18 Aug 2017

Autogard® Torque Limiters • Installation & Maintenance Manual

820 Series (Page 1 of 14)

AUTOGARD 820 SERIES TORQUE LIMITER INSTALLATION AND MAINTENANCE

Contents Page
1. General Notes & Tightening Torques.............................................................................................2
2. Principle of Operation.....................................................................................................................3
3. British Autogard Ltd
Installation — 820 Series Torque Limiter........................................................................................4
2 Wilkinson Rd., Love Lane Industrial Estate, Cirencester, Glos., GL7 1YT UK
4. Tel. +44 (0)1285 640333 – Fax. +44 (0)1285 659476
Torque Adjustment.........................................................................................................................8
5. Manual Disengagement (not applicable to Auto-Reset versions)..................................................8
6. [Link]/autogard
Resetting.........................................................................................................................................8
7. Removing Modules.........................................................................................................................8
8. Re-fitting of Existing Modules into a Torque Limiter.......................................................................9
9. Fitting New Modules to a Torque Limiter........................................................................................9
10. Switch Plate Removal and Refitting..............................................................................................11
11. Seat Replacement........................................................................................................................11
12. Routine Maintenance....................................................................................................................12
13. Fault-Finding.................................................................................................................................13
14. Spare Parts...................................................................................................................................13

Rexnord PT3-006 (DB0009)

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Autogard® Torque Limiters • Installation & Maintenance Manual
(Page 2 of 14) 820 Series

1. GENERAL NOTES & TIGHTENING TORQUES

1.1. This manual applies to Autogard 820 modular torque limiters types 1,2 and 3, and also special units derived from
these types.
1.2. This manual is to be used in conjunction with the specific assembly drawing for the unit. Unless otherwise specified,
all screwed fasteners should be secured with Loctite 243 and torque tightened to the values given in Table 1.

Table 1
Thread Size Tightening Torque (Nm) Tightening Torque ([Link])
M3 1.5 1.1
M4 3.3 2.4
M5 6.7 4.9
M6 11 8
M8 28 20
M10 55 40
M12 95 70
M16 236 174
M20 461 340
M24 797 588
1/4” UNF 13 10
5/16” UNF 27 20
3/8” UNF 49 36
1/2” UNF 117 86
5/8” UNF 233 172
3/4” UNF 407 300

1.3. Selection verification – The user is responsible to ensure that the unit ordered will in fact meet the duty requirements,
and that the duty has not changed from the time that the coupling was originally selected. Autogard can supply
details of the duty under which the unit was originally selected.

PT3-006 (DB0009) Rexnord

September 2018 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
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 2) Principle of Operation Autogard® Torque Limiters • Installation & Maintenance Manual
The 820 series modular torque limiters include hardened seats in one half of the unit and (Page 3 of 14)
820 Series
module sub-assemblies in the other half such that torque is transmitted between the plunger
and seat (see figs 1 and 2). This produces an end thrust in the plunger in proportion to the
2. applied torque.
PRINCIPLE This force is resisted by a ring of segments trapped between a flat surface and
OF OPERATION
The 820 series modular torqueloaded
a conical washer limitersby disc springs.
include hardened When
seatsthe axialhalf
in one force reaches
of the a level
unit and modulegreater than the in the
sub-assemblies
reaction through the spring mechanism, the plunger will retract forcing the
other half such that torque is transmitted between the plunger and seat (see figs 1 and 2). This produces an segments up theend thrust in
plunger slope and allowing it to disengage from the seat. The segments are then located
the plunger in proportion to the applied torque. This force is resisted by a ring of segments trapped between a flat surface on
thewasher
and a conical larger diameter
loaded byof discthesprings.
plungerWhen and all
theforces are balanced
axial force reaches ainternally allowing
level greater than thethe torquethrough the
reaction
limiter to run free and unloaded (except for the auto-reset version, which maintains some
spring mechanism, the plunger will retract forcing the segments up the plunger slope and allowing it to disengage from the
axial force on the plunger at all times).
seat. The segments are then located on the larger diameter of the plunger and all forces are balanced internally allowing the
torque limiter to run free and unloaded (except for the auto-reset version, which maintains some axial force on the plunger at
all times). The trip torque is externally adjustable and resetting may be manual or automatic, depending
on the application. Some 820 series units incorporate a limit switch plate, which moves on
The trip torque is externally adjustable and resetting may be manual or automatic, depending on the application. Some 820
trip and can operate a switch to stop the drive.
series units incorporate a limit switch plate, which moves on trip and can operate a switch to stop the drive.
A complete 820 series torque limiter may be supplied, in which case the modules will be
A complete 820 series torque limiter may be supplied, in which case the modules will be already fitted, or loose modules
already fitted, or loose modules may be supplied as components to be incorporated into the
may be supplied as components to be incorporated into the customer’s own design of torque limiter.
customer’s own design of torque limiter.

