MATTHIESEN MAGIC FINGER VV510 User manual

PASSION COMMITMENT QUALITY
WWW.MATTHIESENEQUIPMENT.COM
566 NORTH W.W. WHITE RD.
SAN ANTONIO, TEXAS 78219
1-800-624-8635
EQUIPMENT OWNERS MANUAL
MATTHIESEN MAGIC FINGER BAGGER

OPERATION MANUAL INDEX
1. Specifications / Serial Number / Final Inspection Sign-off..........................................3
2. Brief Overview of Model VV510-MOD operation......................................................4
3. Installation, Maintenance, and Operation / Safety Guidelines .....................................5
4. General Instructions......................................................................................................6
* Purpose
* Manual
5. Set-up Instructions (Mechanical and Electrical Connections)......................................7
* Unpacking
* Conveyor Mounting
* Conveyor Electrical Connection
* Wicketed Bag Installation
* Hamer 125 Ring Bag Closer Mounting
* Infeed Conveyor Electrical Connection
6. Set-up Instructions (Mechanical and Electrical Connections) continued.....................8
* Magic Finger Bagger Electrical Connection
7. Timing and Adjusting the Model VV510-MOD Magic Finger Bagger.......................9
* Timing the Sure-Fall Mechanism
* Timing the Magic Finger Mechanism
* Adjusting the Stroke on the Magic Finger Mechanism
* Adjusting the Height of the Ice Bag Shelf
8. Timing and Adjusting the Model VV510-MOD Magic Finger Bagger.......................10
* Bag Retainer Rod Adjustment
* Air Flow into Ice Bag Adjustment
* Conveyor Belt Height Adjustment
9. Start-up Instructions for Model VV510-MOD Magic Finger Bagger..........................11
* Running Machine and Checking the Ice Bag Weight
* Changing the Ice Bag Weight
10 Troubleshooting Guide ................................................................................................12
11. Maintenance / Lubrication Location.............................................................................13-64
12. Suggested Spare Parts List............................................................................................65
13. Lubrication / Maintenance Location.............................................................................66
14. Adjustment / Maintenance Location.............................................................................67
16. Magic Finger VV510 Assembly...................................................................................68
17. Hopper Assembly, Drawing # B0041 sheet 1 of 1 .......................................................69
18. Blower Assembly, Drawing # B0042 sheet 1 of 1........................................................70
19. Magic Finger Assembly, Drawing #B0043 sheet 1 of 1...............................................71
20. Sure-Fall Assembly, Drawing #B0044 sheet 1 of 1 .....................................................72
21. Volumetric Drum Assembly, #B0045 sheet 1of 1........................................................73
22. Ice/Air Chute Assembly, #B0047 sheet 1 of 1 .............................................................74
22. Conveyor Assembly, Drawing #B0050 sheet 1 of 1.....................................................75
23. Hamer 125 Mounting Assembly, Drawing...................................................................76
24. Parts List .......................................................................................................................77-80
25. Wiring Diagrams...........................................................................................................81
26. Cleaning and Sanitizing................................................................................................82
27. Warranty .......................................................................................................................83
28. Decal Reorder Sheet .....................................................................................................84-85
2

INSPECTION REPORT
VISUAL:
CLEANLINESS:
DRUM PASS FAIL
EXTERIOR PASS FAIL
METAL FINISH (UNIFORM) PASS FAIL
DECALS: PASS FAIL
MECHANICAL:
ROTATION OF MOTOR PASS FAIL
LIMIT SWITCH PASS FAIL
TIMING OF DRUM PASS FAIL
MANUAL MODE AND AUTO PASS FAIL
CHAIN:
TENSION PASS FAIL
ALIGNMENT PASS FAIL
POWER CORD VOLT/AMP
SAME AS CONTROL BOX REQ.: PASS FAIL
CONFIRM VOLTAGE W/W.O.: PASS FAIL
FINAL INSPECTION:
DRY TEST RUN PASS FAIL
VISUAL PASS FAIL
FASTENERS FOR TIGHTNESS PASS FAIL
PROXIMITY SWITCH FUNCTION PASS FAIL
COMMENTS: _________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
INSPECTED BY _____________________DATE:______________________________________
SERIAL NUMBER _______________________________________________________________
G:\equ i p men t manuals \ ma g ic f inger\inspec t i o n re port Created by: R on de Leon Approv e d by: Pe te Ruiz Date: 04/25/07
3

