Quad Ring
 

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How the Quad Ring works
Symptoms of failure
Typical causes for failure of the Quad Ring
Quad Ring replacement
Replacing the Quad Ring Seals
Adjustments
Recommended backlash adjustments intervals
End play in the wormshaft assembly
Electrical
Tailstock
Chuck
Manual 5C, 16C or 3J collet fixture
Clamp Quad Ring Seal Replacement
How the Clamp or Brake Operates
Reasons for Failure of the Quad Rings
Replacing the Quad Ring seals
Repair parts

How the Quad Ring works:

The internal pneumatic brake relies on the two quad ring seals for proper function. If either of these seals fail the brake will be less affective or will not work at all.

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Symptoms of failure:

If the internal quad ring seal fails while the clamp is energized the air escapes past the seal into the base cavity. Evidence of this internal air pressure will cause the pressure relief valve located at the top of the base to continuously release air. If the external quad ring seal fails while the clamp is energized the air escapes past the seal into the atmosphere. Evidence of this air pressure escaping externally is found by bubbling and or hissing at the rear of the table where the seal is located.

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Typical causes for failure of the Quad Ring:

  1. Age or exceeding the designed cycle life of the quad ring.
  2. Improper installation or lack of lubrication.

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Quad Ring replacement:

  1. Turn off machine power and disconnect all electrical cables and pneumatic lines from the rotary table.
  2. Locate the limit switch at the rear of the base. Remove the two socket head cap screws to disassemble it from the base. Leave the limit switch cable attached to the motor enclosure.

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Replacing the Quad Ring Seals:

  1. Remove the three button head screws and pulley cover to expose the timing belt and pulleys. Remove the four flange hex nuts holding the motor enclosure to the pulley plate. Slide the motor enclosure in towards the rotary table to relax the tension on the timing belt. Remove the timing belt from the pulleys and slide the motor enclosure out of the way of the back of the rotary table.
  2. Remove the socket head cap screws from the clamp cap, located near the center hole on the rear of the base. Put air in the side of the base where the stainless steel braided airline threads into side of the base; this will raise the clamp cap partially out of the base. Remove the air from the base and continue.
  3. Mark the location of the clamp cap and remove it by rocking it back and forth.  It may be necessary to use the tapped holes for the trip dog or counter-bored holes to rock the clamp cap out of the base. Note: do not try to pry on the O.D. of the clamp cap.
  4. Mark the location of the clamp disk and remove it by rocking it back and forth using the blind holes in the clamp disk. Note: do not try to pry on the O.D. of the clamp disk. 

    Note: If cast iron and steel shavings are found, the table probably has been operated with the brake engaged while it was rotating.  This is a problem that must be solved or it may destroy the rotary table.  Contact the company that installed the table for further instructions.

  5. Remove the old Quad Ring seals and thoroughly clean the clamp cap, clamp disk and inside of the base.
  6. Pre-lubricate the new Quad Rings with heavy oil and install the new Quad Rings in the clamp cap and clamp disk.  Do not twist the Quad Ring seals during installation.
  7. Assemble the clamp disk to the clamp cap the same way they were disassembled using the four alignment dowel pins.  Place two socket head cap screws in the counter-bored holes in the clamp cap, 180 degrees apart.
  8. Place a small amount of silicone sealant on the end of the table stem with the tapped holes.
  9. Align the two socket head cap screws with the tapped holes in the end of the table stem. Press the assembled clamp cap and clamp disk into the base until it is possible to thread two socket head cap screws into the tapped holes 180 degrees apart, in the end of the table stem.  Note: assembly is in the same position as it was when it was disassembled.
  10. Remove the two socket head cap screws and put a thread-locking compound on all of the socket head cap screws.  Thread the socket head cap screws through the clamp cap and into the table stem.
  11. Put air in the side of the base where the stainless steel braided airline threads into the base.  Spray a soap and water solution around the O.D. and I.D. of the clamp cap. If there is any bubbling from either of these two areas, reverse the above steps to find what has not been installed properly.
  12. Replace the limit switch and two socket head cap screws.
  13. Replace the motor enclosure and flange nuts.
  14. Inspect and replace the timing belt. Set the tension on the belt by sliding the motor enclosure away from the base and tightening the four flange nuts. The timing belt should twist 90 degrees from horizontal without a lot of pressure. Do not set the tension on the belt too tight, as it may damage the motor or table bearings. - Replace the timing belt cover and three button head screws.

