KTR RUFLEX-torque limiter Operating/Mounting Instructions

RUFLEX® Torque limiter
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46010 EN
1 of 26
9
RUFLEX®
Torque limiter
RUFLEX®
RUFLEX® with sprocket
RUFLEX® max.
RUFLEX® with ROTEX®
RUFLEX® with BoWex®
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46010 EN
2 of 26
9
RUFLEX® is a torque limiting and load-holding overload system with positive locking. It protects
adjacent components in the drive train from damage.
Table of contents
1
Technical data
3
2
Advice
8
2.1
2.2
2.3
2.4
2.5
2.6
8
8
8
9
9
9
3
4
General advice
Safety and advice symbols
General hazard warnings
Intended use
Selection of torque limiter
Reference to EC Machinery Directive 2006/42/EC
Storage, transport and packaging
9
3.1
3.2
9
9
Storage
Transport and packaging
Assembly
10
®
5
4.1 Components of RUFLEX
4.2 Layering of disk springs
4.3 Advice for finish bore
4.4 Assembly (general)
4.5 Centering plain bush
4.6 Assembly of RUFLEX® torque limiter
4.7 Assembly of RUFLEX® torque limiter with ROTEX® coupling
4.8 Assembly of RUFLEX® torque limiter with BoWex® coupling
4.9 Disassembly of the torque limiter / replacement of single parts
4.10 Assembly of the torque limiter
10
12
12
13
14
14
15
16
16
18
Adjustment of torque
18
5.1
5.2
18
21
Initial setting resp. re-setting of slipping torque
Setting diagrammes
6
Breakdowns, causes and elimination
25
7
Disposal
26
8
Maintenance and service
26
9
Spares inventory, customer service addresses
26
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
KTR-N
Sheet:
Edition:
RUFLEX® Torque limiter
Operating/Assembly instructions
1
46010 EN
3 of 26
9
Technical data
Illustration 1: RUFLEX® size 00
Illustration 2: RUFLEX® size 0 to 5
Illustration 3: RUFLEX® size 6 to 9
Table 1: Technical data and dimensions
Size
00
0
01
1
2
3
4
5
6
7
8
9
Size
00
0
01
1
2
3
4
5
6
7
8
9
Max. speed
[rpm]
10000
8500
6600
5600
4300
3300
2700
2200
1900
1600
1300
1000
Torque [Nm]
1TF
(0.5) 5) 1 - 3
2 - 10
5 - 35
20 - 75
25 - 140
50 - 300
90 - 600
400 - 800
300 - 1200
600 - 2200
900 - 3400
2500 - 6000
DA
B
30
45
58
68
88
115
140
170
200
240
285
350
8.5
8.5
16
17
19
21
23
29
31
33
35
53
2TF
2-5
4 - 20
10 - 70
40 - 150
50 - 280
100 - 600
180 - 1200
800 - 1600
600 - 2400
1200 - 4400
1800 - 6800
6000 - 12000
3TF 3)
130 - 200
250 - 400
550 - 800
1100 - 1600
1400 - 2100
-
Dimensions [mm]
Bore d
D 2)
Pilot bore
Max.
10
21
20 1)
35
22
40
25
44
35
58
45
72
55
85
65
98
38
80
116
45
100
144
58
120
170
65
140
237
Dimensions [mm]
Drive component b1
s1
Min.
Max.
2
6
2.5
2
6
2.5
3
8
3
3
10
3
4
12
3
5
15
4
6
18
4
8
20
5
8
23
5
8
25
5
8
25
5
16
28
6
L
31
33
45
52
57
68
78
92
102
113
115
162
D1
45
40
45
58
75
90
102
120
150
180
225
Thread for setscrews
t
G
3
M4
3
M4
4
M5
5
M5
5
M6
5
M6
5
M8
8
M8
8
M8
8
M10
8
M10
11
M12
1) Finish bore exceeding Ø19, feather keyway according to DIN 6885 sheet 3
2) Bore tolerance (drive component):
F8 with size 00 - 4
H8 with size 5 - 9
3) With clamping setting nut to be used on types limited in dimensions only
4) Hexagon nuts with size 9
5) With special disk spring
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
46010 EN
4 of 26
9
Technical data
Illustration 4: RUFLEX® with sprocket
Table 2: Technical data and dimensions
Size
Max. speed [rpm]
01
1
2
3
4
6600
5600
4300
3300
2700
Size
01
1
2
3
4
1TF
5 - 35
20 - 75
25 - 140
50 - 300
90 - 600
Torque [Nm]
2TF
10 - 70
40 - 150
50 - 280
100 - 600
180 - 1200
B
s1
L
16
17
19
21
23
3
3
3
4
4
45
52
57
68
78
3TF 1)
130 - 200
250 - 400
550 - 800
1100 - 1600
Dimensions [mm]
Max. bore d
D1
22
40
25
45
35
58
45
75
55
90
Dimensions [mm]
Thread for setscrews
t
G
4
M5
5
M5
5
M6
5
M6
5
M8
DA
58
68
88
115
140
Standard sprocket 2)
06 B-1 (3/8 x 7/32) z = 23
08 B-1 (1/2 x 5/16) z = 22
