Professional Documents
Culture Documents
BA 3500 EN 01.98
ZAPEX couplings types
ZWN, ZWNA, ZWD, ZWDA, ZZS, ZZSA, ZZSD, ZZDA,
ZWNV and ZZSV
ZWN
ZZS
A. Friedr. Flender AG, D 46393 Bocholt, Tel. 02871/92-0, Telefax 02871/922596, www.flender.com
Contents
1. Technical data 4
1.1 Types ZWN, ZWNA, ZWD, ZWDA 4
1.2 Types ZZS, ZZSA, ZZSD, ZZDA 5
1.3 Types ZWNV 6
1.4 Types ZZSV 7
1.5 Dimension table 8
2. General notes 10
2.1 General 10
3. Safety notes 10
3.1 Safety notes 10
3.1.1 Notes and symbols in the operating instructions 11
5. Technical description 12
5.1 General description 12
5.1.1 Types ZWN, ZWNA, ZWD, ZWDA and ZWNV 13
5.1.2 Types ZZS, ZZSA, ZZSD, ZZDA and ZZSV 14
6. Assembly 14
6.1 Notes on fitting the finished bore, the axial securing, the set screws, the balancing 14
6.1.1 Finished bore for parallel keyway connection 15
6.1.1.1 Parallel keyway 15
6.1.2 Axial securing in case of parallel key connection 16
6.1.3 Set screws in case of parallel key connections 16
6.1.4 Balancing 17
6.2 General installation notes 17
6.3 Installing the coupling parts (1/2) in case of shaft / hub connection with parallel key 18
6.4 Installing the coupling parts (1/2) in case of cylindrical
and tapered interference fit set for oil hydraulic removal by shrinking 19
6.5 Assembly of the coupling 20
6.6 Aligning 20
6.7 Possible misalignments 21
6.7.1 Axial misalignment 21
6.7.2 Angular misalignment in dependence on the operating torque and the operating speed 21
6.7.3 Radial misalignment 21
6.8 Alignment values 22
6.9 Distance dimensions S1, S2, S3, S8, S9, S11 and S12 23
6.10 Assignments of the tightening torques and wrench width 24
7. Start-up 25
7.1 Lubricant recommendation 25
7.2 Oil filling quantity / grease filling quantity 25
7.3 Measures before startup 26
8. Operation 26
8.1 General operating data 26
1 2
da
d4
P P
d3
d6
D1
D2
l l
ZWN
1 2
S1
Version A a
a
1 2
ZWNA
S2
Version AB
1 2
ZWD
S3
Version B
a
a
ZWDA
1 20 2
da
d4
d3
P P
d6
D1
D2
l LZ l
1 2 LA ZZS
S9 S9
Version A
a
a
1 2
ZZSA
S8 S8
Version B
ZZSD
a
a
ZZDA
The distance dimensions S11 and S12 will be found in section 6., item 6.9.
d6
D1
1 Top
S 11
S 12
l
P
2 Bottom
D2
d3
d4
da
The distance dimensions S8 and S12 will be found in section 6., item 6.9.
d6
D1
Top
l
1
S8
LZ
20
LA
S 12
l
P
2 Bottom
D2
d3
d4
da
Nominal Axial
Speed Bore 3) Weight
torque back-
TN nmax D1 / D2 da d3 d4 d6 l P lash
Size
1) 2) from to 4) 4) a 5)
Nm 1/min mm mm mm mm mm mm mm mm mm kg
Nm 1/min mm mm mm mm mm mm mm mm mm kg
550 620 1055 10000
> 620 655 1120 10500
1440 6250000 670 1600 1440 975 670 825 2.5
> 655 685 1170 10500
> 685 860 1240 11000
575 655 1120 12000
> 655 685 1170 12000
1540 7200000 630 1710 1540 1030 700 875 2.5
> 685 730 1240 12500
> 730 910 1310 13000
1) The given torques refer to the tooth system and not to the shaft / hub connection. This must be checked
separately.
2) The max. speed of the types ZZS, ZZSA, ZZSD, ZZDA and ZZSV is restricted by the weight and the critical
speed. Speed nmax. on request.
3) Maximum bore in case of keyway according to DIN 6885/1; bores > Dmax for shrinking on request
4) Space required for aligning the coupling parts and renewing the sealing rings.
