT HOUSING SUB ASSEMBLY Secondary Input Shaft and Output Shaft Figure 10 6 SECONDARY INPUT and OUTPUT HOUSING SUB ASSEMBLY Secondary Input Worm Shaft Figure 10 7 FORCE CONTROL INDUS PRIES INC INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 MSN QRO 442 1 95 72 60 ventasQindustrialmagza com CESS mlaazea MEX 55 53 63 2331 MTY 81 83 54 10 18 227 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com Section 1 DESCRIPTION AND OPERATION 1 1 UNIT DESCRIPTION MSDr The Multi Speed Drive as shown in Figure consists of a Primary Input Shaft Secondary Input Worm Shaft and Output Shaft Both the Primary Input Shaft and the Secondary Input Shaft can be a Male Shaft or a Quill Shaft The Male Input Shaft is either belt driven or directly coupled to the Drive Motor The Quill Input Shaft enables the drive motor to be C Face Mounted directly to the Clutch Brake Unit Figure 1 1 The Secondary Input C Face is also available with a male shaft and coupling for down shifting applications MALE PRIMARY INPUT SHAFT MALE SECONDARY INPUT SHAFT C FACE FLANGE 4 1 2 AK WITH COUPLING IS ALSO AVAILABLE MALE OUTPUT SHAFT QUILL SECONDARY INPUT SHAFT WITH C FACE FLANGE 4 1 2 AK QUILL PRIMARY INPUT SHAFT WITH C FACE FLANGE 4 1 2 or 8 1 2 AK MALE OUTPUT SHAFT WITH C FACE FLANGE 4 1 2 or 8 1 2 AK Figure 1 1 Drive Unit Configur
41. a flashlight observe the Clutch Piston to see if it actuates quickly and smoothly Internal damage may be indicated if the piston action is irregular or if it sticks or binds FORCE CONTROL INDUS PRIES INC INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 MSN Also listen for air leaks and look for air bubbles in the oil that would indicate damage to the piston seals 2 Exhaust the air pressure from the Primary Clutch Port A and observe to see that the Clutch Piston moves back smoothly from the Primary to the Secondary Clutch 3 Apply air to the Secondary Clutch port B S SAand C logic only The piston should not move The internal springs should have already shifted the pis ton from the primary to the secondary clutch stack Listen for air leaks and look for air bubbles in the oil that would indicate damage to the piston seals 4 Exhaust air from the Secondary Clutch port B 5 Apply air to the Brake port C The piston inside the brake should shift but it won t be visible Listen for air leaks and look for air bubbles in the oil that would indicate damage to the piston seals 6 Exhaust air from the Brake port C Replace the inspection plugs and breather 5 3 CHECKING CLUTCH AND BRAKE ENGAGEMENT or INPUT SHAFT Vs OUTPUT SHAFT ROTATION WITH MALE INPUT SHAFT When applying air pressure to the desired Clutch port A or B and Brake port C simply rotate the proper Input Shaft by hand and observe th
42. als with the same oil as used in the drive unit immediately before reassembly and installation of any mating parts 2 Outside diameter sealing Teflon Liners will be easi er to install if they are heated in a oven to 200 F maximum 3 The installation of press fitted parts can be eased by heating the outside parts in an oven Heat Bearings to 250 F maximum CAUTION Wear suitable gloves when handling heated parts 4 Placea light coating of Gasket Sealant Permatex 30 in the bore for all Oil Seals immediately before pressing them into the bore REASSEMBLY OF MAJOR SUB ASSEMBLIES The Reassembly Procedure is basically just a reverse order of the Disassembly Procedure 9 2 INSTALLING BEARINGS ON OUTPUT SHAFT See Figure 10 6 1 Press Bearing 35 onto the Output Shaft 1 with an arbor press IMPORTANT Outboard Bearing 35 must be installed with the loading slots towards the output end of the shaft See Figure 9 1 2 Screw Locknut 34 onto the Output Shaft 1 Use Red Locktite 271 on the threads 3 Press Bearing 28 onto the other end of the Output Shaft 1 LOADING SLOTS 2222 OUTPUT SHAFT 1 BEARING 35 Figure 9 1 Installing Bearing 35 On Output Shaft 20 INDUSTRIAL 9 3 OUTPUT HOUSING SUB ASSEMBLY 1 Guide the Output Shaft Sub Assembly into the Output Housing 9 See Figure 9 2 BEARING 35 OUTPUT SHAFT 1 Figure 9 2 Installing Output Shaft Sub As
