DOCUMENTATION

VULKAN RATO-S Coupling

rigid membrane clamping

Customer: Caterpillar Motoren GmbH, 24159 Kiel

Dimension Group: G333T

Series: 2200

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
Technical data

RATO-S-333T

Nominal torque TKN = 63,0 kNm

Max. torque 1 Tkmax1 = 94,5 kNm

Max. torque 2 Tkmax2 = 284,0 kNm

Permissible vibratory torque TKW = 15,75 kNm

Permissible power loss PKV50 = 3,49 kW

Permissible revolutions/min. nKmax = 1350 rpm

Permissible axial shaft displacement ∆Ka = 7,0 mm

Permissible radial shaft displacement ∆K`r = 13,5 mm

Axial reaction force Fax1,0 = 0,4 kN

Radial stiffness Crdyn = 3,25 kN/mm

Dynamic torsional stiffness nominal C’Tdyn = 190,0 kNm/rad

warm C’Tdyn = 133,0 kNm/rad

Relative damping nominal ψ = 1,13

warm ψ = 0,79

Please pay attention to the instructions in the enclosed sheet RATO-ETD-1/1 - 7/1
for RATO couplings.
Technical data RATO-S-333T

General drawing 1G33300016

Partslist 1G333T0016

Flexible part EG3330A007

Partslist EG333TA007

Membrane dimension group 2G33R5013M

Partslist 2G33R5013M

Installation and Operating Instruction E 11109

Alignment Instructions „Alignment Instructions for highly-

flexible VULKAN-RATO-S/R-
Couplings“

Delivery condition AG33300016

Technical data RATO-S-333T

General drawing 1G33300033

Partslist 1G333T0033

Flexible part EG3330A007

Partslist EG333TA007

Membrane dimension group 2G33R5013M

Partslist 2G33R5013M

Installation and Operating Instruction E 11109

Alignment Instructions „Alignment Instructions for highly-

flexible VULKAN-RATO-S/R-
Couplings“

Delivery condition AG33300033

Echtfirma VULKAN: PRODUKTIONSSTÜCKLISTE OHNE SUFFIX Datum : 06.12.01 10:53
Seite : 1
gedruckt von: sprung
Fert.-Art. 1G333T0016
RATO-S Author : werner
Drawing 1G33300016 Info: Date : 21.11.2000
------------------------------------------------------------------------------------------------------------------------------------
Pos |Quant. |Article |Discription |Measurement |Material |Remark
-----+-------+----------------------+--------------------------------+---------------------+-----------------------+----------------
1 | 1|EG333TA007 |FLEX.ELEMENT | |ST/GUMMI |
| | | | | |
5 | 1|3G33B2000M |HUB |FM 545X 125 X300 |42CRMO4V |VERG.17200
| | | | | |
7 | 1|4G33B6001M |INN.CLAMP.RING |FM 545X 300 X351 |C45N |
| | | | | |
9 | 1|4G33630030 |SLEEVE BEARING |FM 376X 351 X 80 |LUYTEXC320 |
| | | | | |
10 | 1|2G33R5013M |MEMBRANE-DG. | | |
| | | | | |
18 | 24|3G33S9000M |HEX FITTEDBOLT |M 16X 17js6X105 |42CRMO4V |
| | | | | |
20 | 32|7001120060 |HEXAGON BOLT |M 20 X 60 |10.9 | 933M
| | | | | |
22 | 24|7000130100 |HEXAGON BOLT |M 30 X100 |10.9 | 931M
| | | | | |
27 | 24|7020116000 |HEX NUT |M 16 |10 | 934
| | | | | |
35 | 24|7033630000 |DISC |30 |42CRMO4V |VERG.17200
| | | | | |
39 | 32|7033620000 |DISC |20 |42CRMO4V |VERG.17200
| | | | | |
40 | 48|7033716000 |DISC |16 |42CRMO4V |VERG.17200
| | | | | |
50 | 32|7020120000 |HEX NUT |M 20 |10 | 934
Echtfirma VULKAN: PRODUKTIONSSTÜCKLISTE OHNE SUFFIX Datum : 15.01.02 07:19
Seite : 1
gedruckt von: sprung
Fert.-Art. 1G333T0033
RATO-S Author : grihn
Drawing 1G33300033 Info: Date : 11.01.2001
------------------------------------------------------------------------------------------------------------------------------------
Pos |Quant. |Article |Discription |Measurement |Material |Remark
-----+-------+----------------------+--------------------------------+---------------------+-----------------------+----------------
1 | 1|EG333TA007 |FLEX.ELEMENT | |ST/GUMMI |
