1304 Twin Oaks Street · Wichita Falls, Texas 76302 · (940) 723-7800 · Fax: (940) 723-7888E-mail: sales@brunelcorp.com · www.brunelcorp.com

World Leader in Modular Torque Limiters

Installation and Maintenance Instructions

JSE.5-0234AEA Extruder Clutch

P R OT ECT I N G

EQU IPM ENT&

M A C H I N E R Y

YEARS

Installation and Maintenance InstructionsJSE.5-0234AEA Extruder Clutch

1. 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”.

3. RESETTINGOn 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 12-14 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 12-14 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 12-14 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.

Figure 1Section view of

Part # JSE.5-0234AEAParts 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 10 1

7 SKT Set Screw M5 X 20 3

8 Rigid Hub JSE.5-0234-8 1

9 Module Ext Adj JSE.5-0025 2

*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 25 6

16 Cover Assembly JSE.5-0234-16 1

17 Inner Member JSE.5-0234-17 1

18 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

17 3 2

4

19

18 7

2016

5 1 6 9 8

1

Installation and Maintenance InstructionsJSE.5-0234AEA 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.5-0234AEA 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).

Figure 2Sectioned View of JSE.5-0025

Externally Adjustable Safety Element

14

5

22

13

11

4

16

19

10

15

9

8

1

3

18

2

7

20

6

Item No. Part No. Description Qty.

1 JSE.5-0025-1 Plunger 1

2 JSE.5-0015-2 Outer Thrust Race 1

3 JSE.5-0014-3 5mm Ball 9

4 JSE.5-0015-4 Inner Thrust Race 1

5 JSE.5-0015-5 STD Spring Set 20

6 JSE.5-0014-6 M5 x 30mm SHCS 4

7 JSE.5-0025-7 Housing Nut 1

8 JSE.5-0014-8 Bushing 1

9 JSE.5-0014-9 12mm Ball 1

10 JSE.5-0015-10 Detent Pocket (BH) 1

11 JSE.5-0015-11 Housing 1

12

13 JSE.5-0014-13 6mm Grease Fitting 1

14 JSE.5-0014-14 ‘O’ Ring Housing 1

15 JSE.5-0014-15 M4-0.7 x 16mm SHCS 1

16 JSE.5-0014-16 Shim 1

17

18 JSE1-0014-18 Locking Pellet 1

19 JSE.5-0014-19 O-Ring Bushing 1

20 JSE.5-0015-20 Security Screw 1

22 JSE.5-0015-22 O-Ring Adj Nut 1

2

—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 ~ (0.003”-.008”) less than measurement in above.

e. Remove Safety Element assembly, install shims of correct thickness and re-install Safety Element assembly (1-9). 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.5-0234AEA TORQUE SETTING CURVE

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4

Torque(lb‐in)

RevolutionsfromZeroSpringCompression

JSE.5‐0234AEA

3

4

DRIVING FLANGE OUTERMEMBER CAVITIES FOR

RUBBER ELEMENTS

BOLTED JOINT INNER COVERMEMBER

RBCOUPLINGASSEMBLY

INSTRUCTIONS

5

OVERVIEW OF INSTALLATION

1. MOUNT HUBS TO SHAFTS...

Place the cover over theshaft. Fit the keys to shaft.Heat inner member anddriving flange. Fit thehubs to the shafts. Seepage 4 for details.

2. FIT RUBBER ELEMENTS...

Brush coupling cavitiesand rubber elementswith silicone fluid. Fitelements in sequenceshown in diagram. Seepage 5 for details

1 2 3

4 5 6

2

RB COUPLING INSTALLATION

6

OVERVIEW OF INSTALLATION

3. BOLT UP FLANGES... FLANGE BOLTS COVER BOLTS

Set shaft end gap andtighten cover and flangebolts. For shaft gap andtightening torque valuessee page 6.

4. CHECK SHAFT ALIGNMENT... "D" "E"

Check the axial, radialand angular alignmentof coupling. Allowablevalues and measuringprocedure are given onpage 7.

5. INSPECT ANNUALLY...VISUAL INSPECTION OF RUBBER ELEMENTS

Check the alignment ofthe coupling. Removethe cover and examinethe rubber elements forsigns of damage. Seepage 8 for details

RB COUPLING INSTALLATION

shaft end gap

"B"

" A "

" C"

3

7

KEYED SHAFTS...

The coupling is supplied in a loosely assembled condition along with assembly instructions andsilicone fluid. After installation, the instructions should be passed on to the end user. Completelydisassemble the coupling. If the coupling has limitied end float pads (blue or white circular padslocated in the inner member of the coupling) remove them. Check the shaft diameters andcoupling bores against the drawings.

CAUTION!

Unless a split cover is supplied with the coupling, fitthe cover over the shaft before fitting the inner mem-ber to the shaft.

Heat the hub to 250oF in either an oil bath or oven. Liftthe hub from the heating device either by using steellifting chains wrapped around the blades of the innermember or by using steel chains and shackles in-serted through the bolt holes (take care not to damagethe surface of these holes). Handle hot compo-nents with extreme care. Make sure that the liftingchains 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 flangeshould be flush with the end of the shaft unless other-wise specified on the drawing.