08 B-1 (1/2 x 5/16) z = 27
12 B-1 (3/4 x 7/16) z = 22
16 B-1 (1 x 17,02) z = 21
1) With clamping setting nut to be used on types limited in dimensions only
2) Number of teeth required at the minimum. Other sprockets available on request.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
46010 EN
5 of 26
9
Technical data
Illustration 5: RUFLEX® max.
Table 3: Technical data and dimensions
Size
Max. speed [rpm]
01
1
2
3
4
6600
5600
4300
3300
2700
Size
01
1
2
3
4
Max. bore d
22
25
35
45
55
Torque [Nm]
2TF
10 - 70
40 - 150
50 - 280
100 - 600
180 - 1200
1TF
5 - 35
20 - 75
25 - 140
50 - 300
90 - 600
D1
40
45
58
75
90
DA
58
68
88
115
140
Dimensions [mm]
B
16
17
19
21
23
Max. b
33.0
43.0
54.0
62.0
91.5
3TF 2)
130 - 200
250 - 400
550 - 800
1100 - 1600
D 1)
40
44
58
72
85
Max. L
70
85
100
115
154
1) Bore tolerance (drive component):
F8
2) With clamping setting nut to be used on types limited in dimensions only
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
KTR-N
Sheet:
Edition:
RUFLEX® Torque limiter
Operating/Assembly instructions
1
46010 EN
6 of 26
9
Technical data
Illustration 6: RUFLEX® with ROTEX®
Table 4: Technical data and dimensions
Size
00
0
01
1
2
3
4
5
6
7
8
9
ROTEX®
size
14
19
24
28
38
48
75
90
100
110
140
160
ROTEX® torque [Nm]
98 ShA
TKN
TK max
12.5
25
17
34
60
120
160
320
325
650
525
1050
1920
3840
3600
7200
4950
9900
7200
14400
12800
25600
19200
38400
Torque [Nm]
1TF
(0.5) 3) 1 - 3
2 - 10
5 - 35
20 - 75
25 - 140
50 - 300
90 - 600
400 - 800
300 - 1200
600 - 2200
900 - 3400
2500 - 6000
3TF 1)
130 - 200
250 - 400
550 - 800
1100 - 1600
1400 - 2100
-
2TF
2-5
4 - 20
10 - 70
40 - 150
50 - 280
100 - 600
180 - 1200
800 - 1600
600 - 2400
1200 - 4400
1800 - 6800
6000 - 12000
Dimensions [mm]
Size
00
0
01
1
2
3
4
5
6
7
8
9
Bore d
Pilot bore
Max.
10
20 2)
22
25
35
45
55
65
38
80
45
100
58
120
65
140
Max.
bore d1
16
25
35
40
48
62
95
110
115
125
160
185
DH
DA
l1
l2
E
L
LG
30
40
55
65
80
105
160
200
225
255
320
370
44
63
80
98
120
162
185
260
285
330
410
460
11
25
30
35
45
56
85
100
110
120
155
175
35
37
50
58
64
82
80
114
130
142
152
199
13
16
18
20
24
28
40
45
50
55
65
75
31
33
45
52
57
68
78
92
102
113
115
161
59.5
78
98
113
133
166
205
259
290
317
372
449
1) With clamping setting nut to be used on types limited in dimensions only
2) Finish bore exceeding Ø19, feather keyway according to DIN 6885 sheet 3
3) With special disk spring
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
KTR-N
Sheet:
Edition:
RUFLEX® Torque limiter
Operating/Assembly instructions
1
46010 EN
7 of 26
9
Technical data
Illustration 7: RUFLEX® with BoWex®
Table 5: Technical data and dimensions
Size
00
0
01
1
2
Size
00
0
01
1
2
BoWex®
size
19
28
38
48
65
Max. bore d
10
20 2)
22
25
35
1TF
(0.5) 3) 1 - 3
2 - 10
5 - 35
20 - 75
25 - 140
Torque [Nm]
2TF
2-5
4 - 20
10 - 70
40 - 150
50 - 280
Max. bore d1
19
28
38
48
65
BoWex® torque [Nm]
TKN
TK max
16
32
45
90
80
160
140
280
380
760
3TF 1)
130 - 200
250 - 400
Dimensions [mm]
DA
l1
48
25.0
66
40.0
83
35.5
95
45.5
132
64.0
L
31
33
45
52
57
E
2.5
2.5
1.0
1.0
1.0
LG
58.5
75.5
81.5
98.5
122.0
1) With clamping setting nut to be used on types limited in dimensions only
2) Finish bore exceeding Ø19, feather keyway according to DIN 6885 sheet 3
3) With special disk spring
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
46010 EN
8 of 26
9
Advice
2.1 General advice
Please read through these operating/assembly instructions carefully before you start up the torque limiter.
Please pay special attention to the safety instructions!
The operating/assembly instructions are part of your product. Please store them carefully and close to the torque
limiter. The copyright for these operating/assembly instructions remains with KTR.
2.2 Safety and advice symbols
STOP
!

