WORK PROCEDURE

Assembly instructions for tapered hubs

Table of contents
1.0 Validity 2
2.0 Purpose of instruction 2
3.0 Content 2
3.1 Layout of Tools and Hub Design 2
3.1.1 Arrangement for Marine type coupling hub 2
3.1.2 Arrangement for Reversed coupling hub 4
3.2 Cold shrink mounting with hydraulic oil 5
3.2.1 Mandatory checks prior shrinkage operation 5
3.2.2 Preparation for shrinkage 5
3.2.3 Shrinkage of hub (Mounting) 6
3.2.4 Verification 7
3.2.5 Securing 7
3.2.6 Taking into service (Loading of hub) 7
3.3 Cold dismounting with hydraulic oil 8
3.3.1 Preparation 8
3.3.2 Dismounting of hub 8
3.4 Oil Pressures 9

00
Rev. Changed Date Checked Date Change no. Change description
Bächler M. 06.07.2009
Issued Date Checked Date Released Date

Type/Size: Project no.:

Description: Assembly instructions for tapered hubs Project:

Document: 10000711605 Type: INS Part: 002 Rev.: 00 Lang.: EN Page 1 of 9

The reproduction, distribution and utilisation of this document as well as the communication of its contents to other without explicid authorization is
prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grand of a patent, utility model or design.
WORK PROCEDURE

1.0 Validity
This instruction is valid for all divisions of MAN Turbo AG Schweiz (MTM-CH).

2.0 Purpose of instruction

The enclosed procedure describes the mounting and dismounting of coupling hubs, designed in
accordance to the MTM-CH Standard with a 1:20 taper. The same method of operation may be used
for marine type and reversed hub design using shaft end nuts or shaft end disks, or with designs
using a shaft internal oil supply.

3.0 Content
3.1 Layout of Tools and Hub Design
3.1.1 Arrangement for Marine type coupling hub

Hydraulic nut

Oil pump with reservoirs

Adaptor and pressure gauges

High pressure hoses

Distributor

Figure 1: Layout for marine type coupling hubs with shaft diameters < 180mm, using a single pump to
feed the oil to the hub.

Description: Assembly instructions for tapered hubs Project:

Document: 10000711605 Type: INS Part: 002 Rev.: 00 Lang.: EN Page 2 of 9

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Adaptor
High pressure hoses

Hydraulic nut

Oil pump with reservoirs

and pressure gauges

Figure 2: Layout for marine type coupling hubs shaft diameters ≥ 180mm, using two individual pumps
to feed the oil to the hub.

Hub prior shrinkage operation

(Positioned by hand only)

Hydraulic nut

Shaft end nut

Hub in final position

(After shrinkage operation)

The shaft end nut and the hydraulic nut are mounted on the shaft end thread.

Figure 3: Marine coupling hub design with shaft end nut.

Description: Assembly instructions for tapered hubs Project:

Document: 10000711605 Type: INS Part: 002 Rev.: 00 Lang.: EN Page 3 of 9

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3.1.2 Arrangement for Reversed coupling hub
Oil pump with reservoirs
and pressure gauges

Adaptor

Hydraulic nut

High pressure hoses

Figure 4: Layout for reversed coupling hubs with shaft diameters < 110mm, using a single pump to
feed the oil to the hub.

Oil pump with reservoirs

and pressure gauges
High pressure hoses

Hydraulic nut

Adaptor

Figure 5: Layout for reversed coupling hubs with shaft diameters ≥ 110mm, using two pump to feed
the oil to the hub.

Description: Assembly instructions for tapered hubs Project:

Document: 10000711605 Type: INS Part: 002 Rev.: 00 Lang.: EN Page 4 of 9

WORK PROCEDURE

Hub prior shrinkage operation

(Positioned by hand only)
Hydraulic nut

Shaft end nut Hub in final position

(After shrinkage operation)

The shaft end nut and the hydraulic nut are mounted on the shaft end thread.

Figure 6: Reversed coupling hub design with shaft end nut.

