AGBsBARREL

COUPLING
Assemblyandmaintenanceinstructions
GOSANS.A.
Pol.Ind.GranadaC1
E48530Ortuella
Vizcaya,SPAIN
Tel.:+34946642423
Fax:+34946640603
www.gosan.net

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SCOPEOFRESPONSIBILITY.
The information and data compiled in this technical
manualmaybemodifiedwithoutnotice.
GOSAN S.A. will not accept any claims whatsoever on
the grounds of the lack of information contained in this
manual.
The technical specifications as well as the specified
data are subject to possible modifications that serve to
improvethecapacityandsafetyofthefinalproduct.

INTELLECTUALPROPERTYREGULATIONS.
The contents of this manual are governed by the
internationalintellectualpropertylegislation.
No part of this technical manual may be reproduced,
storedordisclosedinanyform,exceptwithinthelimitsof
the legislation on intellectual property rights, without the
priorwrittenauthorisationofGOSANS.A.

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Table of Contents

Operating instructions manual _________________________________________________________ 4

Intended use of the AGBs couplings ____________________________________________________ 4
Safety regulations __________________________________________________________________ 4
Transport and storage _______________________________________________________________ 6
Technical instructions ________________________________________________________________ 7
Installation _______________________________________________________________________ 10
Assembly of coupling in the gear box shaft ______________________________________________ 12
Bolted connections _________________________________________________________________ 14
Alignment of the coupling ____________________________________________________________ 14
Lubrication _______________________________________________________________________ 15
Before commissioning check _________________________________________________________ 17
Up and running __________________________________________________________________________ 18
Maintenance ______________________________________________________________________________ 19

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OPERATINGINSTRUCTIONSMANUAL:

This technical manual compiles all the necessary instructions for the
installation and commissioning, as well as the maintenance tasks required
for the proper operation and long service life of the AGBs couplings. This
manualis suppliedwiththecouplingandshouldalwaysbekeptaccessible
and near the coupling. All legal requirements applicable at the location of
theinstallationmustbecompliedwith.

INTENDEDUSEOFTHEAGBsCOUPLINGS:
GOSANs AGBs couplings have been designed exclusively for cable
drumsforuseinhoistliftingmechanisms.Itservestotransmittorquesand
radialloadsbetweenthegearboxandthecabledrum.

Any other use or misuse may result in bodily harm. Noncompliance

of the rules on intended use or the non compliance with the instructions
shallbethesoleliabilityoftheuserandshallgiverisetothemanufacturers
warrantybecomingnullandvoid.
SAFETYREGULATIONS:
The AGBs couplings for cable drums must be used only under
conditions where the permitted load capacity in accordance with GOSANs
AGBsbarrelcouplingscatalogueisnotexceeded.

The GOSAN drumcoupling is suppliedfully assembled. The lubricant

whichissuppliedwiththecouplingisintendedtofacilitatetheassemblyof
the various components reason why it is necessary to add a suitable
lubricantforitssubsequentproperoperation.Modificationsthataffectthe
operational reliability are strictly prohibited. No modifications may be
carried out without the prior authorisation of GOSAN, since that would
implythevoidanceofthewarranty
Should the coupling that is supplied have a roughing hole, its
disassembly must be carried out so as to perform the machining to the
necessary extent. Once the machining has been completed, in its

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subsequentassemblythehubandsleevemustbealignedsoastocoincide
withtheopeningofthehubwiththoseofthesleeve.

Personnel related to installation and maintenance of coupling

operations must haveread and understood everythingthat is contained in
thismanual,beforeattemptingtoinstall,maintainorcarryoutmaintenance
operations. The starting up or carrying out of maintenance operations by
unqualifiedandnonauthorisedpersonnelisstrictlyprohibited.

Before any work is commenced using the coupling switch the motor
offandensurethatitcannotbeunintentionallyswitchedon.
Fortransport,operation,maintenanceordisassemblytheregulations
onoccupationalhealthandsafetyandenvironmentalprotectionapplicable
tothelocationmustbecompliedwith.

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TRANSPORTANDSTORAGE:

The GOSAN drum couplings are supplied fully assembled, although

the lubricant with which the coupling is supplied is intended only to
facilitatetheassemblyofthevariouscomponentsreasonwhyitisnecessary
toaddasuitablelubricantforitssubsequentproperoperation.

