Maintenance Instructions 100, 150, 200 & 400 Series Water & Waste Water Safety Element Torque Limiters with Externally Adjustable Modules
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1 World Leader in Modular Torque Limiters PROTECTING EQUIPMENT& MACHINERYYEARSInstallation and Maintenance Instructions 00, 50, 200 & 400 Series Water & Waste Water Safety Element Torque Limiters with Externally Adjustable Modules 304 Twin Oaks Street Wichita Falls, Texas (940) Fax: (940)
2 Brunel Safety Element Torque Limiters General Engineering Data A E J G H (Axial Movment on Overload) B X JSE-005 JSE-002 JSE-0022 JSE-0026 JSE-009 C K F D Externaly Adjustable (EA) L Externally Adjustable Disconectable Style (EAD) Externally Adjustable Short (EAS) Internally Adjustable Disconnectable (D) Internally Adjustable Style (Standard) 30 X Brunel Part No. Series JSE-000 Safety Element Qty. 2 Externally Adjustable Torque Range lb in,604-7,356 3,208-4,72 Internally Adjustable Torque Range lb in,05-9,044 2,20-8,086 JSE-050 2,024-9,287,395 -,45 JSE-0200 JSE ,29-0,50 4,582-2,02 6,872-3,532 3,07-4,256 6,24-28,52 9,32-42,768 2,428-57,023,579-2,920 3,57-25,840 4,736-38,760 2,4-7,523 4,282-35,047 6,423-52,570 8,564-70,093 Safety Element Style Chart A B C D max. Dimensions in inches E F G H J K L M Min H78 Sprocket EA EAD Qty 6 9 EAS /8-6 Tooth D Standard EA EAD Qty 6 EAS /2-3 Tooth D Standard EA EAD Qty 6 EAS /2-3 Tooth D Standard EA EAD Qty 8 EAS /8-6 Tooth D Standard Series Exploded View P/N: JSE-040EA Chart 2 Item Description Qty. Item Description Qty. Item Description Qty. Module Carrier Hub 9 PTFE Bearing 2 7 Blanking Plate Bolts 2 2 Detent Pocket Plate 0 PTFE Thrust ring 2 8 Grease Zerk 3 Retaining Plate Sprocket 9 Grease Relief Valve 4 JSE-005 EA SE 2 Blanking Plate 20 JSE Detent 5 Retaining Plate Bolts 6 3 Blanking Plate Seal 2 Alignment Bolt 6 O-ring Seal 4 Sprocket Bots (SHCS) 8 22 O-ring Seal 7 O-ring Seal 5 Sprocket Lock Washers 8 23 Name Plate 8 Socket Set Screw 2 6 Split Clamping Ring 2 24 Rivets 2 Consult factory for special application
3 Installation and Maintenance Instructions Water & Waste Water Safety Element Torque Limiters JSE-000EA Series JSE-0200EA, LEA Series with a JSE-005 Module Refer to Chart column H with a JSE-005 Module Refer to Chart column H B.C.D Mounting Bolts Equ. Spaced on a 4.488" B.C.D. Figure Sectioned View JSE-00EA Note: Part Numbers Refered to by (Figure No.- Part No.) R.925 MODULE PCR Part No. Description Qty. Module Carrier Hub 2 Detent Pocket Plate 3 Retaining Plate 4 SE Determined by Clutch P/N or 2 5 /4-28 x 5/8 36 SS SHCS (Loctite RED) 8 6 O Ring Seal 7 O Ring Seal 8 /4-28 x /2 36 SS SSS 2 9 PTFE Bearing 2 0 PTFE Thrust Pad 2 Sprocket 2 N/A 3 N/A 4 3/8-6 x 3/4 36 SS SHCS 6 5 3/8 36 SS Lock Washer 6 6 3/8 36 SS Flat Washer 6 7 N/A *8 Grease Fitting 36 SS (/8 NPT) *9 Grease Relief Valve (/8 NPT) 20 Detent Pocket 2 5/6-24 x 5/8 36 SS SHCS 22 O Ring Seal *23 Brunel Name Plate 36 SS 24 #4 x /4 SUD (Rivet) 36 SS 3 25 Pointer (Alignment) 36 SS *Not Shown Mounting Bolts Equ. Spaced on a 5.75" B.C.D. 0 9 R2.750 MODULE RADIUS Part No. Description Qty. Module Carrier Hub 2 Detent Pocket Plate 3 Retaining Plate 4 SE Determined by Clutch P/N,2 or 3 5 5/6-24 x 5/8 36 SS SHCS (Loctite