KTR EVOLASTIC Operating/Mounting Instructions
KTR EVOLASTIC is a highly torsionally flexible, non-slip and backlash-free shaft and flange coupling. It dampens torsional vibrations and load shocks, reduces structure-borne noise transmission and compensates for axial, radial and angular displacements above average. Types D2H and DFH are double-cardanic drive shafts. They bridge larger shaft distances and connect the power packs in a homokinetic and flexibly soft way.
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EVOLASTIC® Operating/Assembly instructions Type D2H and DFH KTR-N Sheet: Edition: EVOLASTIC® highly flexible coupling type D2H and DFH and their combinations Type D2H Type DFH Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- 48611 EN 1 of 20 1 EVOLASTIC® Operating/Assembly instructions Type D2H and DFH KTR-N Sheet: Edition: 48611 EN 2 of 20 1 EVOLASTIC® type D2H and DFH is a highly torsionally flexible, non-slip and backlash-free shaft and flange coupling. It dampens torsional vibrations and load shocks, reduces structure-borne noise transmission and compensates for axial, radial and angular displacements above average. Types D2H and DFH are double-cardanic drive shafts. They bridge larger shaft distances and connect the power packs in a homokinetic and flexibly soft way. Table of contents 1 2 3 4 Technical data 3 1.1 1.2 3 5 Coupling dimensions and technical data General dimensions and torques Advice 6 2.1 2.2 2.3 2.4 2.5 2.6 6 6 6 7 7 7 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 8 3.1 3.2 8 8 Storage Transport and packaging Assembly 8 4.1 Types of hubs 4.2 Components of the couplings 4.3 Advice for finish bore 4.4 General advice for assembly 4.5 Assembly of clamping sleeves (component 9 and 10) 4.6 Assembly of the hubs (component 3) 4.7 Assembly of the flange (component 4) 4.8 Assembly of elastomer part (component 1) 4.9 Assembly of the intermediate shaft (component 2) 4.10 Displacements - alignment of the couplings 8 9 11 12 12 13 13 13 14 15 5 Start-up 17 6 Breakdowns, causes and elimination 17 7 Disposal 19 8 Maintenance and service 19 9 Spares inventory, customer service addresses 20 Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48611 EN 3 of 20 1 Type D2H Illustration 1: EVOLASTIC® type D2H (size 12 to 280) Illustration 2: EVOLASTIC® type D2H (size 360 and 560) Table 1: Dimensions - type D2H Size 12 24 48 60 86 125 200 280 360 560 DH 122 150 170 200 200 260 260 300 340 370 DN1 80 100 115 140 140 160 160 160 195 200 D1 55 70 85 100 100 110 110 110 130 140 DR 60 70 85 100 100 125 125 145 160 170 Dimensions 1) [mm] B1 32 42 46 58 58 70 70 80 85 105 B2 28 36 40 50 50 63 63 72 78 95 E 4 6 6 8 8 8 8 8 8 10 L2 42 50 55 66 66 80 80 94 100 125 Cap screws DIN EN ISO 4762 M Z x Pitch M10 3 x 120° M12 3 x 120° M14 4 x 90° M16 3 x 120° M16 4 x 90° M20 3 x 120° M20 4 x 90° M20 4 x 90° M20 4 x 90° M24 4 x 90° N 32 38 41 50 50 60 60 70 80 100 1) Dimension L and DBSE as well as total weight depend on the mounting length. Table 2: Technical data - type D2H Mass moment of inertia 2) with maximum bore of coupling [kgm2] Size J1 0.0030 0.0080 0.0160 0.0360 0.0370 0.1110 0.1160 0.1960 0.3540 0.5890 12 24 48 60 86 125 200 280 360 560 J4 0.0030 0.0080 0.0160 0.0360 0.0370 0.1110 0.1160 0.1960 0.3540 0.5890 2) Mass moments of inertia J2 and J3 depend on the mounting length. ! In case if a dimensional drawing was prepared for the coupling, the dimensions specified have to be primarily observed. Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48611 EN 4 of 20 1 Type DFH Illustration 3: EVOLASTIC® type DFH (size 12 to 280) Illustration 4: EVOLASTIC® type DFH (size 360 and 560) Table 3: Dimensions - type DFH Size 12 24 48 60 86 125 200 280 360 560 Flange connection acc. to SAE - J620 / diameter 1) 6.5“ 7.5“ 6.5“ 7.5“ 7.5“ 8“ 10“ 10“ 11.5“ 10“ 11.5“ 10“ 11.5“ 10“ 11.5“ 14“ 11.5“ 14“ 14“ 14“ Dimensions 2) [mm] D5 180 190 180 190 190 200 260 270 310 270 310 270 310 270 310 405 310 405 405 405 Cap screws DIN EN ISO 4762 DH DN1 D1 DR B1 B2 E L5 L7 L2 N M Z x Pitch 122 80 55 60 32 28 4 4 6 42 32 M10 3 x 120° 150 100 70 70 42 36 6 6 6 50 38 M12 3 x 120° 170 115 85 85 46 40 6 8 6 55 41 M14 4 x 90° 4 10 200 140 100 100 58 50 8 6 10 66 50 M16 3 x 120° 200 140 100 100 58 50 8 6 10 66 50 M16 4 x 90° 260 160 110 125 70 63 8 9 10 80 60 M20 3 x 120° 260 160 110 125 70 63 8 9 10 80 60 M20 4 x 90° 300 160 110 145 80 72 8 9 10 94 70 M20 4 x 90° 340 370 195 200 130 140 160 170 85 105 78 95 8 10 9 15 10 25 100 125 80 100 M20 M24 4 x 90° 4 x 90° 1) For dimensions of flange connection see table 5. 2) Dimension L and DBSE as well as total weight depend on the mounting length. ! In case if a dimensional drawing was prepared for the coupling, the dimensions specified have to be primarily observed. Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 1 Technical data 1.2 General dimensions and torques KTR-N Sheet: Edition: 48611 EN 5 of 20 1 Table 4: Technical data - type DFH Mass moment of inertia 2) with maximum bore of coupling [kgm2] J1 J4 0.013 0.003 0.020 0.016 0.008 0.023 0.026 0.034 0.016 0.091 0.103 0.036 0.165 0.105 0.037 0.166 0.129 0.111 0.199 0.135 0.205 0.116 0.572 0.226 0.196 0.593 0.628 0.354 0.794 0.589 Flange connection acc. to SAE - J620 / diameter 1) Size 6.5“ 7.5“ 6.5“ 7.5“ 7.5“ 8“ 10“ 10“ 11.5“ 10“ 11.5“ 10“ 11.5“ 10“ 11.5“ 14“ 11.5“ 14“ 14“ 14“ 12 24 48 60 86 125 200 280 360 560 1) For dimensions of flange connection see table 9. 2) Mass moments of inertia J2 and J3 depend on the mounting length. Table 5: Flange dimensions according to SAE J 620 Nominal size 6.5“ 215.9 200.02 6 x 60° 9 Dimension DA Dimension D4 Z x Pitch Dimension DL Flange dimensions [mm] 8“ 10“ 263.52 314.32 244.47 295.27 6 x 60° 8 x 45° 11 11 7.5“ 241.3 222.25 8 x 45° 9 11.5“ 352.42 333.37 8 x 45° 11 14“ 466.62 438.15 8 x 45° 14 Table 6: Torques Size 12 24 48 60 86 125 200 280 360 560 Elastomer type SN MN SN MN SN MN SN MN SN MN SN MN SN MN WN MN WN SN MN WN SN MN Please observe protection note ISO 16016. Torque [Nm] TKN 100 120 200 240 420 480 500 600 760 860 1100 1250 1700 2000 2400 2800 3200 3400 3600 5000 5200 5600 Drawn: Verified: TK max 200 240 400 480 840 960 1000 1200 1520 1720 2200 2500 3400 4000 4800 5600 6400 6800 7200 10000 10400 11200 TK max1 300 360 600 720 1260 1440 1500 1800 2280 2580 3300 3750 5100 5250 6100 6100 9600 10200 10800 14000 14000 14000 2022-05-03 Pz/Ex 2022-05-12 Pz TKW 40 48 80 96 168 192 200 240 304 344 440 500 680 800 960 1120 1280 1360 1440 2000 2080 2240 Replacing: Replaced by: Perm. operating speed [rpm] n nmax. 4500 5000 5400 6000 3780 4200 4500 5000 3780 4200 4500 5000 3240 3600 3600 4000 3600 4000 4050 4500 2880 3200 3240 3600 3060 3400 3240 3600 2700 3000 3060 3400 2700 3000 3060 3400 3060 3400 2250 2500 2520 2800 2700 3000 --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 1 Technical data 1.2 General dimensions and torques KTR-N Sheet: Edition: 48611 EN 6 of 20 1 Maximum torque of coupling TK max = rated torque of coupling TKN x 2.0. The maximum torque TK max. signifies short-term torque peaks (e.g. when passing through the resonance). TK max may arise at the maximum 50,000 times as vibratory torque or 100,000 times as pulsating torque. Triple torque of coupling TK max1 = rated torque of coupling TKN x ~3.0. The triple rated torque TK max1 is the torque that may arise only rarely, but only 1,000 times at the maximum. Exceeding the triple torque of TK max1 may cause impairment resp. damage of the coupling components. 