| | | | | |
5 | 1|4G33B2015M |HUB |FM 545x237,4x300 |42CRMO4V |EN 10083-1
| | | | | |
7 | 1|4G33B6001M |INN.CLAMP.RING |FM 545X 300 X351 |C45N |
| | | | | |
9 | 1|4G33630030 |SLEEVE BEARING |FM 376X 351 X 80 |LUYTEXC320 |
| | | | | |
10 | 1|2G33R5013M |MEMBRANE-DG. | | |
| | | | | |
18 | 24|3G33S9000M |HEX FITTEDBOLT |M 16X 17js6X105 |42CRMO4V |
| | | | | |
20 | 32|7001120060 |HEXAGON BOLT |M 20 X 60 |10.9 | 933M
| | | | | |
22 | 24|7000130140 |HEXAGON BOLT |M 30 X140 |10.9 | 931M
| | | | | |
27 | 24|7020116000 |HEX NUT |M 16 |10 | 934
| | | | | |
35 | 24|7033630000 |DISC |30 |42CRMO4V |VERG.17200
| | | | | |
39 | 32|7033620000 |DISC |20 |42CRMO4V |VERG.17200
| | | | | |
40 | 48|7033716000 |DISC |16 |42CRMO4V |VERG.17200
| | | | | |
50 | 32|7020120000 |HEX NUT |M 20 |10 | 934
| | | | | |
61 | 1|4G3376017M |SPACER |FM 545X 408 X 49,2 |42CRMO4V |EN 10083-1
| | | |
Echtfirma VULKAN: PRODUKTIONSSTÜCKLISTE OHNE SUFFIX Datum : 06.12.01 10:54
Seite : 1
gedruckt von: sprung
Fert.-Art. EG333TA007
ELAST.TEIL Author : werner
Drawing EG3330A007 Info: Date : 21.11.2000
------------------------------------------------------------------------------------------------------------------------------------
Pos |Quant. |Article |Discription |Measurement |Material |Remark
-----+-------+----------------------+--------------------------------+---------------------+-----------------------+----------------
1 | 1|EG3315A004 |FLEX.ELEMENT |G 3315 |ST/GUMMI |
| | | | | |
1A | 2|EG33150011 |FLEX.ELEMENT | |ST/GUMMI |
| | | | | |
2 | 24|3G3372050M |HEX FITTEDBOLT |M 16X 17js6X 70 |42CRMO4V |
| | | | | |
3 | 24|7020116000 |HEX NUT |M 16 |10 | 934
| | | | | |
4 | 16|7000120075 |HEXAGON BOLT |M 20 X 75 |10.9 | 931M
| | | | | |
5 | 16|7020120000 |HEX NUT |M 20 |10 | 934
| | | | | |
6 | 16|4G3372006M |HEX FITTEDBOLT |M 20X 23js6X 75 |42CRMO4V |
| | | | | |
7 | 16|7020120000 |HEX NUT |M 20 |10 | 934
| | | | | |
8 | 1|4G33380010 |MEMBRANE |FM 995X 400 X 1.6 |50CRV4V |
| | | | | |
9 | 1|4G33780010 |CENTERING RING |FM 485X 376 X100 |C45N |
| | | | | |
10 | 1|4G33970010 |COVER |FM 485X 400 X 20 |C45N |
| | | | | |
11 | 32|7033620000 |DISC |20 |42CRMO4V |VERG.17200
| | | | | |
12 | 16|7001016060 |HEXAGON BOLT |M 16 X 60 |8.8 | 933M
| | | | | |
13 | 16|7020016000 |HEX NUT |M 16 |8 | 934
| | | | | |
14 | 48|7033716000 |DISC |16 |42CRMO4V |VERG.17200
| | | | | |
15 | 16|7033722000 |DISC |22 |42CRMO4V |VERG.17200
| | | | | |
16 | 16|7033620000 |DISC |20 |42CRMO4V |VERG.17200
Echtfirma VULKAN: PRODUKTIONSSTÜCKLISTE OHNE SUFFIX Datum : 06.12.01 10:57
Seite : 1
gedruckt von: sprung
Fert.-Art. 2G33R5013M
MEMBRANE-BG. Author : GRIHN
Drawing 2G33R5013M Info: Date : 14.10.1998
------------------------------------------------------------------------------------------------------------------------------------
Pos |Quant. |Article |Discription |Measurement |Material |Remark
-----+-------+----------------------+--------------------------------+---------------------+-----------------------+----------------
1 | 4|3G33R5030M |MEMBRANE |FM 995X 420 X 0.85|50CRV4 |
| | | | | |
2 | 16|3G33R80200 |SPACER SHEET |FM 700X 175.10X 0.25|CUSN6 F55 |
| | | | | |
3 | 20|3G33R70200 |SPACER SHEET |FM 379X 120 X 0.25|CUSN6 F55 |
| | | | | |
4 | 1|3G33S7000M |CLAMPING RING |FM1010X 899 X 56.20|C45N |
| | | | | |
5 | 32|3G33S20000 |DISC |FM 45X 22 X 5 |42CRMO4V |VERG.17200
| | | | | |
6 | 32|7001120060 |HEXAGON BOLT |M 20 X 60 |10.9 | 933M
| | | | | |
7 | 32|3G33S50000 |DISTANCE DISC. |FM 45X 22 X 0.25|CUSN6 F55
 Installation
and
Operating Instruction