RED) 8 6 O Ring Seal 7 O Ring Seal 8 5/6-24 x /2 36 SS SSS 2 9 PTFE Bearing 2 0 PTFE Thrust Pad 2 Sprocket 2 Blanking Plate 36 SS 2 3 Blanking Plate Seal 4 /2-3 x 2 36 SS SHCS 6 5 / SS Lock Washer 6 6 / SS Flat Washer 6 7 /4-28 x /2 36 SS SHCS 2 *8 Grease Fitting 36 SS (/8 NPT) *9 Grease Relief Valve (/8 NPT) 20 Detent Pocket 2 5/6-24 x 5/8 36 SS SHCS 22 O Ring Seal *23 Brunel Name Plate 36 SS 24 #4 x /4 SUD (Rivet) 36 SS 3 25 Pointer (Alignment) 36 SS *Not Shown Figure 2 Sectioned View JSE-020EA Note: Part Numbers Refered to by (Figure No.- Part No.) 3
4 Installation and Maintenance Instructions Water & Waste Water Safety Element Torque Limiters JSE-0400 Series JSE-050 Series upon release Refer to Chart column H R3.830 MODULE RADIUS Mounting Bolts Equ. Spaced on a 6.60" B.C.D. 0 Figure 3 Sectioned View JSE-040EA Note: Part Numbers Refered to by (Figure No.- Part No.) Part No. Description Qty. Module Carrier Hub 2 Detent Pocket Plate 3 Retaining Plate 4 SE Determined by Clutch P/N or 2 5 5/6-24 x 3/4 36 SS SHCS (Loctite RED) 6 6 O Ring Seal 7 O Ring Seal 8 3/8-6 x /2 36 SS SSS 2 9 PTFE Bearing 2 0 PTFE Thrust Pad 2 Sprocket 2 Blanking Plate 36 SS 3 Blanking Plate Seal 4 3/8-6 x 2 36 SS SHCS 8 5 3/8 Lock Washer 36 SS 8 6 Split Clamping Ring 36 SS 7 /4-28 x /2 36 SS SHCS 2 *8 Grease Fitting 36 SS (/8 NPT) *9 Grease Relief Valve (/8 NPT) 20 Detent Pocket 2 5/6-24 5/8 36 SS SHCS 2 22 O Ring Seal *23 Brunel Name Plate 36 SS *24 #4 x /4 SUD (Rivet) 36 SS 2 25 /4-28 x /4 36 SS SHCS *Not Shown Part No. Description Qty. Module Carrier Hub 2 Detent Pocket Plate 3 Retaining Plate 4 Safety Element Module 5 Retaining Ring 6 O Ring /8 x 6 /2 7 O Ring 3/32 x 4 /2 8 O Ring /6 x 3 /2 9 PTFE Bearing 0 Inner Thrust Bearing Outer Thrust Bearing 2 Sprocket 3 3/8-24 x /2 Set Screw 36 SS 4 /2-3 x 3/4 HHCS 36 SS 6 5 /2 Lock Washer 36 SS 6 6 /2 Flat Washer 36 SS 36 SS 6 7 3/8-24 x /4 36 Set Screw 36 SS *8 Grease Fitting 36 SS (/8 NPT) *9 Grease Relief Valve (/8 NPT) *20 Brunel Name Plate 36 SS *2 #4 x /4 SUD (Rivet) 36 SS 2 *Not Shown 3
5 . PRIOR TO INSTALLATION Check shaft extension & installation area where Torque Limiter is to be mounted to make sure there is sufficient space available for resetting after disengagement. 2. MOUNTING TORQUE LIMITER ON SHAFT release torque. As a guide when making adjustments, refer to the proper torque setting graph for the torque limiter model that you are using. Setting graphs for the various models are included at the back of this manual. After adjustment of the release torque is complete, reinstall the Security Cover (6-20) and retighten the Security Screws (6-7) to lock the torque setting in place. a. Make sure bore & keyway are clean and free of burrs, and keyway set screws are in place. b. Mount tooth UHMW sprocket onto torque limiter using the /2"-3 x 2" stainless steel socket head cap screws and washers supplied. Use loctite on screws. c. Slide torque limiter onto shaft and align sprockets and chain. Lock torque limiter to shaft with set screws. 