CAMCO. SERVICE MANUAL R SERIES GEAR REDUCERS MODELS R200, & R250Table of Contents INTRODUCTION WARNING AND CAUTIONS OIL SEAL REMOVAL... SPARE PARTS KIT DISASSEMBLY. WORMSHAFT REMOVAL. BEARING REPLACEMENT........ INSTALLING SEAL SLEEVE... REMOVING HOUSING. PRIOR TO REASSEMBLY... ASSEMBLY... CENTERING WORMSHAFT. INSTALLING GEAR... SETTING GEARS... HOW TO ORDER PARTS. EXPLODED PARTS DRAWING.. PARTS LISTINTRODUCTION This service manual pertains to the disassembly and assembly of CAMCO's R Series Gear Reducer Models R200 & R250. The manual is to be used in conjunction with the General Service Manual which describes the lubrication and general maintenance of CAMCO Index Drives and Gear Reducers... ‘An exploded view of your specific reducer is included in this manual. Also included is a complete Bill of Materials for your convenience in identifying and ordering spare or re- placement parts. ‘Some users of CAMCO Drives have the facilities and trained personnel to accomplish service repair. You must determine the extent to which intricate servicing should be done in your own facility. When in doubt, CAMCO recommends that CAMCO trained servicemen make the repairs. WARNINGS AND CAUTIONS ‘Statements in this manual preceded by the words WARNING or CAUTION and printed in italics are very important. We recommend you take special notice of these during ser- vice or repair. WARNING Means there is the possibility of personal injury to yourself or others. CAUTION Means there is the possibility of damage to the CAMCO unit.OIL SEAL REMOVAL The only repair possible without disassembly of the indexer is replacement of oil seals. To remove oil seals, drill a number of holes into the case of the seal. The seal may then be removed with a pointed tool. Be sure to remove all metalic chips created during the drilling of removal holes. A new seal may be installed as outlined in the "Oil Seal Instal- lation Recommendations” section of the "General Service Manual”. SPARE PARTS KIT CAMCO offers a Spare Parts Kit for all CAMCO index drive models CAMCO builds. These kits include oil seals, bearings, shims and cam followers. These are components that will most likely require replacement during repair of your index drive. CAMCO recommends a Spare Parts Kit be purchased and kept on hand prior to any disassemb- ly of your CAMCO drive. ‘A complete list of components supplied in the Spare Parts Kit can be found in the parts list located in the rear of this manual. The asterisk behind the item number indicates those parts supplied with the Spare Parts Kit. BEFORE STARTING Before starting disassembly of your CAMCO unit you should read and review the follow- ing instructions. These provide important information on parts and procedures neces- sary to successtully complete your repair. Comply with all Warnings and Cautions. Read the "Trouble Shooting Guide" section of your "General Service Manual” before dis- assembling CAMCO units. CAMCO racammends raturning dafective equipment for in- spection and repair whenever possible. CAMCO uses Loctite to secure all screws and setscrews. If you encounter a fastener that is difficult to remove, apply heat to the screw and remove while still warmDISASSEMBLY 1, Remove all accessory equipment such ‘as motors, couplings, clutch brakes, pulleys, sprockats, etc. 2. Drain oil and flush unit with flushing sol- vent. Retain any chips or broken pieces you may find. These may aid in diagnosis. 