for

Highly-flexible

VULKAN RATO-S-Couplings
Dimension Group 2100 and 2200
(without flywheel adapter)

Dimension Group G1930 - G 5630

Triple-Row Execution

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 E11109-1

Herne, 13.05.1997
Contents:

1. Generalities E11109

2. Installation of the coupling E11109

2.1 Design of the flexible part E11109

2.2 Installation of the flexible part E11109

3. Putting in operation and safety measures E11109

4. Maintenance E11109

5. Replacement of the flexible part E11109

5.1 Disassembly of the flexible part E11109

5.2 Assembly of the flexible part E11109

Installation and Operating Instruction E11109-2

Herne, 13.05.1997
1. Generalities

The highly-flexible VULKAN-RATO-S coupling is a rubber coupling, flexible in all directions.

Its essential parts are the flexible part, the membrane part and the connecting parts.
All connecting elements of the coupling are arranged without clearance, so no wear will oc-
cur during operation. For this reason the RATO-S coupling is free of maintenance.
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 flexible part is fit for use at ambient temperatures comprised between -50° (C) to +80°
(C). The segmental construction form of the flexible part guarantees good heat dissipation
properties. The free-of-play torque transmission in the coupling and the large sectional rub-
ber area of the flexible element provide good noise attenuation.
Basically, the connection surfaces and the fitted as well as the finish bores of the coupling
are protected by Tectyl. Prior to installation, these surfaces must be cleaned by conventional
solvants. When the cleaned surfaces are completely dry, they must be greased lightly.

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

The torsional vibration behaviour of the driving system has been checked and approved by
the classification society. The expected and satisfactory behaviour is guaranteed only, provi-
ded that all components comply to the values, the torsional vibration calculation is based
upon. With respect to the coupling, this means to exactly keep to the dynamic stiffness and
damping.
In case of a replacement of the elements, only original VULKAN elements with coordinated
technical data approved by the classification societies must be used!
To guarantee faultless function and optimum usage of the highly-flexible RATO-S coupling,
certain installation instructions have to be observed. Basically, each bolt connection partici-
pating in the transmission of the torque must be tightenend by means of a torque spanner.
The individual tightening torques are given on the general drawing of the RATO-S coupling
and on the drawing of the flexible part.

In case of a flexible mounted system, please agree the alignment with the manufacturer of
engine, coupling and gearbox.

2. Installation of the coupling

As the coupling is supplied in the partially assembled condition, extensive disassembly work
will not be necessary in order to carry out the installation.
Only the connection elements for connecting the individual flexible segment-rows must be
removed.