KEYLESS FITS...Specific instructions are supplied with couplings whichhave high interference keyless fits. Please refer tothese instructions when mounting the hubs.

RB COUPLING INSTALLATION

MOUNT HUBS TO SHAFTS

4

8

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 memberof the coupling over the inner member. Set the axial position of the outer member relative to theinner member. The outer member should be centered axially over the inner member. Fit the rubberelements in the sequence shown in the diagram below.

FITTING SEQUENCE...

To ease installation of the rubberelements, silicone fluid shouldbe used as a lubricant. Use afluid which has a viscosity be-tween 1000 and 3000 cs (suchas Dow Corning 200 Fluid),con-tainers. Brush each rubber elementand the cavities of the couplingswith the fluid before inserting therubber elements.

FITTING THE RUBBER ELEMENTS

RB COUPLING INSTALLATION

1 2 3

4 5 6

5

9

At this stage, all the rubber blocks should be in place and the driving and driven machineryshould be brought together with the correct gap between the ends of the shafts. The shaft endgap is shown on the drawing and in the table below.

Fit the cover and secure with bolts.Do not force the rubber elementsinto their cavities by tightening thecover bolts.

Connect the two halves of the cou-pling using the bolts supplied withthe coupling.

Bolts normally have metric threads.Their sizes are shown in the table.Tighten the bolts to the torque val-ues shown in the table.

BOLTING UP FLANGES

RB COUPLING INSTALLATION

6

COUPLING SHAFT ENDSIZE GAP (in)

RB 0.12 0.125

RB 0.24 0.125

RB 0.20 0.125

RB 0.37 0.125

RB 0.73 0.125

RB 1.15 0.125

RB 2.15 0.188

RB 3.86 0.250

RB 5.5 0.250

COUPLING FLANGE BOLT COVER BOLTSIZE SIZE TORQUE SIZE TORQUE

RB 0.12 M8 17.0 ft lb M8 17.0 ft lb

RB 0.24 M10 33.2 ft lb M8 17.0 ft lb

RB 0.20 M10 33.2 ft lb M8 17.0 ft lb

RB 0.37 M10 33.2 ft lb M10 33.2 ft lb

RB 0.73 M12 62.7 ft lb M10 33.2 ft lb

RB 1.15 M12 62.7 ft lb M12 62.7 ft lb

RB 2.15 M12 62.7 ft lb M12 62.7 ft lb

RB 3.86 M16 162 ft lb M12 62.7 ft lb

RB 5.5 M16 162 ft lb M12 62.7 ft lb

FLANGE BOLTSCOVER BOLTS

SHAFT END GAP

10

The following section describes how to verify that the alignment of the coupling is sufficient toprevent premature deterioration of the rubber elements. Note that the values given in the tableare 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 thediagram. Total reading on the dial indicatorfor one complete turn of the drive (maximumreading minus minimum reading) should beless 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 thediagram. Total reading on the dial indicatorfor one complete turn of the drive (maximumreading minus minimum reading) should beless than the value shown in the table.

RB COUPLING INSTALLATION

7

COUPLING AXIAL (inch)

RADIAL (inch)

ANGULAR (inch)

RB 0.12 0.015 0.007 0.013

RB 0.24 0.015 0.007 0.016RB 0.37 0.015 0.007 0.018RB 0.73 0.015 0.010 0.022RB 1.15 0.015 0.015 0.025RB 2.15 0.020 0.015 0.031RB 3.86 0.030 0.015 0.037RB 5.5 0.030 0.015 0.043

Installation Alignment Values

RB 0.20 0.015 0.007 0.016

A

B

C

D E

11

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 valuescompared to those in the table below.

To inspect the rubber elements, unbolt the cover of the coupling so that the faces of the rubberblocks can be seen. It is not necessary to remove the rubber elements from the couplings. Therubber 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 coverare signs of excessive misalignment.

VISUAL INSPECTION OF RUBBER

RB COUPLING INSTALLATION

INSPECTION

8

COUPLING AXIAL (inch)

RADIAL (inch)

ANGULAR (inch)

RB 0.12 0.059 0.030 0.054

RB 0.24 0.059 0.030 0.064RB 0.37 0.059 0.030 0.072RB 0.73 0.059 0.039 0.086RB 1.15 0.059 0.059 0.101RB 2.15 0.079 0.059 0.124RB 3.86 0.118 0.059 0.149RB 5.5 0.118 0.059 0.172

Maximum Alignment Values

RB 0.20 0.059 0.030 0.060

12

RB COUPLING INSTALLATION

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 thatyou 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 orgreen) 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 theorder number printed on the drawing and the part number of the hub.

ORDERING OF REPLACEMENT PARTS

9

1304

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in O

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Wic

hita

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940-

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7800

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ax: 9

40.7

23.7

888

13

Phone: 940.723.7800Fax: 940.723.7888

www.brunelcorp.com1304 Twin Oaks Street

Wichita Falls, TX 76302

Publication: JSE.5-0234AEA 10-14