SEALING PLUGS SEALING PLUGS - TracePartsOnline.net

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Toll Free: 866-4-SHEREX 

(866-474-3739) 

SEALING PLUGS 

SYSTEM FOR SEALING AUXILIARY 

DRILLED HOLES 

■ Largest selection of permanent 

sealing plugs 

■ For use in fluid power, automotive, 

industrial, aerospace and 

machine tools applications 

■ Blowout pressure exceeds 

40,000 PSI 

■ QS 9000/ ISO 9001/ ISO 14001 

■ Available in metric and inch sizes 

■ No tapping or reaming of holes 

required 

■ Special sizes available upon 

request

© 2001 by KVT 

Sherex Industries Ltd. 

www.sherex.com 

Sherex Industries Ltd. has been the North American exclusive 

representative for Koenig Verbindungstechnik AG and the Koenig 

Expander Plugs since 1976. We are an award winning company 

who specializes in the distribution of niche Fluid Power products 

for both the Fluid Power and Automotive Markets. In this capacity, 

Sherex prides itself in the ability to act as the manufacturer here in 

North America. Sherex has degreed engineers on staff to assist 

customers in properly applying the products we sell. Visit us on 

the web at www.sherex.com for our other products and services. 

Sherex's award winning service includes: 

• Extensive In-House Stock ready for overnight delivery 

• 100% Technical Backup 

• JIT & Can-Ban Delivery Experience 

• EDI Compatible 

• Bar Coding 

• Returnable Packaging System Experience 

• QS 9000 & ISO 9000 Compliant 

Email: info@sherex.com Toll free: 866-4-SHEREX (866-474-3739) 

SHEREX Industries Ltd., 1400 Commerce Parkway, Lancaster, NY U.S.A. 14086 Tel: (716) 681-6250 Fax: (716) 681-0270 

SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537

© 2001 by KVT 

SHEREX INDUSTRIES PRESENTS: 

KOENIG-Expander Sealing Plugs 

Leakproof Sealing 

of Auxiliary Drilled Holes 

Overview 

MB Series Plugs 

SK Series Plugs 

HK Series Plugs 

LK Series Plugs 

LP Series Plugs 

Technical Information 

i • 

T 


SHEREX Industries Limited, 4180 Morris Drive, Burlington, Ontario, Canada L7L 5L6 Tel: (905) 639-7701 Fax: (905) 639-9537 

I

Tension-Pressure Test Equipment: 

For verification of mechanical properties of 

raw materials and component parts as well 

as functional characteristics of Expanders. 

▲ 

Roughness Measuring: 

For functional testing and tests 

where accurate hole roughness 

of base material is needed. 

II 

▲ 

Production-Line 

KOENIG-Expander: 

The automated assembly 

equipment and outside 

diameter checking equipment 

is in the background. 

In the forefront is eddy 

current testing equipment 

for 100% comparison 

measurement of important 

characteristics of Expanders. 

▲ 

▲ Pressure Testing Facility: 

Static burst pressure unit (left) heating/cooling 

chamber (right) for extended life cycle testing.

KOENIG-Expander Sealing Plugs 

System For Sealing Auxiliary Drilled Holes 

Unique sealing and tightening system for holes 

i 

The KOENIG Expander is a system to seal holes with absolute integrity in various components in the Mobile and Industrial 

Fluid Power Markets, as well as the Automotive Market. Compared to earlier methods, such as threaded 

plugs with or without sealing software, press-in pins, welding, etc., the KOENIG Expander distinguishes itself by its 

fast and reliable installation while incorporating reasonable installation tolerances. Thanks to the continuous 

expansion of our product offering along with the capability to custom design sealing components to customer 

specifications, Sherex offers a leak-tight sealing solution for every application. 

As designed, the KOENING Expander plug pressure 

ratings incorporate a minimum Factor of Safety to 

accommodate for pressure spikes and cyclic 

pressure loading. As a result of this reliable and leaktight 

sealing system, the expanders have found 

broad application on components such as: hydraulic 

and pneumatic control valves and manifolds, 

hydraulic pumps and motors, power transmission 

components, brake components, engine components, 

etc. 



III

Applications 

KOENIG Expanders are used extensively in hydraulic and pneumatic components, for example: 

• Control and regulator valves 

• Pumps 

• Connecting and distribution manifolds 

• Power units 

• Cylinders 

• Hydraulic transmissions 

• etc. 

IV 

i 

The engineered process makes possible a quick and safe sealing of bores and channels. KOENIG EXPANDER has 

established a name world-wide in a variety of industries. 

Machine tools and other custom equipment 

• Clamping devices 

• Cooling and lubricating systems 

• Molds for injection molding machines 



Applications 

Mobile hydraulics/materials 

handling equipment 

• Control and drive units 

• Lifts and platforms 

• Elevators 

• Construction equipment 

• Fork lifts 

Transportation 

• ABS brake systems 

• Power steering 

• Vehicular dynamic control 

systems 

• Automatic door openers 

• Railroad brake systems 

Aircraft Industry 

• Control gear 

• Landing gear 

• Flight simulators 

Werksfoto Knorr-Bremse AG 

i 



V

System for Sealing Auxiliary Drilled Holes 

VI 

i 

MB Series 

Expansion and anchorage of sleeve in hole 

wall is achieved by pressing the ball into the 

sleeve. The MB Series plug is designed for 

use in base materials from low to high 

hardness. 

SK Series 

Pull/Expand principle. The installation tool 

maintains sleeve position in the hole while 

pulling the mandrel into and expanding the 

sleeve until the mandrel breaks off at a 

predetermined point. Anchorage is achieved 

by the serrations on the outside of the sleeve 

anchoring into the base material, especially in 

soft material. 

HK Series 

This installation is also based on the 

Pull/Expand principle. Thanks to the soft 

sleeve material, anchorage is achieved by the 

flow of sleeve material into the surface 

roughness of the drilled hole. The HK Series 

plug is especially suitable for use in hard 

materials. 



System for Sealing Auxiliary Drilled Holes 

LK Series 

Available in both steel and stainless steel,this 

plug has been designed for applications in the 

low pressure range. It has an anchorage 

principle similar to the SK Series plugs. 

LP Series 

This low pressure sealing plug is installed by 

pressing the plug into a tapered hole. The 

surface-hardened but flexible plug achieves 

anchorage by gripping the hole wall. 

i 



VII

VIII 

NOTES 



MB Series 

• Quantities in stock from 3 to 22 mm 

diameter, also available in inch 

versions 

• Corrosion resistant construction 

• Normal working tolerances 

0/+ 0.1mm 

• Simple, quick installation 

• Complete mechanical sealing 

through anchoring in base material 

Contents Page 

– MB 600 2 

– MB 600, Inch-Version 3 

– MB 700 4 

– MB 800 5 

– Installation instructions 6 

– Setting Tools 8 

– Automated Production Tools 9

MB 600 Series Sealing Plugs 

Sleeve: Stainless Steel 

DIN 1.4305, AISI 303 

Sleeve and Ball clear passivated per MIL S 5002 

Aerospace Quality 

Dimensions in MM 

2 

d 1 

l 1 

l2 ~ 

d2 + 0.1 

0 

d 3 

max. 

l 3 

min. 

Ball: Stainless Steel 

DIN 1.4301, AISI 304 

x 

± 0.2 

3.0 3.6 4.6 3.0 2.2 3.4 0.4 MB 600-030 1000 

4.0 4.0 5.2 4.0 3.3 3.8 0.2 MB 600-040 1000 

5.0 5.5 7.0 5.0 4.3 5.3 0.4 MB 600-050 1000 

6.0 6.5 8.6 6.0 5.3 6.3 0.4 MB 600-060 500 

7.0 7.5 10.1 7.0 6.4 7.3 0.4 MB 600-070 250 

8.0 8.5 11.7 8.0 7.4 8.3 0.3 MB 600-080 250 

9.0 10.0 13.7 9.0 8.4 9.8 0.4 MB 600-090 250 

10.0 11.0 15.2 10.0 9.4 10.8 0.4 MB 600-100 250 

12.0 13.0 18.0 12.0 10.6 12.8 0.4 MB 600-120 100 

14.0 15.0 20.8 14.0 12.7 14.5 0.4 MB 600-140 100 

Type 




MB 600 Series Inch-Version Sealing Plugs 


DIN 1.4305, AISI 303 

Sleeve and ball clear passivated to MIL S 5002 

Aerospace Quality 

Dimension in Inches 

d 1 

l 1 

l2 ~ 

d 2 

d 3 

max. 

Ball: Stainless Steel 

DIN 1.4034, AISI 420 (.093" Dia.) 

DIN 1.4301, AISI 304 (.125"-.281" Dia.) 