43. ansportation charges for shipping any product or part there of that the buyer claims is covered by this limited warranty shall be paid by the buyer If Force Control determines that any product or part thereof should be repaired or replaced under the terms of this limited warranty it will pay for shipping the repaired or replaced product or part thereof back to the buyer EXCEPT FOR THE EXPRESS WARRANTY SET OUTABOVE FORCE CONTROL DOES NOT GRANTANY WARRANTIES EITHER EXPRESSED IMPLIED INCLUDING IMPLIED WARRANTIES OF MERCHANTABIL ITY OR FITNESS FOR USE The warranty obligation set forth above is in lieu of all obli gations or liabilities of Force Control for any damages Force Control specifically shall not be liable for any costs incurred by the buyer in disconnecting or re installing any product or part thereof repaired or replace under the limited warranty set out above FORCE CONTROL EXPRESSLY EXCLUDES ALL LIABILITY FOR ANY INDIRECT OR CONSE QUENTIAL DAMAGES THE BUYER MAY SUSTAIN IN CONNECTION WITH THE DELIVERY USE OR PERFORMANCE OF FORCE CONTROL PRODUCTS Under no circumstances shall any liability for which Force Control is held responsible exceed the selling price to the buyer of the Force Control products that are proven to be defective This limited warranty may be modified only in writing signed by a duly authorized officer of the company This limited warranty applies exclusively to Force Control products war ranties for motors and gear
44. ations 1 2 THE OIL SHEAR PRINCIPLE Conventional clutches and brakes depend on friction between solid surfaces operating in air to transmit torque Friction does the job but produces a great amount of heat and wear The MSDr uses the friction surfaces FORCE CONTROL INDUS TRIES INC INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 QA operating in a continually replenished re circulating supply of oil The oil molecules tend to cling to each other and to the friction surfaces As moving and sta tionary elements are brought together a thin but posi tive film of oil is maintained between them controlled by the clamping pressure and carefully designed grooves in the elements Torque is transmitted from one element to the other through the viscous shear of the oil film So long as there is relative motion between the elements they are protected by the oil thus greatly reducing wear The oil also effectively transmits heat away from the fric tion elements ORIVE PLATE KEYED TO IN PUT SHAFT INPUT SHAFT DRIVING KEYS FRICTION DISC RESILENT PAPER BASED FRICTION MATERIAL OUTPUT SHAFT WITH SPLINE M I ROTATION OIL FLOW OIL INLET CAVITY OIL CONTROL 4 CENTRIFUGAL GROOVES IMPELLER BLADES Figure 1 2 The Oil Shear Principle 1 3 DESCRIPTION OF CLUTCH AND BRAKE STACKS In the MSDr clutch and brake stacks the friction sur faces consist of alternate carbon steel drive plates and
45. cts to both drive motors Shut off the air supply to the drive and lock them out Also bleed off any remaining air pressure trapped in the pneumatic lines These steps must be taken to avoid any possibility of personal injury 3 1 RECEIVING THE DRIVE Check the drive for shortage or damage immediately after arrival Prompt reporting to the carrier s agent with notations made on the freight bill will expedite satisfac tory adjustment by the carrier When unloading or han dling the drive keep it upright All Drives are filled with oil ready to run when shipped However before plac ing the unit in service or storage check the oil level to make sure none has spilled out in transit Add oil if nec essary refer to Section 4 LUBRICATION If the drive is not to be installed and operated soon after arrival store it in a clean dry place having a slow moderate change in ambient temperature Actuate pistons and rotate shafts once a month to re lubricate working sur faces 3 2 MOUNTING THE DRIVE Installation of the drive should be made in much the same manner and receive the same care as for a pre cision gear reducer Standard drives are designed for horizontal operation Note the following procedure and precautions when mounting the drive 1 The Drive should be mounted to a firm level base or foundation IMPORTANT When first mounting the Drive Unit to the base visually check to see if the Unit 15 setting flat on the ba