3. TORQUE ADJUSTMENT & INITIAL STARTUP a. These torque limiters were preset at the factory, no further adjustment is required at this time. If it is desired to adjust the torque at a later date, proceed as follows. b. To adjust torque at the job site: For Externally Adjustable Modules (EA) refer to Figure 5. Loosen Set Screw (5-7) on the safety element Housing (5-) and adjust the torque by turning the Housing Nut (5-7) using a -/8 wrench. Turning the Housing Nut (5-7) clockwise increases the release torque and turning counter clockwise will decrease the release torque. As a guide when making adjustments, refer to the proper torque setting graph for the torque limiter model that you are using. Setting graphs for the various models are included at the back of this manual. After adjustment of the release torque is complete, retighten Set Screw (5-7) to lock the torque setting in place. 4. CHECKING RELEASE TORQUE SETTING Clamp & lock the Detent Pocket Plate (-2) in a vise or test stand, by clamping thru the /2-3 bolts. Apply torque to hub with a dummy shaft and key. Torque may be applied by a torque wrench. 5. RESETTING On overload, the safety element ball is displaced and the Module Carrier Hub disengages from the Detent Pocket Plate, allowing the Hub (-) to rotate freely. With the drive at rest (the power off) and the overload cleared, align the two reset arrows on the Detent Pocket Plate and Hub by jogging the drive motor. After aligning the match marks strike the safety element plunger with a soft mallet and the plunger will move back into the safety element /4 inch signifying that the unit is engaged and the drive can be restarted. Loosen Set Screw For Externally Adjustable/Disconnectable Modules (EAD) refer to Figure 6. Remove the Security Screw (6-7) from the Security Cover (6-20) and remove the cover. Loosen the Security Screw (6-7) in the side of the Housing (6-). Torque adjustments are made by turning the Housing Nut (6-7) with a suitable wrench. Turning the Housing Nut (6-7) clockwise increases the release torque and turning counter clockwise will decrease the 4 Use straight on blow with soft mallet ONLY.
6 6. DISCONNECT (EAD MODULES ONLY) To manually disconnect the module, turn the disconnecting nut (6-2) counter clockwise with a wrench until rotation stops. Modules are now disconnected and torque limiter is free for checking motor rotation or for greasing bearings and modules. To reengage module, turn disconnecting nut (6-2) clockwise until flush with housing nut. Once the disconnection nut is turned all the way down, follow the resetting instructions in #5 above. Loosen Shroud Security Screw Remove Shroud 7. GENERAL MAINTENANCE a. Insert grease using a grease gun into Grease Fitting (5-3) or (6-3) every 6 months. Add grease into Module grease fitting until grease comes out the grease relief valve (vent). DO NOT exceed -2 pumps into Grease Fitting (5-3) (6-3) (7-3) every 6-months. Recommended grease; Mobilith SHC PM Series. b. Safety elements should be stripped, inspected and re-assembled at least once every 3 years, more frequently where frequent tripping occurs. Inspect Detent Pocket and Ball Disconnect Inspect all removed module parts 5