Brief Overview of the Operation
Model VV510 Magic Finger Bagger
Ice is harvested and delivered to the Hopper at the top of the Magic Finger Bagger by other
conveying equipment. When the ice fills the Hopper to a level above the lower limit switch the
Bagger is ready to operate in automatic mode. During normal operation, the ice is fed down from
the Hopper into a cavity in the Volumetric Drum Assembly. This cavity has an adjustment that
allows the user to determine the volume of ice that will be dropped into the bag which in turn
determines the weight of the ice in the bag being run. The ice is then moved over the Ice Chute
Assembly by the rotating motion of the Volumetric Drum Assembly where it is guided to the pre-
positioned, wicketed bag. The ice bag is opened by an inrush of air from the Blower Assembly and
the ice fills it. This bagger incorporates a method of mechanically vibrating the Hopper and
Volumetric Drum Assemblies with the Sure-Fall Assembly during the drop cycle to assure
consistent finished bag weights. The Magic Finger Assembly (take-off) then indexes forward to
mechanically move the filled ice bag onto the Conveyor Assembly. Usually while it is being moved
along the Conveyor Assembly, it passes through some type of bag closing system like a wire closer
(not supplied with the Magic Finger Bagger). The Conveyor Assembly then delivers the finished
bag to another conveyor to be palletized or baled into multi-packs.
4

Installation, Maintenance, and Operation / Safety Guidelines
1. During installation or service, LOCK-OUT the power supplied to the machine to
prevent accidental start-up which could cause severe injury or death.
2. NEVER operate this machine without the factory-supplied guards in place. Severe
injury or death could result.
3. Do not override any of the safeguards built into and supplied with this machine. They
are there to protect life and limb.
4. Do not put hands down into the Hopper Assembly or up into the Ice Chute Assembly
to try to dislodge ice. After removing the ice, the bagger parts will be free to move
and could cause severe injury or death.
5. NEVER operate this or any machinery while fatigued, under the influence of alcohol,
controlled substances, prescription drugs, over the counter medications that may
cause drowsiness, alcohol, or controlled substances.
6. Immediately discontinue use of the machine if it exhibits a distinct change in
performance or makes any significantly different noises or smells.
7. Before, during, and after use, check the machine for proper alignment, breakage, and /
or binding of all moving parts.
8. STAY ALERT and CAUTIOUS of moving parts. USE COMMON SENSE.
9. During normal use in un-refrigerated rooms, some melting of product will occur. The
machine is not watertight and the floor below and around it will get wet. Some
consideration as to the machine's placement and the flow of this water to run-offs or
drains should be made prior to installation. For continued operator safety during
normal operation and good housekeeping, an effort to squeegee off standing water
near the machine should be made.
10. Routine safety checks and a regular maintenance schedule will assure maximum
safety, machine life, and productivity.
11. Keep all power cords and the electrical source off the floor and away from standing
water. Electrocution of the operator(s) could result.
12. Use only factory authorized replacement parts. This machine has been engineered
using components with known characteristics and ratings. Failure to use factory
authorized replacement parts can lead to a voided warranty, and / or failure in the
components resulting in severe injury or death. A list of factory suggested spares to
have on hand is located in the Maintenance section of this manual. Parts can be
identified by the number in the circle, and the drawing number they are located on.
Use the drawings supplied in this manual when calling to order replacement parts.
13. The use of petroleum based, harsh, or abrasive cleaners on the clear plastic window in
the hopper will dull the surface and make it harder to see through. Clean with mild
glass cleaner and a soft cloth.
5