3. Remove input cartridge mounting capscrews. If equipped with a motor adaptor, remove the motor adaptor mounting capscrews. Remove the cartridge and adaptor. Fig. 1. Removing motor adaptor 4, Remove the wormshatt from the hous- ing. Fig. 2. Removing wormshatt 5, Remove the output shaft cartridge. 6. For replacement of bearings: A. Use a whee! puller to remove the cone portion of the bearing from the wormshatt. You may also block up the edges of the bearing cone and gently drive the shaft through the bearing. Either method will automatically remove the oil seal sleeve while removing the bearing cone. B. Removal of the bearing cup from the cartridge or motor adaptor: If prying is not successful, it may require fabrica- tion of a pulling device. On the motor adaptor and open cartridge, it is pos- sible to place a small diameter aluminum bar against the backside edge of the cup and tap with a ham- mer, working from side to side to prevent cocking. ©. If required, use an arbor to press the bearing cone onto the shaft. Coat the shaft with anti-seize lubricant prior to installation. Heat the cone prior to in- stallation if a heat gunis available. This will allow the bearing to slide onto the shaft without requiring a press. D. Use an arbor to press the bearing cups the cup with anti-seize lubricant prior to pressing.E. Install the seal sleeve onto the ex- | tended end of the shaft. Use a piece of round tubing just large enough to fit over the sealing portion of the sleeve. Insert the sleeve over the shaft flange first. Place the tube over the sleeve and drive the flange portion of the sleeve up against the bearing cone. If @ motor adaptor Is used on the ex- tended end, the shoulder of the seal sleeve should stop approximately 1/8" from the bearing cone. Fig. 4. Removing housing from indexer 9. Use a spanner wrench to remove the gear locknut from the index drive input shatt | 10. Use a wheel puller to remove the gear | from the shaft. NOTE the shims behind the gear. Sava these shims for lator inotallation. Fig. 3. Instaling seal sleeve 7. Remove the two exposed capscrews | fastening the reducer housing to the index drive housing or adaptor. To remove the remaining two capscrews inside the reducer housing, it will be necessary to remove the two pipe plugs from the outside face of the hous- | Fig. 5. Removing gear ing. These plugs may be a sight gauge | or breather, depending upon the orien. | tation of the housing. Use a long exten- sion hex key to remove the inner capserews. | 8. Gently tap on the housing to break the seal and remove the housing from the | indexer.ASSEMBLY OF CAMCO’S "R" SERIES GEAR REDUCERS PRIOR TO ASSEMBLY Clean and deburr all parts before reas- sembly. Follow tightening torque and Loctite recom- mendations as outlined in the "General Ser- vice Manual". ASSEMBLY 1. Assembling and centering wormshaft: A. Place the housing on an inspection table. B. Measure the distance from the input cartridge mounting surface to the cen- ter of the output cartridge mounting role, Record this dimension. C. Place the input cartridge on an inspec- tion table with the bearing facing up. Place the bearing cone into tne cartridge. Measure the distance from the top of cone to the cartridge mount: | ing flange. Record this dimension. Fig. 6. Establishing shim requirement D. Use the attached dimensional chart to determine the "A" dimension from the center of the worm and the "HELD" shoulder. (the "HELD" shoulder will have a key slot or spline at the edge.) E. Add the "A" dimension from the chart land the bearing to oartridgo flange dimension