.093 ( 3 / 32") .100 .120 .0937 .062 .095 MB 600-093 A 1000 

.125 ( 1 / 8") .138 .170 .1250 .093 .125 MB 600-125 A 1000 

.156 ( 5 / 32") .150 .195 .1562 .125 .130 MB 600-156 A 1000 

.187 ( 3 / 16") .193 .260 .1875 .156 .152 MB 600-187 A 500 

.218 ( 7 / 32") .225 .300 .2187 .187 .187 MB 600-218 A 500 

.250 ( 1 / 4") .260 .350 .2500 .218 .212 MB 600-250 A 500 

.281 ( 9 + .002 

0 

+ .004 

0 

+ .004 

0 

.0 

+ .004 

to max. 

0 

.012 

+ .004 

0 

+ .004 

0 

/ + .004 

32") .285 .380 .2812 .250 .250 MB 600-281 A 500 

0 

l 3 

min. 

x 

Type 




3



DIN 1.4305, AISI 303 


4 

d 1 

l 1 

l2 ~ 

d2 + 0.1 

0 

d 3 

max. 

l 3 

min. 

Ball: Bearing Steel 

Heat Treated 

3.0 3.6 4.6 3.0 2.2 3.4 0.4 MB 700-030 1000 

4.0 4.0 5.2 4.0 3.3 3.8 0.2 MB 700-040 1000 / 5000 

5.0 5.5 7.0 5.0 4.3 5.3 0.4 MB 700-050 1000 

6.0 6.5 8.6 6.0 5.3 6.3 0.4 MB 700-060 1000 / 2000 

7.0 7.5 10.1 7.0 6.4 7.3 0.4 MB 700-070 1000 

8.0 8.5 11.7 8.0 7.4 8.3 0.3 MB 700-080 500 

9.0 10.0 13.7 9.0 8.4 9.8 0.4 MB 700-090 500 

10.0 11.0 15.2 10.0 9.4 10.8 0.4 MB 700-100 500 

12.0 13.0 18.0 12.0 10.6 12.8 0.4 MB 700-120 250 

14.0 15.0 20.8 14.0 12.7 14.5 0.4 MB 700-140 250 

16.0 17.0 23.7 16.0 14.7 16,5 0.6 MB 700-160 100 

18.0 19.0 26.3 18.0 16.7 18.5 0.6 MB 700-180 100 

20.0 22.0 30.5 20.0 18.7 21.5 0.8 MB 700-200 100 

22.0 25.0 34.2 22.0 20.7 24.5 0.8 MB 700-220 50 

x 

± 0.2 

Type 





Sleeve: Case Hardening Steel 

DIN 1.0403, AISI 10L15 

Zinc plated chromate finish 


d 1 

l 1 

l2 ~ 

d2 + 0.1 

0 

d 3 

max. 

l 3 

min. 

Ball: Bearing Steel 

Heat Treated 

3.0 3.6 4.6 3.0 2.2 3.4 0.4 MB 800-030 1000 

4.0 4.0 5.2 4.0 3.3 3.8 0.2 MB 800-040 1000 / 5000 

5.0 5.5 7.1 5.0 4.3 5.3 0.4 MB 800-050 1000 / 2500 

6.0 6.5 8.7 6.0 5.3 6.3 0.4 MB 800-060 500 / 2000 

7.0 7.5 10.2 7.0 6.4 7.3 0.4 MB 800-070 1000 

8.0 8,5 11.6 8.0 7.4 8.3 0.3 MB 800-080 500 

9.0 10.0 13.6 9.0 8.4 9.8 0.4 MB 800-090 500 

10.0 11.0 15.2 10.0 9.4 10.8 0.4 MB 800-100 500 

12.0 13.0 17.9 12.0 10.6 12.8 0.4 MB 800-120 250 

14.0 15.0 20.6 14.0 12.7 14.5 0.4 MB 800-140 250 

16.0 17.0 23.4 16.0 14.7 16.5 0.6 MB 800-160 100 

18.0 19.0 26.4 18.0 16.7 18.5 0.6 MB 800-180 100 

20.0 22.0 30.1 20.0 18.7 21.5 0.8 MB 800-200 100 

22.0 25.0 34.0 22.0 20.7 24.5 0.8 MB 800-220 50 

x 

± 0.2 

Type 




5

Installation Instruction for MB Series 

Drilled Hole 

• The drilled hole must be within the tolerances shown on the preceding dimensional sheets. 

• The counterbored hole (d 2 ) must be properly sized for the through hole (d 3 ) according to the dimensional sheets. 

• Holes must be round within 0.05 mm. 

• With hard materials the bore roughness should be from R z = 10 - 30 µm for best results. 

• Longitudinal rifles and spiral grooves should be avoided. These influence the sealing effectiveness. 

• The bore must be free of oil, grease and chips. 

Installation Chart 

6 

F 

Fig. 1 

Fig. 2 

Fig. 3 

d1 [in] 

.093 .125 .156 .187 .218 .250 .281 

S [in] Stroke .031 .047 .059 .079 .094 .109 .118 

X [in] 

MB 600 Series Inch-Version 

Position of top of ball 

relative to top of sleeve 

Flush to .012 below 

the sleeve 

Setting Procedure 

• With the ball facing out the KOENIG-Expander is 

inserted in the counterbored hole. The top sleeve 

should not be above the surface of the base material. 

(Fig. 1) 

• With only a slight or no counterbore, the base of the 

sleeve must be adequately supported during 

installation. 

• The ball can now be pressed in until the top of the 

ball is below the edge of the sleeve. (Fig. 2 and 3) 

Corresponding approximate values for stroke S as 

well as the dimensions X are from the Table below. 

• Note: Use the proper size setting tool for the 

KOENIG-Expander according to the Data Sheet. 

Press 

Small quantities or single parts can be installed with a 

hammer and setting tool. Installation can also be done 

with an arbor press. It is preferred to limit travel when 

using a press because insertion force is difficult to control. 

KOENIG-Expanders are also ideal for automated installation 

because they are problem free. 

d1 [mm] 

3 4 5 6 7 8 9 10 12 14 16 18 20 22 

S [mm] Stroke 1.2 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.5 6.35 7.0 8.0 9.0 10.0 

X [mm] 

±0.2 

Position of top of ball 

relative to top of sleeve 

MB 600 / MB 700 / MB 800 

0.4 0.2 0.4 0.4 0.4 0.3 0.4 0.4 0.4 0.4 0.6 0.6 0.8 0.8 



Installation Instructions MB Series 

Setting Force 

MB 600/700 MB 800 MB 600 Inch-Version 

d 1 d 1 d 1 

Note: 1 kN = 224.8 lbf 

Measured in steel with a tensile strength of 1,000 N/mm 2 (145 ksi) . When installing in material with less strength 

the values are less. 

a) Force with minimum bore diameter tolerance. 

b) Force with maximum bore diameter tolerance. 

Plug Removal 

With KOENIG-Expander MB Series removal of the plug is possible. The plug can be drilled out with a carbide tipped 

drill or with a high speed steel drill. 

MB 600-030 to 140, Ball HB ~200: High Speed Steel Drill 

MB 600-093 A, Ball HRC ~ 55: Carbide Tipped Drill 

MB 600-125 A to 281 A, Ball HB ~200: High Speed Steel Drill 

MB 700-030 to 220, Ball HRC ~ 45: Carbide Tipped Drill 

MB 800-030 to 220, Ball HRC ~ 45: Carbide Tipped Drill 

Procedure 

• To Expander Diameter 6 mm or .250 inch. 

Drill out, in one process, to the next larger diameter according to the Data Sheet. 

• Expander-Diameters over 6 mm or .250 inch: 

Drill out in several steps with last step to the next larger diameter according to the Data Sheet. 

• Clear chips, remnants of the sleeve, and oil and grease from the bore. 

• Install a new KOENIG-Expander. 

Note: After plug removal always use the next larger diameter Expander. 



