KTR SINULASTIC Operating/Mounting Instructions
KTR SINULASTIC is a highly flexible flange coupling that is easy to plug in axially. It dampens torsional vibrations and compensates for shaft misalignment. The SINULASTIC coupling features overload protection guarding your drive against excessive torque.
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SINULASTIC® Operating/Assembly instructions Type A and T KTR-N Sheet: Edition: 48710 EN 1 of 27 2 SINULASTIC® highly flexible flange coupling type A, T and their combinations Type AK Type AL Type AKC Type ALC Type T Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T KTR-N Sheet: Edition: 48710 EN 2 of 27 2 SINULASTIC® type A and T is a highly torsionally flexible flange coupling easy to plug in axially with a linear torsional stiffness characteristic curve. It dampens torsional vibrations and compensates for axial, radial and angular shaft displacements. The SINULASTIC® coupling has an overload function protecting the drive against impermissibly high torques. Table of contents 1 2 3 4 Technical data 3 1.1 1.2 3 8 Coupling dimensions and technical data General dimensions and torques Advice 10 2.1 2.2 2.3 2.4 2.5 2.6 10 10 10 11 11 11 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 12 3.1 3.2 12 12 Storage Transport and packaging Assembly 13 4.1 4.2 4.3 4.4 4.5 13 16 16 17 17 17 18 18 18 19 20 20 4.6 4.7 4.8 Components of the couplings Advice for finish bore General advice for assembly Assembly of hub (type AK and AL) Assembly/Disassembly of clamping ring hub (type AKC and ALC) 4.5.1 Assembly of clamping ring hub (type AKC and ALC) 4.5.2 Disassembly of clamping ring hub (type AKC and ALC) Assembly/Disassembly of taper clamping sleeve (type T) 4.6.1 Assembly of taper clamping sleeve (type T) 4.6.2 Disassembly of taper clamping sleeve (type T) Assembly/Disassembly of elastomer part resp. connection flange 4.7.1 Assembly of connection flange (component 2.1 or 2.2) 4.7.2 Assembly of elastomer part (component 1) with hub resp. clamping ring hub (only valid with type AK, AL, AKC and ALC) 4.7.3 Assembly of elastomer part with connection flange 4.7.4 Disassembly of connection flange (component 2.1 or 2.2) 4.7.5 Disassembly of elastomer part (component 1) from the hub resp. clamping ring hub (only valid with type AK, AL, AKC and ALC) Displacements - alignment of the couplings 20 21 21 21 22 5 Start-up 23 6 Breakdowns, causes and elimination 24 7 Disposal 25 8 Maintenance and service 26 9 Spares inventory, customer service addresses 27 Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48710 EN 3 of 27 2 Type AK and AL Illustration 1: SINULASTIC® type AK Illustration 2: SINULASTIC® type AL Table 1: Dimensions - type AK and AL Size Finish bore D in mm Pilot Max. bored 20 - 80 28 - 115 38 - 115 53 - 115 96 - 175 114 - 175 140 - 175 180 - 175 Flange connection acc. to SAE - J620 / diameter 1) 11.5“ 14“ 14“ 18“ Ø475 2) 14“ 18“ Ø475 2) 14“ 18“ Ø475 2) 18“ 21“ 24“ 18“ 21“ 24“ 21“ 24“ 21“ 24“ Cap screws DIN EN ISO 4762 Dimensions 3) in mm DN D6 LE L1 112 164 65 75 162 244 44 162 244 162 L4 AK AL L6 L7 MxLM TA in Nm 5.5 41.0 13.6 M12x30 120 90.5 127.5 +3.5/-4.5 +3.5/-4.5 90 93.5 ±3 109 ±3 7.0 7.0 M16x40 300 58 100 93.5 ±3 123 ±3 7.0 7.0 M16x40 300 247 70 105 92.5 ±3 146 ±3 13.0 7.0 M16x40 300 248 352 84 150 129 ±4 192 ±4 1.0 11.0 M20x50 590 248 352 98 150 129 ±4 206 ±4 1.0 11.0 M20x50 590 248 431 94 200 200 ±3.5 280 ±3.5 3.0 14.0 M20x60 590 248 431 114 200 200 ±3.5 300 ±3.5 3.0 14.0 M20x60 590 1) For dimensions of flange connection see table 7. 2) Flange connection differing from SAE standard, dimensions in mm. 3) For dimensions G and T see table 10. ! 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: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48710 EN 4 of 27 2 Table 2: Technical data - type AK and AL Size 20 28 38 53 96 114 140 180 Flange connection acc. to SAE - J620 / diameter 1) Total weight with maximum bore of coupling in kg 11.5“ 14“ 14“ 18“ Ø475 2) 14“ 18“ Ø475 2) 14“ 18“ Ø475 2) 18“ 21“ 24“ 18“ 21“ 24“ 21“ 24“ 21“ 24“ 13.70 14.79 21.89 26.54 22.15 25.53 30.18 25.79 29.44 34.09 29.70 63.86 72.34 77.90 68.00 76.48 82.05 101.52 108.59 109.82 116.90 Mass moment of inertia with maximum bore of coupling in kgm2 JA JL 0.0947 0.0533 0.1353 0.1873 0.4968 0.1667 0.2013 0.2444 0.5539 0.1994 0.2584 0.2906 0.2378 0.6000 0.3046 0.7310 1.5407 1.0321 2.2186 0.8367 1.6464 1.1212 2.3243 1.6664 2.1577 2.5280 1.9539 2.4188 2.8167 1) For dimensions of flange connection see table 7. 