Maintenance Manual 21 KPTO

8/12/2019 Maintenance Manual 21 KPTO

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M-TECH TRANSMISSIONS AB Kvarsebovaegen 124 S-618 93 Kolmarden - SWEDENTel. +46 (0)11 396 444 - Fax +46 (0)11 396 480

21 KPTO

INSTALLATIONUSE and

MAINTENANCE

MANUAL

Type : 21 KPTO

Specification number : 2490-E

Serial number :


2/27

21 KPTO - SPEC. 2490-ESPECIAL FOR SANDVIK

TABLE Rev FILE DESCRIPTIONTF 6113 6 TF6113-gb.doc Features-use and maintenance

TF 6231 1 TF6231-gb .doc Procedures for conservation

TF 6093-A 2 TF6093-A.doc. Radial load (N / lb)

TF 6042 2 TF6042.doc Torsional vibration calculation data

TF 6114 1 TF6114.doc Arcusaflex technical data

TF 6115 TF6615.doc Recommended oil

TF 6014 2 TF6014.dwg Hydraulic scheme

TF 6007R TF6007 R.dwg Instruments

TE 3013 TE3013.dwg Spare parts junction boc

TE 6163 (1-3) 5 TE6163 1-3.doc Control panelElectric junction box

TE 6165 (1/3) TE6165 1/3.doc Logic diagram (control panel)

TE 6165 (2/3) TE6165 2/3.doc Electric interface (control panel)

TE 6165 (3/3) TE6165 3/3.doc Electric junction box

TF 5938-E 2 TF5938-ek.doc Filter

TF 6051 2 TF6051.doc Solenoid valve spares

TB 1066-C 2 TB1066-C.dwg KPT spares

TB 1070-B 3 TB1070-B.dwg KPT spares

TB 1071-A 4 TB1071-A.dwg KPT sparesTB 1072-B 8 TB1072-B.doc KPT spares description

TF 6119/1 4 TF6119/1-gb.dwg Trouble shooting

A 6560-E A6560-E.dwg KPT installation drawing


3/27

WORKING AND MAINTENANCE

INSTRUCTIONS FOR

KPTO/U FLUID COUPLING SERIES

TF 6113

Rev. 6

Sheet 1/3

TF6113-rev6-GB.doc 01-00

FEATURES

1- KPT for internal conbustion engine (named KPTO or KPTU depending on radial output or inline output) is a drain type fluid coupling. If drained out it works as a disconnected clutch.; if

progressively filled up it works as a soft starter.

2- KPT can be flanged to any internal combustion engine having a SAE housing and flywheel.

3 - KPT has a incorporated feed oil pump. This oil flow is used to fill up the fluid coupling, to

dissipate the heat generated during start up and steady running, to lubricate bearings.

4- KPT has some orifices, fitted on peripheral part, which continuously drain the oil supplied

by feed oil pump. Orifices have calculated diameter depending on application.Because orifices are made in threaded plugs, they can be replaced to optimise

performances. Quick release valves, supplied as optional, drain oil in few seconds.

5- Through an electric valve (24V d.c. [standard] or: 12V d.c.; 110V a.c.; 220V a.c.) the pump

oil flow can be diverted to the oil tank. In such a way the fluid coupling is drained out (time

required depends by orifices diameter and input speed) while oil flow continues to assurethe tank cooling and bearings lubrication.

6- Oil is cleaned through a 25 micron filter with replaceable paper cartridge. Filter clogging

is indicated on pressure switchgauge dial (see TF6007-) when is 1.7 bar over the rated

pressure (rated pressure is established during first start up as soon as oil temperature hasreached the working value). Pressure switch, already set during workshop test (becarefull to

check if setting was correct according to actual working condition like pipes length and oil

temperature) must be usedas alarm signal for filter clogging.

7- Temperature switch (see TF6007-), already set (see the test certificate), must be used as

alarm signal therefore should be connected to any device in respect of safety rules. Just as

suggestion, it could switch off electric valve or shut down the engine. When KPT is cooled

by engine jacket water, temperature switch setting could be max 95C.

