DOCU1A3415A026E

Highly-flexible

VULKAN - RATO – DS - Couplings

Customer: Caterpillar Motoren, Kiel

Comm.-No.: 310505631

Dimension Group: A3415A

Series: 2200

Drawing No.: 1A3410A026

Partslist No.: 1A3415A026

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: [email protected]
http://www.vulkan24.com
Documentation Contents:

Technical data RATO – DS – A3415A

Assembly drawing 1A3410A026

Partslist 1A3415A026

Delivery condition AA3410A026

Installation and Operating Instruction E&B RATO-DS A2110A-A3910A BR2200

Criteria for the inspection of

VULKAN-RATO-DS/DG Couplings DS/DG-CRIT-1 to 5

Surface Protection COATING 113

Form VULKAN RATO- S/R/DS Couplings S/R/DS-COAT-1/2 to 7/2

Assembly- and Disassembly Instruction

for Oil Pressure Connections
with cone bush 1:30 and hydraulic nut E12178
Technical Data for RATO-DS Coupling
Size A3415 Drawing-No.: 1A3410A026

Rubber qual. 5
T KN kNm 50
T K max.1 kNm 55,5
T K max.2 kNm 225
∆ T max kNm 66,5
T KW kNm 15
P KV50 - total kW 0,62
n K max min -1 1250
∆Ka mm 10,3
∆Kr mm 2
F ax1,0 kN 1,3
C rdyn kN/mm 5,25
nominal 262,50
C T dyn-total kNm/rad
warm 183,75
nominal 1,13
rel . Damping Ψ
warm 0,79

The guide lines in the RATO -DS catalogue

DS-ETD-5 have to be considered
 VULKAN: PRODUCTION Partslist

Manuf.Prod: 1A3415A026-B Date: 10.04.2006

RATO-DS Page: 1
Drawing: 1A3410A026 Printed by: SPRUNG

Item Quant Part Number Description Dimensions Material Remark

1 1 EA3415A002 FLEX.ELEMENT ST/GUMMI

3 1 4A3403033M-B HUB FM 495 X 135 X 300 42CRMO4+QT EN 10083-1

4 1 3A3404000M-B ANGLE RING FM 605X 395 X120 CK45V EN 10083-1

7 24 7000124125-C HEXAGON BOLT M 24 X125 10.9 931M

8 4 7001124085-C HEXAGON BOLT M 24 X 85 10.9 933M

10 16 7001124065-C HEXAGON BOLT M 24 X 65 10.9 933M

11 20 7033624000 DISC 24 42CrMo4+QT EN10083-1 VERG.17200

15 24 7033624000 DISC 24 42CrMo4+QT EN10083-1 VERG.17200

16 16 7033622000 DISC 22 42CRMO4+QT EN 10083-1

17 16 7000122200-C HEXAGON BOLT M 22 X200 10.9 931M

 Installation
and
Operating Instruction

E&B A2110A – A3910A – series 2200

VULKAN-RATO-DS Couplings

VULKAN Kupplungs- und Getriebebau

B. Hackforth GmbH & Co. KG
PO Box 200462, 44634 Herne / Germany
Heerstraße 66, 44653 Herne / Germany
Phone: ++49-2325/922-0
Fax: ++49-2325/71110
E-Mail: [email protected]
http://www.vulkan24.com

Title Installation and Operating Instruction Subject RATO-DS Standard Execution

Respon- Authoring Checked and released Document: E&B_RATO-DS_A2110A-
A3910A BR2200 E.doc
sibility 25.11.2003 25.11.2003 Version: 001
TB 10 Wolfgang Sprung Jürgen Kestermann Page: 1/7
Contents:

1. General safety instructions ............................................................................................................... 3

1.1 Symbol for industrial safety........................................................................................................ 3

1.2 Attention remark ........................................................................................................................ 3

1.3 Safety regulations ...................................................................................................................... 3

2 Generalities....................................................................................................................................... 3

3 Installation of the coupling ................................................................................................................ 4

3.1 Delivery condition of the highly-flexible RATO-DS coupling ...................................................... 4

3.2 Procedure before the installation of the highly-flexible RATO-DS coupling .............................. 4

3.3 Assembly of the highly-flexible RATO-DS coupling................................................................... 5

4 Alignment of the highly-flexible RATO-DS coupling ......................................................................... 5