7

Setting Tools –MB Series 

Tools: Tool Steel 

Heat Treated Hardness ~ HRC 50 

8 

TOOLS 

d1 d3 - h9 

d2 l2 x 

Type 

l 1 

3.0 10 100 2.8 10 0.4 HT MB 030 

4.0 10 100 3.8 10 0.2 HT MB 040 

5.0 10 100 4.8 12 0.4 HT MB 050 

6.0 10 100 5.8 15 0.4 HT MB 060 

7.0 10 100 6.8 18 0.4 HT MB 070 

8.0 10 100 7.8 20 0.3 HT MB 080 

9.0 14 100 8.8 22 0.4 HT MB 090 

10.0 14 100 9.8 25 0.4 HT MB 100 

12.0 14 150 11.7 30 0.4 HT MB 120 

14.0 20 150 13.7 35 0.4 HT MB 140 

16.0 20 150 15.7 40 0.6 HT MB 160 

18.0 20 150 17.7 45 0.6 HT MB 180 

20.0 25 150 19.7 50 0.8 HT MB 200 

22.0 25 150 21.7 55 0.8 HT MB 220 

d 1 

d 3 

0 

–.002 

MB 600 / MB 700 / MB 800 (Dimensions in MM) 

MB 600 Inch-Version (Dimensions in Inches) 

.093 ( 3/32") .394 3.94 .082 .137 .012 HT MB 093 A 

.125 ( 1/8") .394 3.94 .117 .137 .012 HT MB 125 A 

.156 ( 5/32") .394 3.94 .148 .137 .012 HT MB 156 A 

.187 ( 3/16") .394 3.94 .180 .137 .012 HT MB 187 A 

.218 ( 7/32") .394 3.94 .211 .400 .012 HT MB 218 A 

.250 ( 1/4") .394 3.94 .242 .400 .012 HT MB 250 A 

.281 ( 9/32") .394 3.94 .273 .400 .012 HT MB 281 A 

± 0.2 

l 1 d 2 l 2 x 

0 

–.012 

Type 




Assembly Press–MB Series–Pressure and Stroke Control 

Type PH-450 

Type PH-550 

Technical Data PH-450 

AUTOMATION 

Hydropneumatic Table Press for the installation of MB 

and LP Series Koenig Sealing Plugs. Stroke control of 

press allows for consistent, repeatable installations to 

meet quality system performance goals. On-board 

monitoring of installation force with graph printing 

capabilities as well as computer data output. 

Further Equipment Styles: PH-400 / PH-500 

Table Press with stroke control but without 

installation force monitoring, graph printing capabilities, 

and data output. 

Dimensions Width 250 mm 

Width (control unit) 470 mm 

Height 1,190 mm 

Depth 750 mm 

Diameter Range 3 –7 mm (.093–.281 in.) 

Air Pressure 6 bar 

Air Consumption 5.3 L / Stroke 

Pressing Force 28 kN 

Power Stroke 3 mm 

Cylinder Ram ~ 60 mm 





Depth 750 mm 

Diameter Range 3 – 14 mm 


Air Consumption 16 L / Stroke 


Power Stroke max. 16 mm 





9

10 

NOTES 




Sidex-SK Series 

• 4-10 mm diameter, 

Extended mandrels for below 

surface installation 

•Working pressure to 500 Bar 

(7,250 psi) 

• Shorter Installed Length 

• Larger working tolerances 

0/+0.12 mm 

• Installs directly into drilled holes 

• Clean mechanical sealing through 

positive anchoring 

• Quick installation using handy rivet 

type tools 

Contents Page 

– Sidex-SK Series 12 

– Installation Instructions 13 

– Spacers 14 

– Setting Tools 15

Sidex-SK Series 


DIN 1.0403 ~ AISI 10L15 

Gun metal–finish 

One Piece Construction ideal for automated 

high production requirements. 

12 

d 1 

l3 

d1 l1 d2 l2 l3 max. 

l1 

d 2 

l 2 

l 4 

max. 

Mandrel: Heat Treatable Steel 

~ DIN 1.0728 

Special Oil Film Lubrication 

Bore Diameter 

4.0 4.5 2.50 39 9.0 6.5 4.0 SK 550-040 1000 

5.0 5.5 3.00 41 10.0 7.5 5.0 SK 550-050 1000 

6.0 6.5 3.40 43 12.0 8.0 6.0 SK 550-060 500 

7.0 

8.0 

7.5 

8.5 

4.10 

4.20 

38 

40 

14.0 

15.0 

9.0 

10.5 

7.0 

8.0 

+0.12 

0 

SK 550-070 

SK 550-080 

500 

500 

9.0 9.5 4.50 43 17.0 11.0 9.0 SK 550-090 250 

10.0 10.5 4.75 45 19.0 12.5 10.0 SK 550-100 250 

Extended Mandrel Version - allows insertion of up to 30 mm deep 


l 4 

max. 

Bore Diameter 

4.0 4.5 2.50 69 9.0 6.5 4.0 SK 552-040 1000 

5.0 5.5 3.00 71 10.0 7.5 5.0 SK 552-050 500 

6.0 6.5 3.40 73 12.0 8.0 6.0 SK 552-060 500 

7.0 

8.0 

7.5 

8.5 

4.10 

4.20 

68 

70 

14.0 

15.0 

9.0 

10.5 

7.0 

8.0 

+0.12 

0 

SK 552-070 

SK 552-080 

250 

250 

9.0 9.5 4.50 73 17.0 11.0 9.0 SK 552-090 100 

10.0 10.5 4.75 75 19.0 12.5 10.0 SK 552-100 100 

l4 

Type 

Type 




Installation Instructions Sidex-SK 

Drilled Hole 

• The drilled hole must be within the tolerances shown on the preceding data sheets. 






Fig. 1 

Fig. 2 

Fig. 3 

1. Insert the plug in the tool, making sure that the 

sleeve is against the nosepiece. (Fig. 1) 

2. After inserting the plug into the hole (making sure 

the tool is flush to the work surface) activate the tool 

to expand the plug. The mandrel will break apart 

when the proper tension has been reached. 

(Fig. 2 & 3) 

Note 

• The assembly of KOENIG-Expanders should only be 

done in a clean working area. 

• The sleeve and mandrel of the plug should not be 

cleaned or lubricated. 

Tools 

For trouble free installation of KOENIG-Expanders use the tools and appropriate components according to the data 

sheet. 

Plug Removal 

With KOENIG-Expander Sidex-SK Series plug removal is possible. 

Procedure: 

1. Drive the mandrel from the sleeve with a punch. 

2. Drill out the sleeve and remove the mandrel. 

3. Bore the hole to the next larger Expander diameter per the data sheet. 

4. Clear chips, remnants of the sleeve, and oil and grease from the bore. 

5. Install a new KOENIG-Expander. 

Note: After plug removal always install the next larger size plug. 



13

Spacers, Sidex Series 

Case Hardening Steel 

DIN 1.0403, ~AISI 10L15 

Case Hardened 

For setting KOENIG-Expander Sidex SK 

plugs with 30 mm longer mandrels 

14 


d1 d2 Type 

Sidex SK Series 

4.0 2.7 4X30-SK SK 552-040 

5.0 3.2 5X30-SK SK 552-050 

6.0 3.7 6X30-SK SK 552-060 

7.0 4.6 7X30-SK SK 552-070 

8.0 4.8 8X30-SK SK 552-080 

9.0 5.2 9X30-SK SK 552-090 

10.0 5.6 10X30-SK SK 552-100 

TOOLS 




Setting Tools–SK Series 

TOOLS 




15

Setting Tools–Sidex-SK Series 

Type KW-010 (shown) 

Hydraulic/Pneumatic Tool 

Type KW-010 MCS available. 

Features a vacuum mandrel collection system. 

Air Pressure max. 6.5 bar (95 psi) 

Air Consumption per Expander 1 dm 3 (61 in3 ) 

Weight 2.1 kg (4.6 lb.) 

16 

4 SKW-104 

Type KW-020 


Air pressure max. 6.5 bar (95 psi) 


d1 Nosepiece Jaw Case Jaws Jaw Pusher 

Tool 

TOOLS 

Type Type Type Type Type Type 

5 SKW-105 PRG740-11AE PRG540-46E 

6 SKW-106 PRG740-7A 

7 SKW--107 

8 SKW-108 

HKW-010308 HKW-014208 HKW-010508 

9 SKW-109 – 

10* SKW-110 

* For installation of d 1 =10 mm diameter plugs, the mandrel 

collection system must be turned off. 

PRG-14 

KW-010 KW-020 




HK Series 

• Extensive available stock from 

3-12 mm diameter, special 

oversize version and extended 

mandrels for below surface 

installation 

• Normal working tolerances 0/+0.1 

mm or 0/+0.05 mm 

• Direct installation in Hydraulic 

Component through holes 

• Clean, mechanical sealing 

• Quick installation using hand rivet 

type tools 

Contents Page 

– HK 55 Series 18 


– Spacers 21 


HK 55 Series 


DIN 1.0403, ~AISI 10L15 

Soft Annealed Gun Metal Finish 


18 


l 4 

max. 

