World Leader in Modular Torque Limiters Installation and Maintenance Instructions JSE.5-0104MAEAD 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 JSE.5-0104MAEAD Extruder Clutch 1. INSTALLATION 4.311 11.035 4.25 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 (1-13) Using qty. 8, M10 x 25 S.H.C.S. (1-17). Torque tighten to 480 lb.in. g. Dial indicate coupling Misalignment tolerance: Angular.004, Radial.003, if misalignment is beyond tolerance, realign. h. Assemble bolts and Buffers with Buffer Bush (1-6) inside of Buffer (1-7) and a M12 Washer (1-5) on each side of the buffer. Re-install 8 cap screws (1-4) with loctite on threads. Torque tighten to 780 lb.in. Figure 1 Section view of Part # JSE.5-0104MAEAD Parts referred to by (Figure # - Part #) Part No. Description Qty. 1 Eflex Hub 1 2 Sensor Segment 2 3 Set Screw M6x25 Csk Hd 4 4 Shoulder Bolt-Hex Head 8 5 Washer M12 Nord-Lock 8 6 Flanged Bush 195 8 7 Buffer 195 Arntel 8 8 Blanking Plate 1 9 Detent Pocket Plate 1 10 Pressure Release Valve 1 11 Clamp Plate 1 12 Blind Hole Fixing 2 13 Module Carrier Plate 1 14 JSE.5-0018 Safety Element 2 15 Rigid Hub 1 16* Grubscrew (Rigid Hub) 2 17* Capscrew M10 x 25 SKT HD 8 18* JSE.5 Metric Fastener Kit 1 19 Grubscrew (Eflex Hub) 2 20 Set Screw M5 x 12 Skt Head 1 21 Capscrew M5 x 12 SKT HD 6 22 Taper Roller Bearing 2 23* Grease Nipple M6 Hydraulic 1 24 Oil Seal 1 25 Setscrew M5 x 10 Skt head (Dog Point) 4 *Not shown on this view 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 (2-9) is displaced and the Module Carrier Plate (1-13) disengages from the Detent Pocket Plate (1-9). With the drive at rest (the power off) and the overload cleared, align the two reset arrows (or grooves) on the Detent Pocket Plate (1-9) and Module Carrier Plate (1-13) by turning the drive motor shaft by hand. After aligning the match marks strike each Safety Element plungers with a soft mallet and the plunger will move back into the Safety Element 1/8 inch signifying that the unit is engaged. 4. DISCONNECTING To manually disconnect modules/clutch. Turn jacking nuts (2-23) counter clockwise with wrench until rotation stops. Modules are now disconnected & torque limiter is free for checking motor rotation or greasing bearings/modules. To re-engage, turn jacking nuts (2-23) clockwise until flush with housing nut (2-7). Then strike plungers caps (2-25) with a soft mallet to re-engage modules. 5. GENERAL MAINTENANCE a. Grease 2-3 pumps from a grease gun into Module Grease Fitting (2-13) every 3 months with modules in disengaged mode. 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. Disconnect modules and rotate clutch by hand and Add grease with a grease gun into fitting (1-10). Then re-engage modules. Recommended Grease: Mobil SHC220 1
Installation and Maintenance Instructions JSE.5-0104MAEAD Extruder Clutch 2 6. 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.5-0104AEA 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 (2-20) using special tool and take off Nut Shield. (2-21) 2) Release Set Screw (2-20) 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. 20 22 13 14 26 25 24 23 8 10 9 Figure 2 Section View of Part # JSE.5-0018 Safety Element Parts referred to by (Figure # - Part #) 1 21 7 5 2 3 4 11 16 19 4) Using box or open end wrench, turn housing nut until the required number of setting marks from zero are obtained. 5) Turn Set Screw (2-20) until tight. Re-install Nut Shield using security screws. 6) Repeat steps 1 through 6 for each Safety Element. 7. 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 (1-12) prior to preloading follow steps (a) thru (e). If preloading a mounted Safety Element (1-14), start with step (e). a. Grease and insert the Detent Pocket (2-10) into the Detent Pocket Plate (1-9). 