46. d Station 2 Solenoid A is commonly connected to an auxiliary contactor on the Secondary Motor Starter to prevent this problem 5 SA and C Logic only Figure 5 2 Pneumatic Control Diagram INDUSTRIAL FORCE CONTROL INDUSTRIES INC 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com Section 6 TROUBLESHOOTING CAUTION Open disconnect to prime movers and lock it out while making repairs or checking machinery to avoid any personal injury 6 1 TROUBLESHOOTING CHART SYMPTOM POSSIBLE CAUSE REMEDY Primary clutch engages too quickly 1 Air pressure too high 2 Low oil level or wrong kind of oil B Primary clutch engages too slowly 1 Air pressure too low 2 Worn friction surfaces 3 Stuck or damaged piston assembly 4 Wrong oil C Secondary clutch engages too quickly 1 Air pressure too high Secondary clutch acts as a brake 2 100 many springs in piston assembly when stopping from high speed 3 Low oil level or wrong oil D Secondary clutch engages too slowly 1 Air pressure too low Secondary clutch acts as a brake 2 Not enough springs or damaged piston assembly when stopping from high speed 3 Worn friction surfaces 4 Wrong oil E Brake engages too quickly when 1 Too much brake torque stopping from low speed 2 Low oil level or wrong oil F Brake engages too quickly when 1 Too little brake torque stopping from
47. e 2 Install the Secondary Clutch Stack onto the Output Shaft spline Start with 2 Drive Plates 1 3 and then a Friction Disc 12 Alternate the Drive Plates and Friction Discs ending with a Friction Disc FORCE CONTROL INDUS PRIES INC 25 INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Slide the Drive Plates over the lugs of the Secondary Input Shaft and the internal teeth of the Friction Discs with the Output Shaft spline 3 Align the Gasket 53 with the Output Housing using the dowel pins for proper alignment 4 Lower the Piston Retainer and Housing Sub Assembly onto the Output Housing aligning the Dowel Pins 68 with the dowel pin holes make sure that the Piston Housing 10 is down towards the Output Housing Press the Piston Housing down until the dowel pins engage the Output Housing Check the Gasket 53 to see if it is prop erly aligned 5 Install the Primary Clutch Stack onto the Output shaft Spline Start with a Friction Disc 12 and then a Drive Plate 13 ending with a Drive Plate Align the notches in the Drive Plates with each other and the internal teeth of the Friction Discs with the spline on the Output Shaft 6 Align Gasket 53 onto the Piston Retainer f1 using the dowel pins for proper alignment 7 Lower the Primary Input Housing Sub Assembly down onto the Piston Retainer aligning the l
48. e 10 3 for Cooling Options PRIMARY CLUTCH STACK PISTON RETAINER and HOUSING SUB ASSEMBLY See Figure 10 4 SECONDARY CLUTCH STACK PS r a agit 4 N K i 56 E SECONDARY INPUT and OUTPUT HOUSING SUB ASSEMBLY See Figure 10 6 and 10 7 MB 056 BRAKE See Figure 10 5 for Access to the Brake Stack HUB and COLLET See Figure 10 5 A 627 652 Figure 10 1 Major Sub Assemblies and Clutch Stacks FORGE GONTROL INDUS PRIES INC 31 INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Parts List For Figure 10 2 PRIMARY INPUT HOUSING SUB ASSEMBLY PART PART REF No PART NAME e REF No PART NAME B Input Shaft Bearing Retainer Input Housing Pipe Plug 1 NPT Bearing Retainer Ball Bearing Oil Seal Locknut Ball Bearing Gasket Dowel Pin Soc Hd Cap Screw C Face Adapter Input Soc Hd Cap Screw Lockwasher Indicates parts in Minor Overhaul Kit Indicates parts in Major Overhaul Kit This Major Overhaul Kit also contains all parts that are in the Minor Overhaul Kit 32 FORCE CONTROL INDUSTRIES INC CESS mlaazea MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com PRIMARY INPUT HOUSING SUB ASSEMBLY Male Input Shaft 180 Quill Input Shaft and
49. e rotation of the Output Shaft Likewise when the air pressure is removed from the Brake port C and applied to the Secondary Clutch port B the Output Shaft should be locked in the braking position and should not rotate WITH C FACE MOUNTED DRIVE MOTORS If the C Face mounted Drive Motors are still attached then the Input Shafts are not accessible to be manually rotated to check the Clutch Brake Engagement and Input Shaft vs Output Shaft Rotation Temporarily hook up the Drive Motors and Bump them to check the Clutch or Brake Operating Modes and Output Shaft Rotation CAUTION Do not attempt to run motors with the Inspection Plugs or Breather removed They first must be replaced DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com 5 4 DRIVE MOTORS Check wiring connections against the wiring diagram on the Name Plate Bump the Drive Motors and check direction of rotation Apply air to Brake port C before starting secondary input motor Check all connections for tightness 5 5 PNEUMATIC CONTROL The Pneumatic Control Operational Checks are to be made with all Control Valves hooked up 1 Shut off air supply lock it out and bleed off any trapped air in the system SECONDARY CLUTCH REGULATOR 60 PSI Max S and C Logic 40 PSI Max SA Logic SECONDARY INPUT Opposite Side AND MB 056 BRAKE UNIT SECONDARY CLUTCH S SA amp Logic Only PRIMARY CLUTCH A and B Ports 1
