Installation and Operating Instruction

E12048 E
Highly-flexible
VULKAN RATO - R
Couplings
Dimension Groups: G1620R - G3420R
G1630R - G3430R

Series: 2200 – 2401

VULKAN Kupplungs- und Getriebebau

B. Hackforth GmbH & Co. KG
Postfach 200462, 44634 Herne / Germany
Heerstrasse 66, 44653 Herne / Germany
Tel. ++49-2325/922-0
Fax ++49-2325/71110
E-Mail: info@vulkan-vkg.de
http://www.vulkan-vkg.de
Installation and Operating Instruction Page - No. E12048-1
Modification 1 Herne 2, 10.07.2001
Content:

1. Generalities E12048 - 3 - 4
2. Installation of the RATO-R-coupling E12048 - 4
2.1 Delivery condition E12048 - 4
2.2 Procedure before installation E12048 - 4 - 5
2.3 Assembly of the coupling E12048 - 5 - 6
3. Design of the flexible part E12048 - 7
3.1 Assembly of the flexible part E12048 - 7 -10
4. Commissioning E12048 -10
5. Safety Regulations E12048 -10
6. Maintenance E12048 -11
7. Replacement of the flexible part E12048 -11
7.1 Disassembly of the flexible part E12048 -11 -12
7.2 Assembly of the flexible part E12048 -12

Enclosure:

Alignment Instructions S/R - A - 1/1 to 5/1

Criteria for inspction S/R - CRIT – 1/1a to 9/1a
Surface protection COATING 113 S/R – COAT – 1/1 to 7/1

Installation and Operating Instruction Page - No. E12048-2

Modification 1 Herne 2, 10.07.2001
1. Generalities

The highly-flexible VULKAN-RATO-R couplings are rubber couplings, flexible in all di-
rections. Their essential parts are the flexible part, the membrane part and the connecting
parts.
All connecting elements of the RATO-R coupling are arranged without clearance.
The coupling must be protected against permanent influence of oil and against the radiation
of heat. Oil mist and oil splashes are not detrimental.
The RATO-R elements are fit for use at ambient temperatures comprised between -50° (C)
to +80° (C). Ventilation holes guarantee a good heat dissipation in the RATO-R couplings.
For further details concerning the „Air circulation in the RATO-R coupling“ please refer to the
following principal sketch.

Air escape

Air intake

The free-of-play torque transmission in the RATO-R couplings and the large sectional rubber
area of the RATO-R elements guarantee good noise attenuation.
Basically, the connection surfaces of the RATO-R couplings and the fitted as well as the
finish bores are protected by Tectyl. Before installation of the RATO-R couplings, these sur-
faces must be cleaned by conventional solvants. When the cleaned surfaces are completely
dry, they must be slightly greased.

On behalf of the classification societies we herewith give the following instruction:

The torsional vibration behaviour of the drive system has to be checked and approved by the
classification society. The expected and satisfactory behaviour is guaranteed only, provided
that all components comply to the values, the torsional vibration calculation is based upon.
With respect to the RATO-R coupling, this means to exactly keep to the dynamic stiffness
and damping.
In case of a replacement of the RATO-R elements, only original VULKAN elements with
coordinated technical data approved by the classification societies must be used!

Installation and Operating Instruction Page - No. E12048-3

Modification 1 Herne 2, 10.07.2001
To guarantee faultless function and optimum usage of the highly-flexible RATO-R couplings,
certain installation instructions have to be observed.
Basically, each bolt connection participating in the transmission of the torque must be tighte-
nend by means of a torque spanner. The individual tightening torques are given in the gene-
ral drawing no. 1G... or in the drawing for the flexible part no. 2G... for these RATO-R
couplings.
In case of flexible mounted systems, the alignment must be coordinated with the manu-
facturers of engine, coupling and gearbox.
It is possible to equip the RATO-R couplings with a torsional limit device (50).

