FLEXIBLE COUPLING SERVICE MANUAL

Coupling Information
AVC Order# 63599
Coupling Number 1F57145636-ABS
Description VKF 5714-4400
Drawing Number 1F57105636

American VULKAN Corporation

P.O. Drawer 673 • 2525 Dundee Road
Winter Haven, FL 33882-0673
Tel (863) 324-2424 • www.vulkanusa.com •Fax (863) 324-4008
VULKAN Kupplungs- und Getriebebau
Bernhard Hackforth GmbH & Co. KG
Heerstrasse 66
44653 Herne
Phone.: +49 (0) 2325 / 922-0
Fax.: +49 (0) 2325 / 711 10
E-mail: info.vkg@vulkan.com
Website: www.vulkan.com

American VULKAN Corporation

2525 Dundee Road
Winter Haven, FL 33884
Phone: +1 (863) 324-2424
Fax: 1+ (863) 324-4008
E-mail: us.info@vulkan.com
Website: www.vulkanusa.com

VULKAN do Brasil Ltda.

Rod. Engenheiro Constâncio Cintra, Km 91.
Bairro da Ponte
CEP: 13252-200 – Itatiba – São Paulo – Brazil
Phone: +55 (11) 4894-7300
Fax: +55 (11) 4894-7311
E-mail: assistenciatecnica@vulkan.com
Website: www.vulkan.com
Assembly Manual Vulkardan F

Table of contents

Table of contents

1 General

1.1 Information about the operating manual ....................................................................... 5

1.2 Explanation of symbols ................................................................................................. 5
1.3 Limitation of liability....................................................................................................... 6
1.4 Spare parts ................................................................................................................... 7
1.5 Warranty terms ............................................................................................................. 7
1.6 Customer service .......................................................................................................... 7

2 Safety

2.1 Responsibility of the owner ........................................................................................... 9

2.2 Intended use ................................................................................................................. 10
2.3 Special dangers ............................................................................................................ 10

3 Technical data

3.1 Consignment number.................................................................................................... 11

4 Structure and function

4.1 Mode of operation......................................................................................................... 12

4.2 Structure of the coupling............................................................................................... 12

5 Transport, packaging, and storage

5.1 Safety instructions for transport .................................................................................... 14

5.2 Symbols on the packaging............................................................................................ 14
5.3 Delivery status .............................................................................................................. 15
5.4 Packaging ..................................................................................................................... 15
5.5 Preservation.................................................................................................................. 16
5.5.1 General instructions...................................................................................................... 16
5.5.2 Table Metacorin/VCI/Rolimeco ..................................................................................... 16
5.5.3 Preservation with Metacorin.......................................................................................... 17
5.5.4 Preservation of VCI....................................................................................................... 18
5.6 Transport....................................................................................................................... 19
5.7 Storage ......................................................................................................................... 21

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Table of contents

6 Assembly

6.1 Safety assembly............................................................................................................ 24

6.2 Mounting the hub .......................................................................................................... 26
6.3 Alignment ...................................................................................................................... 28
6.4 Installation of the coupling ............................................................................................ 33
6.5 Concluding tasks and final inspection........................................................................... 43

7 Faults

7.1 Safety faults .................................................................................................................. 44

7.2 Fault table ..................................................................................................................... 44
7.3 Fault correction tasks.................................................................................................... 46
7.4 Start-up after a corrected fault ...................................................................................... 47

8 Maintenance

8.1 Safety maintenance ...................................................................................................... 48

8.2 Maintenance schedule.................................................................................................. 48
8.3 Maintenance tasks........................................................................................................ 49
8.4 Measures after successful maintenance....................................................................... 51

9 Dismantling

9.1 Safety dismantling......................................................................................................... 52

9.2 Dismantling sequence................................................................................................... 52
9.2.1 Replacement element ................................................................................................... 53
9.2.2 Dismounting the hub..................................................................................................... 55
9.3 Disposal ........................................................................................................................ 57

10 Appendix

10.1 Drawing......................................................................................................................... 58
10.2 Parts list ........................................................................................................................ 59

11 Index

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Assembly Manual Vulkardan F

1 General

1 General

1.1 Information about the operating manual

This assembly manual provides important instructions for handling the Vulkardan F. The
prerequisite for safe work is compliance with all specified safety instructions and handling
instructions.
In addition the applicable local accident prevention regulations and general safety regula-
tions must be complied with for the specific area of implementation of the Vulkardan F.
The operating manual must be carefully read prior to starting any task! The operating
manual is a component of the product and must be kept in the vicinity of the coupling
where it is available to personnel at all times.
If the Vulkardan F is provided to a third party then this operating manual must also be pro-
vided.
The illustrations in this manual are provided for better presentation of the described mate-
rial; these illustrations are not necessarily true to scale and may deviate slightly from the
actual version of the Vulkardan F.
The position numbers used in the illustrations and steps correspond to the position num-
bers of the drawing in the Appendix.
This assembly manual corresponds to requirements of ISO/IEC 82079-1. It is subject to
an ongoing review process. Subject to changes and errors.

1.2 Explanation of symbols

Safety instructions are indicated by symbols in this operating manual. The safety instruc-
tions are introduced by signal words that express the scope of the hazard.
The safety instructions must be strictly complied with, you must act prudently to prevent
accidents, personal injury, and material damage.

CAUTION!

... indicates a possible dangerous situation that can result in minor injury if it is not
avoided.

WARNING!

... indicates a possible dangerous situation that can result in death or serious injury if it is
not avoided.

DANGER!

... indicates a directly dangerous situation that will result in death or serious injury if it is
not avoided.

Prohibitory!

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Assembly Manual Vulkardan F

1 General

Note!
i ... indicates useful tips and recommendations, as well as information for efficient and trou-
ble-free operation.

1.3 Limitation of liability

All information and instructions in this operating manual have been provided under due
consideration of applicable guidelines, the current state of technology, as well as our
many years of experience.
The manufacturer assumes no liability for damage due to:

• Failure to comply with the instructions in the operating manual

• Non-intended use

• Deployment of untrained personnel

• Unauthorized conversions

• Technical changes

• Use of non-approved spare parts

The actual delivery condition can vary from the explanations and graphic representations
provided in this manual in the case of special versions, if supplemental order options are
desired, or on the basis of the latest technical changes. The agreed obligations in the de-
livery contract, the general terms and conditions, as well as delivery conditions of the
manufacturer, and the statutory regulations valid at the time the contract was concluded,
apply.

Technical prerequisites
VULKAN requires,

• that consultation with VULKAN’s technical experts occur before selection of the
product.

• that the purchased VULKAN product only be used and operated in accordance with
the “intended use” in the application area prescribed by VULKAN.

• that the technical information (valid at the time the contract is signed) in the Techni-
cal Data Brochures is taken into account during the assembly, disassembly, fault
rectification and maintenance tasks.

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1 General

Note!
i The respective version status of the Technical Data Brochure is specified inside the bro-
chure as shown in the example below:
07/2013
The owner must ensure that the points cited above are complied with.
If consultation does not occur, and the VULKAN product is configured by the owner at the
owner’s own responsibility, the owner also bears the responsibility for selecting the cor-
rect Technical Data Brochure appropriate for the product in the VULKAN Download Por-
tal:
http://www.vulkan.com
Moreover, it must be ensured that the version of the manual corresponds to the current
status at the time the contract is signed.

Note!
i The respective version status of the manual is specified at the beginning of the manual as
shown in the example below:
0000001064
001
7.4.14

1.4 Spare parts

WARNING!

Incorrect or defective spare parts can cause damage, malfunction, or total failure; they
can also impair safety.
Therefore:
• Only use manufacturer's original spare parts.
Spare parts Order via authorized dealers or directly from VULKAN customer service. See
section "Customer service" for the contact address.
Specify the following information when ordering spare parts:

• Order number or consignment number

• Drawing number

• Parts list number

1.5 Warranty terms

The warranty terms are included in the manufacturer's terms and conditions.