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Adjustments:
Refer to assembly drawing No. 4919DL

Center Bearing Adjustment:

Table thrust: Section A-A, C-C and the Top View. To check to see if this adjustment is necessary, attempt to pass a .001” feeler gauge between the table and base track.  The feeler gauge should not pass between the two members. If it does, proceed with the following steps:

  1. Remove the rotary table from the machine.
  2. Remove limit switch No. 55 from the table by removing the (2) socket headspace screws No. 75. Leave the switch attached to the motor enclosure lid.
  3. Remove (3) button head screws No.  70 in pulley cover No. 9.
  4. Remove pulley cover No. 9.  This may be difficult due to the silicone sealant.
  5. Remove (4) flange hex nuts No. 62.
  6. Remove timing belt No. 47 by moving the motor assembly in toward the back of the rotary table to allow enough slack in the timing belt to remove it from the pulleys.
  7. Remove motor and cover assembly No. 31 & 8 from plate No. 6.
  8. Remove (8) socket head cap screws No. 67 and remove clamp cap No. 13 from the table after marking its’ position. The Quad Rings may make it difficult to remove. Rock the clamp cap back and forth to remove it.  Do not try to pry the clamp cap out of the base.
  9. Remove clamp disk No.12.  Rock the clamp disk back and forth to remove it. Do not try to pry the clamp out of the base.
  10. Loosen (2) socket set screws No. 66, in nut No. 10.  Tighten nut No. 10 by turning it slightly clockwise.  There should be no clearance between the turntable and the base.  This can be checked by attempting to put a .007” feeler gauge between the turntable No. 1 and the turcite bearing No. 42.  The feeler gauge should not penetrate between the two members.  Rotate pulley No. 44 to make sure that the table can be rotated without excessive force. 
  11. After nut No.10 has been adjusted, securely tighten the socket set screws No. 66.  Clean clamp disk No. 12 and clamp cap No. 13.  Inspect Quad Rinds No. 38 and 39 and replace if needed.  Lubricate the Quad Rings before reassembling the unit.  Use anti-rust lubricant on clamp pins No. 14 and Quad Rings No. 38 and 39.  Replace the socket head cap screws No. 67.  Use Locktite to keep the screws from backing out.
  12. Replace motor and cover assembly No.’s 8 and 31.
  13. Replace timing belt No. 47 and (4) flange hex nuts No. 62.  The timing belt should have a slight amount of flexibility.  Generally you should be able to rotate the belt 90 degrees from the standard mounting position without a lot of pressure.
  14. Replace cover No.  9 and (3) button head cap screws No. 70.
  15. Replace limit switch No. 55 and (2) socket head cap screws No. 75.

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Worm to Wormwheel (Backlash):

These instructions should be followed carefully as improper meshing between the wormshaft and wormwheel may cause damage.  The dual lead backlash adjustment is a linear adjustment of the bracket cartridge and wormshaft assembly resulting in more or less backlash. The bracket cartridges and wormshaft assembly are on fixed bores in the base.  The wormshaft has a true lead flank and a false read flank resulting in the distance between the teeth to decrease in width allowing the wormshaft to mesh tighter to the wormwheel teeth when the linear adjustment is made in the proper direction.

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Reduce Backlash: Refer to section B-b and section C-c.

To determine if this adjustment is needed, position the stylus of an indicator on the side of one of the T-slots near the turntable O.D. place a rod in another of the T-slots and push and pull the rod rotating the table clockwise and counter-clockwise.  Relax the pressure on the rod in each direction to check table movement.  The total indicated reading should be no more than .001" to .002” of movement.  If the backlash exceeds .001” to .002” at turntable O.D. perform the following steps. 

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Recommended backlash adjustments intervals:

New - after 3 months of operation – then every 6-month of operation.

  1. Loosen socket set screw No. 64.  Loosen only the setscrew on the side of the base as the exposed nut No. 12.  Important: loosen No. 64 set screw only.
  2. Turn bracket cartridge No. 5 clockwise 1/4 of a turn. (See note 2)
  3. Tighten socket set screw No. 64 and test for backlash per previous instructions.
  4. If the backlash is less than the recommended amount then you are finished.  If the backlash is more than the recommended amount, repeat steps 1 thru 3. Do not rotate bracket cartridge No. 5 more than 1 turns. Remove (3) button head screws No.70 in pulley cover No. 9.
  5. Remove pulley cover No. 9.
  6. If the timing belt No. 47 is at the extreme outer flange of the motor pulley No. 46, perform steps 8-15.  If not, go to step 16.
  7. Loosen (4) flange nuts No. 62.
  8. Slide motor and motor enclosure No.’s 31 and 8 toward the table to allow enough slack to remove timing belt No. 47 from the pulleys.
  9. Remove (3) hex head bolts No. 63 in pulley bushing No. 43.
  10. Using the tapped holes in pulley bushing No. 43 thread the (3) hex head bolts No. 63 evenly into pulley No. 44. Drive pulley No. 44 off of pulley bushing No. 43.
  11. Reposition pulley No. 44 approximately 1/4” in toward the table from the previous position to allow timing belt No. 47 to track in toward the motor on pulley No. 46.
  12. Using the (3) hex head bolts No. 63 securely tighten pulley bushing No. 43 into pulley No. 44.
  13. Pull motor and motor enclosure No. 31 and 8 away from the table to set the tension on timing belt No. 47.  The timing belt should be able to be rotated 90 degrees from the normal horizontal position without a lot of pressure. Do not set the tension on the belt too tight or it may damage the servo motor bearings.
  14. Tighten (4) flange nuts No. 62.
  15. Replace pulley cover No. 9 and (3) button head screws No. 70.