2. Installation of the coupling

2.1 Delivery condition of the RATO - R coupling

The RATO - R couplings are delivered according to the following drawing: AG.......

2.2 Procedure before installation of the RATO - R couplings

• Remove the fixation elements (Pos. 22, 35).

• Deposit the membrane dimension group (10) as a unit.
The disassembly of the membrane dimension group (10) can be made by means of some
hexagon bolts (22).
The spacer ring (5) and the hexagon bolts (6) are not allowed to be loosened.
• Deposit the split ring (60).

split

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Modification 1 Herne 2, 10.07.2001
The fixation elements (2, 3, 4, 5) used for connection of the RATO - R elements (1) are not
allowed to be loosened.

1
1

52
47
51
40
50
46

The connection (51, 52) RATO - R element (1) / interm. ring (50), or
the connection (40, 47) RATO - R element (1) / safety ring (46) are not
allowed to be loosened (example above = double-row).

2.3 Assembly of the RATO - R couplings

The hub (5) has to be connected with the shaft butt end of the driven side machine using a
method meeting the requirements of modern engineering practice.
For series 2400, in addition the add. hub (6) and the plate flange (4) have to be connected
with the driving side machine.
Now both machines are to be mounted and aligned according to the installation dimension of
the coupling. Possible thermal expansions specific to the system are to be considered
(please refer to the enclosed alignment instructions no. S/R-A - 1/1 to 5/1).

Installation and Operating Instruction Page - No. E12048-5

Modification 1 Herne 2, 10.07.2001
After having aligned the drive system, the following procedure is necessary:

Membrane dimension group pos. 10

• Mount the membrane dimension group (10) on the

hub (5).
The membrane dimension group (10) has to be dis-
Hub pos . 5
placed in direction of the hub (5) as far as to permit in-
stallation of the flexible part as a unit without any pro-
blems. This displacement can be made by means
of some hexagon bolts (22).

• Insert the connecting ring or SAE flang

(3) into the flywheel and screw them
together. The tightening torque require
for the chosen bolt quality has to be
kept.
When using 10.9 bolts, hardened
washers have to be provided.

Subsequently, the assembly of the

flexible part can be started.

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Modification 1 Herne 2, 10.07.2001
3. Design of the flexible part

Before describing the assembly, we would like to explain the design of the flexible part (1).
The flexible part (1) consists of two or three RATO - R elements (1). The position of the
RATO - R elements towards each other is marked. Information about the marking are given
in the following drawings.

groove

two-row

groove

three-row

3.1. Assembly of the flexible part

For assembly, the flexible part has to be hung into a lifting device as a unit.
First of all the RATO-R element arranged at the connecting ring / SAE-flange (3) has to be
connected with the connecting ring / SAE-flange (3) with the corresponding fixation elements
(20, 39). The prescribed tightening torque (20) is to be kept.

Installation and Operating Instruction Page - No. E12048-7

Modification 1 Herne 2, 10.07.2001
 hex.-bolt

turn in

Installation condition after having turned in the flexible part (example of a two-row RATO-R
coupling).

Installation and Operating Instruction Page - No. E12048-8

Modification 1 Herne 2, 10.07.2001
Now the connection (16, 19, 28, 39, 41) with the clamping ring (7) has to be established.
For this, the membrane dimension group (10) has to be displaced in direction of the flexible
part (1) as far as to permit to establish the connection with the RATO - R Element (Pos. 1)
by the fixation elements (16, 19, 28, 39, 41).
Please pay attention to the marking membrane dimension group (10) / hub (5).
The prescribed tightening torque (28) is to be kept.
The displacement of the membrane dimension group (10) can be made by means of some
hexagon bolts (22).

Now insert the split interm. ring (60) and establish the connection hub (5) / split interm. ring
(60) / membrane dimension group (10) with the connecting elements (22, 35).
Please pay attention to the marking hub (5) / split intermediate ring (60) / membrane
dimension group (10).
The prescribed tightening torque (22) has to be kept.
After having finished this work, the highly-flexible VULKAN - RATO - R coupling is tightly
connected with the aggregates.