2 Advice 2.1 General advice Please read through these operating/assembly instructions carefully 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: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 2 Advice 2.4 Intended use KTR-N Sheet: Edition: 48611 EN 7 of 20 1 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 EVOLASTIC® 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 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 "EVOLASTIC®"). If the operating conditions (performance, speed, modifications on engine and machine) change, the coupling selection must be reviewed. Make sure that the technical data regarding torque refer to the elastomer part 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 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: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 3 Storage, transport and packaging 3.1 Storage KTR-N Sheet: Edition: 48611 EN 8 of 20 1 The coupling hubs are supplied in preserved condition and can be stored in a dry and roofed place for 6 - 9 months. With favourable storage conditions the properties of the elastomer part remain unchanged for up to 5 years. ! ! 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 %. Please bear in mind that the elastomer part may be stored horizontally only. 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. 4 Assembly The coupling is supplied in the following subassemblies and single parts. Before assembly the coupling has to be inspected for completeness. 4.1 Types of hubs Type 1.0 Hub with feather keyway and setscrew Type 3.0 Hub with spline bore Type 3.1 Clamping hub N with spline bore Illustration 5: Types of hubs Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 4 Assembly 4.2 Components of the couplings KTR-N Sheet: Edition: Components of type D2H Component 1 2 3 5 6 7 8 9 1) 10 1) Quantity 2 1 2 see table 7 see table 7 see table 7 see table 7 see table 7 see table 7 Description Elastomer part E Intermediate shaft Hub axial Cap screw DIN EN ISO 4762 - 12.9 Ratchet washer Cap screw DIN EN ISO 4762 - 12.9 Ratchet washer Clamping sleeve DIN 7346 Clamping sleeve DIN 7346 1) Component 9 and 10 is omitted with size 12 Illustration 6: EVOLASTIC® type D2H (size 12 to 280) Illustration 7: EVOLASTIC® type D2H (size 360 and 560) Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- 48611 EN 9 of 20 1 EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 4 Assembly 4.2 Components of the couplings KTR-N Sheet: Edition: Components of type DFH Component 1 2 3 4 5 6 7 8 9 1) 10 1) Quantity 1 1 1 1 see table 7 see table 7 see table 7 see table 7 see table 7 see table 7 Description Elastomer part E Intermediate shaft Hub axial Flange Cap screw DIN EN ISO 4762 - 12.9 Ratchet washer Cap screw DIN EN ISO 4762 - 12.9 Ratchet washer Clamping sleeve DIN 7346 Clamping sleeve DIN 7346 1) Component 9 and 10 is omitted with size 12 Illustration 8: EVOLASTIC® type DFH (size 12 to 280) Illustration 9: EVOLASTIC® type DFH (size 360 and 560) Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- 48611 EN 10 of 20 1 EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 4 Assembly 4.2 Components of the couplings KTR-N Sheet: Edition: 48611 EN 11 of 20 1 Table 7: Number of cap screws, ratchet washers and clamping sleeves Size Number of cap screws (component 5) Number of ratchet washers (component 6) Number of cap screws (component 7) Number of ratchet washers (component 8) Number of clamping sleeves (component 9) Number of clamping sleeves (component 10) 4.3 12 6 6 6 6 6 - 24 6 6 6 6 6 12 48 8 8 8 8 8 16 60 6 6 6 6 6 12 86 8 8 8 8 8 16 125 6 6 6 6 6 12 200 8 8 8 8 8 16 280 8 8 8 8 8 16 360 8 8 16 16 8 - 560 8 8 16 16 8 - Advice for finish bore STOP 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. • Hub bores machined by the customer have to observe concentricity resp. axial runout (see illustration 10). • Make absolutely sure to observe the figures for ØDmax.. • Carefully align the hubs when the finish bores are drilled. • If possible, provide for a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the hubs axially. Illustration 10: 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 