Installation & Operating Manual (IOM)

JAW-FLEX Coupling
Series : L,RFC,RRJ,SW,H,RRL,RRS,SWQ,HR,SWS

L RFC RRJ

SW H RRS

SWQ HR SWS
RATHI TRANSPOWER PVT.LTD.
R-II-D-03/02-09/20 Gaia Apex,S No 33/2D,Viman Nagar
Pune, 411014
Installation & Operating Manual /JAW-FLEX Coupling
/L,RFC,RRJ,SW,H,RRL,RRS,SWQ,HR,SWS

INDEX

Page No

1. Introduction & General Guidelines 02

2. Before installation information 02

3. Installation Information 04

3.1 Finish Bore Instruction 04

3.2 Hub Mounting 04

3.3 Shaft Alignment 06

3.4 Final Assembly 09

4. Safety,General Hazard & Environment 10

5. Inspection & Periodic Maintenance 10

6. Spares Management & Complaint Handling 11

7. Breakdown & Trouble-shoot 14

8. Marking Details 15

9. Declaration of conformity 16

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1. Introduction & General Guidelines
 Jaw flex couplings are designed to transmit torque between drive and driven shaft using rubber
element, which compensate radial, angular and axial misalignment and reduce the effect of socks
& vibrations.
 This manual will help you to install and maintain Jaw flex couplings before installing/disassembling
of coupling. It is advisable to read the manual carefully before starting the work.
 Symbol description :
Caution person may get injured

Damage the product

Pay attention

Potentially explosive warning

2. Before installation information

 RN couplings are delivered by RTPL as assembled condition which consists components as shown
in fig. 1.1 & 1.2.
 Inspect coupling assembly for visible damage, if you found contact RATHI.
 Dismantle the coupling; remove protective coating/lubricants from coupling components.

RRS H SWQ
Part No. Component Qty Part No. Component Qty. Part No. Component Qty.
1 Driving Hub 01 1 Driving Hub 01 1 Hex HD Bolt 06
2 Screw 01 2 Screw 01 2 Driving Hub 01
3 O/S Ring 01 3 O/S Ring 01 3 Spacer 02
4 Snap Wrap 14 4 Snap Wrap 14 4 T Cushion 06
5 Spacer 01 5 Spacer 01 5 O/S Ring 01
6 Driven Hub 01 6 Driven Hub 01 6 Screw 03
7 Driven Hub 01

Fig 1.1

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L RFC RRJ

Part No. Component Qty.

1 Driving Hub 01

2 Spider 01

3 Driven Hub 01

SW HR SWS
Part No. Component Qty. Part No. Component Qty. Part No. Component Qty.
1 Driving Hub 01 1 Hex HD Bolt 44 1 Driving Hub
2 Snap Wrap 01 2 Driving Hub 01 2 Spacer
3 O/S Ring 01 3 O/S Ring 01 3 Hex HD Bolt
4 Screw 03 4 Allen HD Bolt 11 4 Hex HD Bolt
5 Driven Hub 01 5 Driving Adaptor 01 5 O/S Ring
6 Cushion 01 6 Jaw Body
7 I/S Ring 01 7 T Cushion
8 Driven Adaptor 01 8 Driven Hub
9 Driven Hub 01 9 Hex HD Bolt

LLL

Fig 1.2

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3. Installation Information

 Ensure the system is disconnected from electrical connection and other possible energy
transmission before starting the work.
3.1 Finish Bore Instruction (Fig. 2.1 & 2.2)
 Hub finish bores machined by customer with
reference to flange outside diameter.
 Finish bore strictly done within specified
limit (H7, Js9 ).
 Maintain face run-out and concentricity as per below table. Fig. 2.1

Outside diameter Face run-out/

(mm) Concentricity(mm)
10-180 0.04
180-400 0.08
400-630 0.1
 Mark the keyway centre line such that keyway should Fig.2.2
come between two jaws (For L, SW, RRS, H, RFC, RRJ & RN hubs, refer Fig. 2.1) and between
two holes (For SWQ, SWS & HR hubs, refer Fig. 2.2).
 Provide set screw at distance LTB /2. If it is not possible, suitable distance nearer to midpoint
of the length through bore (LTB) is provided.
3.2 Hub Mounting.
 Mount hubs/adapters on their respective shafts with keys such that the shaft ends are flush
with inner face of the adapter & tighten the set screw over the keys.
 Insert the spider in one of the hub. Bring both the coupling hubs (along with equipments)
closer so as to maintain gap `G' as shown in fig. 3.1 and to maintain assembled length `F' as
shown in fig. 3.1. Dimensions `G’ & ‘F’ are given in table 2.1 & 2.2.