Installation and Operating Instruction E11109-3

Herne, 13.05.1997
First the hub (5) with the connecting parts must be mounted on the shaft butt end of the
driven machine using a method meeting the requirements of modern engineering practice.
Both machines must be positioned to the installation dimension of the coupling and must be
aligned to the instructions given in sheet E 10341.
Possible thermal expansions specific to the system involved must be taken into account.
In order to guarantee an optimal life expectancy for the bearing bush (9) it is necessary to fit
in the bearing bush (9) and then to grease the inner and outer circumference.
Only grease without a solid matter supplement is to be used.
Now the membrane support is pushed over the bearing bush (9).
Then you can start to install the flexible part (1).

2.1 Design of the flexible part

Prior to describing the assembly, we would explain you the design of the flexible part (1).
The flexible part consists of three flexible segment-rows.
Each flexible segment-row again is divided into four flexible segments.
The position of the flexible segments and segment-rows towards each other has been
marked.
More detailed information on the marking is given in the enclosed sheet E 10623.

2.2 Installation of the flexible part

For assembly, each RATO-segment should be put into a lifting device using suitable aids.
First the RATO-segments of the first row (drawing no. (2) EG...) should be installed one after
the other and must be connected firmly with the flyhweel by means of the corresponding
fixation elements. The prescribed tightening torque for the corresponding screw quality must
be kept.
In case of using 10.9 bolts, please provide hardened washers.

During the tightening process please check whether the outer circumference of the
respective RATO-segment is in metallic contact with the centering of the flywheel!

Now the RATO-segments of the second row should be installed one after the other and
connected firmly with the RATO-segments of the first row by the corresponding fixation
elements. The prescribed tightening torque (3), given on drawing no. (2) EG..., must be kept.
Attention must be paid that the second row of the RATO-segments is displaced by 45° to the
first row, so that a closed-ring formation is obtained (figure 1).

Installation and Operating Instruction E11109-4

Herne, 13.05.1997
 Figure 1

Then the RATO-segments of the third row should be installed one after the other and
loosely connected with the RATO-segments of the second row as well as the membrane
lying in between by means of the respective fixation elements. The third row of the RATO-
segments must be displaced by 45° to the second row (figure 1).

In order to install the third RATO-segment row, the membrane dimension group (10) must
be deflected. In order to carry out the deflection, two ring bolts must be screwed into the
radial threaded bores in the clamping ring (4, drawing no. 2G...), one beside the other.

Then turn this side until these two ring bolts point upwards in a symmetrical position to the
axis of the RATO-S coupling.

After having connected an appropriate traction device to these ring bolts, the membrane
dimension group (10) can be deflected as far as to permit one segment to be placed in this
location (figure 2).

Then the alignment of both RATO segments-rows with the

membrane lying in between must be carried out. Reference
surface for the alignment is the outer diameter of the membrane.
The alignment can be made by use of a straight edge. After both
RATO segment-rows have been aligned, this connection must be
tightened firmly. The tightening torques (5, 7), given on the
drawing no. (2) EG..., must be kept. Now the RATO segments of
Figure 2 the third row must be firmly connected with the membrane
dimension group (10).
The tightening torque (27), given on the general drawing, must be kept.
After this has been done, the highly-flexible VULKAN RATO-S coupling is tightly connected
to the system.

Installation and Operating Instruction E11109-5

Herne, 13.05.1997
3. Putting in operation and safety measures

After the installation has been carried out, the drive system is ready for operation, as far as the
coupling is concerned. We would like to point out that before the first operation you have to
make sure that all installation aid devices have been removed from the coupling.
The coupling must be shielded according to the safety regulations. These shields should be
made from perforated sheet or wire mesh, if it is not in contradiction with prevailing
requirements, in order to guarantee adequate ventilation of the coupling.

4. Maintenance

The highly-flexible VULKAN RATO- S coupling does not require maintenance.

We recommend, however, an annual alignment control and a check of the flexible part (1).

5. Replacement of the flexible part

VULKAN RATO-S couplings are not subject ot wear. Should, however, due to an inad-
missible load a damage occur to the flexible part installed, the individual segments can be
replaced without having to displace the driving or the driven machine.

We would like to explain replacement of the flexible part in detail as follows:

5.1 Disassembly of the flexible part

First remove the fixation elements (18, 27, 40).

Then take out the fixation elements arranged for the connection of the two flexible segment-
rows.