5 Commissioning ................................................................................................................................. 5

6 Maintenance ..................................................................................................................................... 6

6.1 Operating performance considering the mechanical properties of the Elastomer material ...... 6

6.2 Operating performace considering the chemical properties of the Elastomer material ............ 6

7 Replacement of the RATO-DS element ........................................................................................... 6

7.1 Disassembly of the RATO-DS element ..................................................................................... 7

7.2 Assembly of the RATO-DS element.......................................................................................... 7

8 Service and spare parts.................................................................................................................... 7

Title Installation and Operating Instruction Subject RATO-DS Standard Execution

Respon- Authoring Checked and released Document: E&B_RATO-DS_A2110A-
A3910A BR2200 E.doc
sibility 25.11.2003 25.11.2003 Version: 001
TB 10 Wolfgang Sprung Jürgen Kestermann Page: 2/7
1. General safety instructions

1.1 Symbol for industrial safety

This symbol is added to all passages in this documentation concerning industrial safety and including
a risk to people's life and limb. Please follow these instructions and handle with the utmost caution in
these situations. Hand over all industrial safety instructions to other users as well.

1.2 Attention remark

Attention!

This "Attention!" remark is added to passages in this documentation which should be specially noted
in order to stick to the guidelines, regulations, instructions and correct flow of work and to prevent any
damages or destruction of the coupling.

1.3 Safety regulations

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

According to EN 292, part 1 „Safety of Machines“, a shield against mechanical movements of ma-
chine parts (protection against accidental contact) is permissible, if a „usage according to the re-
gulations“ is guaranteed during all working conditions. At the same time a good ventilation of the
coupling has to be ensured (use of perforated plates).
If the possibility of exceeding the permissible speed of the coupling, nkmax, cannot be excluded com-
pletely, e. g. in case of an incident or because of a failure of the over-speed-trip in the system, the
coupling shield has to be so designed that possible coupling fragments cannot escape to the
surrounding environment.
For coupling applications in fast ships (Dynamically Supported Craft), the safety regulations of publi-
cation A373 of IMO (International Maritime Organisation) are valid. Dependant on the construction,
these machine arrangements contain components with a high rotating energy. When the coupling
runs outside of a casing, an external protecting device has to be provided to keep off possible
coupling fragments in any case.

2 Generalities

The highly-flexible VULKAN-RATO-DS coupling is a rubber coupling, flexible in all directions. Its es-
sential parts are the flexible part and the connecting parts.
All connecting elements of the coupling are arranged without clearance.
The coupling must be protected against permanent influence of oil and against the radiation of heat.
Oil mist and oil splashes are not detrimental. The flexible part is fit for use at ambient temperatures
comprised between -50° (C) to +80° (C). The ventilation holes guarantee good heat dissipation
properties of the RATO-DS coupling. The free-of-play torque transmission in the coupling and the
large sectional rubber area of the flexible element provide good noise attenuation.
Basically, the connection surfaces and the fitted bores as well as the finish bores of the RATO-DS
coupling are protected by Tectyl. Before installation of the highly-flexible RATO-DS coupling, these
surfaces have to be cleaned with conventional solvents.

Title Installation and Operating Instruction Subject RATO-DS Standard Execution

Respon- Authoring Checked and released Document: E&B_RATO-DS_A2110A-
A3910A BR2200 E.doc
sibility 25.11.2003 25.11.2003 Version: 001
TB 10 Wolfgang Sprung Jürgen Kestermann Page: 3/7
 Pay attention to wear protective clothes (gloves, safety glasses etc.) while working
with solvents.

When the cleaned surfaces are completely dry, they must be greased slightly.
On behalf of the classification societies we herewith give the following instruction:
The torsional vibration behaviour of the driving system has to be checked and approved by the clas-
sification society. The expected and satisfactory behaviour is guaranteed only, provided that all com-
ponents 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 according to the nominal
values including tolerances.
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-DS coupling, certain
installation instructions have to be observed.

Attention! Basically, each bolt connection participating in the transmission of the

torque must be tightenend with a torque spanner.
The individual tightening torques are given in the corresponding execution drawing of the coupling.
In case of a flexible mounted system, please coordinate the alignment with the manufacturers of en-
gine, coupling and gearbox.
When using 10.9 bolts, hardened washers should be provided.