3.2 Cold shrink mounting with hydraulic oil

3.2.1 Mandatory checks prior shrinkage operation
• Ensure that all hub bores and connections are clean. 1)
• To prevent any damage to either shaft or hub, confirm that all radius’s and recess’s are in
accordance to the applicable drawings. 2)
• Shaft and hub temperatures are to be equal. (Ambient)
• When fitting a new hub to a new shaft, (First mating fit) carry out a contact check with
mechanical blue. (In accordance to the MAN Turbo assembly record)
Contact area must be 85% or higher.
• After such contact check it is essential to clean and degrease the hub and shaft thoroughly.
(Ensure that all remains of the mechanical blue are removed by using a cleaning solvent).

1)

2) 2) 2)

Figure 7: Sketch for mandatory checks.

Description: Assembly instructions for tapered hubs Project:

Document: 10000711605 Type: INS Part: 002 Rev.: 00 Lang.: EN Page 5 of 9

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3.2.2 Preparation for shrinkage
• For toothed couplings, ensure that the end cover is positioned prior fitting the hub.
• In cases there the hub outer diameter is larger than the coupling guard flanges, mount the
interface flange to the adjacent casing prior fitting the hub.
• Position hub on taper. (If the hub has been fitted before, observe the circumferential match
marks and align hub accordingly!) For hubs which are fitted the first time, mark circumferential
position to hub and shaft with a scriber or equivalent tool.
• Mount dial gauge and adjust to zero.
(100 on gauges with a range of 0 – 1000 1/100 mm) The magnetic base of the dial gauge
shall not be positioned on the vibration pick up area. If the magnetic base is positioned on the
bearing pedestal or casing, use a second dial gauge (pedestal/casing to shaft) to monitor
potential shaft/casing movements during the shrinkage operation.
• Check and record verification dimension X1.

3.2.3 Shrinkage of hub (Mounting)

As a rule the shrinkage is performed by using 2 independent oil systems. System 1 is used to
enlarge the hub laterally with pressure p1, whereas system 2 feeds the hydraulic piston to
create the required axial forces with pressure p2.

• When working with high pressure pump systems it is mandatory to wear safety goggles
• During the entire shrinkage operation, as well as possible intermediate checks, prevent
wherever possible a physical location directly in front of the hub and mounting equipment.
• Check and confirm that all threads used during the shrinkage operation are free of any
damages which could lead to seizing of tools and adaptors.
• Grease all threads thoroughly with an anti seize compound.
• Mount the hydraulic nut. If the shaft end design foresees a shaft end disk, mounting and fixing
of the hydraulic nut is to be done with the bolting materials supplied to mount the shaft end
disk. (Grade 8.8). The piston of the coupling hub should be fully inserted to have the
maximum stroke available.
• Connect the high pressure hoses to the hub and the hydraulic piston.
• Vent both oil systems.
• Gradually increase pressure p2 to approximately 50barg. (5 MPa / 725 psi)
• Gradually increase pressure p1 until there is no further progress or increase. This natural
limitation is due to the leakage of hydraulic oil between the shaft and the hub.
(Max. allowable pressures are referred to under item 3.4)
• Alternatively increase pressures p2 and p1, using steps of approximately 50 barg (5 MPa / 725
psi) on p2, and with p1 as described above until there is no further progress or increase.
• Upon reaching the designed shrinkage distance, (Dial Gauges) release pressure p1.
Pressure p2 is to be maintained. (For further information about the shrinkage distance, refer to
the job specific assembly record)
• After releasing of pressure p1, remove hydraulic hoses from the hub and keep bores open.
(Do not close the holes as this will prevent free drainage of oil!)
• After a holding time of minimum 12 hours, release pressure p2. Confirm that hub remains in
shrunk position!
• Slowly remove hydraulic nut while continuously checking that hub remains in the shrunk
position.

Description: Assembly instructions for tapered hubs Project:

Document: 10000711605 Type: INS Part: 002 Rev.: 00 Lang.: EN Page 6 of 9

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• Immediately after removal of the shrinkage tools, secure the hub by fitting the shaft end nut or
where applicable, the shaft end disk.
• Further information on the use and operation of the pumps is given in the FASTEC operating
instructions located in the pump case.
• For mounting we recommend the use of FASTEC mounting oil.
• If the total shrinkage distance exceeds the stroke of the hydraulic piston, the hub must be
shrunk in two (2) working steps.