Warning of personal injury
This symbol indicates notes which may contribute to
preventing bodily injuries or serious bodily injuries that
may result in death.
Warning of product damages
This symbol indicates notes which may contribute to
preventing material or machine damage.
General advice
This symbol indicates notes which may contribute to
preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to
preventing burns with hot surfaces resulting in light to
serious bodily injuries.
2.3 General hazard warnings
STOP
With assembly, operation and maintenance of the torque limiter it has to be made sure that
the entire drive train is secured against accidental switch-on. You may be seriously hurt by
rotating parts. Please make absolutely sure to read through and observe the following
safety indications.
• All operations on and with the torque limiter have to be performed taking into account "safety first".
• Make sure to switch off the power pack before you perform your work on the torque limiter.
• 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 torque limiter as long as it is in operation.
• Please secure the torque limiter against accidental contact. Please provide for the necessary protection
devices and covers.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
46010 EN
9 of 26
9
Advice
2.4 Intended use
You may only assemble, operate and maintain the torque limiter if you
• have carefully read through the operating/assembly instructions and understood them
• had technical training
• are authorized by your company
The torque limiter may only be used in accordance with the technical data (see chapter 1). Unauthorized
modifications on the torque limiter 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 RUFLEX® described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
2.5 Selection of torque limiter
!
For a long-lasting and failure-free operation of the torque limiter it must be selected
according to the respective application (see catalogue drive technology „RUFLEX ®“).
If the operating conditions (performance, speed, modifications on engine and machine)
change, the selection must be reviewed.
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and
is subject to his responsibility.
2.6 Reference to EC Machinery Directive 2006/42/EC
The torque limiters 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.
3
Storage, transport and packaging
3.1 Storage
The torque limiters are supplied in preserved condition and can be stored at a dry and covered place for 6 - 9
months.
!
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less
than 65 %.
3.2 Transport and packaging
!
In order to avoid any injuries and any kind of damage please always make use of proper
transport and lifting equipment.
The torque limiters are packed differently each depending on size, number and kind of transport. Unless
otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
KTR-N
Sheet:
Edition:
RUFLEX® Torque limiter
Operating/Assembly instructions
4
46010 EN
10 of 26
9
Assembly
The torque limiter is supplied in assembled condition.
4.1 Components of RUFLEX®
Subassembly 1: Components of RUFLEX® torque limiter size 00 to 5
Component
1.1
1.2
1.3
1.4
1.6
1.7
Number
1
1
1
6 1)
see
table 7
2
1 2)
1.8
1
1.9
1
1.10
1
1.5
Description
Hub
Pressure ring
Setting nut
Torque setting screws
Disk spring
Friction lining
Centering plain bush
Setscrews
DIN EN ISO 4029
Lock washer
Drive component e. g.
sprocket (optional)
Illustration 8: RUFLEX® size 00 to 5
1) With size 00 number = 3
2) The number of plain bushes of RUFLEX® max.
depends on the width of drive component
(customized).
Subassembly 2: Components of RUFLEX® torque limiter size 6 to 8
Component
2.1
2.2
2.3
2.6
2.7
Number
1
1
1
see
table 6
see
table 7
2
1 1)
2.8
1
2.9
1
2.10
1
2.11
2.12
see
table 6
2.4
2.5
Description
Hub
Pressure ring
Setting nut
Setting screws for disk
springs
Disk spring
Friction lining
Centering plain bush
Setscrews
DIN EN ISO 4029
Cap screw
DIN EN ISO 4762
Drive component e. g.
sprocket (optional)
Disk DIN 1440
Snap ring DIN 7993
Illustration 9: RUFLEX® size 6 to 8
1) The number of plain bushes of RUFLEX® max. depends on the width of drive component (customized).
Table 6:
Size
Number of setting screws for disk springs (component 2.4)
Number of disks (component 2.11)
Number of snap rings (component 2.12)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
6
8
8
8
7
12
12
12
Replacing:
Replaced by:
8
16
16
16
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
46010 EN
11 of 26
9
Assembly
4.1 Components of RUFLEX®
Subassembly 3: Components of RUFLEX® torque limiter size 9
Component
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
Number
Description
1
Hub
1
Pressure ring
1
Setting nut
Setting screws for disk
15
springs
see
Disk spring
table 7
2
Friction lining
1 1)
Centering plain bush
Setscrews
1
DIN EN ISO 4029
Setscrews
1
DIN EN ISO 4029
Drive component e. g.
1
sprocket (optional)
2)
Lock washer
15
Circlip DIN 471
Hexagon nut
15
DIN EN ISO 4035
Illustration 10: RUFLEX® size 9
1) The number of plain bushes of RUFLEX® max. depends on the width of drive component (customized).
2) Number with 1 TF = 30, with 2TFD = 15
Components of RUFLEX® torque limiter with ROTEX® coupling
Component/
subNumber
assembly
1/2/3
1
4
5
6
1
1
1
7
1)
8
1
Description
RUFLEX® (complete
torque limiter) with driving
component (friction
flange)
ROTEX® driving flange
ROTEX® hub
ROTEX® spider
Cap screws
DIN EN ISO 4762 - 12.9
Setscrews
DIN EN ISO 4029
Illustration 11: RUFLEX® with ROTEX®
1) depending on the size of ROTEX® coupling
Components of RUFLEX® torque limiter with BoWex® coupling
Component/
subNumber
assembly
1/2
1
5
6
1
1
8
1
Description
RUFLEX® (complete
torque limiter) with driving
component (friction
flange)
BoWex® hub
BoWex® sleeve
Setscrews
DIN EN ISO 4029
Illustration 12: RUFLEX® with BoWex®
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
KTR-N
Sheet:
Edition:
RUFLEX® Torque limiter
Operating/Assembly instructions
4
46010 EN
12 of 26
9
Assembly
4.2 Layering of disk springs
Single layering (standard)
1TF
Size 0 to 5
1TFD
Size 00
Double layering
1TFD
Size 6 to 9
2TF
Size 0 to 5
2TFD
Size 00
Triple layering
2TFD
Size 6 to 9
3TF
Size 1 to 5
Table 7: Disk springs
Size
00
0
01
1
1TF
1TFD
2TF
2TFD
3TF
2
4
-
1
2
-
1
2
-
1
2
3
2
3
4
Number of disk springs
1
1
1
2
2
2
3
3
3
5
6
7
8
9
1
2
3
16
32
-
24
48
-
32
64
-
30
60
-
4.3 Advice for finish bore
STOP
The maximum permissible bore diameters d (see table 1
to 5 in chapter 1 - technical data) must not be exceeded. If
these figures are disregarded, the torque limiter may tear.
Rotating particles may cause danger to life.
• If the bore of the hub is machined by the customer, the
torque limiter needs to be disassembled (see chapter 4.6).
• Axial run-out or concentricity (see illustration 13) must be
adhered to.
• Please make absolutely sure to observe the figures for
Ø dmax.
• Carefully align the hubs when the finish bores are drilled.
• Please provide for a setscrew according to
DIN EN ISO 4029 with a cup point or an end plate to fasten
the hubs axially.
!
Illustration 13: Concentricity
and axial run-out
The customer bears the sole responsibility for all machining processes performed
subsequently on unbored or pilot bored as well as finish machined components and spare
parts. KTR does not assume any warranty claims resulting from insufficient remachining.
Table 8: Setscrews DIN EN ISO 4029
Size
Dimension G
Dimension t
00
M4
3
Please observe protection
note ISO 16016.
Drawn:
Verified:
0
M4
3
01
M5
4
1
M5
6
2
M6
6
2019-03-05 Pz
2019-03-06 Pz
3
M6
6
4
M8
6
5
M8
8
Replacing:
Replaced by:
6
M8
8
7
M10
8
8
M10
8
9
M12
11
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
46010 EN
13 of 26
9
Assembly
4.3 Advice for finish bore
Table 9: Recommended fit pairs acc. to DIN 748/1
Bore [mm]
above
up to
50
50
Shaft tolerance
Bore tolerance
k6
m6
H7
(KTR standard)
If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR
standard) with standard operating conditions or ISO P9 with complicated 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.
4.4 Assembly (general)