3 Installation of the coupling

During transportation, please pay attention to a sufficient carrying force of the lifting
devices. Only use approved transportation elements.
Thoroughly fix the transportation elements to the attaching devices.

Attention! While lifting the flexible elements, take care not to damage the flexible ele-
ments and the add-on pieces.

3.1 Delivery condition of the highly-flexible RATO-DS coupling

The highly-flexible RATO-DS coupling is delivered as shown on drawing No. AA...

3.2 Procedure before the installation of the highly-flexible RATO-DS coupling

Before the installation of the highly-flexible RATO-DS coupling, the following procedure is to be carried
out:
Remove the hexagon bolts (item 7) and washers (item 15) and separate the hub (item 3) from the
angle ring (item 4). Then establish the installation situation according to drawing E11000E.
If the fasteners (items 6, 12, 18) were delivered with the coupling, they have to be removed as well.

Title Installation and Operating Instruction Subject RATO-DS Standard Execution

Respon- Authoring Checked and released Document: E&B_RATO-DS_A2110A-
A3910A BR2200 E.doc
sibility 25.11.2003 25.11.2003 Version: 001
TB 10 Wolfgang Sprung Jürgen Kestermann Page: 4/7
3.3 Assembly of the highly-flexible RATO-DS coupling
For the assembly, the individual RATO-DS elements are to be hung into a suitable lifting device.

• Install the hub (item 3) onto the shaft of the unit to be driven.

• Erect and align the machines according to the installation dimension of the highly-flexible
RATO-DS coupling (please refer to paragraph 4).

• Arrange the element (item 1) and angle ring (item 4) in the system.

• Attach the element (item 1) with fastening elements (items 6, 12) to the engine flywheel.

• Pull the angle ring (item 4) in direction of the hub (item 3) with the hexagon bolts (item 8).

• Insert and tighten the fasteners (items 7, 15).

• Tighten the hexagon bolts (items 6, 7, 8, 10) with a torque spanner. The corresponding
tightening torques are given on drawing No. 1A...

So the coupling is installed.

4 Alignment of the highly-flexible RATO-DS coupling

The permissible maximum misalignment values in enclosed catalogue data sheet serve as an
indication for the alignment of the RATO-DS coupling, whereas for an exact alignment a value below
20 % of the permissible misalignments is to be aimed for.
The more exactly both units are aligned towards each other, the more reserves are given for the
highly-flexible RATO-DG coupling to compensate radial, axial and angular displacements during ope-
ration.

5 Commissioning

Press „EMERGENCY SHUTDOWN“ in case of danger.

Do not tough any rotating parts.
Equip the coupling with a sufficient protection device against contact.

Attention! Make sure that the coupling is protected against contact with oil, solvents and
other chemicals.

After completion of the assembly, the drive system is ready for operation as far as the coupling is
concerned. We would like to point out that before commissioning you have to make sure that all
assembling auxiliaries have been removed from the coupling.
A coupling shield has to be provided, according to the accident prevention regulations. If there are no
other objections having priority, these shields have to be made of perforated plates or expanded metal
to ensure a good ventilation of the coupling as well. Please refer to safety regulation paragraph 1.3.

Title Installation and Operating Instruction Subject RATO-DS Standard Execution

Respon- Authoring Checked and released Document: E&B_RATO-DS_A2110A-
A3910A BR2200 E.doc
sibility 25.11.2003 25.11.2003 Version: 001
TB 10 Wolfgang Sprung Jürgen Kestermann Page: 5/7
6 Maintenance

Stop the system for maintenance work.

Safely protect the system against unintentional starting resp. rotation.

Function and service life of highly-flexible couplings are decisively determined by construction and
design, but also by the elastomer material selected and its resistance against environmental influ-
ences.

6.1 Operating performance considering the mechanical properties of the Elastomer

material

Basically, the highly-flexible RATO-DS coupling does not require maintenance. In many cases, however,
the highly-flexible RATO-DS coupling is an indicator for malfunctions in the system.
We recommend a check of the highly-flexible part in case of exceptional incidents, e. g. propeller
ground contact, short circuit, disturbance of synchronization, governor hunting or emergency cut-off.
Criteria for this purpose are given in document S/R-CRIT-1/1a up to 9/1a:

• Specification of limit values for the permissible permanent set depending on the size.
• Evaluation of surface cracks caused by ageing and their treatment including additional measures
according to document S/R-COAT-1/2 – 7/2.