2.1 General
These Operating Instructions constitute part of the coupling shipment and should be kept in the
immediate vicinity of the coupling at all times.
Only a precise knowledge of the Operating Instructions will ensure trouble-free operation of the
coupling. It is therefore in the interest of our customer that the operating instructions are read,
understood and observed in all respects by the persons responsible for handling, installation and
operation.
Note: We accept no liability for any damage or malfunction resulting from non-observance
of the operating instructions.
The ”coupling” dealt with in these operating instructions was developed for stationary use in general
engineering.
The coupling is only designed for the field of application as specified in Section 1 ”Technical data”.
Operating conditions which differ from the stated will require fresh contractual agreements.
The coupling described here is in accordance with the state of the art at the time of these operating
instructions go into print.
In the interest of further development, we reserve the right to introduce modifications which, while
retaining the essential features, can be regarded as desirable to increase its efficiency and safety.
The copyright of these Operating Instructions remains the property of Flender AG.
These operating instructions may not be duplicated in part or whole, utilized for the purpose of publicity
or communicated to third parties without our expressed consent.
Please contact our work listed below in respect of all technical queries.
FLENDER AG
D 46393 Bocholt
Telefon: 02871/92-2800
Telex: 813841
Telefax: 02871/92-2801
or one of our service branches which are listed in Section 11 ”Stocking spare parts, service facility
addresses”.
3. Safety notes
S The coupling is constructed in accordance with the state of the art and is reliable in the condition as
shipped. Unauthorized modifications which impair its reliability are not permissible. This also applies
to guards which are fitted as protection against accidental contact.
S The coupling may only be used and operated within the scope of the condition specified in the contract
of performance and supply.
S The customer should ensure that the persons entrusted with installation, operation, care and
maintenance as well as repair have read and understood the operating instructions and observe them
in all respects in order to:
– prevent hazard to life and limb of the user and third parties
Instructions in the operating instructions which concern operating safety are emphasized as follows:
This symbol draws attention to safety measures which must be observed to prevent
personal injury.
This symbol draws attention to safety measures which must be observed to prevent
Caution! damage to the coupling.
Note: This note draws attention to general operating notes which should be especially
observed.
The coupling is delivered in a preserved state and can be stored at a covered dry place up to 6 months.
If the coupling shall be stored for a longer period of time, an appropriate long-term preservation is
necessary (consultation with FLENDER required).
When cleaning the parts for long-term preservation, the DUO sealing rings
Caution! must be protected against contact with solvents and cleaning agents.
4.3.2.1 General
Proper storage maintains the life of the DUO sealing rings. Unfavourable storage conditions and
improper treatment of the DUO sealing rings result in a negative change of the physical characteristics.
These changes can be caused by the effects of e.g. ozone, extreme temperatures, light, moisture or
solvents.
Caution! The DUO sealing rings must not be stored installed on the coupling part (1, 2).
The storage room should be dry and dust-free. The DUO sealing rings must not be stored together with
chemicals, solvents, fuels, acids, etc. Furthermore, they should be protected against light, especially
against direct sunlight and strong artificial light with a high ultra-violet percentage.
The storage rooms must not contain any ozone-producing devices like e.g.
Caution! fluorescent light sources, mercury-vapour lamps, electric high-voltage
devices. Most storage rooms are unsuitable. Make sure that no condensation
develops. The relative humidity of air is most favourable below 65 %.
5. Technical description
ZAPEX couplings type ZWN, ZWNA, ZWD, ZWDA, ZWNV, ZZS, ZZSA, ZZSD, ZZDA and ZZSV are
designed for connecting two shafts. The shaft ends to be connected must be supported in bearings
directly before and behind the coupling.
ZAPEX couplings are suitable for clockwise and counter-clockwise operation as well as reversing
operation.
The coupling parts with external gearing (1, 2) engage in the internal gearing of the sleeves (5).
For the types ZWN, ZWNA, ZWNV, ZZS, ZZSA and ZZSV DUO sealing rings (12) are used on the
outside for sealing the oil wells.
Note: Please observe the data given in the dimensioned drawings which may be delivered
together with the coupling.