8- Cooler, either oil/water (see TF5999...) or oil/air (see relevant dwg.), is supplied according torequired working specifications and must be fitted in line between pump and filter (see

TF6014...; see relevant dwg.).

9- Overload and speed controller is a reading device of KPT output speed and also an alarm

device in case of unwished decreasing of speed (high slip). Connection of alarm switch

has the same target of temperature switch (see TF 5800-).


4/27


INSTRUCTIONS FOR


TF 6113

Rev. 6

Sheet 2/3


INSTALLATION

- Check that flywheel be within SAE tolerances (see FIG.1 and also SAE J1033 rules).

- Mount elastic coupling driving ring on to the flywheel. Then mount KPT on to the flywheel

housing.

- First tight screws on flywheel housing then tight screws on support side flanges (both side

flanges must be fitted).

- Check (KPTO) that belts tension is within permissible value (see radial load table TF6093 in

this manual).

- Connect oil and water pipes (if any) in respect of pump pressure side diameter (suction and

pressure side diameters in case of separate pump).

- Supply correct water flow to the cooler (see final M-TECH technical quotation)

- Supply correct Voltage to electric motors, if any (check electric connections), electric valve and

devices (see test certificate).

START UP

IMPORTANT

- Check rotation direction of the pump. Once the pump is running, if no pressure is read onfilter pressure gauge, check again rotation (electric motor connections), pipes connection and

oil level (see maintenance for correct level).

- Check pressure be within correct value at steady running temperature (see test certificate).

a- Switch OFF electric valve.

b- Switch on the pump (whether electric motor pump is installed) and start engine.

c- Switch ON electric valve.

DISENGAGEMENT (STOP)

Switch OFF electric valve.

WITH ELECTRIC MOTOR PUMP

WHILE ENGINE IS ON AND LOAD STOPPED, FEED PUMP MUST BE ON AND VALVE

OFF. THIS TO ASSURE BEARINGS LUBRICATION.


5/27


INSTRUCTIONS FOR


TF 6113

Rev. 6

Sheet 3/3


MAINTENANCE & CHECKS

1- Change oil after first 100 working hours.Change oil every 4000 working hours unless evidentoil colour change. Correct oil level is the blue line on oil level indicators (first fill KPT, then run

the pump, electric valve OFF, to full fill heat exchanger, hence check level again, while engine

is stopped).

2- Change oil filter cartridge (25 micron) when pressure is 1.7 bar over rated value and/or

pressure switch is ON.

3- Change rotating seals (items 46 and 58 in TB1070-) in case of considerable oil leakage.

Recommended spare parts are supplied from M-TECH or local distributor (see Sales

Network on back page of KPT catalogue).4-Keep the cooler clean.Whether was a water cooler, see dedicated instruction pages in this

manual (TF6094). Whether was an air cooler, clean the radiator pack with air pressure orwash carefully by hand. Do not use water pressure, it can damage the Aluminum pack.

5-Check periodically, possibly every 1000 hours, that pump chain be of correct length (hang 20

kg weight to stretch chain):

15 KPT Max length = 1265 mm

17-19 KPT Max length = 1362 mm

21-24 KPT Max lenght = 1556 mm

27 KPT Max length = 1914 mm

6-Check, periodically, elastic coupling condition.

7-Procedure in case of replacement of following parts (TB1070- and TB1066-):

elastic coupling hub (64) or input shaft (4) or washer (23).

It is necessary to shim the gap between washer and input shaft ; the gap must be within 0.05

mm and 0.15 mm. Be sure to seat hub tightly against bearing before measuring the shim gap

between the end of the input shaft and retainer washer clamping surface in the hub. Use

shims provided by M-TECH or equivalent (ask for table N2912).

Screws (24) must be refitted with Loctite and tightened at 50 Nm.

FIG.1

IMPORTANT


6/27

tf6231-gb.doc/4 02/02/05

PROCEDURES FOR CONSERVATIONOF VARIABLE FILL FLUID COUPLING

KPT - KSL

TF 6231Rev. 1

FOLLOWING PROCEDURES ARE VALID FOR UNIT IN ITS ORIGINAL PACKAGING, STORED IN DRY,

CLEAN, DUST FREE INDOOR AMBIENT.

