MULTISPAN AVH-133 Operating & Assembly Instructions

REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
KTR-N
Sheet:
Edition:
49413 EN
1 of 22
6
REVOLEX® KX / KX-D
Type AB with limitation of axial backlash
Flexible pin & bush couplings types
KX and KX-D and their combinations
Type KX - AB
(taper pin design B)
Type KX-D - AB
(taper pin design B)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
KTR-N
Sheet:
Edition:
49413 EN
2 of 22
6
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
General advice
Safety and advice symbols
General hazard warnings
Intended use
Coupling selection
Reference to EC Machinery Directive 2006/42/EC
Storage, transport and packaging
7
3.1
3.2
7
7
Storage
Transport and packaging
Assembly
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
8
Components of the couplings
Components of the pins
Advice for finish bore
Assembly of the coupling (general)
Assembly of type KX
Assembly of type KX-D
Setting of limitation of axial backlash
Replacement of elastomer rings
Displacements - alignment of the couplings
8
10
12
13
14
15
16
17
18
5
Start-up
20
6
Breakdowns, causes and elimination
20
7
Disposal
22
8
Maintenance and service
22
9
Spares inventory, customer service addresses
22
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
1
KTR-N
Sheet:
Edition:
49413 EN
3 of 22
6
Technical data
Illustration 1: REVOLEX® type KX - AB (taper pin design B)
Table 1: Torques and dimensions - type KX - AB (taper pin design B)
®
REVOLEX KX - AB
Cast iron
Steel
Dimensions [mm]
Finish
Finish
General
Max.
Size
bore
bore
2)
speed
max. 3)
max. 3)
TKN
TK max.
L
l1, l2
E
DH
D1, D2
N1
N2
M*
[rpm]
d1, d2
d1, d2
KX 105
7050
14100
2000
110/125
3475
130
237
117
3
330
180
56
30
115
KX 120
10855
21710
1800
125/145
3100
150
270
132
6
370
206
76
46
140
KX 135
15000
30000
1600
140/150
2725
170
300
147
6
419
230
76
46
140
KX 150
19440
38880
1450
160
2500
185
336
165
6
457
256
76
46
140
KX 170
29285
58570
1250
180
2150
220
382
188
6
533
292
92
63
170
KX 190
40500
81000
1100
205
1900
245
428
211
6
597
330
92
63
170
KX 215
52500 105000
1000
230
1725
275
480
237
6
660
368
92
63
170
KX 240
70000 140000
900
250
1550
310
534
264
6
737
407
122
76
215
KX 265 100500 201000
800
285
1375
350
590
292
6
826
457
122
76
215
1) Standard material NBR (Perbunan) 80 ± 5 Shore A
* Drop-out center dimension required
2) Dynamic balancing required
3) Bores H7 with keyway according to DIN 6885 sheet 1 [JS9] and setscrew on the keyway (see table 7)
Torque 1) [Nm]
Max.
speed 2)
[rpm]
Table 2: Pin - type KX - AB (taper pin design B)
Size
Pin size
M1 [mm]
SW 1 [mm]
Tightening torque TA [Nm]
Please observe protection
note ISO 16016.
KX 105
3
M10
16
67
Drawn:
Verified:
KX 120
KX 135
4
M12
18
115
KX 150
2019-05-29 Pz
2019-06-12 Pz
KX 170
KX 190
5
M16
24
290
Replacing:
Replaced by:
KX 215
KX 240
KX 265
6
M24
36
970
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
1
KTR-N
Sheet:
Edition:
49413 EN
4 of 22
6
Technical data
Illustration 2: REVOLEX® type KX-D - AB (taper pin design B)
Table 3: Torques and dimensions - type KX-D - AB (taper pin design B)
®
REVOLEX KX-D - AB
Cast iron
Steel
Dimensions [mm]
Finish
Finish
General
Max.
Max.
Size
bore
bore
speed 2)
speed 2)
3)
3)
max.
max.
TKN
TK max.