When delivered, the couplings include an appropriate treatment for

itssubsequentstorage,whichvaryaccordingtothefollowingcases:

Openrooms
3months
Closedroomswithhighairhumidity
12months
Closeddryrooms
18months

Therelativeairhumiditymustnotexceed65%.Caremustbetakento
ensurethatnocondensationoccurs.Thesealsmustnotbestoredtogether
withchemicals,solvents,fuels,acidsetc.

WARNING:

As a rule only use cranes or hoists which are suitable to lift the
loadstobetransported.

Theliftingdevicesusedfortransportmusthaveanadequateload
capacity.

No one should be standing in the load movement area so as to

prevent possible risks due to falls, which is a lifethreatening
danger!

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TECHNICALINSTRUCTIONS:

Fasteningoftheset:

There are two types of screws intended for fastening the coupling, which
differ in terms of its role. Listed below are the accessories as well as the
maximumtorquesfortheboltsused:

Fasteningcouplingswithdrum(notsupplied)

ScrewsaccordingtoDIN931,DIN933orDIN6914withastrengthclass
of 10.9 must be used. it can be supplemented with washers according to
DIN6916.

Table1
Strength
class

Fasteners
acc.to

10.9

DIN931,
DIN933,
DIN6914

Max.torque(Nm)*
M12

M16

M20

M24

M30

115

290

560

970

1950

*Africtioncoefficientvalueof0.14willberequiredtodeterminethetorque.

Fixingcoverswithsleeve

BoltsaccordingtoDIN912withastrengthclassof8.8aresupplied.

Table2
Strength
class

Fasteners

8.8

DIN912

Max.torque(Nm)*
M6

M8

M10

M12

10

23

46

80

*Africtioncoefficientvalueof0.14willberequiredtodeterminethetorque.

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WARNING:

Consideration should be given to the maximum admissible torque

forthetighteningofthescrews.Shouldthetorquebeexceeded,the
couplingmaybreak.Usewrencheswithtorquelimiters.

SecureallscrewsusingathreadlockersuchasLOCTITE222orsimilar
inordertopreventloosening.

Theappropriatecouplingforeachusemustbeselectedsothatthe
permitted load capacity according to GOSANs AGBs barrel couplings
catalogueisnotexceeded.

Machiningoffinishbores:

The maximum admissible finish bores are those specified in the

selectiontableofGOSANsbarrelcouplingstablewhicharedesignedforkey
connections accordingto theDIN6885Standard,Sheet 1, and whichmust
notonanyaccountbeexceeded.

Given the need to machine the inner hole of the coupling, the
followingstepsmustbecarriedout:

1. Cleanthepartstoremoveanytracesofanycorrosioninhibitors.

2. Position hub to the chuck as shown in Figure 1 before drilling the

innerdiameterofthefinishbore.

3. WARNING!Thesealbearingsurfacesmustnotbedamaged.

4. Centreandalignbeforemachiningtheinnerfinishborediameter.

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5. TodeterminetheadmissibleconcentricitytolerancesrefertotheDIN
ISO286StandardtolerancegradeIT7.

6. Aftermachiningthehole,cleanthehubandreassemblethecoupling
foritssubsequentinstallation.

Figure1

WARNING:

Should the maximum admissible diameter of the coupling be exceeded,

the coupling may break. The parts tossed in the air are a risk to personal
safety.

The coupling hub must be fixed onto the gearbox output shaft with a
suitableoversizedevicetopreventaxialshifting.

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INSTALLATION:

Beforeinstallation,note:

WARNING:

Beforeperforminganyworkonthecouplingswitchthemotoroff.

Ensurethatthemotorcannotbeunintentionallyswitchedon.

For transporting the coupling use only appropriate lifts or means of

transport.

Ensure that the coupling surfaces, the area where the seals rest and
theinnerdiameterofthejointarenotdamagedduringtransport.

Priortostartingtheinstallation,disassemblethecouplingandcleanall
parts. The surfaces must be clean, dry and free of grease. For this
function.whenusingsolvents,followthemanufacturersinstructions.

Pay attention to the correct positioning of the wear indicator, wear

markandalignmentsurface(Figure2).

After pushing the coupling hub into place, it must be in contact with
theshaftshoulderorspacerringonthegearside.

The use of blows to force the coupling hub into place in its working
positionshouldbeavoided.

Tightenallboltedconnectionswiththeappropriatetorque.

SecureallscrewsusingathreadlockersuchasLOCTITE222orsimilar
inordertopreventloosening.

All work must be carried out with great care and always paying
attentiontosafety.

