INSTALLATION

&
MAINTENANCE MANUAL

For
ALPHA FLUID COUPLING

Supplied by :
JIS SYSTEM (M) SDN BHD
19 , Jalan Dua, Off Jalan Chan Sow Lin,
55200 Kuala Lumpur, Malaysia
Tel :+603-92214849 / Fax :+603-92214850
Email : enquiry@jissystem.com
 ALPHA FLUID COUPLING
INTRODUCTION

The information given in this manual is intended as a general guideline to the

installation, operation & maintenance of Fluid coupling.

Fluid coupling is a compact & efficient unit suitable for mounting directly on motor Shaft
or engine Fly Wheel. In order to ensure the best results from fluid coupling careful
handling & maintenance is required.

SPECIAL FEATURES
- Easy adaptability for fitment to Diesel Engine / Electric motor.
- Available for inline & V & Flat pulley drive.
- Provision for five fills for torque slip adjustment.
- Safety Fusible plug for various temperature conditions.
- Switching pin available as optional for models above 12K.

INSTALLATION INSTRUCTION

Figure shown on drg No 999 000 568

Sequence of operation:-
1) Check that the Shaft end of motor is running true.
2) Fit the Key into Keyway & lubricate the shaft with Molykate etc.
3) Mount fluid coupling on to the motor shaft by means of threaded bar screws into
the threaded hole in motor shaft & a piece of tube with nut. Prevent rotation of
shaft during mounting by using two lock nuts on threaded bar. Tighten the nut in
order to press the coupling against either the shaft collar or face of the shaft end
depending on the variant. Remove the threaded bar.
4) Coupling must be fixed axially by means of axial bolt & washer provided with the
coupling.
5) Mount the flexible coupling on hollow hub depending upon the versions.

DISMANTLING

Remove the axial bolt & use puller to remove the fluid coupling from motor shaft by the
threading provided in the coupling shaft.
(Ref. Figure shown on Drg No 999 000 568)

FILLING INSTRUCTIONS

The fill of oil has a considerable influence on the torque transmitted by coupling. Higher
the fill, higher the starting torque hence for same torque less the slip & higher the drag
torque (100% slip torque). For the correct quantity of oil, refer to the drg no 999 000 567
for capacity of various fills.

In general all couplings are filled to X fill when delivered (Depending upon the selection
made). For no reason the fill is to be changed without prior consent from us.

For refilling, remove both the filler plugs (one for venting air). Bring the recommended
filling mark X, 1, 2, 3, 4 in the vertical position. This will bring the filling plug, in angular
position. Fill the coupling with specified oil unit the oil starts spilling out through filling
plug. Tighten the filling plugs, ensure it is leak free.

Following grades of Oil are recommended.

Light mineral Oil type ESSO Teresso – 32, Indian oil 32 Tellus 32 T-46 or equivalent.

MAINTENANCE

- Check periodically oil level to ensure proper fill. If level is reduced due to any
leakage then top it up & also remove leakage.
- Change oil after 4,000 working hours or once a year whichever is earlier.
- Change oil seals & gasket after every 8000 working hours.
- Change bearing after 30,000 working hours.
- Generally couplings are fitted with fusible plug of 145º C as a safety device to
prevent m/c from continuing, over loading, jamming etc. in which case plug will
melt & drain the oil. In such case coupling should be filled with new oil & correct
fusible plug to be fitted.

Type of plug can be identified by mark on plug. Ref table given below:

Temp. Notch Mark

120º C Single /
145º C Double – –
175º C Triple Y
220º C Quarter –¦ –

WARRANTY

The ALPHA Fluid couplings are warranted for 12 months from the date of supply from
their works or six months from the date of commissioning whichever is early.

ORDERING OF SPARE PARTS

For identification of various components refer part list.

