KTR REVOLEX KX / KX-D Operating/Mounting Instructions

REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
KTR-N
Sheet:
Edition:
49412 EN
1 of 21
4
REVOLEX® KX / KX-D
Type SB with brake disk
Flexible pin & bush couplings types KX and KX-D
and their combinations
Type KX - SB
(taper pin design B)
Type KX-D - SB
(taper pin design B)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
KTR-N
Sheet:
Edition:
49412 EN
2 of 21
4
REVOLEX® KX / KX-D is a torsionally flexible pin & bush coupling. It is able to compensate for
shaft misalignment, for example caused by manufacturing inaccuracies, thermal expansion,
etc.
Table of contents
1
Technical data
3
2
Advice
5
2.1
2.2
2.3
2.4
2.5
2.6
5
5
5
6
6
6
3
4
Coupling selection
General advice
Safety and advice symbols
General hazard warnings
Intended use
Reference to EC Machinery Directive 2006/42/EC
Storage, transport and packaging
6
3.1
3.2
6
7
Storage
Transport and packaging
Assembly
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
7
Components of the couplings
Components of the pins
Advice for finish bore
Assembly of the coupling (general)
Assembly of type KX - SB
Assembly of type KX-D - SB
Replacement of elastomer rings
Displacements - alignment of the coupling
7
9
10
11
12
13
15
16
5
Start-up
18
6
Breakdowns, causes and elimination
18
7
Disposal
20
8
Maintenance and service
20
9
Spares inventory, customer service addresses
21
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
1
KTR-N
Sheet:
Edition:
49412 EN
3 of 21
4
Technical data
Illustration 1: REVOLEX® type KX – SB (taper pin design B)
Table 1: Torques and dimensions – type KX – SB (taper pin design B)
®
REVOLEX KX - SB
1)
Dimensions according
to customer
specification
Torque
[Nm]
Dimensions according
to customer
specification
Dimensions [mm]
Finish bore
max. 2)
General
d1/d2
TKN
TK max.
L
l1; l2
E
DH
D1
D2
N1
N2
M*
A
GS
Cast iron
Steel
KX 105
6485
12970
110/125
120/135
237
117
3
330
180
198
56
29
76
KX 120
10080
21060
125/145
140/155
270
132
6
370
206
223
76
45
100
KX 135
14030
28060
140/150
160/165
300
147
6
419
230
237
76
45
100
KX 150
17960
35920
160
185
336
165
6
457
256
257
76
45
100
KX 170
26360
52720
180
220
382
188
6
533
292
289
92
62
130
KX 190
36160
72320
205
245
428
211
6
597
330
327
92
62
130
KX 215
48160
96320
230
275
480
237
6
660
368
365
92
62
145
KX 240
65740
131480
250
310
534
264
6
737
407
400
122
75
167
1) Standard material NBR (Perbunan) 80 ± 5 Shore A
* Drop-out center dimension required
2) Bores H7 with keyway according to DIN 6885, sheet 1 [JS9] and thread for setscrews on the keyway (see table 9)
Size
Maximum circumferential speed = 60 m/s referring to the maximum outside diameter (dimension A)
Table 2: Hexagon screw DIN EN ISO 4017 - 10.9
Size
Dimension M x l [mm]
Quantity z
Tightening torque TA
[Nm]
KX 105
M16 x 45
12
KX 120
M20 x 50
10
KX 135
M20 x 50
12
KX 150
M20 x 55
14
KX 170
M20 x 55
20
KX 190
M20 x 55
24
KX 215
M20 x 55
28
KX 240
M24 x 65
20
295
580
580
580
580
580
580
1000
KX 150
KX 170
KX 190
5
M16
24
KX 215
KX 240
6
M24
36
Table 3: Pins – type KX - SB (taper pin design B)
Size
Pin size
M1 [mm]
SW 1 [mm]
Tightening torque TA
[Nm]
KX 105
3
M10
16
KX 120
67
Please observe protection
note ISO 16016.
KX 135
4
M12
18
115
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
290
Replacing:
Replaced by:
970
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
1
KTR-N
Sheet:
Edition:
49412 EN
4 of 21
4
Technical data
Illustration 2: REVOLEX®, type KX-D (taper pin design B)
Table 4: Torques and dimensions – type KX-D – SB (taper pin design B)
®
REVOLEX KX-D - SB
1)
Dimensions according
to customer