7 8. TROUBLE SHOOTING a. Continual releasing, further adjustment making no difference. ) Detent Pocket (5-0) or (6-0) worn. Remove Safety Element (-4), extract Detent Pocket (use extraction screw), & Rotate Detent 90º & reinstall. If badly worn replace with new detent pocket. 2) Additional torque capacity is required. (Consult Brunel Corporation) b. Unable to screw Housing Nut (5-7) or (6-7) in any further. ) Loosen Set Screw (5-7) or (6-7) and make sure that the threads on the Housing Nut and Housing are not damaged, if so clean & file burrs until usable or replace defective parts. 2) You have reached maximum torque capacity. c. Unable to reset. Reset arrows not aligned. Check reference marks on Module Carrier Hub (-) and Detent Pocket Plate (-2). 6
8 Maintenance Instructions Safety Elements 9. SAFETY ELEMENT - METHOD OF ASSEMBLY (EA) a. Clean all components and coat all threads with a suitable antiseize compound. b. Grease and install O Ring (5-4) into groove in Housing (5-). c. Grease and install the Inner Thrust Race (5-4) into the Housing (5-). d. Install the Plunger (5-) into the Housing (5-) through the Inner Thrust Race (5-4). e. Install - /4 Balls (5-3), liberally apply grease to hold balls in place. f. Grease and install the Outer Thrust Race (5-2) over the Plunger (5-) and resting on the /4 Balls (5-3). g. Install 6 Springs (5-5) oriented as shown in cross section, and fully greased. h. Grease and install O Ring (5-9) into Housing Nut (5-7). i. Grease the inside surfaces of the Housing Nut (5-7) and install over the Plunger (5-) and screw it into the Housing (5-) until there is contact with the springs. j. Insert the Locking Pellet (5-8) and Set Screw (5-7) into the side of the Housing to facilitate locking the Housing Nut. (Refer to #3 for Torque Adjustment) k. Grease and insert the "O" Ring (5-2) into groove in housing (5-). l. Slide "O" ring (5-2) over Bushing (5-8). Grease and insert the "O" Ring (5-9) into the Bushing (5-8), insert the Detent Ball (5-9) after thoroughly greasing the Bushing ID. Grease the Plunger (5-) and install the Bushing. m. Loctite Shroud (5-2) to the end of Plunger (5-) using Loctite #270. Recommended for Grease: Mobilith SHC PM Series FIGURE 5 SECTIONED VIEW OF JSE-005 Externally Adjustable Item Part No. Description Qty. JSE-005- Plunger 2 JSE Outer thrust race 3 JSE Ball - /4 4 JSE Inner thrust race 5 JSE Disc spring 6 6 JSE /4-28 X 5/8 S.H.C.S. 36 SS 4 7 JSE Housing nut 8 JSE Bushing 9 JSE Detent ball - 5/8 0 JSE Detent pocket JSE-005- Housing 2 JSE Shroud 3 JSE Grease fitting 4 JSE O Ring Housing 5 JSE /6-24 x 5/8 S.H.C.S. 36 SS 6 JSE Shim Pack 7 JSE /4-28 x 3/8 HHS 36 SS 8 JSE Locking Pellet 9 JSE O Ring Bushing/Housing Nut 2 JSE O Ring Bushing/Housing
9 Maintenance Instructions Safety Elements 0. SAFETY ELEMENT - METHOD OF ASSEMBLEY (EAD) 2 22 a. Clean all components and coat all threads with a suitable anti-seize compound. b. Grease and install O Ring (6-4) into groove in Housing (6-). c. Grease and install the Inner Thrust Race (6-4) into the Housing (6-). d. Install the Plunger (6-) into the Housing (6-) through the Inner Thrust Race (6-4). e. Install - /4 Balls (6-3), liberally apply grease to hold balls in place f. Grease and install the Outer Thrust Race (6-2) over the Plunger (6-) and resting on the /4 Balls (6-3). g. Install 6 Springs (6-5) oriented as shown in cross section, and fully greased. h. Grease and install O Ring (6-9) into Housing Nut (6-7). i. Grease the inside surfaces of the Housing Nut (6-7) and install