Fig.3.1 for Non-Spacer coupling

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 In case of Non-spacer couplings the distance between shaft end (DBSE) is equal to the total
length of the coupling less length through bore of both the hubs.
 In case of spacer type of couplings, the spacer length is normally equal to the distance
between shaft ends of the equipments. Refer fig. 2.1 & 2.2.

Fig.3.2 for Spacer-type coupling

 For normal applications the shaft ends should be flush with inner face of hub. They can
protrude beyond the inner face of hub or remain inside if required, but sufficient gap should
be allowed to take care of end float of both shafts (i.e. axial misalignment)
 For H & HR couplings Insert the inner ring before bringing the equipments to their final
mounting positions.
 In case of couplings with outer ring (i.e. SW, SWS, RRS, SWQ, H & HR) mount the outer ring
on one of the hub and slide it towards the nearest equipment.

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3.3 Shaft Alignment.
 In order to achieve optimum service life of the coupling, shafts must be aligned.
 Initial misalignment should not be more than 25 % of maximum misalignment
(Refer Table 2).
Table 1 : Method of misalignment

Method Parallel/Radial Angular

Using dial gauge Using dial gauge

 Clamp dial gauge on the hub of one of the half & set plunger on the OD of another
half.
 Note the reading at each quarter rotation of hub by rotating one end.
 P or X is half the Total Indicated Reading (TIR) shown on dial gauge, which should
not be more than value of allowable initial misalignment.
Using straight edge Using filler gauge

 If the field constraints do not permit to use dial gauge then alternatively use
straight edge & filler gauge to measure parallel and angular alignment
respectively.
 Note the reading og Gap ‘G’ at each quarter without rotating shafts. The
difference in maximum & minimum gap will be the Total Indicated Reading (TIR)

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Table 2.1 : PERMISSIBLE MAXIMUM MISALIGNMENTS/TIGHTENING TORQUE
(L,SW,SWQ,RRS,H,HR)
Permissible Maximum Mis-alignment
Coupling *
Angular Parallel /
Axial GAP
Total Indicated Radial ‘G’ Tightening
Degree (mm)
Type Size Reading ‘P’ Size Torque
(°) () (mm)
(TIR) mm mm (Nm)
035 1° 0.27 ±0.5 0.4 1 - -
050 1° 0.40 ±0.5 0.4 1 - -
L
070 1° 0.6 ±1 0.4 2 - -
075 1° 0.7 ±1 0.4 2 - -
095 1° 0.9 ±1 0.4 2 M6 5
099 1° 1.1 ±1 0.4 2 M6 5
L,
100 1° 1.1 ±1 0.4 2 M6 5
SW,
110 1° 1.4 ±1.5 0.4 3 M8 12.5
RRS,
150 1° 1.6 ±1.5 0.4 3 M10 25
SWQ- 190 1° 2.0 ±1.5 0.4 3 M10 25
226
225 1° 2.2 ±1.5 0.4 3 M12 44
226 1° 2.4 ±1.5 0.4 3 M12 44
276 1° 2.7 ±1.5 0.4 3 M12 44
L , SW,
280 1° 3.3 ±1.5 0.4 3 M14 70
SWQ,
295 1° 4.1 ±1.5 0.4 3 M16 107
SWS
2955 1° 4.1 ±1.5 0.4 3 M16 107
SW,SWQ 300 1° 4.4 ±1.5 0.4 3 M20 215
SWS 350 1° 5.3 ±1.5 0.4 3 M20 215
307 1° 4.4 ±1.5 0.4 3 M16 107
H,HR 357 1° 4.9 ±1.5 0.4 3 M16 107
367 1° 5.3 ±1.5 0.4 3 M16 107
407 1° 5.9 ±1.5 0.4 3 M16 107
457 1° 6.8 ±1.5 0.4 3 M16 107
509 1° 7.0 ±3 0.4 6 M16 107
609 1° 7.7 ±3 0.4 6 M16 107
709 1° 8.8 ±3 0.4 6 M16 107
HR 809 1° 10.0 ±3 0.4 6 M20 215
911 1° 11.0 ±3 0.4 6 M20 215
# 1013 - - - - - - -
# 1015 - - - - - - -
# 1115 - - - - - - -
# 1117 - - - - - - -

 In case of RRS couplings, double the values of axial & angular misalignment for
corresponding size.
 For RRS (sizes from 095 to 226) Parallel misalignment = 0.005 mm per mm of DBSE
 For eg. If DBSE is 140mm then Parallel misalignment will be, 140X0.005=0.7mm.
 * Gap ‘G’ in the above table is when angular and axial misalignments are zero.
 # Products are under development, data will be updated later.