1 12 11 10 5 8 9 6 2 51
ZWN ZWNA
10
33
ZWD
51
31
32
2 ZWNV
ZWDA
Torque transmission is effected from the shaft over parallel key, shrink fit or a comparable connection
to the coupling part (1), then over the tooth system to the sleeve (5) and then via the fitting screw
connection (8, 9) to the second sleeve (5), over the tooth system to the coupling part (2) and then again
via the parallel key, shrink fit or a comparable connection to the shaft.
In case of types ZWNA and ZWDA the axial backlash is restricted by the two-part locking ring (51).
Types ZWD and ZWDA are designed for flow lubrication and are thus not equipped with DUO sealing
rings (12).
The type ZWNV is a vertical version. The support of the covers (10+31) and sleeves (5) is effected by
means of the support ring (33) on the shaft.
1 12 11 10 5 8 9 4 2 52
ZZS ZZSA
1
10
ZZSD 33
52
31
32
2 ZZSV
ZZDA
Torque transmission is effected from the shaft over parallel key, shrink fit or a comparable connection
to the coupling part (1), then over the tooth system to the sleeve (5) and then via the fitting screw
connection (8, 9) and the adapter (4) to the second sleeve (5), over the tooth system to the coupling
part (2) and then again via the parallel key, shrink fit or a comparable connection to the shaft.
In case of types ZZSA and ZZDA the axial backlash is restricted by the two-part locking ring (52).
Types ZZSD and ZZDA are designed for flow lubrication and are thus not equipped with DUO sealing
rings (12).
Type ZZSV is a vertical version. The support of the covers (10+31), sleeves (5) and the adapter (4) is
effected by means of the support ring (33) on the shaft.
6. Assembly
6.1 Notes on fitting the finished bore, the axial securing, the set screws, the balancing
According to the order placed, the coupling parts (1/2) for removal by oil hydraulic shrinking are
delivered with finished bores.
For making the finished bore, the coupling parts must be clamped as shown in the following figure.
Caution! The clamping chuck must always be opposite the sealing surface.
The coupling part must be aligned carefully. For the permissible radial eccentricity see DIN ISO 286
degree of fundamental tolerance IT 6 (see table 6.1).
The maximum permissible boring diameters (see section 1., item 1.5) are
Caution! designed for parallel key connections without tightening according to DIN
6885/1 and must not be exceeded in any case.
When the keyway is to be designed deviating from DIN 6885/1 for a parallel key
connection, FLENDER should be consulted.
If other hub connections (e.g. spline bore hub profile, tapered or stepped bores, parallel key connections
with tightening etc.) are to be used instead of the provided parallel key connection, FLENDER should
be consulted.
Dimension > 18 > 30 > 50 > 80 > 120 > 180 > 250 > 315 > 400 > 500 > 630 > 800
or to to to to to to to to to to to to
nom. dimension 30 50 80 120 180 250 315 400 500 630 800 1000
Perm. deviation
according to 0.013 0.016 0.019 0.022 0.025 0.029 0.032 0.036 0.040 0.044 0.050 0.056
DIN ISO 286/1, IT6
Table 6.1: Permissible radial run-out
Sealing surface Clamping chuck
3.2
IT 6 A
D
In case of a parallel key connection the following is recommended for bore and shaft:
The tolerance field must be observed in anyway, in order to restrict the hub
Caution! tension resulting from the oversize to the permissible load. In case of
non-observance of the tolerance field, the shaft / hub connection may be
damaged.
In case of one keyway, the tolerance field of hub keyway width ISO P9 is recommended.
In case of two keyways, the tolerance field of hub keyway width ISO JS9 is recommended.
The set screws should generally be arranged on the parallel key. Check the
Caution! length of the parallel key.
The tapped holes are to be arranged in accordance with the drawing considering the used version A
or B for the coupling parts (1/2).
