KTR BoWex SD, SD-D, SD1 and SD2 Operating/Mounting Instructions
KTR BoWex SD, SD-D, SD1 and SD2 are flexible shaft connections designed to compensate for shaft misalignment caused by manufacturing inaccuracies, thermal expansion, and other factors. These couplings are suitable for various applications and offer reliable performance in demanding environments.
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BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions KTR-N Sheet: Edition: 40111 EN 1 of 23 9 BoWex® Non-failsafe curved-tooth gear couplings types SD, SD-D, SD1, SD2 and their combinations Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions KTR-N Sheet: Edition: 40111 EN 2 of 23 9 The BoWex® curved-tooth gear coupling® is a flexible shaft connection. 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 9 2.1 2.2 2.3 2.4 2.5 2.6 9 9 9 10 10 10 3 4 General advice Safety and advice symbols General hazard warnings Proper use Coupling selection Reference to EC Machinery Directive 2006/42/EC Storage, transport and packaging 11 3.1 3.2 11 11 Storage Transport and packaging Assembly 12 4.1 4.2 4.3 4.4 4.5 12 14 14 15 4.6 4.7 4.8 4.9 Components of the coupling Advice for finish bore Advice on shifting force Assembly of the coupling (general) Assembly of the additional ring (component 4) and slip ring (component 5) BoWex® SD1 Assembly of the hub (component 1) and shifting element (component 2) Displacements - alignment of the couplings Assembly of the slip ring (component 5) - BoWex® SD2 Assembly of the shiftable linkage (component 3) - BoWex® SD1 and SD2 15 16 17 18 19 5 Start-up 20 6 Breakdowns, causes and elimination 21 7 Disposal 22 8 Maintenance and service 23 9 Spares inventory, customer service addresses 23 Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 KTR-N Sheet: Edition: BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 1 40111 EN 3 of 23 9 Technical data Illustration 1: BoWex® SD Illustration 2: BoWex® SD-D Table 1: Dimensions and technical data - type SD and SD-D Size 24 SD 28 SD 32 SD 45 SD Pilot bore Pilot Unbored bored x x x x 65 SD x 80 SD 100 SD 125 SD - Max. finish bore D D1 DA DH DN L L1 L2 L7 24 28 32 45 48 24 28 32 78 88 100 58 70 84 36 44 50 31 33 33 125 100 65 26 40 40 42 50 50 55 55 45 80 99 99 106 114 60 37 65 65 156 140 95 129 55 70 37 80 100 125 80 100 125 195 135 298 175 210 270 124 152 192 186 228 290 90 110 140 90 110 140 47 55 70 27 70 lg. 25 35 45 Dimensions in mm Dimensions in mm Weight with max. bore Size E LH NH NH1 W 24 SD 28 SD 32 SD 4 4 4 52 57 58 18 20.5 20.5 19 21.5 21.5 45 SD 4 63 21.5 22.5 2.56 65 SD 80 SD 100 SD 125 SD 4 6 8 10 79 96 113 149 10 21.5 20.5 21.5 29.5 26 56 72 89 Shifting hub with sleeve in kg 1.08 1.50 1.85 24 34 43 52 25 35 43 52 5.07 10.60 18.87 40.40 Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Driving hub in kg 0.14 0.33 0.43 0.68 0.79 2.30 5.20 9.37 9.44 Mass moment of inertia J with max. bore Shifting hub Driving hub with sleeve in kgcm2 in kgcm2 8.23 0.36 15.62 1.22 22.87 2.17 Shifting force in N 140 180 180 46.07 5.66 250 158.99 523.7 1350 4919 43.96 150.8 401.3 1362.3 350 350 400 450 Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 1 KTR-N Sheet: Edition: 40111 EN 4 of 23 9 Technical data Illustration 1: BoWex® SD Illustration 2: BoWex® SD-D Table 2: Dimensions - shifting ring (component 17) type SD Connection dimensions of BoWex® SD shifting ring (component 17) for mounting of: slip ring SD1 - see table 6 shifting disk etc. Size 24 SD 28 SD 32 SD 45 SD Dimensions in mm D4 ZxM 58 4 x M6 58 4 x M6 75 4 x M6 90 4 x M8 D5 (h7) 48 48 64 75 Size L5 2 2 2 2 65 SD 80 SD 100 SD 125 SD D5 (h7) 100 130 180 220 Dimensions in mm D4 ZxM 114 4 x M8 145 4 x M8 196 6 x M10 236 6 x M10 L5 2 3 4 4 Table 3: Power, torque and speed Size 24 SD 28 SD 32 SD 45 SD 65 SD 80 SD 100 SD 125 SD Power ๐ ๐ Rated 0.0021 0.0047 0.0063 0.015 0.040 0.073 0.13 0.26 ๐๐ [ ] 1/๐๐๐ Max. 0.0042 0.0094 0.013 0.029 0.080 0.15 0.25 0.52 Torque in Nm TKN 20 45 60 140 380 700 1200 2500 TK max 60 135 180 420 1140 2100 3600 7500 TKW 10 23 30 70 190 350 600 1250 Max. speed in rpm 1) 5000 4400 3900 3100 2500 2000 1650 1300 1) Referring to diameter DA without using a slip ring. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 1 KTR-N Sheet: Edition: 40111 EN 5 of 23 9 Technical data Illustration 3: BoWex® SD1 with shiftable linkage Illustration 4: BoWex® SD1 Table 4: Power, torque and speed Size 24 SD1 28 SD1 32 SD1 45 SD1 65 SD1 80 SD1 100 SD1 125 SD1 Power ๐ ๐ Rated 0.0021 0.0047 0.0063 0.015 0.040 0.073 0.13 0.26 Please observe protection note ISO 16016. Drawn: Verified: ๐๐ [ ] 1/๐๐๐ Max. 0.0042 0.0094 0.013 0.029 0.080 0.15 0.25 0.52 Torque in Nm TKN 20 45 60 140 380 700 1200 2500 2023-07-11 Pz/Rt 2023-08-09 Pz TK max 60 135 180 420 1140 2100 3600 7500 Replacing: Replaced by: TKW 10 23 30 70 190 350 600 1250 Max. speed in rpm 3200 3200 2500 2100 1700 1300 1200 1000 KTR-N dated 2022-07-20 KTR-N Sheet: Edition: BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 1 40111 EN 6 of 23 9 Technical data Table 5: Dimensions - type SD1 Size 24 SD1 28 SD1 32 SD1 45 SD1 65 SD1 80 SD1 100 SD1 125 SD1 Finish bore 1) D, D1 min. Max. 10 24 10 28 12 32 45 20 48 7) 25 65 30 80 40 100 50 125 DA DH DH1 50 55 55 Dimensions in mm BS ± 0.1 A5 (keyway) 11 3 12.5 11 3 12.5 13.5 2 17.5 78 78 100 58 70 84 78 88 100 60 14 18.0 125 100 125 20.5 25.5 30.5 35.5 145 182 230 275 140 175 210 270 156 195 235 298 L L1 L2 80 99 99 106 114 129 186 228 290 26 40 40 42 50 55 2) 90 110 140 A1 70 90 110 140 2 16 18.5 28 30.5 -4 1 5 1 2) Dimensions in mm Size DI DN 24 SD1 28 SD1 32 SD1 45 45 60 36 44 50 45 SD1 70 65 3) 65 SD1 80 SD1 100 SD1 125 SD1 96 125 174 214 96 / 95 124 152 192 E LH LH1 L6 NH NH1 W 4 4 4 67 72 78 46 48 53 16 16 21 3 5.5 0.5 19 21.5 21.5 112.5 4 84 58 22 0.5 22.5 250 130.5 164.5 210.5 250.5 4 6 8 10 103 124 152 193 61 75 94 114 25 29 39 44 10 21.5 20.5 21.5 29.5 26 56 72 89 Shifting force set in N 140 180 180 0 6 4 8 25 35 43 52 350 350 400 450 DS ± 1 (keyway) 70.5 70.5 89.5 6) Table 6: Dimensions of shift gear - type SD1 Size Shiftable linkage size Slip ring size DS1 DS2 DS3 DS5 24 SD1 28 SD1 32 SD1 45 SD1 65 SD1 80 SD1 100 SD1 125 SD1 1 1 2 3 3 4 5 5 1.1 1.1 2.2 3.3 4.4 5.5 6.6 7.7 20 20 25 30 30 35 40 40 12 12 17 17 17 21 25 25 11 11 13.5 13.5 13.5 13.5 13.5 13.5 94 94 120 146 170 214 250 290 Dimensions in mm LS1 4) min. Max. 180 190 180 190 240 270 280 310 280 310 321 365 365 410 410 LS2 LS3 4) LS4 LS5 320 320 430 490 490 565 630 630 55 55 60 70 70 70 80 80 35 35 40 40 40 45 45 45 25 25 27 32.5 32.5 37.5 46 46 Dimensions in mm Size 24 SD1 28 SD1 32 SD1 45 SD1 65 SD1 80 SD1 100 SD1 125 SD1 LS6 LS7 LS8 LS9 LS10 LS11 LS12 LS13 30 30 40 40 40 50 50 5) 50 5) 70 70 97.5 120 120 147.5 190 190 400 400 450 600 600 750 1068 1068 90 90 111 140 170 200 250 300 114 114 151 180 210 244 300 350 75 75 100 100 100 120 120 120 110 110 140 140 140 160 160 160 18 18 25 25 25 25 25 25 DS4 16 16 20 20 20 30 30 30 Dimensions with LS1 max. LS14 LS15 LS16 20 55 16 20 55 16 20 80 34 20 90 44 20 90 44 30 100 54 30 110 62 30 110 62 1) Finish bore according to ISO fit H7, feather keyway according to DIN 6885 sheet 1 [JS9]; standard - setscrew on the keyway. With size 24 the setscrew is located opposite the keyway. 2) For radial disassembly the hub collar must be reduced by 5 mm. 3) With size 45 hub component 1 with LS1 = 50 mm, ØDN = 68 mm. 4) Dimension LS3 and LS1 max. = standard mounting dimensions 5) With a continuous base plate dimension LS6 with shiftable linkage size 5 has to be increased by 10 mm at the minimum and with shiftable linkage size 6 by 15 mm at the minimum. The brackets of the driving and driven side have to be adjusted accordingly. 6) ØDN = x / y x = driving hub / y = driven hub 7) Only valid with dimension D. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 1 KTR-N Sheet: Edition: 40111 EN 7 of 23 9 Technical data Illustration 5: BoWex® SD2 with shiftable linkage Illustration 6: BoWex® SD2 Table 7: Power, torque and speed Size 24 SD2 28 SD2 32 SD2 45 SD2 65 SD2 80 SD2 100 SD2 125 SD2 Power ๐ ๐ Rated 0.0021 0.0047 0.0063 0.015 0.040 0.073 0.13 0.26 Please observe protection note ISO 16016. Drawn: Verified: ๐๐ [ ] 1/๐๐๐ Max. 0.0042 0.0094 0.013 0.029 0.080 0.15 0.25 0.52 Torque in Nm TKN 20 45 60 140 380 700 1200 2500 2023-07-11 Pz/Rt 2023-08-09 Pz TK max 60 135 180 420 1140 2100 3600 7500 Replacing: Replaced by: TKW 10 23 30 70 190 350 600 1250 Max. speed in rpm 3200 2500 2100 1700 1300 1200 1000 850 KTR-N dated 2022-07-20 KTR-N Sheet: Edition: BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 1 40111 EN 8 of 23 9 Technical data Table 8: Dimensions - type SD2 Size 24 SD2 28 SD2 32 SD2 45 SD2 65 SD2 80 SD2 100 SD2 125 SD2 Finish bore 1) D, D1 min. Max. 10 24 10 28 12 32 45 20 48 7) 25 65 30 80 40 100 50 125 Dimensions in mm L L1 L2 A1 A5 80 99 99 106 114 129 186 228 290 26 40 40 42 50 55 2) 90 110 140 50 55 55 9.5 16 16 3 3 2 60 16 2 70 90 110 140 18 23 28 30 -4 1 5 1 BS ± 0.1 (keyway) 12.5 17.5 18 DA DH 88 113 136 58 70 84 20.5 154 100 25.5 30.5 35.5 38.5 198 250 295 355 140 175 210 270 2) Dimensions in mm Size DN 24 SD2 28 SD2 32 SD2 36 44 50 45 SD2 65 3) 65 SD2 80 SD2 100 SD2 125 SD2 96 / 95 124 152 192 E LH LH1 NH NH1 W Shifting force set in N 4 4 4 51 56 57 30 32 32 19 21.5 21.5 19 21.5 21.5 140 180 180 130.5 4 62 36 22.5 22.5 250 164.5 210.5 250.5 300.5 4 6 8 10 78 95 113 149 36 46 55 70 10 21.5 20.5 21.5 29.5 26 56 72 89 25 35 43 52 25 35 43 52 350 350 400 450 DS ± 0.1 (keyway) 70.5 89.5 112.5 6) Table 9: Dimensions of shift gear - type SD2 Size Shiftable linkage size Slip ring size DS1 DS2 DS3 DS5 24 SD2 28 SD2 32 SD2 45 SD2 65 SD2 80 SD2 100 SD2 125 SD2 1 2 3 3 4 5 5 6 1.1 2.2 3.3 4.4 5.5 6.6 7.7 8.8 20 25 30 30 35 40 40 40 12 17 17 17 21 25 25 35 11 13.5 13.5 13.5 13.5 13.5 13.5 13.5 94 120 146 170 214 250 290 360 Dimensions in mm LS1 min. Max. 180 190 240 270 280 310 280 310 321 365 365 410 410 540 LS2 LS3 4) LS4 LS5 320 430 490 490 565 630 630 760 55 60 70 70 70 80 80 80 35 40 40 40 45 45 45 45 25 27 32.5 32.5 37.5 46 46 56 Dimensions in mm Size 24 SD2 28 SD2 32 SD2 45 SD2 65 SD2 80 SD2 100 SD2 125 SD2 LS6 LS7 LS8 LS9 LS10 LS11 LS12 LS13 30 40 40 40 50 50 5) 50 5) 50 5) 70 97.5 120 120 147.5 190 190 265 400 450 600 600 750 1068 1068 1068 90 111 140 170 200 250 300 360 114 151 180 210 244 300 350 420 75 100 100 100 120 120 120 120 110 140 140 140 160 160 160 160 18 25 25 25 25 25 25 25 DS4 16 20 20 20 30 30 30 30 Dimensions with LS1 max. LS14 LS15 LS16 20 55 16 20 80 34 20 90 44 20 90 44 30 100 54 30 110 62 30 110 62 30 110 62 1) Finish bore according to ISO fit H7, feather keyway according to DIN 6885 sheet 1 [JS9]; standard - setscrew on the keyway. With size 24 the setscrew is located opposite the keyway. 2) For radial disassembly the hub collar must be reduced by 5 mm. 3) With size 45 hub component 1 with L1 = 50 mm, ØDN = 68 mm. 4) Dimension LS3 and LS1 max. = standard mounting dimensions 5) With a continuous base plate dimension LS6 with shiftable linkage size 5 has to be increased by 10 mm at the minimum and with shiftable linkage size 6 by 15 mm at the minimum. The brackets of the driving and driven side have to be adjusted accordingly. 6) ØDN = x / y x = driving hub / y = driven hub 7) Only valid with dimension D1. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 2 Advice 2.1 General advice KTR-N Sheet: Edition: 40111 EN 9 of 23 9 Please read carefully through these operating/assembly instructions before you start up the coupling. 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 STOP ! ๏ 2.3 STOP Safety and advice symbols 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. General hazard warnings 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. 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. • Secure the coupling against accidental contact. Provide for the necessary protection devices and covers. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 2 Advice 2.4 Proper use KTR-N Sheet: Edition: 40111 EN 10 of 23 9 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 BoWex® described in here corresponds to the state of the art at the time of printing of these operating/assembly instructions. 2.5 ! Coupling selection For a long-lasting 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 „BoWex®“). If the operating conditions (performance, speed, modifications on engine and machine) change, the coupling selection must be reviewed. Make sure the technical data regarding torque refer to the sleeve only. The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility. For drives subjected 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 subjected 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: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 3 Storage, transport and packaging 3.1 Storage KTR-N Sheet: Edition: 40111 EN 11 of 23 9 The coupling hubs are supplied in preserved condition and can be stored in a dry and roofed place for 6 - 9 months. The features of the coupling sleeves remain unchanged for up to 5 years with favourable storage conditions. ! 3.2 ! 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. Make sure that condensation is not generated. The best relative air humidity is less than 65 %. 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: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 4 KTR-N Sheet: Edition: 40111 EN 12 of 23 9 Assembly The coupling is generally supplied with the shifting force set (see table 1, 5 and 8). Before assembly the coupling has to be inspected for completeness. 4.1 Components of the coupling Components of BoWex® type SD Component 1 2 7 Quantity 1 1 2 Description Hub Shifting element "SD" Setscrew DIN EN ISO 4029 Illustration 7: BoWex® SD Components of BoWex® type SD-D Component 1 2 7 Quantity 1 1 2 Description Hub Shifting element "SD-D" Setscrew DIN EN ISO 4029 Illustration 8: BoWex® SD-D Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 4 Assembly 4.1 Components of the coupling KTR-N Sheet: Edition: 40111 EN 13 of 23 9 Components of BoWex® SD1 with shiftable linkage Component 1 2 3 4 5 6 7 Quantity 1 1 1 1 1 4/6 1) 2 Description Hub Shifting element "SD" Shiftable linkage Additional ring Slip ring with lubricating nipple Cap screws DIN EN ISO 4726 Setscrew DIN EN ISO 4029 1) Quantity depends on coupling size Illustration 9: BoWex® SD1 with shiftable linkage Components of BoWex® SD2 with shiftable linkage Component 1 2 3 5 7 Quantity 1 1 1 1 2 Description Hub Shifting element Shiftable linkage Slip ring with lubricating nipple Setscrew DIN EN ISO 4029 Illustration 10: BoWex® SD2 with shiftable linkage Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 4 Assembly 4.2 Advice for finish bore KTR-N Sheet: Edition: 40111 EN 14 of 23 9 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 (steel hubs) machined by the customer have to observe concentricity resp. axial runout (see illustration 11). • Make absolutely sure to observe the figures for ØDmax.. • Carefully align the hubs when the finish bores are drilled. • Provide for a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the hubs axially. Illustration 11: 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 10: Setscrew DIN EN ISO 4029 (component 7) Size Dimension G in mm Dimension T in mm Tightening torque TA in Nm 24 M5 6 2 28 M8 10 10 32 M8 10 10 45 M8 10 10 65 M10 15 / 20 1) 17 80 M10 20 17 100 M12 30 40 125 M16 40 80 1) Length of hub 55 mm T = 15 mm, length of hub 70 mm T = 20 mm Table 11: Recommended fit pairs acc. to DIN 748-1 Bore in 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.). The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility. 4.3 ๏ Advice on shifting force Before delivery the shifting force is set and the screw plug is marked with marking lacquer. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 4 Assembly 4.4 Assembly of the coupling (general) ๏ KTR-N Sheet: Edition: 40111 EN 15 of 23 9 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 make sure that the distance dimension E (see table 1, 5 and 8) is observed to allow for axial clearance of the sleeve while in operation. Disregarding this advice may cause damage to the coupling. 4.5 Assembly of the additional ring (component 4) and slip ring (component 5) - BoWex® SD1 ๏ Before assembly inspect the slip ring (component 5) for any damages and make sure the lubricating nipples exist. • Push the slip ring (component 5) on the additional ring (component 4) (see illustration 12). Illustration 12: Assembly of slip ring • Set the additional ring with the slip ring onto the shifting element (component 2) (see illustration 13). • Hand-tighten the components via the cap screws (component 8) first. Afterwards tighten the cap screws to the tightening torques TA specified in table 12. • Lubricate the slip ring through the lubricating nipples with a heat-resistant bearing grease while turning the slip ring manually repeatedly. Illustration 13: Assembly of additional ring ! Make sure the max. permissible speed of the slip ring is not exceeded (see table 13). After assembly it must be possible to rotate the slip ring manually. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 KTR-N Sheet: Edition: BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 40111 EN 16 of 23 9 4 Assembly 4.5 Assembly of the additional ring (component 4) and slip ring (component 5) - BoWex® SD1 Table 12: Cap screws DIN EN ISO 4762 (component 6) Size Slip ring size Cap screw DIN EN ISO 4762 Tightening torque TA in Nm 24 SD1 1.1 M6 x 20 14 28 SD1 1.1 M6 x 20 14 32 SD1 2.2 M6 x 25 14 45 SD1 3.3 M8 x 25 35 65 SD1 4.4 M8 x 30 35 80 SD1 5.5 M8 x 30 35 100 SD1 6.6 M10 x 50 69 125 SD1 7.7 M10 x 55 69 5.5 M12 86 1300 6.6 M16 210 1200 7.7 M16 210 1000 8.8 M16 210 850 Table 13: Slip ring (component 5) Slip ring size Screw Tightening torque TA in Nm Max. perm. speed in rpm 4.6 1.1 M6 10 3200 2.2 M8 25 2500 3.3 M8 25 2100 4.4 M10 49 1700 Assembly of the hub (component 1) and shifting element (component 2) • Mount the hub (component 1) on the shaft of the driving side and the shifting element (component 2) on the shaft of the driven side (see illustration 14). Illustration 14: Assembly of hub and shifting element • Shift the power packs in axial direction until the distance dimension E is achieved (see illustration 15). • 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 with a cup point (component 7) (tightening torque see table 10). Illustration 15: Assembly of coupling Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 4 Assembly 4.7 Displacements - alignment of the couplings KTR-N Sheet: Edition: 40111 EN 17 of 23 9 The displacement figures specified in table 14 provide for sufficient safety to compensate for external influences like, for example, thermal expansion or foundation settling. 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 14). If the figures are exceeded, the coupling will be damaged. ! Please note: • The displacement figures specified in table 14 are maximum figures which must not arise in parallel. If radial and angular displacement arises at the same time, the permissible radial displacements of the coupling halves have to be reduced as follows: ๐ฅ๐พ๐ ๐ฅ๐พ๐ ๐ง๐ข๐. = ๐ฅ๐พ๐ − • ๐ฅ๐๐ค 2๐ฅ๐พ๐ค ๏Ww = angular shaft displacement • The displacement figures specified are general standard figures that apply up to an ambient temperature of 80 °C, ensuring a sufficient service life of the BoWex® coupling. • Inspect with a dial gauge, ruler or feeler gauge whether the permissible displacement figures specified in table 14 can be observed. Axial displacements Radial displacements Angular displacements Radial and angular displacements Illustration 16: Displacements Examples of the displacement