While ordering spares, please specify the model, item number and serial number of
coupling for correct supply.
 CAPACITY OF VARIOUS FILLS OF FLUID COUPLING

Total FILL QUANTITY / LITRE

Model
volume
X 1 2 3 4
7K 1.200 0.920 0.860 0.800 0.730 0.650

8K 1.680 1.280 1.190 1.100 1.000 0.900

9K 2.450 1.950 1.820 1.690 1.550 1.400

11K 3.400 2.750 2.550 2.350 2.100 1.850

12K 5.325 4.100 3.875 3.575 3.250 2.900

13K 6.800 5.200 4.850 4.450 4.050 3.600

15K 9.800 7.650 7.150 6.600 6.000 5.400

17K 15.000 11.700 10.900 10.000 9.100 8.200

19K 18.400 14.200 13.300 12.300 11.200 10.000

21K 24.400 19.000 17.800 16.400 15.000 13.500

24K 36.400 28.400 26.500 24.500 22.600 20.500

DRG No. 999 000 567

MAX ALLOWABLE FILL

SPARE PART LIST – KSD

POS DESCRIPTION POS DESCRIPTION

1 Inner Impeller 20 Seal
2 Outer Impeller 21 Ball Bearing
3-3a Cover 22 Spacer
4 O-Ring 23 Snap Ring
5-5a Gasket / O-Ring 24 Bearing Carrier
6 Gasket / O-Ring 25 Shaft
7-7a Screw 26 Fixing Screw
8 Screw 27 Washer
9 Screw 28 Integral Sheave
10 Nut 29 Bolted Sheave
11 Nut 30 Screw
12 Lock Washer 31 Wave Spring
13 Plug 32 Cover
13a Fusible Plug 33 Delay Filled Chamber
14-14a Bearing Carrier 34 Screw
15 Seal 35 Lock Washer
16 Ball Bearing 39 Lock Washer
17 Plate / Lock Washer 47 Oil Retainer
18 Snap Ring 50 Lock Washer
SPARE PART LIST - KR

POS DESCRIPTION POS DESCRIPTION

1 Inner Impeller 23 Bearing Carrier
2 Outer Impeller 24 Shaft
3-3a Cover 25 Fixing Screw
4 O-Ring 26 Washer
5-5a Gasket / O-Ring 27 Flange G
6 Gasket / O-Ring 28 Rubber Block for BT
7-7a Screw 29 Half Joint G
8 Screw 30 Half Joint B
9 Screw 31 Shaft D
10 Nut 31.1 Key
11 Nut 33 Delay Filled Chamber
12 Lock Washer 34 Screw
13 Plug 35 Lock Washer
13a Fusible Plug 36 Screw
14-14a Bearing Carrier 37 Nut
15 Seal 38 Lock Washer
16 Ball Bearing 39 Lock Washer
17 Plate / Lock Washer 40 Plate
18 Snap Ring 41 O-Ring
19 Seal Carrier 47 Oil Retainer
20 Seal 48 Screw
21 Ball Bearing 49 Lock Washer
22 Snap Ring
SYMPTONS, CAUSES AND REMEDIAL ACTIONS

SYMPTON CAUSES REMEDIAL ACTION

Too High Temperature Insufficient oil level Check level and possibly top up.

Fusible plug intervention Too many consecutive Wait for cooling before restarting, or
start-ups. reduce number of start-ups.

High absorptions than Remove causes and/or review

specified. dimensioning.

High ambient Improve coupling ventilation.

temperature.

Jammed or overloaded Remove causes.

driven machine.

Too near heat source. Remove source or introduce a shield.

Too close protection Introduce convenient air passages to

cover. improve heat exchange.

Performance decrease Oil level Check oil level and fill with the right type
if necessary.

Oil type specification Replace if necessary.

Ambient temperature Use correct oil type.

lower than 0 deg C.

Insufficient Operating Faulty Motor Check motor rotating speed (if electric,
speed and/or excessive check connection).
slip
Star/Delta insertion time If required time is too long, reduce it to
3s max.
Jammed or Braked driven Remove causes.
machine

Noise and vibration Alignment Check alignment

Faulty bearings Disassemble, check, replace bearings

(and relative seals).

Whistle Protection cover Avoid small air passages between cover

and machine.