Ex COMPONENTS FOR HAZARDOUS AREAS Engine Bellhousings & JXL Anti-Static, Flameproof Flywheel Couplings Installation & Maintenance Instructions 03 19 Quality Products for Mechanical & Fluid Power
jbj Techniques Limited 28 Trowers Way, Holmethorpe Industrial Estate Redhill, Surrey RH1 2LW United Kingdom telephone: 01737 767493 fax: 01737 772041 email: email@example.com www.jbj.co.uk jbj Techniques Limited of the address given above confirm that Engine bellhousings and JXL anti-static flywheel couplings of serial number: ....................................................................................................................................................................... have been produced in accordance with the requirements specified within: Directive 2014/34/EU Harmonised Standards: BS EN ISO 60079-0:2018 BS EN ISO 80079-36:2016 BS EN ISO 80079-37:2016 BS EN 1834-1:2000 BS EN 1834-3:2000 Ex h I Mb Ex h IIC TX Gb Ex h IIIC TX Db -50°C ≤ Service Temp ≤ 105°C Intertek dossier receipt number: G102928206 Client: .................................................................................................................................................................................................... Date: ........................................................................................................... .......................................................................................................................... Signed by Mike Davis (Managing Director) Separation of this certiicate from the remaining pages of this documentation will render it ineffective. 1 of 6 EX Component EC Declaration of Conformity Certificate Number .0002 Note Tx = Maximum surface temperature depends on operating conditions. (see notes on page 3). Ex Apparatus for Inclusion in Ex Equipment Correct installation and actual surface temperature when incorporated into completed equipment is the responsibility of the machine builder.
Standard SAE Flywheel Non-Standard Flywheel technical department, For details please contact: Dimension ‘e’ can be machined to various sizes typically from 10 to 62 mm, this can further be increased using spacers. or email: firstname.lastname@example.org tel: 01737 767493 jbj Techniques Ltd manufacture bespoke spacers in-house. 2 of 6 Engine Bellhousing and JXL Anti-Static Flame Proof Flywheel Coupling
Engine Bellhousing and JXL Anti-Static Flame Proof Flywheel Coupling 3 of 6 The coupling pins are tightened to the correct torque prior to leaving jbj Techniques Ltd; these values should be re-checked prior to installation. Under no circumstances should the couplings be assembled with the pins tightened to any torque other than the specified values. Mounting This guide is for the installation of JXL flywheel couplings when an engine bellhousing is used. In most cases the diameter of the hub is smaller than the centre locating diameter of the bellhousing. The hub passes through the bore in the bellhousing which connects the pump with the flywheel housing. In this case the installation can be carried out as follows: 1) Fit the drive flange to the engine flywheel and tighten bolts to enginemanufacturers recommendations. 3) Fit the coupling hub to the pump shaft, position the hub suitably to obtain the correct setting distance (see the arrangement drawing if supplied), tighten grub screw(s) or L-Lock screw(s) if the pump has a splined shaft and re-check the setting distance. Coupling hubs with cylindrical bores are supplied with an additional grub screw at 90° to the keyway. If the additional grub screw is not to be used it must be removed from the coupling hub. the housing and that no rotating component is within 5mm of any non-rotating component and tighten bolts to the engine manufacturer’s recommendations. Tightening Torques for JXL Couplings Maintenance 2) Fit the bellhousing to the engine flywheel housing and tighten bolts to enginemanufacturers recommendations. If the additional grub screw is not to be used it must be removed from the coupling hub. For the occasional case where the hub diameter is larger than the bore in the bellhousing, the installation should be carried out as follows: 3) Fit the pump centring to the pump (when supplied) then fit the coupling hub to the pump shaft, position the hub suitably to obtain the correct setting distance, (see arrangement drawing if supplied), tighten grub screw(s) or L-Lock screw(s) if the pump has a splined shaft, and re-check the setting distance. Coupling hubs with cylindrical bores are supplied with an additional grub screw at 90° to the keyway. If the additional grub screw is not to be used it must be removed from the coupling hub. 1) Fit the drive flange to the engine flywheel and tighten bolts to enginemanufacturer’s recommendations. 2) Fit the bellhousing to the pump. 4) Offer up the pump, coupling hub and bellhousing to the engine flywheel housing ensuring that there is no loosematter i.e. grub screws, washers, etc. remaining inside Tighten all bolts to the correct torque values. We recommend the use of shake proof washers with all bolts. 4) Fit the pump and coupling hub to the bellhousing ensuring that there is no loose matter i.e. grub screws, washers, etc. remaining inside the housing and that no rotating component is within 5mmof any non rotating part. Periodically check flange alignment and resilient elements for wear. Worn elements must We recommend the resilient elements are inspected on an annual basis. be replaced and are available from jbj Techniques. Please quote serial number. Misalignment must be rectified. Inspection and maintenance is the responsibility of the end user. Note All couplings plus or minus 50% of flange gap (dimension C) setting distance. Axial Misalignment All JXL couplings are capable of accepting a momentary overload of twice nominal torque and have an operating temperature range of -50°C to +105°C. TX note During operation bellhousings and JXL couplings do not generate heat therefore operational surface temperature will depend on the temperature of mating components and surroundings. Refer to BS EN ISO 80079:36 11.2f) Equipment ‘T’ class or maximum temperature (T max) to be determined by machine builder but must not exceed 105°C.