L
l1, l2
E
DH
D1, D2 N1, N2
M1*
M2*
[rpm]
[rpm]
d1, d2
d1, d2
KX-D 75
4300
8600
4500
100
193
95
3
255
136
56
115
76
KX-D 85
5500
11000
4175
110
213
105
3
274
152
56
115
76
KX-D 95
7200
14400
3825
125
227
112
3
298
168
56
115
76
KX-D 105
9400
18800
2000
110
3475
130
237
117
3
330
180
56
115
76
KX-D 120 15200
30400
1800
125
3100
150
270
132
6
370
206
76
140
100
KX-D 135 20000
40000
1600
140
2725
170
300
147
6
419
230
76
140
100
KX-D 150 25000
50000
1450
160
2500
190
336
165
6
457
256
76
140
100
KX-D 170 41000
82000
1250
180
2150
220
382
188
6
533
292
92
170
130
KX-D 190 54000 108000
1100
205
1900
245
428
211
6
597
330
92
170
130
KX-D 215 67500 135000
1000
230
1725
275
480
237
6
660
368
92
170
130
KX-D 240 98000 196000
900
250
1550
310
534
264
6
737
407
122
215
170
KX-D 265 134000 268000
800
285
1375
350
590
292
6
826
457
122
215
170
KX-D 280 170000 340000
720
315
1225
385
628
311
6
927
508
122
215
170
KX-D 305 205000 410000
675
330
1150
405
654
324
6
991
533
122
215
170
KX-D 330 265000 530000
625
355
1075
435
666
330
6
1067
572
122
215
170
KX-D 355 350000 700000
575
380
975
450
721
356
9
1156
610
122
215
170
KX-D 370 430000 860000
535
450
900
530
773
382
9
1250
720
122
215
170
1) Standard material NBR (Perbunan) 80 ± 5 Shore A
* Drop-out center dimension required
2) Dynamic balancing required
3) Bores H7 with keyway according to DIN 6885 sheet 1 [JS9] and setscrew on the keyway (see table 7)
Torque 1) [Nm]
Table 4: Pin - type KX-D - AB (taper pin design B)
Size
Pin size
M1 [mm]
SW 1 [mm]
Tightening torque TA [Nm]
75
Size
Pin size
M1 [mm]
SW 1 [mm]
Tightening torque TA [Nm]
215
5
M16
24
290
Please observe protection
note ISO 16016.
85
95
105
120
135
4
M12
19
115
3
M10
17
67
Drawn:
Verified:
240
265
2019-05-29 Pz
2019-06-12 Pz
280
6
M24
36
970
305
150
170
190
5
M16
24
290
330
355
370
7
M30
46
1350
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
2
KTR-N
Sheet:
Edition:
49413 EN
5 of 22
6
Advice
2.1 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.
2.2 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.
2.3 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".
 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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
2
KTR-N
Sheet:
Edition:
49413 EN
6 of 22
6
Advice
2.4 Intended use
You may only assemble, operate and maintain the coupling if you
 have carefully read through the operating/assembly instructions and understood them
 are technically qualified and specifically trained (e. g. safety, environment, logistics)
 are authorized by your company
The coupling may only be used in accordance with the technical data (see 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.
2.5 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 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.
2.6 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 refer to the present
operating/assembly instructions considering the warnings.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
3
KTR-N
Sheet:
Edition:
49413 EN
7 of 22
6
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 %.
3.2 Transport and packaging
!
In order to avoid any injuries and any kind of damage 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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
8 of 22
6
Assembly
The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for
completeness.
4.1 Components of the couplings
Components of REVOLEX®, type KX - AB (taper pin design B)
Component
1)
1
1)
2AB
3a
3e
4
7a
8
9
10
11
2)
12
Number
1
1
see table 5
see table 5
see table 5
1
see table 5
see table 5
see table 5
see table 5
Description
Hub part 1
Hub part 2AB
Pins KX complete (design B)
Pins KX AB complete (design B)
KX bush
AB disk KX
Hexagon screw DIN EN ISO 4017
Setscrew DIN EN ISO 4029
Setscrew DIN EN ISO 4029
Hexagon nut DIN EN ISO 4032
Setscrew 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 - AB (taper pin design B)
Table 5:
Number z of
components
3a, 3e, 8, 9, 10
4, 11
KX 105
6
12
KX 120
5
10
Please observe protection
note ISO 16016.