50. egulator Air valve may be faulty Replace air valve FORCE CONTROL INDUSTRIES INC MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com SECTION 7 DISASSEMBLY WARNING Before attempting any repairs on the Drive Unit open disconnects to the prime mover shut off air supply and lock them out to avoid any possibility of per sonal injury 7 1 GENERAL DISASSEMBLY PROCEDURE 1 Disconnect the drive and move it to a suitable work area NOTES On belt driven or direct coupled units remove all necessary safety guards belts sheaves and couplings Disconnect water inlet and outlet piping on water cooled units Disconnect all necessary pneumatic piping 2 Remove drain plugs at the bottom of the Drive Unit and the Brake Drain all of the oil into a suitable con tainer and either save for reuse or discard as the condition warrants NOTES For ease of disassembly we rec ommend that you set the Drive Unit on the output end with the output shaft in a vertical down position Supply suitable bracing and clamping to stabilize the Drive Unit An overhead crane and a soft sling is also recommended to remove heavy castings and parts IMPORTANT Unless the drive is to be completely over hauled it should only be disassembled to the extent necessary to gain access to the worn or damaged parts The MSDr Unit is comprised of 4 basic Sub Assemblies which can be disassembled as com
51. feeler gauge thickness 0 005 thickness Remove the Brg Retainer or Adapter 155 and place Shims 293 between them and the Housing Replace the Brg Retainer or C Face Adapter 155 and attaching Screws and Washers Replace Key 166 back into the Worm Shaft 153 9 6 SECONDARY INPUT HOUSING SUB ASSEMBLY See Figure 10 5 and 10 7 WITH QUILL INPUT WORM SHAFT Insert the brake end of the Quill Worm Shaft 153 into the Secondary Input Housing 9 Manually lift the shaft when inserting it to clear the Worm Gear 154 See Figure 9 5 Slide the worm shaft through the housing until the bearing shoulder of the worm shaft is visible past the housing Heat the Bearing 157 and slide it onto the shaft making sure it seats against the bearing shoulder See Figure 9 6 Slide the Worm Shaft and Bearing back into the housing until the bearing seats against the bearing bore shoulder SECONDARY INPUT WORM GEAR 154 QUILL WORM SHAFT 153 HEAT UP BEARING 157 AND PUSH IT ON THE QUILL WORM SHAFT UNTIL IT SEATS ON THE SHOULDER N 5 4 N AA AM Figure 9 6 Installing Bearing 157 Quill Worm Shaft CAUTION DO NOT USE MOLYBDENUM DISULFIDE MOLYKOTE OR ANY OTHER SIMILAR LUBRICANT ON THE SHAFT The collet hub locking element is keyless and depends on friction to transmit torque from the brake to the shaft 4 Press Oil Seal 158 into C Face Adapter
52. from the Adapter Plate 678 See Figure 10 7 3 Remove and discard Gasket 622 Carefully remove 2 Screws 655 and 2 Lockwashers 628 from the back side of the Brake Unit Back off screws partially and be sure Adapter Plate 679 separates from End Housing 609 before completely removing screws CAUTION The Brake Assembly is under Spring Pressure and care must be taken to avoid personal injury when removing Screws 655 and separating the Brake Sub Assembly 5 Remove and discard Gasket 622 12 INDUSTRIAL 6 Remove Springs 636 The quantity of springs are predetermined at the factory for your Brake Torque Requirements When removing these springs if all the holes are not used it would be helpful for you to make a freehand sketch locating the position of the springs This will help at Reassembly 7 Remove the Piston Sub Assembly Inject com pressed air into actuation port if necessary to pop out the piston 8 The Brake Stack can now be removed from the Brake Housing If repair or replacement of the Clutch or Brake Stack is the only repair to be done then proceed to Section 8 CLEANING AND INSPECTION 7 5 REMOVAL OF HEAT EXCHANGER See figure 10 3 1 Remove all external fittings from Input Housing 2 Remove 2 Screws 56 and with a suitable punch tap out the tube ends and remove the Heat Exchanger 48 DISASSEMBLY OF MAJOR SUB ASSEMBLIES 7 6 PRIMARY INPUT HOUSING SUB