4 of 6 Engine Bellhousing and JXL Anti-Static Flame Proof Flywheel Coupling Typical Arrangement. Diesel engine, 85 hp At 2,000 rpm. Hydraulic pump, spline 12/24 DP 14 teeth, shaft SAE C 2 bolt flange. Special Design With Spacer. Diesel engine, 490 hp at 1,950 rpm. Hydraulic pump with extended cylindrical shaft.
Safety related information. Resilient element bolt tightening torque Shipment date Type 1 Type 3 Type 4 5 of 6 Coupling assembly part number Traceable serial number Part number of individual component ATEX Marking Information ASY JXL 55/12/S11.5/14TX70CL P/N RL3/060/021 ELEMENT BOLT TORQUE 9.2 Nm Ex Components for Hazardous Areas JBJ - RH1 2LW - UK Ex h I Mb Ex h IIC Tx Gb Ex h IIIC T105°C Db Certificate No: YY.0002 Equipment Group I EPL Mb - mines Equipment Group II EPL Gb Gas Group IIC Maximum surface temperature 105°C (See note on certificate page 3) Equipment Group III EPL Db dust group IIIC Maximum surface temperature 105°C (See note on certificate and page 3) jbj Techniques Limited, 28 Trowers Way Holmethorpe Industrial Estate, Redhill Surrey RH1 2LW, United Kingdom S/N 123456 DD/MM/YY Marking to BS EN ISO 80079-37:2016 -50°C ≤ Service Temp ≤ 105°C Service temperature
Coupling Housing ATEX Marking Information 6 of 6 Ex Components for Hazardous Areas
Getting the most out of your machinery often depends on close integration between all components. An organisation that manufactures and integrates all the diverse components of a drivetrain provides the experience to help you select the best component combination for your application. jbj Techniques’ in-house design team and manufacturing facility provide tailored solutions for your applications at competitive prices with quick delivery. The following examples are a simplistic view of how jbj Techniques assists customers. Hydraulic Adaptors Designed primarily to allow the close coupling of hydraulic pumps to a variety of prime movers, such as diesel / petrol engines, electric, air or hydraulic motors, they can also be used in the connection from prime mover to alternative driven parts i.e. gear boxes, generators, water or vacuum pumps etc. An additional range of engine front PTO adaptors, which provide additional connection between the engine pulley and the driven part are also available. The kit comprises of a and flexible bellhousing drive that are fully machined to suit the coupling driving and driven components. These can be to suit either shaft to shaft, flange (flywheel) to shaft or even flange to flange connections. Getting the most out of your equipment will demand close integration between all components. In specifying jbj Techniques as your preferred supplier, you will have selected a company with the experience to specify, manufacture and integrate all of the diverse components that will ensure the best component combination for your application. jbj's in house design team and manufacturing facility provide tailored solutions for your applications at competitive pricing and on-time deliveries. Pump shaft alignment is key to preventing unnecessary wear and damage to the pump shaft seal and bearing. Improper alignment may lead to premature pump failure. Also to be considered are unwanted torsional resonant frequencies in the system which can quickly cause damage to components in the drivetrain and reduce system life and performance. Improper pump installation can lead to premature failure, increased maintenance costs and reduced production levels of final product. jbj Techniques can advise on the correct installation of into Industrial / hydraulic pumps mobile / marine / machine tool / agricultural / offshore industries and can specify complete driveline systems from their extensive range of components which are available from stock or manufactured to order, albeit simple or complex, standard or bespoke. Electric Motor – Hydraulic Pump Adaptors (safe area) jbj Techniques Limited offer the most comprehensive range of in Europe. bellhousings Designed to connect electric motors with frame size IEC D56 - D400 (0.06kW – 750kW) and can be compatible with electric motor 'B5' or 'B14' flange configurations. Accompanying the metric frame units above is a complete range of mountings to suit Nema and imperial frame motors with 'C' face or 'D' flange fitments. With fully machined , torsionally flexible couplings or available, jbj ensure torsionally rigid