CHECK CONTROL

1 - INTERNAL PARTS

1.1 - SPRAY INSIDE HOUSING 0.25 Lt. OF OIL TECTYL 930 SAE 30.

1.2- PUT INSIDE HOUSING SUITABLE AMOUNT OF DRYER PACKS (g/m3

ACCORDING TO PACKS

INSTRUCTIONS). ATTACH, EXTERNALLY, A WARNING SIGNAL LIKE REMOVE BEFOREOPERATION.

1.3- SEAL ALL OPENINGS AND PASSES BETWEEN HOUSING AND AMBIENT ( I.E. BREATHER,

INPUT/OUTPUT FOR COOLER).

2 - EXTERNAL PARTS

2.1 - WET WITH PROTECTIVE FLUID CRC 3.36 (OR EQUIVALENT) ALL STEEL PARTS NOT ALREADY

PAINTED OR PHOSPHATED.

IN CASE OF MARINE ENVIROMENT, USE PROTECTIVE FLUID CRC 6.66 MARINE (OR

EQUIVALENT) FOR 3 MONTHS PROTECTION, OR CRC PROTECTIVE MARINE FOR 6 MONTHS

PROTECTION.

AFTER THE 3 OR THE 6 MONTHS PERIOD, OPERATION MUST BE REPEATED FIRST

CLEANING CRC.

CRC IS CLEANABLE BY MEANS OF CRC MARIN ELMEC CLEAN DILUENT.

2.2 - ROTATING SEALS OR LABYRINTHS MUST BE PROTECTED WITH GREASE AGIP 33 FD OR

SHELL ALVANIA R3 OR EQUIVALENT.

2.3 -CHECK THAT CONNECTION WIRING BOX BE WELL SEALED.

2.4 -FOR MOTORS, PUMPS, INSTRUMENTS, PRESERVE THE ORIGINAL PACKAGING, IF ANY.


7/27

KPTO & KPTEPERMISSIBLE SIDE LOAD (N)

AND SUGGESTED PULLEY TRANSMISSION

TF 6093-A

Rev. 2

tf6093-a.doc 02-00

- Calculated bearings life over 10.000 hours.

- Engine speed over the max listed below, needs approval by M-TECH.

- Pulley diameter is the minimum permissible. (Over 35 m/s, dynamic balancing is recommended).

- Belts nr. is maximum permissible.

- Timing belts must be approved by M-TECH.- X distance is according to belts type & number.

- Side load includes 2.5 belt tensioning factor.

15Up to

kW/rpm

Max X (mm)

Max load (N)

Max belts nr

Type - Min pulley

200 / 2600 91 / 17.000 10 x 5V - 220 mm

17 - 19Up to

kW/rpm

Max X (mm)

Max load (N)

Max belts nr

Type - Min pulley

250 / 1800

95 / 20.000

91 / 20.000

95 / 20.000

10 x 5V - 335 mm

6 x 8V - 335 mm

7 x SPC - 335 mm

300 / 2200 102 / 18.000105 / 18.000

107 / 18.000

11 x 5V - 355 mm7 x 8V - 355 mm

8 x SPC - 355 mm

21Up to

kW/rpm

Max X (mm)

Max load (N)

Max belts nr

Type - Min pulley

400 / 1800150 / 31.000

160 / 31.000

10 x 8 V - 335 mm

12 x SPC - 335 mm

470 / 2200165 / 29.000

170 / 29.000

11 x 8 V - 355 mm

13 x SPC - 355 mm

24

Up to

kW/rpm

OverlapMax X (mm)

Max load (N)

OverlapMax belts nr

Type - Min pulley

545 / 180088 / 40.000

95 / 40.000

12 x 8 V - 355 mm

14 x SPC - 355 mm

620 / 2200117 / 35.000

120 / 35.000

14 x 8 V - 380 mm

16 x SPC - 380 mm

Pulley must be installed overlapping bearing carrier by 89 mm.

