Maintenance Instructions. World Leader in Modular Torque Limiters. JSE AEA Extruder Clutch

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1 World Leader in Modular Torque Limiters PROTECTING EQUIPMENT& MACHINERYYEARSInstallation and Maintenance Instructions JSE AEA Extruder Clutch 1304 Twin Oaks Street Wichita Falls, Texas (940) Fax: (940)

2 Installation and Maintenance Instructions JSE AEA Extruder Clutch INSTALLATION a. Refer to the RB Coupling Assembly Instructions (page 4). b. Slide motor hub onto shaft. c. If interference or press fit is specified, heat coupling hub per fit specified before putting hub onto shaft. d. Bolt Rigid Hub (1-8) to the Module Carrier Plate (1-2). Using qty. 8, M10 x 25 S.H.C.S. (1-10). Torque tighten to 40 lb-ft. e. Dial indicate coupling misalignment max tolerance, Angular.003 /.002, Radial.002 /.003. If misalignment is beyond tolerance, realign. 2. 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 # JSE AEA Parts referred to by (Figure # - Part #) Part No. Description Qty. 1 Detent Pocket Plate 1 2 Module Carrier Plate 1 3 Taper Roller Bearing 2 4 Bearing Screw 1 5 Nitrile Rotary Oil Seal 1 6 SKTSet Screw M4 X SKT Set Screw M5 X Rigid Hub JSE Module Ext Adj JSE *10 Capscrew M10 X 25 8 *11 Tab Washer Steel 6 *12 Drive Screw No.4 SS 6 *13 Sealing Disc 1 *14 Grease Nipple 1 15 Setscrew M8 X Cover Assembly JSE Inner Member JSE Sensor Ring 2 19 Capscrew M8 X 12 SKT.HD 2 20 Rubber Block RB 0.20 RB 12 *21 Seloc Pin 8 x 30 2 *Not Shown 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 marks strike the safety element plunger shroud with a soft mallet and the plunger will move back into the safety element 1/4 inch signifying that the unit is engaged. 4. GENERAL MAINTENANCE a. After an overload event, before the safety elements are reset, grease 8-10 pumps from a grease gun into grease fitting (2-13). If multiple overload events occur in a short time frame, repetitive greasing is not required. Recommended grease is Mobil XTC. Before the safety elements are reset, bearings should be re-greased with Mobil SHC220. Grease pumps from a grease gun into grease fitting (1-14) and rotate the driving from the driven side. b. If after 3 months of operation and no overload events occur, loosen the four mounting bolts (2-6) from safety element (1-9), grease 8-10 pumps from a grease gun into grease fitting (2-13). Recommended grease is Mobil XTC. Bearings should be re-greased with Mobil SHC220. Grease pumps from a grease gun into grease fitting (1-14). c. If after 6 months of operation and no overload events occur, loosen the four mounting bolts (2-6) grease 8-10 pumps from a grease gun into grease fitting (2-13). Remove the four mounting bolts (2-6) from each safety element (1-9). Recommended grease is Mobil XTC. Remove the safety elements (1-9). Ensure that all parts of the safety elements are bagged and identified for the specific location they were removed from and reinstalled in the same location after maintenance has been completed. Bearings should be re-greased with Mobil SHC220. Grease pumps from a grease gun into grease fitting (1-14) and rotate the driving from the driven side. d. Every 12 Months remove each safety element (1-9) and replace or turn detent pocket (2-10) ninety degrees, replace detent ball (2-9) and refer to preload instruction, item 6 on page 2. e. Every 3 years, all safety elements should be removed, disassembled, inspected, and reassembled. Inspect more frequently where repetitive overload events or no trips occur in this time frame. Refer to torque setting, item 5 on page 2 and preload instructions, item 6 on page 2 for installation of reassembled safety elements. 1

3 Installation and Maintenance Instructions JSE AEA Extruder Clutch 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 JSE AEA 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 refers 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) Loosen Security Screw (2-20) using special tool. 2) Turn Housing Nut (2-7) counter-clockwise using socket until spring force is removed and the housing nut is free to 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. 3) Using socket wrench, turn housing nut until the required number of setting marks from zero are obtained. 4) Turn Security Screw (2-20) until tight. 5) Repeat steps 1 through 5 for each safety element. 6. METHOD OF PRELOADING EACH SAFETY ELEMENT (BLIND HOLE DETENT) Safety Elements must be preloaded anytime they are mounted onto assembly. If mounting the Safety Element (1-9) prior to preloading follow steps (a) thru (e). If preloading a mounted Safety Element (1-9), start with step (e) Item No. Part No. Description Qty. 1 JSE Plunger JSE Outer Thrust Race 1 3 JSE mm Ball JSE Inner Thrust Race 1 5 JSE STD Spring Set JSE M5 x 30mm SHCS 4 7 JSE Housing Nut JSE Bushing 1 9 JSE mm Ball JSE Detent Pocket (BH) 1 11 JSE Housing JSE mm Grease Fitting 1 14 JSE O Ring Housing JSE M4-0.7 x 16mm SHCS 1 16 JSE Shim JSE Locking Pellet 1 19 JSE O-Ring Bushing 1 Figure 2 Sectioned View of JSE Externally Adjustable Safety Element 20 JSE Security Screw 1 22 JSE O-Ring Adj Nut 1 2