2) Flange connection differing from SAE standard, dimensions in mm. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48710 EN 5 of 27 2 Type AKC and ALC Illustration 3: SINULASTIC® type AKC Illustration 4: SINULASTIC® type ALC Table 3: Dimensions - type AKC and ALC Size 1) 2) 3) 4) 5) 1) Finish bore D in mm Pilot Max. bored 20 30 50 28 46 65 38 46 80 53 46 80 Flange connection acc. to SAE - J620 / diameter 2) 11.5“ 14“ 14“ 18“ Ø475 3) 14“ 18“ Ø475 3) 14“ 18“ Ø475 3) Cap screws DIN EN ISO 4762 Dimensions 4) 5) in mm DN D6 LE L1 109 164 65 57 139 244 44 139 244 139 247 L4 AKC ALC L6 L7 MxLM TA in Nm 5.5 41.0 13.6 M12x30 120 70.5 95.5 +3.5/-4.5 +3.5/-4.5 63 56.5 ±3 72 ±3 7.0 7.0 M16x40 300 58 69 65 ±3 92 ±3 7.0 7.0 M16x40 300 70 83 83 ±3 124 ±3 13.0 7.0 M16x40 300 Other sizes on request. For dimensions of flange connection see table 7. Flange connection differing from SAE standard, dimensions in mm. For dimensions G and T see table 10. For dimensions M1 and LM1 see table 11. ! 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: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48710 EN 6 of 27 2 Table 4: Technical data - type AKC and ALC Size 1) 20 28 38 53 Flange connection acc. to SAE - J620 / diameter 2) Total weight with maximum bore of coupling in kg 11.5“ 14“ 14“ 18“ Ø475 3) 14“ 18“ Ø475 3) 14“ 18“ Ø475 3) 13.93 15.02 21.15 25.79 21.40 24.05 28.70 24.31 28.72 33.37 28.98 Mass moment of inertia with maximum bore of coupling in kgm2 JA JL 0.0947 0.0520 0.1353 0.1873 0.4968 0.1525 0.2013 0.2444 0.5539 0.1837 0.2584 0.2906 0.2240 0.6000 0.3046 1) Other sizes on request. 2) For dimensions of flange connection see table 7. 3) Flange connection differing from SAE standard, dimensions in mm. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 1 Technical data 1.1 Coupling dimensions and technical data KTR-N Sheet: Edition: 48710 EN 7 of 27 2 Type T Illustration 5: SINULASTIC® type T Table 5: Dimensions - type T Size Finish bore D in mm min. Max. 20 35 90 28 35 90 38 40 110 53 55 125 Flange connection acc. to SAE - J620 / diameter 1) 11.5“ 14“ 14“ 18“ Ø475 2) 14“ 18“ Ø475 2) 14“ 18“ Ø475 2) Dimensions 3) in mm D6 LE L1 L4 L6 70.5 5.5 L7 41.0 13.6 Taper clamping sleeve 164 60 63.5 244 44 63.5 57.0 ±3 7.0 7.0 3525 244 58 76.2 70 ±3 7.0 7.0 4030 247 70 89.0 83 ±3 13.0 7.0 4535 +3.5/-4.5 3525 1) For dimensions of flange connection see table 7. 2) Flange connection differing from SAE standard, dimensions in mm. 3) For dimensions M2 and LM2 see table 12. ! 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: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 1 Technical data 1.2 General dimensions and torques KTR-N Sheet: Edition: 48710 EN 8 of 27 2 Table 6: Technical data - type T Size Flange connection acc. to SAE - J620 / diameter 1) Total weight with maximum bore of coupling in kg 11.5“ 14“ 14“ 18“ Ø475 3) 14“ 18“ Ø475 1) 14“ 18“ Ø475 1) 13.75 14.83 24.37 29.02 24.63 28.68 33.33 28.93 33.72 38.36 33.97 20 28 38 53 Mass moment of inertia with maximum bore of coupling in kgm2 JA JL 0.0947 0.0568 0.1353 0.1873 0.4968 0.1919 0.2013 0.2444 0.5539 0.2404 0.2584 0.2906 0.2993 0.6000 0.3046 1) For dimensions of flange connection see table 7. 2) Flange connection differing from SAE standard, dimensions in mm. Table 7: Flange dimensions according to SAE J 620 Nominal size Dimension DA Dimension D4 Number Z Dimension DL 11.5“ 352.42 333.37 8 11 14“ 466.72 438.15 8 13 Flange dimensions [mm] 18“ 21“ 571.50 673.10 542.90 641.35 6 12 17 17 24“ 733.42 692.15 12 21 Ø475 1) 475.00 450.00 12 11 1) Flange connection differing from SAE standard, dimensions in mm. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 1 Technical data 1.2 General dimensions and torques KTR-N Sheet: Edition: 48710 EN 9 of 27 2 Table 8: Torques Torque in Nm Size 20 28 38 53 96 114 140 180 Natural rubber (NR) and synthetical rubber (EPDM) Elastomer type S M H U W 1) S M H U S M H U S M H U S M H U S M H U S M H U S M H U TKN TK max TK max1 1800 2000 2500 2850 2000 1) 2200 2800 3400 3750 3100 3800 4600 5100 4200 5300 6200 7000 8100 10000 11200 13200 10000 11400 13400 15600 13000 14000 16200 19000 16000 18000 22000 25000 2700 3000 3750 4275 3000 1) 3300 4200 5100 5625 4650 5700 6900 7650 6300 7950 9300 10500 12150 15000 16800 19800 15000 17100 20100 23400 19500 21000 24300 28500 24000 27000 33000 37500 3600 4000 5000 8550 4000 1) 4400 5600 10200 11250 6200 7600 13800 15300 8400 10600 18600 21000 16200 20000 33600 39600 20000 22800 40200 46800 26000 28000 48600 57000 32000 36000 66000 75000 with 10 Hz TKW 720 800 1000 1140 800 1) 880 1120 1360 1500 1240 1520 1840 2040 1680 2120 2480 2800 3240 4000 4480 5280 4000 4560 5360 6240 5200 5600 6480 7600 6400 7200 8800 10000 Silicone rubber (SI) torque with an ambient temperature of +80 °C with TKN RT 2) TKN TK max TK max1 10 Hz TKW 1800 1385 2077 2769 554 2000 1538 2308 3077 615 2200 1692 2538 3385 677 2800 2154 3231 4308 862 3100 2385 3577 4769 954 3800 2923 4385 5846 1169 4200 3231 4846 6462 1292 5300 4077 6115 8154 1631 8100 6231 9346 12462 2492 10000 7385 11077 14769 2954 10000 7077 10615 14154 2831 11400 8769 13154 17538 3508 13000 9615 14423 19231 3846 14000 10769 16154 21538 4308 16000 12308 18462 24615 4923 18000 13846 20769 27692 4800 - Operating speed in rpm n nmax. 2700 3000 3240 3600 2340 2600 2520 2800 2520 2800 2880 3200 2340 2600 2700 3000 2070 2300 2250 2500 2070 2300 2250 2500 1890 2100 2070 2300 1890 2100 2070 2300 1) Elastomer part available in the material natural rubber (NR) only. 2) Reference value with an ambient temperature of +20 °C Maximum torque of coupling TK max = rated torque of coupling TKN x 1.5. 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. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 2 Advice 2.1 General advice KTR-N Sheet: Edition: 48710 EN 10 of 27 2 Read carefully through these operating/assembly instructions before you start up the coupling. Pay special attention to the safety instructions! The operating/assembly instructions are part of your product. Please store them carefully and close to the coupling. The copyright for these operating/assembly instructions remains with KTR. 2.2 STOP ! 2.3 STOP Safety and advice symbols Warning of personal injury This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death. Warning of product damages This symbol indicates notes which may contribute to preventing material or machine damage. General advice This symbol indicates notes which may contribute to preventing adverse results or conditions. Warning of hot surfaces This symbol indicates notes which may contribute to preventing burns with hot surfaces resulting in light to serious bodily injuries. General hazard warnings With assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is secured against accidental switch-on. You may be seriously hurt by rotating parts. Make absolutely sure to read through and observe the following safety indications. • All operations on and with the coupling have to be performed taking into account "safety first". • Make sure to switch off the power pack before you perform your work on the coupling. • Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on or removing the fuse for current supply. • Do not reach into the operating area of the coupling as long as it is in operation. • Secure the coupling against accidental contact. Provide for the necessary protection devices and covers. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 2 Advice 2.4 Proper use KTR-N Sheet: Edition: 48710 EN 11 of 27 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 SINULASTIC® 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 "SINULASTIC®"). 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 subjected to torsional vibrations are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the coupling selection and the torsional vibration calculation. 2.6 Reference to EC Machinery Directive 2006/42/EC The couplings supplied by KTR should be considered as components, not machines or partly completed machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of incorporation. For details about safe assembly, start-up and safe operation refer to the present operating/assembly instructions considering the warnings. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 3 Storage, transport and packaging 3.1 Storage KTR-N Sheet: Edition: 48710 EN 12 of 27 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. ! ! 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. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 4 KTR-N Sheet: Edition: 48710 EN 13 of 27 2 Assembly The coupling is supplied in the following subassemblies and single parts. Before assembly the coupling has to be inspected for completeness. 4.1 Components of the couplings Components of type AK and AL Component 1 2.1 2.2 3 6 7 8 Quantity 1 1 1 1 see table 9 1 see table 9 Description Elastomer part Connection flange made of steel Connection flange made of cast aluminium Hub Cap screw DIN EN ISO 4762 - 12.9 Setscrew DIN EN ISO 4029 Disk DIN EN ISO 7092 Illustration 6: SINULASTIC® type AK Illustration 7: SINULASTIC® type AL Illustration 8: SINULASTIC® type AK Illustration 9: SINULASTIC® type AL Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 4 Assembly 4.1 Components of the couplings KTR-N Sheet: Edition: 48710 EN 14 of 27 2 Components of type AKC and ALC Component 1 2.1 2.2 4 (4.1) (4.2) (4.3) 6 8 Quantity 1 1 1 1 1 1 see table 9 see table 9 see table 9 Description Elastomer part Connection flange made of steel Connection flange made of cast aluminium Clamping ring hub complete Clamping ring Clamping ring hub Cap screw DIN EN ISO 4762 - 12.9 Cap screw DIN EN ISO 4762 - 12.9 Disk DIN EN ISO 7092 Illustration 10: SINULASTIC® type AKC Illustration 11: SINULASTIC® type ALC Illustration 12: SINULASTIC® type AKC Illustration 13: SINULASTIC® type ALC Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 4 Assembly 4.1 Components of the couplings KTR-N Sheet: Edition: 48710 EN 15 of 27 2 Components of type T Component 1 2.1 2.2 5 (5.1) (5.2) 8 Quantity 1 1 1 1 1 see table 9 see table 9 Description Elastomer part Connection flange made of steel Connection flange made of cast aluminium Taper clamping sleeve complete Taper clamping sleeve Cap screw DIN EN ISO 4762 - 12.9 Disk DIN EN ISO 7092 Illustration 14: SINULASTIC® type T Illustration 15: SINULASTIC® type T Table 9: Number of cap screws of type A and T Size Number of cap screws (component 4.3) Number of cap screws (component 5.2) Number of cap screws (component 6) Number of disks (component 8) 20 28 38 53 96 114 140 180 6 6 8 1) 8 1) - - - - 3 3 3 3 - - - - 14 8 8 12 12 12 24 24 8 - - 8 - - - - 1) up to finish bore Ø65 mm = number of pieces 6; from finish bore Ø65 mm = number of pieces 8 Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 4 Assembly 4.2 Advice for finish bore STOP KTR-N Sheet: Edition: 48710 EN 16 of 27 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 16). • Make absolutely sure to observe the figures for ØDmax.. • Carefully align the hubs when the finish bores are drilled. • Provide for a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the hubs axially. Illustration 16: Concentricity and axial runout The customer bears the sole responsibility for all machining processes performed subsequently on unbored or pilot bored as well as finish machined coupling components and spare parts. KTR does not assume any warranty claims resulting from insufficient remachining. ! Table 10: Setscrew DIN EN ISO 4029 Size Dimension G Dimension T Tightening torque TA [Nm] 4.3 ! 20 M10 30 17 28 M12 35 40 38 M12 35 40 53 M12 40 40 96 M16 40 80 114 M16 40 80 140 M16 35 80 180 M16 35 80 General advice for assembly The SINULASTIC® coupling may only be assembled in the order described below. 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 an 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, 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: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 4 Assembly 4.4 Assembly of hub (type AK and AL) KTR-N Sheet: Edition: 48710 EN 17 of 27 2 • Mount the hub on the shaft of the driven machine. • Fasten the hub by tightening the setscrew DIN EN ISO 4029 with a cup point (tightening torque TA see table 10) or an end plate. 