27

Up to

kW/rpm

Overlap

Max X (mm)

Max load (N)

Overlap

Max belts nr

Type - Min pulley

800 / 1800 133 / 55.000 17 x 8V - 380 mm

Pulley must be installed overlapping bearing carrier by 115 mm.

ASK M-TECH FOR ANY APPLICATION DIFFERENT THAN ABOVE.


8/27

RBD or AC ELA STIC COUPLING + KPT INPUT SIDE

(for torsional vibration calculation)TF 6042

Rev.2

tf6042.doc date: 02-00

Dim.

Size TKN TKmax TKW(10Hz) CT CTdyn VR J1 JL rpm maxT (C)

max

15/11S 860 2150 430 93 100 0.726 8.65 0.035 0.736 2600 120

15/11D 2060 6530 1030 461 691 0.726 8.65 0.082 0.782 2600 120

15/14S 1690 4220 845 206 309 0.726 8.65 0.180 0.836 2600 120

17/11D 2060 6530 1030 461 691 0.726 8.65 0.082 1.215 2600 120

17/14S 1690 4220 845 206 309 0.726 8.65 0.180 1.276 2600 120

19/11D 2060 6530 1030 461 691 0.726 8.65 0.082 1.773 2600 120

19/14S 1690 4220 845 206 309 0.726 8.65 0.180 1.833 2600 120

19/AC5-11 2500 7500 1250 13 1.25 5.03 0.065 1.832 2600 80

19/AC5-14 2500 7500 1250 13 1.25 5.03 0.179 1.830 2600 80

21/14D 3490 11040 1745 1010 1515 0.726 8.65 0.187 2.869 2200 120

21/AC6-14 4200 12600 2100 45 1.25 5.03 0.220 2.999 2600 80

24/14D 3490 11040 1745 1010 1515 0.726 8.65 0.187 5.332 2200 120

24/14D18 3490 11040 1745 1010 1515 0.726 8.65 0.870 5.332 2200 120

24/AC7-14 6300 18900 3100 100 1.25 5.03 0.312 5.742 2600 80

24/AC7-18 6300 18900 3100 100 1.25 5.03 0.519 5.742 2300 80

27/18D 5300 16720 2650 1885 2827 0.726 8.65 0.652 8.805 1800 120

27/AC8-18 7800 23400 3900 110 1.25 5.03 0.478 9.105 2300 80

TKN Nominal torque (Nm)

TKmax Max torque (Nm)

TKW (10Hz)Continuous vibratory torque at 10 Hz

For different fxfrequencies TKW(10/fx) is valid

CT Static stifness factor (Nm/rad)10

CTdyn Dynamic stifness factor (Nm/rad)10

Relative damping

VR Resonance factor

J1 Elastic coupling driving part inertia

JL Elastic coupling driven part inertia + KPT input side


9/27

ARCUSAFLEX

TECHNICAL DATATF 6114Rev. 1

tf6114-rev.1.doc 02/2002

ARCUSAFLEX

Type / Size

Shore

hardness

Nominal Torque

TkN (Nm)

Max Torque

Tk max

(Nm)

Continuous

Vibration Torque*TkW 10 Hz (Nm)

Dynamic

Stiffness

CTdyn.(Nm/rad)

Flange Size

SAE J 620

Max

Speed

(rpm)