4 continued a. Grease and insert the Detent Pocket (2-10) into the Detent Pocket Plate (1-1). Fix with SHCS. b.grease the bushing (2-8) complete with O ring (2-19) and install over the greased plunger (2-1). Install the greased ball (2-9) in the hole in the Module Carrier Plate (1-2). c. Insert the Safety Element assembly (1-9) into the Module Carrier Plate (1-2) and using feeler gauge, determine shim thickness required between Housing (2-11) and Module Carrier Plate (1-2). d. Group shims to obtain a shim thickness ~ ( ) less than measurement in above. e. Remove Safety Element assembly, install shims of correct thickness and re-install Safety Element assembly (1-9). Securely fix with socket head Cap Screws (2-6). Torque tighten to 70 lb.-in. 7. TROUBLE SHOOTING a. Continual releasing, further adjustment making no difference. 1) Detent Pocket (2-10) worn. Remove Safety Element (1-9) 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 (2-20) and make sure that the threads on the Housing Nut and Housing are not damaged. 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 Plate (1-2) and Detent Pocket Plate (1-1). 8. 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 (2-11). c. Grease inner walls of Housing Nut (2-7). d. Grease and Install O Ring (2-14), 16 springs (2-5), oriented as shown in cross section into housing nut (2-7) e. Grease Plunger (2-1) and install thru Housing (2-11) and Inner Thrust Race (2-4). f. Install 11-1/4 Balls (2-3), apply grease over balls. g. Grease and install Outer Thrust Race (2-2). 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 (2-18) and Security Screw (2-17) into the side of the Housing to facilitate locking (Refer to #2 Torque Adjustment). j. Grease and insert the O Ring (2-19) into the Bushing (2-8). Insert the Detent Ball (2-9) after throughly ID. Grease the Plunger (2-1) and install the Bushing. 9. JSE AEA TORQUE SETTING CURVE JSE AEA Torque (lb in) Revolutions from Zero Spring Compression 3

5 RB COUPLING ASSEMBLY INSTRUCTIONS DRIVING FLANGE OUTER MEMBER CAVITIES FOR RUBBER ELEMENTS BOLTED JOINT INNER COVER MEMBER 4

6 OVERVIEW OF INSTALLATION 1. MOUNT HUBS TO SHAFTS... Place the cover over the shaft. Fit the keys to shaft. Heat inner member and driving flange. Fit the hubs to the shafts. See page 4 for details. 2. FIT RUBBER ELEMENTS Brush coupling cavities and rubber elements with silicone fluid. Fit elements in sequence shown in diagram. See page 5 for details

7 OVERVIEW OF INSTALLATION 3. BOLT UP FLANGES... FLANGE BOLTS COVER BOLTS shaft end gap Set shaft end gap and tighten cover and flange bolts. For shaft gap and tightening torque values see page CHECK SHAFT ALIGNMENT... "D" "E" "B" "A" "C" Check the axial, radial and angular alignment of coupling. Allowable values and measuring procedure are given on page INSPECT ANNUALLY... VISUAL INSPECTION OF RUBBER ELEMENTS Check the alignment of the coupling. Remove the cover and examine the rubber elements for signs of damage. See page 8 for details 6

8 MOUNT HUBS TO SHAFTS KEYED SHAFTS... The coupling is supplied in a loosely assembled condition along with assembly instructions and silicone fluid. After installation, the instructions should be passed on to the end user. Completely disassemble the coupling. If the coupling has limitied end float pads (blue or white circular pads located in the inner member of the coupling) remove them. Check the shaft diameters and coupling bores against the drawings. CAUTION! Unless a split cover is supplied with the coupling, fit the cover over the shaft before fitting the inner member to the shaft. Heat the hub to 250 o F in either an oil bath or oven. Lift the hub from the heating device either by using steel lifting chains wrapped around the blades of the inner member or by using steel chains and shackles inserted through the bolt holes (take care not to damage the surface of these holes). Handle hot components with extreme care. Make sure that the lifting chains hold the hub securely. (do not use lifting equipment rated at less than the weight of the hubs). With the key in place in the shaft, fit the hub to the shaft. The end face of the inner member or drive flange should be flush with the end of the shaft unless otherwise specified on the drawing. KEYLESS FITS... Specific instructions are supplied with couplings which have high interference keyless fits. Please refer to these instructions when mounting the hubs. 7

