KTR EVOLASTIC Operating/Mounting Instructions
KTR EVOLASTIC is a highly flexible coupling for shafts and flanges. It's designed for applications requiring torsional flexibility and vibration dampening, making it ideal for demanding industrial environments. EVOLASTIC can handle axial, radial and angular displacements, reducing noise transmission and ensuring smooth operation.
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EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP KTR-N Sheet: Edition: 48612 EN 1 of 24 2 EVOLASTIC® highly flexible coupling type EP, EHP, E2HP, EFHP and their combinations Type EP Type EHP Type E2HP Type EFHP Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP KTR-N Sheet: Edition: 48612 EN 2 of 24 2 EVOLASTIC® type EP, EHP, E2HP and EFHP is a highly torsionally flexible, non-slip and backlashfree shaft and flange coupling. The coupling is capable of axial plug-in. It dampens torsional vibrations and load shocks, reduces structure-borne noise transmission and compensates for axial, radial and angular displacements above average. Table of contents 1 2 3 4 Technical data 3 1.1 1.2 3 7 Coupling dimensions and technical data General dimensions and torques Advice 8 2.1 2.2 2.3 2.4 2.5 2.6 8 8 8 9 9 9 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 10 3.1 3.2 10 10 Storage Transport and packaging Assembly 10 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 10 11 15 15 16 16 17 17 19 Types of hubs Components of the couplings Advice for finish bore General advice for assembly Assembly of clamping sleeves (component 8) Assembly of the hubs (components 2 and 3) Assembly of the flange (component 4) Assembly of elastomer part (component 1) Displacements - alignment of the couplings 5 Start-up 21 6 Breakdowns, causes and elimination 21 7 Disposal 23 8 Maintenance and service 23 9 Spares inventory, customer service addresses 24 Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48612 EN 3 of 24 2 Type EP Illustration 1: EVOLASTIC® type EP (size 12 to 280) Illustration 2: EVOLASTIC® type EP (size 360) Illustration 3: EVOLASTIC® type EP (size 560) Table 1: Dimensions - type EP Dimensions in mm Size 12 24 32 48 60 86 125 200 280 360 560 DH 122 150 150 170 200 200 260 260 300 340 363 DI1 60 70 70 85 100 100 125 125 145 160 170 B1 32 42 42 46 58 58 70 70 80 85 105 B2 28 36 36 40 50 50 63 63 72 78 95 E 4 6 6 6 8 8 7 7 8 7 10 D4 100 125 125 140 165 165 215 215 250 280 300 Z x Pitch 3 x 120° 3 x 120° 4 x 90° 4 x 90° 3 x 120° 4 x 90° 3 x 120° 4 x 90° 4 x 90° 4 x 90° 4 x 90° LG 10 12 12 14 16 16 20 20 20 20 20 DB 4 5 5 5 5 5 8 8 8 - A1 14.0 18.0 18.0 20.0 25.0 25.0 31.5 31.5 36.0 2 x 23.0 2 x 28.5 A4 10.0 13.5 13.5 14.0 18.0 18.0 22.5 22.5 22.5 - LB2 5 5 5 5 5 5 5 5 - Cap screws DIN EN ISO 4762 M1 SW M2 M10 8 M10 M12 10 M12 M12 10 M12 M14 12 M14 M16 14 M16 M16 14 M16 M20 17 M20 M20 17 M20 M20 17 M20 M20 17 M20 M24 19 M20 Table 2: Technical data - type EP ! Size Total weight of coupling in kg 12 24 32 48 60 86 125 200 280 360 560 0.55 1.03 1.26 1.74 1.52 3.08 5.16 6.35 8.71 12.21 17.67 Mass moment of coupling in kgm2 JA JL 0.001 0.001 0.002 0.001 0.003 0.002 0.005 0.003 0.009 0.007 0.010 0.008 0.028 0.022 0.036 0.028 0.068 0.050 0.110 0.096 0.203 0.145 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: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48612 EN 4 of 24 2 Type EHP Illustration 4: EVOLASTIC® type EHP (size 12 to 280) Illustration 5: EVOLASTIC® type EHP (size 360) Illustration 6: EVOLASTIC® type EHP (size 560) Table 3: Dimensions - type EHP Cap screws DIN EN ISO 4762 Dimensions in mm Size 12 24 32 48 60 86 125 200 280 360 560 Max. finish bore D 38 46 46 55 65 65 85 85 105 115 120 DH DN B1 B2 E L L1 D4 Z x Pitch LG SW M1 122 150 150 170 200 200 260 260 300 340 363 60 70 70 85 100 100 125 125 145 