53. he Worm Shaft 153 until one of the Bearing Cones 168 slides off of the bearing shaft diameter See Figure 7 8 ARBOR PRESS BEARING CONE 168 Will remain in Housing MALE WORM SHAFT 153 N S N N N N DRIVE SIDE BEARING CONE 168 Will stay on Worm Shaft Figure 7 8 Pressing Male Worm Shaft Out Of Housing 15 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com SECONDARY INPUT WORM GEAR 154 WORM SHAFT 153 BRAKE END 22222 DRIVE END f a prs EL LIFT UP Me 2 2508 NT PULL OUT Figure 7 9 Removing Male Worm Shaft From Housing 11 From the end of the Worm Shaft that still has Bearing Cone 168 on it pull the Worm Shaft 153 out of the Housing 9 lifting and tilting it over the Worm Gear See Figure 7 9 ARBOR PRESS 12 Use a bearing puller to remove the remaining Bearing Cone 168 off of the Worm Shaft 153 SHAKE SIDE f 7 12 SECONDARY INPUT SUB ASSEMBLY Se EN See Figure 10 7 ws aN WITH QUILL INPUT WORM SHAFT ak 1 On the Brake End remove 4 Screws 199 and P 4 Lockwashers 4627 and take the Bearing 27 N Retainer 678 off N 2 Check the Oil Seal 4631 and if necessary 27 5 remove it from the Bearing Retainer 678 122 QUILL WORM Remove and discard Gasket 623 22 N SHAE EARS Slide the Spacer 677 off the Worm Shaft 153 zas On t
54. he drive side remove 4 Screws 199 4 N Lockwashers 202 E 6 Slide the C Face Adapter 155 off the Quill Input EE Shaft 153 being careful not to damage the lip of the Oil Seal 158 DRIVE SIDE Check Oil Seal 158 and replace if necessary Hemove and discard Gasket 623 Figure 7 10 Pressing Bearing 157 Off Worm shaft Press the brake end of the Worm Shaft 1 53 until the Bearing 157 slides off the bearing shaft diam eter See Figure 7 10 10 Pull the Bearing 157 out of the bearing bore 11 From the Quill End of the shaft pull the Worm Shaft 153 out of the housing lifting it over the Worm Gear See Figure 7 11 16 FORCE CONTROL INDUSTRIES INC CESS mlaazea MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com SECONDARY INPUT WORM GEAR 154 WORM SHAFT 153 BRAKE END 222222 eg DRIVE END N T MASS yeg a 7 LIFT UP Why T p AN an LAS FC h N 7j ARBOR PRESS SECONDARY INPUT AND OUTPUT HOUSING BEARING 27 SPACER 849 SS BEARING 41 SECONDARY INPUT WORM GEAR 154 SHAFT SUB ASS Y and KEY 182 BEARING 27 g e SPACER 49 WORM GEAR 154 e KEY 182 e BEARING 41 e SECONDARY INPUT SHAFT 192 SECONDARY INPUT SHAFT 192 Figure 7 12 Removing Secondary Input Shaft Sub Assembly Figure 7 13 Disassembly of Secondary Input Shaft
55. idge is worn in any of the drive plates replace all of the drive plates and friction discs as a complete set 3 Carefully check the piston and bore surfaces for nicks scratches scoring or other damage which would affect operation or cause leakage FORCE CONTROL INDUS PRIES INC INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 MSN 4 Pay particular attention to the shafts in the area of rotary oil seals Check for nicks scratches which would cause leakage Replace any damaged parts 5 It is not necessary to remove the ball bearings to check their operation Slowly rotate the free race of each bearing by hand checking to see if it turns freely without rough or flat spots 8 2 GENERAL REPAIR INFORMATION A fine stone or crocus cloth may be used to remove minor surface defects from parts so long as the operat ing or sealing action of the part is not affected The use of coarser abrasives or other machining methods should not be attempted Otherwise damaged parts should be replaced Replacement is recommended also for the following as applicable 1 Replace all O Rings liners gaskets springs and oil seals removed during the course of disassembly 2 clutch or brake discs and drive plates in complete sets only 19 DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com Section 9 REASSEMBLY 9 1 GENERAL REASSEMBLY INSTRUCTIONS 1 Lubricate O Rings and the lip of all Oil Se
56. low speed 2 Worn friction surfaces 3 Excessive high speed inertia 4 Wrong oil Noise or vibration 1 Mounted on poor foundation 2 Misaligned couplings 3 Belt drive misaligned Over under tensioned 4 Damaged bearings 5 Low oil level or wrong oil H Drive overheats 1 Improper oil level or wrong oil Oil Temp above 225 F 2 Excessive clutch or brake slippage 3 Excessive friction in machine 4 Cooling not functioning properly I Oil leakage out breather 1 Oil level too high 2 Piston seals leaking air J Positioning not consistent 1 Inconsistent electrical signal 2 Oil temperature change 3 Air pressure inconsistent 4 Faulty air valve FORCE CONTROL INDUS PRIES INC INDUSTRIAL MEX 55 53 63 2331 81 83 54 10 18 MSN DIST AUTORIZADO 442 1 95 7260 ventasQindustrialmagza com 6 2 REMEDIES When checking pneumatics shut off air supply lock it out and bleed off any trapped air in the system Insert diagnostic pressure gauges in the air supply between the a b e 10 valves and drive or in the extra ports in the drive Reduce air pressure See Section 4 LUBRICATION Increase air pressure d Disassemble to extent nec essary and replace disc stack See Sections 5 1 and 5 2 for diagnosis Disassemble and repair Piston Assembly Contact factory for assistance Contact factory if more springs are required Disassemble and repair Piston Assemb