Bore Diameter 

Mandrel: Heat Treatable Steel 

~DIN 1.0728 


3.0 5.0 2.0 36.5 9.0 7.0 3.0 HK030-CK55-111 100 

4.0 5.0 2.2 38.0 9.5 8.0 4.0 HK040-CK55-111 100/1000 

5.0 6.0 2.8 43.0 11.0 9.5 5.0 HK050-CK55-111 100/1000 

6.0 6.5 2.8 43.0 12.0 10.0 6.0 HK060-CK55-111 100/1000 

7.0 

8.0 

7.5 

8.5 

3.8 

4.5 

43.0 

38.0 

13.0 

13.5 

11.0 

11.5 

7.0 

8.0 

+ 0.1 

0 

HK070-CK55-111 

HK080-CK55-111 

Standard 

100/500 

100/500 

9.0 9.5 4.5 41.0 14.5 13.0 9.0 HK090-CK55-111 100/500 

10.0 10.5 4.5 41.0 15.5 13.5 10.0 HK100-CK55-111 100/250 

4.3 5.0 2.2 38.0 9.5 8.0 4.3 HK043-CK55-111 Oversize 

5.3 6.0 2.8 43.0 11.0 9.5 5.3 HK053-CK55-111 Version 

6.3 6.5 2.8 43.0 12.0 10.0 6.3 HK063-CK55-111 

7.3 

8.3 

9.3 

7.5 

8.5 

9.5 

3.8 

4.5 

4.5 

43.0 

38.0 

41.0 

13.0 

13.5 

14.5 

11.0 

11.5 

13.0 

7.3 

8.3 

9.3 

+ 0.1 

0 

HK073-CK55-111 

HK083-CK55-111 

HK093-CK55-111 

100 

10.3 10.5 4.5 41.0 15.5 13.5 10.3 HK103-CK55-111 

HK 11 Series 

Sleeve: Aluminum Alloy 

DIN 3.0615, AlMgSiPb 

Plain Finish 



l 4 

max. 

Bore Diameter 

Type 

Mandrel: Heat Treatable 

~DIN 1.0728 


12.0 12.0 6.0 40.0 17.5 15 12.0 + 0.5 

0 

HK120-CK11-111 Standard 250 

Type 







19

20 



TOOLS 




21

22 

HKW-002103 • 

HKW-002104 • 

HKW-002103 • 

HKW-002104 • 

HKW-002105 • 

TOOLS 




Setting Tools – HK Series 

TOOLS 




23

Setting Tools–HK-55 






Air Consumption per Expander 1 dm3 (61 in3 ) 


24 

Type KW-020 




TOOLS 

KW-010 KW-020 




Setting Tools–HK-11 



Type KW-010 MSC available. 





Type KW-020 




TOOLS 

KW-010 KW-020 




25

26 

NOTES 



LK Series 

• 4-12 mm diameter, 

•Working pressure to 60 Bar 

(870 psi) 

• Shortest Installed Length 

• Larger working tolerances 

0/+0.12 mm 

• Installs directly into drilled holes 

• Clean mechanical sealing through 

positive anchoring 

• Quick installation using handy rivet 

type tools 

• No axial loading imposed on 

component 

•Available in stainless steel 

Contents Page 

– LK 600 Series 28 

– LK 950 Series 29 



LK 600 Series 


DIN 1.4305, Plain Finish 




28 


l 4 

max. 

Mandrel: Stainless Steel 

DIN 1.4305, Plain Finish 


Bore Diameter 

4.0 3.7 2.2 36 5.5 4.0 4.0 LK-600-040 100/1000 

5.0 4.5 2.95 36 6.9 4.8 5.0 LK-600-050 100/1000 

6.0 5.0 3.4 36 7.4 5.3 6.0 LK-600-060 100/1000 

7.0 

8.0 

5.5 

6.5 

4.2 

4.3 

34 

34 

8.0 

9.8 

5.8 

6.8 

7.0 

8.0 

+0.12 

0 

LK-600-070 

LK-600-080 

100/500 

100/500 

9.0 6.5 4.7 34 9.8 6.8 9.0 LK-600-090 100/500 

10.0 6.5 5.1 36 9.8 6.8 10.0 LK-600-100 100/500 

12.0 7.5 5.9 36 10.8 7.8 12.0 LK-600-120 100/250 

Type 




LK 950 Series 


Soft Annealed Gun Finish 




l 4 

max. 

Mandrel: Steel Plain Finish 


Bore Diameter 

4.0 3.7 2.2 36 5.5 4.0 4.0 LK-950-040 100/1000 

5.0 4.5 2.95 36 6.9 4.8 5.0 LK-950-050 100/1000 

6.0 5.0 3.4 36 7.4 5.3 6.0 LK-950-060 100/1000 

7.0 

8.0 

5.5 

6.5 

4.2 

4.3 

34 

34 

8.0 

9.8 

5.8 

6.8 

7.0 

8.0 

+0.12 

0 

LK-950-070 

LK-950-080 

100/500 

100/500 

9.0 6.5 4.7 34 9.8 6.8 9.0 LK-950-090 100/500 

10.0 6.5 5.1 36 9.8 6.8 10.0 LK-950-100 100/500 

12.0 7.5 5.9 36 10.8 7.8 12.0 LK-950-120 100/250 

Type 




29

Installation Instructions LK Series 

Drilled Hole 

• The drilled hole must be within the tolerances shown on the preceding data sheets. 






30 

Fig. 1 

Fig. 2 

Fig. 3 

1. Insert the plug in the tool, making sure that the 

sleeve is against the nosepiece. (Fig. 1) 

2. After inserting the plug into the hole activate the tool 

to expand the plug. The mandrel will break apart 

when the proper tension has been reached. 

(Fig. 2 & 3) 

Note 

• The assembly of KOENIG-Expanders should only be 

done in a clean working area. 

• The sleeve and mandrel of the plug should not be 

cleaned or lubricated. 

Tools 

For trouble free installation of KOENIG-Expanders use the tools and appropriate components according to the data 

sheet. 

Plug Removal 

With KOENIG-Expander LK Series plug removal is possible. 

Procedure: 

1. Drive the mandrel from the sleeve with a punch. 

2. Drill out the sleeve and remove the mandrel. 

3. Bore the hole to the next larger Expander diameter per the data sheet. 

4. Clear chips, remnants of the sleeve, and oil and grease from the bore. 

5. Install a new KOENIG-Expander. 

Note: After plug removal always install the next larger size plug. 



Setting Tools–LK Series 

TOOLS 




31

Setting Tools–LK Series 








32 

4 LKW-104 

Type KW-020 




d1 Nosepiece Jaw Case Jaws Jaw Pusher 

Tool 

TOOLS 

Type Type Type Type Type Type 

5 LKW-105 PRG740-11AE PRG540-46E 

6 LKW-106 PRG740-7A 

7 LKW--107 

8 LKW-108 

9 LKW-109 

HKW 010308 

PRG-14 

HKW 014208 HKW 010508 

10 LKW-110 

12 LKW-112 HKW-014210 10X30 

KW-010 KW-020 




LP Series 

• Mechanical labyrinth sealing 

• Satisfactory corrosion protection 

• Rated pressure performances up to 

60 bar (870 psi) 

• Suitable for fully automated 

installation 

Contents Page 

– LP 900 Series 34 



LP 900 Series Sealing Plugs 

Material: Free Cutting Steel 

Nitrocarburized, Lubricated 

34 





Installation Instructions LP Series 



35

Setting Tools, LP Series 

Tools: Tool Steel 

Heat Treated Hardness – HRC50 

36 

TOOLS 




Assembly Press–LP Series–Pressure and Stroke Control 

Type PH-450 

Type PH-550 


AUTOMATION 

Hydropneumatic Table Press for the installation of MB 

and LP Series Koenig Sealing Plugs. Stroke control of 

press allows for consistent, repeatable installations to 

meet quality system performance goals. On-board 

monitoring of installation force with graph printing capabilities 

as well as computer data output. 

Further Equipment Styles: PH-400 / PH-500 

Table Press with stroke control but without 

installation force monitoring, graph printing capabilities, 

and data output. 




Depth 750 mm 

Diameter Range 3 –7 mm (.093–.281 in.) 


Air Consumption 5.3 L / Stroke 


Power Stroke 3 mm 






Depth 750 mm 

Diameter Range 3 – 14 mm 


Air Consumption 16 L / Stroke 


Power Stroke max. 16 mm 




37

38 

NOTES 



Technical 

Information 

Engineering: 

Design and development 

with state-of-the-art 

CAD-Design. 

Profile Projector – 

Measuring Instrument for in-process 

control of production. 

Contents Page 

– Pressure Performance Tests 41 

– Pressure Performance 

MB 600 42 

MB 600, Inch-Version 44 

MB 700 46 

MB 800 48 

Sidex-SK 50 

HK 55 52 

LK 600 54 

LK 950 56 

LP 900 58 

– Anchorage Principle 60 

– Hole Roughness: Requirements 62 

– Design Guidelines 63 

– Galvanic Corrosion 67 

– Chart: Hardness cross reference for 

plain and low alloy steels 69 

– SI-Units of Measurement 70 

– American and British 

Units of Measurement 72

40 

NOTES 



T 



41

42 

T 



Pressure Performance MB 600 

Installation Requirements 

The working pressure specifications on the preceding page are obtainable under the following conditions. 