Now the first four segments can be disassembled using an appropriate lifting device. The
membrane dimension group (10) must be deflected as required (figure 2).
When removing the segments, care must be taken not to damage the centering of the
respective counterpieces.
After the fixation elements installed at the other side of the individual segment have been
removed, the next four segments can be disassembled one after the other.
Now the remaining segments can be removed one after the other.

Installation and Operating Instruction E11109-6

Herne, 13.05.1997
Please note: If one segment is damaged, it is a basic requirement to replace all other
segments of the segment-row concerned, too.
When ordering spares for the flexible part (1) or one segment-row
respectively, the following information has to be given with respect to the
coupling:
1. order no.
2. drawing no.
3. partslist no.

5.2 Assembly of the flexible part

Before starting the assembly, it is recommended to check the alignment of the system.
The procedure for assembling the flexible part has already been described in paragraph 2.
After the assembly has been finished, the system is ready for operation, as far as the
coupling is concerned.

Installation and Operating Instruction E11109-7

Herne, 13.05.1997
Kriterien für die Beurteilung von
VULKAN-RATO-S-/R-Kupplungen
Die außenliegenden Oberflächen einer rotierenden
Kupplung sind im ständigen Kontakt mit der sie
umgebenden Luft. Dies gewährleistet eine gute
Belüftung der Kupplung, bringt sie aber gleichzeitig
auch in Kontakt mit Sauerstoff, Ozon und besonders
aggressiven Abgasen. In Kombination mit Tempera-
turschwankungen, Feuchtigkeit und UV-Strahlung
kann dies zu irreversiblen Veränderungen der Mate-
rialstruktur an der Oberfläche des Gummis führen.
Diesen nicht vermeidbaren Prozeß nennt man
”ALTERN“.
Da das ”ALTERN“ durch die Kombination der unter-
schiedlichsten Einflüsse hervorgerufen wird, ist es
nicht möglich, den Vorgang unter Laborbedingungen
zu simulieren. Um trotzdem eine Aussage über den
Einfluß der ”ALTERUNG“ auf die Betriebssicherheit
der Kupplung machen zu können, wurden RATO-
Kupplungen mit einer langen Betriebszeit von
VULKAN untersucht. Die Ergebnisse dieser Unter-
suchungen sind in den folgenden Abschnitten
zusammengefaßt.
Bedingt durch den konstruktiven Aufbau der Ele-
mente und die verschiedenen Beanspruchungsarten
und -größen zeigen sich nach einer mehr oder
weniger langen Betriebszeit an den Elementen
Gebrauchsspuren. Die häufigsten Erscheinungs-
formen sind:
1. Bleibende Verformung
Bild 1
Figure 1
Die Kontrolle der bleibenden Verformung eines
RATO-S-Segmentes erfolgt durch die Ermittlung von
”s” am äußeren Durchmesser des Gummielementes
(Bild 1). Bei einem RATO-R-Element kann das Maß
”s” über die Verformung der Gummiwulst ermittelt
werden (Bild 2).
Überschreitet die vorhandene Verformung ”s” die
Werte in der folgenden Tabelle, müssen die elasti-
schen Teile ausgetauscht werden; andernfalls sind
die elastischen Teile für den weiteren Betrieb
geeignet, sofern keine anderen Anzeichen für eine
Schädigung der elastischen Teile vorhanden sind.
Criteria for the inspection of
VULKAN-RATO-S/R couplings
The outer surface of a rotating coupling is contin-
uously in contact with the surrounding air.
This ensures a good ventilation of the coupling but
also gives rise to permanent contact with oxygen,
ozone and especially aggressive exhaust gases.
This, in combination with temperature, humidity and
UV-radiation, causes irreversible changes in the
material structure at the external surface of the
RATO segment. This unavoidable process is gener-
ally known as AGEING.
Due to the fact that AGEING is a combination of
various influences it is impossible to simulate under
laboratory conditions. VULKAN has therefore exam-
ined RATO elements, with a long operational life,
to investigate the influence of AGEING on the
operational-safety of the coupling.
The results of these investigations can be summa-
rized as follows.
Due to the constructional design of the element,
and the different types and values of stresses,
the element will, after a certain period of service,
show indications of having undergone operational
service. The most frequent symptoms are:
1. Permanent set
Bild 2
Figure 2
To determine the permanent set of a RATO-S seg-
ment the dimension ”s”, measured at the outer
diameter of the coupling segment, is determined
(figure 1). The permanent set ”s” of a RATO-R
element can be measured through the deformation
of the rubber roll (figure 2).
If the permanent set ”s” exceeds the criteria in the
following table, the elements must be replaced;
otherwise the elements are suitable for further
service provided there are no other indications of
elements damage.
S/R-CRIT-1/1
 Zulässige bleibende Verformung für ein RATO-S-Segment
Permissible permanent set for a RATO-S segment