We recommend to clean bores, shaft, keyway and feather keyway and inspect for
dimensional accuracy before assembly.
Heating the RUFLEX® torque limiter respectively ROTEX® or BoWex® hub lightly (approx.
80 °C) allows for easier mounting onto the shaft.
STOP
Touching the heated torque limiter, coupling or hub causes burns.
Please wear safety gloves.

The mounting process of the torque limiter via a mounting device should be done through
the hub (component 1.1, 2.1 or 3.1).
• Please make sure the perfect technical condition of the RUFLEX® torque limiter.
• Clean the bores, shafts, sliding surfaces of the hub, driving component, thrust washer and friction linings from
dirt, oil and grease.
• Please only use original KTR components (no purchased parts).
!
Dirty friction surfaces affect the torque limiter's functioning.The friction linings must not get
in contact with oil or grease.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
KTR-N
Sheet:
Edition:
RUFLEX® Torque limiter
Operating/Assembly instructions
4
46010 EN
14 of 26
9
Assembly
4.5 Centering plain bush
• Inspect the width of the centering plain bush.
Only valid for size 00:
Centering plain bush = b1 - 0.5 to 1.0
Only valid for size 0 to 9:
Centering plain bush = 1.5 x s1 + b1
Example:
RUFLEX® torque limiter size 1
Width of driving component e. g.
b1 = 8 mm
Width of friction lining s1 = 3 mm
Centering plain bush =
1.5 x 3 + 8 = 12.5 mm
Illustration 14: Centering plain bush
with RUFLEX® size 00
Illustration 15: Centering plain bush
with RUFLEX® size 0 to 9
Centering plain bush = Unless any width of driving component is specified in the order, the centering plain bush
is supplied with maximum width.
!
If the specified width of the centering plain bush is not observed, the functioning of the
torque limiter is not ensured.
Table 10: Width of centering plain bush
Size
Max. width of
centering plain
bush
00
0
01
1
2
3
4
5
6
7
8
9
4.2
10
13
15
17
21.5
24.5
28
31
33
33
33
4.6 Assembly of RUFLEX® torque limiter
• Mount the RUFLEX® torque limiter (subassembly 1, 2 or 3) onto the shaft of the driving or driven side.
• Fasten the RUFLEX® torque limiter by tightening the setscrew DIN EN ISO 4029 with a cup point (component
1.8, 2.8 resp. 3.8) (tightening torques see table 11).