In case of size 112, the set screws must generally be arranged in the hub side which has not been
ground.
e1 Version B Version A e2
Sealing surface
d1 d1
D
Size Bore D d1 e1 e2
112 20 ... 45 M 6 15 –
25 ... 30 M 6
128 > 30 ... 50 M 8 14 20
> 50 ... 55 M10
30 M 6
146 > 30 ... 38 M 8 16 26
> 38 ... 65 M10
35 ... 75 M10
175 20 26
> 75 ... 80 M12
40 ... 44 M10
198 > 44 ... 58 M12 22 36
> 58 ... 95 M16
50 ... 58 M12
230 25 38
> 58 ... 110 M16
60 ... 110 M16
255 30 45
> 110 ... 125 M20
70 ... 75 M16
290 30 48
> 75 ... 145 M20
315 80 ... 160 M20 40 55
90 ... 170 M20
342 40 60
>170 ... 180 M24
100 ... 110 M20
375 35 70
> 110 ... 200 M24
415 120 ... 220 M24 40 90
465 140 ... 250 M24 40 110
505 160 ... 275 M24 45 130
545 180 ... 300 M24 80
585 210 ... 330 M24 90
6.1.4 Balancing
Prebored couplings resp. prebored coupling parts are shipped unbalanced. For these parts et is
recommended to balance them depeding on the application case after finish boring (see also DIN ISO
1940 part 1).
Note: Flender recommendation:
Balancing on two levels Q6.3 for velocities v = 36 m/s or exceeding this value
measured at d4 according to item 1.5.
Balancing is usually carried out by material cutting through boring. In order to restrict the material
quantity to be cut to a minimum, the biggest possible balancing radius is to be selected.
Balancing bore
Part 1/2
Before starting the assembly all coupling parts (1/2) and shaft ends must be cleaned thoroughly.
Grease the back or the sides of the DUO sealing ring (12) and the groove in the cover (10) thoroughly
and fit it in the cover (10 or 21). Apply a grease padding in the ring-shaped hollow space. When using
two-part covers (21) the connecting points must be sealed with sealing compound on one side.
Marking
Back
Sealing compound
from size 1020 12 10 12 10 21 21
with hubs-∅ 800,
DUO sealing ring
Back
in rectangular
shape Side 12
The cover (10 or 21) with fitted DUO sealing ring (12) should be installed on the shaft such that the DUO
sealing ring (12) cannot be damaged by the coupling parts (1/2).
Check the required space for inserting the cheese head screws (11) and insert the screws (11) in the
cover (10 or 21), if necessary.
Heating (max. +80 °C) the coupling parts (1/2) with cylindrical bore may ease pulling on. Heating can
be effected inductively in the oven or by means of a burner. Heating by means of a burner must be
carried out in longitudinal direction of the hub above the groove.
The heated coupling parts (1/2) are to be fitted by means of suitable devices in
Caution! order to prevent damage to the shaft bearing by the axial fitting force.
Make sure that suitable hoists are used.
Make sure that the bore and the sealing surface for the DUO sealing ring are not
damaged by hoists etc.
Note: The coupling parts (1/2) with tapered bore should be secured by means of appropriate
end plates. For this purpose, apply sealing compound to the hub face on the shaft face
and screw on the end plate.
In case of coupling parts (1/2) with cylindrical bore, the tapped hole for the set screw 2/3 must be filled
with sealing compound after cooling down to ambient temperature, in order to prevent the lubricant from
leaking through the parallel keyway. Screw in the set screw.
Tightening of the set screws only by means of a hexagon socket head wrench
Caution! according to DIN 911, without an extension pipe.
Caution! The data given in the dimensioned drawing must be observed in any case.
Before the assembly, the plug screws (22) should be unscrewed from the coupling parts (1/2) and the
shaft ends and coupling parts (1/2) must be cleaned thoroughly and dried. Under no circumstances may
the oil channels and oil circulating grooves be dirty.
The fit surfaces may never be greased with grease containing molybdenum
Caution! sulphide (Molykote or comparable products).
Grease the back or the sides of the DUO sealing ring (12) and the groove in the cover (10) thoroughly
and fit it in the cover (10 or 21). Apply a grease padding in the ring-shaped hollow space. When using
two-part covers (21) the connecting points must be sealed with sealing compound on one side.
Marking
Back
Sealing compound
from size 1020 12 10 12 10 21 21
with hubs-∅ 800,
DUO sealing ring
Back
in rectangular
shape Side 12
The cover (10 or 21) with fitted DUO sealing ring (12) should be installed on the shaft such that the DUO
sealing ring (12) cannot be damaged by the coupling parts (1/2).
Check the required space for inserting the cheese head screws (11) and insert the screws (11) in the
cover (10 or 21), if necessary.