specification
Torque
[Nm]
Dimensions according
to customer
specification
Dimensions [mm]
Finish bore
General
max. 2)
d1/d2
TKN
TK max.
L
l1; l2
E
DH
D1
D2
N1
N2
M*
A
GS
Cast iron
Steel
KX-D 105
8650
17300
110
120
237
117
3
330
180
177
56
55
76
KX-D 120
14110
28220
125
140
270
132
6
370
206
203
76
75
100
KX-D 135
18690
37380
140
160
300
147
6
419
230
227
76
75
100
KX-D 150
23100
46200
160
185
336
165
6
457
256
253
76
75
100
KX-D 170
36900
73800
180
220
382
188
6
533
292
289
92
91
130
KX-D 190
48210
96420
205
245
428
211
6
597
330
327
92
91
130
KX-D 215
61900 123800
230
275
480
237
6
660
368
365
92
91
145
KX-D 240
92030 184060
250
310
534
264
6
737
407
404
122
121
167
1) Standard material NBR (Perbunan) 80 ± 5 Shore A
* Drop-out center dimension required
2) Bores H7 with keyway according to DIN 6885, sheet 1 [JS9] and thread for setscrews on the keyway (see table 9)
Size
Maximum circumferential speed = 60 m/s referring to the maximum outside diameter (dimension A)
Table 5: Hexagon screw DIN EN ISO 4017 - 10.9
Size
Dimension M x l [mm]
Quantity z
Tightening torque TA
[Nm]
KX-D 105
M12 x 45
16
KX-D 120
M16 x 50
14
KX-D 135
M16 x 60
16
KX-D 150
M16 x 60
18
KX-D 170
M24 x 65
14
KX-D 190
M24 x 65
16
KX-D 215
M24 x 65
18
KX-D 240
M30 x 70
14
120
295
295
295
1000
1000
1000
2000
KX-D 150
KX-D 170
KX-D 190
5
M16
24
KX-D 215
KX-D 240
6
M24
36
Table 6: Pins – type KX-D - SB (taper pin design B)
Size
Pin size
M1 [mm]
SW 1 [mm]
Tightening torque TA
[Nm]
KX-D 105
3
M10
16
KX-D 120
67
Please observe protection
note ISO 16016.
KX-D 135
4
M12
18
115
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
290
Replacing:
Replaced by:
970
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
1
KTR-N
Sheet:
Edition:
49412 EN
5 of 21
4
Technical data
The rated torques apply under the following conditions:
 Use of original KTR components made of Perbunan or natural rubber in 80 Shore
 Permanent operation
 Up to 25 torque shocks (up to 3 times the rated torque) per hour
 Observing the misalignment figures specified
 Operation within the permissible temperature range taking into account the service factors for temperature
 - 30 °C to + 80 °C with elastomers made of Perbunan (NBR)
 - 50 °C to + 70 °C with elastomers made of natural rubber (NR)
2
Advice
2.1 Coupling selection
!
For a permanent and failure-free operation of the coupling it must be selected according to
the selection instructions (according to DIN 740 part 2) for the particular application (see
®
catalogue drive technology "REVOLEX “).
We would recommend balancing from a circumferential speed of 30 m/s.
If the operating conditions (performance, speed, modifications on engine and machine)
change, the coupling selection must be reviewed.
Please make sure that the technical data regarding torque refer to the elastomers only. The
transmittable torque of the shaft-hub-connection must be reviewed by the customer and is
subject to his responsibility.
For drives subject to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to
perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations
are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the
coupling selection and the torsional vibration calculation.
2.2 General advice
Please read through these operating/assembly instructions carefully before you start up the coupling.
Please pay special attention to the safety instructions!
The operating/assembly instructions are part of your product. Please store them carefully and close to the
coupling. The copyright for these operating/assembly instructions remains with KTR.
2.3 Safety and advice symbols
STOP
!