General Instructions for Model VV510 Magic Finger Bagger
PURPOSE
This machine has been specifically engineered to briefly store, handle, and package ice. Any
other use or misuse can result in severe injury or death. Please read and understand all of the
information in operation manual prior to setting up, adjusting, or operating it. Failure to follow
these instructions can lead to a voided warranty, improper or dangerous function, and decreased
machine life. If you have questions, need installation, factory trained service, replacement
parts or additional information contact your authorized dealer or Matthiesen at 1(800) 624-
8635.
MANUAL
Save these instructions. They contain installation, safety, maintenance, service, factory
authorized parts, and operation information. (This manual should be left with the machine
by the installer or technician.)
6

Set-up Instructions for Model VV510 Magic Finger Bagger
UNPACKING
Carefully remove equipment from crating.
CONVEYOR MOUNTING
Loosen the setscrews on the Conveyor Assembly support arms and flip the assembly over so
the motor is below the Conveyor belt and away from the Magic Finger Bagger.
CONVEYOR ELECTRICAL CONNECTION
Connect the L5-15 twist-lock plug on the Conveyor motor cord to one of the receptacles on the cords
from the Magic Finger Bagger pendant station. Keep excess cord away from standing water on floor.
WICKETED BAG INSTALLATION
Swing the wicket rod catch, item 20 on the Top Assembly drawing #B0000 backwards and down. Place
a correct sized wicket of bags (not supplied) on the wicket rods and slide them all the way forward to
the stop. Place the Gravity Weight, item 13 on the rods and allow it to slide down to the bags. Swing
the wicket rod catch, up and forward making sure that the wicket rods fall into the correct notches.
HAMER 125 BAG CLOSER MOUNTING
Loosen the setscrews on the Hamer 125 base (not supplied) and position it over the vertical tube on the
Hamer 125 mount on the Magic Finger Bagger. Retighten the setscrews. Loosen the screws, item 4 on
the Hamer 125 Mounting Assembly Drawing #B0056 on the topside of the Hamer 125 mount bracket
and move the Hamer 125 until its centerline is on the centerline of the Magic Finger Bagger. (Be certain
to hold the Hamer 125 upright when loosening the screws so that it does not rotate.) Retighten the
screws. Loosen the screws, item 5 on the underside of the Hamer 125 mount bracket and position it
along the horizontal, square tube on the Magic Finger Bagger frame so that the tips of the feeder plates
on the Hamer 125 are approximately 6.00” from the first bag. Position Hamer with approximately 5˚tilt
down this allows finger motion without interference. Retighten the screws. Connect the L5-15 twist-
lock plug on the Hamer Ring Bag Closer cord to the remaining receptacle on the Magic Finger Bagger
pendant station cords. Keep excess cord away from standing water on floor.
INFEED CONVEYOR ELECTRICAL CONNECTION
Connect the control circuit from feed conveyor motor (or mechanism that will deliver ice to the Magic
Finger Bagger Hopper) to the top proximity switch on the Magic Finger Bagger Hopper. When the
Hopper is full, it will open up the circuit and stop the flow of ice to the Hopper. When the ice in the
Hopper is beyond set proximity switch sensing range, it will close again, starting the flow of ice to the
Hopper.
7

Set-up Instructions for Model VV510 Magic Finger Bagger
MAGIC FINGER BAGGER ELECTRICAL CONNECTION
Before connecting the twist-lock plug from the Magic Finger Bagger Control Enclosure cord to
an electrical source, push the maintained emergency stop switch, on the Control Enclosure in to
make certain the machine does not start when it is connected.
8