Protect the DUO sealing ring against damage and heating above +80 °C.
Caution! (Use heat insulation shields against heat radiation.)
The coupling parts (1/2) should be mounted while they are warm and heated to the temperature given
in the dimensioned drawing in accordance with the shrinking dimension.
Before mounting, the bore size of the heated coupling parts (1/2) must be checked, e.g. by means of
a gauge for bore holes.
The heated coupling parts (1/2) are to be fitted by means of suitable devices in
Caution! order to prevent damage to the shaft bearing by the axial fitting force.
Make sure that suitable hoists are used.
Make sure that the bore and the sealing surface for the DUO sealing ring are not
damaged by hoists etc.
The coupling parts (1/2) should be pulled quickly onto the shaft according to the specifications in order
specific dimensioned drawing.
Note: Until the coupling parts (1/2) have cooled down and are tight, they must be held on
the shaft by means of a suitable holding device.
After the coupling parts (1/2) have cooled down to room temperature, the oil channels must be filled with
clean oil, e.g. ISO VG 150 and closed with the plug screws (22) (protection against corrosion).
Dial gauge
Measuring
tape
Ruler
Dial gauge
Ruler Ruler
Measuring tape
Instead of ruler and measuring tape, a feeler gauge, a measuring bolt or a calliper gauge can be used
in case of small distance dimensions S.
The max. permissible misalignments depend on the operating factor and the
Caution! coupling speed. When changing the speed, a check is absolutely necessary. As
further misalignments may occur during operation (expansion due to heat,
bending of the shaft, foundation settling, etc.), only 10% of the max. permissible
misalignments are to be obtained during aligning. However, the misalignments
may not be less than 0.05°. The alignment values will be found under item 6.8.
∆ Kr
∆Kw
S2
∆Ka ∆Ka
∆ S = S1 – S2
Axial misalignment Angular misalignment Radial misalignment Axial, radial and angular
figure 6.4 figure 6.5 figure 6.6 misalignment figure 6.7
Misalignments of the coupling parts may result from an inexact alignment during the assembly but also
from the operation of the plant (expansion due to heat, bending of the shaft, machine frame to soft, etc.).
The following max. permissible misalignments must not be exceeded during
Caution! operation under any circumstances.
6.7.1 Axial misalignment
Axial misalignment ∆Ka (figure 6.4) of the coupling parts to each other is permissible within the
”permissible variation” for the dimension S (see item 6.9).
6.7.2 Angular misalignment in dependence on the operating torque and the operating speed
TN from section 1., item 1.5 angular misalignment data ∆ Kw in °
n = operating speed 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
0.9
n = 0.63 n max
0.4
0.3 n = n max
0.2
0 2 4 6 8 10 12 14 16 17.5
angular misalignment ∆ Kw in 10-3 rad
For reasons of simplification, the angular misalignment ∆Kw (figure 6.5) is determined as difference
(∆S) of the dimension S (alignment surface A , see item 6.6). The measurement should be carried
out at several points on the periphery.
For the permissible alignment values see item 6.8
6.7.3 Radial misalignment
The max. possible radial misalignment ∆Krmax (figure 6.6) corresponds to a possible angular deviation
per coupling half of ∆Kwmax = 0.0175 rad = 1°.
For the permissible alignment values see item 6.8
Angular and radial misalignment (figure 6.7) may occur at the same time. The
Caution! sum of both misalignments must not exceed ∆Kw or ∆Kr.