1.6 Customer service

Our customer service organization is available for technical information.

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Assembly Manual Vulkardan F

1 General

The responsible contact is always available at the following contact address:

Customer service:
VULKAN Kupplungs- und Getriebebau B. Hackforth GmbH & Co. KG
Heerstrasse 66
44653 Herne Germany
Tel.: +49 (0) 2325 / 922-0
Fax: +49 (0) 2325 / 711 10
Mobile: +49 (0) 178 / 8 922 179

In addition our employees are always interested in new information and experiences as-
sociated with the application that could be valuable for the improvement of our products.

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Assembly Manual Vulkardan F

2 Safety

2 Safety

2.1 Responsibility of the owner

This section provides an overview of all the important safety aspects for optimal protec-
tion of personnel, as well as for safe and trouble-free operation.
Significant hazards can occur if the handling instructions and safety instructions in this
manual are not complied with.
The Vulkardan F coupling is used in commercial operation. Consequently the owner of
the Vulkardan F coupling is subject to legal occupational health and safety obligations.
In addition to the occupational health and safety instructions in this assembly manual,
generally valid safety and accident protection guidelines, and environmental protection
guidelines must be complied with for the area of implementation of the Vulkardan F cou-
pling.
In this regard the following particularly applies:

• The owner must inform himself of applicable occupational health and safety regula-
tions, and in a risk assessment identify other hazards that may exist at the installa-
tion site of the coupling due to the special work conditions. The owner must convert
this information relative to hazards into operating instructions for operation of the
coupling.

• The owner must ensure during the entire implementation period of the coupling that
the operating instructions created by the owner correspond to the current state of
legislation, and if necessary the owner must adapt these operating instructions.

• The owner must clearly regulate and specify responsibilities for installation, opera-
tion, maintenance, and cleaning.

• The owner must ensure that all employees who handle the coupling have read and
understood the assembly manual. In addition, the owner must train personnel and
inform them of hazards at regular intervals.

• The owner must attach a distance protection fixture in the form of a coupling protec-
tion before commencing operation of the system. Aeration and ventilation must
remain ensured.

• The owner must provide the required protective equipment for personnel.

Moreover the owner is responsible for ensuring that the coupling is always in technically
faultless condition; consequently the following applies:

• The owner must ensure that the maintenance intervals described in this assembly
manual are complied with.

• The owner must have all safety devices inspected regularly for function and for com-
pleteness.

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2 Safety

2.2 Intended use

The VULKAN Vulkardan F coupling is a highly elastic, all-round ductile coupling for use in
ship main drives, ship auxiliary drives, generator drives, compressor drives, pump drives,
and blower drives with the requirement for average rotary and offset resiliency.
It has been especially developed for a particular application case and can only be used
for a different application after consultation with the manufacturer.

2.3 Special dangers

Residual risks that have been determined based on a risk assessment are cited below.
Follow the safety instructions listed here and the warning instructions in the other sections
of this manual to reduce health hazards and to avoid dangerous situations.

WARNING!

Life-threatening danger and danger of material damage due to incomplete or incorrect

assembly!
If there is a mechanical failure of components and incomplete or incorrect assembly, cou-
pling parts can be thrown out at high speed due to rotation. This poses a life-threatening
hazard and danger of material damage.
Therefore:
• Only place the coupling in service after complete assembly in accordance with the
instructions in this operating manual.
• Only operate the coupling within the protective fixture described in the "Assembly"
section. This protective fixture must be installed by the owner.
• After working on the coupling, ensure that all bolt connections are firmly tightened in
accordance with the specified tightening torques (see drawing).

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Assembly Manual Vulkardan F

3 Technical data

3 Technical data

3.1 Consignment number

Consignment number:
The consignment number is stamped on the product for clear identification.

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Assembly Manual Vulkardan F

4 Structure and function

4 Structure and function

4.1 Mode of operation

The Vulkardan F coupling is a highly elastic, elastomer coupling capable of withstanding
axial shear stress.
All connecting elements of the coupling are positioned in such a way that there is no
backlash. Play-free torque transmission and the large elastomer cross section guarantee
good structure-borne sound absorption.

4.2 Structure of the coupling

Structure and function of the hub:

The hub is the machine element that is used to fasten the coupling on the shaft. Depend-
ing on the version (see drawing) it is pre-bored, has a feather key groove as carrier ele-
ment, or it is shrink-fit onto the shaft via a pull-on device and hydraulic support (oil
pressure connection).

Fig. 4-1

Membrane
The membrane consists of a circular steel plate. This is connected on the outer diameter
(A) with the elastic element, and with the hub on the inner diameter (B). The spring de-
flection of the membrane enables angular and axial displacement.

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4 Structure and function

Fig. 4-2

Elastic element
The elastic element is the basic element of the coupling.
The elastic element is used to tune torsional vibration behavior and to compensate radial
shaft displacement. The elastic element cannot compensate axial and angular displace-
ment.

Fig. 4-3

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5 Transport, packaging, and storage

5 Transport, packaging, and storage

5.1 Safety instructions for transport

CAUTION!

Improper transport can cause damage!

Significant damage can occur if the device is transported improperly.
Therefore:
• Proceed with caution when unloading packages at delivery, as well as for inner-com-
pany transport, and comply with the symbols and instructions on the packaging.
• Only use the intended attachment points.
• Do not attach on projecting machine parts or on the eyes of installed components.
Ensure that the sling gear is securely seated!
• Only use approved hoists and sling gear with sufficient bearing capacity.

5.2 Symbols on the packaging

Attachment point
Only place sling gear (attachment chain, lifting strap) at the points marked with this sym-
bol.

Fig. 5-1

Weight, attached load

Indicates the weight of packages. Handle the marked package in accordance with its
weight.

Fig. 5-2

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5 Transport, packaging, and storage

5.3 Delivery status

The coupling is delivered in commissioned status for easier assembly.

5.4 Packaging
About the packaging
VULKAN recommends not to destroy the original packaging and to remove it just prior to
assembly. Deviant behavior must not lead to premature product ageing, damage or re-
strictions in function and service life. The measures necessary for this must be realized
effectively until the VULKAN product is installed. Individual packed goods are packaged
according to the expected transport conditions. Environmentally-friendly materials have
been used exclusively for the packaging. Packaging should protect the specific compo-
nents from transport damage, corrosion and other damage until assembly.

Fig. 5-3

Fig. 5-4

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5 Transport, packaging, and storage

Handling packaging materials

Dispose of packaging materials in accordance with the respectively valid statutory regula-
tions and local guidelines.

5.5 Preservation

5.5.1 General instructions

CAUTION!

Corrosion preventatives are harmful!

Toxic hazard if fumes or aerosols of the corrosion preventative are inhaled! Repeated or
longer contact can cause skin irritation or skin diseases.
Therefore:
• Only unpack the coupling in well-ventilated areas.
• Only remove the corrosion preventative in well-ventilated areas.
• Avoid contact with skin and eyes: When working, wear chemical-resistant protective
gloves and protective goggles with side protection. After work wash thoroughly and
use skin-care cream.
• If inhaled get the person affected to fresh air immediately. If there is skin or eye con-
tact rinse immediately and thoroughly with water.
• In case of accidents immediately consult a doctor!
• The individual manufacturers' safety data sheets must be strictly complied with!