Timing and Adjusting the Model VV510 Magic Finger Bagger
TIMING THE SURE-FALL MECHANISM
The Magic Finger Bagger comes from the factory with the Sure-Fall timing correctly set. These
instructions are given in case of a drive chain breakage or some other unusual event that affects the
timing of the machine. Remove the ice from the Hopper and run the Magic Finger Bagger until the
Volumetric Drum’s cavity rotates over the Ice Chute and the Sure-Fall mechanism operates. Verify that
the pushing side of the cavity lines up with the beginning of the Ice Chute. If it does not line up, loosen
the three screws, item 76 on the Top Assembly parts list #B-0000 that clamp the cam plate, item 46 to
the modified sprocket, item 36. Rotate the cam plate until it is in the correct position to allow the Sure-
Fall mechanism to operate when the pushing side of the cavity in the Volumetric Drum lines up with the
beginning of the Ice Chute. Retighten the screws and recheck the timing. Additional information about
switch locations, this and following steps can be found on the Adjustment / Maintenance Schedule
drawing B-0009.
TIMING THE MAGIC FINGER MECHANISM
The Magic Finger Bagger only comes from the factory with the correct Magic Finger mechanism
settings if a wicket of the customer’s bags had been sent to the factory for testing prior to shipping.
These instructions are given in case of bag size changes or start-up from scratch. If you are uncertain
about the timing of the Magic Finger mechanism (the J-shaped hook on the front of the machine) it is
best to loosen the setscrews, item 13 on Magic Finger Assembly drawing #B0043. These hold the drive
lever, item 2 to the main shaft, item 8. With a wicket of bags installed, run the Magic Finger Bagger
until the all-threaded connecting rod, item 11 extends forward, out of the main guard the farthest. Stop
the Magic Finger Bagger. When the drive lever is pushed to the maximum forward position the Magic
Finger wand will be at the maximum rearward position. To set the correct item 1, Magic Finger wand
position, move the wand rearward until it is at a location ½” from the position that the ice chute door
will be when it opens fully. Retighten the setscrews in the drive lever. Run the Magic Finger Bagger
with the Blower Fan on until the first bag on the wicket is opened up. Check that the fingers at the
bottom of the wand are pointing forward and that they contact about 1 ½” down from the forward most,
inside lip of the opened bag. To adjust, loosen the setscrews, item 13 in the wand attachment block,
item 10 and set the height of the wand to the correct position. Retighten the setscrews. Note: The wand
should be ½” above the tops of the feeder plates on the Hamer 125 ring closer.
ADJUSTING THE STROKE ON THE MAGIC FINGER MECHANISM
If the stroke (length of travel) that the Magic Finger wand moves is too long or short it can be adjusted
by loosening the setscrews, item 13 on Magic Finger Assembly drawing #B0043 that hold the drive
shaft attachment block, item 7 to the drive lever, item 2. If it is moved upward (away from the main
shaft, item 8) it will shorten the stroke. If the drive shaft attachment block is moved downward (towards
the main shaft, item 8) it will lengthen the stroke. Retighten the setscrews and recheck the stroke. Note:
The wand should move forward and take the ice bag to a position about 1 ½” passed the tips of the tips
of the feeder plates on the Hamer 125 bag closer.
ADJUSTING THE HEIGHT OF THE ICE BAG SHELF
Run the Magic Finger Bagger with the Blower Fan on until the first bag on the wicket is opened
completely. The bottom of the bag should be on the top of the Bag Shelf Assembly. To adjust, loosen
the two screws, item 5 on Bag Shelf Assembly drawing #B-0040-C, move to the desired height (while
keeping it level) and retighten screws.
9

Timing and Adjusting the Model VV510 Magic Finger Bagger
ADJUSTING THE BAG RETAINER RODS ON THE BAG SHELF ASSEMBLY
The bag retainer rods can be adjusted for different width ice bags. To adjust the bag retainer rods, item
2 on Bag Shelf Assembly drawing #0062-B, loosen the setscrews in the collar and move them to the
desired position and retighten the setscrews. The bag retainer rods should be the same distance from the
Magic Finger Bagger and bag centerlines. When the bag is filled with ice, it starts to tear from the
wicket rods. When the Magic Finger take-off mechanism pulls the bag from the Bag Shelf Assembly
forward to the Conveyor Assembly it completes the separation. The bag retainer rods keep the wicketed
bags that are not being filled from being drawn forward and getting caught or pulled off too soon.
ADJUSTING THE AMOUNT OF AIR FLOWING TO OPEN THE ICE BAG
If the amount of air flowing to open the ice bag is too small, the ice bag will not open up all the way
which could result in a partially filled or an unfilled bag. It may also prevent the Magic Finger wand
from getting into the inside of the bag resulting in the bag not getting taken off the Bag Shelf. If it is too
large, it could blow the bag completely off of the wicket before the ice is even dropped. To adjust the
airflow, loosen the wingnut, item 10 on the Blower Assembly drawing #B0042 and rotate the shroud
damper, item 4 to cover either more of the opening for a smaller airflow, or cover less of the opening,
for a larger airflow. Retighten wingnut. The metering door, item 4 on the Ice / Air Chute Assembly
drawing #B0047 should close to about a ½” gap. To adjust the amount of gap, loosen the screws, item
11 and move the stop, item 5 to the desired location. This setting also affects the air-flow into the bag.
ADJUSTING THE CONVEYOR BELT HEIGHT
The Conveyor belt height and angle can be adjusted by loosening the setscrews, item 41 on the
Conveyor Assembly drawing #B0050 that connect the Conveyor to the support arms on the frame and
repositioning it. The top of the Conveyor belt end near the Magic Finger Bagger should be just below
the bottom of the Bag Shelf Assembly. The top of the other end of the Conveyor belt should be
positioned to allow a smooth transition (hand-off) to any ancillary take-off equipment being used.
10