All screw connections can be secured against working loose additionally, e. g.
conglutinating with Loctite (average strength).
Table 11: Tightening torques of setscrews DIN EN ISO 4029 (component 1.8, 2.8 and 3.8)
Size
Dimension G
Tightening torque TA [Nm]
00
M4
1.5
Please observe protection
note ISO 16016.
Drawn:
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0
M4
1.5
01
M5
2
1
M5
2
2
M6
4.8
2019-03-05 Pz
2019-03-06 Pz
3
M6
4.8
4
M8
10
5
M8
10
Replacing:
Replaced by:
6
M8
10
7
M10
17
8
M10
17
9
M12
40
KTR-N dated 2011-05-24
KTR-N
Sheet:
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RUFLEX® Torque limiter
Operating/Assembly instructions
4
46010 EN
15 of 26
9
Assembly
4.7 Assembly of RUFLEX® torque limiter with ROTEX® coupling

Please consider our operating/assembly instructions KTR-N 40210 additionally when using
the ROTEX® coupling.
• Mount the RUFLEX® torque limiter (subassembly 1,
2 or 3) resp. ROTEX® hub (component 5) onto the
shafts of the driving and driven side).
• Fasten the RUFLEX® torque limiter (subassembly 1,
2 resp. 3) by tightening the setscrew (component
1.8, 2.8 resp. 3.8) DIN EN ISO 4029 with a cup
point (tightening torques see table 11).
• Hand-tighten the ROTEX® driving flange
(component 4) and RUFLEX® torque limiter with the
cap screws (component 7) first.
Illustration 16: RUFLEX® with ROTEX®
• Tighten the cap screws (component 7) crosswise via a suitable torque key to the tightening torques T A
specified in table 12.
• Insert the ROTEX® spider (component 6) into the cam section of the ROTEX® hub (component 5).
• Shift the power packs in axial direction until the distance dimension E has been achieved (see illustration 6 or
table 4).
• If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for setting the
distance dimension E.
• Fasten the ROTEX® hub (component 5) by tightening the setscrews (component 8) DIN EN ISO 4029 with a
cup point (tightening torque see KTR-N 40210).
!

With the assembly make sure that the distance dimension E (see illustration 6 and table 4) is
observed so that the components are not in contact with each other during the operation.
Disregarding this advice may cause damage to the torque limiter resp. coupling.
All screw connections can be secured against working loose additionally, e. g.
conglutinating with Loctite (average strength).
Table 12: Tightening torques of the cap screws DIN EN ISO 4762 (component 7)
Size
Screw size
Tightening torque TA
[Nm]
Please observe protection
note ISO 16016.
00
M3
0
M4
01
M4
1
M5
2
M5
3
M6
4
M12
5
M12
6
M12
7
M16
8
M20
9
M20
1.2
2.8
2.8
5.5
5.5
14
115
115
115
290
560
560
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RUFLEX® Torque limiter
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
46010 EN
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9
Assembly
4.8 Assembly of RUFLEX® torque limiter with BoWex® coupling

Please consider our operating/assembly instructions KTR-N 40110 additionally when using
the BoWex® coupling.
• Mount the RUFLEX® torque limiter (subassembly 1
or 2) resp. BoWex® hub (component 5) onto the
driving or driven side.
• Fasten the hub of the RUFLEX® torque limiter by
tightening the setscrew (component 1.8 or 2.8)
DIN EN ISO 4029 with a cup point (tightening
torques see table 11).
• Put the BoWex® sleeve (component 6) onto the
spline of the BoWex® hub (component 5).
• Shift the power packs in axial direction until the
distance dimension E has been achieved (see
illustration 7 or table 5).
Illustration 17: RUFLEX® with BoWex®
• If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for setting the
distance dimension E.
• Fasten the BoWex® hub (component 5) by tightening the setscrew (component 8) DIN EN ISO 4029 with a cup
point (tightening torque see KTR-N 40110).
!