5.5.2 Table Metacorin/VCI/Rolimeco

Overview of corrosion preventatives used by VULKAN

Standard Standard Additional corro-

corrosion protec- Standard corrosion protec- sion protection
tion corrosion protec- tion Steel parts, cast
Steel and cast tion Membrane assem- parts and vulcan-
parts up to 6 Vulcanized steel blies up to ized steel and cast
months and cast parts up 6 months parts > 12 months
(stored outdoors to 4 months (stored outdoors (stored indoors in
under a roof) (stored outdoors under a roof) a dry room)
under a roof)

See freight over- Metacorin 835, dry Metacorin 850, dry Rolimeco 397, dry Parts in VCI foil or
seas, tropical and layer thickness min. layer thickness min. layer thickness min. aluminum foil; inside
sub-tropical regions 4 µm / max. 6 µm 5 µm / max. 8 µm 4 µm / max. 6 µm with VCI foam dis-
penser, if necessary

Intercontinental Metacorin 835, dry Metacorin 850, dry Rolimeco 397, dry Parts in VCI foil;
shipping points layer thickness min. layer thickness min. layer thickness min. inside with VCI foam
4 µm / max. 6 µm 5 µm / max. 8 µm 4 µm / max. 6 µm dispenser, if neces-
sary

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5 Transport, packaging, and storage

Standard Standard Additional corro-

corrosion protec- Standard corrosion protec- sion protection
tion corrosion protec- tion Steel parts, cast
Steel and cast tion Membrane assem- parts and vulcan-
parts up to 6 Vulcanized steel blies up to ized steel and cast
months and cast parts up 6 months parts > 12 months
(stored outdoors to 4 months (stored outdoors (stored indoors in
under a roof) (stored outdoors under a roof) a dry room)
under a roof)

within Metacorin 835, dry Metacorin 850, dry Rolimeco 397, dry Parts in VCI foil
Europe layer thickness min. layer thickness min. layer thickness min.
4 µm / max. 6 µm 5 µm / max. 8 µm 4 µm / max. 6 µm

Short hauls, domes- Metacorin 835, dry Metacorin 850, dry Rolimeco 397, dry Not necessary!
tic, bordering states layer thickness min. layer thickness min. layer thickness min.
per carrier 4 µm / max. 6 µm 5 µm / max. 8 µm 4 µm / max. 6 µm

Tbl. 5-1

5.5.3 Preservation with Metacorin

Note!
i Material damage due to improper removal of the corrosion preventative!
Mechanical removal of the corrosion preventative (e.g. with abrasive agents or tools) can
damage surfaces and fit.
Therefore:
Use a suitable solvent or alkaline cleaning agents.

Note!
i Material damage due to solvent!
Do not bring the rubber elements into contact with solvents!

Preservation of steel and cast parts with Metacorin 835 and Metacorin 850

The following types of steel parts are generally protected against corrosion with the corro-
sion preventative METACORIN 835/850:
For steel and cast parts on surfaces and stamped images treated to finish dimension
Metacorin 835 offers sufficient protection in case of:

• dry indoor storage: more than 12 months

• outdoor storage under a roof: 6 months

The layer thickness of the preservation agent is 4 - 6 µm.

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5 Transport, packaging, and storage

Metacorin 850 offers sufficient protection in case of:

• dry indoor storage: more than 12 months

• outdoor storage under a roof: 4 months

The layer thickness of the preservation agent is 5 - 8 µm.

Cleaning
To clean off the Metacorin 835 corrosion preventative film we recommend spraying or im-
mersing in an aqueous-alkaline solution.
The cleaning process should generally be supplemented by mechanical cleaning.

Note!
i Always use lint-free cloths for cleaning.

Note!
i The connection surfaces and bores are preserved with corrosion preventative or the cou-
pling is packed in VCI foil.
Before installing the coupling, use cleaner to clean surfaces that have been treated with
corrosion preventative.

5.5.4 Preservation of VCI

Note!
i Do not treat elastomers and rubber parts with the corrosion preventative.
Preservation of elastomer will void the warranty.

Preservation with VCI 126 foil

Note!
i The VCI foil used by VULKAN is PE foil with the VCI additive as vapour-phase inhibitors.
The inhibitors emerge from the foil in the form of vapour, saturate the enclosed air space
and adhere to the bare metal surfaces as invisible, monocular films.
They can also reach hard-to-access areas.
When used as specified, they provide protection of 2-5 years with an airtight seal.
Do not allow the VCI foil to become damaged!
If the VCI foil is not replaced immediately after being damaged, VULKAN will assume no
liability for any adverse effects on the coupling as a result of corrosion!

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5 Transport, packaging, and storage

Fig. 5-5

5.6 Transport

Hub

Horizontal transport
1. Screw two eye bolts (T) into the tapped bores of the hub, until the collar rests on the
hub.
2. Attach the hub on eye bolts (T) and connect it with the lifting gear.

Fig. 5-6

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5 Transport, packaging, and storage

Vertical transport
1. Use a shackle to attach the hub to the marked bore (see arrow) and connect with the
lifting gear.

Fig. 5-7

Transport – membrane
Use a shackle to fasten the membrane to the marked bore (arrow) and connect with the
lifting gear. Use suitable shackles.

Fig. 5-8

Transport – elastic element

Attach the elastic element to the lifting gear.

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5 Transport, packaging, and storage

Fig. 5-9

5.7 Storage

Environmental influences and storage of packages

Only store packages under the following conditions:

• Do not store outdoors.

• Store in a dry and dust-free location.

• Do not expose to aggressive media.

• Protect from direct sunlight and artificial UV sources.

• Do not store close to ozone producing machinery.

• Avoid mechanical vibration.

• Storage temperature: 15 to 25°C.

• Relative humidity: Max. 60%

• For longer periods of storage (> 3 months) regularly check the general status of all
parts and the status of the packaging. Touch up or re-apply anti-corrosion agents as
needed.

• If stored for longer than 3 years, a repetition of the static test of the elastic elements
is required.

• For storage longer than 5 years the technical data, such as dynamic torsion spring
stiffness and static angle of rotation characteristic of the elastic elements, must be
checked.

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5 Transport, packaging, and storage

If it is not possible to fully avoid the environmental influences mentioned above, please do
not hesitate to contact us. We can offer you special treatments for a surface conservation.

Note!
i Under certain circumstances storage instructions are on the packages that extend
beyond the requirements cited here. Comply with these instructions accordingly.

Note!
i Material damage if stored incorrectly!
Incorrect storage of the elastic elements can cause irreversible deformation of the elasto-
mer. The consequence is uncontrolled torsional oscillation that can destroy the elastic
element.
Therefore:
Store the elastic element horizontally.
Do not stress the elastic element axially, e.g. by stacking additional weights.
Do not set up the elastic element diagonally or on one side.

Storing the elastic elements

Fig. 5-10

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5 Transport, packaging, and storage

Fig. 5-11

Fig. 5-12

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Assembly Manual Vulkardan F

6 Assembly

6 Assembly

6.1 Safety assembly

WARNING!

There is an injury hazard if the device is not installed and commissioned properly!
Improper assembly and commissioning can cause serious injury or material damage.
Therefore:
• Prior to starting the tasks ensure that there is adequate free space for assembly.
• Handle open, sharp-edged components carefully.
• Ensure order and cleanliness at the installation location! Parts and tools that are
lying loose or on top of each other are accident hazards!
• Mount components properly. Maintain the prescribed bolt torque and fastening
torque.
• Secure the components so that they do not fall down or fall over.

Safety personnel

• Only trained, specialized personnel should perform assembly work.

• If the customer desires assembly can also be executed by VULKAN employees.

DANGER!

Life-threatening danger due to commissioning and restarting without authorization!

When installing there is danger of the energy supply being switched on without authoriza-
tion. This poses a life-threatening danger for persons in the danger zone.
Therefore:
• Prior to starting the tasks switch off all energy supplies and safeguard them from
being switched on again.
• If combustion motors supply the motive power then the safety instructions and the
instructions for switching off and safeguarding against restart in the assembly manu-
als provided by the manufacturers must be complied with.

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6 Assembly

WARNING!

Life-threatening hazard - High elastic forces!