combinations specified in illustration 17: Example 1: ๏Kr = 30 % ๏Kw = 70 % Illustration 17: Combinations of displacement Example 2: ๏Kr = 60 % ๏Kw = 40 % ๏Ktotal = ๏Kr + ๏Kw ๏ฃ 100 % Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 KTR-N Sheet: Edition: BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 4 Assembly 4.7 Displacements - alignment of the couplings 40111 EN 18 of 23 9 Table 14: Displacement figures Size Max. axial displacement ๏Ka in mm Max. radial displacement with n=1500 rpm ๏Kr in mm Max. angular displacement with n=1500 rpm ๏Kw in degree 4.8 24 ±1 28 ±1 32 ±1 45 ±1 65 ±1 80 ±1 100 ±1 125 ±1 0.2 0.2 0.25 0.25 0.3 0.3 0.3 0.3 1 1 1 1 1 1 1 1 Assembly of the slip ring (component 5) - BoWex® SD2 ๏ Before assembly inspect the slip ring (component 5) for any damages and make sure the lubricating nipples exist. • Before separating the slip ring halves (component 5) mark the position of the slip ring halves screwed by the manufacturer. • Insert the unscrewed slip ring halves in the shifting keyway of the shifting element (component 2) (see illustration 18). Pay attention to the marked position of the slip ring halves. • Hand-tighten the components by means of the screws first. Afterwards tighten the screws at the tightening torque TA specified in table 15. • Lubricate the slip ring through the lubricating nipples with a heat-resistant bearing grease while turning the slip ring manually repeatedly. Illustration 18: Assembly of slip ring Table 15: Slip ring size Screw Tightening torque TA in Nm Max. perm. speed in rpm ! 1.1 M6 10 3200 2.2 M8 25 2500 3.3 M8 25 2100 4.4 M10 49 1700 5.5 M12 86 1300 6.6 M16 210 1200 7.7 M16 210 1000 8.8 M16 210 850 Make sure the max. permissible speed of the slip ring is not exceeded (see table 15). After assembly it must be possible to rotate the slip ring manually. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 KTR-N Sheet: Edition: BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 4 Assembly 4.9 Assembly of the shiftable linkage (component 3) - BoWex® SD1 and SD2 40111 EN 19 of 23 9 Before starting the assembly the coupling resp. shiftable linkage has to be inspected for completeness. Component 3.1 3.2 3.3 3.4 3.5 3.6 3.7 5 Quantity 2 1 1 2 1 2 2 1 Quantity Shifting fork Shift lever with clamp Shifting shaft Eye type bearing DIN 504 with lubricating nipple Clamping ring Clamping screws for shifting forks Clamping screws for shift lever Slip ring with lubricating nipple Illustration 19: BoWex® SD with shiftable linkage • Insert the spigot of the slip ring (component 5) in the shifting forks (component 3.1) (see illustration 19). • Align the shifting forks, shifting shaft (component 3.3) and eye type bearings (component 3.4) flush with the slip ring. Observe dimensions LS7 and LS9 (see illustration 20 resp. table 6 and 9). Make sure the shifting forks evenly fit with the shifting spigots. ๏ ! STOP Unscrew the clamping screws (component 3.6) for setting the shifting forks. The shifting forks have to be arranged vertically to the base plate. Illustration 20 Make absolutely sure to observe the sequence of assembly, since otherwise the slip ring may get stuck resp. jammed during operation of the coupling. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions KTR-N Sheet: Edition: 4 Assembly 4.9 Assembly of the shiftable linkage (component 3) - BoWex® SD1 and SD2 40111 EN 20 of 23 9 • Tighten the clamping screws (component 3.6) of the shifting forks to the tightening torques T A specified in table 16. • Mount the eye type bearing to the base plate. With a continuous base plate the dimension LS6 (see illustration 20 resp. table 6 and 9) with shiftable linkage size 5 has to be increased by 10 mm at the minimum and with shiftable linkage size 6 by 15 mm at the minimum. The brackets of the driving and driven side have to be adjusted accordingly. ! • Fasten the shifting lever (component 3.2) on the shifting shaft (component 