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Table 2.2 : PERMISSIBLE MAXIMUM MISALIGNMENTS (RRJ & RFC)

Permissible Maximum Mis-alignment

Coupling *
Angular Parallel / Assemble
Axial GAP
Total Indicated Radial Length ‘F’
Degree (mm) ‘G’
Type Size Reading ‘P’ (mm)
(°) () (mm)
(TIR) mm mm
19 0.8° 0.78 1.6 0.15 2 -
24 0.8° 0.94 1.8 0.20 2 -
28 0.8° 1.13 2 0.20 2.5 -
38 0.9° 1.48 2.2 0.25 3 -
42 0.9° 1.68 2.3 0.30 3 -
RRJ
48 1° 2.01 3 0.35 3.5 -
55 1° 2.22 3 0.35 4 -
65 1° 2.39 3.5 0.40 4.5 -
75 1.1° 2.74 3.5 0.45 5 -
90 1.1° 3.35 4.5 0.50 5.5 -
7 1° 2.2 ±0.2 0.3 - 28
9 1° 2.4 ±0.5 0.3 - 34.5
11 1° 2.7 ±0.6 0.3 - 45
13 1° 3.3 ±0.8 0.4 - 54
RFC 15 1° 4.1 ±0.9 0.4 - 60
18 1° 4.1 ±1.1 0.4 - 73
23 1° 4.4 ±1.3 0.5 - 84.5
28/28A 1° 5.3 ±1.7 0.5 - 107.5

 Distance ‘F’ in above table is given when angular and axial misalignments are zero.

Note:
 Given tightening torques are for the bolts engaging with the spacer & driving/driven hubs.
 Consult M/s RATHI for #-marked sizes.

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3.4 Final Assembly
 Ensure equipment is aligned properly.
3.4.1 L, RFC & RRJ
 As the spider has been already inserted in one of the hub while aligning the
equipments, no separate procedure is required to be followed.
3.4.2 SW, H
 Wrap the snap wrap/cushions of required size in the space between the jaws.
Then slide the outer ring over the snap wrap/cushions & fix it to the hub with the
help of screws/bolts provided along with the washers .
3.4.3 SWQ & HR
 Take the spacer jaw body assembly with the inside ring (Only HR) & outside rings
without elastomeric elements.
 Insert spacer assembly in the steps provided in the hubs.
 Tighten the bolts with the torque given in table 2.1 for tightening torque. Wrap
the snap wrap/cushions of required size in the space between jaws.
 Slide the outer ring over the snap wrap/cushions accordingly & fix it to the hub
with the help of screws/bolts along with the washers.
3.4.4 RRS
 Insert the spacer between RRS hubs as mentioned in clause 3.2
 Wrap/insert the snap wrap/'T' cushions in the space between jaws.
 Slide the outer ring over the snap wrap/T-cushions
& fix it to the hub with the help of
screws/bolts along with washers.
3.4.5 SWS
 Insert jaw body over the pump side hub.
 Assemble one half of the jaw body with the
pump side hub with the help of bolts.
 Slide another jaw body over pump side hub.
Insert the spacer along with outer ring between
motor side hub & jaw body as shown in fig. 4.
 Locate the spacer in steps provided on motor
side hub and jaw body and assemble each other
with the help of bolts.
 insert the cushions between jaws of jaw bodies
& fix the outer ring over the cushions.

Fig 4. ASSEMBLY OF SWS COUPLING

 If the coupling is dynamically balanced, ensure that the match marks are in straight
line & unidirectional before bolting the assembly.
 Customer must provide required safety guards, RTPL does not supply safety guards or
shields.