The rubber elements and the membrane can accumulate extreme quantities of energy
when they are deflected. Sudden loosening of obstructions can cause high energy move-
ments of coupling parts, and in the process cause life-threatening injury.
Therefore:
• Prior to working on the coupling ensure that it is force-free and that the resilient ele-
ments are not deflected.
• For tasks that require deflection of resilient elements only employ the work methods
described in this manual. Only use tools and clamping devices that are designed for
high forces.
• Only specialized personnel familiar with the installation should select the thrust bear-
ing required for deflection of the membrane assemblies.
To ensure an ideal assembly sequence, VULKAN recommends to comply with the work
steps described here.

Note!
i Prior to assembly any danger to persons and material damage must always be excluded.

In case of any questions regarding assembly, please contact the VULKAN customer ser-
vice (chapter "Customer service").

Note!
i Material damage due to change in the direction of rotation for used elastic elements!
Elastic elements are subject to premature material wear if the original direction of rotation
is changed and the parts are reused.
Therefore:
When reusing elastic elements install them in the original direction of rotation.
Pay attention to the markings on the elastic element and the connecting components.

Note!
i
Insert connecting elements coated with PTFE and connecting elements treated with "Loc-
tite 245 medium strength" in dry condition!
Standard fastening elements and tapped bore holes must be lubricated with motor oil
before such elements are inserted!
Fitting bolts must additionally be lubricated in the shaft area, e. g. with gleitmo 800!

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6 Assembly

6.2 Mounting the hub

Hub assembly - feather key connection

1. Check the feather key (P) in the hub for sealing seat and clean again.
2. Turn the shaft until the feather key (P) is pointing up.
3. Lubricate the shaft with hydraulic oil in the area of the hub seat.

Fig. 6-1

4. Heat the hub uniformly in an oil bath or with a burner so that the temperature is 150
to 200 °C higher than the ambient temperature.

CAUTION!

Danger of burn injuries due to hot surfaces!

Contact with the heated hub or shaft can cause burn injuries.
Therefore:
• Always wear protective work clothing and protective gloves for all tasks performed in
the vicinity of hot components.
• After pulling on the hub and before further assembly of coupling parts, ensure that all
components have cooled to ambient temperature.

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6 Assembly

CAUTION!

Excessive temperature or non-uniform heating can cause material damage!

At temperatures in excess of 350 °C or if not heated uniformly, the structure of the hub
can change and it can lose strength.
Therefore:
• Monitor the temperature when heating.
• If the temperature of the hub exceeds 350 °C, use a new hub or inform the manufac-
turer in order to coordinate other measures.
5. Insert two threaded rods (F) into the bores of the hub as guiding aids and secure.
6. Select the bore in such a manner that the threaded rods (F) on the left and right side
are at the same height.
7. Attach the hub to the lifting gear via the attachment devices (T).

Note!
i The threaded rods (F) and the attachment devices (T) are not included in the VULKAN
scope of delivery and must be configured by the owner!

Fig. 6-2

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6 Assembly

8. Press the threaded rods (F) down so that the hub is in horizontal position.
9. Push the hub onto the shaft until the stop and ensure that the hub rests on the stop
correctly.
10. Maintain the axial pressure on the hub until the hub has cooled down, and in doing
so secure it against slipping. Then check the connection again.
11. Remove the threaded rods (F) with the attachment devices (T).

Fig. 6-3

6.3 Alignment

Alignment principles
The more accurate the alignment, the more effective the compensation of operational
misalignments by the coupling.
The Vulkardan F couplings are capable of compensating for significant displacement of
the connected machines without forfeiting service life.

CAUTION!

Improper alignment can cause system damage!

In case of excessive misalignments, high forces can be transferred to the adjoining
machine parts.
Therefore:
• Make sure the system is aligned correctly.
• If the tolerances specified here are exceeded, do not operate the system. Coordi-
nate additional measures with the manufacturer.

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6 Assembly

To align the system, the following prerequisites must be fulfilled:

• The elastic element is not installed yet.

• The preservation agent applied to the connecting surfaces has been completely
removed.

Radial displacement

Fig. 6-4

1. Determine the dimension Xr1.

2. Turn drive unit 180° and determine the dimension Xr2.
3. Turn drive unit 90° and determine the dimension Xr3.
4. Turn drive unit 180° and determine the dimension Xr4.
5. Determine the value Xr according to the formula below:

 X  X r1   X r 3  X r 4 
2 2

X r   r 2   
 2   2 

Fig. 6-5

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6 Assembly

Axial displacement

Fig. 6-6

1. Determine the dimension Xa1.

2. Turn drive unit 180° and determine the dimension Xa2.
3. Turn drive unit 90° and determine the dimension Xa3.
4. Turn drive unit 180° and determine the dimension Xa4.
5. Determine the value Xa according to the formula below (Xa corresponds to the in-
stalled dimensions from the installation drawing):

X a1  X a 2  X a 3  X a 4
X a   Xa
4

Fig. 6-7

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6 Assembly

Angular displacement

Fig. 6-8

1. Determine the dimension of the angle gap Xw1 on the appropriate reference radius R.
2. Turn drive unit 180° and determine the dimension Xw2.
3. Turn drive unit 90° and determine the dimension Xw3.
4. Turn drive unit 180° and determine the dimension Xw4.
5. Determine the value Xw according to the formula below:

2 2
 X  X w1   X w3  X w4 
X w   w 2   
 2   2 

Fig. 6-9

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6 Assembly

6. Determine the maximum angle gap Xwmax according to the formula below. In this re-
gard the maximum value for Xw degrees specified below must be used.

X w max  R  tan(X wGrad )

7. The measured value Xw must be less than or equal to the calculated value Xwmax.

32/62
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6 Assembly

Note!
i The tolerance values recommended here refer to the warmed-up condition of the system.
System-specific thermal expansion must be determined by the system engineer and
these values must be used.
For flexibly mounted systems, please contact the motor manufacturer or mount manufac-
turer for further information on the setting behavior of the elastic mount. Due to the setting
behavior of the elastic mount, it may be necessary to operate the system slightly outside
the recommended tolerances at the beginning.
In this regard, the restoring forces of the coupling must be taken into account.
For realignment in cold condition, system-specific values apply and must be determined
and complied with by the system engineer. The maximum displacement values are pro-
vided in the technical data brochure (product catalog) and must not be exceeded.
For further information please contact the motor manufacturer or mount manufacturer.
In case of questions regarding VULKAN mounts, please contact your local VULKAN
agency or the VULKAN customer service (chapter "Customer service").

Recommended alignment tolerances for rigid installations

Xr (mm) Xa (mm) Xw

Degrees(°)

± 0,5 ± 0,25 ± 0,05

Tbl. 6-1

6.4 Installation of the coupling

Mounting the coupling:

Note!
i If the installation space allows for it, the assembly steps described here (mounting of the
membrane and the elastic element) may also be executed in reverse sequence!
1. Screw the catch bolts (20) with washers (21) and nuts (22) offset 180° to the elastic
element (7).

Note!
i The tightening torques must be complied with!

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Assembly Manual Vulkardan F

6 Assembly

22 21 20

Fig. 6-10

2. Lift the elastic element (7) into the system and screw it to the customer connection
(S) using suitable fastening elements (arrow).

Note!
i The fastening elements are not included in the VULKAN scope of delivery and must be
configured by the owner!

Fig. 6-11

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Assembly Manual Vulkardan F

6 Assembly

3. Insert the fastening elements (9, 15) into the 12:00 position of the hub (1).

Fig. 6-12

4. Slide the hub-side spacer plate (4) and the membrane (3) onto the fastening element
(9).

Fig. 6-13

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Assembly Manual Vulkardan F

6 Assembly

5. Screw on the inner cover ring side spacer plate (4) and the inner cover ring (6) using
the fastening element (9) (do not tighten to torque!).

1 9

Fig. 6-14

6. Position and center the inner cover ring side spacer plate (4) and the inner cover ring
(6) by releasing.

1 9 6

Fig. 6-15

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Assembly Manual Vulkardan F

6 Assembly

Note!
i The work steps below describe the assembly with the aid of the "aligning device" tool that
is available separately from VULKAN.
Naturally the alignment can also be executed with the dial gauge.
Lightly grease the aligning devices after use (corrosion protection)!