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 (1-13). c. Insert the Safety Element assembly (1-14) into the Module Carrier Plate (1-13) and using feeler gauge, determine shim thickness required between Housing (2-11) and Module Carrier Plate (1-13). Item Part No. Description Qty. 1 JSE.5-0018-1 Plunger 1 2 JSE.5-0018-2 Outer thrust race 1 3 JSE.5-0018-3 Balls (5 mm) 9 4 JSE.5-0018-4 Inner thrust race 1 5 JSE.5-0018-5 Disc spring 20 6* JSE.5-0018-6 M5 x 25 SHCS 4 7 JSE.5-0018-7 Housing nut 1 8 JSE.5-0018-8 Bushing 1 9 JSE.5-0015-9 Detent ball 12mm 1 10 JSE.5-0015-10 Detent pocket (blind hole) 1 11 JSE.5-0018-11 Housing 1 12 13 JSE.5-0018-13 Grease fitting - 6mm 1 14 JSE.5-0018-14 O Ring housing 1 15* JSE.5-0018-15 M4 x 15 SHCS 1 16 JSE.5-0018-16 Shim Pack 4 17 18* JSE.5-0018-18 Locking pellet 1 19 JSE.5-0018-19 O Ring - bushing 1 20 JSE.5-0018-20 Security screw 2 21 JSE.5-0018-21 Security cover 1 22 JSE.5-0018-22 O -Ring (Adjusting Nut) 1 23 JSE.5-0018-23 Jacking nut 1 24 JSE.5-0018-24 End cap 1 25 JSE.5-0018-25 Plunger cap 1 26 JSE.5-0018-26 Setscrew M5 x 10 2LG C Sunk HD 2 * Not shown on this view
d. Group shims to obtain a shim thickness ~ (0.003 -.008 ) less than measurement in above. e. Remove Safety Element assembly, install shims of correct thickness and re-install Safety Element assembly (1-14). Securely fix with socket head cap screws (2-6). Torque tighten to 36 lb.-in. 8. TROUBLE SHOOTING Continual releasing, further adjustment making no difference. Detent Pocket (2-10) worn. Remove Safety Element (1-14) and remove Detent Pocket. Rotate Detent 90 and reinstall. If badly worn replace with new detent pocket. Additional torque capacity is required. 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. If so clean & file burrs until usable or replace defective parts. You have reached maximum torque capacity. Unable to reset. Reset arrows not aligned. Check reference marks on Module Carrier (1-13) and Detent Pocket Plate (1-9) 9. SAFETY ELEMENT - METHOD OF ASSEMBLY Clean all components and coat all surfaces with a suitable antiseize compound. Grease inside surfaces of the Housing and install Outer Thrust Race (2-2) and O Ring (2-14). Grease Plunger (2-1 ) and install thru Housing and Outer Thrust Race. Install 9-5 mm Balls (2-3), apply grease over balls Grease and Install Inner Thrust Race (2-4). Grease inner walls of Housing Nut (2-7). Grease and Install 20 springs (2-5), oriented as shown in cross section. Screw in the Housing Nut (2-7) into the Housing until there is contact with the springs (2-5). Insert the Locking Pellet (2-18) and Security Screw (2-20) into the side of the Housing to facilitate locking the Housing Nut. (Refer to #2 Torque Adjustment) Grease and insert the O Ring (2-19) 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. Screw on jacking nut (2-23) onto housing nut (2-7). Attach plunger cap and plunger end cap to plunger with cap screws (2-26) Secure Nut Shield onto Housing Nut (2-7) with Security Screws (2-20) using special tool provided. 10. JSE.5-0104AEA SETTING CURVE 12000 RELEASE TORQUE vs. SETTING Set each Module to Mark which corresponds to Required Release Torque RELEASE TORQUE (lb-in) 10000 8000 6000 4000 2000 0 0 2 4 6 8 10 12 14 16 18 20 Setting of each Safety Element (10 marks per revolution) First Revolution 3
11. 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 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 capscrew 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) Installation 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 0.020 0.012 M12 65 M10 40 JSE1-0128A 240 0.098-0.276 0.187 0.020 0.014 M16 120 M10 40 JSEI -0129A&B 240 0.098-0.276 0.187 0.020 0.016 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
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Publication: EC JSE.5-0104 5-10 Phone: 940.723.7800 Fax: 940.723.7888 www.brunelcorp.com 1304 Twin Oaks Street Wichita Falls, TX 76302