WN 200 500 100 1100NN 250 750 125 1700AC 2SN 330 1000 165 3300

6.5

84200

WN 330 750 165 1100

NN 360 900 180 1700AC 2,3

SN 400 1000 200 2500

6.5

84200

WN 500 1250 250 2100 4200

NN 600 1800 300 3100 3600AC 2,6

SN 700 2100 350 4500

8

10

11.5 3500

WN 800 2000 400 3600

NN 900 2700 450 5000AC 3

SN 1000 3000 500 7500

10

11.5

3600

3500

WN 1200 3000 600 8000

NN 1350 3600 650 10000AC 4

SN 1550 4200 750 13500

11.5

14

3500

3000

WN 1800 4500 900 8500

NN 2000 5400 1000 13000AC 5

SN 2500 7500 1250 22000

14 3000

WN 3100 7700 1500 16000

NN 3450 10000 1700 30000AC 6SN 4200 12600 2100 45000

14

18

3000

2300

WN 4600 10000 2300 35000

NN 5200 15600 2600 56000AC 7SN 6300 18900 3100 100000

14

18

2600

2300

WN 6200 14000 3100 38000

NN 7000 21000 3500 75000AC 8SN 7800 23400 3900 110000

18

21

2300

2000

WN 12400 28000 6200 76000NN 14000 42000 7000 150000AC 8 DSN 15600 46800 7800 220000

1821

23002000

WN 8000 18000 4200 55000

NN 9000 27000 4800 100000AC 9SN 10000 30000 5500 190000

18

21

2300

2000

WN 16000 36000 8400 110000

NN 18000 54000 9600 200000AC 9 DSN 20000 60000 11000 380000

21 2000

Shore hardness: WN = 50-55Shore ANN = 60-65Shore A

SN = 70-75Shore A

*Continuous Vibration Torque TkW: at = 10 Hz, for other frequency xx is valid TkW10

fx

Resonance factor VR and relative Damping

Shore hardness VR

WN 7.85 0.8

NN 5.46 1.15

SN 5.0 1.25


10/27

RECOMMENDED OIL

(ISO HM 32)

TF 6115

REV. 0

tf6115.doc 17/03/97

AGIP OSO 32

ARAL VITAM GF 32

BP ENERGOL HLP 32

CASTROL HYSPIN AWS 32

CHEVRON RPM EP HYDRAULIC 32

ESSO NUTO H 32

MOBIL DTE 24

SHELL TELLUS 32

TEXACO RANDO HD 32

TOTAL AZOLLA ZS 32


11/27

OIL FILTER TF 5938...REV. 2

TF5938-EK.doc / 14/09/01

REFERNCE DIMENSION CARTRIDGE

TF 5938-O 1 25 m

X TF 5938-E 25 m

TF 5938-K 10 m

4CARTRIDGE

3VITON SEAL

2BY-PASS

1FILTER HEAD


12/27

M-TECH


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16/27


17/27


18/27


19/27


20/27


21/27

KPTO (U)TROUBLE SHOOTING

TF 6119/1

REV. 4

tf6119-1-gb.doc/4 05/03/01

UNIT FAILS TO OPERATE

1 - Check KPT output shaft turns freely with engine shutdown.

2 -Check solenoid valve (item 87 - TB1071-) is operating.

3 -Check oil level. It must be at blue line on level indicator (item 37 - TB1070-).

4 - Check oil pressure (item 109 - TB1071-) (see test certificate).

5 -Remove cover plate (item 42 - TB1070-) and check:

a) four orifice plugs (item 10 - TB1066-) be tight

b) nuts (item 20 - TB1066-) be tight.

6 - Check oil flow by inserting flow meter in feed line from pump to KPTO.

7 - Check (on KPTO with integral pump) condition of pump driving chain.

8 - Check temperature alarm switch (item 110 - TB1071-) is set at correct level (see test

certificate).

UNIT OPERATES AT REDUCED OUTPUT SPEED

1 - Carry out checks from 1) to 7) as above.

2 - Check engine high idle speed with KPTO dis-engaged.

3 - Check driven machine condition.

OIL LOSS

1 - Check all pipe connections.

3 - Check seals (item 46 and 58 - TB1070-).

3 - Check engine flywheel housing.

4 - Check engine coolant is not contaminated.

If vapor comes out from the breather, wait until oil temperature reaches more than 55-

60 C. If oil comes out from the breather, check orientation of oil keeper under cover

(item 42 - TB1070-B).

TOO MUCH OIL PRESSURE

1 - Check filter cartridge and replace if necessary (item 97 - TB1071-).

2 - Check pressure gauge (item 109 - TB1071-) be not defective.

3 - Check not obstruction inside oil tubes.