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4. Safety General Hazard & Environment
4.1 Safety General Hazard
 Proper care and safety must be taken care before work started.
 The relevant safety and environmental regulations must be complied during installation,
commissioning, operation, assembly, disassembly and maintenance.
 Coupling must be maintained and/or repaired in the presence of skilled or qulified
persons for particular work.
 During installation or maintenance ensure the drive unit is cut off from the power
supply and caution notice should be display on switch.
 Immediate stop the drive unit if anything abnormalities observed on coupling (e.g.
cracks, chips, wear, or deformation)
 Check all the bolts are tightened as per torque specified in the manual or as specified in the
GA drawing.
 The supplied coupling may have to rotate at high speed, it is most important to guard the area
in compliance to ATEX and various other local applicable standards.
 This coupling is certified as per ATEX requirement. Please check the suitability of hazardous
environment at the time of selection of the coupling or during installation of the coupling.
 All spare parts are to be purchased from manufacturer only.
4.2 Environment
 Our products are comply with EMS standard ISO 14001:2015, any instruction which are
impermissible according to standard are not followed.

5. Inspection & Periodic Maintenance

 Jaw-flex couplings can be monitored under running condition as well as under idle condition.
 Inspect the coupling once in 6 months in idle condition or whenever it is taken for periodic
maintenance.
 During running condition, it is recommended to check the vibration and noise on either side of the
equipments to be under specified limits.
 Visual inspection is recommended to check below defects,
- Axial, Angular & Parallel misalignments.
- Bolt loosening.
- Flexible elements for wear, cracks, swelling or deep impression.
- Replace bushes immediately if they observed any of the above defects.

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6. Spare Management & Complaint Handling
6.1 Spare management
 We recommend to store spare items as given below, in order to have continuos operation and
to reduce down time due to failures.
 Spare component list.(Fig.1.1 & 1.2)

Components/
Sr.No. Part descriptions Quantity
part No.

1 Rubber Element Refer Fig. 1.1 & 1.2 1 set

 Spare bushes storage condition should be maintain as below,

- Away from direct sunlight.
- Temperature shall be in the range of 20°C - 30°C.
- Environment shall be free of extraordinary gases, vapours & chemical contacts, including
oils, grease etc.
- No stress on bond in case of rubber to metal bonded products.
6.2 Complaint Handling
 In case of any failure,for proper root cause, fill up Product Performance Datasheet (PPDS) and
provide us alongwith images/videos.

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 Product Performance datasheet(PPDS)

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7. Breakdown & Trouble Shooting

SR.
FAILURE MODE PROBABLE CAUSES CORRECTIVE ACTIONS
NO.
Worn out cushions
Excessive Replace cushions &
1
misalignments. Realign the coupling.
Shaft bearing failure

Torsional vibration
Fatigue of scushions Perform torsional analysis
Excessive starts and
2
stops
Overheated cushions Use larger coupling
High peak load

Swollen or cracked Use more chemically resistant

3 Chemical attack
cushions spider/cushions (*)

Distorted or Use more heat-resistant

4 Excessive heat
deteriorated cushions cushions (*)

Use special low temperature

5 Shattered cushions Low temperature
cushions (*)
Loose hubs on shaft Find & eliminate causes of
6 Torsional shock overload
with sheared keys. overload.
Coat hub with anticorrosive
7 Severe hub corrosion Chemical attack
coating (*)

(*) - Consult M/s RATHI if required

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8. Marking Details
 The ATEX marking for JAW coupling will be given on outer surface or front side (Fig. 5).
 Example : RRS Coupling

Fig. 5. Marking example

 ATEX Punching sample
A. RATHI JAW-FLEX 129 L/SW-150 32 II 2GD -25°C +120ºC
B. RATHI JAW-FLEX 129 RRS-150/140 II 2GD -25°C +120ºC
 Similarly for other JAW-FLEX coupling series the marking will be as per below,
For RFC couplings, RATHI JAW-FLEX [1] [2] [3] II 2GD -25°C+120ºC
For RRJ couplings, RATHI JAW-FLEX [1] [2] [3] II 2GD -30°C+120ºC
For RN couplings, RATHI JAW-FLEX [1] [2] [3] II 2GD -25°C+120ºC
 Where,
1. Manufacturing code e.g. 129 for December 2019
2. Product code e.g. RRS-150/140
3. Finish bore size code e.g. 32
 Please note that, operating temperature in the marking will differ as per type of elastomers
for respective coupling series.

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9. Declaration of Conformity

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