Figure 1 — Typical 820 Series Torque Limiter

Fig. 1 Typical 820 Series Torque Limiter

3) Installation – 820 Series Torque Limiter

Rexnord PT3-006 (DB0009)

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Autogard® Torque Limiters • Installation & Maintenance Manual
(Page 4 of 14) 820 Series

3. INSTALLATION — 820 SERIES TORQUE LIMITER

3.1 All Types

3.1.1. Unpack the unit and examine for any signs of transit damage. Ensure that the bores are free from burrs. Verify that
all parts have been properly supplied as per the order.
3.1.2. Before installation, ensure that the rotating equipment is isolated so that the installation can be carried out in a safe
manner.
3.1.3. There are a number of different arrangements depending on the application. Refer to the specific assembly drawing
for the unit. Unless stated otherwise the following will generally apply:
3.1.4. On large units tapped holes are provided to allow the use of lifting eyes for safe handling. The threads are M12, M16,
½” UNC or 5/8” UNC, depending on application.
3.1.5. For keyed hubs the standard clearance-fit bore should permit the hub to be pushed, pressed or lightly tapped in
place on the shaft. Do not strike heavy hammer blows on the hub as this could cause damage. Always use a soft-
faced hammer.
3.1.6. If interference-fit hubs have been specified, the hubs alone should be heated to 150°C (302°F) in an oil bath or an
oven prior to fitting. Do not use spot heat or exceed 300°C (572°C) as this may cause distortion.
3.1.7. The hubs should be positioned such that the end of the shaft is flush with the end face of the hub. Most units have
two cup point set screws to lock each hub in position on the shaft. When the hub is correctly positioned on the shaft
and the key is fitted, apply Loctite 243 or equivalent to the set screws and tighten.
3.1.8. On manual reset versions ensure there is sufficient clearance at the end of the modules to allow the use of a mallet to
strike the reset pin (see fig. 2). Also note the reset pins extend on trip by the dimensions shown in table 2. Check for
adequate clearance in the tripped condition.
3.1.9. For ease of maintenance, it is also recommended to allow sufficient clearance to withdraw the modules with the
unit installed. The required clearance is shown on the assembly drawing. This will allow the modules and seats to
be replaced more easily. Also, if the modules can be withdrawn, the unit can be disconnected from the hubs and
removed without the need to move the shafts or hubs.

Figure 2 — Typical Module Sub-assembly

Fig. 2 Typical module sub-assembly
Table 2.
PT3-006 (DB0009) Rexnord
September 2018 Unit Module sub-assembly 3001Reset pin/switch
W. Canal plate
St., Milwaukee, WI 53208-4200 USA
Supersedes 09/2017 866-REXNORD/866-739-6673 • [Link]
movement on trip
size
 Autogard® Torque Limiters • Installation & Maintenance Manual
820 Series (Page 5 of 14)

Table 2
Reset Pin/Switch Plate
Unit Module Sub-Assembly Size
Movement on Trip
820-1 Types 1,2,3 1 3.7mm (0.145 in)
820-2 & -3 Types 1,2,3 2 5.0mm (0.197 in)
820-4 Types 1,2,3 3 6.0mm (0.236 in)
820-5 Types 1,2,3 4 8.0mm (0.315 in)

3.1.10. On all versions ensure that access to the grease nipples in the end of the modules is possible (see fig. 2).
3.1.11. Threaded fasteners on flanges etc. should be secured with Loctite 243 or equivalent and torque tightened to the
values given in table 1, unless otherwise specified on the specific assembly drawing for the unit.
3.1.12. If the unit was supplied to a set torque this will be stated on the label. Otherwise see section 4 'Torque Adjustment'.
3.1.13. Some units are fitted with a limit switch plate, which moves axially on trip and can be used to operate a switch to
stop the drive. The movement on trip is shown in table 2.
3.1.14. With auto-reset units the drive should be stopped within a few seconds after trip, to minimise wear of the plungers
and seats (use limit switch, speed sensors or other methods). For manual reset versions the drive may continue to
run after trip.
3.1.15. 820 series units may be supplied with some unused module ports, which are fitted with blanking plates. This is often
the case when the torque requirement is uncertain, as it allows the torque capacity to be increased by adding extra
modules. Additional modules should be positioned such that they will not cause out-of-balance forces (eg. Add 2 off
modules diametrically opposite each other).
3.1.16. General Safety: In common with all mechanical devices, the user must ensure safe application and use of the
product with respect to local conditions, e.g. lifting applications, explosive environments etc. As a rotating
component, adequate guarding must be provided, in accordance with current codes of practice.

