WESTCAR ROTOMEC Series User manual

Original Instructions
WESTCAR s.r.l.
Via Monte Rosa 14
20149 - MILANO
Tel. [phone]
Fax [phone]
[e-mail]
www.westcar.it
Constant-fill
HYDRO
MECHANIC
COUPLINGS
ROTOMECROTOMEC
®
ROTOMEC ALFA
ROTOMEC BETA
M2021-ENG - ed. 2021-04

2
Po w e r T r a n s m i s s i o n
Installation and maintenance manual ROTOMEC
Denition: Constant - ll FLUID COUPLING
Type: _______________________________________ Code: _______________________________________
Series No _____________________________________ Year: ________________________________________
Transmission Fluid: _________________________ Filling: Standard Calibration
Actuation on primary wheel: internal ___________________
Temperature during start-up: max ____________ °C Rated operating temperature: ___________________ °C
Expected start-up time: _______________________ S Maximum start-up time: ________________________ S
Lubrication: standard constant self-lubricating
SAFETY/TEMPERATURE CONTROL DEVICES SUPPLIED:
TF (Fusible Plug) 96°C 120°C 145°C 180°C ____°C
ETP (Expandable Thermal Plug) 96°C 120°C 145°C 180°C ____°C
T09
(Plug with Thermostat and RPM counter) 100°C 120°C 145°C 160°C ____°C
STANDARD MANUFACTURE ATEX MANUFACTURE
Ambient: _____________ Max Temp.: __________°C Ambient: ZONE ______________ Max Temp: _______°C
DRIVE SIDE DATAS:
Installation: Horizontal Vertical
Type of engine: Diesel Petrol ________________________ Rpm
Electric Voltage: _____ V _____ Hz _____ Rpm
Installed Power: __________________ kW Power input: __________________________ kW
DRIVEN SIDE DATAS:
Installation: Flexible coupling:
YES NO
Drive - through pulley
ROTOFLEXI type ______ bore Ø _____ Primitive diameter: ___________________________
ROTOPIN type ______ bore Ø _____ Grooves section: ________ N° grooves: ___________
ROTOGEAR type ______ bore Ø _____ bore Ø ______________ bore Ø ________________
LAMELLAR type ______ bore Ø _____ ___________________________________________
OPTIONS:
Brake Disc type __________________ Brake drum type ___________________
CUSTOMER
TYPE OF MACHINE: __________________________ TYPE OF WORK: _______________________________
No-load start-up Full-load start-up Start-up n./hour _________ Consecutive start-up n. ____
Load inertia (PD2) ________________________ kgm2N° overloads ___________ Load start-up _______ sec.
Full-load start-up _________________________ sec. Bore drive end shaft _________________________ mm
Bore of driven end shaft ____________________ mm Operating area temperature ____________________ °C
ROTOMEC COUPLINGS
ORDER N.
ROTOMEC ALFA ROTOMEC BETA
WESTCAR s.r.l.