Note!
i In the next two work steps it must be ensured that every 120° a bore (arrow) is left free for
the aligning devices!
7. Insert and tighten the fastening elements (9, 15).

15

Fig. 6-16

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Assembly Manual Vulkardan F

6 Assembly

8. Insert the bushes (18) with the fastening elements (10, 16, 17).

Fig. 6-17

9. Insert the aligning devices (K) and screw them on using the fastening elements (B).

Fig. 6-18

 The aligning devices are inserted.

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Assembly Manual Vulkardan F

6 Assembly

Fig. 6-19

Note!
i VULKAN recommends that you tighten the fastening elements that are inserted directly
next to the aligning devices only after removal of the aligning devices.
10. Screw on the bushes (18) with the fastening elements (10, 16, 17).

Fig. 6-20

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Assembly Manual Vulkardan F

6 Assembly

11. Unscrew the fastening elements (B) and remove the aligning devices (K).
12. Insert the remaining bushes (18) with the fastening elements (10, 16, 17) and tighten
all fastening elements.

Fig. 6-21

Note!
i VULKAN recommends checking the concentricity on the membrane-side element plate!
The concentricity tolerance must not exceed 0.4 mm! The actual value that must be set
initially depends on the customer requirements imposed on the balance quantity!
 The coupling assembly with aligning device is concluded!

Note!
i In the following work steps, assembly of the coupling with a precision try square and a
dial gauge is described. The precision try square is not included in VULKAN scope of
delivery!

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Assembly Manual Vulkardan F

6 Assembly

1. Insert and tighten the fastening elements (9, 15).

15

Fig. 6-22

2. Insert the bushes (18) with the fastening elements (10, 16, 17).

Fig. 6-23

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Assembly Manual Vulkardan F

6 Assembly

3. Only screw on the fastening elements far enough that all components are in contact,
but they can still be moved.
4. Check the radial position of the membrane-side element plate relative to the mem-
brane with a precision try square at three positions offset by 90°.

Fig. 6-24

Note!
i If with this check a displacement is determined, then this displacement must be corrected
through counter-pressures (e.g. with an offset pin) or through light knocks (e.g. with a rub-
ber hammer) on the membrane-side element plate.
This step must be repeated until the precision try square rests full surface on both sides
on the outer perimeter.
5. Tighten the fastening elements (10, 16, 17).

Note!
i VULKAN recommends checking the concentricity on the membrane-side element plate!
The concentricity tolerance must not exceed 0.4 mm! The actual value that must be set
initially depends on the customer requirements imposed on the balance quantity!
 This concludes assembly of the coupling with precision try square and dial
gauge.

42/62
Assembly Manual Vulkardan F

6 Assembly

6.5 Concluding tasks and final inspection

Concluding tasks and final inspection

1. Tighten all threaded connections with a torque wrench in compliance with the speci-
fied torque (see Tightening torques).
2. Installation of the coupling is concluded. Execute a concluding alignment check (-->
Chapter “Alignment”).
3. Ensure that on the owner side a distance-protection fixture in the form of a coupling
guard has been attached before the unit is placed in service (--> chapter “Responsi-
bility of the owner”).
 This concludes assembly of the coupling.

43/62
Assembly Manual Vulkardan F

7 Faults

7 Faults

7.1 Safety faults

Possible fault causes and the tasks to correct these faults are described in the following
section.
If faults occur more frequently, the maintenance intervals must be shortened to corre-
spond to actual system load.
Contact the manufacturer if there are faults that cannot be corrected by following the in-
structions below (see "Customer service").
Personnel

• The maintenance and troubleshooting tasks described here should only be per-
formed by experts with special training, or exclusively by the manufacturer. Special
reference will be made to the requirement for personal protective equipment or the
requirement for experts with special training in the description of the specific fault.

DANGER!

Life-threatening danger if restarted without authorization!

When correcting faults there is danger of the power supply being switched on without
authorization. This poses a life-threatening hazard for persons in the danger zone.
Therefore:
• Prior to starting the tasks switch off all energy supplies and safeguard them from
being switched on again.
• If combustion motors supply the motive power then the safety instructions and the
instructions for switching off and safeguarding against restart in the assembly manu-
als provided by the manufacturers must be complied with.

Note!
i The fault table provided below lists personnel who are authorized to correct the fault.

7.2 Fault table

Standard fault table

The faults described here refer to the components of the actual scope of delivery.

Component Fault Possible cause Fault correction Corrected by

Elastic element Cracks in the Maintenance interval Execute maintenance Specialist

/ segment elastomer exceeded and eliminate crack for-
mation

Elastic element Cracks in the Service life limit exceeded Replace elastic ele- Specialist
/ segment elastomer ment

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Assembly Manual Vulkardan F

7 Faults

Component Fault Possible cause Fault correction Corrected by

Elastic element Cracks in the Inadequate coupling ven- Improve ventilation and Specialist
/ segment elastomer tilation eliminate crack forma-
tion

Elastic element Cracks in the Faulty alignment Check the alignment Specialist
/ segment elastomer and eliminate crack for-
mation

Elastic element Cracks in the Overload Only operate the cou- Specialist
/ segment elastomer pling in the prescribed
load range and elimi-
nate crack formation

Elastic element Cracks in the Insufficient surface pro- Reapply surface pro- Specialist
/ segment elastomer tection tection and eliminate
crack formation

Coupling Unusual Faulty alignment Alignment check Specialist

operating
noise

Elastic element Unusual Incorrect mounting of Check the radial run- Specialist
/ segment / operating elastic element or mem- out and correct assem-
membranes noise brane assembly bly errors

Elastic element Unusual Elastomer detaches from Replace elastic ele- Specialist
/ segment operating the metal ment
noise

Coupling Increased Faulty alignment Alignment check Specialist

mount forces

Elastic element Increased Incorrect mounting of Check the radial run- Specialist
/ segment / mount forces elastic element or mem- out and correct assem-
membranes brane assembly bly errors

Elastic element Increased Elastomer detaches from Replace elastic ele- Specialist
/ segment mount forces the metal ment

Elastic element Destruction Maintenance interval Replace elastic ele- Specialist

/ segment of an elastic exceeded ment
element

Elastic element Destruction Service life limit exceeded Replace elastic ele- Specialist
/ segment of an elastic ment
element

Elastic element Destruction Blocking in the system Resolve blocking and Specialist
/ segment of an elastic replace elastic element
element

Elastic element Destruction Grounding of the ship's Replace elastic ele- Specialist
/ segment of an elastic propeller ment
element

45/62
Assembly Manual Vulkardan F

7 Faults

Component Fault Possible cause Fault correction Corrected by

Elastic element Destruction Short circuit in generator Replace elastic ele- Specialist
/ segment of an elastic operation ment
element

Elastic element Destruction Faulty synchronization in Replace elastic ele- Specialist

/ segment of an elastic generator operation ment
element

Tbl. 7-1

7.3 Fault correction tasks

Venting the coupling

• Execution only by a specialist assigned by the owner.

• To prevent unnecessary and impermissible warming of the elastic elements, a suita-

ble coupling protection element (e.g. perforated plate) with appropriate ventilation
cross-sections must be selected.

• Ensure that applicable standards for separating spacing protection fixtures are com-
plied with.

Alignment check

• Execution only by a specialist.

• Special tools required

1. Radial measuring device

2. Axial measuring device

3. Angle measuring device

The alignment process is described in detail in the "Alignment" chapter.

Correcting crack formation

• Execution only by a specialist.

1. Check for surface cracks (see chapter "Checking for surface cracks").
Replacing the surface protection

• Execution only by a specialist.

Replacing the elastic part

• Execution only by a specialist.