3.2 820 Type 1 and 2

3.2.1. Fit the S1 hub to its shaft and secure the locking set screws with Loctite 243.
3.2.2. If applicable, place the switch plate over the hub, ensuring the wide flanges of the plastic bushes are on the correct
side (see assembly drawing and fig.8)
3.2.3. Attach the module unit to the S1 hub, observing match marking if present (balanced units only). Apply Loctite 243 to
the fixing screws and torque tighten (see table 1).
3.2.4. Attach the switch plate (if applicable) as described in section 10
3.2.5. Fit the S2 hub to its shaft and secure the locking set screws with Loctite 243.

3.3 820 Type 1 only

3.3.1. Assemble the flexible buffers, sleeves,
washers and screws to the seat plate as
shown in fig.3, using Loctite 243 on the
screw threads and torque tightening to the
value specified in table 3.

Figure 3

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Autogard® Torque Limiters • Installation & Maintenance Manual
(Page 6 of 14) 820 Series

Table 3
820 Size Buffer Screw Size Hex Key Size A/F (mm) Tightening Torque (Nm)
1 M12 10 80
2 M16 14 197
3 M20 17 385
4 M20 17 385
5 M20 17 385

3.3.2. Bring the shafts together, engaging the flexible buffers in the holes in the S2 hub. Align the shafts to ensure that
gap ‘G’ and the angular and parallel misalignment are within the limits stated in table 4. Fix the shafts in the correct
position.

Table 4
820 Size Gap ‘G’ Min (mm) Gap ‘G’ Max (mm) Max Angular Misalignment Max Parallel Misalignment (mm)
1 3.0 9.0 0.25° 0.13
2 3.0 9.0 0.25° 0.13
3 3.5 10.5 0.25° 0.13
4 3.5 10.5 0.25° 0.13
5 3.5 10.5 0.25° 0.13

3.4 820 Type 2 only

3.4.1. Place the Samiflex ring over the S2 hub.
3.4.2. Bring the shafts together. Align the shafts to ensure that the gap between the coupling halves is correct (refer to
assembly drawing) and angular, parallel and axial misalignment are within the limits stated on the assembly drawing.
Fix the shafts in the correct position.
3.4.3. Rotate one half of the coupling to align the teeth, and fit the flexible element.
3.4.4. To fit the Samiflex ring, align the pins on the inside of the ring with the slots which run the full width of the elastic
insert. Tap the ring into position with a soft-faced hammer until the pins locate in the central holes in the elastic insert.
3.4.5. The ring is retained by two set screws which engage with holes in the elastic insert. Apply Loctite 243 and fit the
screws flush with the outside diameter of the ring.

3.5 820 Type 3 only

3.5.1. Position the shafts at the correct distance between shaft ends (see assembly drawing) and ensure angular, parallel
and axial misalignment are within the limits stated on the assembly drawing. Fix the shafts in this position.
3.5.2. Fit the S1 hub to its shaft and secure the locking set screws with Loctite 243.
3.5.3. If applicable, place the switch plate over the hub, ensuring the wide flanges of the plastic bushes are on the correct
side (see assembly drawing and fig.8)
3.5.4. Attach the module unit to the S1 hub, observing match marking if present (balanced units only). Apply Loctite 243 to
the fixing screws and torque tighten (see table 1).
3.5.5. Attach the switch plate (if applicable) as described in section 10.
3.5.6. The coupling will be supplied as a spacer/adaptor sub assembly including one flexring pack, with the S2 hub and its
flexring pack and fixings supplied separately.
3.5.7. Fit the S2 hub to its shaft, check the dimension from the hub face to the torque limiter face is correct to the assembly
drawing, and secure the hub locking set screws with Loctite 243.
3.5.8. Mount the spacer/adaptor sub-assembly on the spigot of the torque limiter as shown on the assembly drawing,
observing match marking if present (balanced units only). Apply Loctite 243 to the fixing screws and torque tighten
as per table 1. Support the spacer.