57. ly See Parts List for Figure 10 5 for Torque Options Coupling or belt drive between secondary motor and secondary input should be low inertia small diameter Change to different coupling or belt drive Check mounting bolts and foundation Align coupling to manufacturers specifications Install belt drive to manufacturers specifications INDUSTRIAL mE MEX 55 53 63 23 31 Disassemble to extent necessary and replace dam aged bearings Clutches and brake should not slip for more than 2 seconds Increase clutch or brake torque Machine may need lubrication Examples Ways on a slide drive may have run dry also most gear reduc ers are shipped from the manufacturer without oil On water cooled drives check the water supply and drain for restriction or loss of flow On fan cooled drives check for restriction around fan or shroud Limit switch proximity switch or relay may be faulty Circuit may not be hardwired to eliminate PLC scan time Replace switch or relay Hardwire stop switch to eliminate PLC scan time For installations requiring precise positioning oper ating temperatures are important Operating tem peratures between 115 and 165 F are recom mended If the oil is allowed to drop to ambient tem perature overnight the primary clutch input shaft should be run for approx 112 hour before operating machinery Line pressure may be fluctuating Regulator may be faulty Check air supply Replace air r
58. m the Output Shaft 1 Use a standard Bearing Puller to remove both THIS COMPLETES THE DISASSEMBLY PRO Bearings 28 and 35 from the Output Shaft 1 CEDURE FOR THE MULTI SPEED DRIVE 18 FORCE CONTROL INDUSTRIES INC CESS IMacGza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com Section 8 CLEANING INSPECTION AND GENERAL REPAIR INFORMATION WARNING Petroleum based cleaning solvents are flammable and open flames or smoking by personnel in the vicinity of these solvents is extremely hazardous and must not be permitted 8 1 CLEANING AND INSPECTION Clean metal parts in a suitable solvent and dry in a stream of low pressure compressed air The Clutch and Brake Drive Plates can be cleaned in a solvent but DO NOT clean the Clutch and Brake Friction Discs in sol vent Use only a clean dry and lint free rag to clean these Friction Discs Solvent will damage the resilient paper based friction material used on the Friction Discs Keep the Drive Plates and Friction Discs in the same order as they were removed After cleaning inspect parts for cracks distortion scoring nicks burrs or other damage would affect serviceability Pay partic ular attention to the following 1 Check the disc wear surfaces for scoring galling or evidence of uneven wear 2 Check the clutch and brake plates for scoring or galling Make sure they are flat If a perceptible r
59. ng ARBOR PRESS PRIMARY INPUT SHAFT 2 with an arbor press See Figure 7 1 BEARING 26 6 Remove Bearing 26 from the Input Housing 7 With an Arbor Press and Bearing Splitter press the Input Shaft 2 out of the Bearing 38 See PRIMARY INPUT Figure 7 2 NOTE If leakage was indicated within the Quill Input Shaft then the O Ring 104 needs to be replaced 8 With a suitable dull punch knock out the Freeze Plug 99 from the input end of the Input Shaft Check and replace O Ring 104 if necessary APPROX 2 SPACERS AL Figure 7 1 Removing Primary Input Shaft 7 9 PRIMARY PISTON RETAINER AND HOUSING SUB ASSEMBLY See Figure 10 4 Remove Bearing 26 from the Input Housing 3 With an Arbor Press and a Bearing Splitter press the Input Shaft 2 out of the Bearing 38 See 1 Tu ka 7 4 Screws 62 and Figure 7 2 4 Lockwashers 127 CAUTION The Piston Retainer Sub Assembly is under spring pressure and care must be taken to avoid injury when removing these Screws 62 BEARING 438 2 Separate the Piston Retainer 191 from the Piston Housing 10 3 Remove Springs 36 The number of springs are predetermined at the factory for your Torque Requirements When removing these springs it would be helpful for you to make a freehand sketch locating the position of the springs This will help at Reassembly Remove and discard Gasket 51 SHAFT