Via Monte Rosa 14
20149 - MILANO
Tel. [phone]
Fax [phone]
[e-mail]
www.westcar.it
0.1 TECHNICAL SHEET HYDROMECHANIC COUPLING
ALFA K0
ALFA K1
ALFA K2
BETA H
BETA J
BETA X
BETA Z
Part 0 – technical Sheet

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Po w e r T r a n s m i s s i o n
Installation and maintenance manual ROTOMEC
INDEX
PART 0 REFERENCE DOCUMENTS 2 - 7
0.0 DECLARATION OF INCORPORATION (ENCLOSED)
0.1 ROTOMEC COUPLING TECHNICAL DATA SHEET 2
0.2 INDEX 3
0.3 COMPONENT DEFINITIONS 4
0.4 MANUAL LAYOUT AND SYMBOLS 5 - 7
PART 1 INTRODUCTION INFORMATION 8 - 16
1.1 WESTCAR INSTRUCTION LETTER ON DELIVERY 8
1.2 HYDROMECHANIC COUPLING IDENTIFICATION 9
1.3 MARKING OF HYDROMECHANIC COUPLING ACCORDING TO ATEX STANDARD 10
1.4 WARRANTY 11
1.5 GENERAL INFORMATION ON DELIVERY 12
1.6 HYDROMECHANIC COUPLING DESCRIPTION 12
1.7 OPERATING PRINCIPLE 13
1.8 INTENDED USE AND SAFETY DEVICES 13 - 14
1.9 IMPROPER AND FORBIDDEN USE OF STANDARD AND ATEX COUPLINGS
15
1.10 REQUIREMENTS FOR STANDARD and/or ATEX INSTALLATION 16
PART 2 WARNINGS AND PRESCRIPTIONS 17 - 23
2.1 GENERAL SAFETY RULES 17 - 20
2.2 SAFETY RULES FOR POTENTIALLY EXPLOSIVE ATMOSPHERES 21
2.3 SAFETY DEVICES AND WARNING LABELS 22
2.4 SAFETY INSPECTIONS 23
PART 3 TRANSPORT AND INSTALLATION 24 - 31
3.1 TRANSPORT OF COUPLING WITH PACKAGE 24
3.2 HANDLING OF COUPLING WITHOUT PACKAGE 25
3.3 COUPLING STORAGE AND CONSERVATION 26 - 27
3.4 COUPLING PRE-ASSEMBLY 28 - 29
3.5 ASSEMBLY OF PULLEY FOR BETA COUPLINGS 30 - 31
PART 4 INSTALLATION AND COMMISSIONING 32 - 47
4.1 PRESCRIPTIONS FOR ROTOMEC COUPLING INSTALLATION IN HAZARDOUS ATMOSPHERES 32 - 33
4.2 FITTING OF ROTOMEC COUPLING ON DRIVE SHAFT 34 - 41
4.3 ASSEMBLY AND ALIGNMENT OF ROTOFLEXI FLEXIBLE COUPLING 42 - 43
4.4 ASSEMBLY AND ALIGNMENT OF SERIES AB FLEXIBLE COUPLING 44
4.5 SCREW TIGHTENING TORQUES FOR COUPLINGS AND ACCESSORIES 45
4.6 ROTOMEC COUPLING COMMISSIONING - STANDARD and ATEX MANUFACTURE 46 - 47
PART 5
OPERATION, REPLACEMENT AND/OR RESETTING OF OVERHEATING PROTECTION DEVICES 48 - 51
5.1 FUSIBLE PLUG - TF 48
5.2 EXPANDABLE PLUG - TE 49
5.3 PLUG WITH THERMOSTAT AND rmp CONTROLLER - T09 con PM 50 - 51
PART 6 TRANSMISSION OIL FILLING AND CALIBRATION 52 - 68
6.1 TRANSMISSION OIL TECHNICAL CHARACTERISTICS 52 - 53
6.2 TABLES FOR COUPLING FILLING 54
6.3 FILLING AND CALIBRATION OF HORIZONTALLY MOUNTED COUPLINGS 55 - 59
6.4 FILLING AND CALIBRATION OF VERTICALLY MOUNTED COUPLINGS 60 - 63
6.5 TRANSMISSION OIL REPLACEMENT IN HORIZONTALLY MOUNTED COUPLINGS 64 - 65
6.6 TRANSMISSION OIL REPLACEMENT IN VERTICALLY MOUNTED COUPLINGS 66 - 67
6.7 TABLE FOR RESIDUAL OIL DEPLETION IN VERTICALLY MOUNTED COUPLINGS 68
PART 7 ORDINARY MAINTENANCE 69 - 76
7.1 OIL LEAKAGE CHECK 69
7.2 OIL LEVEL CHECK AND TOP-UP 70 - 71
7.3 EXTERNAL CLEANING OF THE COUPLING 72
7.4 INSPECTION OF OVERHEATING CONTROL DEVICES 73
7.5 SERVICE RECORD 74 - 75
7.6 COUPLING OUTER PROFILE AND MAIN ELEMENTS 76
PART 8 INCONVENIENCES AND REMEDIES 77 - 78
PART 9 EXTRAORDINARY MAINTENANCE 79 - 82
9.1 COUPLING DISASSEMBLY FROM MACHINE 79
9.2 OPENING OF THE COUPLING AND SPARE PARTS REPLACEMENT 80 - 81
9.3 SPARE PARTS 82
PART 10 DECOMMISSIONING AND DEMOLITION 83
10.1 COUPLING DECOMMISSIONING 81
10.2 FLUID COUPLING DISMANTLING AND DEMOLITION 81

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Po w e r T r a n s m i s s i o n
ROTOMEC USe and Maintenance handbook
0.3 COMPONENTS DEFINITIONS
Layout and graphic design: Briefnglab. The rights of translation, reproduction and total or partial adaptation are prohibited in all countries.