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Figure2

WorkingpositionIndicator

Indicatocenteredwithregardstowearmark

Surfacealignment

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ASSEMBLYOFCOUPLINGONGEARBOXSHAFT:

Couplinghub/shaftconnectionsbymeansofkeyways:

Boththeshaftandtheinteriorofthehubmustbefreeofallandanydirt.

Tofacilitateassemblyandsoastoavoiddamagetothesealsthecoupling
maybeheatedinanoilbathatamaximumtemperatureof80.

Theuseofblowstoinsertthehubintotheshaftshouldbeavoided.

Thesleevemustallowaxialdisplacement.

Secure all screws using a threadlocker such as LOCTITE 222 or similar in

ordertopreventloosening.

Couplinghub/shaftconnectionsbymeansofinterference,withoutkeyway:

The outer cover, sleeve, guide ring and barrels must be disassembled
beforehand.

Fittheoutercoverwithitssealontotheshaft.

If it is envisaged that there will be sufficient space to mount the fixing

screw,theymaybeinsertedintheirslotsonthecover.Checktheallowance
Y(Figure3)accordingtothefollowingtable:

Couplingsize
Min.allowanceY
(mm)

65
75

85
120

135
145

175
230

280

290
300

315
400

425
450

45

50

55

70

75

85

95

100

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Figure3

Slowly and uniformly heat the hub to the required temperature

(dependingonthedegreeofinterferencewiththeshaft).Asaguideline,a
temperatureofabout200250isusuallysuffice.Thistemperaturemustnot
be exceeded and excessive local overheating must be avoided, taking care
to prevent contact with the hub seals, so that they do not sustain any
damageduetotemperature.Continuewiththeassemblyafterallowingthe
hubtocool.

Mountthesleeveonthehubpayingregardtotherelativepositionofthe
mountingmark.

Insert the barrels in their corresponding housings and fasten them by

meansoftheguidering.

Lightlygreasetheoutercoverwithsuitablegrease(seeTable3).Position
theoutercoverwithitscorrespondingsealandscrewitontothesleeve.The
wearindicatormustbepositionedasshowninFigure2.

Thesleevemustallowaxialdisplacement.

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WARNING:

Useappropriatetoolstopositiontheseals.

Takecaretoavoidburnswhenhandlinghotparts.

BOLTEDCONNECTIONS:

Tofastenthehubcouplingtothecabledrum,boltsaccordingtoDIN
931, DIN933 or DIN6914 of strength class 10.9 and the prestressed high
tensilewashersaccordingtotheDIN6916Standardmustbeused.Allbolts
mustbetightenedwithatorquewrenchtothevaluesgiveninTable1.

The tightening bolts for the covers shall be according to DIN912,

strengthclassof8.8andthewashersusedshallbeAETforboltsaccording
toDIN912.Allboltsmustbetightenedwithatorquewrenchtothevalues
giveninTable2.

WARNING:

Theappropriatetoolsmustbeusedtotightenandloosenthebolts.

SecureallscrewsusingathreadlockersuchasLOCTITE222orsimilar
inordertopreventloosening.

ALIGNMENTOFTHECOUPLING:

Prior to drilling the fastening holes for the support of the drum
bearing, the drum must be aligned axially with respect to the couplings
hub. To this end, the front edge of the indicator fixed on the outer cover
must be aligned with the groove on the hub. The tolerances specified in
Table4willbetakenintoaccount.

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Table4

Couplingsize
65175
205400

Tolerance(mm)
+/0.5
+/1.0

Subsequently,thealignmentofthewindingdrumwithrespecttothe
gearboxoutputshaftismadebymeasuringthedistanceX,atfourpoints
offsetat90fromeachotherasshowninFigure3.Thedifferencebetween
thefourdimensionsXtakenmustnotexceedthevaluesgiveninTable5.
Table5

Drum
diameter
(mm)
1000
>1000

Distance
between
max.and
min.min.X
0.5mm
0.8mm

WARNING:

Thesumoftheangularandradialoffsetmustnotexceedadeflection
of1.

LUBRICATION:

For the assembly of the coupling and the cable drum and always
beforethecomingintoserviceofthemechanismalonglubricantpipetobe
supplied by the customer must be inserted and screwed into the oil hole
which is located on the outer cover of the coupling (next to the wear
indicator).

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WARNING:

If the filling of the lubricant does not correspond to the prescribed

volume, there is a risk that the coupling will become a source of
ignition.
.
SecureallscrewsusingathreadlockersuchasLOCTITE222orsimilar
inordertopreventloosening.