Start-up Instructions for Magic Finger Bagger
RUNNING MACHINE AND CHECKING THE ICE BAG WEIGHT
After completing all of the set-up procedures outlined in this operation manual, double check
that the correct bags are installed on the wicket rods and that the Gravity Weight is in place.
Fill the Hopper with the same type of ice that you will be running. Turn the MANUAL /
AUTOMATIC switch, item 8 on the Magic Finger Bagger Adjustment / Maintenance drawing
#B0000 sheet 9 of 14 to the “MAN” position. Press the start button, item 9 one time. The
Magic Finger Bagger should go through one complete cycle and then stop. Verify that all of
the adjustments are correct, that the ring from the closer is positioned where it is desired, and
that all of the ice is out of the Ice Chute
Assembly . Weigh the bag of ice to verify that the
Volumetric Drum
Assembly setting is correct.
CHANGING THE ICE BAG WEIGHT
To change the weight of the bag loosen the three screws, item 5 on the Volumetric Drum
Assembly drawing #B0045 and rotate the outer drum, item 2 in the direction desired per the
increase / decrease label, item 4. Repeat the previous step and fill another bag. If all of the
adjustments appear to be correct, move the MANUAL / AUTOMATIC switch to the “AUTO”
position. Make certain that the Hopper is full of ice. Press the start button one time and allow
the Magic Finger Bagger to run a dozen bags or so. Verify that the bag weights are consistent
and that the infeed conveyor motor is cycling on and off properly when the Hopper proximity
switches open and close.
11

Troubleshooting the Model VV510 Magic Finger Bagger
If the Magic Finger Bagger does not operate properly after completing the start-up
adjustments and timing procedures please check the following before consulting the
factory:
1. The circuit breaker at the power source that supplies the Bagger is in the “ON” position.
2. The power cord on the Control Enclosure is plugged into the proper receptacle and that
power is making it to the terminal blocks, on the back panel assembly where the cord wires
are connected.
3. The circuit breakers are in the “ON” position.
4. The main power fuse in panel is not blown and is installed properly in the fuse holder.
5. The two fuses on back panel assembly are not blown and are installed properly in the
holders. Check motor speed control heat sink.
6. After checking the items on the back panel assembly in the Control Enclosure, close the
cover and check that the main power lock-out switch on the enclosure cover is in the “ON”
position.
7. The power cords are properly connected from the Conveyor Assembly and Closure unit
(heat or wire) to the two twist-lock receptacles on the Magic Finger Bagger pendant station.
8. The automatic / manual switch on the Control Enclosure is in the “MAN” position if one
single cycle per push of the “START” button is desired and in the “AUTO” position for
continuous operation. Note: If the ice in the Hopper is not above the level of the lower
sensor, it will not allow machine operation in the “AUTO” mode.
9. All of the mechanical adjustments are correct and that all screws and setscrews are tight.
10. On FSV (Feed Screw Volumetric) if auger does not run check lower chain and sprockets of
auger. If align is set correctly check top hopper sensor adjustment, reset overloads, fuses
and motor.
11. If after going through the troubleshooting procedures and your Magic Finger Bagger is still
not operating properly, contact your authorized dealer.
12