PT3-006 (DB0009) Rexnord

September 2018 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
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 3.5.8) Mount the spacer/adaptor sub-assembly on the spigot of the torque limiter as shown
on the assembly drawing, observing match marking if present (balanced units only). Apply
Loctite 243 to the fixing screws and torque
Autogard ®
tighten Limiters
Torque • Installation
as per table 1. Support the
& spacer.
Maintenance Manual
3.5.9) Rotate the S2 shaft to align the small holes of the S2 hub with the large holes of(Page
820 Series the 7 of 14)
coupling spacer.
3.5.9. Rotate3.5.10) Install
the S2 shaft threethe
to align of small
the drive
holesbolts
of thethough
S2 hubthe
withsmall holes
the large in the
holes hubcoupling
of the and then through
spacer. the
membrane pack and overload collar as shown in fig.3. Note the correct orientation of the
3.5.10. Install three of the drive bolts though the small holes in the hub and then through the membrane pack and overload
membrane pack - the integral thin washers should be adjacent to the overload collars Hand
collar as shown in fig.4. Note the correct orientation of the membrane pack - the integral thin washers should be
tighten
adjacent the
to the drive nuts.
overload collars. Hand tighten the drive nuts.

Figure 4 — Installation of First Three Drive Bolts

3.5.11) Install the three remaining drive boltsofthrough
Fig.3 Installation the drive
first three overload
boltscollar, the large holes in
thethe
3.5.11. Install hub, theremaining
three membrane pack
drive and
bolts the small
through holes incollar,
the overload the spacer as holes
the large shown in fig.4
in the Hand
hub, the tighten pack
membrane
andthe
thedrive
small nuts.
holes in the spacer as shown in fig.5 Hand tighten the drive nuts.

Figure 5 — Installation of Final Three Drive Bolts

Fig. 4 Installation of final three drive bolts
3.5.12. Remove the spacer support and tighten all drive nuts to the torque shown in table 5. The drive nuts are self-locking
and should be assembled dry - Loctite is not required.
3.5.12) Remove the spacer support and tighten all drive nuts to the torque shown in table 3.
The drive nuts are self-locking and should be assembled dry - Loctite is not required.
Table 3
Drive nut thread Drive nut A/F Nut tightening torque Nut tightening torque
(dry) Nm (dry) [Link]
Rexnord M12 19mm 50 37 PT3-006 (DB0009)
3001 W. Canal St., Milwaukee, WI 53208-4200 USA September 2018
M14
866-REXNORD/866-739-6673 22mm
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Autogard® Torque Limiters • Installation & Maintenance Manual
(Page 8 of 14) 820 Series

Table 5
Nut Tightening Torque Nut Tightening Torque
Drive Nut Thread Drive Nut A/F
(dry) Nm (dry) [Link]
M12 19mm 50 37
M14 22mm 76 56
M16 24mm 118 87
M18 27mm 160 118
M20 30mm 220 162
M22 32mm 300 221
M24 36mm 350 258
M27 41mm 600 443

4. TORQUE ADJUSTMENT
4.1. The torque limiter trip torque should be set high enough so that tripping does not occur under normal start-up and
running conditions, (noting that the start-up torque is often greater than the running torque), but not so high as to
reduce the level of protection against overload.
This may be achieved by trial and adjustment on site, or, if the required trip torque is known, by reference to the
calibration curve supplied with the unit. Some units are supplied factory-set to a specific trip torque (+/-5%), which
will be stated on the label. (Factory-set units can be adjusted on-site if necessary).
4.2. The trip torque can be adjusted by turning the adjuster (see fig. 2), clockwise to increase torque and vice versa.
If the required trip torque is known then the gap 'X' can be obtained from the calibration curve supplied with the
unit. Alternatively the setting can be determined on site, starting with a low setting, and progressively increasing it
until the unit starts and runs without tripping under normal load. In some applications it may be more convenient to
reverse this, starting with a high setting and progressively reducing it until tripping occurs on start-up or running, then
increasing it until the unit starts and runs without tripping.
Proceed as follows;
4.2.1. Ensure the torque limiter is engaged before adjusting the torque (see section 6).
4.2.2. Unscrew the three unpainted set screws which lock the adjuster hexagon on each module. Do not disturb the three
set screws which are sealed with red paint. Do not disturb the single clamp screw which is sealed with red paint. On
some units access to the set screws will be easier if the switch plate is removed (see section 10).
4.2.3. Adjust the gap 'X' by turning the adjuster on each module (ensure the module body does not turn) to give the
required torque as indicated by the calibration curve. Alternatively, if setting by trial, change the setting in
increments of 1/4 turn of the adjusters.
4.2.4. When the correct setting has been achieved apply Loctite 243 or equivalent to the locking set screws and re-fit.
(Note for size 1 module sub-assemblies only, fit the longest set screws which will fit without protruding from their
holes when tightened against the module body. Use 3 off M3 cup point set screws, length 6mm, 8mm or 10mm).
4.2.5. If the switch plate was removed re-fit it (see section 10).

