World Leader in Modular Torque Limiters Installation and Maintenance Instructions JSE1-0128MAEAD Extruder Clutch 1304 Twin Oaks Street Wichita Falls, Texas 76302 (940) 723-7800 Fax: (940) 723-7888 E-mail: sales@brunelcorp.com www.brunelcorp.com
Installation and Maintenance Instructions JSE1-0128MAEAD Extruder Clutch 23 20 10 29 1 8 21 17 3 24 4 22 13 12 Figure 1 Section view of Part # JSE1-0128MAEAD Parts referred to by (Figure # - Part #) 15 14 11 5 26 9 25 7 2 27 28 Part No. Description Qty. 1 Rigid Hub 1 2 Eflex Hub 1 3 Module Carrier Plate 1 4 Detent Pocket Plate 1 5 Blanking Plate 1 6* Flange Blanking Plug 2 7 Clamp Plate 1 8 Capscrew M10 x 55 LG 12 9 Taper Roller Bearing 2 10 Oilseal 98 x 120 x 13 1 11 Capscrew M5 x 16 LG 6 12 Eflex Flanged Bush 240 8 13 Buffer 240 Eflex Arnitel 8 14 Shoulder Bolt 8 15 Washer M16 Nord-Lock 8 16* Blanking Plate 2 17 Through Hole Fixing 2 18* Capscrew M6 x 25 SKT.HD 8 19* Capscrew M6 x 20 SKT.HD 8 20 Grubscrew 1 21 Safety Element JSE1 2 22 JSE1 Through Hole Ext Adj. Fixing 2 23 Nipple M6 Hyd.ST/Steel 1 24 Pressure Release Valve 1 25 Capscrew M6 x 18 SKT HD 1 26 Grubscrew 2 27 Sensor Segment 2 28 Setscrew M6 x 25 Csk Skt Hd 4 29 Setscrew M6 x 15 Skt hd 4 *Not shown on this view 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 (1-2) 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 (1-1) to the Module Carrier Plate (1-3). Using qty. 12, M10 x 55 S.H.C.S. (1-8). Torque tighten to 140 lb-ft. g. Dial indicate coupling Misalignment tolerance: Angular.004, Radial.003. If misalignment is beyond tolerance, realign. h. Assemble bolts and Buffers with Buffer Bush (1-12) inside of Buffer (1-13) and a M16 Washer (1-15) on outboard side of the buffer. Re-install 14 Shoulder bolts (1-14) with loctite on threads. Torque tighten to 120 ft-lbs. 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. 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 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. DISCONNECTING To manually disconnect the module, turn the disconnecting nut (2-21) 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 disconnecting nut (2-21) clockwise until flush with housing nut (2-7), then strike plunger shroud (2-12) with a dead blow mallet. 4. GENERAL MAINTENACE a. Grease 2-3 pumps from a grease gun into Grease Fitting (2-13) 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 SHC220 every 3 months. Add grease with a grease gun into fitting (1-23) and old grease is purged from grease relief valve (1-24) Recommended Grease: Mobil SHC220. 1
Installation and Maintenance Instructions JSE1-0128MAEAD 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 JSE1-0129MAEAD 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) Remove security screws (2-15) using special tool and take off Nut Shield(2-20). 13 2) Release Set Screw (2-15) in housing (2-11) using special tool. 3) 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. 4) Using socket wrench, turn housing nut until the required number of setting marks from zero are obtained. 5) Turn Set Screw (2-15) until tight. Re-install Nut Shield using security screws. 6) Repeat steps 1 through 6 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 (1-21) prior to preloading follow steps (a) thru (e). If preloading a mounted safety element (1-1), start with step (f). 