VA1
VA3
VA4
VA2
ZWNV
ZZSV
ZZS, ZZSA, ZZSD, ZZDA
Table 6.5: Distance dimensions S for types ZWN, ZWNA, ZWD, ZWDA (S1, S2, S3),
for types ZZS, ZZSA, ZZD, ZZDA (S8, S9)
and for types ZWNV, ZZSV (S8, S11, S12)
Tightening torque TA
Wrench width SW
(with m = 0.14)
Part No. 9 Part No. 11, 32 Part No. 6 Part No. 9 Part No. 11, 32
Size
hexagon hexagon hexagon
socket wrench wrench socket wrench
Nm Nm mm mm mm
112 25 10 3 13 5
128 25 10 3 13 5
146 25 10 5 13 5
175 49 25 5 17 6
198 49 25 6 17 6
230 49 25 6 17 6
255 86 25 8 19 6
290 86 49 8 19 8
315 210 49 8 24 8
342 210 49 8 24 8
375 210 49 10 24 8
415 410 86 10 30 10
465 410 86 10 30 10
505 410 86 10 30 10
545 710 86 10 36 10
585 710 86 10 36 10
640 1450 210 10 46 14
690 1450 210 10 46 14
730 1450 210 12 46 14
780 2530 210 12 55 14
852 2530 210 12 55 14
910 2530 410 12 55 17
1020 4070 410 12 65 17
1080 4070 410 17 65 17
1150 4070 410 17 65 17
1160 4070 410 17 65 17
1240 6140 710 17 75 19
1310 6140 710 17 75 19
1380 6140 710 17 75 19
1440 6140 710 17 75 19
1540 7350 1450 17 80 22
Table 6.6: Tightening torques and wrench width
The following lubricants are recommended for the FLENDER ZAPEX mentioned in these Operating
Instructions.
Manufacturer
Flender
Aralub Energrease CLS Orona Fibrax
Liquified greases Fließfett ANO LS-EP 00 Grease FG EP 0 EP 370
Hoch-
leistungsfett
Manufacturer
Optigear Renolin
Structovis Mobilgear Omala Tribol 1100
Oils BHD-MF 634/636
BM
460/680 460/680
CLP
460/680 460/680 Plus
For normal operating conditions, we recommend an oil filling. This is advantageous because the
lubricant is easy to change and the surface is wetted adequately.
The lubricants are suited for operating temperatures from -10 °C to +80 °C. In case of deviating
temperatures, consult FLENDER.
1) In case of types ZZS and ZZSA the oil filling quantities are valid for one coupling side.
When using liquefied grease, 1.3 x given oil filling quantity must be used.
Before startup, check the proper assembly, the alignment and the oil or grease filling and correct, if
necessary and check all screw connections for the prescribed tightening torques.
8. Operation
If irregularities are detected during operation, the drive assembly should be set
Caution! off immediately. The cause of the malfunction should be determined with the
aid of the Troubleshooting Table (Section 9.).
The Troubleshooting Table lists possible malfunctions, their causes and
suggestions for remedying them.
If the cause cannot be determined or there is no facility for repair with suitable
equipment, we recommend calling in one of our service fitters (see Section 11.).
9.1 General
In case of a complex plant, all other components have always to be included in the troubleshooting.
The coupling has to run with low noise and without shaking in all operating phases. Any deviating
behaviour is to be regarded as malfunction and should be repaired immediately.
Before maintenance work the operator should make sure that the whole drive
train is stationary. Especially the drive motors are to be secured against
accidental start up.
Futhermore, we refer to the relevant regulations on the prevention of accidents
at the place of installation.
Sudden change of the noise Exceeding the permissable Shut down the plant
level and/or sudden shaking misalignments
Re-align according to Section 6,
if necessary
10.1 General
Check the coupling for leakages, heating, change of noise level at the regular maintenance intervals,
at least every three months.
The coupling must run at low noise and without vibration during all operation phases. Any deviating
behaviour should be regarded as malfunction and rectified immediately.
The space required for changing the DUO sealing rings (12) in the cover (10) is given in the dimension
table in section 1. ”Technical data”, item 1.5 with letter P and d6.
When carrying out the regular inspections, check the coupling for leakages, check the lubricant level
and refill, if necessary.
Change of lubricant after approx. 8000 operating hours max. 2 years in case of use up to 70 °C , above
70 °C and after approx. 3000 operating, max. 1 year.
When dimensions d6 and P are observed (see section 1. “Technical data”, item 1.5), the DUO sealing
rings (12) can be replaced by open-ended (cut) DUO sealing rings (12) by screwing off the cover (10)
without separating the coupling. For this purpose, cut the DUO sealing ring (12) once radially. Before
fitting the DUO sealing rings (12), grease the groove.
DUO sealing rings (12) with trapezoidal back can be inserted without bonding. For this purpose, insert
the connecting point without clearance into the V-groove and then insert the DUO sealing ring (12)
starting at the connecting point on both sides.