160 170 32 42 42 46 58 58 70 70 80 85 105 28 36 36 40 50 50 63 63 72 78 95 4 6 6 6 8 8 7 7 8 7 10 46 56 56 61 74 74 88 88 102 108 135 42 50 50 55 66 66 80 80 94 100 125 100 125 125 140 165 165 215 215 250 280 300 3 x 120° 3 x 120° 4 x 90° 4 x 90° 3 x 120° 4 x 90° 3 x 120° 4 x 90° 4 x 90° 4 x 90° 4 x 90° 10 12 12 14 16 16 20 20 20 20 30 8 10 10 12 14 14 17 17 17 17 19 M10 M12 M12 M14 M16 M16 M20 M20 M20 M20 M24 Table 4: Technical data - type EHP Size 12 24 32 48 60 86 125 200 280 360 560 ! Total weight with maximum bore of coupling in kg 1.09 1.85 2.08 3.07 4.79 5.32 9.15 10.30 14.29 19.44 28.41 Mass moment of inertia with maximum bore of coupling in kgm2 JA JL 0.001 0.001 0.002 0.002 0.003 0.003 0.004 0.005 0.009 0.010 0.010 0.012 0.028 0.024 0.036 0.039 0.068 0.076 0.110 0.131 0.203 0.203 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: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48612 EN 5 of 24 2 Type E2HP Illustration 7: EVOLASTIC® type E2HP (size 12 to 280) Illustration 8: EVOLASTIC® type E2HP (size 360) Illustration 9: EVOLASTIC® type E2HP (size 560) Table 5: Dimensions - type E2HP Cap screws DIN EN ISO 4762 Dimensions in mm Size 12 24 32 48 60 86 125 200 280 360 560 Max. finish bore D D1 38 55 46 70 46 70 55 85 65 100 65 100 85 110 85 110 105 110 115 130 120 140 DH DN DN1 B1 B2 E N L L1 L2 SW M1 122 150 150 170 200 200 260 260 300 340 363 60 70 70 85 100 100 125 125 145 160 170 80 100 100 115 140 140 160 160 160 195 200 32 42 42 46 58 58 70 70 80 85 105 28 36 36 40 50 50 63 63 72 78 95 4 6 6 6 8 8 7 7 8 7 10 32 38 38 41 50 50 60 60 70 80 100 88 106 106 116 140 140 168 168 192 208 260 42 50 50 55 66 66 80 80 94 100 125 42 50 50 55 66 66 80 80 90 100 125 8 10 10 12 14 14 17 17 17 17 19 M10 M12 M12 M14 M16 M16 M20 M20 M20 M20 M24 Table 6: Technical data - type E2HP Size 12 24 32 48 60 86 125 200 280 360 560 ! Total weight with maximum bore of coupling in kg 2.44 4.26 4.53 6.41 10.62 11.13 20.55 21.65 29.05 41.25 58.62 Mass moment of inertia with maximum bore of coupling in kgm2 JA JL 0.003 0.001 0.009 0.002 0.009 0.003 0.016 0.005 0.038 0.010 0.039 0.012 0.115 0.034 0.123 0.039 0.208 0.073 0.368 0.104 0.640 0.203 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: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48612 EN 6 of 24 2 Type EFHP Illustration 10: EVOLASTIC® type EFHP (size 12 to 280) Illustration 11: EVOLASTIC® type EFHP (size 360) Illustration 12: EVOLASTIC® type EFHP (size 560) Table 7: Dimensions - type EFHP Size 12 24 32 48 60 86 125 200 280 360 560 Flange connection acc. to SAE - J620 / diameter 1) 6.5“ 7.5“ 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“ Cap screws DIN EN ISO 4762 Dimensions 1) in mm D DH DN B1 B2 E L L1 L4 L5 L7 SW 38 122 60 32 28 4 56 42 52 4 6 8 46 150 70 42 36 6 68 50 62 6 6 10 46 150 70 42 36 6 68 50 62 6 6 10 55 170 85 46 40 6 75 55 67 8 6 71 4 10 12 65 200 100 58 50 8 90 66 84 6 10 14 65 200 100 58 50 8 90 66 84 6 10 14 85 260 125 70 63 7 107 80 98 9 10 17 85 260 125 70 63 7 107 80 98 9 10 17 105 300 145 80 72 8 121 94 112 9 10 17 115 120 340 363 160 170 85 105 78 95 7 10 127 160 100 125 118 145 9 15 10 10 17 19 D5 180 190 180 190 180 190 190 200 260 270 310 270 360 270 310 270 310 405 310 405 405 405 M1 M10 M12 M12 M14 M16 M16 M20 M20 M20 M20 M24 1) For dimensions of flange connection see table 9. ! 