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Modification 1 Herne 2, 10.07.2001
4. Commissioning and Safety Regulations

After having finished the assembly, the drive system is ready for operation, as far as the
coupling is concerned. We would like to point out that before first operation, you have to
make sure that all installation aid devices have been removed from the RATO - R coupling.

5. Safety regulations

A coupling shield has to be provided, according to the accident prevention regulations.

According to EN 292, part 1 „Safety of Machines“, a shield against mechanical movements
of machine parts (protection against accidental contact) is permissible, if a „usage accor-
ding to the regulations“ is guaranteed during all working conditions. At the same time a
good ventilation of the coupling has to be ensured (use of perforated plates).
If the possibiltiy of exceeding the permissible speed of the coupling, nkmax, cannot be exclu-
ded completely, e. g. in case of an incident or because of a failure of the over-speed-trip in
the system, the coupling shield has to be so designed that possible coupling fragments
cannot escape to the surrounding environment.
For coupling applications in fast ships (Dynamically Supported Craft), the safety regulations
of publication A383 of IMO (International Maritime Organisation) are valid. Dependant on the
construction, these machine arrangements contain components with a high rotating energy.
When the coupling runs outside of a casing, an external protecting device has to be provided
to keep off possible coupling fragments in any case.

Installation and Operating Instruction Page - No. E12048-10

Modification 1 Herne 2, 10.07.2001
6. Maintenance

Basically, the highly-flexible RATO-R coupling does not require maintenance. In many cases,
however, the highly-flexible RATO-R coupling is an indicator for malfunctions in the system.
We recommend a check of the flexible part in case of exceptional incidents, e. g. propeller
ground contact, misfiring operation, short circuit, disturbance of synchronization or emergency
cut-off.
In addition, an alignment control and a check of the flexible part should be carried out within
the scope of the engine service intervals.
The flexible elements can be judged according to leaflet „Criteria for the inspection of RATO-
S/R couplings“ and reworked, if necessary.

7. Replacement of the flexible part

The elements of VULKAN RATO-R couplings can be removed and installed without the dri-
ving or driven machine having to be displaced.

7.1 Disassembly of the flexible part

Before starting the disassembly, the flexible part (1) has to be hung into a lifting device.

• First remove the fixation elements (16, 19, 28, 39, 41).

• Then remove the fixation elements (22, 35).

• Now deposit the split interm. ring (60).

• Move the membrane dimension group (10) as far in direction of the hub (5) as to permit
disassembly of the flexible part (1) / torsional limit device or safety ring as a unit.
The displacement of the membrane dimension group (10) can be carried out by means of
some hexagon bolts (22).

• After removal of the fixation elements (20, 39) installed at the connecting ring (3), the
flexible part (1) / torsional limit device or safety ring can be disassembled as a unit using a
lifting device.

Skt. bolt

turn out

Installation and Operating Instruction Page - No. E12048-11

Modification 1 Herne 2, 10.07.2001
 Please note: If a damage occurs at one RATO - R element, basically the second
RATO-R element has to be replaced as well.

When ordering spare parts for the flexible part (1) / torsional limit
device (50) or safety ring (46) respectively, the following information
concering the RATO-R coupling should be given:

1. order no.
2. drawing no.
3. partslist no.

7.2 Assembly of the flexible part

Before starting the assembly, it is recommended to carry out a new alignment control at the
drive system. The procedure for assembling the flexible part (1) / torsional limit device (50)
or safety ring (46) as a unit has already been described in paragraph 2 and 3.

After the assembly has been finished, the drive system is ready for operation, as far as the
coupling is concerned.

Installation and Operating Instruction Page - No. E12048-12

Modification 1 Herne 2, 10.07.2001