Baugröße X = 1 X=2 X=7 X=W X=T Baugröße X = 1 X=2 X=7 X=W X=T
Size mm mm mm mm mm Size mm mm mm mm mm

141 X 19,0 12,0 20,0 – – 391 X 67,0 38,0 67,0 – 67,0

151 X 23,0 16,0 23,0 – – 431 X 73,0 42,0 76,0 – 73,0
161 X 24,0 17,0 26,0 – – 451 X – – – 105,00 105,00
171 X 26,0 18,0 30,0 – – 461 X 34,0 20,0 41,0 – 34,0
191 X 28,0 19,0 27,0 – – 481 X 67,0 40,0 82,0 – 67,0
211 X 30,0 20,0 36,0 – 30,0 491 X 36,0 22,0 44,0 – 36,0
231 X 32,0 22,0 34,0 – 32,0 511 X 72,0 43,0 78,0 – 72,0
251 X 36,0 22,0 38,0 – 36,0 531 X – – – 120,00 120,00
271 X 37,0 24,0 38,0 – 37,0 541 X 39,0 23,0 48,0 – 39,0
031 X – – – 55,0 55,0 561 X 88,0 47,0 95,0 – 88,0
291 X 41,0 26,0 44,0 – 41,0 581 X 94,0 56,0 103,00 – 94,0
311 X 49,0 28,0 51,0 – 49,0 601 X 47,0 28,0 52,0 – 47,0
051 X – – – 65,0 65,0 631 X – – – 85,0 85,0
331 X 53,0 31,0 51,0 – 53,0 651 X 51,0 30,0 56,0 – 51,0
341 X 58,0 33,0 59,0 – 58,0 681 X – – – 103,00 103,00
081 X – – – 75,0 75,0 701 X 55,0 33,0 60,0 – 55,0
361 X 62,0 36,0 64,0 – 62,0 731 X – – – 110,00 110,00
381 X – – – 90,0 90,0

Zulässige bleibende Verformung für eine RATO-R-Reihe

Permissible permanent set for one RATO-R row

Baugröße X = 1 X=2 X=7 X=5

Size mm mm mm mm

161 X 23,0 14,0 25,0 21,0

171 X 25,0 15,0 27,0 22,0
191 X 27,0 16,0 29,0 27,0
211 X 29,0 18,0 32,0 24,0
231 X 31,0 19,0 35,0 28,0
251 X 35,0 21,0 39,0 30,0
271 X 38,0 23,0 42,0 34,0
2 271 X 2 23,0 14,0 26,0 32,0
291 X 40,0 24,0 45,0 26,0
2 291 X 2 25,0 15,0 27,0 26,0
311 X 45,0 27,0 50,0 41,0
2 331 X 2 30,0 18,0 33,0 27,0
2 341 X 2 39,0 23,0 42,0 35,0

2 3reihige Elemente
3 row elements

Werden die zulässigen Werte durch die vorhandene It is advisable to determine and eliminate the
Verformung überschritten, sollten, bevor die neuen reasons for the permanent set, that is in excess of
Elemente eingebaut werden, die Ursachen für die zu the permissible values given in the table, before
große bleibende Verformung beseitigt werden. installing replacement elements.

S/R-CRIT-2/1
2. Oberflächenrisse 2. Cracks

Der ”ALTERUNGSPROZESS” führt zu einer Ober-
flächenverhärtung des Gummis und dadurch zu einer
verringerten Elastizität der Oberfläche. Durch die
Verformung des elastischen Teiles im Betrieb kann
es deshalb zu Rissen kommen, die bis zu einer
begrenzten Tiefe zulässig sind (Bild 3).
AGEING gives rise to a hardening of the surface
rubber. Due to the reduced elasticity at the outer
surface cracks can be formed when the elements
are deformed during service. Cracks with a depth
LESS than the permissible value are acceptable
(figure 3).