Drawn:
Verified:
KX 135
6
12
KX 150
7
14
2019-05-29 Pz
2019-06-12 Pz
Size
KX 170
5
10
KX 190
6
12
Replacing:
Replaced by:
KX 215
7
14
KX 240
5
10
KX 265
6
12
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
9 of 22
6
Assembly
4.1 Components of the couplings
Components of REVOLEX®, type KX-D - AB (taper pin design B)
Component
1)
5
1)
5AB
3c
3f
6
7b
8
9
10
11
2)
12
Number
1
1
see table 6
see table 6
see table 6
1
see table 6
see table 6
see table 6
see table 6
Description
Hub part 5
Hub part 5AB
Pin KX-D complete (design B)
Pins KX-D AB complete (design B)
KX-D bush
AB disk KX-D
Hexagon screw DIN EN ISO 4017
Setscrew DIN EN ISO 4029
Setscrew DIN EN ISO 4029
Hexagon nut DIN EN ISO 4032
Setscrew 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 - AB (taper pin design B)
Table 6:
Number z of
components
3c, 3f, 8, 9, 10
6, 11
KX-D 75
5
10
Number z of
components
3c, 3f, 8, 9, 10
6, 11
KX-D 215
9
18
Please observe protection
note ISO 16016.
KX-D 85
6
12
KX-D 240
7
14
Drawn:
Verified:
KX-D 95
7
14
KX-D 105
8
16
KX-D 265
8
16
Size
KX-D 120
7
14
KX-D 135
8
16
Size
KX-D 280
KX-D 305
9
10
18
20
2019-05-29 Pz
2019-06-12 Pz
KX-D 150
9
18
KX-D 330
12
24
Replacing:
Replaced by:
KX-D 170
7
14
KX-D 355
13
26
KX-D 190
8
16
KX-D 370
15
30
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
10 of 22
6
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
Number
1
4
2
1
1
Description
Pin KX (design B)
Elastomer ring
Disk
Hexagon screw DIN EN ISO 4017
Circlip DIN 471
Illustration 5: Pin KX complete (design B)
Components of complete pin KX AB (design B) - component 3e
Component
3.1c
3.2
3.3b
3.4a
3.5
Number
1
4
2
1
1
Description
Pin KX AB (design B)
Elastomer ring
Disk
Hexagon screw DIN EN ISO 4017
Circlip DIN 471
Illustration 6: Pin KX AB complete (design B)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
11 of 22
6
Assembly
4.2 Components of the pins
Components of complete pin KX-D (design B) - component 3c
Component
3.1b
3.2
3.3b
3.4c
3.5
Number
1
4
2
1
1
Description
Pin KX (design B)
Elastomer ring
Disk
Hexagon screw DIN EN ISO 4017
Circlip DIN 471
Illustration 7: Pin KX-D complete (design B)
Components of complete pin KX-D AB (design B) - component 3f
Component
3.1c
3.2
3.3b
3.4c
3.5
Number
1
4
2
1
1
Description
Pin KX AB (design B)
Elastomer ring
Disk
Hexagon screw DIN EN ISO 4017
Circlip DIN 471
Illustration 8: Pin KX-D complete (design B)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
12 of 22
6
Assembly
4.3 Advice for finish bore
The maximum permissible bore diameters d (see 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 9).
 Please make absolutely sure to observe the figures for Ø dmax.
 Carefully align the hubs when the finish bore is drilled.
 The bore tolerance should preferably be selected as per table 8.