5. MANUAL DISENGAGEMENT (NOT APPLICABLE TO AUTO-RESET VERSIONS)

To manually disengage the torque limiter rotate the disengaging sleeve (smaller of the two hexagons – see fig. 2) on each
module in a clockwise direction through several turns until it reaches its stop (note this is a left-hand thread).

6. RESETTING
6.1. Manual Reset versions: Ensure that the disengaging sleeve (smaller hexagon) is tightened anti-clockwise against
the adjuster (larger hexagon) on each module. Rotate either the input or output member of the torque limiter until
the markers on the periphery of both members are in alignment. Tap the reset pins with a soft-faced mallet until they
spring back to the engaged position.
6.2. Auto-Reset versions: The torque limiter will reset automatically with a loud 'click' each time the modules are aligned
with their corresponding seats.

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 Autogard® Torque Limiters • Installation & Maintenance Manual
820 Series (Page 9 of 14)

7. REMOVING MODULES
7.1. Reset the torque limiter before removing the modules (see section 6). Do not attempt to remove a module which
has not been reset. The energy stored in the spring when the module is tripped could cause injury or damage
to the module.
7.2. If the modules are to be re-used, mark them to identify which port they fit into.
7.3. If a switch plate is fitted, remove it, referring to section 10.
7.4. Remove the four fixing screws from each module clamp ring, but do not disturb the single clamp screw (sealed with
red paint) which locks the clamp ring to the module body.
7.5. Withdraw the module, complete with clamp ring, from the unit. If it is tight, use levers under the chamfered edges of
the clamp ring.
7.6. Do not attempt to trip or reset a module which is not fitted into a torque limiter. The energy stored in the
spring when the module is tripped could cause injury or damage to the module.

8. RE-FITTING OF EXISTING MODULES INTO A TORQUE LIMITER

8.1. If existing modules are to be re-fitted into their original ports with the original module seats, and the module clamp
screws have not been disturbed, proceed as follows; (otherwise proceed as for new modules – see section 9).
8.2. Rotate either the input or output member of the torque limiter until the module ports are aligned with the seats. Apply
grease to the seats (see section 12 for suitable grease).
8.3. Fit the first module, complete with clamp ring, into its original port. Apply Loctite 243 or equivalent to the mounting
ring fixing screws and tighten progressively to the torque shown in table 1.
8.4. Fit the remaining modules in a diametrically opposite sequence to reduce unbalanced loading of the bearing.
8.5. If a switch plate was fitted, re-fit it, referring to section 10.
8.6. Lubricate the modules as described in section 12.1.2.

9. FITTING NEW MODULES TO A TORQUE LIMITER

9.1. Do not attempt to trip or reset a module which is not fitted
into a torque limiter. The energy stored in the spring when
the module is tripped could cause injury or damage to the
module.
9.2. Rotate either the input or output member of the torque limiter
until the module ports are aligned with the seats. Apply grease
to the seats (see section 12.1.2 for suitable grease).
9.3. The axial position of the module bodies in relation to the main
unit is important, to obtain the correct preload of the plungers.
Proceed as follows for each module:
9.4. Ensure that the manual disengage sleeve (see fig. 2) is
tightened (left hand thread) against the adjuster. If the modules
are not pre-set for a specific torque, it is important to ensure
that there is some preload in the module. To achieve this,
back off the adjuster locking set screws, then turn the adjuster
clockwise until resistance is felt, plus one further turn.
9.5. Take the module and place under a hand press, supported on
the adjuster, with the plunger uppermost (see fig. 6).
9.6. Press on the plunger so that it moves approximately 1mm and
then slowly release the force so the plunger springs back. This
ensures the segments inside the module are in contact with the
cone of the plunger. Figure 6 — Preparing a Module for Fitting
Fig.5 Preparing a module for fitting

Rexnord 9.6) Press on the plunger so that it moves approximately

PT3-006 1mm and then slowly re
(DB0009)
3001 W. Canal St., Milwaukee, WI 53208-4200 USA force so the plunger springs back. This ensures the segments inside
September the module ar
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with the cone of the plunger.
Autogard® Torque Limiters • Installation & Maintenance Manual
(Page 10 of 14) 820 Series

9.7. Screw the clamp ring onto the module as far as it will go by hand, with the chamfers towards the plunger end of the
module. Fit the clamp screw without Loctite, tighten, then loosen slightly so the module can just rotate in the clamp
ring.