Thefillingofthecouplingshouldalways becarriedoutwithoutload
and beforethe mechanism operations commence. The lubricant should be
KP2KgreaseaccordingtotheDIN51502Standardoralubricantgreaseof
thesamequality.Table3showsthetypesofgreasesthatmaybeused:

Table3

Manufacturer
BP
CASTROL
KLBER
MOBIL
SHELL
TEXACO
TOTAL
FUCHS

Productname
EnergreaseLSEP2
SpheerolEPL2
CENTOPLEX2EP
MobiluxEP2
AlvaniaEP(LF)2
MULTIFAKEP2
MULTISEP2
RENOLITH443HD88

If none of the above lubricants are available, the lubricant to be used,

must,withoutexception,havethefollowingproperties:

- DesignationasperDIN51502KP2KStandard
- ConsistencyasperNLGIclass:2
- Operatingtemperaturebetween20Cand100C
- Baseoilviscosity:>150mm/sat40C
- EPAdditives:Required
- Corrosioninhibitors:Required

PleaseconsultGOSANfortemperaturesabovethespecifiedrange(20a
100C).

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QuantityofgreaseforAGBscouplings
AGBs

75

85

95

105

120

135

Greasequantity(dm3) 0.06 0.14

0.17

0.18

0.19

0.22

0.23 0.25 0.33 0.42

230

280

290

300

315

355

Greasequantity(dm3) 0.43 0.44

0.67

1.00

1.05

1.20

1.30 1.40 1.44 2.12

AGBs

65

205

145

400

175

425

190

450

BEFORECOMMISSIONINGCHECK:

Thesumoftheangularandradialoffsetmustnotexceedadeflection
of1.
Before first use check whether all bolted connections have the
prescribedtorqueandcorrectseal.
Before commissioning, check that the coupling has been filled with
thesufficientquantityofalubricantsuitableforthatcoupling.
The coupling must be completely airtight so as to avoid the
introductionofforeignbodies.
Beforefirstuse,allnecessaryprotectivedevicesmustbefittedsoas
topreventaccidentalcontactwithfreelymovingparts.
Turn the motor off immediately should you discover any
abnormalitiesduringcommissioningoroperation.

WARNING:

Theproperalignmentofthecouplingwillprolongitsservicelife.

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UPANDRUNNING:

Pay attention to possible changes in the running noises, vibrations

and leakages. Should any of the above behaviour be noted during
operation,turnoffthemotorimmediately.

Troubleshootingpossibleerrorsandsolutions.
Problems
Solutions
Alignmenterror.
Correctalignment
Incorrectlubricant.
Checkandcorrecttypeoflubricant.
Toolittlelubricant.
Imbalance.
Vibrations.
Wornteeth.
Looseboltedconnections.
Overloading.

Fillwithlubricant.
Checkbalanceweightsofthesystem
components
and
correct
if
necessary.
Checkthecouplingpartsfordamage
andreplaceifnecessary.
Tightenboltstothespecifiedtorque
andfasten.
Check coupling design, and install a
largercouplingifnecessary.

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MAINTENANCE:

GOSANsbarrelcouplingsmustbeservicedandlubricatedatregular
intervals. The complete changing of the lubricant will be carried out as
shown in the below table. To this end, the new lubricant will be inserted
throughaloadtubelocatedontheoutercover,expellingalltheusedgrease
fromtheoverflowoutlet.

FEM1.001

Operatinghours

LubricationInterval*

M3M6

2,000hrs

Min.onceevery2years

M7M8

3,000hrs

Min.onceayear

*Seetheaboveparagraphforthequantitiesoflubricantrequired

Thefollowingchecksmustalsobecarriedoutatleastonceayear:

- Axial setting of the coupling: Check the distance X as shown in

Figure3.

- Examinationofseals:Replacethesealsifanydeteriorationisnotedin
theirlips.

- Verification of the bolted connections: if any of the screws are

observed to be in a bad state, it is recommended that all screws be
changed,applyingthenecessarytorque,accordingtoTables1and2.

- Verification of the internal wear of thetoothing: The position of the

wear indicator relative to the slot in the coupling should be noted,
since the relative position between both parts indicates the wear of
the coupling. This coupling is originally supplied with the indicator
centred relative to the slot (Position A). When the indicator mark
reaches the slot limit, it is necessary to replace the entire coupling
(PositionB).

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Whenthecouplingisbeingusedintwoloaddirections,themaximum
admissible wear values must be divided by two m/2. It should be
specified when making the purchase order, so as to have the
correspondingwearnotch.

Couplingsize

Max.permissiblewearm/2

6595

4mm

105175

6mm

190400

8mm

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