couplings the most suitable combination is selected for the application in hand. As an example spider couplings are available in various materials including aluminium, grey cast iron, nodular iron, steel and stainless steels and can be finish machined with parallel, taper or splined bores to DIN, SAE, ANSI or ISO standards. Bellhousings can be manufactured in aluminium or cast iron material as standard, however, units can be produced in a variety of exotic materials on request. The aluminium product range is produced in either monoblock or composite formats giving great flexibility in design and allows for early delivery time, often with same or next day delivery possibilities. For applications where low noise levels are a quality products for mechanical & fluid power #DriveLineHarmony www.jbj.co.uk an excellence in engineering
ensuring a continuing high quality service in which customers can have complete confidence. “ “ requirement then a complete range of antivibration and noise reduction components add to the range. Electric motor – Hydraulic Pump Adaptors (hazardous area) Designed to meet the exacting safety standards of the offshore and chemical process industries, jbj Techniques produce certificated to adaptor kits Directive 2014/34/EU II2GD-IM2-TX -50 C< Service Temp < +105 C. Harmonised standards BS EN 1127:1, BS EN 13463:1, BS EN13463:5, BS EN 50303, BS EN 1834-1,BS EN 1834-3. Generally manufactured in Cast or Nodular iron, bellhousings can be produced in steel, stainless steel or alternative exotic materials on customer request. Couplings supplied for these applications are the jbj Techniques 'JXL' pin and bush range which provide an anti-static and flameproof drive which meet zone 1 area requirements, conforming to all of the above standards. Also available are spider and gear couplings which are certified to zone 2 standards. (Contact jbj Techniques for details). An important development of equipment for use within hazardous areas is the wet mount series of bellhousings. Commissioned to research and develop a product that would control the high temperature generated by a piston pump shaft seal when working within cycling applications. A little considered issue is the frictional heat generated at the shaft seal when the application requires the pump to cycle between different pressures causing the seal temperature to increase. This process will often take the seal temperature out and above the levels required by the relevant ATEX standards requirement. This specially designed assembly allows a pumped cooling flow to be passed over the seal face and through an auxiliary cooler, this in turn reduces the seal face temperature which can be maintained at an acceptable level. With a vast array of components to select from, jbj are well placed to provide all required components to support the required cooling system. Diesel Engine – Hydraulic Pump Adaptors A complete range of bellhousing and couplings exist for the connection of a diesel engine flywheel to a specified driven component, be it an oil hydraulic pump, water pump, generator or similar device. With the bellhousing available in various materials to suit all application areas. With a standard range to connect Diesel engines with SAE dimensions from SAE '6' to SAE '0' jbj are well placed to satisfy the majority of customer requirements. Couplings to complete the assembly are available in either torsionally flexible or torsionally rigid design ad can be supplied to suit SAE flywheel dimensions from SAE 6.5” to SAE 18”. For hydraulic pumps to be mounted to engines that do not conform to SAE dimensions, we offer a full range of assembly parts, some of which (but not all) are shown here » for diesel engines All bellhousings within this range can be finished machined to accept any, piston, vane or gear pump interfaces requested by customer. As with the electric motor range of product jbj offer complete solutions for ATEX environments, using our well proven 'JXL' coupling range which has standard design to connect to the engine flywheel. Directive 2014/34/EU II2GD-IM2-TX -50°C ≤ Service Temp ≤ +105°C. Harmonised Standards: BS EN 1127:1 BS EN 13463:1 BS EN 13463:5 BS EN 50303. Petrol Engine – Hydraulic Pump Adaptors Petrol engine adaptors have been developed for use with industrial petrol engines. Design exists to suit Honda, Briggs and Stratton, Kawasaki, Kubota, Hatz, Mag, Robin, Suzuki, Winsconsin, to name but a few, all adaptors can be finished to accept most hydraulic pumps. Adaptors to suit engine crankshaft drives and for vertical mounting are available on request. #DriveLineHarmony www.jbj.co.ukl to Large Combinations Small Individual Components
