Installation & Maintenance

Instructions

Coupling : LGF-432H-EMH-1025(490) /
4174 SPL. CPLG.
Drg. No. : R/LM-4174
CLIENT : BHEL , HYDERABAD.

CONTENTS

1) General Notes
2) Requirements
3) Cautions
4) Attention
5) Handling & Storage
6) Before Installation
7) Installation Instructions
8) Removal Instructions
9) Maintenance Instructions
10) Recommended Spares
1) GENERAL NOTES
• It is essential that all the Instructions contained in the following documents be carried out by a
competent person. Should any problem be anticipated or encountered then Rathi
Transpower Pvt. Ltd. personnel are available for site visits or, alternatively, repairs and
overhauls can be undertaken in our works. The persons responsible for selection, handling,
installation, use & maintenance shall require & understand these instructions.
• Prior to performing any maintenance work (including inspections) it is essential that the
power supply is isolated and that no accidental movement of rotating machinery is possible.
• This product is designed for a specific purpose. It is vital that it is not used for any purpose
other than that for which it is designed and supplied, and that the limits of it’s capacities, as
detailed here or in any other document, are not exceeded.
• No liability will be accepted and any other warranty, either expressed or implied, will be null
and void should any component of whatever kind, including nuts, bolts and washers, be used
in the assembly, or modifications be made to all or part of the product which are not supplied,
specified or agreed by Rathi Transpower Pvt. Ltd.

2) REQUIREMENTS
• The following instructions should be read and understood prior to starting any assembly or
maintenance work on the disc coupling.
• Prior to fitting any component, care should be taken to ensure that it is clean and free from
any dirt.
• Where hub/shaft connections require a standard interference fit the hubs may be heated in oil
at 200-250°C and rapidly positioned on the shaft. It is essential that this heat is evenly
applied over the whole hub and that spot heating is avoided.

3) CAUTIONS
• Do not use any component that is not supplied or approved by Rathi Transpower Pvt. Ltd. in
the assembly of this product.
• Do not attempt to lift the coupling, or component parts, without first ascertaining their weight
from drawings or data sheets. The use of lifting equipment may be necessary.
• The inherent balance of these couplings could be disturbed if they are knocked either by
striking or rolling. Care must be taken when transporting and fitting to avoid such knocks.
This is particularly important when a coupling has been carefully balanced and designed to
run at high speed.
4) ATTENTIONS
• IMPORTANT: The necessity for shields & guards varies with individuals installations. The
owner or user must provide the required safety guards. Safety guards or shields are not
furnished by us with this equipments.

For all technical queries please contact -

Rathi Transpower Pvt. Pvt. Ltd.
Rathi Chambers, 7, Deccan College Road, PUNE – 411 006 (INDIA)
Phone : 91-20-30517201, Fax: 91-20-30517212
E-mail : enquiry@rathigroup.com , Website : www.rathitcouplings.com
5) HANDLING & STORAGE
The coupling is normally dispatched with standard commercial packing and the case should contain
a copy of required documentation. During transport the transit screws will be in a position to ensure
that the elements are not in free state. The coupling should be stored in this condition. On receipt
and also immediately before assembly, all the items should be checked to ensure that they are all in
good condition and free of damage. The coupling should be stored horizontally. It should be
protected against corrosion if stored for long periods or outdoors.

6) BEFORE INSTALLATION :-

* Remove the coupling from packing & thoroughly inspect for signs of damage.
* For motor end half coupling :- disassemble the coupling by removing grid, nuts & bolts. Clean all
the parts carefully.
* Remove protective coatings / lubricants from bores & keyways.