Figure
Fig.6 7Fitting
— Fitting a New
a new Module
module
9.8. Fit the module into its port, and tap on the end of the adjuster hexagon (not the reset pin) with a mallet to make sure
9.9)
the Rotate
module theseated
is fully clamp(seeringfig.
or 7).
module body and use feeler gauges to obtain the specified gap
between the ring and the main unit (see table 4), whilst maintaining hand pressure on the
adjuster or module body to keep the module seated.
9.9. Rotate the clamp ring or module body and use feeler gauges to obtain the specified gap between the ring and the
main unit4.(see table 6), whilst maintaining hand pressure on the adjuster or module body to keep the module seated.
Table
Table 6 Unit Module Clamp Ring Gap Clamp Ring Gap Clamp Screw Torque
sub-assy (except Auto- Auto-Reset
Clamp Ring Gap Clamp Ring Gap
Unit size Sub-Assy Size
Module Reset) (except Auto-Reset) Auto-Reset
Clamp Screw Torque

820-1820-1 types
Types 1,2,3 1 1 0.20mm (0.008”) 0.25mm
0.20mm (0.008”) (0.010”) 3.3 Nm
0.25mm (0.010”) (2.4 [Link])
3.3 Nm (2.4 [Link])
1,2,3
820-2 & -3 Types 1,2,3 2 0.25mm (0.010”) 0.38mm (0.015”) 6.7 Nm (4.9 [Link])
820-4 Types 1,2,3
820-2 & -3 2 3 0.25mm (0.010”) 0.38mm0.38mm
(0.015”) (0.015”) 0.51mm (0.020”)
6.7 Nm (4.9 [Link])
28.0 Nm (20.6 [Link])
820-5 Types 1,2,3 4 0.51mm (0.020”) 0.76mm (0.030”) 55.0 Nm (40.6 [Link])
types 1,2,3
820-4
9.10. Mark types of the3module0.38mm
the position (0.015”)
body in the clamp ring.0.51mm
Remove (0.020”) 28.0
the clamp screw, NmLoctite
apply (20.6 243
[Link])
or equivalent
and refit, tightening to the torque specified in table 6, without rotating the clamp ring relative to the module body.
1,2,3
4 for each
9.11. Repeat stages 9.4 to 9.10
820-5 types 0.51mm (0.020”)
module. 0.76mm (0.030”) 55.0 Nm (40.6 [Link])
9.12. For each module, align the four holes in the clamp ring with those in the main unit, apply Loctite 243 or equivalent to
1,2,3
the four screws and tighten progressively to the torque specified in table 1.

9.10) inMark
Repeat the position
a diametrically of thesequence
opposite module for
body
the in the clamp
remaining ring. Remove
modules. the clamp screw,
9.13. If apply Loctite
a switch 243fitted,
plate was or equivalent and refit,
re-fit it, referring tightening
to section 10. to the torque specified in table 4, without
rotating the clamp ring relative to the module body.
9.14. Lubricate the modules as described in section 12.1.2.
9.11) Repeat stages 9.4 to 9.10 for each module.
9.15. Adjust the torque setting of the modules if necessary (see section 4).
9.12) For each module, align the four holes in the clamp ring with those in the main unit,
apply Loctite 243 or equivalent to the four screws and tighten progressively to the torque
specified in table 1.
Repeat in a diametrically opposite sequence for the remaining modules.
9.13) If a switch plate was fitted, re-fit it, referring to section 10.
PT3-006 (DB0009) Rexnord
September 2018 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
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12
 9.15) Adjust the torque setting of the modules if necessary (see section 4).
Autogard® Torque Limiters • Installation & Maintenance Manual
820 Series (Page 11 of 14)
10) Switch Plate Removal and Refitting
10.1) Some units are fitted with a limit switch plate. A typical arrangement is shown in fig.7.
10. SWITCH PLATE REMOVAL AND REFITTING
Refer to the specific assembly drawing for further detail. To remove the switch plate, use a
10.1. Some units are fitted with a limit switch plate. A typical arrangement is shown in fig.8. Refer to the specific assembly
spanner on the reset pin flats (behind the switch plate) to prevent rotation, and remove the
drawing for further detail. To remove the switch plate, use a spanner on the reset pin flats (behind the switch plate) to
retaining nuts, and
prevent rotation, taking
removecarethetoretaining
retain the springs
nuts, andtoplastic
taking care bushes.
retain the springs and plastic bushes.