4.5 Assembly/Disassembly of clamping ring hub (type AKC and ALC) 4.5.1 Assembly of clamping ring hub (type AKC and ALC) The power transmission of SINULASTIC® clamping hubs is made frictionally engaged. The necessary surface pressure is transmitted via the clamping ring with internal taper to the taper hub and consequently to the shaft. • Clean and degrease the hub bore, clamping ring hub, clamping ring and the shaft. Afterwards they have to be inspected for dimensional accuracy. • Lightly unscrew the clamping screws (component 4.3) and pull the clamping ring (component 4.1) from the clamping ring hub (component 4.2) only marginally to make sure the clamping ring is fitted loosely. • Push the clamping ring hub onto the shaft against a stop. • Tighten the clamping screws evenly crosswise gradually at the tightening torque specified in table 11. Repeat this process until all clamping screws have reached the tightening torque. Illustration 17: Assembly of clamping ring hub with clamping ring Table 11: Cap screws DIN EN ISO 4762 - 12.9 (component 4.3) Size Screw size M1 Screw length LM1 Tightening torque TA1 [Nm] ! 20 M10 30 71 28 M10 40 71 38 M10 40 71 53 M12 45 123 96 - 114 - 140 - 180 - If the clamping screws are not tightened at the correct tightening torque, there is the risk of a) a fracture of the hub and plastic deformation with a too high tightening torque T A1 b) early slippling, untightening of the screws with a too low tightening torque T A1 Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T KTR-N Sheet: Edition: 4 Assembly 4.5 Assembly/Disassembly of clamping ring hub (type AKC and ALC) 48710 EN 18 of 27 2 4.5.2 Disassembly of clamping ring hub (type AKC and ALC) Unscrew the clamping screws (component 4.3) evenly one after another. During each revolution every screw may only be unscrewed by half a turn. Unscrew all clamping screws by 3 - 4 pitches. Remove the screws located next to the extraction threads and screw them into the intended extraction threads until they fit (see illustration 18). The clamping ring is released by tightening the screws in the extraction threads evenly gradually and crosswise. Pull the clamping ring hub (component 4.2) with the clamping ring (component 4.1) from the shaft. ! Illustration 18: Disassembly of clamping ring hub with clamping ring If these hints are not observed, the operation of the coupling may be affected. For reassembly the bores of the hub and the shaft have to be cleaned and degreased. The same applies for the taper surfaces of clamping ring hub and clamping ring. ! 4.6 Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used. Assembly/Disassembly of taper clamping sleeve (type T) 4.6.1 Assembly of taper clamping sleeve (type T) Clean and degrease the contact surfaces of the taper clamping sleeves (component 5.1) as well as shaft and elastomer part (component 1). The taper clamping sleeves have axially parallel, cylindrical and smooth tapped blind holes. Only half of these holes are located in the material of the sleeve. The other half located in the elastomer part has got threads. Fit the elastomer part and taper clamping sleeve with one another, make sure the bores cover each other and loosely screw in the cap screws (component 5.2) lightly lubricated or oiled and lightly tighten afterwards. Fit the elastomer part with the taper clamping sleeve onto the shaft. Push on the taper clamping sleeve until the mounting position LX (see illustration 20) is reached. Tighten the cap screws evenly to the tightening torque specified in table 12. Light blows with a soft hammer (e. g. made of nylon, rubber, etc.) on the taper clamping sleeve deplete settlements in the taper clamping connection which allows to retighten the screws. We recommend to repeat this process at least once until retightening the screws is no longer possible. Axial fastening of the Taper Lock hub (elastomer part with taper clamping sleeve) is obtained by proper assembly only. Illustration 19: Assembly of taper clamping sleeve Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 4 Assembly 4.6 Assembly/Disassembly of taper clamping sleeve (type T) KTR-N Sheet: Edition: 48710 EN 19 of 27 2 4.6.1 Assembly of taper clamping sleeve (type T) ! ! ! Make sure with assembly that the taper clamping sleeve is in the right mounting position LX (see illustration 20). 