8: Setscrew DIN EN ISO 4029 Size Dimension G Dimension T Tightening torque TA [Nm] 12 M8 15 10 Please observe protection note ISO 16016. Drawn: Verified: 24 M8 15 10 48 M8 20 10 60 M10 20 17 2022-05-03 Pz/Ex 2022-05-12 Pz 86 M10 20 17 125 M10 20 17 200 M10 20 17 Replacing: Replaced by: 280 M12 30 40 --- 360 M12 30 40 560 M16 40 80 EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 4 Assembly 4.4 General advice for assembly ! KTR-N Sheet: Edition: 48611 EN 12 of 20 1 The EVOLASTIC® coupling may only be assembled in the order described in here. In case if a dimensional drawing was prepared for the coupling, the dimensions specified have to be primarily observed. 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 on the shaft. STOP ! 4.5 Touching the heated hubs causes burns. Please wear safety gloves. We recommend to secure all screw connections against working loose additionally to securing screws by the ratchet washer, e. g. applying Loctite screw adhesive (average strength), while the elastomer parts must not come into contact with any type of adhesive. Assembly of clamping sleeves (component 9 and 10) • Only valid from size 24: Drive the clamping sleeves (component 9) in the hub axial (component 3) or flange (component 4) (see illustration 11 and 12). • Only valid for size 24 to 280: Drive the clamping sleeves (component 10) in the intermediate shaft (component 2) (see illustration 13). ! For the assembly of the clamping sleeves observe dimensions DB, LB1 and LB2 according to catalogue "EVOLASTIC® type E". Any kind of twisting must be eliminated with assembly of the elastomer part (component 1). Illustration 11: Assembly of clamping sleeves (component 9) (Type D2H) Please observe protection note ISO 16016. Drawn: Verified: Illustration 12: Assembly of clamping sleeves (component 9) (Type DFH) 2022-05-03 Pz/Ex 2022-05-12 Pz Illustration 13: Assembly of clamping sleeves (component 10) Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 4 Assembly 4.6 Assembly of the hubs (component 3) KTR-N Sheet: Edition: 48611 EN 13 of 20 1 • Mount the hubs (component 3) on the shaft of the driving and driven side. • Fasten the hubs by tightening the setscrew DIN EN ISO 4029 with a cup point (tightening torque TA see table 8) or an end plate. 4.7 Assembly of the flange (component 4) • Push the flange (component 4) into the centering of the flywheel. • Align the through holes of the connection flange to the threads of the flywheel. • Hand-tighten the components via suitable screws (not part of the scope of delivery) first. • Tighten the screws at the tightening torques TA specified in table 9 by means of a suitable torque key. We recommend to secure all screw connections against working loose additionally, e. g. applying Loctite screw adhesive (average strength), while the elastomer parts must not come into contact with any type of adhesive. ! Table 9: Screw tightening torques for screwing the connection flange to the engine flywheel Size of flywheel acc. to SAE - J620 1) Screw size Tightening torque [Nm] Minimum screw strength Inch screw Tightening torque [Nm] Minimum screw strength 6.5“ 7.5“ 8“ 10“ 11.5“ 14“ M8 25 8.8 5/16 - 18 24 5 M8 25 8.8 5/16 - 18 24 5 M10 49 8.8 3/8 - 16 42 5 M10 49 8.8 3/8 - 16 42 5 M10 49 8.8 3/8 - 16 42 5 M12 120 10.9 1/2 - 13 150 8 1) For dimensions of flange connection see table 5. 