➀ 

➁ 

➂ 

➃ 

➎ 

➅ 

➐ 

Base Material of the 

Installation 

High Strength St. 

ETG-100 

AISI 1144 

Free Machining Case 

Hard. Stl. 

C15 Pb 

DIN 1.0403 

Cast Iron 

GG-25 

DIN 1691 

Ductile Cast Iron 

GGG-50 

DIN 1693 

Aluminum Alloy 

Al Mg Si Pb 

DIN 3.0615 

AA6262 


Al Cu Mg 2 

DIN 3.1354 

AA2024 

Cast Al Alloy 

G-Al Si 7 Mg 

3.2371 

AA356-T6 

Tensile Strength 

(avg.) [N/mm 2 ] 

Elongation (min.) 

[%] 

1000 6 865 280 

560 6 300 180 

250 – – 160 

500 7 320 170 

340 8 300 90 

480 8 380 120 

300 4 250 80 

• Equivalent working pressure capability can be obtained when using base materials with similar mechanical 

characteristics. However, the appropriate installation instructions must be followed. 

• Applications for other non-ferrous metals and non-metallic materials upon request. 

• Factors which may lower the working pressure capability are: 

- anchorage principle 

- bore roughness requirements 

- design guidelines 

Ultimate Strength 

(avg.) Rp 0.2 [N/mm 2 ] 

Hardness 

(min.) HB 

Drilled Hole 

Tolerance [mm] Roughness R z [µm] 

• Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB=30 greater than 

the base material. If the hardness difference is less, hole roughness of 10 to 30 µm is needed to achieve 

indicated working pressures. 

Security Range 

The security range (the difference between working pressure and Test B pressure) allows for uncontrollable 

variations. For instance, dynamic loading at 1 million cycles and a frequency of 3-4Hz has shown that burst 

pressure Test A and Test B pressure are reduced about 20% after this point. 

+ 0.1 

0 

T 

10 to 30 

anchorage 

in 

base metal 



43

Pressure Performance MB 600, Inch-Version 

Sleeve Material: X 10 CrNiS 18 9 Tensile Strength Rm = 640 N/mm 2 

DIN 1.4305 Hardness HB = 220 

44 

p [bar] 

1600 

1400 

1200 

1000 

800 

600 

400 

200 

.093 

( 3/32") 

➀➁➂➃➅ 

➎➐ 

1,400 bar (20,300 psi) 

1,200 bar (17,400 psi) 

450 bar (6,500 psi) 

380 bar (5,500 psi) 

.125 

( 1/8") 

.156 

( 5/32") 

Proof Pressure Test B 

Base Material 

.187 

( 3/16") 

➀➁➂➃➅ 

➎➐ 

➀➁➂➃➅ 

➎➐ 

.218 

( 7/32") 

Expander Diameter [in] 

.250 

( 1/4") 

.281 

( 9/32") 

20,000 

15,000 

10,000 

5,000 

T 

p [psi] 

Max. Allowable Working Pressure = Nominal Pressure 



Pressure Performance MB 600, Inch-Version 



➀ 

➁ 

➂ 

➃ 

➎ 

➅ 

➐ 


Installation 


ETG-100 

AISI 1144 


Hard. Stl. 

C15 Pb 

DIN 1.0403 

Cast Iron 

GG-25 

DIN 1691 


GGG-50 

DIN 1693 


Al Mg Si Pb 

DIN 3.0615 

AA6262 


Al Cu Mg 2 

DIN 3.1354 

AA2024 

Cast Al Alloy 

G-Al Si 7 Mg 

3.2371 

AA356-T6 


(avg.) [N/mm 2 ] 


[%] 


(avg.) Rp 0.2 [N/mm 2 ] 

Hardness 

(min.) HB 

1000 6 865 280 

560 6 300 180 

250 – – 160 

500 7 320 170 

340 8 300 90 

480 8 380 120 

300 4 250 80 

Drilled Hole 

T 

Tolerance [in.] Roughness R z [µm] 

ø .093 

from 

ø .125 

+ 0.002 

0 

+ 0.004 

0 

10 to 30 

anchorage 

in 

base metal 

















45


Sleeve Material: Stainless Steel, AISI 303 Tensile Strength Rm = 640 N/mm 2 


p [bar] 

46 

1600 

1400 

1200 

1000 

800 

600 

400 

200 

3 

1,400 bar (20,300 psi) 

1,200 bar (17,400 psi) 

450 bar (6,500 psi) 

380 bar (5,500 psi) 

➀➁➂➃➅ 

➎➐ 

4 5 6 7 8 9 10 12 14 16 18 20 22 


Base Material 

➎➐ 

➀➁➂➃➅ 

➎➐ 

➀➁➂➃➅ 

Expander Diameter [mm] 

1,150 bar (16,700 psi) 

900 bar (13,000 psi) 

350 bar (5,100 psi) 

280 bar (4,100 psi) 

T 

20,000 

15,000 

10,000 

5,000 




p [psi]




➀ 

➁ 

➂ 

➃ 

➎ 

➅ 

➐ 


Installation 


ETG-100 

AISI 1144 


Hard. Stl. 

C15 Pb 

DIN 1.0403 

Cast Iron 

GG-25 

DIN 1691 


GGG-50 

DIN 1693 


Al Mg Si Pb 

DIN 3.0615 

AA6262 


Al Cu Mg 2 

DIN 3.1354 

AA2024 

Cast Al Alloy 

G-Al Si 7 Mg 

3.2371 

AA356-T6 


(avg.) [N/mm 2 ] 


[%] 

1000 6 865 280 

560 6 300 180 

250 – – 160 

500 7 320 170 

340 8 300 90 

480 8 380 120 

300 4 250 80 









(avg.) Rp 0.2 [N/mm 2 ] 

Hardness 

(min.) HB 

Drilled Hole 

T 









+ 0.1 

0 

10 to 30 

anchorage 

in 

base metal 



47


Sleeve Material: Case Hardening Steel Tensile Strength Rm = 500 N/mm 2 

DIN 1.0403 Hardnesss H = 180 

p [bar] 

48 

1600 

1400 

1200 

1000 

800 

600 

400 

200 

3 

1,100 bar (16,000 psi) 

1,000 bar (14,500 psi) 

350 bar (5,100 psi) 

320 bar (4,600 psi) 

4 5 6 7 8 9 10 12 14 16 18 20 22 

➀➁➂➃➅ 

➎➐ 

➎➐ 


Base Material 

➎➐ 

➀➁➂➃➅ 

➀➁➂➃➅ 


900 bar (13,000 psi) 

800 bar (11,600 psi) 

280 bar (4,100 psi) 

250 bar (3,600 psi) 

T 

20,000 

15,000 

1,000 

5,000 




p [psi]




➀ 

➁ 

➂ 

➃ 

➎ 

➅ 

➐ 


Installation 


ETG-100 

AISI 1144 

Free Machining 

CasehHard. St. 

C15Pb 

DIN 1.0403 

Cast Iron 

GG-25 

DIN 1691 


GGG-50 

DIN 1693 


Al Mg Si Pb 

DIN 3.0615 

AA6262 


Al Cu Mg 2 

DIN 3.1354 

AA2024 

Cast Al Alloy 

G-Al Si 7 Mg 

DIN 3.2371 

AA356-T6 


(avg.) 

Rm [N/mm 2 ] 


[%) 

1000 6 865 280 

560 6 300 180 

250 – – 160 

500 7 320 170 

340 8 300 90 

480 8 380 120 

300 4 250 80 








Ultimate Stength 

(avg.) 

Rp 0.2 [N/mm 2 ] 

T 

Hardness 

Drilled Hole 

(min.) 

HB Tolerance [mm] Roughness Rz [µm] 








+ 0.1 

0 

10 to 30 

anchorage 

in 

base metal 



49

Pressure Performance Sidex-SK 

Sleeve Material : Case Hardening Steel Tensile Strength Rm = 500 N/mm 2 


50 

➀➁➂➃➅ 

➎➐ 

1800 

1600 

1400 

1200 

1000 

800 

600 

400 

200 

4 

1,600 bar (23,200 psi) 

1,400 bar (20,300 psi) 

500 bar (7,200 psi) 

450 bar (6,500 psi) 


Base Material 

➀➁➂➃➅ 

➎➐ 

➀➁➂➃➅ 

➎➐ 

5 6 7 8 9 10 


25,000 

20,000 

15,000 

10,000 

5,000 

p [psi] 

T 




Pressure Performance Sidex-SK 



➀ 

➁ 

➂ 

➃ 

➎ 

➅ 

➐ 


Installation 


ETG-100 

AISI 1144 


Hard. Stl. 