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: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 1 Technical data 1.2 General dimensions and torques KTR-N Sheet: Edition: 48612 EN 7 of 24 2 Table 8: Technical data - type EFHP Size 12 24 32 48 60 86 125 200 280 360 560 Flange connection acc. to SAE - J620 / diameter 1) 6.5“ 7.5“ 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“ Total weight with maximum bore of coupling in kg 3.33 3.84 4.30 4.86 4.57 5.13 6.20 6.80 10.09 12.30 14.73 12.82 15.24 17.10 19.95 18.20 21.06 30.57 24.35 33.87 38.25 51.35 Mass moment of inertia with maximum bore of coupling in kgm2 JA JL 0.014 0.001 0.020 0.001 0.016 0.002 0.249 0.002 0.017 0.003 0.024 0.003 0.027 0.005 0.035 0.005 0.091 0.005 0.105 0.011 0.166 0.011 0.107 0.012 0.168 0.012 0.134 0.034 0.204 0.034 0.141 0.039 0.212 0.039 0.578 0.039 0.239 0.072 0.606 0.072 0.642 0.130 0.847 0.203 1) For dimensions of flange connection see table 9. Table 9: Flange dimensions according to SAE J 620 Nominal size Dimension DA Dimension D4 Z x Pitch Dimension DL 6.5“ 215.9 200.02 6 x 60° 9 7.5“ 241.3 222.25 8 x 45° 9 Flange dimensions in mm 8“ 10“ 263.52 314.32 244.47 295.27 6 x 60° 8 x 45° 11 11 11.5“ 352.42 333.37 8 x 45° 11 14“ 466.62 438.15 8 x 45° 14 Table 10: Torques Size 12 24 32 48 60 86 125 200 280 360 560 Type of elastomers SN MN 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. TKN 100 120 200 240 280 320 420 480 500 600 760 860 1100 1250 1700 2000 2400 2800 3200 3400 3600 5000 5200 5600 Torque in Nm TK max TK max1 200 300 240 360 400 600 480 720 560 840 640 960 840 1260 960 1440 1000 1500 1200 1800 1520 2280 1720 2580 2200 3300 2500 3750 3400 5100 4000 5250 4800 6100 5600 6100 5400 9600 6800 10200 7200 10800 10000 14000 10400 14000 11200 14000 TKW 40 48 80 96 112 128 168 192 200 240 304 344 440 500 680 800 960 1120 1280 1360 1440 2000 2080 2240 Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: Perm. operating speed in rpm n nmax. 4500 5000 5400 6000 3780 4200 4500 5000 3800 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 KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 1 Technical data 1.2 General dimensions and torques KTR-N Sheet: Edition: 48612 EN 8 of 24 2 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 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 Safety and advice symbols STOP ! 2.3 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 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. 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: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 2 Advice 2.4 Proper use KTR-N Sheet: Edition: 48612 EN 9 of 24 2 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: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 3 Storage, transport and packaging 3.1 Storage KTR-N Sheet: Edition: 48612 EN 10 of 24 2 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. ! 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. ! 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. 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 1.3 Hub with spline bore Type 3.1 Clamping hub N with spline bore Illustration 13: Types of hubs Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.2 Components of the couplings KTR-N Sheet: Edition: 48612 EN 11 of 24 2 Components of type EP Component 1 5 5.1 5.2 6 7 8 1) Quantity 1 see table 11 see table 11 see table 11 see table 11 see table 11 see table 11 Description Elastomer part EP Locking pin Plug-in sleeve Cap screw DIN EN ISO 4762 - 12.9 Cap screw DIN EN ISO 4762 - 12.9 Ratchet washer Clamping sleeve DIN 7346 1) Component 8 is omitted with size 12 Illustration 14: EVOLASTIC® type EP (size 12 to 280) Illustration 15: EVOLASTIC® type EP (size 360) Illustration 16: EVOLASTIC® type EP (size 560) Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.2 Components of the couplings KTR-N Sheet: Edition: 48612 EN 12 of 24 2 Components of type EHP Component 1 2 5 5.1 5.2 6 7 8 1) Quantity 1 1 see table 11 see table 11 see table 11 see table 11 see table 11 see table 11 Description Elastomer part EP Hub radial Locking pin Plug-in sleeve Cap screw DIN EN ISO 4762 - 12.9 Cap screw DIN EN ISO 4762 - 12.9 Ratchet washer Clamping sleeve DIN 7346 1) Component 8 is omitted with size 12 Illustration 17: EVOLASTIC® type EHP (size 12 to 280) Illustration 18: EVOLASTIC® type EHP (size 360) Illustration 19: EVOLASTIC® type EHP (size 560) Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.2 Components of the couplings KTR-N Sheet: Edition: 48612 EN 13 of 24 2 Components of type E2HP Component 1 2 3 5 5.1 5.2 6 7 8 1) Quantity 1 1 1 see table 11 see table 11 see table 11 see table 11 see table 11 see table 11 Description Elastomer part EP Hub radial Hub axial Locking pin Plug-in sleeve Cap screw DIN EN ISO 4762 - 12.9 Cap screw DIN EN ISO 4762 - 12.9 Ratchet washer Clamping sleeve DIN 7346 1) Component 8 is omitted with size 12 Illustration 20: EVOLASTIC® type E2HP (size 12 to 280) Illustration 21: EVOLASTIC® type E2HP (size 360) Illustration 22: EVOLASTIC® type E2HP (size 560) Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.2 Components of the couplings KTR-N Sheet: Edition: 48612 EN 14 of 24 2 Components of type EFHP Component 1 2 4 5 5.1 5.2 6 7 8 1) Quantity 1 1 1 see table 11 see table 11 see table 11 see table 11 see table 11 see table 11 Description Elastomer part EP Hub radial Flange Locking pin Plug-in sleeve Cap screw DIN EN ISO 4762 - 12.9 Cap screw DIN EN ISO 4762 - 12.9 Ratchet washer Clamping sleeve DIN 7346 1) Component 8 is omitted with size 12 Illustration 23: EVOLASTIC® type EFHP (size 12 to 280) Illustration 24: EVOLASTIC® type EFHP (size 360) Illustration 25: EVOLASTIC® type EFHP (size 560) Table 11: Number of cap screws, ratchet washers and clamping sleeves Size Number of locking pins (component 5) Number of plug-in sleeve (component 5.1) Number of cap screws (component 5.2) Number of cap screws (component 6) Number of ratchet washers (component 7) Number of clamping sleeves (component 8) Please observe protection note ISO 16016. Drawn: Verified: 12 3 3 3 - 24 3 3 3 6 32 4 4 4 8 48 4 4 4 8 2022-11-29 Pz/Mai 2022-12-01 Pz 60 3 3 3 6 86 4 4 4 8 125 3 3 3 6 Replacing: Replaced by: 200 4 4 4 8 280 4 4 4 8 360 8 8 8 - 560 4 4 8 8 - KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.3 Advice for finish bore STOP KTR-N Sheet: Edition: 48612 EN 15 of 24 2 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 26). • 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 26: 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 12: Setscrew DIN EN ISO 4029 Size Dimension G Hub radial (component 2) Dimension T Hub axial (component 3) Tightening torque TA [Nm] 4.4 12 M8 24 M8 32 M8 48 M8 60 M10 86 M10 125 M10 200 M10 280 M12 360 M16 560 M16 9 9 9 10 10 10 11 11 14 14 20 15 15 15 20 20 20 20 20 30 30 40 10 10 10 10 17 17 17 17 40 80 80 General advice for assembly ! 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 ! 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. Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.5 Assembly of clamping sleeves (component 8) KTR-N Sheet: Edition: 48612 EN 16 of 24 2 • Only valid for size 24 to 280: Drive the clamping sleeves (component 8) in the hub radial (component 2) (see illustration 27). • Only valid for type EP: Drive the clamping sleeves (component 8) in the attachment provided by the customer or the elastomer part (component 1) (see illustration 28). For the assembly of the clamping sleeves observe dimensions A1, DB and LB2 according to table 1. • Only valid for type EP as spare part versus other manufacturers: The clamping sleeves (component 8) and the bores for the relevant clamping sleeves can be omitted. ! Please note that the hub radial must have some kind of knurling respectively another provision against twisting of the elastomer part on the hub radial. Any kind of twisting must be eliminated with assembly of the elastomer part (component 1). Illustration 27: Assembly of clamping sleeves (component 8) 4.6 Illustration 28: Type EP - Assembly of clamping sleeves (component 8) Assembly of the hubs (components 2 and 3) • Mount the hubs (component 2 and 3) on the shaft of driving and driven side. • Fasten the hubs by tightening the setscrew DIN EN ISO 4029 with a cup point (tightening torque TA see table 12) or an end plate. Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.7 Assembly of the flange (component 4) KTR-N Sheet: Edition: 48612 EN 17 of 24 2 • Push the flange (component 2) 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 14 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 14: 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 9. 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. • Screw the locking pins (component 5) resp. plug-in sleeves (component 5.1) with the cap screws (component 5.2) in the hub axial (component 3) or to the flange (component 4) respectively the attachment provided by the customer (see illustration 29 and 30). Secure the locking pin against working loose by means of an adhesive (e. g. Loctite average strength). • Tighten the locking pins (component 5) resp. the cap screws (component 6) to the tightening torques T A1 specified in table 15 by a suitable torque key. Illustration 29: Assembly of locking pins (Example: type E2HP - size 12 to 360) Please observe protection note ISO 16016. Drawn: Verified: Illustration 30: Assembly of plug-in sleeve (Example: type E2HP - size 560) 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.8 Assembly of elastomer part (component 1) KTR-N Sheet: Edition: 48612 EN 18 of 24 2 • Push the elastomer part (component 1) on the hub radial (component 2) (see illustration 31). • Hand-tighten the elastomer part and the hub via the cap screws (component 6) and the ratchet washers (component 7) first. Make sure that the ratchet washer (component 7) is inserted with the convex side to the screw head of the cap screw (component 6). • Tighten the cap screws (component 6) to the tightening torques TA2 specified in table 15 by a suitable torque key. • Preferably shift the power pack of the driven side with the elastomer part (component 1) mounted in axial direction until the mounting dimension E is achieved. For that purpose align the bores of the elastomer part to the locking pins (component 5) resp. plug-in sleeves (component 5.1) (see illustration 32). Preferably push the power packs together so that the elastomer part fits to the hub axial (component 3) or the flange (component 4) respectively the attachment provided by the customer. Illustration 31: Assembly of the elastomer part to the hub radial (Example: type E2HP) The clamping sleeves (component 8) prevent twisting of the elastomer part with mounting. Illustration 32: Assembly of the coupling Table 15: Cap screws DIN EN ISO 4762 - 12.9 (component 5, 5.2 and 7) Size Dimension M1 Tightening torque TA1 [Nm] Dimension M2 Tightening torque TA2 [Nm] 12 M10 71 M10 71 Please observe protection note ISO 16016. Drawn: Verified: 24 M12 123 M12 123 32 M12 123 M12 123 48 M14 195 M14 195 60 M16 302 M16 302 2022-11-29 Pz/Mai 2022-12-01 Pz 86 M16 302 M16 302 125 M20 592 M20 592 Replacing: Replaced by: 200 M20 592 M20 592 280 M20 592 M20 592 360 M20 592 M20 592 560 M24 1017 M20 592 KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.9 Displacements - alignment of the couplings KTR-N Sheet: Edition: 48612 EN 19 of 24 2 The EVOLASTIC® flange couplings compensate for position deviations of the machine components to be connected up to the data specified in table 16. 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 16). 