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. Oils and greases with molybdenum disulphide or highpressure additives, additives of Teflon and silicone as well as internal lubricants reducing the coefficient of friction significantly must not be used. Illustration 20: Mounting position of taper clamping sleeve to the shaft end Table 12: Cap screws (component 5.2) Taper clamping sleeve 3525 4030 4535 M2 1/2“ 5/8“ 3/4“ Screw dimensions [mm] LM2 SW2 38 10 44 12 50 14 TA2 [Nm] 115 170 190 Quantity (component 5.2) 3 3 3 4.6.2 Disassembly of taper clamping sleeve (type T) The taper clamping sleeve is untightened by removing the cap screws (component 5.2). Afterwards two of the cap screws serving as forcing screws are screwed in the thread of the sleeve and tightened. The elastomer part untightened in this way can be manually pulled from the shaft with the taper clamping sleeve. Illustration 21: Disassembly of clamping ring hub with clamping ring Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T KTR-N Sheet: Edition: 4 Assembly 4.7 Assembly/Disassembly of elastomer part resp. connection flange 48710 EN 20 of 27 2 4.7.1 Assembly of connection flange (component 2.1 or 2.2) • Insert the connection flange (component 2.1 or 2.2) into the centering of the flywheel. • Align the through holes of the connection flange to the threads of the flywheel. • Only valid with assembly of the connection flange made of steel (component 2.1): Hand-tighten the components via suitable screws (not part of the scope of delivery) first. • Only valid with assembly of the connection flange made of cast aluminium (component 2.2): Hand-tighten the components via the suitable screws (not part of the scope of delivery) and the disks (component 8) first. • Tighten the screws at the tightening torques TA specified in table 13 by means of a suitable torque key. ! Table 13: 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 tightening torques for screwing the external 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 11 ½“ 14“ M10 49 8.8 3/8 - 16 42 5 M12 120 18“ 21“ 24“ M16 295 M10 49 8.8 3/8 - 16 42 5 10.9 1/2 - 13 150 Ø475 2) 5/8 - 11 286 8 1) For dimensions of flange connection see table 7. 2) Flange connection differing from SAE standard, dimensions in mm see table 7. 4.7.2 Assembly of elastomer part (component 1) with hub resp. clamping ring hub (only valid with type AK, AL, AKC and ALC) ! Make sure with assembly that the elastomer part has the right position to the hub resp. clamping ring hub after screwing. Otherwise it is not assured in the further process of assembly that both splines cover completely. Disregarding this advice may cause damage to the coupling. • Insert the elastomer part on the centering of the hub resp. clamping ring hub. • Align the through holes of the elastomer part to the threads of the hub resp. clamping ring hub. • Hand-tighten the components first. • Tighten the cap screws (component 6) by a suitable torque key to the tightening torques T A specified in table 14. ! 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. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 4 Assembly 4.7 Assembly/Disassembly of elastomer part resp. connection flange KTR-N Sheet: Edition: 48710 EN 21 of 27 2 4.7.2 Assembly of elastomer part (component 1) with hub resp. clamping ring hub (only valid with type AK, AL, AKC and ALC) Table 14: Cap screws DIN EN ISO 4762 - 12.9 (component 6) Size Screw size M Screw length LM Tightening torque TA [Nm] 20 M12 30 120 28 M16 40 300 38 M16 40 300 53 M16 40 300 96 M20 50 590 114 M20 50 590 140 M20 60 590 180 M20 60 590 4.7.3 Assembly of elastomer part with connection flange • Rotate the elastomer part so that the internal spline of the elastomer part can be pushed into the external spline of the connection flange. • Shift the power pack of the driven side in axial direction until the mounting dimension L4 is achieved. ! Make sure with assembly that the dimension L4 (see chapter 1) is observed to make sure the external spline of the connection flange is fully covered by the internal spline of the elastomer part. Disregarding this advice may cause damage to the coupling. ! Make sure with assembly that the splines of the elastomer part resp. connection flange are free of oil and grease. If necessary, talcum powder or a soap solution can be used to facilitate the assembly. 