3.3). • When the coupling is engaged, the shifting lever has to be vertically installed. When the coupling hub is in operation the slip ring has to be disengaged. Support or fasten the shifting lever in vertical position. ! Make absolutely sure to observe the sequence of assembly, since otherwise the slip ring may get stuck resp. jammed during operation of the coupling. STOP • Tighten the clamping screws (component 3.7) of the shifting lever to the tightening torques T A specified in table 16. • Secure the shifting shaft axially via the clamping ring (component 3.5) and the clamping screws of the shifting lever (component 3.7 and see illustration 19). • Lubricate the eye type bearing with bearing grease after assembly. Table 16: Shiftable linkage size Shifting fork Clamping screw (component 3.6) Tightening torque TA in Nm Shift lever Clamping screw (component 3.7) Tightening torque TA in Nm 5 1 2 3 4 5 6 M6 M8 M8 M12 M12 M12 10 25 25 86 86 86 M6 M6 M8 M12 M12 M12 10 10 25 86 86 86 Start-up Before start-up of the coupling, 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 directive 2014/14/EU and must protect against • access with a little finger • falling down of solid foreign objects. The coupling protection is not part of KTR's scope of delivery and is the customer's responsibility. It must have sufficient distance to the rotating components to safely avoid contact. Depending on the outside diameter DH of the coupling, we recommend the following minimum distance: ØDH to 50 mm = 6 mm, ØDH 50 mm to 120 mm = 10 mm, ØDH from 120 mm = 15 mm. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 5 KTR-N Sheet: Edition: 40111 EN 21 of 23 9 Start-up Please check if a proper enclosure (ignition protection, coupling protection, contact protection) has been mounted and the operation of the coupling is not affected by the enclosure. The same applies for test runs and rotational direction inspections. The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with DIN EN ISO 13857. 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 can result in an improper use of the BoWex® coupling. 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 improper use: • Important data for the coupling selection are not forwarded. • The calculation of the shaft-hub-connection is 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 are fallen below/exceeded. • Components are mixed up by mistake/assembled incorrectly. • No original KTR components (purchased parts) are used. • Old/already worn out sleeves or sleeves stored for too long are used. • Maintenance intervals are not observed. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 6 40111 EN 22 of 23 9 Breakdowns, causes and elimination Breakdowns Different operating noise and/or vibrations occuring Causes Elimination Micro friction by faulty alignment on the spline of the nylon sleeve Screws for axial fastening of hubs working loose Fracture of the nylon sleeve/spline due to high shock energy/overload Fracture of the nylon sleeve/spline Operating parameters do not meet with the performance of the coupling Operating error of the unit Vibrations of drive Excessive wear on the spline of sleeve e. g. contact with aggressive liquids/oils, ozone influence, too high/low ambient temperatures etc. causing a physical modification of the nylon sleeve 7 KTR-N Sheet: Edition: 1) Set the unit out of operation 2) Eliminate the reason for the misalignment (e. g. loose foundation bolts, fracture 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) Inspect alignment of coupling 3) Tighten the screws 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) Disassemble the coupling and remove remainders of the nylon sleeve 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert nylon sleeve, assemble coupling components 5) Find out the reason for overload 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) Disassemble the coupling and remove remainders of