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Assembly Manual Vulkardan F

7 Faults

1. Dismount the elastic part (see "Dismounting the elastic part”).

2. Mount new elastic part (see "Mounting the elastic part”).

3. Perform final inspection (see "Concluding tasks and final inspection").

7.4 Start-up after a corrected fault

After correcting the fault and before switching on, perform the following steps:

1. Firmly tighten all previously unscrewed threaded joint to the specified tightening
torque.
2. Ensure that all previously removed protective devices and covers have been prop-
erly installed.

3. Ensure that all tools, materials, and other equipment have/has been removed from
the work area.

4. Clean the work area and remove any substances that may have escaped, such as
liquids, processing material, or similar items.

5. Ensure that all system safety devices are again functioning properly.

6. Owner-installed emergency stop devices, if present, must be reset.

7. Ensure that no one is in the danger zone.

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Assembly Manual Vulkardan F

8 Maintenance

8 Maintenance

8.1 Safety maintenance

Personnel

• The maintenance and troubleshooting tasks described here should only be per-
formed by experts with special training, or exclusively by the manufacturer. Special
reference will be made to the requirement for personal protective equipment or the
requirement for experts with special training in the description of the specific fault.

DANGER!

Life-threatening danger if restarted without authorization!

When correcting faults there is danger of the power supply being switched on without
authorization. This poses a life-threatening hazard for persons in the danger zone.
Therefore:
• Prior to starting the tasks switch off all energy supplies and safeguard them from
being switched on again.
• If combustion motors supply the motive power then the safety instructions and the
instructions for switching off and safeguarding against restart in the assembly manu-
als provided by the manufacturers must be complied with.

8.2 Maintenance schedule

Maintenance schedule
Maintenance tasks are described in the sections below that are required for optimal and
trouble-free operation.
If increased wear is detected during regular inspections, then reduce the required mainte-
nance intervals according to the actual indications of wear.
Contact the manufacturer, if you have questions concerning maintenance tasks and inter-
vals.

Interval Maintenance task Execution by:

Yearly Visual inspection Specialist

Yearly after a repair has Visual inspection Specialist

been carried out

If there is damage or mal- Dismantle the elastic ele- Specialist

function ment (after a defect has
been determined)

Tbl. 8-1

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Assembly Manual Vulkardan F

8 Maintenance

Damage or malfunction due to:

• Grounding of the ship's propeller

• Short circuit in generator operation

• Faulty synchronization in generator operation

• Regulator oscillation

• Emergency switch off

8.3 Maintenance tasks

Check surface cracks

• Execution only by a specialist.

• Special tools required:

• Caliper gauge
• Depth gauge

1. Remove the coupling protection installed by the owner.

2. To determine the depth of the crack in the interior diameter, the elastic element must
be removed (see "Dismantling the elastic part").

3. Use the caliper gauge and depth gauge to measure the crack depth "X" on the inner
and outer diameter of the elastic element.

4. Compare the measured value with the maximum permissible values in the table
below.

5. If the maximum permissible crack depths are exceeded then the elastic element
must be replaced (see "Replacing the elastic part").
X

Fig. 8-1

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Assembly Manual Vulkardan F

8 Maintenance

Permissible crack depths on the inner and outer diameter

• 3.8 mm.

Permissible crack depth on the outer diameter and crack-free inner diameter

• 6.4 mm.

Alignment check

• Execution only by a specialist

• Required special tools

• Radial measuring device

• Axial measuring device
• Angle measuring device
Alignment of the Vulkardan F coupling is described in detail in the chapter “Aligning”.

Inspecting for irreversible deformations

• Execution only by a specialist.

• Special tools required:

• Caliper gauge
• Measuring angle
1. Remove the coupling protection installed by the owner.
2. Turn the coupling until the lip is visible and easily accessible.

Fig. 8-2

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Assembly Manual Vulkardan F

8 Maintenance

3. Measure the irreversible deformation "S" on the lip.

Fig. 8-3

4. Compare the measured value with the maximum permissible values in the table be-
low.
5. If the maximum permissible irreversible deformation is exceeded then the elastic el-
ement must be replaced (see "Dismantling the elastic part").

Permissible permanent deformation

• 48 mm.

8.4 Measures after successful maintenance

Execute the following steps after concluding maintenance tasks and before switching the
system on:
1. Check all previously loosened threaded unions for firm seat.
2. Ensure that all previously removed protective devices and covers have been properly
installed.
3. Ensure that all tools, materials, and other equipment have/has been removed from
the work area.
4. Clean the work area and remove any substances that may have escaped, such as
liquids, processing material, or similar items.
5. Ensure that all system safety devices are again functioning properly.
6. Owner-installed emergency stop devices, if present, must be reset.
7. Ensure that no one is in the danger zone.

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9 Dismantling

9 Dismantling

9.1 Safety dismantling

• Only trained, specialized personnel should perform dismantling work.

• If the customer so desires the dismantling process can also be executed by VUL-
KAN employees.

DANGER!

Life-threatening danger due to commissioning and restarting without authorization!

When installing there is danger of the energy supply being switched on without authoriza-
tion. This poses a life-threatening danger for persons in the danger zone.
Therefore:
• Prior to starting the tasks switch off all energy supplies and safeguard them from
being switched on again.
• If combustion motors supply the motive power then the safety instructions and the
instructions for switching off and safeguarding against restart in the assembly manu-
als provided by the manufacturers must be complied with.

WARNING!

Life-threatening hazard - High elastic forces!

The rubber elements and the membrane can accumulate extreme quantities of energy
when they are deflected. Sudden loosening of obstructions can cause high energy move-
ments of coupling parts, and in the process cause life-threatening injury.
Therefore:
• Prior to working on the coupling ensure that it is force-free and that the resilient ele-
ments are not deflected.
• For tasks that require deflection of resilient elements only employ the work methods
described in this manual. Only use tools and clamping devices that are designed for
high forces.
• Only specialized personnel familiar with the installation should select the thrust bear-
ing required for deflection of the membrane assemblies.

9.2 Dismantling sequence

To ensure an ideal dismounting sequence, VULKAN recommends to comply with the

work steps described here.

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9 Dismantling

Note!
i Prior to dismounting any danger to persons and material damage must always be
excluded.
In case of any questions regarding dismounting, please contact the VULKAN customer
service (chapter "Customer service").

Note!
i To avoid material damage due to change in the direction of rotation, it is necessary to
check the markings of the elements (chapter "Marking") if reuse is planned.

9.2.1 Replacement element

Replacing the elastic element:

Note!
i When replacing an element the hub does not have to be dismounted! Sufficient space for
removal is provided by removing the bushes, membrane, spacer plates and the inner
cover ring!
1. Unscrew the fastening elements (10, 16, 17) and remove the bushes (18).

Fig. 9-1

Note!
i Secure the components against falling!

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9 Dismantling

2. Unscrew the fastening elements (9, 15) from the hub (1) and lift the inner cover ring
(6) with the spacer plates (4) and the membrane (3) out of the system.

Fig. 9-2

3. Unscrew the fastening elements from the elastic element (7) to the customer connec-
tion (S) (arrow) and lift the elastic element (7) radially out of the system.

Note!
i The fastening elements are not included in the VULKAN scope of delivery and must be
configured by the owner!

Fig. 9-3

4. Unscrew the catch bolts (20) with washers (21) and nuts (22) and re-insert them at
the same position in the new elastic element.

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9 Dismantling

Note!
i The tightening torques must be complied with!

20

Fig. 9-4

Note!
i For assembly of the coupling, see chapter "Mounting the coupling".

9.2.2 Dismounting the hub

Dismounting the hub - “feather key connection”

WARNING!

Life-threatening danger due to heavy dead weight and parts under tension when pulling
off the hub!
Life-threatening crushing injuries can result if the pull-off device slips or if the hub sud-
denly becomes detached from the shaft.
Therefore:
• Only specialized personnel familiar with the installation should select the thrust
mount required for the axial path limitation of the hub after loosening.
• If in doubt contact the manufacturer.