Warning of personal injury
This symbol indicates notes which may contribute to
preventing bodily injuries or serious bodily injuries that
may result in death.
Warning of product damages
This symbol indicates notes which may contribute to
preventing material or machine damage.
General advice
This symbol indicates notes which may contribute to
preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to
preventing burns with hot surfaces resulting in light to
serious bodily injuries.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
2
KTR-N
Sheet:
Edition:
49412 EN
6 of 21
4
Advice
2.4 General hazard warnings
STOP
With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is secured against accidental switch-on. You may be seriously hurt by
rotating parts. Please make absolutely sure to read through and observe the following
safety indications.
 All operations on and with the coupling have to be performed taking into account "safety first".
 Please make sure to switch off the power pack before you perform your work on the coupling.
 Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on
or removing the fuse for current supply.
 Do not reach into the operating area of the coupling as long as it is in operation.
 Please secure the coupling against accidental contact. Please provide for the necessary protection devices
and covers.
2.5 Intended use
You may only assemble, operate and maintain the coupling if you
 have carefully read through the operating/assembly instructions and understood them
 had technical training
 are authorized by your company
The coupling may only be used in accordance with the technical data (see table 1 to 6 in chapter 1). Unauthorized
modifications on the coupling design are not admissible. We will not assume liability for any damage that may
arise. In the interest of further development we reserve the right for technical modifications.
®
The REVOLEX KX / KX-D described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
2.6 Reference to EC Machinery Directive 2006/42/EC
The couplings supplied by KTR should be considered as components, not machines or partly completed
machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a
declaration of incorporation. For details about safe assembly, start-up and safe operation please refer to the
present operating/assembly instructions considering the warnings.
3
Storage, transport and packaging
3.1 Storage
The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9
months.
The features of the elastomer rings remain unchanged for up to 5 years with favourable storage conditions.
!
The storage rooms must not include any ozone-generating devices like e. g. fluorescent
light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less
than 65 %.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
3
KTR-N
Sheet:
Edition:
49412 EN
7 of 21
4
Storage, transport and packaging
3.2 Transport and packaging
In order to avoid any injuries and any kind of damage please always make use of proper
transport and lifting equipment.
!
The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise
contractually agreed, packaging will follow the in-house packaging specifications of KTR.
4
Assembly
The coupling is supplied in the following component assemblies and single parts. Before assembly the coupling
has to be inspected for completeness.
4.1 Components of the couplings
Components of REVOLEX®, type KX - SB (taper pin design B)
Component
1)
1
1)
2SB
3a
4
8a
9
2)
10
Quantity
1
1
see table 7
see table 7
1
see table 7
Description
Hub part 1
FN hub part 2SB
Pins KX complete (design B)
KX bush
Brake disk
Hexagon screw acc. to DIN EN ISO 4017
Setscrew acc. to DIN EN ISO 4029
1) Material and balancing condition as specified by the customer
2) Axial fastening of the hub and tolerances of the shaft-hub-connections as specified by the customer
Illustration 3: REVOLEX® type KX – SB (taper pin design B)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
8 of 21
4
Assembly
4.1 Components of the couplings
If requested, the FN hub part 2SB and brake disk are supplied with the hexagon screws mounted.
Table 7:
Quantity z of
components
3a, 4
9
®
KX 105
12
12
KX 120
10
10
KX 135
12
12
REVOLEX size
KX 150
KX 170
14
10
14
20
KX 190
12
24
KX 215
14
28
KX 240
10
20
Components of REVOLEX®, type KX-D - SB (taper pin design B)
Component
1)
5
1)
5SB
3c
6
8b
9
2)
10
Quantity
1
1
see table 8
see table 8
1
see table 8
Description
Hub part 5
FN hub part 5SB
Pin KX-D complete (design B)
KX-D bush
Brake disk
Hexagon screw acc. to DIN EN ISO 4017
Setscrew acc. to DIN EN ISO 4029
1) Material and balancing condition as specified by the customer
2) Axial fastening of the hub and tolerances of the shaft-hub-connections as specified by the customer
Illustration 4: REVOLEX® type KX-D - SB (taper pin design B)
If requested, the FN hub part 5SB and brake disk are supplied with the hexagon screws mounted.
Table 8:
Quantity z of
components
3c, 6, 9
®
KX-D 105
16
Please observe protection
note ISO 16016.
KX-D 120
14
Drawn:
Verified:
KX-D 135
16
REVOLEX size
KX-D 150 KX-D 170
18
14
2016-11-29 Kb
2016-12-08 Kb
KX-D 190
16
Replacing:
Replaced by:
KX-D 215
18
KX-D 240
14
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
9 of 21
4
Assembly
4.2 Components of the pins
Components of complete pin KX (design B) – component 3a
Component
3.1b
3.2
3.3b
3.4a
3.5
Quantity
1
4
2
1
1
Description
Pin KX (design B)
Elastomer ring
Disk
Hexagon screw acc. to DIN EN ISO 4017
Circlip DIN 471
Illustration 5: Pin KX complete (design B)
Components of complete pin KX-D (design B) – component 3c
Component
3.1b
3.2
3.3b
3.4c
3.5
Quantity
1
4
2
1
1
Description
Pin KX (design B)
Elastomer ring
Disk
Hexagon screw acc. to DIN EN ISO 4017
Circlip DIN 471
Illustration 6: Pin KX-D complete (design B)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
10 of 21
4
Assembly
4.3 Advice for finish bore
The maximum permissible bore diameters d (see table 1
and 4 in chapter 1 - technical data) must not be exceeded.
If these figures are disregarded, the coupling may tear.
Rotating particles may cause danger to life.
STOP
 Hub bores machined by the customer have to observe concentricity or
axial runout, respectively (see illustration 7).
 Please make absolutely sure to observe the figures for dmax.
 Carefully align the hubs when the finish bores are drilled.
 The bore tolerance should preferably be selected as per table 10.
 Please provide for a setscrew according to DIN EN ISO 4029 with a cup
point or an end plate to fasten the hubs axially.
Illustration 7: Concentricity and axial runout
The customer bears the sole responsibility for all machining processes performed
subsequently on unbored or pilot bored as well as finish machined coupling components
and spare parts. KTR does not assume any warranty claims resulting from insufficient
remachining.
!
Table 9: Setscrews DIN EN ISO 4029
Size (KX / KX-D)
Dimension G [mm]
Dimension t1 [mm]
Dimension t2 [mm]
Tightening torque TA [Nm]
105
M20
40
140
120
M24
30
220
135
M24
45
220
150
M24
45
220
170
M24
50
220
190
M24
50
220
215
M24
50
110
220
240
M24
50
110
220
Table 10: Recommended fit pairs acc. to DIN 748/1
Bore [mm]
above
up to
50
50
Shaft tolerance
Bore tolerance
k6
m6
H7
(KTR standard)
If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR
standard) with normal operating conditions or ISO P9 with difficult operating conditions (frequently alternating
torsional direction, shock loads, etc.). In this case the keyway should be flush with one of the hub bores for the
pins. With axial fastening by setscrews the tapping should be located on the keyway.
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his
responsibility.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
11 of 21
4
Assembly
4.3 Advice for finish bore
Unbored/pilot bored hubs are supplied without
balancing. If balancing is necessary subject to the
application, it should be made on completion of the
finish bore. The balancing bores have to be made in
the positions marked in illustration 8.
!
The balancing bores have to be made
between the pin bores in every case.
Illustration 8
4.4 Assembly of the coupling (general)