22/27

tf6051.doc/4 02/02/05

ELECTRIC VALVE TF5937-EDFE20/3A18ES.W201 - 24VDC - BSP

TF 6051

REV. 2

6

4

3

1

2

4

7

8

9

5

POS. CODE Q. DESCRIPTION

1 3CO2261320 1 Housing DFE/20/3-BSP

2 4SPI512040 3 Pin UNI6874 12x40

3 3CAS120341 1 Spool DFE20/3A

4 4GUA123526 2 O Ring 23.47x2.62

5 3MOL117310 1 Spring DF20 V.18ES

6 3TAP332200 1 Plug DFE20

7 4GUA130018 1 O Ring 29.87x1.78

8 4SOL519024 1 Solenoid 24VDC D19-46.79

9 4SOL519000 1 Pusher D19x4O


23/27

ONLYFOR

15KPTO

ONLYFO

R

27KPTO


24/27

O

NLYFOR

15KPTO

M-TECHTRANSMISSIONSAB


25/27


26/27

KPTO - KPTUparts list

(TB1066-C & TB1070-B & TB1071-A)

TB 1072-B

Rev. 8

tb1072b-gb.doc

1 inner impeller 53 screw 105 drain tube

2 outer impeller 54 lock washer 106 plug

3 cover 55 SAE flange 107 copper packing

4 outer impeller shaft 56 roll bearing 108 panel

5 roll bearing 56a --- 109 pressure switch gauge

6 snap ring 57 bearing carrier 110 temperature switch gauge

7 screw 58 seal 111 pressure gauge pipe

8 lock washer 59 O-ring 112 ---

9 ring 60 screw 113 ---

10 orifice plug 61 lock washer 114 lubrication pipe

11 splined hub 62 screw 115 spacer

12 snap ring 63 lock washer 116 short end studs

13 coupling bearing carrier 64 splined hub 117 ---

14 ball bearing 65 flange (RBD) 118 suction flange

15 snap ring 66 rubber block (RBD) 119 straight union fitting

16 snap ring 67 driving ring (RBD) 120 suction pipe

17 screw 68 screw (RBD) 121 straight end fitting

18 ring 69 nut (RBD) 122 lock washer

19 short end stud / screw (for 27kpto) 70 lock washer (RBD) 123 chain drive

20 nut 71 key 124 cover

21 lock washer 72 feed pump 125 screw

22 O-ring 73 screw 126 lock washer

23 lock washer 74 lock washer 127 shim(s)

24 screw 75 hub 128 O-ring

25 --- 76 key 129 tab washer

26 --- 77 lock washer 130 tab washer

27 --- 78 screw 131 seal (not for 17/19)28 --- 79 gear 132 flange

29 --- 80 screw 133 screw

30 --- 81 --- 134 lock washer

31 housing 82 --- 135 screw

32 baffle 83 --- 136 gasket

33 screw 84 --- 137 gasket

34 lock washer 85 straight end fitting 138 elastic coupling (AC)

35 screw 86 breather 139 driving ring (AC)

36 lock washer 87 solenoid valve 140 screw (AC)

37 oil level indicator 88 nut 142 lock washer (AC)

38 --- 89 lock washer 143 washer

39 --- 90 adapter 148 reducing fitting

40 magnetic plug 91 adapter 149 adapter

41 O-ring 92 reducing fitting 151 snap ring

42 cover 93 copper packing 152 nut (AC)

43 screw 94 T adapter 153 snap ring

44 lock washer 95 lubrication pipe 154 QD-bushing

45 bearing carrier 96 straight end fitting 155 hub for QD-bushing

46 seal 97 oil filter 156 screw

47 double roll bearing (KPTO) 98 adapter 157 key

47a ball bearing (KPTU) 99 copper packing 232 reducing fitting

48 snap ring 100 adapter 263 shim(s)

49 inner impeller shaft 101 copper packing

50 shim 102 feed tube

51 snap ring 103 adapter

52 O-ring 104 copper packing


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Maintenance Manual 21 KPTO

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Transcript of Maintenance Manual 21 KPTO