ROTOMEC ALFA ROTOMEC BETA
POS. DEFINITION
1TRANSMISSION FLUID
2OUTER SHELLS (external part)
3
HOLLOW SHAFT and INNER PRIMARY WHEEL (internal part)
4OIL PLUG POSITION (STANDARD)
5RADIAL PLUG POSITION (OPTIONAL)
6FLEXIBLE COUPLING
7PRIMARY WHEEL
8ROTATING GASKETS
POS. DEFINITION
9CENTRIFUGAL MASSES
10 ROLLERS CENTRIFUGAL COUPLING
11 RADIAL SHELL SEALING
12 HEAD SCREW
13 PULLEY SLEEVE
14 PULLEY
15 RADIAL BEARINGS
TYPES OF HYDROMECHANIC COUPLINGS
ROTOMEC ALFA (in-line) ROTOMEC BETA (belt driven)
3 5 2
4 1 11 7
3 5 2
4 1 11 7 9
146
138 10 8 1515
12
10
Part 0 – reference docUMentS
12 15
9 8
8 15

5
Po w e r T r a n s m i s s i o n
ROTOMEC USe and Maintenance handbook
0.4 MANUAL LAYOUT AND SYMBOLS
Part 0 - reference docUMentS
This handbook has been subdivided into topics in order to classify information and operators’ activity.
This handbook is composed of several PARTS (chapters) and sections dealing with operational topics to
enable correct installation, use and maintenance of the ROTOMEC hydromechanic couplings.
Pages have the following layout and contents:
This document is the property of WESTCAR srl. All copyrights reserved.
This handbook is an integral part to this partly completed machine and it has to be considered as a SAFETY
DEVICE; it provides both the purchaser and the personnel (operators and qualied technicians) with the
necessary installation, use and maintenance instructions in order to keep the product safe and in good working
order for its whole life-cycle.
We recommend to read and to fully understand the content of this manual.
Topics are dealt with in chapters and sections, so that each stage is clearly illustrated in a numbered step-
by-step sequence. At the beginning of each section a bar shows the symbols associated with the personnel
qualied for the task.
Any operation-related residual risk is highlighted through suitable symbols in the text. In the handbook some
symbols are used to highlight and differentiate particular instructions or recommendations, which are of crucial
importance for safe operation and/or correct use and maintenance.
These measures allow WESTCAR to draw operators’ and qualied technicians’ attention to the CAUTIONS,
WARNINGS OR NOTES concerning them.