Maintaining the Model VV510 Magic Finger Bagger
The effort required to maintain the Magic Finger Bagger is far less than the trouble caused by
frequent breakdowns, premature part wear resulting in early replacement, and process down
time.
Refer to the Magic Finger Bagger Lubrication / Maintenance Schedule drawing #B0000, sheet
8 for the bearing, bushing, and required lubrication or maintenance locations listed below.
Reducers, bearings and chain are lubricated at the factory. Because of use in wet conditions
they should be inspected and lubricated accordingly.
Matthiesen recommends the use of food grade lubricants on all necessary parts.
Reducers and gear motors: Food grade oil
Flange bearings: Food grade grease
Note: A small amount of grease at frequent intervals is preferable to large amounts at infrequent
intervals.
Matthiesen stocks the following food grade Lubriplate® products:
Matthiesen Stock#
PT560 – FMO 900 AW gear oil
RS035 – FGL-1 grease cartridge
RS036 – FMO 350 spray
Every 500 hours of operation:
1. Grease the top and bottom 1 ½” upper and lower main bearings call-out 2 and 3.
Quarterly:
1. Lubricate the end of the blower motor shaft bearings; call-out 5 with light machine oil.
Monthly:
1. Grease the upper and lower 1” pillow block bearings on the Sure-Fall Assembly call-out 1.
2. Lubricate the end of the main motor shaft bearings; call-out 4.
3. Lubricate the end of the Conveyor motor shaft bearings; call-out 6.
4. Grease the four ¾” flanged bracket bearings on the Conveyor Assembly call-out 7.
5. Lubricate the two Magic Finger Assembly shaft bushings; call-out 8.
6. Lubricate the two Ice Chute door shaft bushings; call-out 9.
7. Lubricate the three cam follower bearings; call-out 10.
8. Grease the four, caster bearings call-out 11 and lubricate the axles with light machine oil.
9. Lubricate the flywheel shaft and bushing; call-out 13.
10. Lubricate the two flywheel drive shaft ball joints; call-out 14.
11. Lubricate the three roller chains on the Magic Finger, call-out 15.
12. Remove and clean the air intake filter. Replace if filter material is damaged or can not be
cleaned without the use of soap or solvents. Note position of input baffle before removing.
13. Check for loose hardware, belts, chains, or wiring. Tighten as required.
13

14

15

16

17

Dayton Speed Reducers
Operating Instructions & Parts Manual 2Z306F thru 2Z3 0F
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described.
Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or
property damage! Retain instructions for future reference.
Form 5S4807 ®
®
Printed in U.S.A.
02263
1102/254/VCPVP
Description
Dayton ri ht-an le speed reducers are desi ned for continuous duty, hi h torque,
slow speed applications such as packa in , food processin , etc. Units are
equipped with hardened worm and bronze worm ear, Timken roller bearin s on
output shaft, double lip seals and cast aluminum housin .
NOTE: Speed reducers are built for direct couplin or V-belt drive with up to a 1
HP, 1725 RPM motor. Lower input speed may be used with a proportional
decrease in input HP and output speed. Lower input HP may be used with a
proportional reduction output torque. (Consult Specifications)
Figure
Dimensions
AC DD
EFHNN
5 ¾ 71/16 2 ½ 4 ½ 23/84¾11/32 113/32 2
OU U
VV AB XL
513/16 0.7500/0.7495 0.6250/0.6245 15/817/16 27/16 8
NOTE: All dimensions iven in inches.
General Safety Information
The safety information followin refers
to the complete installation as well as
the reducer.
Disconnect
power before
installing or servicing.
1. Follow all local electrical and safety
codes, the United States National
Electrical Code (NEC) and the
Occupational Safety and Health Act
(OSHA).
2. Motor (not included with this unit)
must be securely and adequately
rounded. This can be accomplished
by wirin with a rounded, metal-
clad raceway system, by usin a
separate round wire connected to
the bare metal of the motor frame,
or other suitable means. Refer to
NEC Article 250 Groundin for
additional information
3. Always disconnect power source
before workin on or near a motor
or its connected load. If the power
disconnect point is out of si ht, lock
it in the open position and ta it to
prevent unexpected application of
power.
4. All movin parts should be uarded.
5. Be careful when touchin the
exterior of an operatin motor; it
may be hot enou h to be painful or
cause injury. Modern-desi n motors
run hot when operated at rated
load and volta e.
6. Prevent the power cable from
touchin sharp objects, oil, rease,
hot surfaces, or chemicals
7. Do not kink the power cable.
8. Make certain that the power source
conforms to the requirements of
your equipment.
9. Keep cleanin ra s and other
flammable waste materials in a
ti htly closed metal container and
dispose of in the proper fashion.
10.Clean electrical or electronic
equipment with approved cleanin
a ent such as dry cleanin solvent.
11.Be sure the output shaft key is fully
captive or is removed before
runnin the reducer.
Do not install
an automatic
reset motor starting device in
applications where unexpected
starting could harm personnel or
equipment.
!WARNING
!CAUTION
Figure 2
18