Bild 3 Bild 4
Figure 3 Figure 4

Nach unseren heutigen Erfahrungen kann man einen
Riß im elastischen Teil einer RATO-S-/R-Kupplung bis
zu einer Tiefe von ca. 5 % der radialen Gummihöhe
auf dem kompletten Umfang als zulässig betrachten
(Bild 4).
According to our present experience, for a
RATO-S/R flexible element a crack with a depth of
about 5 % of the segment’s radial thickness of the
total circumference is to be considered acceptable
(figure 4).

Risse sollten so bald wie möglich ausgeschliffen The cracks should be ground out as soon as
(ausgemuldet) werden. Diese von Stahl- und Gußtei- possible. This procedure, usually used for steel and
len bekannte Methode kann auch bei Gummikörpern cast components, can also be used for rubber
angewendet werden. elements.

Zulässige Rißtiefe einer RATO-S-/R-Kupplung

Permissible crack depth of a RATO-S/R coupling

Baugruppe Tiefe / Depth [mm] Baugruppe Tiefe / Depth [mm]

Dimension Dimension
group RATO-S RATO-R group RATO-S RATO-R

1410 5,0 3610 14,0

1510 6,0 3910 15,0
1610 6,0 6,0 4310 16,0
1710 6,0 6,0 4610 18,0
1910 7,0 7,0 4810 18,0
2110 7,0 7,0 4910 19,0
2310 8,0 8,0 5110 19,0
2510 9,0 9,0 5410 20,0
2710 9,0 9,0 5610 20,0
2910 10,0 10,0 5810 22,0
3110 11,0 11,0 6010 22,0
3310 12,0 12,0 6510 24,0
3410 13,0 13,0 7010 25,0

