Installation and Maintenance Instructions JSE2-0241MAEAD Extruder Clutch. World Leader in Modular Torque Limiters

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1 World Leader in Modular Torque Limiters Installation and Maintenance Instructions JSE2-0241MAEAD Extruder Clutch 1304 Twin Oaks Street Wichita Falls, Texas (940) Fax: (940)

2 Installation and Maintenance Instructions JSE2-0241MAEAD Extruder Clutch 1. INSTALLATION a. Coupling should be installed with pins/buffers removed. b. Apply an anti-seize compound to the gearbox input shaft. c. Slide gearbox coupling half (1-1) onto gearbox shaft. d. Slide motor hub onto shaft. e. If interference or press fit is specified, heat coupling hub per fit specified before putting hub onto shaft. f. Bolt Rigid Hub (1-15) to the Module Carrier Plate (1-11) Using qty. 12, M20 x 75 S.H.C.S. (1-13). Torque tighten to 3360 lb.in. g. Dial indicate coupling Misalignment tolerance: Angular.008, Radial.005, If misalignment is beyond tolerance, realign. h. Assemble bolts and Buffers with Buffer Bush (1-5) inside of Buffer (1-6) and a M20 Washer (1-4) on each side of the buffer. Re-install 16 bolts (1-3) with loctite on threads. Torque tighten to 3360 lb.in TORQUE ADJUSTMENT & INITIAL STARTUP a. These torque limiters were preset at the factory, no further adjustment is required at this time. b. If it is desired to adjust the release torque at a later date, refer to #5 Torque Adjustment Figure 1 Section view of Part # JSE2-0241MAEAD Parts referred to by (Figure # - Part #) Part No. Description Qty. 1 Eflex Hub 1 2 Grubscrew M Capscrew M20 x 100 Skt Hd 16 4 Washer M20 Plain 16 5 Buffer Bush 290/320 Eflex 16 6 Buffer 290/320 Eflex Arnitel 16 7 JSE2 Fixing Pack 2 8 Detent Pocket Plate 1 9 JSE2 Through Hole Fasteners 2 10 Pressure Release Valve 1 11 Module Carrier Plate 1 12 JSE2-0018TH Ext Adj/Disc. SE 2 13 Capscrew M20 x Grubscrew M20 x Rigid Hub 1 16 Sensor Segment 2 17 Capscrew M6 x 16 Lg Skt 8 18 Clamping Plate 1 19 Blanking Plate 1 20 Grease Nipple 1 21 Taper Roller Bearing 2 22 Oilseal 260 x 230 x 15 Type R Grubscrew M6 x 20 Skt Hd 4 24 Grubscrew M8 x 20 (W Point) 1 25* Set Screw M8 x 25 CSK Hd 4 26* Capscrew M8 x 25 Skt Hd 16 27* Blanking Plug 1 28* Blanking Plate 1 *Not shown on this view 3. RESETTING On overload, the Safety Element Ball is displaced and the Module Carrier Plate disengages from the Detent Pocket Plate. With the drive at rest (the power off) and the overload cleared, align the two reset arrows (or grooves) on the Detent Pocket Plate and Module Carrier Plate by turning the drive motor shaft by hand. After aligning the match mrks strike the safety element plunger shroud with a soft mallet and the plunger will move back into the safety element 0.34 inch signifying that the unit is engaged. DISCONNECTING To manually disconnect the module, turn the jacking nut (2-13) counter clockwise with a wrench until rotation stops. Modules are now disconnected and torque limiter is free for checking motor rotation or for greasing bearing and modules. To re-engage module, turn jacking nut (2-13) clockwise until flush with housing nut (2-7), then strike plunger shroud (2-26) with a dead blow mallet. 4. GENERAL MAINTENACE a. Grease 2-3 pumps from a grease gun into Grease Fitting (2-18) every 3 months. Recommended grease is Mobil XTC. b. Safety elements should be disassembled, inspected and reassembled at least once every 3 years, more frequently where frequent tripping occurs. c. Bearings should be re-greased with Mobil SHC 200 every 3 months. Add grease with a grease gun into fitting (1-20) and old grease is purged from grease relief valve (1-10). Recommended Grease: Mobil SHC220 1