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Note 1: do not adjust the backlash too tight, as the torque required to rotate the table will greatly increase and it may damage the wormwheel.

Note 2: it may be necessary to cut a pleat out of the Gortiflex Protector No. 48 to allow bracket cartridge No. 5 to thread in deeper. Replace the phenolic washer No. 49 in the Gortiflex protector just inside the first pleat.

End play in the wormshaft assembly:

Refer to section B-b and section C-c this is not an adjustment that should be performed often.  Adjustment once every 500 hours of operation is recommended or if the backlash adjustments do not eliminate the backlash.

  1. To determine if this adjustment is needed place the stylus of an indicator on the end of nut No. 11, place a rod in one of the T-slots and push and pull the rod moving the table clockwise and counter-clockwise and also forcing the wormshaft in an out. There should be no more than .0005” end play in the wormshaft assembly.  If the end play of wormshaft No. 3 exceeds .0005" then continue.  Be sure that the movement is not due to movement in bracket cartridge No. 5. Tighten socket set screw No. 64.
  2. Remove (3) button head screws No. 70 from pulley cover No. 9.
  3. Remove pulley cover No. 9.
  4. Loosen (2) socket set screws No. 65 in nut No. 11.
  5. Tighten nut No. 11 by turning it slightly clockwise for take up.  Prevent wormshaft No. 3 from rotating while adjusting nut No. 11 by placing a rod in the hole in the O.D. of pulley bushing No. 43.
  6. Securely tighten (2) socket set screws No. 65 in nut No. 11.
  7. Re-check the end play per the above instructions, step 1.
  8. Replace pulley cover No.  9 and button head screws No. 70.

Note:  Due to condensation in the air, the pulleys may be rusty.  If excessive rust is present, the pulleys can be removed and sandblasted, cleaned or replaced.  The pulleys have been electroless nickel plated to help prevent this problem. Be sure to drain and vent hole in pulley cover No. 9.

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Electrical:  Refer to section C-c
To gain access to the electrical enclosure, remove the (8) pan heads Phillips head screws No. 71 in enclosure No. 8 lid.  Remove the lid and this will allow access to the servo motor / solenoid valve / pressure switch / zero return switch leads and the terminal strip. Refer to the proper Troyke wiring diagrams.

Tailstock: TS-10 - optional
A manual tailstock may be supplied with the rotary table. The tailstock is ground to the same center height as the table (approximately 7.00”). The tailstock has a removable #3 dead center. It also incorporates a manual quill lock. To lock the quill, rotate the manual quill-lock handle clockwise to move the manual quill lock from one side of the tailstock body to the other side, remove the quill-lock handle by rotating it counter-clockwise until the handle is free. Drive out the threaded stud from the tailstock body and move it to the other side of the tailstock body. Replace the quill lock handle.  The tailstock should be lubricated with waylube thru the ball oilers located on the top of the unit. Refer to assembly drawing 3144 for part and assembly information.

Chuck: CK-8 or CK-10 - Optional
A manual 8 1/4” or 10” diameter 3 jaw buck chuck may be supplied with the rotary table. All the mounting hardware is supplied with this option. To mount the chuck, first mount the adapter plate to the faceplate of the table by using the (4) t-nuts and (4) socket head cap screws (supplied). Use a 50mm plug gauge to align the adapter to the thru hole in the table before tightening the (4) socket head cap screws. Remove the 50mm plug gauge and mount the chuck to the adapter. The buck chuck has (4)-adjusting socket set screws in the O.D. of the chuck for fine alignment. Adjust true feature after adjusting the chuck in true, and then tighten mounting bolts in the chuck to securely fasten the chuck to the mounting adapter plate.

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Manual 5C, 16C or 3J collet fixture: M5C-5, M16C-5, and M3J-5 - Optional
A manual 5C, 16C or 3J collet fixture may be supplied with the rotary table. All the mounting hardware is supplied with this option.

To mount the 5C, 16C or 3J collet fixture, mount the manual 5C, 16c and 3J fixture to the face plate of the table by using the (4) T-nuts and (4) socket head cap screws (supplied).  Place a ground part in the collet and align the fixture before tightening the (4) socket heads cap screws.