With the assembly make sure that the distance dimension E (see illustration 7 and table 5) is
observed to allow for axial clearance of the BoWex® sleeve (component 6) when in
operation.
Disregarding this advice may cause damage to the torque limiter resp. coupling.
All screw connections can be secured against working loose additionally, e. g.
conglutinating with Loctite (average strength).
4.9 Disassembly of the torque limiter / replacement of single parts
Only valid for size 00 to 5:
• Unscrew the torque setting screws (component 1.4)
evenly sequentially. During every revolution every
screw may only be unscrewed by half a turn.
Unscrew all clamping screws until they do no longer
protrude in the locking washer.
• Disassemble the setting nut (component 1.3) from
the hub (component 1.1).
• Remove the disk springs (component 1.5).
Illustration 18: RUFLEX® size 00 to 5

Please note the disk spring layer for assembly.
Please observe protection
note ISO 16016.
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2019-03-06 Pz
Replacing:
Replaced by:
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RUFLEX® Torque limiter
Operating/Assembly instructions
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KTR-N
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Edition:
46010 EN
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9
Assembly
4.9 Disassembly of the torque limiter / replacement of single parts
Only valid for size 6 to 9:
• Turn back the setting screws for disk springs
(component 2.4 resp. 3.4) until the disk springs
(component 2.5 resp. 3.5) fit the interior of the
setting nut (component 2.3 resp. 3.3).
• Only valid for size 6 to 8:
Unscrew the cap screw (component 2.9) from the
setting nut (component 2.3).
Only valid for size 9:
Unscrew the setscrew (component 3.9) from the
setting nut (component 3.3).
• Disassemble the setting nut (component 2.3 resp.
3.3) from the hub (component 2.1 resp. 3.1).
Illustration 19: RUFLEX® size 6 to 8
• Screw the setting screws for disk springs
(component 2.4 resp. 3.4) into the setting nut
(component 2.3 resp. 3.3) until there is no pressure
on the disk springs (component 2.5 resp. 3.5).
• Only valid for size 6 to 8:
Remove the snap ring (component 2.12) from the
setting screws for disk springs (component 2.4).
Only valid for size 9:
Remove the snap ring (component 3.12) from the
setting screws for disk springs (componenent 3.4).
• Only valid for size 6 to 8:
Take the locking washer (component 2.11) and disk
springs (component 2.5) from the setting screws for
disk springs (component 2.4).
Only valid for size 9:
Take the locking washer (component 3.11) and disk
springs (component 3.5) from the setting screws for
disk springs (component 3.4).

Illustration 20: RUFLEX® size 9
Please note the disk spring layer for assembly.
Continuation of disassembly with all sizes:
• Remove the thrust ring (componen 1.2, 2.2 resp. 3.2).
• Take the friction linings (component 1.6, 2.6 resp. 3.6) and the driving component (component 1.10, 2.10 resp.
3.10) from the hub (1.1, 2.1 resp. 3.1).
• Remove the centering plain bushes (component 1.7, 2.7 resp. 3.7).

A needle bearing can be installed instead of the centering plain bush (component 1.7, 2.7
resp. 3.7).
Please observe protection
note ISO 16016.
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Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
46010 EN
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9
Assembly
4.10 Assembly of the torque limiter
The assembly is done in reverse order with the disassembly (see chapter 4.9). For that purpose observe the
exploded-view drawings illustration 8 to 10 resp. 18 to 20. Components lubricated by the manufacturer may have
to be re-lubricated.

Lubrication by usual greases has to be done. Make sure that the friction linings remain free
from grease.
Please note the disk spring layer for the assembly as per chapter 4.2.
!
Table 13:
Tightening torques of torque setting screws (component 1.4) resp. setting screw for disk
springs (component 2.4)
Size
Width across flats SW
Tightening torque TA
[Nm]
5
00
3
0
3
01
3
1
4
2
5
3
6
4
6
5
6
6
24
7
24
8
24
2.5
2.5
2.5
5
8.5
21
21
21
200
200
200
Adjustment of torque
5.1 Initial setting resp. re-setting of slipping torque
!
!
Setting a slipping torque not covered by the slipping torque as per table 1 may cause failure
and damage of the torque limiter.
The slipping torques specified in the diagrammes refer to driving components made of steel
or cast iron as well as friction linings run in. For torque limiters supplied by KTR without
being set, run in of the friction linings must be done by the customer. Please contact KTR
for further details.
When being set the RUFLEX® torque limiter should slip at approx. 50 % of the respective
maximum torque several times to achieve a maximum contact ratio of the friction lining. To
achieve the maximum slipping torques specified the contact ratio must be at least 50 %.
The level of the slipping torque set depends on several factors and may vary heavily. That is
why we recommend to inspect the slipping torque set of the torque limiter via suitable tools.
During the operation there may be bigger deviations from the slipping torque set subject to
environmental influences, operating conditions or wear.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
KTR-N
Sheet:
Edition:
RUFLEX® Torque limiter
Operating/Assembly instructions
5
46010 EN
19 of 26
9
Adjustment of torque
5.1 Initial setting resp. re-setting of slipping torque
Table 14: Tools for torque setting
Hook spanner
DIN 1810-A
Jointed pin wrench
Jointed face wrench
Size
0
1
2
3
4
5
Ø40-42
Ø52-55
Ø68-75
Ø80-90
Ø110-115
Ø120-130
Ø18-40x4
Ø35-60x4
Ø40-80x5
Ø60-90x5
Ø80-125x6
Ø90-155x8
Ø125-200x8
RUFLEX® size 00 to 5:
1) Fix the hub (component 1.1) to avoid twisting.
2) Turn back the torque setting screws (component 1.4) until they no
longer protrude through the setting nut (component 1.3).
3) Turn the setting nut (component 1.3) manually until it fits with the
locking washer (component 1.9). Now you have achieved zero
position.
4) To achieve the maxium slippling torque fully screw in the torque setting
screws (component 1.4).
5) For a smaller slipping torque unscrew the setting nut (component 1.3)
pursuant to the setting diagramme (see diagramme 1 to 8, chapter 5.2)
by the angle of setting specified before starting with step 4. Afterwards
fully screw in the torque setting screws (component 1.4) (tightening
torque TA see table 13).
Illustration 21: Torque setting
RUFLEX® size 00 to 5
RUFLEX® size 6 to 8:
1) Fix the hub (component 2.1) to avoid twisting.
2) Turn back the setting screws for disk springs (component 2.4) until the
disk springs (component 2.5) fit the interior of the setting nut
(component 2.3).