4.8 ! Assembly of elastomer part (component 1) We recommend to secure all screw connections against working loose additionally, e. g. applying Loctite screw adhesive (average strength), while the elastomer parts must not come into contact with any type of adhesive. • Mount the elastomer part (component 1) to the hub axial (component 3) or the flange (component 4) and align the bores to the clamping sleeves (component 9) (see illustration 14). • Hand-tighten the elastomer part and the hub via the cap screws (component 5) and the ratchet washers (component 6) first. Make sure that the ratchet washer (component 6) is inserted with the convex side to the screw head of the cap screw (component 5). • Tighten the cap screws (component 5) to the tightening torques TA1 specified in table 10 by a suitable torque key. Please observe protection note ISO 16016. Drawn: Verified: Illustration 14: Assembly of the elastomer part to the hub axial 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 4 Assembly 4.9 Assembly of the intermediate shaft (component 2) KTR-N Sheet: Edition: 48611 EN 14 of 20 1 • Insert the intermediate shaft (component 2) in one of the two elastomer parts. Align the threads of the intermediate shaft (component 2) to the bores of the elastomer part (see illustration 15). • Hand-tighten the elastomer part and the hub resp. flange via the cap screws (component 7) and the ratchet washers (component 8) first. Make sure that the ratchet washer (component 8) is inserted with the convex side to the screw head of the cap screw (component 7). • Shift the power pack of the driven side resp. the opposite side in axial direction until the mounting dimension DBSE or E1 is achieved. Align the threads of the intermediate shaft (component 2) to the bores of the second elastomer part (see illustration 15). Illustration 15: Assembly of the elastomer parts to the intermediate shaft • Hand-tighten the elastomer part and the hub resp. flange via the cap screws (component 7) and the ratchet washers (component 8) first. Make sure that the ratchet washer (component 8) is inserted with the convex side to the screw head of the cap screw (component 7). • Tighten the cap screws (component 7) by a suitable torque key to the tightening torques T A specified in table 10. The clamping sleeves (component 9) respectively double radial screw connection (cap screws, component 7) prevent twisting of the elastomer parts with the assembly. Table 10: Cap screws DIN EN ISO 4762 - 12.9 (component 5 and 7) Size Dimension M Tightening torque TA [Nm] 12 M10 71 Please observe protection note ISO 16016. Drawn: Verified: 24 M12 123 48 M14 195 60 M16 302 2022-05-03 Pz/Ex 2022-05-12 Pz 86 M16 302 125 M20 592 200 M20 592 Replacing: Replaced by: 280 M20 592 --- 360 M20 592 560 M24 1017 EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 4 KTR-N Sheet: Edition: 48611 EN 15 of 20 1 Assembly 4.10 Displacements - alignment of the couplings The EVOLASTIC® flange couplings compensate for position deviations of the machine components to be connected up to the data specified in table 11. With alignment, the radial and angular displacement should be kept as small as possible, because the service life is increased in this way provided that the operating conditions are maintained besides that. The EVOLASTIC® flange coupling has to be aligned from the coupling hub on the shaft side to one of the machined surfaces of the flywheel or machine. ! 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 displacements arise simultaneously, the permissible displacement values may only be used proportionally (see illustration 17). • The radial and angular displacement figures specified refer to a reference speed of 1500 rpm. The diagramme of displacement alignment (see illustration 18) provides for a speed-dependent increase or reduction of displacement figures by factor frpm. The displacement figures between the speeds specified have to be interpolated accordingly. • The figures of maximum displacements refer to the mounting process, in addition they are permissible for a short time respectively rarely at standstill or with start-up operation as well as with unusual loading conditions. • The displacement figures are general standard figures that apply up to an ambient temperature of +80 °C, ensuring a sufficient service life of the EVOLASTIC® coupling. • Inspect