3 Installation and Maintenance Instructions JSE2-0241MAEAD Extruder Clutch 2 5. TORQUE ADJUSTMENT a. To adjust torque at the job site: Prior to setting Safety Elements which are new or which have been re-assembled, the desired release torque for the torque limiter must be known. On the graph labeled JSE2-0241MAEAD Setting Curve (Page 3) read the desired release torque on left. Follow across until that point meets the setting curve and then follow down to the required setting for each Safety Element. The numbers at the bottom of the graph refer to the number of setting marks on the housing of the Safety Element as measured from zero. Zero varies slightly on each safety element and must be determined independently prior to setting. b. In order to determine zero and set each safety element: 1) Remove security screw (2-15) using special tool and take off Security Cover (2-11). 2) Release Set Screw (2-15) using special tool. 3) Turn housing nut (2-7) counter-clockwise using 1-7/8 socket until spring force is removed and the housing nut is free to Figure 2 Section View of Part No. JSE2-0018TH Safety Element Parts refered to by (Figure # - Part #) turn by hand. Now turn the housing by hand clockwise and determine the point at which resistance is first felt as the springs become engaged. This is the zero point. The number of setting marks required from the Setting Chart must be counted from this zero point. 4) Using 1-7/8 socket turn housing nut until the required number of setting marks from zero are obtained. 5) Turn Set Screw (2-15) until tight. Re-install Security Cover using security screws. 6) Repeat steps 1 through 6 for each safety element. safety element. 6. METHOD OF PRELOADING EACH SAFETY ELEMENT (THRU HOLE DETENT) (Safety Elements must be preloaded anytime they are mounted onto assembly) If mounting the safety element (1-12) prior to preloading follow steps (a) thru (e). If preloading a mounted safety element (1-12), start with step (f). a. Back out set screw (1-9), grease and insert the Detent Pocket (2-19) into the Detent Pocket Plate (1-8). b. Grease the bushing (2-8) complete with O ring (2-12) and install over the greased plunger (2-1). Install the greased ball (2-9) in the hole in the Module Carrier Plate (1-11) Item Part No. Description Qty. 1 JSE Plunger 1 2 JSE Outer Thrust Race 1 3 JSE Balls (10 mm) 12 4 JSE Inner Thrust Race 1 5 JSE Disc Springs 16 6* JSE M8 x JSE Housing Nut 1 8 JSE T Bushing - Through Hole 1 9 JSE Detent Ball JSE O Ring - Housing 1 11 JSE Security Cover 1 12 JSE O Ring - Bushing 1 13 JSE Jacking Nut 1 14 JSE Locking Pellet 1 15 JSE Security Screw 1 16 JSE Housing 1 17 JSE O Ring - Housing Nut 1 18 JSE Grease Fitting M JSE Detent Pocket (EATH) 1 20* JSE M10 x 20 DPSS 1 21 JSE Flange Plate 1 22 JSE M16 x 2.0 x 20 DPSS 1 23 JSE M16 Hex Head Lock Nut 1 24* JSE M8 x JSE Shroud 1 * Not Shown on This View

4 6. cont c. Insert the Safety Element assembly (1-12) in to the Module Carrier Plate (1-11) and securely fix with socket head cap screws (2-6). Torque tighten to 352 lb.-in. d. Grease and fit the Flange Plate (2-21), firmly fix to the Coupling Body by Socket Head Cap Screws (2-24) e. Insert the Adjusting Screw (2-22) and attach the Locknut (2-23) f. With a suitable measuring device (such as a dial indicator) placed on the head of the Plunger (2-1), turn the adjusting screw (2-22) with a hex wrench until the turning torque suddenly increases significantly. From this point turn the adjusting screw (2-22) until of movement on the Plunger head is achieved, then lock in position by tightening the Nut (2-23) and Set Screw (1-9). 7. TROUBLE SHOOTING a. Continual releasing, further adjustment making no difference. 1) Detent Pocket (2-19) worn. Remove Safety Element (1-12) and remove Detent Pocket. Rotate Detent 90 and reinstall. If badly worn replace with new detent pocket. 2) Additional torque capacity is required. b. Unable to screw Housing Nut (2-7) in any further. 1) Loosen Set Screw (2-15) 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 (1-11) and Detent Pocket Plate (1-8) 100,000 90, SAFETY ELEMENT - METHOD OF ASSEMBLY a. Clean all components and coat all surfaces with a suitable anti-seize compound. b. Grease inside surfaces of the Housing and install Inner Thrust Race (2-4) and O Ring (2-10). c. Grease Plunger (2-1 ) and install thru Housing and Inner Thrust Race. d. Install mm Balls (2-3), apply grease over balls e. Grease and Install Outer Thrust Race (2-4). f. Grease and Install 16 springs (2-5), oriented as shown in cross section. g. Grease inner walls of Housing Nut (2-7) and install O ring (2-17). h. Screw in the Housing Nut (2-7) into the Housing until there is contact with the springs (2-5). i. Insert the Locking Pellet (2-14) and Security Screw (2-15) into the side of the Housing to facilitate locking the Housing Nut. (Refer to #2 Torque Adjustment) j. Screw Jacking Nut (2-13) onto Housing Nut (2-7). Hold non threaded Plunger end (2-1) securely in bench vise, after applying Loctite 262 to plunger threads screw Shroud (2-26) onto threaded plunger. Slide Security Cover (2-11) over Housing Nut and Jacking Nut and Hold in place with Security Screw (2-15) using special Allen Wrench provided. k. Grease and insert the O Ring (2-12) into the Bushing (2-8). insert the Detent Ball (2-9) after throughly greasing the Bushing ID. Grease the Plunger (2-1 ) and install the Bushing. 9. JSE2-0241AEA SETTING CURVE RELEASE TORQUE vs. SETTING Set each Module to Mark which corresponds to Required Release Torque RELEASE TORQUE (lb-in) 80,000 70,000 60,000 50,000 40,000 30,000 20,000 10, Setting of each Safety Element (10 marks per revolution) First Revolution 3