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs lightly (approx. 80 °C) allows for easier mounting onto the shaft.
STOP
!
!
Touching the heated hubs causes burns.
Please wear safety gloves.
With the assembly please make sure that the distance dimension E (see table 1 and 4) is
observed so that the hubs are not in contact with each other during the operation.
Disregarding this advice may cause damage to the coupling.
With the assembly of screw connections only those screws specified by the manufacturer
have to be used. When tightening the screws the torque indicated by the manufacturer has
to be observed. The screws have to be secured against working loose (e. g. Loctite 243
average strength).
In order to avoid any injuries please always make use of proper lifting equipment.
STOP
Tappings exist on the face and outside diameter of the coupling serving for using proper sling gears or lifting
equipment, respectively. If proper sling gears are used they should be dismounted after assembly of the coupling.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
12 of 21
4
Assembly
4.5 Assembly of type KX - SB
With supply of components only (FN hub and brake disk):
 Screw up the brake disk (component 8a) with the FN hub part
2SB (component 2SB) and tighten the hexagon screws
(component 9) evenly to the tightening torques specified in
table 2 by means of a torque key (see illustration 9).
Illustration 9
 Drive the sleeves (component 4) into the bores of the FN-hub
part 2SB by light blows (see illustration 10).
Illustration 10
 Please assemble the hubs onto the shafts of the driving and
driven side in a way that the flat faces of the coupling hubs
are flush with the faces of the shafts (see illustration 11).
Illustration 11
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
13 of 21
4
Assembly
4.5 Assembly of type KX - SB
 Shift the power packs in axial direction until the distance
dimension E has been achieved (see illustration 12).
 If the power packs are already firmly assembled, shifting the
hubs axially on the shafts allows for setting the distance
dimension E.
 Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 at the tightening torque acc. to table 9.
 Align the coupling hubs in a way that the bores for the pins
are flush.
!
Please consider permissible shaft
displacements from chapter 4.8!
Illustration 12
 Insert the pins (component 3a) in the hub part 1
(component 1) (see illustration 13).
 Screw up the pins to the hexagon screws (component 3.4a)
and tighten them evenly to the tightening torques specified in
table 3 by means of a torque key (see illustration 13).
!
!
Secure screws against relieving by means of
glue (e. g. Loctite 243 average strength).
Having started up the coupling the tightening
torques of the screws have to be inspected
during the usual inspection intervals.
Illustration 13
4.6 Assembly of type KX-D - SB
With supply of components only (FN hub and brake disk):
 Screw up the brake disk (component 8b) with the FN hub part
5SB (component 5SB) and tighten the hexagon screws
(component 9) evenly to the tightening torques specified in
table 5 by means of a torque key (see illustration 14).
Illustration 14
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
14 of 21
4
Assembly
4.6 Assembly of type KX-D - SB
 Drive the sleeves (component 6) into the smaller bores of the
hubs part 5 (component 5) or part 5SB by light blows (see
illustration 15).
Illustration 15
 Please assemble the hubs onto the shafts of the driving and
driven side in a way that the flat faces of the coupling hubs
are flush with the faces of the shafts (see illustration 16).
 Shift the power packs in axial direction until the distance
dimension E is achieved (see illustration 17).
 If the power packs are already firmly assembled, shifting the
hubs axially on the shafts allows for setting the distance
dimension E.
Illustration 16
 Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 at the tightening torque acc. to table 9.
 Align the coupling hubs in a way that the bores for the pins
are flush.
!
Please consider permissible shaft
displacements from chapter 4.8!
Illustration 17
 Insert the pins (component 3c) in the larger holes of the hub
part 5 or FN hub part 5SB (see illustration 18).
 Screw up the pins with the hexagon screws (component 3.4c)
and tighten them evenly to the tightening torques specified in
table 6 by means of a torque key (see illustration 18).
!
!
Secure screws against relieving by means of
glue (e. g. Loctite 243 average strength).
Having started up the coupling the tightening
torques of the screws have to be inspected
during the usual inspection intervals.
Please observe protection
note ISO 16016.
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Illustration 18
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REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
15 of 21
4
Assembly
4.7 Replacement of elastomer rings
Option 1: Replacement of elastomer rings without dismounting the pins:
 Pull the driving and driven side so far apart that the coupling is separated or shift the coupling free from load.
 Remove the circlip (component 3.5) and the disk (component 3.3b).
 Disassemble the elastomers (component 3.2).
 Replace the elastomer rings in sets only.