as measured in Step "C". Subtract the total from the housing center distance as measured in Step "B". This will determine the amount of shims required to be added to the input cartridge flange in order to center the wormshatt F. Install the "HELD" side input cartridge. Insert the wormshatt through the op- posite opening and install the opposite cartridge or motor adaptor loosely. G. Use a feeler gauge to determine the approximate shim stack requirements. Remove the cartridge or motor adap- tor, reinstall with shims. H. Add or remove shims from this side to ‘eliminate all endplay and axial play while not preloading the bearings. The shaft should turn freely by hand. If there is an obvious drag felt, the bear- ings are excessively preloaded. 2. Installing the gear A. Slip the spacer tube onto the shaft (if applicable). Not all units will have a spacer. Some will have a shouldered shaft. B. Replace the shims removed in gear disassembly. Be sure to replace the exact amount of shims, since thisis the critical thickness necessary in center- ing the gear on the wormshattC. Determine the side of the gear to be facing out. To do this, see the "As- sembly Instruction/ Cone-Drive Gears” dimensional Data Form #FA-5. 1) Worm Over: When looking at the end of the wormshatt opposite the "HELD" shoulder, the stamping on the gear should face to the left. 2) Worm Under: When looking atthe ‘endof the wormshatt opposite the "HELD" shoulder, the stamping on the gear should face to the rigD. Heat the gear in an oven or with a heat gun. Coat the shatt with anti-seize lubricant. Install the gear onto the shaft. Lock the gear in place using a spanner wrench. Be sure to bend the washer locking tab. 3. Remove the input cartridge opposite the "HELD" shoulder. Remove the input shaft from tha housing. Leave the "HELD" cartridge in place. Key, FATS Of SPUNES MOLD AT ASseuoty ow THs "Helo" SHOULDER Vee wo.o AT asseuaty I ~\ ier 4, Install the reducer housing onto the in- dexer. Be sure the housing gasket is in place. Coat the housing and mating surface with Permatex prior to installa- tion. Align the housing with the dowel holes if applicable. Some units do not require doweling due to a plating provision provided on the mounting adaptor. Install and tighten the mount- ing screws. 5. Reinstall the wormshaft and cartridge or motor adaptor. CAUTION! If an "O" is stamped on the worm thread and gear tooth space, then at assembly the worm thread stamped "O" must enter the gear tooth space stamped "0". This will apply to some of the lower ratio gearsets. swe[e 0.» a a0 [roofs 252 [ae] R250 | 2.500] 2.095 4.188 | -375] NOTE (AS REQUIRED) oa WAN 7G" IS STAMPED ON THE WORM THREAD AND GEAR TOOTH SPACE, THEN AT ASSEMBLY, THE WORM THREAD STAMPED, "O°" MUST ENTER THE GEAR TOOTH ‘SPACE STAMPED “0”. i © L—e. o. oF HOUSING Fig. 7. Matching gears and gear setting dimensions6. Setting the gears a. Apply a light coat of Prussian Blue or Red lead to the worm. b.Rotate the wormshatt in both directions and check the contact patterns as shown on Page 6 and 7 of "Cone-Drive Bulletin CA55". CAMCO will furnish a copy of this bulletin upon request. c. Correct, if required, as described in the Cone Drive bulletin. 7. Remove the input cartridge and reinstall using Permatex on both sealing sur- faces. 8. Install new oil seals as described in the "General Service Manual”. 9. Fill the index drive with the recom- mended oil to level indicator. See "General Service Manual”. too high an oil level will cause no damage, too low a level may result in unit failure. 