A L L ATION &

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INSTR C E O F GEA
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INSTRUCTIONS FOR INSTALLATION & MAINTENANCE OF GEARED COUPLING
Geared couplings are delivered without lubricant. The coupling parts
should be stored in dry surroundings.
Before installation, all parts of the coupling should be thoroughly cleaned.
Use light oil for cleaning, to remove rust preventive agent and to pre-
vent foreign matters mingling therein. Damage to lip seals, O-rings and
the metal sealing surfaces should be strictly avoided.
INSTALLATION
1. Mounting of hubs with rectangular, tangential or tapered keyed
connections.
Grease pack the lip seal in the end cover and slide it into
the correct position on the hub which should then be drawn onto the
shaft ends to the desired installation position. With normal fits (H7/m6
or k6) the need for axial locations to the hubs can often be eliminated.
2. Mounting the hubs with shrink fit.
Push the end cover with a seal to the correct installation
position to the shaft in such away that the seals are not touched or
damaged by the hot hubs. Heat hubs (About 140 C max.) either in an oil
bath or by induction heater or on a heating plate or by means of ring
burner until they can easily be pushed on to the shafts. Avoid heating of
teeth surfaces directly with flame.
3. Installation of the housings
Oil or grease the teeth of the teeth of the hubs and the
housing. Push the housing on to the hub in away that distance “N” oth-
erwise the complete tooth contact of Hub and Housing will not be en-
sured thereby reducing the life of the coupling.
4. Alignment
Axial distance “N” (feeler gauge) and straight alignment of
the two hubs (straight edge, light-cap-free contact) to be checked at
different points on the circumference (fig.1, fig.2). Completely assembled
coupling is to be also checked, (as Shown fig.2.).
It is very much essential to align the coupling accu-
rately. The coupling’s life depends on the amount of misalign-
ment. In case of large misalignment coupling’s life will be reduced
considerably.
5. Connecting the housing halves.
Push the housing halves together and connect by means of
the fitted bolts. The housing should be able to move easily without the
end cover.
6. Mounting the connected end cover.
Cover the sealing surface of the end cover with sealing
compound and affix to the housing.
7. Exchanging a sealing
Disconnect the end cover with the damage seal from the
housing. Push the housing as far as possible on the second hub. Re-
move the damaged seal. Glue the new seal (split) over the hub.
Before re-mounting the end covers the metal sealing sur-
faces should be cleaned and covered with sealing compound.
8. Lubrication
Before putting the coupling into operation, it must be filled
with the correct amount of oil/grease as indicated in the chart. After
filling, the filler holes must be plugged with the screw threads treated
with a suitable compound to give good sealing. It is also recommended
that keyways be sealed either by a sealing compound like Bond silicon,
Hermoseal SS60F or an end cap with fitted ‘O’ ring.
MAINTENANCE
For oil lubricated couplings, the oil must be renewed every 8000
hours of operation. In addition, regular (6 months) checks should be
made between oil changes to ensure that the correct oil level is main-
tained . For grease lubricated couplings, the level should be checked at
8000 hours and at regular intervals (6 months) to ensure correct levels.
It is recommended that grease be renewed at 2 years interval.
The first oil/grease change should take place before 3 months
in operation.
To exchange lubricating oil for the first time, dismantle the coupling after
three month - throughly clean away inside to remove used oil and abra-
sive powder etc. reassemble it so that same teeth before dismantling
are meshed each other again. Thereafter supplement or exchange oil
from the oil plug hole every six months.
When using grease, ensure that the recommended quantity of
grease is applied on the coupling teeth (internal & external) to such an
amount that their addendum cannot be seen any more and assemble
them in. After tightening the coupling casing, fill the casing with speci-
fied amount of grease from the oil plug hole by the use of grease gun
etc.
When exchanging grease dismantle the coupling and exchange
the entire used grease.
Grease lubrication is inferior or the oil lubrication in its lubricat-
ing performance.
Axial displacement of the housing part should also be checked
during all inspections. If it is not easily movable, a check can be made
with end covers loosened. Re-alignment should be carried out as nec-
essary.
Damaged seals (lip type or O-rings) must be replaced. Split
replacement seals are available which can be glued together after be-
ing placed over the shaft. For replacement, the lubricating medium must
be drained and the end covers loosened. Before reassembly. all metal
sealing surfaces should be cleaned and treated with a sealing com-
pound wherever necessary.
Maintenance Checks:
1. Check for vibration and noise
2. Check for leakage
3. Check for damages on gear teeth
4. Check for damages and deterioration of ‘O’ ring
5. Check for deterioration of oil
Checks mentioned above in 1 & 2 can be made by observing
from outside after comparing with condition under normal operation.
The other checks should be carried out every six months by
dismantling the coupling.
In case of high ambient temperature, frequent overloaded con-
dition, frequent reversion operation, large parallel misalignment and
angular misalignment, ensure that the checking intervals are short-
ened.
Note:
Correct initial installation, accurate alignment, usage of
right quantity and quality of lubricant will ensure longer life and
smooth/trouble free operation of the coupling.
RECOMMENDED QUANTITY OF OIL/GREASE

Size 63 112 190 300 560 900 1500 2240 3000 3750 5600
of oil or grease (liters)
MInimum quantity