over the Plunger (6-) and screw it into the Housing (6-) until there is contact with the springs. j. Screw the Disconnecting Nut (6-2) onto the Housing Nut (6-7) until it is tight. k. Apply Loctite to the threads of the Plunger Shroud (6-2) and screw it onto the end of the Plunger (6-) and tighten it securely. l. Insert the Locking Pellet (6-8) and Security Screw (6-7) into the side of the Housing (6-) to facilitate locking the Housing Nut (6-7). (Refer to #3 Torque Adjustment) m. Grease and insert the O Ring (6-9) into the Bushing (6-8). Insert the Detent Ball (6-9) after thoroughly greasing the Bushing ID. Grease the Plunger (6-) and install 2 O Rings (6-23) and the Bushing (6-8). n. Install the Security Cover (6-20) onto the Housing Nut (6-7) with the Security Screw (6-7) using a special hex key FIGURE 6 Sectioned View of JSE-002 Externally Adjustable Disconnectable Safety Element Item Part No. Description Qty. JSE-008- Plunger 2 JSE Outer Thrust Race 3 JSE /4 Ball 4 JSE Inner Thrust Race 5 JSE Disc Spring 6 6 JSE SS /4-28 x 3/4 SHCS 4 7 JSE Housing Nut 8 JSE Bushing 9 JSE Detent Ball 5/8 0 JSE Detent Pocket JSE-002- Housing 2 JSE Plunger Shroud 3 JSE /4-28 Grease Fitting 4 JSE Housing O Ring 5 JSE /6 24 x 5/8 SHCS 6 JSE Shim Pack 7 JSE Security Screw 2 8 JSE Locking Pellet 9 JSE Bushing/Housing Nut O Ring 20 JSE Security Cover *2 JSE Disconnecting Nut 22 JSE Plunger Shroud O Ring 23 JSE O Ring Bushing/Housing 2 *Not Shown 8
10 Item Part No. Description Qty. JSE Plunger 2 JSE Outer Thrust Race 3 JSE /4 Ball 4 JSE Inner Thrust Race 5 JSE Disc Spring 6 6 JSE /4-28 x 5/8 SHCS 4 7 JSE Housing Nut 8 JSE Bushing 9 JSE Detent Ball 5/8 0 JSE Detent Pocket JSE Housing 3 JSE Grease Fitting 4 JSE O Ring Housing 5 JSE /6-24 x 5/8 SHCS 6 JSE Shim Pack 7 JSE /4-28 x 5/6 Set Screw 8 JSE Locking Pellet 9 JSE O Ring Bushing 20 JSE O Ring Housing Nut 2 JSE O Ring Bushing/Housing 2 5 FIGURE 7 Sectioned View of JSE-0022 Externally Adjustable Short Safety Element 0. SAFETY ELEMENT - METHOD OF ASSEMBLY (EAS) a. Clean all components and coat all threads with a suitable antiseize compound. b. Grease and install O Ring (7-4) into groove in Housing (7-). c. Grease and install the Inner Thrust Race (7-4) into the Housing (7-). d. Install the Plunger (7-) into the Housing (7-) through the Inner Thrust Race (7-4). e. Install - /4 Balls (7-3), liberally apply grease to hold balls in place. f. Grease and install the Outer Thrust Race (7-2) over the Plunger (7-) and resting on the /4 Balls (7-3). g. Install 6 Springs (7-5) oriented as shown in cross section, and fully greased. h. Grease and install O Ring (7-20) into Housing Nut (7-7). i. Grease the inside surfaces of the Housing Nut (7-7) and install over the Plunger (7-) and screw it into the Housing (7-) until there is contact with the springs. j. Insert the Locking Pellet (7-8) and Set Screw (7-7) into the side of the Housing to facilitate locking the Housing Nut. (Refer to #3 for Torque Adjustment) k. Grease and insert the "O" Ring (7-2) into groove in housing (7-). l. Slide "O" ring (7-2) over Bushing (7-8). Grease and insert the "O" Ring (7-9) into the Bushing (7-8), insert the Detent Ball (7-9) after thoroughly greasing the Bushing ID. Grease the Plunger (7-) and install the Bushing. Recommended for Grease: Mobilith SHC PM Series 9