2 21 20 17 3 8 14,15 9 18 12 10 19 16 5 1 7 2 11 Figure 2 Sectioned View of JSE1-0018 Externally Adjustable Disconnectable Safety Element 4 Item Part No. Description Qty. 1 JSE1-0018-1 Plunger 1 2 JSE1-0018-2 Outer Thrust Race 1 3 JSE1-0014-3 Balls (1/4 ) 11 4 JSE1-0018-4 Inner Thrust Race 1 5 JSE1-0015-5 Disc Springs 16 6* JSE1-0015-6 Mounting Bolts SHCS 4 7 JSE1-0018-7 Housing Nut 1 8 JSE1-0015-8T Bushing Through Hole 1 9 JSE1-0014-9 Detent Ball 5/8 1 10 JSE1-0015-10T Detent Pocket 1 11 JSE1-0018-11 Housing 1 12 JSE1-0018-12 Plunger Shroud 1 13 JSE1-0014-13 Grease Fitting 1 14 JSE1-0015-14 Locking Pellet 1 15 JSE1-0015-15 Security Screw 2 16 JSE1-00 15-16 O Ring Housing Nut 1 17 JSE1-0014-17 O Ring - Housing 1 18 JSE1-0014-13 Grease Fitting 1 19 JSE1-0014-19 Bushing O Ring 1 20 JSE1-0018-20 Security Cover 1 21 JSE1-0018-21 Disconnecting Nut 1 22* JSE1-0018-22 Set Screw (locking detent) 1 23* JSE1-0015-23 Flange Plate 1 24* JSE1-0015-24 Lock Nut 1 25* JSE1-0014-25 Set Screw 1 26* JSE1-0015-26 Socket Screw (preload) 1 * Not Shown on This View
6. continued a. Back out set screw (2-22), grease and insert the Detent Pocket (2-10) into the Detent Pocket Plate (1-4). 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 (1-3). c. Insert the Safety Element assembly (1-21) in to the Module Carrier Plate (1-2) and securely fix with socket head cap screws (2-6). Torque tighten to 132 lb-in. d. Grease and fit the Flange Plate (2-23), firmly fix to the Coupling Body by Socket Head Cap Screws (2-26). e. Insert the Adjusting Screw (2-25) and attach the Locknut (2-24). f. With a suitable measuring device (such as a dial indicator) placed on the head of the Plunger (2-1), turn the adjusting screw (2-25) with a hex wrench until the turning torque suddenly increases significantly. From this point turn the adjusting screw (2-25) until.003 -.008 of movement on the Plunger head is achieved, then lock in position by tightening the Nut (2-24) and Set Screw (2-26). 7. TROUBLE SHOOTING a. Continual releasing, further adjustment making no difference. 1) Detent Pocket (2-10) worn. Remove Safety Element (1-1) 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. 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 (1-3) and Detent Pocket Plate (1-4). 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 and install Outer Thrust Race (2-2) and O Ring (2-14). c. Grease Plunger (2-1 ) and install thru Housing and Outer Thrust Race. d. Install 11-1/4 Balls (2-3), apply grease over balls. e. Grease and Install Inner Thrust Race (2-4). f. Grease inner walls of Housing Nut (2-7). g. Grease and Install 16 springs (2-5), oriented as shown in cross section. 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 (2-20) 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. k. Secure Nut Shield onto Housing Nut (2-7) with Security Screws (2-20) using special tool provided. 9. JSE1-0128MAEAD TORQUE SETTING CURVE JSE1-0128MAEAD Setting Curve 45000 40000 35000 30000 Release Torque (lb-in) 25000 20000 15000 10000 5000 0 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 Setting of each Safety Element (10 marks per revolution) 3
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 fits 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 1. 6.2 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, re-align. 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) Operational Max. Alignment Limit Eflex Coupling Tightening Torque Rigid Hub Tightening Torque Angular (inches) Bolt Size (Ib-ft) Bolt Size (Ib-ft) JSE.5-0104A 195 0.098-0.276 0.187 0.008 0.008 M12 65 M10 40 JSE1-0128A 240 0.098-0.276 0.187 0.008 0.010 M16 120 M10 40 JSEI -0129A/B 240 0.098-0.276 0.187 0.020 0.020 M16 120 M16 120 JSE2-0241A/B 340 0.118-0.354 0.236 0.020 0.020 M20 280 M20 280 JSE2-0243A/B 630 0.118-0.354 0.236 0.020 0.030 M30 800 M20 280 4
4.75 13.33 5.315 5
Publication: JSE1-0128MAEAD 6-10 Phone: 940.723.7800 Fax: 940.723.7888 www.brunelcorp.com 1304 Twin Oaks Street Wichita Falls, TX 76302