Figure 8 — Typical Switch Plate Mounting

Fig.7 Typical switch plate mounting
10.2. On re-assembly, ensure that the parts are fitted in the correct positions. Apply Loctite 243 or equivalent to the switch
plate retaining nuts. Hold the reset pin hexagon with a spanner to prevent rotation, and ensure that the retaining
nuts are pushed through the plastic bushes as they are tightened, to avoid trapping the plastic bush between the
10.2) Onnutre-assembly,
retaining and reset pin. ensure that the
Check thread sizeparts are fitted
and torque intothe
tighten the correct
followingpositions.
value; Apply Loctite
243 or equivalent to the switch plate retaining nuts. Hold the reset pin hexagon with a
spanner
Thread Size toTightening
preventTorque
rotation,
(Nm) and ensure that the retaining nuts are pushed through the plastic
bushes
M12 as they are 10 tightened, to avoid trapping the plastic bush between the retaining nut and
reset pin. Check thread
M16 30 size and torque tighten to the following value;

11. Thread size Tightening torque

SEAT REPLACEMENT
11.1. Remove the modules as described in section 7.
M12 10Nm
11.2. Remove the screw from the centre of the seat. Remove the seat using an extractor screwed into the tapped hole
M16 30Nm
in the centre of the seat (see table 7 for thread size). The force from the extractor should be reacted by the metal
surrounding the seat, so that the torque limiter bearing is not loaded. A suitable arrangement is shown in fig. 9.

Table11)
7 Seat Replacement
Unit Module Sub-Assembly Size Thread Size in Seat
11.1) Remove the modules as described in section 7.
820-1 Types 1,2,3 1 M6
11.2)
820-2 Remove
& -3 Types the screw from
1,2,3 2 the centre of the M8
seat. Remove the seat using an extractor
screwed
820-4 into the tapped hole
Types 1,2,3 3 in the centre of the seat (see table 5 for thread size). The force
M12
from the extractor should be reacted by the metal surrounding the seat, so that the torque
820-5 Types 1,2,3 4 M16
limiter bearing is not loaded. A suitable arrangement is shown in fig. 8.

13

Rexnord PT3-006 (DB0009)

3001 W. Canal St., Milwaukee, WI 53208-4200 USA September 2018
866-REXNORD/866-739-6673 • [Link] Supersedes 09/2017
 11.3) To fit the new seat first ensure that the hole is free from old adhesive. Degrease the
hole and the new seat, and apply Loctite 641 or equivalent to the outside diameter of the seat.
Autogard
Push the
®
Torque Limiters
new seat • Installation
fully home and fit the& seat
Maintenance Manualusing Loctite 243 or equivalent
retaining screw,
on 12
(Page theofthread,
14) and torque tighten to the value given in820 table 1. Remove any excess adhesive.
Series
11.4) Lubricate the seats and fit the modules, referring to sections 8 or 9 as appropriate.
11.3. To fit the new seat first ensure that the hole is free from old adhesive. Degrease the hole and the new seat, and apply
Loctite 641 or equivalent to the outside diameter of the seat. Push the new seat fully home and fit the seat retaining
screw, using Loctite 243Fig.8 Method
or equivalent on of
theremoving
thread, andseat
torque tighten to the value given in table 1. Remove any
excess adhesive.
11.4. Lubricate the seats and fit the modules, referring to sections 8 or 9 as appropriate.

Figure 9 — Method of Removing Seat

12) Routine Maintenance

12. 12.1) All Types
ROUTINE MAINTENANCE
12.1.1) The frequency of maintenance will depend on the operating environment and number
12.1 All Types
of trips, but once every three months should be adequate in most applications. Proceed as
12.1.1. The frequency of maintenance will depend on the operating environment and number of trips, but once every three
follows:
months should be adequate in most applications. Proceed as follows:
12.1.2)
12.1.2. A greaseA grease
nipple isnipple
locatedisinlocated ineach
the end of the end of each
module, module,
and some and some
units have units
additional havenipples
grease additional
for the
grease
bearings and the module seats. Apply a good quality lithium grease such as Shell Alvania R3 orgrease
nipples for the bearings and the module seats. Apply a good quality lithium BP Energrease LS3
such as grease
to all Shell Alvania R3 or BP
points. A general Energrease
inspection LS3
of the unit to allalso
should grease points. atAthis
be performed general inspection
time, checking of fasteners
that all
theare
unit should
tight etc. also be performed at this time, checking that all fasteners are tight etc.
12.1.3. For manual disengage versions each module should be manually disengaged then reset as part of the maintenance
12.1.3) For manual disengage versions each module should be manually disengaged then
procedure (refer to sections 5 and 6).
reset as part of the maintenance procedure (refer to sections 5 and 6).
12.1.4. For unusual conditions such as high ambient temperatures, high vibration or dirty environment, special maintenance
may be required. Please consult Autogard.