9 FITTING THE RUBBER ELEMENTS The rubber elements may be fitted either before or after the coupling flange is bolted up. All RB couplings have 1 rubber element in each cavity. Refit the limited end float pads, if supplied (circular blue or white buttons). Place the outer member of the coupling over the inner member. Set the axial position of the outer member relative to the inner member. The outer member should be centered axially over the inner member. Fit the rubber elements in the sequence shown in the diagram below. FITTING SEQUENCE To ease installation of the rubber elements, silicone fluid should be used as a lubricant. Use a fluid which has a viscosity between 1000 and 3000 cs (such as Dow Corning 200 Fluid),containers. Brush each rubber element and the cavities of the couplings with the fluid before inserting the rubber elements

10 BOLTING UP FLANGES At this stage, all the rubber blocks should be in place and the driving and driven machinery should be brought together with the correct gap between the ends of the shafts. The shaft end gap is shown on the drawing and in the table below. Fit the cover and secure with bolts. Do not force the rubber elements into their cavities by tightening the cover bolts. Connect the two halves of the coupling using the bolts supplied with the coupling. Bolts normally have metric threads. Their sizes are shown in the table. Tighten the bolts to the torque values shown in the table. COUPLING FLANGE BOLT COVER BOLT SIZE SIZE TORQUE SIZE TORQUE RB 0.12 M ft lb M ft lb RB 0.20 M ft lb M ft lb RB 0.24 M ft lb M ft lb RB 0.37 M ft lb M ft lb RB 0.73 M ft lb M ft lb RB 1.15 M ft lb M ft lb RB 2.15 M ft lb M ft lb RB 3.86 M ft lb M ft lb RB 5.5 M ft lb M ft lb FLANGE BOLTS COVER BOLTS COUPLING SHAFT END SIZE GAP (in) RB RB RB SHAFT END GAP RB RB RB RB RB RB

11 The following section describes how to verify that the alignment of the coupling is sufficient to prevent premature deterioration of the rubber elements. Note that the values given in the table are in inches. AXIAL ALIGNMENT... Use a straight edge held on face A and a depth gage to measure the distance between faces A and B. Check the measurement with the allowable values given in the table. RADIAL ALIGNMENT... Mount the dial indicator to the shaft at C with the pointer at D as shown in the diagram. Total reading on the dial indicator for one complete turn of the drive (maximum reading minus minimum reading) should be less than the value shown in the table. ANGULAR ALIGNMENT... Mount the dial indicator to the shaft at C with the pointer at E as shown in the diagram. Total reading on the dial indicator for one complete turn of the drive (maximum reading minus minimum reading) should be less than the value shown in the table. Installation Alignment Values COUPLING AXIAL (inch) RADIAL (inch) ANGULAR (inch) RB RB RB RB RB RB RB RB RB D E B A C 10

12 INSPECTION Check the alignment of the coupling and the condition of the rubber elements annually. The alignment of the coupling should be checked as described on page 7 and the values compared to those in the table below. Maximum Alignment Values COUPLING AXIAL (inch) RADIAL (inch) ANGULAR (inch) RB RB RB RB RB RB RB RB RB To inspect the rubber elements, unbolt the cover of the coupling so that the faces of the rubber blocks can be seen. It is not necessary to remove the rubber elements from the couplings. The rubber elements should be replaced if any of the following are found: Deep cuts, over 10% of the width of the rubber elements. Rubber elements which are loose in their cavities. Rubber elements with cracked or sticky surfaces. Large amounts of rubber dust and an impression of the coupling inner member on the cover are signs of excessive misalignment. VISUAL INSPECTION OF RUBBER 11

13 ORDERING OF REPLACEMENT PARTS BOLTS Quote reference number and quantity shown in parts list on drawing. If no drawing is available, quote the size of the coupling (eg. RB 1.15). RUBBER ELEMENTS Various types of rubber elements are available for each coupling size. The type of element that you have can be identified by a round colored sticker which is molded into each rubber element. When ordering replacement rubber elements, specify the color of this sticker (eg. blue or green) and the number printed on it (eg. 60, 70, 80). HUBS To ensure that you recieve the correct bore in your replacement hub, always refer to the order number printed on the drawing and the part number of the hub. 12

14 1304 Twin Oaks Street Wichita Falls, TX Fax:

15 Publication: JSE AEA Phone: Fax: Twin Oaks Street Wichita Falls, TX 76302

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