The setting screw for disk springs (component 2.4) must
not be unscrewed exceeding the resistance of the snap
ring (component 2.12).
3) Screw in the setting nut (component 2.3) until the disk (component
2.11) is in contact with the front surface of the thrust ring (component
2.2). Now you have achieved zero position. Fasten the setting nut
(component 2.3) via the cap screw (component 2.9) (tightening torque
see table 15).
Illustration 22: Torque setting
RUFLEX® size 6 to 8
4) To achieve the maximum slippling torque tighten the setting screws for disk springs (component 2.4) evenly
(tightening torque see table 13).
5) For a smaller slipping torque unscrew the setting nut (component 2.3) pursuant to the setting diagramme (see
diagramme 9 to 11, chapter 5.2) by the angle of setting specified before starting with step 4.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
KTR-N
Sheet:
Edition:
RUFLEX® Torque limiter
Operating/Assembly instructions
5
46010 EN
20 of 26
9
Adjustment of torque
5.1 Initial setting resp. re-setting of slipping torque
Table 15: Tightening torques of cap screws (component 2.9)
Size
Screw size
Tightening torque TA [Nm]
6
M6x16
14
7
M6x16
14
8
M6x16
14
RUFLEX® size 9:
1)
2)
3)
Fix the hub (component 3.1) to avoid twisting.
Unscrew the hexagon nuts (component 3.13).
Turn back the setting screws for disk springs (component 3.4) until
the disk springs (component 3.5) fit the interior of the setting nut
(component 3.3).

The setting screw for disk springs (component 3.4) must
not exceed the resistance of the snap ring (component
3.12).
4)
Remove the setscrew (component 3.9) from the safety groove of the
hub (component 3.1).
5) Screw in the setting nut (component 3.3) until the locking washer
(component 3.11) is in contact with the front surface of the thrust ring
(component 3.2).
6) Afterwards turn the setting nut (component 3.3) counterclockwise until
the setscrew (component 3.9) is flush with the safety groove of the
hub (component 3.1).
7) Tighten the setscrew (component 3.9) to the tightening torque
TA = 40 Nm.
8) Hand-tighten the setting screws for disk springs (component 3.4)
clockwise until the locking washer (component 3.11) is in contact with
the front surface of the thrust ring (component 3.2).
Now you have achieved zero position.
9) Afterwards turn the setting screw for disk springs (component 3.4)
evenly clockwise by the number of setting points (each 3 setting
points at the maximum) pursuant to the setting diagramme (see
diagramme 12).
One revolution corresponds to 12 setting points (see illustration 24).
10) Having set the torque, fasten the setting screw for disk springs
(component 3.4) by tightening the hexagon nuts (component 3.13) at
the tightening torque TA = 300 Nm.