Note: do not operate this equipment without proper safety training.

Warning: do not perform any repairs to this equipment until the table has been disconnected from all electrical and pneumatic circuits.

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Clamp Quad Ring Seal Replacement
Symptoms of Leaking Quad Ring seal: 

  1. Oil seeping and/or bubbling out between the turntable and base when the table is clamped.
  2. Air escaping from the vent (DL units only) in the base when the table is clamped. To test the NC-tables remove the oil fill pipe plug and seal the tapped hole in the base for 10 seconds with your finger while the table is clamped and then releasing your finger. There should be no air pressure building up in the base.
  3. Air is escaping, or bubbling out from the clamp cap on the back of the base.

How the Clamp or Brake Operates:

Air pressure (80 to 120 p.s.i.) enters the side of the base and forces the clamp cap (visible on the back of the base. The clamp cap is mounted to the table stem using socket head cap screws) and turntable track down against the turcite bearing on the base track and forces the clamp disk (not visible from the outside of the base) up against a shoulder on the base (metal to metal contact). Four dowel pins align the clamp cap and clamp disk. The Quad Ring seals trap air in between the clamp disk and clamp cap.

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Reasons for Failure of the Quad Rings:

  1. The Quad Ring seals will wear over time and may need to be replaced periodically depending on use.

Replacing the Quad Ring seals:

  1. Disconnect all electrical and pneumatic lines to the rotary table.
  2. For A or C model tables, proceed to step 8.
  3. B models only-remove two socket head cap screws and the limit-switch from the back of the table. Leave the limit switch cable attached to the motor enclosure. 
  4. Remove the three-button head screws and pulley cover to expose the timing belt and pulleys.
  5. Remove the four flange hex nuts holding the motor enclosure to the pulley plate.
  6. Slide the motor enclosure in towards the rotary table to relax the tension on the timing belt.
  7. Remove the timing belt from the pulleys and slide the motor enclosure out of the way of the back of the rotary table.
  8. Remove the socket head cap screws from the clamp cap located near the center hole on the rear of the base. Put air in the side of the base where the stainless steel braided airline threads into side of the base. This will raise the clamp cap partially out of the base. Remove the air from the base and continue.
  9. Mark the location of the clamp cap and remove it by rocking it back and forth. It may be necessary to use the tapped holes for the trip dog or counter-bored holes to rock the clamp cap out of the base. Do not try to pry on the O.D. of the clamp cap. 
  10. Mark the location of the clamp disk and remove it by rocking it back and forth using the blind holes in the clamp disk.  Do not try to pry on the O.D. of the clamp disk. 

    Note: if cast iron and steel shavings are found the table probably has been operated with the brake engaged while it was rotating.  This is a problem that must be solved or it may destroy the rotary table.  Contact the company that installed the table for further instructions.

  11. Remove the old Quad Ring seals and thoroughly clean the clamp cap, clamp disk and inside of the base.
  12. Pre-lubricate the new Quad Rings with a heavy oil and install the new Quad Rings in the clamp cap and clamp disk.  Do not twist the Quad Ring seals during installation.
  13. Assemble the clamp disk to the clamp cap the same way they were disassembled using the four alignment dowel pins.  Place two socket head cap screws in the counter-bored holes in the clamp cap 180 degrees apart.
  14. Place a small amount of silicone sealant on the end of the table stem with the tapped holes.
  15. Align the two socket head cap screws with the tapped holes in the end of the table stem. Press the assembled clamp cap and clamp disk into the base until it is possible to thread two socket head cap screws into the tapped holes 180 degrees apart in the end of the table stem.  The assembly should be in the same position it was when it was before disassembly.
  16. Remove the two socket head cap screws and put a thread-locking compound on all of the socket head cap screws. Thread the socket head cap screws through the clamp cap and into the table stem.
  17. Put air in the side of the base where the stainless steel braided airline threads into the base.  Spray a soap and water solution around the O.D. and I.D. of the clamp cap. If any bubbling out of either of these two areas is visible, reverse the above steps to find what has not been installed properly.
  18. Replace the limit switch and two socket head cap screws.
  19. Replace the motor enclosure and flange nuts.
  20. Inspect and replace the timing belt. Set the tension on the belt by sliding the motor enclosure away from the base and tightening the four flange nuts. The timing belt should be able to be twisted 90 degrees from horizontal without a lot of pressure. Do not set the tension on the belt too tight as it may damage the motor or table bearings.
  21. Replace the timing belt cover and three button head screws.

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Repair parts:

For NC model tables, refer to the assembly drawing or contact the factory for part number and price.  For DL model tables refer to the assembly drawing and the following information. The part numbers for the Quad Rings are (1) sos-q4232 and (2) sos-q4262.

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