60. ontaminents out of the cylinders when they are exhausted The use of top porting will not purge the cylinders BRAKE Spring Set Air Release Not Used on C Logic DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com Section 4 LUBRICATION 4 1 CHECKING THE OIL LEVEL When the drive is installed and weekly thereafter or until experience dictates otherwise check the oil level Always check the oil level with the drive at room temper ature and while the motors are not running The drive has oil sight gauges located at the output end of the drive and on the MB 056 brake The oil level is to show at the center of the gauges See Figure 4 1 4 2 CHANGING THE OIL IMPORTANT Open the disconnects to the drive motors before attempting to change the oil Every three months completely drain the oil from the drive and brake using the drain plugs provided as shown in Figure 4 1 If the oil sight gauge is dirty it should be removed and cleaned Reinstall the drain plugs and refill the drive and brake to the center of the sight gauges with fresh oil CAUTION Do not overfill the Drive Unit Excess oil will cause the unit to overheat 4 3 TYPE OF OIL Use only Mobil Automatic Transmission Fluid ATF 210 Type or Multi Purpose Automatic Transmission Fluid Other fluids may be specified for special applications Always use the type of fluid specified on the name plate AIR BREATHER 645 REMOVE T
61. plete sub assemblies for easy access to the Clutch and Brake Stacks See Figure 10 1 1 PRIMARY INPUT HOUSING SUB ASSEMBLY See Figure 10 2 a Optional Fan Cooling and Water Cooling See Figure 10 3 2 PISTON RETAINER AND HOUSING SUB ASSEM BLY See Figure 10 4 3 BRAKE SUB ASSEMBLY See Figure 10 5 4 SECONDARY INPUT OUTPUT HOUSING SUB ASSEMBLY a Secondary Input Shaft and Output Shaft See Figure 10 6 b Secondary Input Worm Shaft See Figure 10 7 7 2 REMOVING C FACE MNTD DRIVE MOTORS 1 Attach an appropriate soft sling or lifting hook to the Drive Motor for support and removal 2 Remove the motor mounting screws and lockwash ers from the C Face Adapter 3 Pull motor back to disengage pilot and quill shaft or coupling IMPORTANT Be sure to support the motor so its weight is not pushing down on the Posidyne Input Shaft FAN COOLED UNITS ONLY 7 3 REMOVING FAN SHROUD AND FAN See Figure 10 3 1 Remove 2 Screws 66 from the front of the Fan Shroud 24 2 Pull the Fan Shroud 24 away from the Primary Input Housing Sub Assembly 3 Loosen Set Screw 70 and remove Fan 25 from the Primary Input Shaft 2 4 Remove both Keys 37 and 180 7 4 SEPARATION AND REMOVAL OF MAJOR SUB ASSEMBLIES FOR ACCESS TO THE CLUTCH AND BRAKE STACKS See Figure 10 1 and 10 5 NOTES 1 Jackscrew holes are provided to aid in separation of the main housings from each other 2 Do
62. s with Oil Shear Clutch and Brake Drives that delivers Flexibility e Efficiency Endurance Performance Dependability Built to Last Guaranteed to Perform FORCE CON TROL FORCE CONTROL INDUSTRIES INC MAIN OFFICE P O Box 18366 Fairfield Ohio 45018 3660 Dixie Highway Fairfield Ohio 45014 Tel 513 868 0900 Fax 513 868 2105 E Mail info forcecontrol com Web Site www forcecontrol com CESS mlaazea MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventas industrialmagza com
63. se If not use a standard feeler gauge to determine gap thickness and shim under appropriate feet before installing hold down bolts INDUSTRIAL P Use 3 8 x 1 1 4 Lg SAE grade 5 Hex Hd Cap Screws Flat Washers and Lockwashers to bolt the Drive Unit securely in place Before tightening down the bolts check alignment with the driven machinery then recheck after tightening 2 If the Primary Input Shaft is to be directly coupled use only a flexible coupling with horsepower serv ice factor of 3 to 1 to take care of maximum torque requirements Make sure that the shafts to be cou pled are aligned within the coupling manufacturer s specifications Check for horizontal vertical or angular misalignment Use shims as necessary to correct any misalignment Avoid the use of slipfit coupling bores they tend to damage keys and key ways over time CAUTION Do not drive couplings or bushings onto shafts as this may damage the bearings 3 Ifthe Primary Input Shaft is to be connected through a belt chain or gear drive locate the sheave sprocket or gear as close as possible to the drive housing and the drive motor bearing to minimize overhung loads Align to run true and adjust belt or chain tension per manufacturer s specifications CAUTION Excessive belt or chain tension will damage bearings or break shafts 4 Furnish and install appropriate safety guards for all external rotating drive parts 5 With Piggy Back mounting
