BRUNEL JSE.5-0104MAEAD User manual

1304 Twin Oaks Street · Wichita Falls, Texas 76302 · [phone] · Fax: [phone]
E-mail: [email protected] · www.brunelcorp.com
World Leader in Modular Torque Limiters
Installation and Maintenance
Instructions
JSE.5-0104MAEAD Extruder Clutch

Installation and Maintenance Instructions
JSE.5-0104MAEAD 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 t is specied, heat coupling hub per t
specied 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.
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 ush 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 tting (1-10). Then re-engage
modules. Recommended Grease: Mobil SHC220
Part No. Description Qty.
1 Eex 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 (Eex 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
11.035’’
4.311’’ 4.25’’
Figure 1
Section view of
Part # JSE.5-0104MAEAD
Parts referred to by (Figure # - Part #)
1

Installation and Maintenance Instructions
JSE.5-0104MAEAD Extruder Clutch
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 tting - 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
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 rst
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”.
14 26 25 24 23
1
21
7
5
2
20
22
810 9
19
16
11
4
3
13
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).
Figure 2
Section View of
Part # JSE.5-0018
Safety Element
Parts referred to by (Figure # - Part #)
2

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
x 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 & le 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 anti-
seize 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
3
0
2000
4000
6000
8000
10000
12000
JSE.5-0104MAEAD Setting Curve
Setting of each Safety Element (10 mar ks per r evolution)
RELEASE TORQUE (lb-in)
0 2 4 6 8 10 12 14 16 18 20
RELEASE TORQUE vs. SETTING
First Revolution
Set each Module to Mark which corresponds to Required Release Torque
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 specied it is essential that torque tightening
gures are not exceeded nor should it be allowed for them to be
below specication.
4. To ensure that where hub/shaft connections require a standard
interference t 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
ts. Therefore axial restraint of the hub should be provided
by set screws when these ts are specied. Steel hubs are
recommended when interference ts are specied, 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 ush 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 specied 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 specied in Table 1. Fit the coupling pins and
exible elements ensuring that each capscrew has one
washer under its head and one washer on the other side
of the exible element. Tighten all foundation bolts to
torques specied 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 exible elements for wear to determine if
replacements are required. Excessive misalignment, high
ambient temperatures and / or frequent rapid reversing may
necessitate more frequent inspection.
TABLE 1
Brunel Part No. Coupling Installation Max.
Alignment Limit
Eflex Coupling
Tightening Torque
Rigid Hub
Tightening Torque
Size
or O.D.
(mm)
Gap
Tolerance
(inches)
Gap
Preferred
(inches)
Parallel
(inches)
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

5

Phone: [phone]
Fax: [phone]
www.brunelcorp.com
1304 Twin Oaks Street
Wichita Falls, TX 76302
Publication: EC JSE.5-0104 5-10