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Assembly Manual Vulkardan F

9 Dismantling

Note!
i The threaded rods and push-off devices described here are not included in the VULKAN
scope of delivery and must be configured by the owner.
The necessary tensile strength must be complied with in this regard.
1. Attach the hub to a suitable lifting gear (see Transport).
2. Attach a suitable device to push off the hub and build up axial pressure against the
shaft.
3. Heat the hub uniformly with a suitable burner so that the temperature is 150 to 200 °C
higher than ambient temperature. Bring the heat into the hub quickly, especially in the
area of the groove and the flange.

CAUTION!

Danger of burn injuries due to hot surfaces!

Contact with the heated hub or shaft can cause burn injuries.
Therefore:
• Always wear protective work clothing and protective gloves for all tasks performed in
the vicinity of hot components.
• After pulling off the hub and prior to further dismounting and transport, ensure that all
components have cooled to ambient temperature.

Fig. 9-5

Note!
i For thin-walled hubs the entire hub surface can be heated. For thick-walled hubs only
heat the base area and the areas above and opposite of the feather key. If there are
questions, contact VULKAN ("Customer Service").

56/62
Assembly Manual Vulkardan F

9 Dismantling

4. Uniformly increase the axial pressure until the hub detaches from the shaft. Comply
with the maximum load specifications of the push-off device (see separate operating
manual).

9.3 Disposal
If a return or disposal agreement has not been concluded, then recycle dismantled com-
ponents:

• Dispose of rubber mixtures in accordance with governmental guidelines.

• Sort and dispose of remaining components in accordance with national regulations

and with material condition.

• Remove fuels and auxiliary materials, as well as residual processing materials and
dispose of these items in an environmentally responsible manner.

57/62
 4 3 2 1
REVISIONS
REV DESCRIPTION BY/DATE APPROVED
A INITIAL RELEASE ASE/2024-07 MTM/2024-07

3 471.3 0.8
NOTES:
18.56 .03
1. REFER TO SERVICE MANUAL FOR
INSTALLATION INSTRUCTIONS.
D D
155.25 169.5 2. DELIVERY CONDITION ACCORDING TO
6.11 6.67 DRAWING AF-VKF-10-4400. ALL HARDWARE
SECURED WITH LOCTITE 242 AT FINAL
15 10 18 15 17 6
INSTALLATION.
18 18 18 18 18 .24

3 THE AXIAL SPACING DIMENSION MUST BE

10 15
CORRECTED FOR THE THERMAL EXPANSION OF
2 2
DETAIL B THE SYSTEM.

4. SEE CATALOGS FOR AVAILABLE STIFFNESSES.

15 9 9 15
24 24
A 24 24
DETAIL C 5 STANDARD: ANSI/AGMA 9112-A04
28 P9 ( -0.022
-0.074 )
-.001 SHAFT DIAMETER: 110n5 (+0.038MM/+0.023MM)
1.102 P9 -.002
INTERFERENCE RANGE: 0.053MM TO 0.090MM
M1
C C
101.3

11°
3.99 6 STANDARD: ANSI/AGMA 9103-C17
REMOVAL +0.5 GAUGE DIAMETER: 157.732MM 0.020
10

)
+.000

+.000
PUSH UP DISTANCE: 11.2MM +0.5MM

-.001

-.001

+.000
( -0.032

( -0.032
+.01

-.005
.04

-0.224
-0.264
157.732 0.02)
SETTING ANGLE: 0.5729 +0.0000/-0.0058

-.009
-.010
+.009

571.5 -0.127
-.00
-.000
+0.25

571.9
22.52
0

0
8.19

8.19
10.748 h6

10.748 h6
208

208

0
6.210 .000
0

GAUGE

22.500
159.2
6.268
116.4
4.583

1:50
273 h6

273 h6
175
6.89 175
6.89

(
6
M2

GAUGE
1 (101.6) 5

B
A 1 6
1 4.00 1
B
110 P6 ( -0.052 )
-0.030
5
-.002
4.331 P6 -.002
12 15
3 17 200-220 270-300
7020116000

1 22 22 12
7010416035
200-220 270-300
10 200-220 270-300
7001116070

9 215-235 290-320
7009916055

ITEM lb-ft Nm

7 8 BOLT TORQUES
BOLT TORQUES ARE BASED ON UNLUBRICATED CONDITIONS
1 1
TOTAL 118.7

SECTION A-A ITEM

M2
M1
14.69
11.42
1.66
1.29
146.1
115.6
66.3
52.4
NUMBER
120° lb-in-sec² kgm² lb kg
4 4 INERTIA WEIGHT
1 1 25
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION
This document, the technical information, and the subject matter thereof are
QUANTITY the exclusive property of American VULKAN Corporation. Any reproduction or
.98 OF ITEM
distribution thereof in whole or in part in any form or media without the
express written consent in advance in each case by American VULKAN Corporation
.04

is strictly prohibited.
G1/4"
1

UNSPECIFIED MILLIMETERS
A TOLERANCES:
ISO 2768-mK
INCHES
INCH VALUES ARE FOR
American VULKAN Corporation A
REFERENCE ONLY
12
.59

.5

CONTRACT NUMBER
15

COUPLING
CUSTOMER APPROVAL
DRAWN BY/DATE

ASE/2023-12
VKF 5710-4400
4 CHECKED BY/DATE SIZE FSCM/NSCM DRAWING NUMBER REV
.16 NAME MTM/2023-12 D 1F57105636 A
PICTORIAL VIEW
DETAIL B DETAILC ENG RELEASE BY/DATE SCALE
THIRD ANGLE
60248/D9090
SHEET

NO SCALE SCALE 2/1 SCALE 7/8 DATE 7/16 PROJECTION

DO NOT SCALE DRAWING
1 OF 1

4 3 2 1
 American VULKAN Corporation
P.O. Drawer 673, Winter Haven, Florida 33882
Tel (863) 324-2424 Fax (863) 324-4008

Parts List
Seq Part No Description Qty
1 4F5721Z299-ABS VKF 57 HUB 1.00
3 3F5724000M VKF 57 MEMBRANE SHEET 1.00
4 3K57260010 VKG 57 SPACER SHEET 2.00
5 4F5721Z300-ABS VKF 57 HUB 1:50 TAPER 1.00
6 3F57600000 VKF INNER COVER RING 1.00
7 2F5714A001 VKF 5714 ELEMENT SAE18 1.00
8 3F5767001M-ABS VKF 57 4400 ADAPTER RING 1.00
9 7009916055 CSCR SOCHD M16x1.5 X 55 -10.9 48.00
10 7001116070 BLT HEXHD M16 X 70 -10.9 20.00
12 7010416035 CSCR SOCHD M16 X 35 -10.9 22.00
15 7033616000 WSHR FL M16 108.00
17 7020116000 NUT HEX M16 -10 18.00
18 3F5449000M VKF 54 BUSHING 18.00

Date: 07/29/2024
Part No: 1F57145636-ABS
Description: VKF 5714-4400 CPLG
Page: 1 of 1
Assembly Manual Vulkardan F

10 Appendix

60/62
Assembly Manual Vulkardan F

11 Index

11 Index

A L
Alignment 28 Liability 6
Alignment - prerequisites 29 Limitation of liability 6
Alignment check 50
Alignment principles 28 M
Alignment tolerances 33 Maintenance schedule table 49
Assembly drawing 58 Measures after successful maintenance 51
Assembly Manual 5 Membrane 12
Assembly parts list 59 Mounting the coupling 33
Assembly sequence 25
Attachment 14 P
Personnel 44,48
C Preservation 17,17,18
Commissioning 24
Concluding tasks and final inspection 43 R
Consignment number 11 Replacing the elastic element 53
Contact 8
Customer service 8
S
Safety assembly 24,52
D Safety instructions 5
Dangers 10 Safety personnel 24
Delivery status 15 Spare parts 7
Dismounting sequence 52 Startup after troubleshooting 47
Displacement – angular 31 Storage 22
Displacement - axial 30 Structure and function 12
Displacement - radial 29 Structure and function of the hub 12
Disposal 57 Surface cracks 49
Disposal of packaging 16 Symbols on the packaging 14