C15 Pb 

DIN 1.0403 

Cast Iron 

GG-25 

DIN 1691 


GGG-50 

DIN 1693 


Al Mg Si Pb 

DIN 3.0615 

AA6262 


Al Cu Mg 2 

DIN 3.1354 

AA2024 

Cast Al Alloy 

G-Al Si 7 Mg 

3.2371 

AA356-T6 


(avg.) [N/mm 2 ] 


[%] 

1000 6 865 280 

560 6 300 180 

250 – – 160 

500 7 320 170 

340 8 300 90 

480 8 380 120 

300 4 250 80 









(avg.) Rp 0.2 [N/mm 2 ] 

Hardness 

(min.) HB 

Drilled Hole 

T 


+ 0.12 

0 

• If pressure is applied to both sides of the Sidex-SK plug, allowable working pressure on the insertion side is reduced 

by 50%. 








10 to 30 

anchorage 

in 

base metal 



51

Pressure Performance HK 55 

Sleeve Material : Case Hardening Steel, soft annealed Tensile Strength Rm = 350 N/mm 2 


52 

p [bar] 

1600 

1400 

1200 

1000 

800 

600 

400 

200 

3 

➀➁➂➃➅ 

➎➐ 

1,200 bar (17,400 psi) 

500 bar (7,200 psi) 

350 bar (5,100 psi) 

160 bar (2,300 psi) 

450 bar (6,500 psi) 

4 5 6 7 8 9 10 


Base Material 

➀➁➂➃ 

➎➏➐ 

➀➁➂➃ 

➎➏➐ 


20,000 

15,000 

10,000 

5,000 

p [psi] 

T 




Pressure Performance HK 55 



➀ 

➁ 

➂ 

➃ 

➎ 

➏ 

➐ 


Installation 


ETG-100 

AISI 1144 


Hard. Stl. 

C15 Pb 

DIN 1.0403 

Cast Iron 

GG-25 

DIN 1691 


GGG-50 

DIN 1693 


Al Mg Si Pb 

DIN 3.0615 

AA6262 


Al Cu Mg 2 

DIN 3.1354 

AA2024 

Cast Al Alloy 

G-Al Si 7 Mg 

3.2371 

AA356-T6 


(avg.) [N/mm 2 ] 


[%] 

1000 6 865 280 

560 6 300 180 

250 – – 160 

500 7 320 170 

340 8 300 90 

480 8 380 120 

300 4 250 80 









(avg.) Rp 0.2 [N/mm 2 ] 

Hardness 

(min.) HB 

Drilled Hole 

T 


• If HK plugs are used to keep channels separate, allowable working pressure on the insertion side is reduced by 

50%. 








+ 0.1 

0 

10 to 30 

roughness 

anchoring not 

effective 

* 

anchorage 

in 

base metal 

not possible 



53

Pressure Performance LK 600 

54 

p [bar] 

200 

180 

160 

140 

120 

100 

80 

60 

40 

➀➁➂➃➄➅➆ 

Base Material 

4 

180 bar (2,600 psi) 

60 bar (870 psi) 


➀➁➂➃➄➅➆ 

➀➁➂➃➄➅➆ 

5 6 7 8 9 10 


p [psi] 

T 

3,000 

2,500 

2,000 

1,500 

1,000 


➀➁➂➃➄ Temperature range for Proof Pressure Test B : -40ºC to +150ºC 

➅➆ Temperature range for Proof Pressure Test B : -40ºC to +100ºC 



12




➀ 

➁ 

➂ 

➃ 

➄ 

➅ 

➆ 


Installation 


ETG-100 

AISI 1144 


Hard. Stl. 

C15 Pb 

DIN 1.0403 

Cast Iron 

GG-25 

DIN 1691 


GGG-50 

DIN 1693 


Al Mg Si Pb 

DIN 3.0615 

AA6262 


Al Cu Mg 2 

DIN 3.1354 

AA2024 

Cast Al Alloy 

G-Al Si 7 Mg 

3.2371 

AA356-T6 


(avg.) [N/mm 2 ] 


[%] 

1000 6 865 280 

560 6 300 180 

250 – – 160 

500 7 320 170 

340 8 300 90 

480 8 380 120 

300 4 250 80 









(avg.) Rp 0.2 [N/mm 2 ] 

Hardness 

(min.) HB 

• Series LK are not suitable for pressure load applied on the insertion side of plug. 

Drilled Hole 

T 


+ 0.12 

0 








10 to 30 

anchorage 

in 

base metal 



55


56 

p [bar] 

200 

180 

160 

140 

120 

100 

80 

60 

➀➁➂➃➄➅➆ 

Base Material 

180 bar (2,600 psi) 

60 bar (870 psi) 

4 5 6 7 8 9 10 


➀➁➂➃➄➅➆ 

➀➁➂➃➄➅➆ 


12 

T 

2,500 

2,000 

1,500 

1,000 

p [psi] 









➀ 

➁ 

➂ 

➃ 

➄ 

➅ 

➆ 


Installation 


ETG-100 

AISI 1144 


Hard. Stl. 

C15 Pb 

DIN 1.0403 

Cast Iron 

GG-25 

DIN 1691 


GGG-50 

DIN 1693 


Al Mg Si Pb 

DIN 3.0615 

AA6262 


Al Cu Mg 2 

DIN 3.1354 

AA2024 

Cast Al Alloy 

G-Al Si 7 Mg 

3.2371 

AA356-T6 


(avg.) [N/mm 2 ] 


[%] 

1000 6 865 280 

560 6 300 180 

250 – – 160 

500 7 320 170 

340 8 300 90 

480 8 380 120 

300 4 250 80 









(avg.) Rp 0.2 [N/mm 2 ] 

Hardness 

(min.) HB 

• Series LK are not suitable for pressure load applied on the insertion side of plug. 

Drilled Hole 

T 


Diameter 

4 to 12mm 

+ 0.12 

0 








10 to 30 

Partial 

Anchorage 

10 to 30 

Anchorage in 

base material 



57

Pressure Performance LP 900 

58 

p [bar] 

200 

180 

160 

140 

120 

100 

80 

60 

➀➁➂➃➄➅➆ 

Base Material 

180 bar (2,600 psi) 

60 bar (870 psi) 

4 5 6 7 8 9 10 


➀➁➂➃➄➅➆ 

➀➁➂➃➄➅➆ 


12 

T 

2,500 

2,000 

1,500 

1,000 

p [psi] 






Pressure Performance LP 900 



➀ 

➁ 

➂ 

➃ 

➄ 

➅ 

➆ 


Installation 


ETG-100 

AISI 1144 


Hard. Stl. 

C15 Pb 

DIN 1.0403 

Cast Iron 

GG-25 

DIN 1691 


GGG-50 

DIN 1693 


Al Mg Si Pb 

DIN 3.0615 

AA6262 


Al Cu Mg 2 

DIN 3.1354 

AA2024 

Cast Al Alloy 

G-Al Si 7 Mg 

3.2371 

AA356-T6 


(avg.) [N/mm 2 ] 


[%] 

1000 6 865 280 

560 6 300 180 

250 – – 160 

500 7 320 170 

340 8 300 90 

480 8 380 120 

300 4 250 80 









(avg.) Rp 0.2 [N/mm 2 ] 

Hardness 

(min.) HB 

Drilled Hole 

T 


Diameter 

3 to 12 mm 

(see data 

sheet) 








10 to 30 

anchorage 

in 

base metal 



59

Anchorage Principle 

60 

T 

The required bore roughness is directly related to the hardness and the mechanical characteristics of the base 

material. Depending on the combination of sealing plug and base material, anchorage takes place either by the 

groove profile of the expander sleeve biting into the base material or on anchorage to the surface roughness of 

the bore. 

NOTE: When selecting a KOENIG Expander the bore roughness must always be adjusted according to the 

hardness of the base material. 

Anchorage principle related to base material 



Anchorage Principle 

Anchorage due to plug sleeve serrations 

KOENIG Expander Series MB 800 

in aluminum alloy HB = 90 


KOENIG Expander Series LP 900 



KOENIG Expander Series SK 

in aluminum alloy HB=90 

Anchorage due to bore roughness 

KOENIG Expander Series HK 55 

in gray cast iron HB = 160 


KOENIG Expander Series LK 950 


T 



61

Bore Roughness Requirements 

62 

T 

When installing KOENIG-Expanders in hard base material no positive anchoring is possible. So, to attain suitable 

working pressures and anchorage, it is necessary to have a bore roughness of Rz=10-30 µm. At a roughness greater 

than Rz=10-30 µm leakage might occur. 