 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 9: Concentricity and axial run-out
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 7: Setscrew DIN EN ISO 4029
Size
Dimension G [mm]
Dimension t1 [mm]
Dimension t2 [mm]
Tightening torque TA [Nm]
75
M16
25
80
Size
Dimension G [mm]
Dimension t1 [mm]
Dimension t2 [mm]
Tightening torque TA [Nm]
215
M24
50
110
220
85
M16
25
80
95
M20
30
140
240
M24
50
110
220
105
M20
40
140
265
M24
60
120
220
120
M24
30
220
280
M24
70
140
220
135
M24
45
220
305
M24
70
150
220
150
M24
45
220
330
M24
70
150
220
170
M24
50
220
355
M24
80
160
220
190
M24
50
220
370
M24
80
160
220
Table 8: Recommended fit pairs acc. to DIN 748-1
Bore [mm]
above
up to
50
Shaft tolerance
Bore tolerance
k6
m6
H7
(KTR standard)
50
If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR
standard) with standard operating conditions or ISO P9 with complicated operating conditions (frequently
alternating torsional direction, shock loads, etc.). In this case the keyway should be flush with one of the locating
bores for the pins. With axial fastening by the setscrew the tapped hole 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:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
13 of 22
6
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 10.
!
The balancing bores have to be made
between the pin bores in every case.
Illustration 10
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 an easier mounting on 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. The
motor shaft has to be located in the magnetic center. 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 specified by the manufacturer has
to be observed. The screws have to be secured against working loose, e. g. by
conglutinating with Loctite (average strength).
In order to avoid any injuries please always make use of proper lifting equipment.
STOP
There are tapped holes 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:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
14 of 22
6
Assembly
4.5 Assembly of type KX
 Before assembly make sure that the motor shaft is located in
the magnetic center.
 Drive the sleeves (component 4) into the bores of the hub
part 2AB (component 2AB) by light blows (see illustration 11).
Illustration 11
 Suspend the disk (component 7a) on the shaft for the hub
part 1 (component 1) (see illustration 12).
 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 12).
Illustration 12
 Shift the power packs in axial direction until the distance
dimension E has been achieved (see illustration 13). Please
make sure that the motor shaft is located in the magnetic
center.
 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 7.
 Align the coupling hubs in a way that the bores for the pins
are flush.
!
Illustration 13
Please consider permissible shaft
displacements of chapter 4.8!
 Insert the pins (component 3a and 3e) into the hub part 1
(see illustration 14).
 Screw up the pins to the hexagon screws (component 3.4a)
and tighten them evenly to the tightening torques specified in
table 2 by means of a torque key (see illustration 14).
!
The screws have to be secured against working
loose, e. g. by conglutinating with Loctite
(average strength).
!
Having started up the coupling the tightening
torques of the screws have to be inspected
during usual inspection intervals.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Illustration 14
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
15 of 22
6
Assembly
4.6 Assembly of type KX-D
 Before assembly make sure that the motor shaft is located in
the magnetic center.
 Drive the sleeves (component 6) into the smaller bores of the
hubs part 5 (component 5) or part 5AB (component 5AB) by
light blows (see illustration 15).
Illustration 15
 Suspend the disk (component 7b) on the shaft for the hub
part 5 (see illustration 16).
 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).
Illustration 16
 Shift the power packs in axial direction until the distance
dimension E has been achieved (see illustration 17). Please
make sure that the motor shaft is located in the magnetic
center.
 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 7.
 Align the coupling hubs in a way that the bores for the pins
are flush.
!
Illustration 17
Please consider permissible shaft
displacements of chapter 4.8!
 Insert the pins (components 3c and 3f) in the larger holes of
the hub part 5 or part 5AB (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 4 by means of a torque key (see illustration 18).
!
The screws have to be secured against working
loose, e. g. by conglutinating with Loctite
(average strength).
!
Having started up the coupling the tightening
torques of the screws have to be inspected
during usual inspection intervals.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Illustration 18
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
16 of 22
6
Assembly
4.7 Setting of limitation of axial backlash
 Mount the disk (component 7a or 7b) to the hexagon screws
(component 8) of the coupling (see illustration 19) and tighten
it evenly to the tightening torques specified in table 9.
 Screw the hexagon nuts (component 11) onto the setscrews
(component 9 or 10).
 Screw the setscrews (component 9 or 10) into the disk
(component 7) or hub part 5AB.
 Identify the axial backlash of the entire coupling. It should be
half as big as the axial backlash of the motor. Please make
sure that the permissible axial displacement of the coupling is
not exceeded (see table 11).