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 16 are maximum figures which must not arise in parallel. If radial and angular displacements arise simultaneously, the permissible displacement figures may only be used proportionally (see illustration 34). • The radial and angular displacement figures specified refer to a reference speed of 1500 rpm. The diagramme of displacement alignment (see illustration 35) 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 exceptional 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 16 can be observed. Axial displacement Radial displacement Angular displacement Illustration 33: Displacements Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 4 Assembly 4.9 Displacements - alignment of the couplings Examples of the displacement combinations specified in illustration 34: KTR-N Sheet: Edition: 48612 EN 20 of 24 2 Illustration 34: Combinations of displacement Example 1: Kr = 30 % Kw = 70 % Example 2: Kr = 60 % Kw = 40 % Ktotal = Kr + Kw 100 % Table 16: Displacement figures Size Perm. axial displacement Ka [mm] 1) Perm. radial 1500 rpm displacement Kr [mm] max. 2) Perm. angular 1500 rpm displacement Kw [°] max. 2) 12 ±2.5 2.0 3.6 3.0 6.0 24 ±3.0 2.0 3.6 3.0 6.0 32 ±3.0 2.0 3.6 2.0 4.0 48 ±2.5 2.0 3.6 2.0 4.0 60 ±3.0 2.5 4.5 3.0 6.0 86 ±3.0 2.0 3.6 2.0 4.0 125 ±3.5 2.5 4.5 3.0 6.0 200 ±3.0 2.5 4.5 2.0 4.0 280 ±3.5 2.5 4.5 2.0 4.0 360 ±4.0 3.0 5.4 2.0 4.0 560 ±4.0 3.0 5.4 2.0 4.0 1) The axial displacement stated specifies the permissible displacement of the elastomer part. The elastomer part should fit to the hub axial (component 3) or the flange (component 4) respectively the attachment provided by the customer. 2) for short-term start-up operation Illustration 35: Diagramme of displacement alignment Please observe protection note ISO 16016. Drawn: Verified: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 5 KTR-N Sheet: Edition: 48612 EN 21 of 24 2 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 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 avoid contact safely. We recommend a minimum distance of 15 mm from the outside diameter DH of the coupling. 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 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 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: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 6 KTR-N Sheet: Edition: 48612 EN 22 of 24 2 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: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 7 KTR-N Sheet: Edition: 48612 EN 23 of 24 2 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 35. 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 17, 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 35: Visual inspection Table 17: Crack depth Size Max. perm. crack depth [mm] 12 3.0 Please observe protection note ISO 16016. Drawn: Verified: 24 4.0 32 4.0 48 4.0 60 4.0 2022-11-29 Pz/Mai 2022-12-01 Pz 86 4.0 125 6.0 Replacing: Replaced by: 200 6.0 280 6.0 360 8.0 560 10.0 KTR-N dated 2021-02-22 EVOLASTIC® Operating/Assembly instructions Type EP, EHP, E2HP and EFHP 9 KTR-N Sheet: Edition: 48612 EN 24 of 24 2 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: 2022-11-29 Pz/Mai 2022-12-01 Pz Replacing: Replaced by: KTR-N dated 2021-02-22 ">

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Key features
- Highly torsional flexible
- Backlash free
- Axial plug-in
- Dampens vibrations
- Reduces noise
- Compensates for displacements
Frequently asked questions
EVOLASTIC is available in various types, including EP, EHP, E2HP, and EFHP, each with specific features and applications. Please consult the manual for detailed specifications.
The maximum permissible bore diameters vary depending on the EVOLASTIC type and size. Please refer to the technical data section in chapter 1 of the manual for specific figures.
EVOLASTIC couplings compensate for position deviations, but accurate alignment is essential for optimal performance and longevity. Refer to section 4.9 of the manual for alignment instructions and displacement figures.