to Large Combinations from Small Individual Components ensuring a continuing high quality service in which customers can have complete confidence. “ “ # Driveline jbj Techniques is a specialist supplier of high-quality products for the mechanical power transmission and fluid power sectors. The company offers a high level of in-house expertise plus a huge selection of products to meet a very broad range of customer applications. From specification, through technical advice and manufacture to after-sales support, jbj Techniques provides a comprehensive and valued service to the power transmission and hydraulics industries. The company fields a UK-wide team of technical sales engineers to ensure that the business is close to its customers, and it enjoys excellent associations with European manufacturers, acting as sole UK distributor in many cases. jbj’s team is recognised for its expertise in the selection and configuration of hydraulic and mechanical transmission systems. Able to draw on an that extensive product range provides the building blocks for bespoke systems both large and small, the in-house design team offers a complete service, ranging from an assessment of customer requirements to full technical backup, including product specification, CAD based system design, system build and certification. Moreover customers can take advantage of jbj’s own machine-shop facilities and skilled engineers guarantee to quality and control costs. jbj Techniques provides one of the widest ranges of couplings available within the UK; mechanical power transmission couplings for a vast range of applications. Ranging from miniature couplings, all steel gear couplings, flexible spider couplings, shaft couplings, torque limiting couplings, disc and grid type couplings, ATEX compliant and shaft locking devices. Magnetic couplings for power transmission between hermetically sealed areas. However as extensive as the selection is, couplings make up a fraction of jbj’s portfolio. As power transmission specialists the company stock and provide gearboxes, clutches, pumps, hydraulic motors, flow meters, fluid power accessories including: cooling & heat exchange products, reservoirs, pipe flanges, seals and level indicators, as well as a variety of bellhousings and engine adaptors, to name just a few of the product categories. jbj Techniques Limited is proud of it’s relationship and reputation with customers and suppliers. The core client base is stable and loyal, which is testament to the quality of service provided by the company. A similar relationship exists with suppliers, ensuring a continuing high quality service in which customers can have complete confidence. Dampers Engine Adaptor Kits Hydraulic Adaptors Torque Limiting Couplings Tyre Couplings Anti-static/Flameproof Couplings Torsionally Rigid Couplings Torsionally Flexible Couplings Bellhousings Permanent Magnetic Couplings Torsional Couplings
ne Harmony comprehensive range of components www.jbj.co.uk an excellence in engineering 01737 767493 email@example.com www.jbj.co.uk - registered in England No: 1185469 - jbj Techniques Limited is ISO certificated, committed to international coordination & unification of industrial standards. A range of products ATEX certificated to directive 94/9/E requirements Screw Pumps Pneumatic Motors & Starters Gear Pumps/Motors Axial & Radial Piston Motors Vane Pumps LSHT Motors/Geared Motors Splitter Gearboxes Planetary Gearboxes BDS Clutches BD Clutches & Gearboxes Oil Bath Clutches Flow Dividers Tanks/Accessories Fluid Level Indicators Flanges Mini Power Packs Coolers Pressure Intensifiers You Tube
registered in England No: 1185469 jbj Techniques Limited is ISO certificated, committed to international coordination & unification of industrial standards. A range of products ATEX certificated to directive 94/9/EC requirements jbj Techniques Limited 28 Trowers Way Holmethorpe Industrial Estate Redhill Surrey RH1 2LW. UNITED KINGDOM 01737 767493 firstname.lastname@example.org www.jbj.co.uk quality products for mechanical & fluid power You Tubewww.jbj.co.uk