In addition to a check of the flexible part it is recommended to carry out an alignment control within the
scope of the engine inspection intervals.
Standard values are given in document S/R-A-1/2 up to 5/2.

6.2 Operating performace considering the chemical properties of the Elastomer

material

Caoutchouc (NR) is mainly used as elastic material in highly-flexible Elastomer couplings. Because of
its excellent dynamic properties (stablility / elasticity), actually there is no equivalent alternative material
available. Caoutchouc (NR) belongs to the DIEN caoutchoucs, however, it is subject to various
environmental influences, known under the collective noun „ageing“.
The immediate surrounding of the highly-flexible coupling in the system should be ventilated well in
order to prevent high ambient temperatures. To prevent early ageing, however, it should be ensured
that no „airflow“ will occur directly onto the rubber surface (especially waste air from generators).
An air swirl occurs closely above the coupling’s rubber surface which is desired because of its cooling
effect on the one hand, and on the other hand, however, continuously providing fresh air (O2). To pro-
tect the Elastomer material of the VULKAN couplings against these environmental influences, they are
equipped with the most progressive ageing protecting agents available for the rubber industry. Ageing
protecting agents which are chemically dispersed in the material’s matrix, however, use up when ful-
filling their purpose.

7 Replacement of the RATO-DS element

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

Title Installation and Operating Instruction Subject RATO-DS Standard Execution

Respon- Authoring Checked and released Document: E&B_RATO-DS_A2110A-
A3910A BR2200 E.doc
sibility 25.11.2003 25.11.2003 Version: 001
TB 10 Wolfgang Sprung Jürgen Kestermann Page: 6/7
7.1 Disassembly of the RATO-DS element

We would like to explain the replacement of the RATO-DS element in detail as follows:

• Remove fastening elements (items 7, 15 and 10, 11).

• Establish the disassembly situation with the hexagon bolts (item 8) (please refer to drawing No.
E11000E).
• Hang the flexible element (item 1) with angle ring (item 4) into a suitable lifting device.
• Remove fasteners (items 6, 12).
• Remove the flexible element (item 1) with angle ring (item 4) out of the system and deposit it.

Attention! Make sure not to damage any other machine parts during the
disassembly of the flexible element.

• Remove fasteners (items 8, 11).

• Separate flexible element (item 1) and angle ring (item 4) from each other.
• Clean all reusable coupling parts and the connection surfaces.

So the RATO-DS element is disassembled.

Please note: When ordering spares for the RATO-DS element, please give us the following
information with respect to the highly-flexible RATO-DS coupling:

• order no.
• drawing no.
• partslist no.

7.2 Assembly of the RATO-DS element

Before starting the assembly, a new alignment control should be carried out at the driving system.
The assembly of the RATO-DS element (item 1) has to be carried out as described in paragraph 7.1,
however, in the reversed order.
After completion of the assembly, the drive system is ready for operation, as far as the coupling is con-
cerned.

8 Service and spare parts

Contact address:
VULKAN Service dept.
Heerstraße 66
D-44653 HERNE
Phone: +49 (0)2325 922 179
FAX: +49 (0)2325 71110
Mobile: +49 (0)1782922179

Title Installation and Operating Instruction Subject RATO-DS Standard Execution

Respon- Authoring Checked and released Document: E&B_RATO-DS_A2110A-
A3910A BR2200 E.doc
sibility 25.11.2003 25.11.2003 Version: 001
TB 10 Wolfgang Sprung Jürgen Kestermann Page: 7/7
 Criteria for the inspection of
VULKAN-RATO DS/DG couplings

The outer surface of a rotating coupling is continuously 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 the temperature, humidity
and UV-radiation, causes irreversible changes in the material structure at the rubber surface. This
unavoidable process is generally 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 examined 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 summarised as follows.

Due to the constructional design of the elements, and the different types and values of stresses, the
elements will, after a certain period of service, show indications of having undergone operational
service. The most frequent symptoms are:

1. permanent set

RATO-DS RATO-DG

Figur 1 Figur 2

The control of the permanent set of a RATO DS/DG element is made by the measurement of "s" at
the rubber outer diameter of the element (picture 1).

If the permanent set „s“ exceeds the criteria in the following table, the flexible parts must be
replaced; otherwise the flexible parts are suitable for further service provided there are not other
indications of a damage.