7) INSTALLATION INSTRUCTIONS

The gearbox end disc-pack coupling bolts & nuts are factory tightened by Rathi Transpower Pvt. Ltd.
and are not to be disturbed since it may affect the balance of the coupling.
Following installation procedure shall be followed:-
1. Bring the shaft ends of driver and driven machinery together and check that the distance
between shaft ends is as close as possible to the 490 mm.
2. Coupling is must be dismantled as shown in fig. of installation procedure (Ref. attached
installation procedure)
3. Fit respective hubs onto driver and driven shafts and align them using your chosen method.
The hub face should be flush in line with shaft end. The misalignment shall be less than ¼th
of the maximum misalignment values given on the assembly drawing. Rathi Transpower do
not recommended any specific alignment method as many methods are available. The lowest
values of misalignment ensure long and trouble free operation of the coupling & connected
machinery. It is recommended to note down the initial alignment readings.
4. At this stage before any further assembly takes place, provision shall be made to align match
marks on the coupling components.
5. After fitment the both end hub then transmission unit could be easily inserted between two
hub faces (kindly note that before inserting transmission unit the gear-box end gagging screw
tighten & compress the element assembly (Ref. fig.3).
6. Position the coupling transmission unit between two hub faces, ensuring all relevant match
marks and attachment bolt holes are aligned. The coupling transmission unit shall be
supported to ensure that the weight is not imposed on the joint during assembly.
7. Insert attachment bolts (bolt between gear-box end -hub to adapter from the transmission
unit) in position and release the gagging screw carefully & evenly, making sure that the
spigots and recesses are properly seated. Note: Do not torque tighten the attachment bolts
before removing the gagging screw.
 8. FOR MOTOR SIDE GRID COUPLING ASSEMBLY PROCEDURE: -

(i) Grid Assembly:-

Insert gasket (If provided) through the gap and support on either hub or shaft. Before inserting the
grid segments, thoroughly pack the grooves with the specified lubricant. When grids are supplied in
two or more segments assemble so the cut ends at a segment joint extend in the same direction.
Spread the grid slightly so that it will pass over the coupling teeth, and tap all the rungs into the
respective slots with a soft mallet. (Refer Fig.)

(ii) Cover Assembly:-

Remove lube plugs to ease cover assembly. Slide cover halves, complete assembly with seal (If
provided), on to hubs. Position lube holes at 180°apart. Align cover and gasket (If provided) bolt
holes and fasten flanges together using the bolts & nuts. Insert the gasket (if provided) between
cover in std. V/H coupling and for spacer type, between one of the cover & spacer along with spacer
plate. Position the flanged cover with lubrication plugs.
9. Greasing:-
Fill with recommended grease/oil (RSG/RSL) with required qty. (approx 2.81 Kg.) lubrication for
LGF coupling. Tighten the lubrication plug. Change the grease after the interval of 3 months.
(Use Loctite to prevent the loosening of threads, if required.)

IMPORTANT: The necessity for shields & guards varies with individuals installations. The owner or
user must provide the required safety guards. Safety guards or shields are not furnished by us with
this equipment.

10. Motor end grid coupling disassembly and Grid

removal. :-

Whenever it is necessary to disconnect the

Coupling, remove the cover halves and grid. A
Round rod or screw driver can be a convenient
Tool to remove the grid.(As shown in fig.)
 11. Torque tighten the attachment bolts. The tightening torque mentioned on Assembly drg. shall
be maintained on attachment bolts.
12. Ensure that all match marks are aligned, all transit bolts are removed, all the fasteners are
correctly tightened and all the coupling components are in good condition before operating
the machine.

8) REMOVAL INSTRUCTIONS
Coupling removal is the reverse of the installation process – Ensure that on reinstallation the process
is followed in careful sequence.

9) MAINTENANCE INSTRUCTIONS
General maintenance of the coupling consists of a check of the following during normal machinery
maintenance schedules.
• Axial, Angular & Parallel misalignment to ensure that these are still within the acceptable
limits and that no major movements have occurred. It is recommended that a record of
misalignment readings is maintained.
• All bolts to ensure that they are correctly tightened.
• The flexible elements, by visual inspection, for signs of fatigue cracking local to the washer
anchoring points or general signs of fretting corrosion. Slight bowing or “S” like distortion is
not detrimental to the operation of the unit. Note that any cracking will begin at the outermost
edge of the outside blade. This means that, this inspection is still possible without disturbing
the element bolting.
• Rathi Transpower use self locking nuts. This gives a high level of performance over many
reinstallations. It is recommended by Rathi Transpower that these be replaced after being re-
torqued 8 to10 times.
Note : Any requirement for spare parts should be made quoting the original purchasers original
purchase order number and the coupling drawing number. Suggested maintenance intervals are:-
ii) 12 months
iii) At planned machine down time intervals.

10) RECOMMENDED GEAR-BOX END DISC CPLG. SPARES :

Sr. No. Part Description Qty/Coupling Recommended Qty.
1 Shim Pack 1 Nos. 1 Nos.
2 Bolts with Lock Nut 1 Sets 1 Sets