Replacing Followers Without Removing Follower Plate   INST 90.3

Service Bulletin: INST 90.3

Subject: Replacing Followers Without Removing Follower Plate

Recommendations: 

Follower Removal & Replacement

1. Lockout machine electrically and hand turn machine to position Cam Follower plate for ease of access to 1 Follower.
2. Loosen 4 mounting bolts at a time in the following order:
   1. The 2 bolts holding the follower to be removed (A & A shown in Figure 1), loosen both bolts, 2 complete revolutions.
   2. Loosen the bolts marked as B in Figure 1, 1 revolution. This will allow for the complete removal of 1 follower.
      NOTE: Secure the follower nuts by hand when removing follower to prevent injury.
3. Upon removal of the follower, make sure that the bore is clean and free from Burrs and any foreign matter.
4. Lubricate the hole with machine oil. Install a new follower in the now cleaned & lubricated hole.
   a. Snug mounting bolts (A & A and B & B) on the new Follower and Torque the follower to 150 ft/lbs.
   b. Torque the mounting bolts to 90 ft/lbs.
   c. Repeat the removal and installation procedure for the remaining followers.
5. When all followers have been installed proceed to Bluing Step 1.

Bluing Step 1

The following Bluing procedure will determine that the cam is on center before the clearance can be checked:

1. Position the main shaft to center-of-dwell, on the tightest set of followers. See Figures 2, 3, 4 & 5.
2. Apply bluing to the dwell portion of the cam, as shown in Figures 2, 3 & 4.
3. Roll the main shaft back and forth to smear the bluing in the applied area only.
4. Check the smeared bluing pattern to make sure that contact is exactly the same on both sides of the cam surfaces.
   • Centering is achieved when contact is exactly the same on both sides.
   • If the bluing is not the same on both sides, it will be necessary to move the cam on the main shaft to correct the pattern.
   • If any of the cams are moved on the main shaft, realignment of the associated turret on the upper base will have to be done, followed by re-pinning of the mandrel or rimming turret.

Measuring & Setting the Proper Clearance for Loading the Followers

With all follower installed and centered to the cam, the clearance must now be checked, and reset if necessary. The proper clearance is 0.0001″ – 0.0002″ on the tightest set (when tightest set measurement is achieved, you should feel contact of the roller to the cam); and 0.0013″ on the loose set. Proceed as follows:

NOTE: The letter “T” is stamped on the follower plate to indicate the tightest set and the letter “L” to indicate the loose set. The letters are stamped on the follower plate with the original set of followers at the factory but may change when new followers are installed. It may be necessary to re-stamp these if the new followers checked out differently.

1. Using a tenth dial indicator, m 1. ount the indicator to the machine base with the probe touching the inside of the follower as shown in Figure 6.
2. Zero the indicator and place a wrench in one of the mounting bolts, in the follower plate. See Figure 7.
3. Pull the assembly gently back and forth to see what the reading is on the dial. Figure 8.
   a. They all must read between 0.0001″- 0.0013″ with the tightest setting being 0.0001″ – 0.0002″
   b. If they do not read between these ranges, the removal and installation procedure will have to be repeated until all the followers are within the required specification.

NOTE: This procedure may have to be repeated until proper set up is achieved.

Bluing Step 2

After all followers have been replaced and the proper clearance set, use the following Bluing procedure to check for hard-lining and flatness of the followers tracking on the cam.

Hard-lining is a heavy mark that is not even across the entire follower.

1. Apply bluing to the following areas of the cam (Figures 9, 10):
   a. Entrance Tips
   b. Exit Tips
   c. Center Track on both sides of the cam.
2. Roll the main shaft through all seven sets of followers, checking each set to make sure they are tracking properly.
   • If evidence of hard-lining is observed during this process, the cam will need to be polished to correct this problem.

If further instructions are needed, please contact Paper Machinery Corporation’s Service Department.

Cam Followers Transition through Index

When the main shaft is rotated (slowly) thru index, under no circumstances should all three followers lock up on the cam. There must be one follower that turns freely. This ensures that the followers are controlled properly as they move thru the index area. Failure to achieve this requirement will result in Cam and Follower damage!

It is strongly recommended to have 2 personnel assisting along during this procedure. One (1) assistant is needed to rotate the machine, by hand. One (1) assistant is needed to insure that proper communication is made between the person rotating the machine and the person checking the followers.

Follower Check:

1. While the machine is slowly being rotated (by hand wheeling), check the rotations of the (middle & outside) followers as they approach the index area of the cam. See Figure 13.
   NOTE: Checking the rotation of the followers must be done while the shaft is in motion!
2. Check all three (3) followers :
   The follower in the middle should turn freely or with a slight drag. If the middle follower does not turn freely, the tips of the cam will need to be polished to free the locked follower; see the “Polishing to Correct Follower Lock Up” procedure, page 8.
3. Repeat this procedure starting with the tight set of followers for the remaining followers and turrets. See Figures 13 – 15. This procedure is the same for all three (3) turrets, with the exception of the transfer turret; which needs to be checked twice due to the double leads. SeeFigures 15 & 16.

Polishing to Correct Follower Lock Up

If follower lock up has occurred during the “Tight Set of Followers” procedure, polishing/stoning of the cam lead tips will be required.

Refer to Figure 17 for the proper location to be polished/stoned.

It is important to understand which tip will need to be polished/stoned if it becomes necessary to do so. Figure 18.

Entrance:
As the shaft is rotated, and the follower on the entrance tip makes contact with the cam, the middle follower should turn freely. See Figure 19. If the middle follower does not turn freely, the entrance tip will need to be polished/ stoned.

Exit:
As the shaft is rotated, and the follower on the exit tip makes contact with the cam, the middle follower should turn freely. If the middle follower does not turn freely, the exit tip will need to be polished/stoned.

CONTACT: Parts orders and customer communication can be made using telephone, FAX, or e-mail. Contact can still be made using the main telephone switchboard at 414-354-8050 or FAX number 414-354-8614. Sending a FAX directly to the Service Department, at 414-354-1710, will convey a faster response. If using e-mail and no response is made within 3 working days, please contact via phone or FAX.

Parts orders can be directed to Holly Warner or Vicky Alcaraz using telephone, FAX, or e-mail. Please make sure to carbon copy (CC) both Holly Warner and Vicky Alcaraz in all e-mails containing parts orders. Service issues can be directed to Steve Evans or Mike Ferguson and electrical issues to Larry Spencer.