DUO sealing rings (12) with rectangular back must be positioned on the shaft after cutting and bonded
flush at the connecting points. Bonding agent e.g. Loctite 401.
Afterwards, insert the connecting point into the groove and insert the DUO sealing ring starting from this
point on both sides.
10.4 Disassembly of the coupling parts (1/2) in case of shaft / hub connection with parallel key
Remove the set screw or the axial securing device. Mount a suitable pulling-off device. Heat the
coupling part by means of a burner above the parallel keyway in longitudinal direction (max. +80 °C).
Caution! Protect the DUO sealing ring (12) against damage and heating over +80 °C.
For the reassembly, observe the instructions in section 6. ”Assembly” and in section 7. ”Startup”.
10.5 Disassembly of the coupling parts (1/2) in case of cylindrical and tapered interference fit set for removal
by oil hydraulic shrinking
– The disassembly of the coupling must be carried out considering all precautions.
– After draining the oil or the grease (see figure), loosen the fitting screws (8, 9) and the screws of
the cover (10, 11).
Ventilation hole
∼ 30°
Drain hole
Check the tooth system, seals (12) and sealing surfaces for damages. Replace damaged parts.
Danger of squeezing!
S One oil pump with pressure gauge (min. 2500 bar) per oil channel (the number can be taken from the
dimensioned drawing)
S 1 Pulling-off device or end plate with locking screws or threaded spindles with nuts (material screw,
spindles and nuts min. 10.9)
S 1 Hydraulic cylinder (Lukas) with oil pump. Consider the displacement of Lukas, it may be necessary
to readjust.
Before pulling off the coupling hub, the pulling-off device must be mounted as shown in the figure.
Lukas
Secure the coupling part and the holding device by means of suitable hoists.
Caution! In case of coupling parts with tapered bore, axial securing against sudden
loosening of the coupling part must be provided.
Remove the plug screws (22) from the oil channels. Bleed the oil pump and connect it to the centre oil
channel.
Afterwards, pressurise the pump with the pressure indicated in the assembly drawing until oil leaks from
the neighboured connections.
Bleed the next oil pumps as described above and pressurise them with the pressure given in the
dimensioned drawing until the oil leaks ring-shaped at the faces and the pressure stops increasing.
During the entire process, the pressure must be kept constant at all
Caution! pressurised oil channels.
If so much oil leaks during pressurising that the pressure cannot be kept, oil with a higher viscosity must
be used.
After pulling off, the oil pumps and holding devices must be removed from the coupling hub.
Check the coupling bore and shaft for damages and protect them against corrosion. Replace damaged
parts if necessary.
For the reassembly, carefully follow the instructions in section 6. ”Assembly” and in section 7. ”Startup”.
10.6 Disassembly of the coupling parts in case of stepped bore for removal by oil hydraulic shrinking
The disassembly is carried out as described under item 10.5. The only difference is that a motor driven
pump is connected to the oil channel at the change-over from the smaller bore to the larger bore since
a larger oil quantity per time unit is required.
For the reassembly, carefully follow the instructions in section 6. ”Assembly” and in section 7. ”Startup”.
Maintaining a stock of the most essential spare and wear parts is an important prerequisite for the
permanent service ability of the coupling.
– Type / size
– Quantity
We would expressly draw attention to the fact that spare parts and accessories
Caution! not supplied by us have not been tested or approved by us either. Fitting and/or
use of such products can therefore under certain circumstances adversely
affect structurally specified properties of the coupling and will thus impair
active and/or passive safety. No form of reliability or warranty will be assumed
by FLENDER AG for damage occasioned by use of non-original spare parts and
accessories.
Please note that production and supply specifications frequently exist for components and we will
always offer spare parts in accordance with the state of the art and in accordance with the latest legal
requirements.
When ordering spare parts or requesting a service fitter, please contact FLENDER AG first of all.
LOHER AG
D- 94095 Ruhstorf - Tel.: (0 85 31) 3 90 - Tx.: 8 531 806 - Fax: (0 85 31) 3 94 37
Shipping address: Hans-Loher-Straße 32, D- 94099 Ruhstorf
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This Manufacturer’s Declaration takes into account all the unified standards (inasmuch as they
apply to our products) published by the European Commission in the Official Journal of the
European Community.
Bocholt, 30.01.1998
Signature (person responible for products)