BZWG 0.07 0.10 0.18 0.31 0.13 0.15 0.23 0.37 0.52 0.70 0.80

BZGR 2*0.35 2*0.05 2*0.09 2*0.16 2*0.06 2*0.08 2*0.12 2*0.19 2*0.26 2*0.35 2*0.40

BZWE 0.02 0.048 0.048 0.077 0.065 0.06 0.12 0.15 0.25 0.35 0.40
max. speed oil = 160 140 140 130 120 110 100 90 90 90 90
min. speed grease

Size 7500 10600 14000 18000 21200 26500 30000 35500 45000 56000 67000
of oil or grease (liters)
MInimum quantity

BZWG 0.9 1.25 1.65 1.75 2.5 2.8 3.0 3.2 4.5 5.0 5.5

BZGR 2*0.45 2*0.63 2*0.83 2*0.88 2*1.25 2*1.4 2*1.4 2*1.6 2*2.25 2*2.5 2*2.75

BZWE 0.45 0.65 0.85 0.85 1.2 1.4 1.55 1.75 2.5 - -
max. speed oil = 80 75 70 70 65 65 60 60 65
min. speed grease

For these couplings oil lubrication should only be used up to this speed.
At higher speeds an oil ring is formed and the necessary fitting level could result
in leakage through the keyway when the coupling is at rest. It is planned to grease
lubricate below this speed, then the coupling must be entirely grease packed. For
verticle installations greae/Oil requirements available on request.

RECOMMENDED OIL/GREASE

OIL TYPES INDIAN OIL INDROL (CASTROL)

+10 C TO +80C
o
SERVOMEHS CASTROL ALPHA
ISO VG 680 SP 680 LS680

SERVOGEM CASTROL
GREASE TYPE
EP-2 BALL BEARING
MULTI PURPOSE
EPL-2
GREASE WITH

EP-ADDITIONS

TEMP.RANGE

-20C TO +100C

Note :
In case of high amblent temperature, frequent overloaded condition, frequent reversing operation,
large parallel and angular misaligment, it is recommended to use high viscous gear oil of 70-110 cst at 100c.
 CORPORATE OFFICE
Elecon Engineering Company Ltd.
Anand Sojitra Road, Vallabh Vidyanagar - 388120, Gujarat, India.
Phone : 91-2692-31170, 31070, 31120, Fax : 91-2692-36559
E-mail: Gear division : bjbabaria@mhe.elecon.com
MHE division : jnshah@gear.elecon.com

SINGAPORE OFFICE E-mail: elecon_sing@eleconsingapore.elecon.com

Elecon Singapore Pte. Ltd. INTERNATIONAL BUSINESS DIVISION
10 Anson Road, #19-13 International Plaza, Singapore -
Elecon Engineering Company Ltd.
079903.
418, 4th floor, World Trade Centre, Babbar Road, New Delhi - 110
Phone : 65-227-8258, 65-227-8425, Fax : 65-227-8942

001.
Phone : 11-341-4339, 341-4341, 341-4069, 341-4634,
Fax : 11-370-9046 E-mail: sales@delemtici.elecon.com.

SELLING AGENT
EMTICI Engineering Ltd.,
Phone : +91-2692-30168, 31082, 31419, 31125
Fax : +91-2692-36508
E-Mail : sales_emtici@emtici.elecon.com

EAST ZONE WEST ZONE SOUTH ZONE

CALCUTTA AHMEDABAD CHENNAI

Phone : +91-33-4761861, 4760876, Ph. No. : +91-79-6406683,84,85,86 Phone : +91-44-4349237, 4349497, 4349643,
4760904, 4760926 Fax No. : +91-79-6401363 4322455
Fax : +91-33-4761831 E-mail : sales@ahdemtici.elecon.com Fax : +91-44-4349643
E-Mail : sales@calemtici.elecon.com E-mail : sales@cheemtici.elecon.com

ASANSOL MUMBAI BANGALORE

Phone : +91-341-205901, 202038, 211726 Phone : +91-22-2821315, 2820725, Phone : +91-80-2260219, 2281834, 2250082
Fax : +91-341-202038 2821365, 2870792, 2815693 Fax : +91-80-2281834
E-Mail : sales@asnemtici.elecon.com Fax : +91-22-2870791 E-Mail : sales@blremtici.elecon.com
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Phone : +91-326-306283, 302320 Phone : +91-20-4330646 Phone : +91-40-7844748, 7845250, 7846984
Fax : +91-326-302320 Fax: +91-20-4330646 Fax : +91-40-7848317
E-Mail : sales@dhnemtici.elecon.com Email : sales@puneemtici.elecon.com E-Mail : sales@secemtici.elecon.com

JAMSHEDPUR VALLABH VIDYANAGAR

Phone : +91-657-428138, 435382 Phone : +91-2692-30168, 31082, NORTH ZONE
Fax : +91-657-428015 31419, 31125
E-Mail : sales@jsremtici.elecon.com Fax : +91-2692-36508 NEW DELHI
E-Mail : sales_emtici@emtici.elecon.com Phone : +91-11-3414339,
3414341, 3414069, 3414634
BILASPUR Fax : +91-11-3709046
Phone : +91-7752-47347, 28922, 24122 CENTRAL ZONE E-Mail : sales@delemtici.elecon.com
Fax : +91-7752-23188
NAGPUR
E-Mail : sales@bspemtici.elecon.com
Phone : +91-712-540771, 531601
Fax : +91-712-531450
E-Mail : sales@ngpemtici.elecon.com

3000/1/2001 Manual No. 04/G/1/2001