5 10. Installation & Maintenance Instructions Eflex Coupling Hubs 1. The following instructions should be read and understood prior to starting any assembly or maintenance work. 2. Prior to replacing any component, care should be taken to ensure that it is clean and free from any dirt. 3. Bolts and screws should be tightened evenly, cylinder head fashion, to 50% torque then to 100% torque in the same sequence. Where specified it is essential that torque tightening figures are not exceeded nor should it be allowed for them to be below specification. 4. To ensure that where hub/shaft connections require a standard interference fit the hubs may be heated in oil at 135 Celsius and rapidly positioned on the shaft. It is essential that this heating is evenly applied over the whole hub and that spot heating is avoided. 5. Mounting Hubs Coupling hubs are generally supplied with running or sliding fits. Therefore axial restraint of the hub should be provided by set screws when these fits are specified. Steel hubs are recommended when interference fits are specified, making it necessary to apply heat to the hubs, preferably in an oil bath or oven to a max. temperature of 135 C. Mount each hub on their respective shafts, normally with the face of each hub flush with the end of its shaft and tighten set screws onto the key, when supplied. 6. Alignment Note satisfactory alignment can be achieved with the use of a straight edge and feeler gauge, although a dial indicator or laser aligning equipment would generally improve accuracy, independent of geometric component errors. 6.1 Gap and Angular Alignment Set gap using a spacer bar equal in thickness to the nominal gap specified in Table 1. With the spacer bar inserted to the same depth, measure clearance between bar and hub face at 90 intervals using feelers. Angular alignment should be as close as possible, the difference between maximum and minimum measurements should not exceed the angular limits stated in Table Parallel Offset Alignment Use a straight edge and feelers, or dial indicator over the coupling outside diameter taking measurements at 90 intervals. Align as close as possible, error must not exceed offset limits specified in Table 1. Fit the coupling pins and flexible elements ensuring that each cap screw has one washer under its head and one washer on the other side of the flexible element. Tighten all foundation bolts to torques specified in Table 1, and repeat steps 6.1 and 6.2. if necessary, realign. 7. Maintenance Instructions Periodically check alignment, check fasteners torques and check flexible elements for wear to determine if replacements are required. Excessive misalignment, high ambient temperatures and / or frequent rapid reversing may necessitate more frequent inspection. Brunel Part No. Size or O.D. (mm) Coupling Gap Tolerance (inches) Gap Preferred (inches) TABLE 1 Parallel (inches) Installation Max. Alignment Limit Eflex Coupling Tightening Torque Rigid Hub Tightening Torque Angular (inches) Bolt Size (Ib-ft) Bolt Size (Ib-ft) JSE A M12 65 M10 40 JSE1-0128A M M10 40 JSEI -0129A&B M M JSE2-0241A&B M M JSE2-0243A&B M M

6 5

7 Publication: JSE2-0241MAEAD 8-10 Phone: Fax: Twin Oaks Street Wichita Falls, TX 76302

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