E T
Elastic element 13 Technical prerequisites 6
Elastic forces 25,52 Transport 14
Environmental influences and storage of package 21 Transport – elastic element 20
Explanation of symbols 5 Transport – elastic part 20
Transport - membrane assembly 20
F troubleshooting 44,48
Fault table 44 Troubleshooting 46,46
Faults 44
Feather key connection 26 W
Warranty 7
H
Hot surfaces 26

I
Intended use 10
Irreversible deformation 50

61/62
Assembly Manual Vulkardan F

11 Index

62/62
 Mounting of hubs with cylindrical resp. Tapered bore with key

1. Clean the hub by customary detergents.

2. Control the key in the hub´s keywey (fit in, if necessary).
3. Clean the shaft and burr it.

Please note:
The hub´s position on the shaft is prescribed by the customer or by the shaft
manufacturer, e.g. by a limit stop, distance bush or special executions.

The lifting device shold be installed that way, so that the hub will move in direction of the
shaft when removing the wooden plate. The hub should be adjusted so far that only little
corrections by the threaded rods must be carried out, if necessary at all. It is easier to
push on a hub when the key is on the top.

4. Heat the hub up to approx. 150°C from the inside.

5. Wait until the hub has heated considerably.
6. Rub the shaft with oil (preferably hydraulic oil).
7. Push on the hub (up to 15 kg by hand, over 15 kg with a suitable lifting defice and
2 persons).
8. Press the hub against the limit stop until the heat has expended.

Mounting Instruction E12030

Herne, den 27.01.1997
 Installation and disassembly instruction for oil pressure units
with taper 1:30, 1:50 etc.

1. Installation instruction for hydraulic assembly

ATTENTION

To work according to the pressure oil method is safe, if the

operating instructions are observed and suitable, flawless
accessories are used.

Please pay attention to the following advice:

• Before operation, check the pump, the high-pressure pipe

and all accessories carefully. Never use even slightly
damaged accessories which are not designed for a pressure
of 300 mPa (3000 bar).
• Make sure that the air has been removed from the pump and
from the high-pressure pipe completely (they have to be filled
with oil).
• The pipe being under pressure is not allowed to be bent or
treated by force. Rough treatment of the pipe can cause
accidents.
• Wear safety glasses.
• In case of higher pressures it is always advisable to work
with pressure gauges.
• Oil under high pressure can cause personal injuries.
• Wear appropriate protective equipments while working with
high pressure oil systems.
• Do not allow high pressure oil to contact skin.

1.1 Checking of the component parts

Before fitting together the component parts (shaft and hub), an inspection of the
tapered surfaces has to be carried out. It has to be checked if the transition points at
Hydraulic installation of high-pressure units Sheet no. E 11198-1
Herne 2, 20.02.1996
 the tapered surfaces and at the oil distributing grooves are without burrs. Burrs and
possible damage have to be removed.

Remark for repair:

For repairs it can be necessary, depending on the nature

of the damage, to check the concentric running of the
shaft including taper and bearing seats.

1.2 Pressure device and preparations for fitting

The expanding of the part to be slipped on (hub) has to be carried out with oil SAE 10
(viscosity 32 cST at 40°C).
The oil used for expanding has to be absolutely free of any impurities and is not
allowed to contain any EP-additives. During installation, the component to be fitted
should have the same temperature. The fitting procedure should be carried out at
room termperature, if possible.
All tapered surfaces have to be cleaned by solvants thoroughly and to be spread with
hydraulic installation oil thinly. SAE 10 (viscosity 32cST at 40°C).

1.3 Control of the push-up distance

The push-up distance is given and can be taken from our mark (block stamp „push-up
distance“) on the component to be fitted.
The push-up distance is given in mm; it consists of the nominal measure and of the
permissible tolerance, for example 13,3 + 1,2 mm.
To determine the push-up distance, slide the component to be fitted (hub) onto the
shaft. The first control measure for checking the push-up distance of the component to
be fitted is calculated from the point at which the tapered surfaces are in snug contact
without pressure being applied.
For further control of the push-up distance, a reference edge has to be fixed. The
measuring edges at the shaft face have to be prefered in this connection.
the control measures.
Screw the tool (hydraulic jack) hand-tight against the component to be fitted.
Pay attention that all thread parts of the tool are screwed on each other completely
(see figure 1).

Connect the hydraulic devices.

For the expanding pressure: connection „B“

For the push-up pressure: connection „A“

Hydraulic installation of high-pressure units Sheet no. E 11198-2

Herne 2, 20.02.1996
 Figure 1: Assembly position

1.4 Expanding and fitting of the hub

To fit the hub, it has to be expanded.

For this purpose, the oil is pressed between the taper surfaces until it seeps at the end
of the unit.
The fitting procedure consists of a permanent mutual increase of the expanding and
the fitting pressure, until the hub has been pushed in its final position according to the
given push-up distance.
During the push-up procedure, the increase of the expanding pressure should not
exceed 100 bar per 3 minutes (to avoid that the max. permissible limits of elasticity
will not be exceeded locally).
After the hub has been pushed in the prescribed position, the expanding pressure
connection „B“ is reduced, so that the oil film between the tapered surfaces can
reduce.
A reduction of the push-up pressure connection „A“ is only allowed after one hour.
A 24 hours waiting period is required before the oil pressure unit can be fully loaded.
This time is necessary to ensure that the pressure liquid has completely drained from
the unit.

Hydraulic installation of high-pressure units Sheet no. E 11198-3

Herne 2, 20.02.1996
1.5

Remark:

For components to be fitted with 2 or more pressure connections,

for the expanding pressure, one pump for each connection has to be
installed.

2. Disassembly instruction for hydraulic disassembly

Attention:

Pressed on component to be fitted are under high pressure and can

cause injuries when they are removed. As the part to be re-moved
can suddenly snap loose, it is necessary to protect these
components with a stop.

To remove the hub from the shaft, the tool and the pressure oil devices have to be
positioned the same as for pushing on.
The piston has to be pressed out of the hydraulic jack (see figure 2) under conside-
ration of the max. push-up distance plus 3-4 mm and to be put against the component
to be removed with 100 bar pushing-on pressure in the hydraulic jack connection „A“.
Then lower the push-up pressure in the tool and shut the valve at the oil pump of the
hydraulic jack connection „A“.
To loosen the hub to be removed, it has to be expanded (connection „B“).
For this purpose the hydraulic oil is pressed between the tapered surfaces slowly.
The increase of the expanding pressure should not exceed 100 bar per 3 min.
The loosening of the component to be fitted is indicated by an increase of the
pressure in the hydraulic jack. This is visible at the pressure gauge for the oil pump,
connection „A“.
In case of a pressure increase in the hydraulic jack, the valve at the oil pump
connection „A“ has to be opened again and the pressure has to be let off. At the same
time the expanding pressure has to be be kept by permanent re-pumping (connection
„B“) until the component to be fitted has entirely separated from the taper seat.

Hydraulic installation of high-pressure units Sheet no. E 11198-4

Herne 2, 20.02.1996
 Figure 2: Disassembly position

If the maximum expanding pressure of 2000 bar is reached and the component to be
removed has failed to loosen:

• the expanding pressure connection „B“ has to be increased by 10 %

• the component has to be left under pressure for an hour

• additionally the component has to be heated (temperature max. 150°C or 294°F)

• additionally a puller has to be installed

Hydraulic installation of high-pressure units Sheet no. E 11198-5

Herne 2, 20.02.1996