Illustration 19
!
The axial limitation of the coupling must in
every case be smaller than the axial backlash of
the motor and big enough to make sure that the
coupling is able to compensate for angular
displacements.
 Set the axial backlash of the coupling (see illustration 20).
Dimension x is each half of the axial backlash identified of the
entire coupling. Please make sure that the motor shaft is
located in the magnetic center.
Example:
Axial backlash of the motor
= 4 mm
Axial backlash of the entire coupling
= 2 mm
Dimension x (axial backlash per coupling hub) =
1 mm
 Fix the position of setscrews (component 9 or 10) by
countering with hexagon nuts (component 11). Tighten them
evenly to the torques specified in table 10. Protect the
setscrew from turning.
Illustration 20
Table 9: Tightening torques - hexagon screws (component 8)
Size
Screw size
Tightening torque
TA [Nm]
75
85
95
M10
105
120
69
135 150
M12
170
190
215
240
265 280
M16
120
305
330
355
370
305
330
355 370
M24
295
Table 10: Tightening torques - hexagon nuts (component 11)
Size
Screw size
Tightening torque
TA [Nm]
75
Please observe protection
note ISO 16016.
85
95
M10
17
Drawn:
Verified:
105
120
135 150
M12
40
2019-05-29 Pz
2019-06-12 Pz
170
190
215
240 265
M16
80
Replacing:
Replaced by:
280
240
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
17 of 22
6
Assembly
4.8 Replacement of elastomer rings
Option 1: Replacement of elastomer rings without dismounting the pins:
 Disassemble the disk (component 7a or 7b) and carefully suspend it on the shaft.
 Pull the driving and driven side far apart so 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. Afterwards set the axial backlash limitation as per
chapter 4.7.
Option 2: Replacement of pins or elastomer rings by dismounting the pins:
 Disassemble the disk (component 7a or 7b) and carefully suspend it on the shaft.
 Pull the driving and driven side far apart so that the coupling is separated or shift the coupling free from load.
 Disassemble the screw (illustration 21; component 3.4a or 3.4c). Afterwards clean the tapping and the thread
of the screw.
Illustration 21: Disassembly of hexagon screw
Illustration 22: Cleaning the tapping
Wear safety glasses.
STOP
 Fill the tapped holes 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 22).
 Screw the screw manually into the pin by 2 to 3 threads.
Illustration 23: Assembly of hexagon screw
Please observe protection
note ISO 16016.
Drawn:
Verified:
Illustration 24: Unscrewing the pin
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
18 of 22
6
Assembly
4.8 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 risk of getting jammed.
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 24; component 4 or 6).
 If feasible resistance is not generated, it may be necessary to refill the grease or vent the system.

If grease escapes from the tapped hole, 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 completed.
 Press all pins out of their seats one after another following the process 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. Afterwards set the axial backlash limitation as per chapter 4.7.
4.9 Displacements - alignment of the couplings
®
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 occur at the same time, the sum of the displacement figures must not exceed Kr or
Kw (see illustration 26).
 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.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
4
KTR-N
Sheet:
Edition:
49413 EN
19 of 22
6
Assembly
4.9 Displacements - alignment of the couplings
Axial displacements
Radial displacements
Angular displacements
Ladm. = L + Ka [mm]
Kw = Emax. - Emin. [mm]
Illustration 25: Displacements
Examples of the displacement
combinations specified in illustration 26:
Example 1:
Kr = 30 %
Kw = 70 %
Example 2:
Kr = 60 %
Kw = 40 %
Ktotal = Kr + Kw  100 %
Illustration 26: Combinations of displacement
Table 11: Displacement figures
Size
Max. axial displacement Ka [mm]
250
500
Max. radial displacement
750
Kr [mm] or
max. angular displacement
1000
Kw [mm]
1500
with speed n [rpm]
2000
3000
75
±1.5
0.95
0.70
0.60
0.50
0.40
0.35
0.30
Size
Max. axial displacement Ka [mm]
250
500
Max. radial displacement
750
Kr [mm] or
max. angular displacement
1000
1500
Kw [mm]
with speed n [rpm]
2000
3000
215
±2.5
2.0
1.4
1.2
1.0
0.8
-
Please observe protection
note ISO 16016.