Elastomer rings of the same size only may be used.
 The new elastomer rings are mounted in reverse order.
Option 2: Replacement of pins or elastomer rings by dismounting the pins:
 Pull the driving and driven side so far apart that the coupling is separated or shift the coupling free from load.
 Disassemble the screw (illustration 19; component 3.4a or 3.4c). Afterwards clean the tapping and the thread
of the screw.
Illustration 19: Disassembly of hexagon screw
Illustration 20: Cleaning the tapping
Wear safety glasses.
STOP
 Fill the tapping of the pin (component 3.1b) with standard grease by three quarters.
 Wrap a thread sealing tape Loctite 55 around the screw. Leave out the first 2 to 3 threads to make sure that
the screw can be screwed in properly (see illustration 20).
 Screw the screw manually into the pin by 2 to 3 tappings.
Illustration 21: Assembly of hexagon screw
Please observe protection
note ISO 16016.
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Illustration 22: Unscrewing the pin
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REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
16 of 21
4
Assembly
4.7 Replacement of elastomer rings
STOP
Abrupt movement of the screw (component 3.4a or 3.4c) or sudden unscrewing of the pin
(component 3.1b) results in the danger of getting jammed.
A sudden movement of the pin can be realized by loud noise.
 Screw the screw slowly deeper into the pin via a spanner. The grease flows through the cross hole of the pin
pressing between pin and bush (illustration 22; component 4 or 6).
 If feasible resistance is not built up, it may be necessary to refill the grease or vent the system.