10. Lubricate ail titings with recom- mended grease specified in the "General Service Manual".HOW TO ORDER PARTS Please refer to parts list shown in this manual. This parts list is for a standard Index Drive, If you feel your drive is nonstandard or you are in doubt you should contact CAMCO Customer Service at (312) 459-5200 and request a Bill of Material for your specific unit based on serial number. CAMCO maintains records on all units for a period of ten years. You may order parts per the standard Bill of Material even if your unit is nonstandard. CAMCO's order entry people will review the closed order file based on the following in- formation and supply you with the correct part. REQUIRED INFORMATION 1. Original purchase order number (if available) 2. Customer name (original purchaser of drive) 3. Model number (located on name plate) 4, Serial number (located on name plate) 5. Approximate date of purchase. TO ORDER PARTS contact CAMCO "Order Entry Department” Wheeling, Illinois Phone(312) 459-5200 or FAX #312-459-3064 A. Describe the parts required and the 14 digit part number as listed in the Standard Bill of Materials or a Special Bill of Materials pertaining to your unit. State if you are using a Standard or Special bill of material. B. Give as much of the above required information as possible. ON WARRANTY Replacement parts CAMCO will send freight prepaid via most practical means. CAMCO will issue a "Returned Material Authorization Number" (RMA#) for the return of defective parts for inspection. CAMCO will bill customer for repair parts. When inspec- tion of returned parts has boon complotod and dotorminod to bo a warranty problom, CAMCO will issue a credit to the customer for the repair parts and freight charges. ON NON-WARRANTY Replacement or spare parts, with approved credit, are sent F.O.B. our plant Wheeling, Minos.R200 & R250PARTS LIST FOR CAMCO R200 REDUCER (STANDARD CONFIGURATION) ITEMNO. DRAWINGNUMBER = DESCRIPTION 1 - - 8100469300102 . - HOUSING 2 - 8180979059950 . GEARSET SGL EXT 5:1 RATIO 8180977910950 GEARSET SGL EXT 10:1 RATIO 8180979159950 . . GEARSET SGL EXT 15:1 RATIO. 8180979209950 . . GEARSET SGL EXT 20 : 1 RATIO. 8180979259950 . . GEARSET SGL EXT 25: 1 RATIO 81809779309950 . . GEARSET SGL EXT 30 : 1 RATIO. 81B09779409950 . . GEARSET SGL EXT 40 : 1 RATIO. 8180979509950 . . GEARSET SGL EXT 50 : 1 RATIO. 81B21218059950 . GEARSET DBL EXT 5:1 RATIO 81B21218109950 . ~ GEARSET DBL EXT 10:1 RATIO 81821218159950 . . GEARSET DBL EXT 15: 1 RATIO. 81B21218209950 . . GEARSET DBL EXT 20:1 RATIO 81821218259950 - GEARSET DBL EXT 25: 1 RATIO. 81821218309950 . GEARSET DBL EXT 30: | RATIO. 81B21218409950 . GEARSET DBL EXT 40: 1 RATIO. 8182121850950 ..... . . GEARSET DBL EXT 50: 1 RATIO 3 8180988200302... . . CARTRIDGE OPEN INPUT 81804697003011 . .. . . . . CARTRIDGE CLOSED INPUT 4 8180578103021 . CARTRIDGE OPEN OUTPUT 5 '81€10000009750 . MOTOR ADAPTOR 6 9760832904001 . COUPLING HALVE 11/16 BORE 7 9780832908000! . SPIDER 8 97808329060001 . COUPLING HALVE 5/8 BORE ot ‘96007328080021 BEARING CONE 09078 10° - 8600732808022 . . BEARING CUP 09196 Ww =. 8400732907000 . . OIL SEAL CONE DRIVE 075W150 12 - 95A26000380000 . . SHCS 1/4-20 X 1/2 13 8180787609000 ‘SPACER, OUTPUT 14 ences NOT USED ON R200 15° - 8400732908000 OIL SEAL CIR 8763 16 - 9542600038000 SHCS 1/4-20 X 1/2 7 2680152018800 ‘SHIM .002 THK ' ~ - 26B01520028800 ‘SHIM .005 THK : - 2680152038800 ‘SHIM ..010 THK 18" 860073281 10013 BALL BEARING ND R14 19 eee - NOT USED ON R200 20" 81804712008700 GASKET, HOUSING 2 9543301010000 SIGHT GLASS 22 ‘9543300201000 PIPE PLUG 23 - 95A26000380000 SHCS 1/4-20 X 1/2 24" - 2601520018800 ....... SHIM.002 THK : - . 