Pressure performance correlation to bore roughness. 

% of test pressure, Test B , and allowable working pressure 

100 

80 

60 

40 

20 

Roughness Profile 

Required roughness profile 

1 2 3 4 5 6 7 8 9 10 20 30 

The ideal bore roughness for anchorage is attained by 

drilling with a twist drill or core drill. 

Roughness R Z [µm] 

(Approximate) 

Undesirable roughness profile 

By reaming, a one-sided, smooth roughness profile is 

created. This is not desirable. 



Design Guidelines 

T 

Wall thickness/distance from edge 

As the radial expansion of the KOENIG Expander sleeve occurs, the base material in which it will be anchored 

plastically deforms. The resultant strength, as well as the hydraulic pressure and temperature service conditions 

depending on the expander type and characteristics of the base material, require minimum wall thickness, or 

distance from edge. 

The guideline values for minimum wall thickness and distance from edge (Wmin) express these influencing factors. 

At these minimum values, only slight deformation on the exterior profile of the base material of less than 20 µm is 

likely. This does not affect the function of the KOENIG Expander. Below the guideline values (Wmin ) the possibility 

of overloading the base material exists, which can adversely influence the function of the KOENIG Expander. In such 

cases tests must be conducted. 

Guideline values W min for wall thickness and distance from edge 

At KOENIG Expander diameters d1 ≥ 4mm: Wmin = fmin · d1 

d1


Required Installation Lengths 

64 


l 3 

d 1 

l 4 

d N 

d 1 

l 4 

d N =d 1 

d 1 

l 4 

d N =d 1 

d 1 

T 

MB Sidex-SK 

HK 

Threaded Plugs 

dN HK 55 HK 11 

DIN 908 

d1 l3 min l4 min* d1 l4 max d1 l4 max d1 l4 max d1 l4 max 

2.0 3.0 3.4 5.0 

3.0 4.0 3.8 5.5 3.0 7.0 3.0 6.5 

4.0 5.0 5.3 7.0 4.0 6.5 4.0 8.0 4.0 8.0 

5.0 6.0 6.3 8.5 5.0 7.5 5.0 9.5 5.0 10.0 M 8x1 11.5 

6,0 7.0 7.3 9.5 6.0 8.0 6.0 10.0 6.0 10.0 M 8x1 11.5 

7.0 8.0 8.3 11.0 7.0 9.0 7.0 11.0 7.0 10.5 M10x1 12.0 

8.0 9.0 9.8 12.5 8.0 10.5 8.0 11.5 8.0 13.5 M10x1 12.0 

9.0 10.0 10.8 13.5 9.0 11.0 9.0 13.0 9.0 13.0 M12x1.5 16.0 

10.0 12.0 12.8 16.0 10.0 12.5 10.0 13.5 10.0 15.5 M12x1.5 16.0 

12.0 14.0 14.5 18.0 12.0 15.0 M14x1.5 16.5 

14.0 16.0 16.5 20.0 M16x1.5 16.5 

16.0 18.0 18.5 22.5 M18x1.5 17.5 

18.0 20.0 21.5 25.5 M20x1.5 19.5 

20.0 22.0 24.5 28.5 M22x1.5 19.5 

d N = given nominal bore/system bore size 

* Installation Lengths MB Series 

Comparison 

The required installation length (l 4 ) min. for MB plugs is for base materials with hardness greater than HB=90. For 

softer materials, deeper installation is required. 



l 4 

d N



T 



65


66 

T 

Roundness Tolerance 

To assure reliable functioning of the KOENIG-Expander with regard to pressure performance and to assure leak tight 

sealing, a roundness tolerance of t=0.05 mm must be held. 

By using a double lipped twist drill, the called out hole 

and roundness tolerances are reached. Better 

tolerances, particularly for larger diameter holes, can be 

held by using a triple lipped twist drill. 

Conicity of the Bore 

Within the effective sealing area of the KOENIG Expander, the bore must be according to the dimensional sheets. 

The bore lead in can be beveled up to a depth of 0.25 x d1 (LK: 0.15 x d1) because this area has no significant effect 

on the sealing function. 

MB SK HK 

LP LK 



Galvanic Corrosion 

T 

In choosing a KOENIG Expander you must consider that the material of the sealing plug and the material of the 

production piece can show different electrical potentials. In the presence of an electrolyte (e.g. 5% Water-NaCl 

solution), this potential difference causes electrochemical attack on the least noble of the metals in contact - galvanic 

corrosion. In this case, either the base material or its surface protection will become the anode and will be 

transferred to the pure metal of the cathode. The corrosion speed or the current density will be determined by the 

relative surface area or volume of the anode and cathode as illustrated below. 

Cathode 

Anode 

KOENIG-Expander = Cathode 

Large Anode Area → Low Current Density at the Anode → Slow Corrosion 

KOENIG-Expander = Anode 

Small Anode Area → High Current Density at the Anode → Fast Corrosion 

Base Material = Anode 

Base Material l = Cathode 



67

Galvanic Corrosion 

Effect of Galvanic Corrosion 

The following table shows the expected galvanic corrosion behavior of KOENIG Expanders in common base 

materials allowing for the relative surface areas of both metals, which influences the speed of corrosion. 

Base Material 

Steel, carbon/low alloy, plain 

Steel, carbon/low alloy, Zn plated, chromate 

Steel, carbon/low alloy, phosphatized 

Nitrided or case hardening steel behavior depends on the method used 

Stainless steel, DIN 1.4305, AISI 303 

Stainless steel, DIN 1.4005, AISI 416 

Cast iron, GG, DIN 1691, plain 

Cast iron, GG, DIN 1691, Zn plated, chromate 

Cast iron, GG DIN 1691, phosphatized 

Ductile cast iron, GGG DIN 1693, plain 

Ductile cast iron, GGG DIN 1693, Zn plated, chromate 

Ductile cast iron, GGG DIN 1693 phosphatized 

Aluminum alloy, Ws-Nr. 3.3211, AA 6061 

Aluminum alloy, Ws-Nr. 3.0615, ~AA 6262 



Cast aluminum alloy, Ws-Nr. 3.2371, AA 356-T6 

Cast aluminum alloy, Ws-Nr. 3.2373 

Cast aluminum alloy, Ws-Nr. 3.2381 

68 

KOENIG Expander Series 

T 

Key to the galvanic corrosion behavior of KOENIG-Expanders in the presence of an electrolytic medium installed in 

base materials per the above table: 

Not accelerated 

Lightly accelerated 

Accelerated 

Marked acceleration 

Suggestions to prevent galvanic corrosion 

• Chose materials with no or low potential difference. 

• Use corrosion reducing designs, i.e. if possible prevent the accumulation of fluids on the outer surface of the 

workpiece. 

• By using suitable surface coatings, corrosion attack can be considerably reduced. 

Salt spray testing per DIN 50021 can be done in our lab. 

MB 600 

MB 700 



MB 800 

SK 

HK 55 

HK 11 

LP 900 

LK 600 

LK 950

Hardness Conversion Table for Hardenable Carbon and Low Alloy Steel. 

Taken from DIN 50150-Issued 12/76 

Tensile Vickers- Brinell- Rockwell 

Tensile Vickers- Brinell- Rockwell 

Strength2) Hardness Hardness1) 