S/R-CRIT-3/1
Richtlinien für
VULKAN-RATO-S-/R-Kupplungen sind:
– Risse sollten so bald wie möglich ausgeschliffen
(ausgemuldet) werden. Das Ausmulden kann
durch unsere Monteure durchgeführt werden
oder mit Hilfe der Arbeitsanweisung „Schleifen”
durch den Kunden.
– Wenn ein Riß entdeckt wird, sollte seine Tiefe
und Länge markiert werden.
– Zur Überwachung des Risses sollte seine Länge
markiert werden.
– Es ist wichtig festzustellen ob die Anlage abnormal
arbeitet oder gearbeitet hat.
– In vielen Fällen ist die Kupplung ein Indikator für
eine Fehlfunktion der Anlage. Wenn trotzdem
keine Fehlfunktion festgestellt werden konnte,
sollte die Kupplung in kürzeren Intervallen über-
prüft werden.
– Sind Risse durch Überlastung der Kupplung
entstanden und die Ursachen werden nicht be-
seitigt, wird der Riß weiter wachsen.
– Ist die Kupplung durch eine „einmalige Fehl-
funktion“ der Anlage beschädigt worden,
kann sich das Schadbild auch unter normalen
Betriebsbedingungen verschlechtern.
– Wird die zulässige Tiefe eines Risses überschrit-
ten, wird empfohlen, das betreffende Element
baldmöglichst auszutauschen.
Inspektionsintervall für RATO-Kupplungen
– Wenn nach einer Inspektion Oberflächenrisse
gefunden wurden, die die zulässigen Werte in
den Tabellen nicht überschreiten, dann sollte das
Wachstum des Risses innerhalb von 3 Monaten
noch einmal überprüft werden.
– Wenn die Kupplungsbelastung zulässig ist und
der Riß sich zwischen zwei Inspektionen nicht
wesentlich verändert hat, ist der Riß auf Grund
von „ALTERUNG“ entstanden. Weitere Inspek-
tionen können dann alle 6 Monate durchgeführt
werden.
– Wenn die Kupplungsbelastung zulässig ist und
der Riß durch eine „einmalige Fehlfunktion“ der
Anlage entstanden ist, muß diese gefunden und
behoben werden. Eine Überprüfung sollte dann
nach 3 Monaten durchgeführt werden oder sobald
es zu einer weiteren Fehlfunktion der Anlage
kommt.
– Wird die zulässige Tiefe eines Risses überschrit-
ten, wird empfohlen, das betreffende Element
baldmöglichst auszutauschen.
S/R-CRIT-4/1
A guidance for
VULKAN-RATO-S/R couplings is as follows:
– The cracks should be ground out as soon
as possible.
This can be done by a VULKAN service engineer,
or the operator can, by using the instructions for
„grinding“, do the job.
– When a crack is noticed, the depth and length
must be measured.
– To aid surveillance of the crack, the length
should be marked.
– It is important to check if the installation is
operating / or has operated abnormally.
– In many cases the coupling acts as an indicator
of installation malfunction.
When no system malfunction can be determined,
then the coupling has to be checked at shorter
intervals.
– When the cracks formed are due to an over-
loading of the coupling and this is not corrected,
the crack will continue to grow.
– An ”unique event” can damage the coupling.
This, however, does not infer, that when the
installation operates ”normally” that the damage
situation will not get worse.
– If the crack depth exceeds the permissible,
we recommend to replace the relevant row
as soon as possible.
Interval for checking RATO couplings
– When, after checking a RATO coupling, surface
cracks have been found which have a depth LESS
than the maximum value given in the table, a
”2nd measurement” of the crack dimensions
should be made at an interval of about 3 months
in order to check crack growth.
– Assuming that the coupling itself is subjected to
permissible load levels, the crack can be defined
as being the result of AGEING, when the crack
dimensions do not significantly change in the
interval between the tests. Subsequent checks
every 6 months can be made.
– After a system ”unique-occurance”, cracks can
appear in couplings that normally operate within
their permissible limits. The reason for the mal-
function must be investigated and repaired.
A check on the crack is necessary after 3 months.
In case of new system malfunction, the coupling
has to be re-checked.
– If the crack depth exceeds the permissible,
we recommend to replace the relevant segment
row as soon as possible.
Arbeitsanweisung Schleifen
Die Arbeitsanweisung Schleifen ist ein Bestandteil
der Kriterien für die Beurteilung von RATO-S-/R-
Kupplungen. Die Nacharbeit der Risse in dem Gummi
der Segmente/Elemente kann mit einem geeigneten
Bandschleifer durchgeführt werden.
Diese Bandschleifer sind als Elektrobandschleifer und
Pneumatikbandschleifer im Fachhandel erhältlich.
Die Schleifbänder dafür gibt es in drei verschiedenen
Körnungen (fein, mittel, grob).
Beim Schleifen ist darauf zu achten, daß die Tempe-
ratur bei der Abschlußbehandlung am Ende des
Schleifvorganges nicht zu hoch wird und das Mate-
rial Gummi aushärtet.
Die Ausmuldung der Risse soll nach Möglichkeit
sehr sauber gerundet sein und keine scharfen
Kanten aufweisen.
Die bearbeitete Fläche sowie die Oberfläche
der elastischen Elemente muß abschließend mit
VULKANOX behandelt werden.
Anbei die Bilder über Werkzeuge und nachgearbei-
tete Segmente.
Working instruction „grinding“
The working instruction „grinding“ is one com-
ponent of the criteria for the inspection RATO-S/R
couplings. The rework of the cracks in the rubber of
the segments/elements can be done with a suitable
belt grinder.
These belt grinders are available in specialist shops
as electric and pneumatic belt grinders. The abrasive
belts are available in three different coarseness
(fine, medium, rough).
When grinding you should take care that the
temperature is not too high at the final end
of the grinding procedure and the material rubber
not hardened.
The moulding of the cracks should be, if possible,
very accuratly rounded and should not show
sharp corners.
The reworked area as well as the surface
of the flexible elements must be coated finally
with VULKANOX.
Enclosed you will find photos about tools and
reworked segments.
S/R-CRIT-5/1
Die Nacharbeit der Risse kann mit einem
geeigneten Bandschleifer durchgeführt
werden.
Die Schleifbänder dafür gibt es in drei
verschiedenen Körnungen (fein, mittel, grob).

The rework of the cracks can be done with

a suitable belt grinder. The abrasive belts are
available in three different coarseness
(fine, medium, rough).

S/R-CRIT-6/1
Bearbeitete Segmentkanten.

Segment corners reworked.

S/R-CRIT-7/1