64. sembly 2 Press the Oil Seal 32 into the Bearing Retainer 7 Use Sealant Permatex 3D on the seal bore Clean off any excess Sealant Align Gasket 55 onto the Bearing Retainer 7 Lubricate the lip of Oil Seal 32 and the ground shaft diameter with Mobil Multi Purpose ATF Slide the Bearing Retainer 7 over the output shaft being careful not to damage the oil seal lip 5 Attach Bearing Retainer 7 with 6 Screws 63 and 6 Washers 126 9 4 WORM GEAR SUB ASSEMBLY See Figure 10 6 1 Press the Bearing 41 onto the Secondary Input Shaft 192 making sure that the bearing seats on the input shaft shoulder 2 Install Key 182 and the Worm Gear 154 onto the Secondary Input Shaft The Worm Gear will have to be pressed onto the input shaft 3 Install Spacer 49 on the Secondary Input Shaft Next press Bearing 27 on the Secondary Input Shaft 192 5 Install the Secondary Input Shaft Sub Assembly into the housing 6 Determine the thickness required for Shim 292 See Figure 9 3 FORCE CONTROL INDUSTRIES INC 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventasQindustrialmagza com Manually raise the Worm Shaft to the top of the bearing bores to give the necessary clearance over SURFACE B the Worm Gear 154 See Figure 9 4 SURFACE A SURFACE C DEPTH MICROMETER 3 Heat the other Bearing Cone 168 and
65. sure to release 056 Brake is 60 PSI To find Torque developed at a given Actuation Pressure e Clutch Torque P S I Cg x C4 Brake Torque P S I Bs x By To find Actuation Pressure needed for Required Torque e Clutch P S I Tn Brake P S I By Bs P S I Air Pressure Posidyne port TR Required Static Torque FORCE CONTROL INDUS TRIES INC INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 QA 442 1 95 72 60 ventas industrialmagza com DIST AUTORIZADO SECONDARY CLUTCH AND BRAKE SPRING SET ONLY TORQUE WITHOUT AIR ASSIST STATIC TORQUE Lb In PRESSURE PSI 1400 60 1554 40 Lb In 2 4 CONTROL LOGICS S Air set clutch Light spring set brake with air assist SA Air set clutch Medium spring set brake with air assist A Air set clutch Medium spring set brake B Air set clutch Heavy spring set brake C Air set clutch No brake Section 3 INSTALLATION The Multi Speed Drive Units described in this manual must not be installed or operated at any Speeds Horsepower Loads or Temperatures not specified in this manual Failure to limit operating conditions of the drive to all specified conditions could damage the Drive Unit and cause damage or malfunction to interconnected equip ment and void the warranty WARNING Before installation or attempting any repairs to the drive open the electrical disconne
66. ugs on the Input Shaft with the notches in the Drive Plates Be sure you do not bend the Drive Plates 13 Press the Input Housing down until the Dowel Pins 68 engage the Piston Retainer Housing Check Gasket 53 to see if it is still aligned properly 8 From the Input End use 4 Screws 61 and 4 Washers 126 and from the Output End use 8 Screws 69 and 8 Washers 126 to attach the units together Use Red Loctite 271 on the threads 9 If your Drive Unit has a Male Input Shaft and is equipped with Fan Cooling then replace the Key 180 into the Input Shaft 10 Set the Drive Unit back in a horizontal position on the mounting feet This completes the Reassembly Procedure for the Major Sub Assemblies Before proceeding any further an Operational Check of the unit should be made Apply 60 to 80 PSI to the Clutch and Brake Ports as indicat ed in Section 5 OPERATIONAL CHECKS and observe the piston movement through the inspection ports 9 13 FAN AND FAN SHROUD INSTALLATION See Figure 10 3 1 Install Key 37 into the Primary Input Shaft 1 2 Place Fan 25 on the Input Shaft and tighten Set Screw 70 26 INDUSTRIAL 3 Place the Fan Shroud 24 into place and attach with 2 Screws 66 from the front of the Shroud 4 Install Key 180 9 14 ATTACHING C FACE MOUNTED DRIVE MOTORS WITH QUILL INPUT SHAFT See Figures 10 2 10 7 1 Apply a light coat of Bostik

SERVICE MANUAL REPAIR PARTS Model 2.5

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