If grease escapes from the tapping, the screw needs to be re-sealed with thread sealing tape
Loctite 55.
 As soon as the pin has come off the taper seat of the bush, the extraction process is finished.
 Press all pins out of their seats one after another following the system described above.
 Replace the elastomer rings on the pins as per chapter 4.7 of option 1 described.

If the pins are re-used they have to be cleaned from grease free from any residues.
 The pins are mounted as per chapter 4.5 or 4.6.
4.8 Displacements - alignment of the coupling
®
The REVOLEX KX / KX-D compensates for displacements generated by the shafts to be combined as specified
in table 11. Excessive misalignment may be generated by inaccurate alignment, production tolerances, thermal
expansion, shaft deflection, twisting of machine frames, etc.
!
In order to ensure a long service life of the coupling, the shaft ends have to be accurately
aligned. Please absolutely observe the displacement figures specified (see table 11). If the
figures are exceeded, the coupling will be damaged.
The more accurate the alignment of the coupling, the longer is its service life.
Please note:
 The displacement figures specified in table 11 are maximum figures which must not arise in parallel. If radial
and angular displacement occurs at the same time, the sum of the displacement figures must not exceed Kr
or Kw (see illustration 24).
 Please check with a dial gauge, ruler, feeler or laser measuring device whether the permissible displacement
figures of table 11 can be observed.
Please observe protection
note ISO 16016.
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REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
4
KTR-N
Sheet:
Edition:
49412 EN
17 of 21
4
Assembly
4.8 Displacements - alignment of the coupling
Axial displacements
Radial displacements
Angular displacements
Ladm. = L + Ka [mm]
Kw = Emax. - Emin. [mm]
Illustration 23: Displacements
Examples of the displacement
combinations specified in illustration 24:
Example 1:
Kr = 30 %
Kw = 70 %
Example 2:
Kr = 60 %
Kw = 40 %
Ktotal = Kr + Kw  100 %
Illustration 24: Combinations of displacement
Table 11: Displacement figures
Size (KX / KX-D)
Max. axial displacement Ka
[mm]
Max. radial
250
500
displacement Kr [mm]
750
or
1000
Max. angular
1500
displacement Kw
2000
[mm] with speed n
3000
[rpm]
Please observe protection
note ISO 16016.
105
120
135
150
170
190
215
240
±2
±2
±2
±2
±2.5
±2.5
±2.5
±2.5
1.2
0.9
0.7
0.6
0.5
0.4
0.4
1.3
0.9
0.8
0.7
0.5
0.5
0.4
1.4
1.0
0.8
0.7
0.6
0.5
-
1.5
1.1
0.9
0.8
0.6
0.5
-
1.7
1.2
1.0
0.9
0.7
0.6
-
1.9
1.3
1.1
0.9
0.8
0.7
-
2.0
1.4
1.2
1.0
0.8
-
2.2
1.6
1.3
1.1
0.9
-
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REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
5
KTR-N
Sheet:
Edition:
49412 EN
18 of 21
4
Start-up
Before start-up of the coupling, please inspect the tightening of the setscrews in the hubs, the alignment and the
distance dimension E and adjust, if necessary, and also inspect all screw connections for the tightening torques
specified.
Finally the coupling protection against accidental contact must be fitted.
During operation of the coupling, please pay attention to