Illustration 23: Torque setting
RUFLEX® size 9
One revolution of the setting screw for disk springs
(component 3.4) corresponds to 12 setting points
(see illustration 24).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Illustration 23: Setting points
Replacing:
Replaced by:
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
46010 EN
21 of 26
9
Adjustment of torque
5.2 Setting diagrammes
Diagramme 1: RUFLEX® size 00
Diagramme 2: RUFLEX® size 0
Diagramme 3: RUFLEX® size 01
Please observe protection
note ISO 16016.
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Replacing:
Replaced by:
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
46010 EN
22 of 26
9
Adjustment of torque
5.2 Setting diagrammes
Diagramme 4: RUFLEX® size 1
Diagramme 5: RUFLEX® size 2
Diagramme 6: RUFLEX® size 3
Please observe protection
note ISO 16016.
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2019-03-06 Pz
Replacing:
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RUFLEX® Torque limiter
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
46010 EN
23 of 26
9
Adjustment of torque
5.2 Setting diagrammes
Diagramme 7: RUFLEX® size 4
Diagramme 8: RUFLEX® size 5
Diagramme 9: RUFLEX® size 6
Please observe protection
note ISO 16016.
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Replacing:
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RUFLEX® Torque limiter
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
46010 EN
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9
Adjustment of torque
5.2 Setting diagrammes
Diagramme 10: RUFLEX® size 7
Diagramme 11: RUFLEX® size 8
Diagramme 12: RUFLEX® size 9
Please observe protection
note ISO 16016.
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2019-03-06 Pz
Replacing:
Replaced by:
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RUFLEX® Torque limiter
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
46010 EN
25 of 26
9
Breakdowns, causes and elimination
The below-mentioned failures can lead to a use of the RUFLEX® torque limiter other than intended. In addition to
the specifications given in these operating/assembly instructions make sure to avoid such failures.
The errors listed can only be clues to search for the failures. When searching for the failure the adjacent
components must generally be considered.
General failures with use other than intended:
•
•
•
•
•
•
•
•
•
Important data for the torque limiter selection were not forwarded.
The calculation of the shaft-hub-connection was not considered.
Components with damage occurred during transport are assembled.
If the heated hubs are assembled, the permissible temperature is exceeded.
The clearance of the components to be assembled is not coordinated with one another.
Tightening torques have been fallen below/exceeded.
Components are mixed up by mistake/assembled incorrectly.
No original KTR components (purchased parts) are used.
Maintenance intervals are not observed.
Breakdowns
The torque limiter
releases in an
undefined position.
The torque limiter
does not release in
case of overload.
Different operating
noise and/or
vibrations occuring
RUFLEX® with
ROTEX® torque is no
longer transmitted
ROTEX®
BoWex®
Causes
Elimination
Torque is not set
Torque set incorrectly
1) Set the unit out of operation
Setting nut resp. setting screws 2) Adjust torque, see chapter 5
have worked loose
1) Set the unit out of operation
Wear
2) Send the torque limiter to KTR for inspection/repair
Oily friction linings
1) Replace friction linings
1) Set the unit out of operation
2) Eliminate the reason for the misalignment (e. g. loose
Misalignment
foundation bolts, breaking of the engine mount, heat expansion
of unit components, modification of the installation dimension E
of the torque limiter)
1) Set the unit out of operation
2) Inspect components and replace components that have been
Screws working loose
damaged
3) Tighten the dowel screws to the tightening torque specified
4) Inspect alignment, adjust if necessary
1) Set the unit out of operation
Screws/setscrew for axial
2) Inspect alignment
fastening of flange hubs
3) Tighten the screws to fasten the flange hubs and secure against
working loose
working loose
1) Set the unit out of operation
Faulty storage
2) Send the torque limiter to KTR for inspection/repair
ROTEX® driving flange has
1) Set the unit out of operation
worked loose
2) Tighten the cap screws
Torque is not set
Torque set incorrectly
1) Set the unit out of operation
Setting nut resp. setting screws 2) Adjust torque, see chapter 5
have worked loose
1) Set the unit out of operation
Wear
2) Send the torque limiter to KTR for inspection/repair
Oily friction linings
Replace friction linings
Please consider our operating/assembly instructions KTR-N 40210 additionally when using the
ROTEX® coupling.
See chapter 6 Breakdowns, causes and elimination
Please consider our operating/assembly instructions KTR-N 40110 additionally when using the
BoWex® coupling.
See chapter 6 Breakdowns, causes and elimination
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
RUFLEX® Torque limiter
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
46010 EN
26 of 26
9
Disposal
In respect of environmental protection we would ask you to dispose of the packaging or products on termination of
their service life in accordance with the legal regulations and standards that apply, respectively.
• Metal
Any metal components have to be cleaned and disposed of by scrap metal.
• Friction linings
Friction linings can be disposed of by residual waste.
• Greases/oils
Greases and oils have to be collected and disposed of by a waste disposal company.
8
Maintenance and service
RUFLEX® is a low-maintenance torque limiter. We recommend to perform a visual inspection on the torque limiter
at least once a year. In case of extreme drive conditions or heavy dirt, respectively, the RUFLEX® has to be
regularly inspected for its operation. If RUFLEX® is ordered in a pilot bored design, the customer has to
disassemble it in order to machine a finish bore.
• Since the flexible machine bearings of the driving and driven side settle during the course of load, inspect the
alignment and re-align the torque limiter, if necessary.
• The components have to be inspected for damages.
• The screw connections have to be inspected visually.
Having started up the torque limiter the tightening torques of the screws have to be
inspected during the usual inspection intervals.
!
9
Spares inventory, customer service addresses
A basic requirement to ensure the readiness for use of the torque limiter is a stock of the most important spare
parts on site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at
www.ktr.com.

KTR does not assume any liability or warranty for the use of spare parts and accessories
which are not provided by KTR and for the damages which may incur as a result.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2019-03-05 Pz
2019-03-06 Pz
Replacing:
Replaced by:
KTR-N dated 2011-05-24
">