11 2. METHOD OF PRELOADING EACH SAFETY ELEMENT (Only required if adding a second Safety Element or if changing Safety Elements from originals supplied) (This section refers to Figure,2 and Figure 5. The procedure is the same for all torque limiters and modules.) a. If adding a second Safety Element, first remove quantity 2, /4-28 x /2 SHCS" Bolts (2-7), then remove the Blanking Plate (2-2) and Blanking Plate Seal (2-3). If replacing original Safety Elements, remove quantity 4, /4"-28 x 5/8" SHCS (5-6) and remove the Safety Element (-4) including Bushing (5-8) Shims (5-6) and Ball (5-9). Replace Detent Pocket (if worn), this may require extracting the Detent using a 3/8"-6 bolt, insert new Detent Pocket and loctite in place with 5/6"-24 x 5/8" socket head cap screw. No O rings and dry b. Place the Detent Ball (5-9) on top of the Detent Pocket, then insert the Bushing (5-8), less Bushing O Rings (5-2), into the hole until the flange of the Bushing bottoms. c. Insert the assembled Safety Element through the bushing until the Plunger comes in contact with the ball. Notes: ) Safety Element must be in the engaged postion 2) Housing Nut (5-7) must be turned past 0 to give some spring compression 3) O Rings (5-2) are to be left out while measuring for shims. 4) Shims must not be in place when measuring for shims. d. With a suitable height gauge or feeler gauge, measure the resultant gap between the inner face of the Housing (5-) and the Module Carrier Hub (-). Deduct " from the measurement (Preload required) and select a suitable sized laminated Shim Pack (5-6) to accomodate this gap. Place the Shim Pack onto the Module Carrier Hub, grease and insert the Bushing, with O rings (5-2) in place and secure the Safety Element with the 4 socket head cap screws. Measure Gap - Subtract to for Shim Thickness 0
12 Torque Adjustment Graphs JSE-00LEA, JSE 00LEA & JSE 00LEAD TORQUE ADJUSTMENT GRAPH JSE-00LEAD & JSE-00LEAS TORQUE (LB IN) TURNS JSE-00EA, JSE 00EA & JSE 00EAD TORQUE ADJUSTMENT GRAPH JSE-00EAD & JSE-00EAS TORQUE (LB IN) TURNS
13 Torque Adjustment Graphs TORQUE (LB IN) JSE-002EA, JSE 002EA & JSE 002EAD TORQUE ADJUSTMENT GRAPH JSE-002EAD & JSE-002EAS TURNS/MODULE JSE-002LEA, JSE 020LEA & JSE 020LEAD TORQUE ADJUSTMENT GRAPH JSE-002LEAD & JSE-002LEAS TORQUE (LB IN) TURNS
14 Torque Adjustment Graphs JSE- 05EA & JSE- 05EAD & JSE- 05EAS TORQUE (LB- IN) TURNS JSE- 05LEA & JSE- 05LEAD & JSE- 05 LEAS TORQUE (LB- IN) TURNS 3
15 Torque Adjustment Graphs JSE-020EA, JSE 020EA & JSE 020EAD TORQUE ADJUSTMENT GRAPH JSE-020EAD & JSE-020EAS TORQUE (LB IN) TURNS JSE-0202EA, JSE 0202EA & JSE 0202EAD TORQUE ADJUSTMENT GRAPH JSE-0202EAD & JSE-0202EAS TORQUE (LB IN) TURNS/MODULE 4
16 Torque Adjustment Graphs JSE-0203EA, & JSE-0203EAD & JSE-0203EAS TORQUE (LB-IN) TURNS/MODULE 5
17 Torque Adjustment Graphs JSE-040EA, JSE 040EA & JSE 040EAD TORQUE ADJUSTMENT GRAPH JSE-040EAD & JSE-040EAS TORQUE (LB IN) TURNS JSE-0402EA, JSE2 0402EA & JSE 0402EAD TORQUE ADJUSTMENT GRAPH JSE-0402EAD & JSE-0402EAS TORQUE (LB IN) TURNS/MODULE 6
18 Publication: WWJSEA 08-6 Phone: Fax: Twin Oaks Street Wichita Falls, TX 76302
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