Criteria for inspection DS/DG-CRIT-1

 permissible permanent set

RATO – DS - elements

Rubber quality
Baugröße X=Z X=1 X=5 X=6 X=7
Size S [mm] S [mm] S [mm] S [mm] S [mm]

211X 55 60 57 39 69
231X 58 65 62 41 74
251X 63 70 66 44 79
271X 67 75 72 47 85
291X 74 82 78 52 92
311X 79 88 83 55 100
331X 85 95 90 61 108
341X 91 102 97 65 115

RATO – DG - elements

Rubber quality
Baugröße X=1 X=8 X=6 X=9
Size S [mm] S [mm] S [mm] S [mm]

211X 25 23 16 11
231X 28 25 18 12
251X 29 27 19 13
271X 32 29 20 14
291X 35 31 22 15
311X 37 33 24 17
331X 40 36 25 18
341X 43 39 28 19
361X 47 42 30 20
391X 50 45 32 22

Criteria for inspection DS/DG-CRIT-2

2. surface cracks

„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.

According to our experience, for a RATO-DS/DG flexible part cracks with a depth up to 5 % of the
axial rubber thickness are to be considered acceptable in case that they occur all-round on the
whole surface.

The cracks should be ground out as soon as possible. This procedure, usually used for steel cast
components, can also be used for rubber elements.

permissible crack depth of a RATO-DS/DG coupling

depth* DS – depth* DG –
coupling coupling
size [ mm ] [ mm ]
21 12 12
23 13,5 13,5
25 15,5 15,5
27 16 16
29 17 17
31 19 19
33 20,5 20,5
34 22 22
36 --- 23,5
39 --- 25,5

values of the schedule:

valid for cracks mainly in one surface; in case of cracks on both surfaces the values have to be halved.

Criteria for inspection DS/DG-CRIT-3

 permissible remaining permanent set of the RATO-DS elements

size x=Z x=1 x=5 x=6 x=7

211x 55 60 57 39 69

23 58 65 62 41 74

25 63 70 66 44 79

37 67 75 72 47 85

29 74 82 78 52 92

31 79 88 83 55 100

33 85 95 90 61 108

34 91 102 97 65 115

RATO-DG elements

size x=1 x=8 x=6 x=9

211x 25 23 16 11

23 28 25 18 12

25 29 27 19 13

27 32 29 20 14

29 35 31 22 15

31 37 33 24 17

33 40 36 25 18

34 43 39 28 19

36 47 42 30 20

39 50 45 32 22

Criteria for inspection DS/DG-CRIT-4

2.1 A guidance for VULKAN-RATO-DS/DG couplings:

• 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 marked in order to monitor it.

• 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 malfunctions. When no

system malfunction can be determined, the coupling has to be checked at shorter
intervals.

• When the cracks formed are due to an overloading 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.

2.2 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 dimension 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-occurrence“, cracks can appear in couplings that normally

operate within their permissible limits. The reason for the malfunction must be
investigated and repaired. A check should be carried out after 3 months or in case of
a new system malfunction.

• If the crack depth exceeds the permissible, we recommend to replace the relevant
element as soon as possible.

Criteria for inspection DS/DG-CRIT-5

2.3 Working instruction „grinding“

The working instruction „grinding“ is one component of the criteria for the inspection of RATO-
DS/DG couplings. The rework of the cracks in the rubber of the 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 accurately rounded and should not
show sharp corners.

During and after the grinding it is not allowed to use French chalk or similar substances
to smooth the surface. A subsequent treatment with the system COATING 113 requires
clean, fat-free and oil-free surfaces.

Subsequently the machined surface as well as the surface of the flexible elements has
to be treated with COATING 113.
Advice concerning this treatment is given in document 7/1.

Enclosed you will find photos about tools.

Photo 1: Grinding tools

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).

Criteria for inspection DS/DG-CRIT-6

 Surface Protection COATING 113
for
VULKAN RATO- S/R/DS Couplings

In case of repair work, the machined surfaces as well as the surface of the flexible
element have to be provided with COATING 113, a protective coating consisting of a
liquid elastomer. This elastomer offers a high protection against environmental
influences, especially against the influence of atmospheric oxygen which causes an
“ageing” of the surface-near areas of the coupling elements
Basically, the system COATING 113 consists of two components:

PRECOATING 113-1
COATING 113-2

Both protective coatings consist of the same elastomer material. PRECOATING 113-1, which
is more liquid, is used for the priming coat of a pretreated surface according to regulation
S/R-CRIT-1/1-7/1,.
For both main coats COATING 113-2 is used.