Drawn:
Verified:
85
±1.5
1.10
0.80
0.65
0.55
0.45
0.40
0.35
240
±2.5
2.5
1.7
1.4
1.2
1.0
-
95
±1.5
1.10
0.80
0.65
0.55
0.45
0.40
0.35
265
±2.5
2.7
1.9
1.6
1.4
-
2019-05-29 Pz
2019-06-12 Pz
105
±2
1.2
0.9
0.7
0.6
0.5
0.4
0.4
120
±2
1.3
0.9
0.8
0.7
0.5
0.5
0.4
280
±2.5
2.9
2.0
1.7
1.4
-
135
±2
1.4
1.0
0.8
0.7
0.6
0.5
305
±2.5
3.1
2.2
1.8
1.5
-
Replacing:
Replaced by:
150
±2
1.5
1.1
0.9
0.8
0.6
0.5
330
±4
3.3
2.3
1.9
1.7
-
170
±2.5
1.7
1.2
1.0
0.9
0.7
0.6
355
±4
3.5
2.5
2.0
1.8
-
190
±2.5
1.9
1.3
1.1
0.9
0.8
0.7
370
±4
3.8
2.8
2.2
-
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
5
KTR-N
Sheet:
Edition:
49413 EN
20 of 22
6
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. It is required in accordance with
DIN EN ISO 12100 (Safety of Machinery) and must protect against
 access with the little finger
 falling down of solid foreign objects.
The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with
DIN EN ISO 13857.
The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium
share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between
pump and electric motor. The cover may only be taken off with standstill of the unit.
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/assembly instructions 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.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
6
KTR-N
Sheet:
Edition:
49413 EN
21 of 22
6
Breakdowns, causes and elimination
Breakdowns
Different operating noise
and/or vibrations occuring
Fracture of hub
Early wear of elastomers
Early wear of pins
(hardening/embrittlement of
the pin elastomer)
!
Causes
Elimination
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
Misalignment
expansion of unit components, modification of the
installation dimension E of the coupling)
3) Inspection of wear
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
Wear of elastomers
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
Screws for axial fastening of
3) Tighten the screws to fasten the hubs and secure against
hubs working loose
working loose
4) Inspection of wear
1) Set the unit out of operation
Fracture of hub due to high 2) Replace complete coupling
impact energy/overload
3) Find out the reason for overload
4) Inspect alignment
1) Set the unit out of operation
2) Replace complete coupling
Operating error of the unit
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
e. g. contact with aggressive
elastomer rings/pins
liquids/oils, ozone influence, 3) Inspect coupling components and replace coupling hubs
too high/low ambient
that are damaged
temperatures etc. causing a 4) Generally assemble new elastomer rings with new pins
physical modification of the 5) Assemble coupling components
elastomer rings
6) Inspect alignment, adjust if necessary
7) Make sure that further physical modifications of the pins are
excluded
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of the
ambient/contact
elastomer rings/pins
temperatures which are too 3) Inspect coupling components and replace coupling hubs
high for the elastomer ring,
that are damaged
max. permissible 4) Generally assemble new elastomer rings with new 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
Vibrations of drive
4) Inspect coupling components and replace coupling hubs
that are damaged
5) Generally assemble new elastomer rings with new pins
6) Assemble coupling components
7) Inspect alignment, adjust if necessary
If you operate with worn elastomer rings proper operation is not ensured.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
REVOLEX® KX / KX-D
Operating/Assembly instructions
Type AB
7
KTR-N
Sheet:
Edition:
49413 EN
22 of 22
6
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, 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 usual inspection intervals.
!
9
Spares inventory, customer service addresses
We recommend to store major spare parts on site to ensure the readiness for use of the machine in case if a
coupling fails.
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:
2019-05-29 Pz
2019-06-12 Pz
Replacing:
Replaced by:
KTR-N dated 2016-11-08
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