with a dial gauge, ruler or feeler gauge whether the permissible displacement figures specified in table 11 can be observed. Axial displacement Radial displacement Illustration 16: Displacements (Example: type D2H, size 12 to 280) Angular displacement Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 4 KTR-N Sheet: Edition: 48611 EN 16 of 20 1 Assembly 4.10 Displacements - alignment of the couplings Examples of the displacement combinations specified in illustration 17: Illustration 17: Combinations of displacement Example 1: Kr = 30 % Kw = 70 % Example 2: Kr = 60 % Kw = 40 % Ktotal = Kr + Kw 100 % Table 11: Displacement figures Size Perm. axial displacement 1) Ka [mm] Perm. radial 1500 rpm displacement 1) Kr max. 2) [mm] Perm. angular 1500 rpm displacement 1) Kw [°] max. 2) 12 ±2.5 24 ±3.0 48 ±2.5 60 ±3.0 86 ±3.0 125 ±3.5 200 ±3.0 280 ±3.5 360 ±4.0 560 ±4.0 2.0 2.0 2.0 2.5 2.0 2.5 2.5 2.5 3.0 3.0 3.6 3.0 6.0 3.6 3.0 6.0 3.6 2.0 4.0 4.5 3.0 6.0 3.6 2.0 4.0 4.5 3.0 6.0 4.5 2.0 4.0 4.5 2.0 4.0 5.4 2.0 4.0 5.4 2.0 4.0 1) each elastomer part 2) for short-term start-up operation Illustration 18: Diagramme of displacement alignment Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 5 KTR-N Sheet: Edition: 48611 EN 17 of 20 1 Start-up Before start-up of the coupling, inspect 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 2014/34/EU and must protect against • access with a 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. 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 lead to improper use of the EVOLASTIC® 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 use other than intended: • 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 hub is 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 elastomer parts or those stored for too long are used. • Maintenance intervals are not observed. Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 6 KTR-N Sheet: Edition: 48611 EN 18 of 20 1 Breakdowns, causes and elimination Breakdowns Causes Elimination 1) Set the unit out of operation 2) Eliminate the reason for the misalignment (e. g. loose Errors in alignment, too high foundation bolts, fracture of the engine mount, heat displacement, internal contact expansion of unit components, modification of the of coupling components installation dimension E of the coupling) 3) For visual inspection/inspection of wear see chapter 8 Different operating noise Maintenance and/or vibrations occuring 1) Set the unit out of operation Axial fastening of hubs 2) Inspect alignment of coupling working loose and screw 3) For visual inspection/inspection of wear see chapter 8 connection unfastened Maintenance 4) Secure the hubs axially and against working loose 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the Fracture of elastomer part/ elastomer part high dynamic energy/ 3) Inspect coupling components and replace coupling overload components that are damaged 4) Insert elastomer part, assemble coupling components 5) Find out the reason for overload 1) Set the unit out of operation Operating parameters do not 2) Review the operating parameters and select a bigger Fracture of elastomer part meet with the performance of coupling (consider mounting space) the coupling 3) Assemble new coupling size 4) Inspect alignment 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the elastomer part Operating error of the unit 3) Inspect coupling components and replace coupling components that are damaged 4) Insert elastomer part, 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 elastomer part Vibrations of drive, resonance 3) Inspect coupling components and replace coupling in the elastomer components that are damaged 4) Insert elastomer part, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Find out the reason for vibrations (selection of loads) 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the