3.2.4 Verification
• Check and protocol radial and axial run-out in accordance to the assembly record.
• Measure and protocol verification dimension X2.
• Shrinkage dimension for marine type coupling hub x = X1 – X2. (see figure 8)
• Shrinkage dimension for reversed coupling hub x = X2 – X1 (see figure 9)
(Shrinkage distance in accordance to job specific assembly record)

If either of the above quoted measurements, run-out’s and dimensions deviate from the specified
tolerances, the hub must be removed and refitted. (Possible phase change to be considered when
witnessing extensive face or lateral run-out deviations)
3.2.5 Securing
• Subject to a successful dimensional verification, (3.2.4) the hub may be secured.
• Secure the shaft end nut with two oppositely placed grub screws. Grub screws to be secured
with a centre punch.
• Close hub hydraulic bores with the supplied plugs and secure them with a centre punch.

3.2.6 Taking into service (Loading of hub)

• The hub shall be loaded to its specified torque earliest 24 hours after shrinkage.

Figure 8: Schematic of control measurements for reversed hub couplings.

Description: Assembly instructions for tapered hubs Project:

Document: 10000711605 Type: INS Part: 002 Rev.: 00 Lang.: EN Page 7 of 9

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Figure 9: Schematic of control measurements for reversed hub couplings.

Cold dismounting with hydraulic oil

3.2.7 Preparation
• Remove shaft end nut or shaft end disk.
• Remove blind plugs from hydraulic oil bores in hub.
3.2.8 Dismounting of hub
As a rule the shrinkage is performed by using 2 independent oil systems. System 1 is used to
enlarge the hub laterally with pressure p1, whereas system 2 feeds the hydraulic piston to
create the required axial retaining/securing forces with pressure p2.
• When working with high pressure pump systems it is mandatory to wear safety goggles.
• During the entire removal operation, as well as possible intermediate checks, prevent
wherever possible a physical location directly in front of the hub and mounting equipment.

• Check and confirm that all threads used during the shrinkage operation are free of any
damages which could lead to seizing of tools and adaptors.
• Grease all threads thoroughly with an anti seize compound.
• Mount the hydraulic nut.
• If the shaft end design foresees a shaft end disk, mounting and fixing of the hydraulic nut is to
be done with the bolting materials supplied to mount the shaft end disk. (Grade 8.8)
Grease all threads thoroughly with an anti seize compound and fit the hydraulic piston on to
the adaptor. The piston position is to be adjusted to value X + 1,0 mm. (Shrinkage distance
plus 1 mm) If the total dismounting distance exceeds the stroke of the hydraulic piston, the
hub must be removed in two (2) working steps.
• Connect the high pressure hoses to the hub and the hydraulic piston.
• Vent both oil systems
• Raise pressure p2 to max. 50 barg (5 MPa / 725 psi).

Description: Assembly instructions for tapered hubs Project:

Document: 10000711605 Type: INS Part: 002 Rev.: 00 Lang.: EN Page 8 of 9

WORK PROCEDURE
• Gradually raise pressure p1 until the hub is set free from the shaft. When the hub is set free
the oil pressure of the hydraulic piston (p2) will raise and oil will leak from the resulting clear
area between the hub and the shaft. Pressure p1 cannot be raised further.
Depending on the hub dimension, the setting free will take some time as large masses cannot
be expanded in the same time period as small ones. For very large hubs, pressure p1 can be
raised gradually to the maximum allowable and kept there until the hub is set free.
(This may take up to approximately three hours)
• When releasing pressure p2 the hub will slide in a controlled manner off the tapered shaft.
• Further information on the use and operation of the pumps is given in the FASTEC operating
instructions located in the pump case.
• For the dismounting operation we recommend the use of FASTEC hydraulic oil.

3.3 Oil Pressures

To prevent any permanent plastic deformation of the tapered hubs, the pressures listed below
are not to be exceeded.
The actual resulting pressures are dependant on the hub design and the friction coefficients of
the two individual contact surfaces.
If by using the pressures quoted below individual hubs cannot be dismounted, use of higher
viscosity type oil is recommended. If further problems prevent a setting free of the hub, please
contact MTM-CH for further assistance.
Pressure p1 Pressure p2
Shrinkage [%] barg MPa psi barg MPa psi
0.15 1400 140 20300 650 65 9425
0.20 1800 180 26100 800 80 11600
0.25 2200 220 31900 850 85 12325

Ende des Dokumentes

Description: Assembly instructions for tapered hubs Project:

Document: 10000711605 Type: INS Part: 002 Rev.: 00 Lang.: EN Page 9 of 9