12.2 820 Type 1 only

14
12.2.1. Periodic inspection of the flexible buffers is recommended. Remove each sub-assembly by removing the fixing
screw, and withdrawing the buffer, washers and sleeve. The buffer sub-assembly should be replaced when the
wall thickness of the elastomeric part reaches the minimum value shown in table 8. All buffers in the unit should be
replaced at the same time.

Table 8
Unit Minimum Wall Thickness
820-1 Type 1 3.3mm (0.130 in)
820-2 Type 1 4.7mm (0.185 in)
820-3 Type 1 5.0mm (0.197 in)
820-4 Type 1 5.0mm (0.197 in)
820-5 Type 1 5.0mm (0.197 in)

12.2.2. Re-assemble as described in section 3.3.1.

PT3-006 (DB0009) Rexnord

September 2018 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 09/2017 866-REXNORD/866-739-6673 • [Link]
 12.2.2) Re-assemble as described in section 3.3.1.
Autogard® Torque Limiters • Installation & Maintenance Manual

12.3) 820 Type 2 only 820 Series (Page 13 of 14)

The condition of the elastic insert should be checked after the first 3000 hours, and at
12.3 820 Type 2 only
convenient intervals thereafter. The life of the insert under average conditions will be
approximately
The condition of the 25000
elastic inserthours.
should Proceed asafter
be checked follows:
the first 3000 hours, and at convenient intervals thereafter. The
life of the insert under average conditions will be approximately 25000 hours. Proceed as follows:
12.3.1) Remove the two locking set screws from the Samiflex ring.
12.3.1. Remove the two locking set screws from the Samiflex ring.
[Link].3.2)
Move theMove thethering
ring over over
S2 hub. the S2 hub.
[Link].3.3)
Remove Remove
the elastic the elastic
insert insertforand
and inspect inspect
wear, fortowear,
referring fig. 10 referring toDiscard
and table 9. fig. 9 and tableif 7.
the insert it is worn beyond
Discard the insert if it is worn beyond the limit shown.
the limit shown.

Figure 10 — Inspecting the Elastic Insert for Wear

Table 9 Fig.9 Inspecting the elastic insert for wear

Unit Dimension ‘h’ Minimum Dimension ‘X’ Maximum
820-1 Type 2 28.0 mm (1.102 in) 6.0 mm (0.236 in)
820-2 Type 2 36.0 mm (1.417 in) 7.5 mm (0.295 in)
820-3 Type 2 37.5 mm (1.476 in) 7.5 mm (0.295 in)
820-4 Type 2 42.0 mm (1.654 in) 8.5 mm (0.335 in)
820-5 Type 2 60.0 mm (2.362 in)
15
10.0 mm (0.394 in)

12.3.4. Re-assemble using either the existing insert or a new insert, as appropriate, referring to sections 3.4.3 to 3.4.5.

13. FAULT-FINDING
See table 10. If in doubt consult Autogard. For contact details see [Link]/autogard

14. SPARE PARTS

For spare module sub-assemblies or other parts, consult Autogard, quoting the part number and serial number from the
label on the torque limiter body. For contact details see [Link]/autogard
If the modules are being replaced because they are worn it is also advisable to replace the seats.

Rexnord PT3-006 (DB0009)

3001 W. Canal St., Milwaukee, WI 53208-4200 USA September 2018
866-REXNORD/866-739-6673 • [Link] Supersedes 09/2017
Autogard® Torque Limiters • Installation & Maintenance Manual
(Page 14 of 14) 820 Series

Table 10 — Fault-Finding
Fault Possible Cause Action

Fault in driven machine Rectify

Torque setting too low Adjust trip torque

Frequent Tripping All modules not reset (manual reset) Reset all modules

Module not resetting (auto-reset) Lubricate or replace module

(possible lack of lubrication)

Worn module plungers or seats Replace worn parts

Torque setting too high Adjust trip torque

Failure to Trip on Overload Module seized (possible lack of lubrication) Manually disengage (not auto-reset) lubricate or replace module

Torque limiter bearing seized Replace bearing

Modules loose or incorrectly fitted Follow installation procedure

Worn module plungers or seats Replace worn parts

Excessive Backlash
Worn torque limiter bearing Replace bearing

Worn coupling or loose fasteners Replace worn parts, tighten fasteners

PT3-006 (DB0009) Rexnord

September 2018 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 09/2017 866-REXNORD/866-739-6673 • [Link]