the nylon sleeve 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert nylon sleeve, assemble coupling components 5) Instruct and train the service staff 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the nylon sleeve 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert nylon sleeve, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Find out the reason for vibrations 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the nylon sleeve 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert nylon sleeve, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Make sure that further physical modifications of the sleeve are excluded Disposal In respect of environmental protection we would ask you to dispose of the packaging resp. products on termination of their service life in accordance with the legal regulations resp. standards that apply. • 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. Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 BoWex® SD, SD-D, SD1 and SD2 Operating/Assembly instructions 8 KTR-N Sheet: Edition: 40111 EN 23 of 23 9 Maintenance and service Shifting hub: • Within the scope of the machine inspection periods the fit of the shifting hub has to be cleaned and lubricated (e. g. with Molykote MoS2, copper paste). • With a high shifting frequency of the coupling we recommend one visual inspection and lubrication of the shifting hub monthly. • In case of operation with dust and granular material as well as high air humidity one visual inspection and lubrication per month and an operational inspection every three months has to be performed (engagement/disengagement of the coupling at standstill). Slip ring: • Before every lubricating process the slip ring has to be inspected for damages (visual inspection). • It must be possible to manually rotate the shifting hub element freely in the slip ring. • The lubrication of the slip ring depends on the speed and operating periods of the machine (see table 17). • The intervals for inspection and lubrication specified apply for drives with standard load. ๏ For drives with high load, e. g. permanent operation during 3 shifts, hot operation, etc., consult with us. Table 17: Max. perm. speed in rpm of the slip rings Daily operating period of machines in h Visual inspection and lubrication intervals ! 9 3200 to 2100 8 16 1/2 month 1700 to 1000 8 16 1 month 1/2 month 850 to 700 8 16 1 1/2 months 1 month For operation sites, e. g. operation with dust and granular materials, high air humidity, high ambient temperatures, outdoor operations, etc., the intervals of visual inspections and lubrication have to be reduced. 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. KTR Systems GmbH Carl-Zeiss-Str. 25 D-48432 Rheine Phone: +49 5971 798-0 E-mail: [email protected] Please observe protection note ISO 16016. Drawn: Verified: 2023-07-11 Pz/Rt 2023-08-09 Pz Replacing: Replaced by: KTR-N dated 2022-07-20 ">

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Key features
- Flexible shaft connection
- Compensates for misalignment
- Suitable for various applications
- Reliable performance
- Shiftable linkage
Frequently asked questions
The BoWexยฎ curved-tooth gear couplingยฎ is a flexible shaft connection. It is able to compensate for shaft misalignment, for example caused by manufacturing inaccuracies, thermal expansion, etc.
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.
Before starting the assembly the coupling resp. shiftable linkage has to be inspected for completeness. ... Make absolutely sure to observe the sequence of assembly, since otherwise the slip ring may get stuck resp. jammed during operation of the coupling.
The displacement figures specified in table 14 provide for sufficient safety to compensate for external influences like, for example, thermal expansion or foundation settling. In order to ensure a long service life of the coupling, the shaft ends have to be accurately aligned.