26801520028800 . . . SHIM 005 THK . - 26B01520038800 ..... . . SHIM.010 THK 1"PARTS LIST FOR R200 CONTINUED 25 .... . .24408898009000 . 26" =. .81A08194028800 . + 1... . 1408194038800 2 . .81A08194058800 . . * 2... 81A08194108800 . + 1... . .81A08194158800 . . +... ... .81A08194208800 27 9526016340000 28 (95433000010000 29 018K150 30 = 31 . . SPACER (REQUIRED ON 250P ONLY) . . SHIM 002 THK . SHIM .003 THK SHIM .005 THK SHIM 010 THK - SHIM .015 THK . SHIM ,020 THK SHCS 5/16-24X1 AIR VENT (BREATHER) KEY 3/16 SAX 11/2LG NOT USED ON R200 NOT USED ON R200 * Indicates parts supplies with Spare Parts Kit #R200 SPK 12PARTS LIST FOR CAMCO R250 REDUCER (STANDARD CONFIGURATION) ITEM NO. at DRAWING NUMBER = 83005157001002 . - 3808047059950 83808047109950 . '83808047159950 183808047209950 89508047259950 83808047309950 . 83808047409950 . 183808047509950 8312617009950 83821219059950 . 83821219109950 93821219159950 83821219209950 83B21219259950 . 83821219309950 8382121940950 8382121950950 8380989100302 8380516100301 3805767003021 ‘3009900009750 9780832905001 9780832908001 . 97808329060001 . ‘9600732813021 . ‘9600732813022 . 8400732911000 = 95A26000590000 . - 95A26009060000 . 9582601006000 8400732910000 9542600053000 83805162018800 99805162020800 . . . 83805162038800 8600732815013 9923803000000 8380516308700 8380754100880 83841903008700 9503301020000 . . GEARSET DBL EXT 20 . . GEARSET DBL EXT 25 . GEARSET DBL EXT 30: 1 RATIO. DESCRIPTION . HOUSING GEARSET SGL EXT 5:1 RATIO GEARSET SGL EXT 10: 1 RATIO GEARSET SGL EXT 15: 1 RATIO GEARSET SGL EXT 20 : 1 RATIO. @CARSET SAL EXT 25: 1 NATIO. GEARSET SGL EXT 30: 1 RATIO. GEARSET SGL EXT 40: 1 RATIO. GEARSET SGL EXT 50 : 1 RATIO. GEARSET SGL EXT 60: 1 RATIO. . GEARSET DBL EXT 5: 1 RATIO GEARSET DBL EXT 10: 1 RATIO GEARSET DBL EXT 15: 1 RATIO 1 RATIO 1 RATIO GEARSET DBL EXT 40: 1 RATIO GEARSET DBL EXT 50: 1 RATIO CARTRIDGE OPEN INPUT CARTRIDGE CLOSED INPUT CARTRIDGE OPEN OUTPUT MOTOR ADAPTOR . . COUPLING HALVE 3/4 BORE . . SPIDER . COUPLING HALVE 5/8 BORE BEARING CONE 23092 . . BEARING CUP 23256 - - OIL SEAL CONE DRIVE 087W168 « SHCS 5/16-18 X 1 3/4 ~ LOCKNUT PN-06 LOCKWASHER W-06 OIL SEAL CIR 8821 SHCS 5116-18 X 5/8 SHIM .002 THK SHIM .008 THK SHIM .010 THK BALL BEARING URB 6305, RETAIN RING 5160 87 (USE ON ‘350RG, 400RA & 425RD ONLY) GASKET, HOUSING GASKET, HOUSING GASKET, (USED IN 902RDM ONLY) SIGHT GLASS 13PARTS LIST FOR R250 CONTINUED 22 - 9543300201000 9543302020000 23 195A26000530000 . 24"... . .89805162018800 + 1... . 8980516201880 . : 83B05162038800 . . 25 5683642609000 . 5 26" 83A08195028800 . . 8308195030600 . 5 83A08195058800 . o 8340819510800 . G 1890819515800 . 7 8308195208800 ar 9542600071000 28 9583300001000 29 025K156 30 8483642500000 31 5603642700302 . . 8180540209100 . 81K16813009100 . . 81B05396009100 . . PIPE PLUG 3/8 NPT PIPE PLUG 1/2 NPT . SHCS 5/16-18 X 5/8 SHIM .002 THK . SHIM 005 THK . . SHIM.010 THK . SPACER (REQUIRED ON 902RDM ONLY) . . SHIM,002 THK + SHIM ,003 THK . SHIM ,005 THK ‘SHIM .010 THK ‘SHIM .015 THK ‘SHIM .020 THK ~ SHCS 3/8-16 X 1 AIR VENT (BREATHER) KEY 1/4 SQX 19/16 LG O-RING (USED ON 902RDM ONLY) . MTG PLATE (USED ON 902RDM ONLY) . . MTG PLATE (USED ON 400RA ONLY) . MTG PLATE (USED ON 425RD ONLY) MTG PLATE (USED ON 401RA ONLY) * Indicates parts supplied with Spare Parts Kit #2250 SPK 14