Figure 3 - Proper Vent Plu Location
and Oil Level
NOTE: Arrow indicates vent plu
location, Dotted line indicates proper
oil level. Use any plu alon this line to
check oil level. (On near or far side).
Installation
Do not install the reducer, motor or
base assembly in an explosive
atmosphere unless the motor and
the complete installation are
qualified and approved for such
use.
When an installation involves a
holding or overhauling application
(such as a hoist or conveyer), a
separate magnetic brake or other
locking device should be used. Do
not depend on gear friction to hold
the load.
Check the oil
level (see
Lubrication section). Depending on
mounting position used, too little
or too much lubrication will
diminish life or reducer.
1. Locate the speed reducer in a clean
and dry area with access to adequate
motor coolin air supply. If
installation is outdoors, make certain
that the unit is protected from the
weather.
2. Mount the motor on mountin base
(steel preferred), usin proper hei ht
spacers (1” thick for 56 frame motor;
1½” thick for 48 frame motor) to
ali n motor shaft with ear reducer
input shaft. Fasten motor to
mountin surface, usin suitable
bolts. Installin couplin on motor
shaft and securely ti hten setscrew
NOTE: Speed reducer may be used with
any NEMA 56 (preferred) or 48 frame,
ri id base motor, up to 1 HP at 1725
RPM, dependin upon which ear ratio
is used.
3. Install couplin body on speed
reducer shaft (if spider cushion-type
couplin is bein used). Place reducer
on mountin surface, ali nin motor
and reducer couplin s. Install spider
cushions between couplin bodies.
Assemble reducer to mountin
surface, usin four 5/16” diameter
bolts. Do not ti hten at this time.
Ali n input shaft of reducer with
motor shaft as best possible,
shimmin if necessary. Minor shaft
misali nment will be compensated
for by the couplin . Excessive
misali nment will cause undue
couplin wear, and possible bearin
dama e. Ti hten speed reducer
mountin bolts.
4. Remove solid pipe plu from
uppermost location on housin , and
replace it with the vent plu
provided. Failure to do so may cause
lubricant leaka e past the shaft seals.
See Fi ure 3 for proper vent location,
dependin on orientation of the
reducer.
5. Before connectin load, turn
couplin by hand to assure no
bindin or excessive
misali nment has occurred.
6. Attachin (couplin ) the load:
NOTE: To determine output torque
capacity for operatin conditions other
than normal 8-hour days with shock-
free operation,multiply the rated
output torque for the speed reducer
(from Specifications and Performance)
by the applicable load
factor listed in the Load Factor Chart.
Avoid shock loads.
2
Dayton Operating Instructions and Parts Manual
Dayton®Speed Reducers
!CAUTION
Specifications and Performance
725 RPM Input 60 RPM Input 875 RPM Input
Output Output Output
Output Torque Max. Output Torque Max. Output Torque Max.
Model Ratio RPM In-Lb Input HP RPM In-Lb Input HP RPM In-Lb Input HP
2Z306F 58: 30 285 /3 20 4 6 /3 5 495 /3
2Z307F 39: 45 337 /2 30 530 /2 22 45 /3
2Z308F 26: 67 385 3/4 45 392 /2 34 498 /2
2Z309F 8: 96 360 64 409 3/4 49 342 /2
2Z3 0F : 57 302 05 403 79 385 3/4
Figure 3
2Z306F thru 2Z3 0F
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3
Installation (Continued)
Load Factors
Applications with few (up to 10)
stops and starts per day
Occasional (1/2 hr. total/day)
1.25 1.10 1.00
Intermittent (2 hrs. total/day)
1.10 1.00 0.80
8 hrs./day 1.00 0.80 0.67
24 hrs./day 0.80 0.67 .057
Applications with frequent (over 10)