RATO-S couplings are coated on the outer surface including the radius passings to the front
surfaces per segment. It is not required to disassemble the segments.
With RATO-R/DS couplings, the complete outer rubber surface is coated.

Processing instructions for the application of

COATING 113

Surfaces of highly-flexible elements which have been ground crack-free within the scope of
inspections according to the „criteria for inspection“.

1.) The surfaces of highly-flexible elements should be ground with a belt grinder on the
complete surface in order to optimally prepare them for the priming coat with
PRECOATING 113-1.
This special surface treatment guarantees an optimum cleaning and removes possi-
ble existing microcracks at the same time.
If the surfaces are in good condition, sufficient cleaning can be reached by careful
brushing (brass brush).

2.) The surfaces are properly cleaned from grinding dust by blowing-off with
compressed air. In order to keep the surfaces dry and free from grease, the
compressed air must be almost free from oil and condensates.

Surface protection COATING 113 S/R/DS-COAT-1/2

Modification 3 Herne, 22.05.2003
COATING 113 e_3.doc
3.) The priming coat is made with PRECOATING 113-1. The drying time is approx. 30
minutes. The coat is dried if it is not tacky when touched by hand.

4.) The first main coat is made with COATING 113-2. The drying time is approx. 30 mi-
nutes. The coat is dried if it is not tacky when touched by hand.

5.) The second main coat is made with COATING 113-2 as well. The procedure is the
same as described under 4.).

All coatings are to be applied thinly, but totally covering the segment.

The waiting time until recommissioning of the coupling should be at least one hour after
having applied the last coating.

COATING 113 can be used for approx. 8 weeks providing it has been stored in a sealed tin.

The safety regulations according to the following safety data sheet (93/112/EG) are to be
observed.

Surface protection COATING 113 S/R/DS-COAT-2/2

Modification 3 Herne, 22.05.2003
COATING 113 e_3.doc
Safety data sheet (93/112/EG)
PRECOATING 113-1 10099544
COATING 113-2
valid from: 19.11.1999
subst. version from: NEW
current date: 27.09.2001

1 IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY

COMPOSITION / INFORMATION ON INGREDIENTS
1.1 Precoating 113-1
precoating solution for coating 113-2
1.2 Coating 113-2
Company:
Phoenix AG
Hannoversche Strasse 88
D-21079 Hamburg

+49 / 40 / 76 67 22 33

2 COMPOSITION / INFORMATION ON INGREDIENTS

2.1 Precoating 113-1 CAS no.: 108-88-3

90 % Toluene EINECS no. 203-625-9
TLV: 380 mg/m3
2.2 Coating 113-2 R-phrases: 11,20
70 % Toluene
Hazard symbol

3 HAZARD IDENTIFICATION

R11 : highly flammable

R20 : harmful by inhalation
R36/37 : irritating to eyes and respiratory system

4 FIRST AID MEASURES

Remove soiled or soaken clothing immediately.

AFTER INHALATION
Remove the casualty into fresh air and keep him calm.
In case of breathing difficulties or no breathing give oxygen. Summon a doctor.
AFTER INGESTION
Induce the patient to vomit only if fully conscious. Summon a doctor.
AFTER SKIN CONTACT
Wash thoroughly with water and soap. The solvent of the product has a strong
degreasing effect, therefore use a skin protection cream afterwards.
AFTER EYE CONTACT
Rinse with plenty of water for several minutes, keeping the eyelid open. Call or go to
a doctor.
ADVISE TO DOCTOR

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5 FIRE-FIGHTING MEASURES

SUITABLE EXTINGUISHING MEDIA

Water, foam, extinguishing powder, carbon dioxide
UNSUITABLE EXTINGUISHING MEDIA
Full water jet
HAZARD ARISING FROM COMBUSTION PRODUCTS
Danger of formation of toxic pyrolysis products.
Use self-contained breathing apparatus.

6 ACCIDENTAL RELEASE MEASURES

Keep people away and stay on the upwind side. Do not discharge into the drains,
surface waters or groundwater.
Take up with absorbant material (e. g. sand, general-purpose binder). Do not use
sawdust or other combustible materials.