High rotational angles during Ambient/contact temperatures elastomer part operation, formation of which are too high for the 3) Inspect coupling components and replace coupling wrinkles up to external cracks elastomer part, components that are damaged in the elastomer part, fracture max. permissible 4) Insert elastomer part, assemble coupling components of elastomer, internal -30 °C/+80 °C 5) Inspect alignment, adjust if necessary depolymerisation 6) Inspect and adjust ambient/contact temperature 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the E. g. contact with aggressive elastomer part liquids/oils, influence by 3) Inspect coupling components and replace coupling ozone, too high ambient components that are damaged temperature etc. causing a 4) Insert elastomer part, assemble coupling components physical change of the 5) Inspect alignment, adjust if necessary elastomer part 6) Make sure that other physical modifications of the elastomer part are excluded Please observe protection note ISO 16016. Drawn: Verified: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 7 KTR-N Sheet: Edition: 48611 EN 19 of 20 1 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. 8 Maintenance and service We recommend to perform a visual inspection on the coupling at least once a year. Pay special attention to the condition of the elastomer part of the coupling. • Remove loose dirt from the coupling. • Inspect the coupling for spalling or missing components, if necessary. Inspect the elastomer part in particular for cracks. • Defective components must be replaced immediately resp. missing components must be replaced immediately. • Inspect and correct the tightening torques of all screw connections, if necessary. • 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. Please perform visual inspection as follows: • Inspect adhesion of the elastomer to the metal insert. • Inspect the elastomer part for wrinkles or cracks in the areas marked with , , , and in illustration 19. Formation of wrinkles is trouble-free, but dependent on the application may generate cracks in the long run. If the cracks in the areas marked achieve or exceed the limit specified in table 12, the elastomer part must be replaced. ! Elastomer parts that are damaged or worn off have to be replaced, with the maintenance interval of the engine at the latest. Illustration 19: Visual inspection Table 12: Crack depth Size Max. perm. crack depth [mm] 12 3.0 Please observe protection note ISO 16016. Drawn: Verified: 24 4.0 48 4.0 60 4.0 2022-05-03 Pz/Ex 2022-05-12 Pz 86 4.0 125 6.0 200 6.0 Replacing: Replaced by: 280 6.0 --- 360 8.0 560 10.0 EVOLASTIC® Operating/Assembly instructions Type D2H and DFH 9 KTR-N Sheet: Edition: 48611 EN 20 of 20 1 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. 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: 2022-05-03 Pz/Ex 2022-05-12 Pz Replacing: Replaced by: --- ">

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Key features
- Highly flexible
- Backlash-free
- Torsional vibration damping
- Load shock absorption
- Noise reduction
- Axial, radial, angular displacement compensation
- Double-cardanic drive shafts
- Homokinetic connection
Frequently asked questions
EVOLASTIC couplings are designed to compensate for axial, radial, and angular displacements. This allows for misalignment between the connected shafts, reducing stress and improving reliability.
The EVOLASTIC line includes types D2H and DFH, which are both double-cardanic drive shafts. These types are well-suited for bridging larger shaft distances and connecting power packs flexibly.
When choosing an EVOLASTIC coupling, you should consider factors such as the torque requirements, speed, and the type and amount of displacement you need to accommodate. The instruction manual contains guidance for coupling selection based on particular applications.