For any further clarication on the content of this handbook, do not hesitate to contact your WESTCAR
Customer Support Service.
tel. [phone] email: [email protected]
fax [phone] web site: www.westcar.it
GRAPHIC DESIGN AND
OPERATION SEQUENCES
PRECAUTIONS,
WARNINGS OR
NOTES
for safety and
operation
SYMBOLS
-
hazard
- prohibition
- obligation
PAGE
NUMBERS
HEADING OF
CHAPTER
OR PART
AUTHORIZED
PERSONNEL
HEADING OF
SECTION OR
TOPIC
24
P ow e r T ra n s m i s s i o n
3.1 TRANSPORT OF COUPLING WITH PACKAGE
The handling and transport operations are reserved to the handling
technicians equipped with suitable personal protective equipment
(protection gloves, safety shoes). DANGER OF CRUSHING, CRASHING
AND/OR INJECTION
3.1.1
Upon reception of the supply, check the weight reported on the label.
CAUTION
DANGER OF TILTING AND CRUSHING:
The load within the packaging could be unbalanced; therefore abide by
the procedures set out. Do not roll or damage the packaging. RISK OF
OVERTURNING.
3.1.2
Spread the forks of the fork-lift truck (with capacity suitable for the weight to be
trasported) as much as possible. Lift the coupling with its packaging slowly and
transport it (keeping it as much close to the soil as possible, about 30 cm) and
put it under a shelter in a dry place; then get the fork-lift out of the way.
3.1.3
Open the upper part and remove the packaging.
CAUTION
DANGER OF ENVIRONMENTAL POLLUTION:
Do not dump packaging material in the environment, but keep it for any future
re-use or shipping to the manufacturer or dispose of it properly as industrial waste.
3.1.4
Remove any stiffening rib, plastic lm for internal protection and brackets that x
the hydromechanic coupling to the pallet.
NOTE
Should the product be sent to the factory for repair works or maintenance,
the hydromechanic coupling will have to be shipped in a new package.
The shipping procedure shall be previously agreed upon with WESTCAR.
3.1.5
Take the Original Instruction Handbook and check that the product is not dam-
aged, no parts are missing and the content complies with the order.
NOTE
Non-compliance must be reported to Westcar and it’s distributor within
eight days from the receipt date.
3.1.6
To store the coupling, observe what set out in section 3.3. STORAGE OF THE
COUPLING.
The transport the of coupling with packaging has thus ended; now it is
possible to follow the steps described in the next section.
Part 3 - tranSPort and inStallationROTOMEC USe and Maintenance handbook
25
P ow e r T ra n s m i s s i o n
To handle the hydromechanic coupling without its package, it is necessary to follow
this procedure:
The handling and transport operations are reserved to handling technicians
equipped with suitable personal protective equipment (protection gloves,
safety shoes). DANGER OF CRUSHING.
3.2.1
Take the instructions and follow the description.
CAUTION
RISK OF CUSHING. In order to hoist and handle the hydromechanic
coupling, use the suitable lugs and devices recommended by the manufac-
turer, available on request; do not use any other reference than the equip-
ment and lifting points recommended by the manufacturer.
3.2.2 - For couplings with more than 30 kg of weight:
The hydromechanic coupling is located inside its packaging with its axis in verti-
cal position. Screw in the threaded pin equipped with hoisting ring in the extrac-
tion hole of the coupling.
3.2.3
Sling the coupling through the hoisting ring with hoist lines of suitable load
capacity for the coupling weight (see Identication Plate).
3.2.4
By slow movements, lift the coupling and transfer it to a dry, sheltered place and lay it
on a wooden plane next to motor and drive end, where the coupling will be installed.
The transport of the coupling without packaging has thus ended; now it is
possible to follow the procedure as set out in the next section.
3.2 HANDLING OF THE COUPLING WITHOUT PACKAGE
3.2.2
3.2.3
3.2.4
3.2.1
Part 2 - WarningS and PreScriPtionS ROTOMEC USe and Maintenance handbook
Original Instructions
WESTCAR s.r.l.
ViaMonte Rosa 14
20149- MILANO
Tel.[phone]
Fax[phone]
[email protected]
www.westcar.it
Constant-fill
HYDRO
MECHANIC
COUPLINGS
ROTOMEC
ROTOMEC
®
ROTOMECALFA
ROTOMECBETA
M2021-ENG- ed. 2021-02