stops and starts per day
Occasional (1/2 hr. total/day)
1.10 1.00 0.80
Intermittent (2 hrs. total/day)
1.00 0.80 0.67
8 hrs./day 0.80 0.67 0.57
24 hrs./day 0.67 0.57 .050
a. Overhun Loads:
Sideward (radial) force on a motor
output shaft is called overhun load.
Drivin a load throu h a ear,
sprocket wheel, or belt pulley which
is mounted on the speed reducer
output shaft causes overhun load
on the shaft. Too much overhun
load can break the shaft or cause the
bearin s to fail prematurely.
Calculate the amount of overhun
load which the speed reducer will
receive in your installation as follows:
Overhun =(2) x (T) x (C) x (L)
Load (Lbs) D
The terms of the above formula are as
follows:
(T) = Full Load Torque of speed
reducer, in in-lbs., from
Specifications and Performance
(C) = Couplin Factor from followin
chart, accountin for type of
couplin
(D) = Pitch Diameter, in inches, of
couplin bein mounted on ear
motor’s output shaft
(L) = “Levera e” Factor from followin
chart, accountin for position of
couplin alon len th of speed
reducers output shaft
Coupling Factors
Chain Sprocket Wheel 1.00
Gear (pinion) 1.25
V-Belt Pulley 1.50
Flat Belt Pulley 2.50
“Leverage” Factors
Coupling Type Factor
End of shaft extension 0.80
Center of shaft extension 1.00
Next to shaft extension shoulder 1.20
After calculatin the amount of
overhun load expected in your
installation, compare it to the
overhun load ratin .
Maximum
allowable
overhung load is 600 lbs.
If the expected amount of overhun
load is hi her than the specified limit,
you must chan e a component or the
location of a component in your
installation to brin the overhun load
within the limit. To increase the
operatin life of the speed reducer
bearin s, desi n your installation to
reduce overhun load as much as
possible.
Excessive static
chain or belt
tension (i.e. tension present when
not running) will cause additional,
unnecessary, overhung load; set
tension no higher than
recommended by chain or belt
manufacturer.
b. On direct-coupled installations,
carefully check shaft and couplin
ali nment while boltin down speed
reducer. Shim as required. Do not
depend on a flexible couplin to
compensate for misali nment.
7. Make final wirin connections
(consult nameplate on motor).
NOTE: Output shaft may be run in
either direction by chan in motor
connections. Per dia ram or
instructions by motor manufacturer.
Figure 4 - Typical Installation
Maintenance
Make certain
that the power
supply is disconnected before
attempting to service or remove
any components! If the power
disconnect point is out-of
sight, lock it in the open position
and tag to prevent unexpected
application of power to
installation.
1.If internal parts have been replaced
on the output shaft assembly, new
adjustment for end play will be
required.
a. Reassemble unit, be innin with
the same shim stack thickness
behind the bearin cup in the
housin cover as before. Oil seal
(Ref. Fi ure 5 No. 20) should be
removed from cover until
shimmin process is completed
and rotation checked to avoid
dama e to seal from possible
repetitious disassemblies of cover.
b. Install new asket (Ref. Fi ure 5
No. 18) if required.
c. As the capscrews (Ref. Fi ure 5 No.
21) holdin the housin cover
(Ref. Fi ure 5 No. 19) are bein
ti htened, pull shaft back and
!CAUTION
!WARNING
Dayton Operating Instructions and Parts Manual
®
Models 2Z306F thru 2Z3 0F
Loading
Type of Moderate Heavy
Service Uniform Shock Shock
!CAUTION
Coupling Type Factor
!WARNING
AC
D
B
E
A-Reducer, B-Motor, C-Couplin , D-Mountin
Base, E-Spacers
20