4.7.4 Disassembly of connection flange (component 2.1 or 2.2) • Push the driven side so far apart from the connection flange (component 2.1 or 2.2) that the spline is completely separated both from the connection flange and the elastomer part. • Unscrew and remove the screws of the connection between connection flange and the flywheel. • Only valid with assembly of the connection flange made of steel (component 2.1): Unscrew and remove the screws of the connection from the connection flange to the flywheel. • Only valid with assembly of the connection flange made of cast aluminium (component 2.2): Unscrew and remove the screws with the disks of the connection from the connection flange to the flywheel. • Pull the connection flange from the centering and remove it. 4.7.5 Disassembly of elastomer part (component 1) from the hub resp. clamping ring hub (only valid with type AK, AL, AKC and ALC) • Unscrew and remove the cap screws (component 6) on the elastomer part. • Pull the elastomer part from the centering of the hub resp. clamping ring hub and remove it. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 4 Assembly 4.8 Displacements - alignment of the couplings KTR-N Sheet: Edition: 48710 EN 22 of 27 2 The SINULASTIC® flange couplings compensate for position deviations of the machine components to be connected up to the data specified in table 15. With alignment, the radial and angular displacement should be kept as small as possible, because the service life is increased in this way under otherwise identical operating conditions. The SINULASTIC® 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 15). 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 15 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 23). • The displacement figures specified are general standard figures that apply up to an ambient temperature of 80 °C, ensuring a sufficient service life of the SINULASTIC® coupling. Displacement figures between the speeds specified have to be interpolated accordingly. If necessary, ask about the displacement for the corresponding coupling type. • Inspect with a dial gauge, ruler or feeler gauge whether the permissible displacement figures specified in table 15 can be observed. Axial displacement Radial displacement Angular displacement Illustration 22: Displacements Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 4 Assembly 4.8 Displacements - alignment of the couplings Examples of the displacement combinations specified in illustration 23: Example 1: Kr = 30 % Kw = 70 % KTR-N Sheet: Edition: 48710 EN 23 of 27 2 Illustration 23: Combinations of displacement Example 2: Kr = 60 % Kw = 40 % Ktotal = Kr + Kw 100 % Table 15: Displacement figures Displacement figures Perm. axial displacement Ka [mm] 2) Perm. radial displacement 1500 rpm Kr [mm] with n= Max. Max. radial displacement Kr [mm] 1) Perm. angular displacement 1500 rpm Kw [degree] with n= Max. Max. angular displacement Kw [degree] 1) Size 20 ±2.0 0.8 0.6 1.6 0.7 0.5 1.1 28 ±3.0 1.1 0.8 2.2 0.6 0.4 0.9 38 ±3.0 1.1 0.8 2.2 0.6 0.4 0.9 53 ±3.0 1.1 0.8 2.2 0.6 0.4 0.9 96 ±3.0 1.25 0.9 2.5 0.5 0.4 0.8 114 ±3.0 1.25 0.9 2.5 0.5 0.4 0.8 140 ±3.0 1.5 1.1 3.0 0.4 0.3 0.6 180 ±3.0 1.5 1.1 3.0 0.4 0.3 0.6 1) for short-term start-up operation 2) Plug-in spline connection must fully bear 5 Start-up Before start-up of the coupling, inspect the alignment and the distance dimension L4 and adjust, if necessary, and also inspect all screw connections for the tightening torques specified. Finally the coupling protection against accidental contact must be fitted. It is required in accordance with DIN EN ISO 12100 (Safety of Machinery) and must protect against • access with 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 DA of the coupling. Please check if a proper enclosure (ignition protection, coupling protection, contact protection) has been mounted and the operation of the coupling is not affected by the enclosure. The same applies for test runs and rotational direction inspections. The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with DIN EN ISO 13857. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 5 KTR-N Sheet: Edition: 48710 EN 24 of 27 2 Start-up 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 SINULASTIC® 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. Breakdowns Causes Elimination Different operating noise and/or vibrations occuring 1) Set the unit out of operation 2) Eliminate the reason for the misalignment (e. g. loose Micro friction by faulty foundation bolts, fracture of the engine mount, heat alignment on the spline of the expansion of unit components, modification of the elastomer part installation dimension L4 of the coupling) 3) For visual inspection/inspection of wear see chapter 8 Maintenance 1) Set the unit out of operation 2) Inspect alignment of coupling Axial fastening of hub working 3) For visual inspection/inspection of wear see chapter 8 loose Maintenance 4) Secure the hubs axially and against working loose Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 6 KTR-N Sheet: Edition: 48710 EN 25 of 27 2 Breakdowns, causes and elimination Breakdowns Causes Elimination 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the Fracture of elastomer elastomer part part/high dynamic 3) Inspect coupling components and replace coupling energy/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 3) Inspect coupling components and replace coupling Vibrations of drive components that are damaged 4) Insert elastomer part, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Find out the reason for vibrations 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the Ambient/contact temperatures elastomer part which are too high for the Excessive wear on the spline 3) Inspect coupling components and replace coupling elastomer part, max. of the elastomer part, fracture components that are damaged permissible of elastomer 4) Insert elastomer part, assemble coupling components -30 °C/+80 °C 5) Inspect alignment, adjust if necessary 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 7 Disposal In respect of environmental protection we would ask you to dispose of the packaging resp. products on termination of their service life in accordance with the legal regulations resp. standards that apply. • Metal Any metal components have to be cleaned and disposed of by scrap metal. • Nylon materials Nylon materials have to be collected and disposed of by a waste disposal company. Please observe protection note ISO 16016. Drawn: Verified: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 8 KTR-N Sheet: Edition: 48710 EN 26 of 27 2 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 the tightening torques of all screw connections and correct, 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 elastomer part to the inner part (metal). • Inspect the elastomer part for cracks in the areas marked with , and in illustration 24. If the depth of cracks achieve the limit of 3.0 mm or exceed it in the area marked with , the elastomer part must be replaced. • A wear of spline of 3.0 - 4.0 mm is permissible on the load side of the elastomer part (see illustration 24 marked with ). • During downtime of the coupling a radial distance of 1.0 - 2.0 mm between connection flange and elastomer part (see illustration 25) is permissible. ! Elastomer parts that are damaged or worn off have to be replaced, with the maintenance interval of the engine at the latest. Illustration 24: Visual inspection Please observe protection note ISO 16016. Drawn: Verified: Illustration 25: Inspection of wear 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 SINULASTIC® Operating/Assembly instructions Type A and T 9 KTR-N Sheet: Edition: 48710 EN 27 of 27 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: 2023-05-05 Pz/Mai 2023-05-30 Pz Replacing: Replaced by: KTR-N dated 2020-10-27 ">

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Key features
- Highly flexible
- Axial plug-in
- Torsional vibration dampening
- Shaft misalignment compensation
- Overload protection
Frequently asked questions
The SINULASTIC coupling compensates for axial, radial, and angular shaft displacements.
The SINULASTIC coupling has an overload function that protects the drive against impermissibly high torques.
The SINULASTIC coupling is available in types A, T, and their combinations, including AK, AL, AKC, ALC, and T.