Hardness Strength2) Hardness Hardness 1) Hardness 

N/mm 2 (F ≥ 98 n) HRB HRC HRA 

255 80 76 

270 85 80.7 41 

285 90 85.5 48 

305 95 90.2 52 

320 100 95 56.2 

335 105 99.8 

350 110 105 62.3 

370 115 109 

385 120 114 66.7 

400 125 119 

415 130 124 71.2 

430 135 128 

450 140 133 75 

465 145 138 

480 150 143 78.7 

495 155 147 

510 160 152 81.7 

530 165 156 

545 170 162 85 

560 175 166 

575 180 171 87.1 

595 185 176 

610 190 181 89.5 

625 195 185 

640 200 190 91.5 

660 205 195 92.5 

675 210 199 93.5 

690 215 204 94 

705 220 209 95 

720 225 214 96 

740 230 219 96.7 

755 235 223 

770 240 228 98.1 20.3 60.7 

785 245 233 21.3 61.2 

800 250 238 99.5 22.2 61.6 

820 255 242 23.1 62 

835 260 247 (101) 24 62.4 

850 265 252 24.8 62.7 

865 270 257 (102) 25.6 63.1 

880 275 261 26.4 63.5 

900 280 268 (104) 27.1 63.8 

915 285 271 27.8 64.2 

930 290 276 (105) 28.5 64.5 

950 295 280 29.2 64.8 

965 300 285 29.8 65.2 

995 310 295 31 65.8 

1030 320 304 32.2 66.4 

1060 330 314 33.3 67 

1095 340 323 34.3 67.6 

1125 350 333 35.5 68.1 

T 

N/mm 2 (F ≥ 98 n) HRB HRC HRA 

1155 360 342 36.6 68.7 

1190 370 352 37.7 69.2 

1220 380 361 38.8 69.8 

1255 390 371 39.8 70.3 

1290 400 380 40.8 70.8 

1320 410 390 41.8 71.4 

1350 420 399 42.7 71.8 

1385 430 409 43.6 72.3 

1420 440 418 44.5 72.8 

1455 450 428 45.3 73.3 

1485 460 437 46.1 73.6 

1520 470 447 46.9 74.1 

1555 480 (456) 47.7 74.5 

1595 490 (466) 48.4 74.9 

1630 500 (475) 49.1 75.3 

1665 510 (485) 49.8 75.7 

1700 520 (494) 50.5 76.1 

1740 530 (504) 51.1 76.4 

1775 540 (513) 51.7 76.7 

1810 550 (523) 52.3 77 

1845 560 (532) 53 77.4 

1880 570 (542) 53.6 77.8 

1920 580 (551) 54.1 78 

1955 590 (561) 54.7 78.4 

1995 600 (570) 55.2 78.6 

2030 610 (580) 55.7 78.9 

2070 620 (589) 56.3 79.2 

2105 630 (599) 56.8 79.5 

2145 640 (608) 57.3 79.8 

2180 650 (618) 57.8 80 

660 58.3 80.3 

670 58.8 80.6 

680 59.2 80.8 

690 59.7 81.1 

700 60.1 81.3 

720 61 81.8 

740 61.8 82.2 

760 62.5 82.6 

780 63.3 83 

800 64 83.4 

820 64.7 83.8 

840 65.3 84.1 

860 65.9 84,4 

880 66.4 84.7 

900 67 85 

920 67.5 85.3 

940 68 85.6 

Numbers in brackets indicate hardness values, which are 

outside the definition area of the standard hardness test, but 

actually often used as approximate values. 

But the Brinell values in brackets are only used when 

measured with a hard metal ball. 

1) Calculated as: HB = 0.95 HV 

2) The tensile strength values shown in the table are only to be used 

as approximate values. To get the exact tensile 

strength values a tensile test must be performed. 



69

SI-Units 

70 

T 

The following table gives an overview of the SI units used in this catalog. 

NOTE: Units listed in previous conversion tables, are no longer valid according to the international unit system (SI). 

Measurement Symbol SI-Unit (Name) Other Valid Units Relationship Between 

SI-Units 

Length l m (Meter) 

Area m2 (Sq. meter) a (Are), ha (Hectare) 1 a = 100 m 2 

A 

Volume m3 (Cubic meter) l (Liter) 1 l = 1 dm3 V 

Time t s (Second) 

min (Minute), h (Hour), 

d (Day) 

1 min = 60 s 

1 h = 3600 s 

Speed v m/s km/h 1 km/h = 0.2778 m/s 

Frequency f Hz (Hertz) 1/s 1 Hz = 1/s 

Revolutions n 1/s 1/min 

Weight m kg (Kilogramm) g (Gram), t (Ton) 1 t = 1000 kg 

Tightness kg/m 3 

δ 

Force N (Newton) 1 kg m/s2 F 

Torque Nm 

1 Pa = 1 N/m 

Pressure Pa (Pascal) 

2 

1 bar = 105 Pa 

1 mm Hg = 1.3332 · 102 Pa 

Mech. Tensile 

Strength N/mm2 Pa 1 N/mm2 = 106 Pa 

Volumetric Flow m3 M 

bar (Bar) 

P 

mm Hg (Millimeters of 

mercury) 

σ,τ 

R 

V /s 

° 

Temperature T K (Kelvin) °C 

Conversion Table 

Former units in comparison and relationship to the SI system 

Units of Force Mechanical Tensile Strength: 

N kp. kgf dyn 

1 N 1 0.102 10 5 

1 kp. 1 kgf 9.81 1 9.81·10 5 

1 dyn 10 –5 1.02·10 6 1 

°C = K - 273.15 

∆T °C = ∆T K 

Pa N/mm 2 kp/mm 2 

1Pa=1N/m 2 1 10 –6 1.02·10 –7 

1 N/mm 2 

10 6 

1 0.102 

1 kp/mm2 9.81·106 9.81 1 



Units 

Pressure Units for Fluid Power: 

1 Pa 

(1 N/m 2 ) 

1 bar 

(1 daN/cm 2 ) 

1 N/mm 2 

(1 MPa) 

1 daN/mm 2 

1 kp/cm 2 

(1 at, 1 atü) 

Pa 

(N/m 2 ) 

1 10 -5 

10 5 

10 -6 

daN/mm 2 

10 -7 

1 0.1 10 -2 

1.02 · 10 -5 1.02 · 10 -7 

1.02 1.02 · 10 -2 

10 6 10 1 0.1 10.2 0.102 

10 7 

9.81 · 10 4 

bar 

(daN/cm 2 ) 

N/mm 2 

(M Pa) 

100 10 1 102 1.02 

0.981 9.81 · 10 -2 9.81 · 10 -3 

kp/cm 2 ) 

(at, atü) 

kp/mm 2 

1 10 -2 

1 kp/mm 2 9.81 · 10 6 98.1 9.81 0.981 100 1 

SI-Prefixes (decimal multipliers for SI units): 

Factor Symbol Name 

0,000,001 = 10 -6 µ Micro 

0,001 = 10-3 m Milli 

0,01 = 10-2 c Centi 

0,1 = 10-1 d Deci 

1 = 10 0 – – 

10 = 10 1 da Deca 

100 = 10 2 h Hecta 

1,000 = 10 3 

k Kilo 

1,000,000 = 10 6 M Mega 

T 

SI-Unit or per standard 

approved units. 



71

American and British Measure Units 

Conversion of commonly used American (US) and British (UK) units to SI Units 

Measurement Name Symbol Conversion 

Length mil 1 mil = 25.4 µm 

inch in 1 in = 1000 mils = 25.4 mm 

foot ft 1 ft = 12 in = 0.3048 m 

Area square inch sq in (in2 ) 1 sq in = 6.4516 cm 2 

72 

square foot sq ft (ft 2 ) 1 sq ft = 144 sq in = 929.03 cm 2 

Volume cubic inch cu in (in 3 ) 1 cu in = 16.3871 cm 3 

cubic foot cu ft (ft 3 ) 1 cu ft = 28.3168 dm 3 

US gallon gal 1 US gal = 3.785 dm 3 = 3.785 l 

T 

Weight ounce oz 1 oz = 28.3495 g 

pound lb 1 lb = 0.453592 kg 

Force pound-force lbf 1 lbf = 4.44822 N 

ounce-force ozf 1 ozf = 0.278014 N 

UK ton-force UK tonf 1 UK tonf = 9964.02 N 

US ton-force US tonf 1 US tonf = 8896.44 N 

Pressure pound-force per square inch lbf/in2 , psi 1 lbf/in 2 = 1 psi = 6.89476 kPa = 0.0689476 bar 

Temperature Degrees Fahrenheit °F °C = (°F -32) · 5 /9 



NOTES 



73

Quality Assurance KOENIG-Expander 

Quality Assurance per ISO 9001, ISO 14001, and QS-9000 (4th Qtr. 2001) is very important to us. 

Koenig (KVT) / Sherex is committed to a system of "Total Quality Management" (TQM) to constantly 

improve our quality of service to our customers. 

74 

Clear specifications 

In cooperation with our suppliers 

Exact instructions and procedures 

For all employees 

Controls 

For inspection 

Process control 

In production and assembly 

Quality control 

Through statistical techniques such as 

SPC, Norm charts, etc. 

Design control 

In development, projects, and revisions. 

Employee training 

Through regular internal auditing and 

implementation of Quality Circles 

NOTE: All KOENIG-Expanders are labeled 

on their package with a Batch Number 

identification. This Batch Number 

guarantees traceability of all pertinent 

quality characteristics from production 

and procurement. 



SHEREX INDUSTRIES LTD. 

1400 COMMERCE PKWY. 

LANCASTER, NY, U.S.A. 14086 

PHONE: (716) 681-6250 

TOLL FREE: 866-4SHEREX 

(866-474-3739) 

FAX: (716) 681-0270 

E-MAIL: info@sherex.com 

WEBSITE: www.sherex.com 

SHEREX INDUSTRIES LIMITED 

4180 MORRIS DRIVE 

BURLINGTON, ON CANADA L7L 5L6 

PHONE: (905) 639-7701 

FAX: (905) 639-9537 

E-MAIL: info@sherex.ca 

WEBSITE: www.sherex.ca

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