different operating noise

vibrations occurring.
!
6
If you note any irregularities with the coupling during operation, the drive unit must be
switched off immediately. The cause of the breakdown must be specified by means of the
table „Breakdowns“ and, if possible, be eliminated according to the proposals. The potential
breakdowns specified can be hints only. To find out the cause all operating factors and
machine components must be considered.
Breakdowns, causes and elimination
®
The below-mentioned failures may result in a use of the REVOLEX KX / KX-D coupling other than intended. In
addition to the specifications given in these operating and assembly instructions please make sure to avoid such
failures. The errors listed can only be clues to search for the failures.
When searching for the failure the adjacent components must generally be considered.
General failures with use other than intended
 Important data for the coupling selection were not forwarded.
 The calculation of the shaft-hub-connection was not considered.
 Coupling components with damage occurred during transport are assembled.
 If the heated hubs are assembled, the permissible temperature is exceeded.
 The clearance of the components to be assembled is not coordinated with one another.
 Tightening torques have been fallen below/exceeded.
 Components are mixed up by mistake/assembled incorrectly.
 A wrong or no pin/elastomer ring is inserted in the coupling.
 No original KTR components (purchased parts) are used.
 Old/already worn out elastomer rings or elastomer rings stored for too long are used.
 Maintenance intervals are not observed.
Please observe protection
note ISO 16016.
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REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
6
KTR-N
Sheet:
Edition:
49412 EN
19 of 21
4
Breakdowns, causes and elimination
Breakdowns
Causes
Elimination
Misalignment
Different operating noise
and/or vibrations occuring
Wear of elastomers
Thread for setscrews for
axial fastening of hubs
working loose
Fracture of hub due to
high impact
energy/overload
Fracture of hub
Operating parameters do
not meet with the
performance of the
coupling
Operating error of the unit
e. g. contact with
aggressive liquids/oils,
ozone influence, too
Early wear of elastomers
high/low ambient
temperatures etc. causing
a physical modification of
the elastomer rings
Please observe protection
note ISO 16016.
Drawn:
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1) Set the unit out of operation
2) Eliminate the reason for the misalignment (e. g. loose
foundation bolts, breaking of the engine mount, heat
expansion of unit components, modification of the
installation dimension E of the coupling)
3) For inspection of wear see item inspection
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of
the elastomer rings/pins
3) Inspect coupling components and replace coupling
hubs that are damaged
4) Generally assemble new elastomer rings with new
pins
5) Assemble coupling components
6) Inspect alignment, adjust if necessary
1) Set the unit out of operation
2) Inspect alignment of coupling
3) Tighten the thread for setscrews to fasten the hubs
and secure against working loose
4) For inspection of wear see item inspection
1) Set the unit out of operation
2) Replace complete coupling
3) Find out the reason for overload
4) Inspect alignment
1) Set the unit out of operation
2) Review the operating parameters and select a bigger
coupling (consider mounting space)
3) Assemble new coupling size
4) Inspect alignment
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
4) Instruct and train the service staff
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of
the elastomer rings/pins
3) Inspect coupling components and replace coupling
hubs that are damaged
4) Generally assemble new elastomer rings with new
pins
5) Assemble coupling components
6) Inspect alignment, adjust if necessary
Make sure that further physical modifications of the
pins are excluded
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2016-12-08 Kb
Replacing:
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REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
6
49412 EN
20 of 21
4
Breakdowns, causes and elimination
Breakdowns
Early wear of elastomers
Early wear of pins
(hardening/embrittlement
of the pin elastomer)
7
KTR-N
Sheet:
Edition:
Causes
Elimination
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of
the elastomer rings/pins
ambient/contact
3) Inspect coupling components and replace coupling
temperatures which are
hubs that are damaged
too high for the elastomer
4) Generally assemble new elastomer rings with new
ring, max. permissible
pins
- 30 °C/+ 80 °C
5) Assemble coupling components
6) Inspect alignment, adjust if necessary
7) Inspect and adjust ambient/contact temperature
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of
the elastomer rings/pins
3) Find out the reason for vibrations
4) Inspect coupling components and replace coupling
Vibrations of drive
hubs that are damaged
5) Generally assemble new elastomer rings with new
pins
6) Assemble coupling components
7) Inspect alignment, adjust if necessary
Disposal
In respect of environmental protection we would ask you to dispose of the packaging or products on termination of
their service life in accordance with the legal regulations and standards that apply, respectively.

Metal
Any metal components have to be cleaned and disposed of by scrap metal.

Nylon materials
Nylon materials have to be collected and disposed of by a waste disposal company.
8
Maintenance and service
®
REVOLEX KX / KX-D is a low-maintenance coupling. We recommend to perform a visual inspection on the
coupling at least once a year. Please pay special attention to the condition of the pins of the coupling.

Since the flexible machine bearings of the driving and driven side settle during the course of load, please
inspect the alignment of the coupling and re-align the coupling, if necessary.

The coupling parts have to be inspected for damages.

The screw connections have to be inspected visually.

Having started up the coupling the tightening torques of the screws have to be inspected
during the usual inspection intervals.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
2016-12-08 Kb
Replacing:
Replaced by:
KTR-N dated 2010.03.12
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type SB
9
KTR-N
Sheet:
Edition:
49412 EN
21 of 21
4
Spares inventory, customer service addresses
A basic requirement to ensure the readiness for use of the coupling is a stock of the most important spare parts
on site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at
www.ktr.com.

KTR does not assume any liability or warranty for the use of spare parts and accessories
which are not provided by KTR and for the damages which may incur as a result.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-11-29 Kb
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Replacing:
Replaced by:
KTR-N dated 2010.03.12
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