7 HANDLING AND STORAGE

Use only in well-ventilated areas.

Keep away from ignition sources – do not smoke.
Take precautionary measures against static discharges.
Wear shoes with conductive soles. Vapours can form an explosive mixture with air.
Provide solvent-resistant and impermeable floor.
Keep container tightly closed. Keep in a cool place. Protect from frost.

8 EXPOSURE CONTROLS AND PERSONAL PROTECTION

INGREDIENTS WITH EXPOSURE LIMITS TO BE MONITORED

Toluene CAS no.: 108-88-3

EINECS no.: 203-625-9
TLV: 380 mg/m3
Hazard symbol: F, Xn R-phrases: 11,20

Do not eat, drink, smoke during work. Wash hands thoroughly with water and soap
before breaks and after work. Use barrier skin cream.
RESPIRATORY PROTECTION
Unsufficient ventilation, short term mask with filter: solvents
HAND PROTECTION
Solvent-resistant gloves
EYE PROTECTION
Framed protective goggles
BODY PROTECTION
protective clothing

9 PHYSICAL AND CHEMICAL PROPERTIES

FORM
liquid
COLOUR
black

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 ODOUR
aromatic
BOILING POINT (DEG. C)
111,000
FIRE POINT (DEG. C)
6,000
FLASH POINT (DEG C)
535,000
SELF IGNITIONABILITY
EXPLOSIVE LIMITS
1,0 / 7,0
VAPOR PRESSURE (hPa at 50 DEG. C)
12,300
DENSITY (kg/l at 20 DEG. C)
1,000
SOLUBALITY (at 20 DEG. C)
VISCOSITY (at 50 DEG. C)
1600 cP
CONTENCE OF SOLVENTS (%)
CA. 80
CONTENCE OF SOLIDS (%)
CA. 20

10 STABILITY AND REACTIVITY

None, if used correctly.

Hydrogen halides are formed in contact with flames, and, under unfavourable
conditions, toxic pyrolysis products.

11 TOXICOLOGICAL INFORMATION

The values of the preparation are not determined.

CLASSIFICATION RELEVANT VALUES
Values of the single components
Toluene, LD 50 (oral, rat) 5000 mg/kg
Frequent persistant contact with the skin can cause skin irritation.

12 ECOLOGICAL INFORMATION

Danger to drinking water is possible if large quantities penetrate into the subsoil and
natural waters.

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13 ADVICE ON DISPOSAL
PRODUCT
Can be disposed of together with household refuse after compaction in accordance
with the regulations and after consultation with the disposal agency and the relevant
authorities.
EAK No.
080402
PACKAGING
Recommendations:
The package units should be completely emptied (drop-free, cleaned with a towel).
The packing material should preferably be recycled or reused, in accordance with
the relevant, applicable local/national regulations.

14 TRANSPORT INFORMATION

TRUCK TRANSPORTATION (ADR)

Dangerous good class 3 figure 5c ADR
UN 1133 Adhesives, containing solvents with a fire point under 23 deg. C
packing group III
ADR-Label 3
written instruction K1

SHIPMENT BY SEA (IMDG-CODE)

Dangerous good class 3.2
UN 1133 Adhesives, containing a inflammable liquid
Packing group III
IMDG-Label K3
EMS: 3-05
MFAG: 330

SHIPMENT BY AIR (IACO/IATA – CODE)

Dangerous good class 3
UN 1133 Adhesives, containing a inflammable liquid
PkgGr III
PkgInst 309
IATA-Label: Inflamm.liquid

15 REGULATORY INFORMATION

HAZARD
Toluene
CLASSIFICATION ACCORDING TO EEC DIRECTIVES
F: highly inflammable
Xn: harmful
CONTAINS
R PHRASES
R11 : highly inflammable
R20 : harmful by inhalation
R36/37 : irritating to eyes and respiratory system

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 S PHRASES
S9 : Keep container in a well-ventilated place
S16 : Keep away from sources of ignition – No smoking
S23 : Do not breath vapor/spray
S33 : Take precautionary measures against static discharges
S51 : Use only in well-ventilated areas
SPECIAL LABELLING FOR CERTAIN PREPARATIONS
Only for industrial users
.
Refer also to point 8
.
A1
.
.
.
2
.
.

16 OTHER INFORMATION
The information given here does not represent any guarantee or properties. Please
refer to our technical leaflets.

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