KTR GEARex FA Handbuch

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

1 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

GEARex®

All-steel gear couplings type:

FA, FB, FAB, DA, DB and DAB along with their combinations

according to directive 2014/34/EU

Type FA

Type FB

Type FAB

Type DA

Type DB

Type DAB

FH, DH, FR and DR along with combinations

for finish bored, pilot bored and unbored couplings

Type FH

Type DH

Type FR

Type DR

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

2 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

The GEARex®all-steel gear coupling is a flexible shaft connection. It is able to compensate for shaft

misalignment, for example caused by manufacturing inaccuracies, thermal expansion, etc.

1Technical data 4

2Advice 8

2.1 General advice 8

2.2 Safety and advice symbols 8

2.3 General hazard warnings 8

2.4 Intended use 9

2.5 Coupling selection 9

2.6 Reference to EC Machinery Directive 2006/42/EC 9

3Storage, transport and packaging 10

3.1 Storage of the coupling 10

3.2 Storage of O-rings 10

3.3 Transport and packaging 10

4Assembly 10

4.1 Components of the couplings 11

4.2 Advice for finish bore 15

4.3 Assembly of the coupling (general) 16

4.4 Assembly of the types FA, FB, FAB, FH and FR 17

4.5 Assembly of types DA, DB, DAB, DH and DR 18

4.6 Displacements - alignment of the couplings 20

5Start-up and lubrication 21

5.1 Start-up of the coupling 21

5.2 Types of grease recommended 22

5.3 Grease feeding 23

5.4 Grease capacity 23

6Breakdowns, causes and elimination 24

7Maintenance and service 27

7.1 Intervals of maintenance 27

7.2 Replacement of grease 27

7.3 Replacement of sealing elements 28

7.4 Standard values for circumferential backlash 29

7.5 Standard values of wear 30

7.6 Cleaning of the coupling 31

7.7 Replacement of coupling 31

7.8 Disassembly of the coupling 31

8Disposal 32

9Spares inventory, customer service addresses 32

Table of contents

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

3 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

10 Enclosure A

Advice and instructions regarding the use in potentially explosive atmospheres 33

10.1 Intended use in potentially explosive atmospheres 33

10.2 Inspection intervals for couplings in potentially explosive atmospheres 34

10.3 marking of coupling for potentially explosive atmospheres 35

10.4 EU Certificate of conformity 36

Table of contents

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

4 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

Illustration 1: Type FA

Illustration 2: Type FB

Illustration 3: Type FAB

Table 1: Dimensions - FA, FB and FAB

Size

Pilot

bore

Max.

finish

bore

d1, d2

Dimensions [mm]

Grease

feeding

2)

[dm3]

l1, l2

l1, l23)

EFA

EFB

EFAB

LFA

LFB

LFAB

L3

D

DA1

DA2

F 1)

d3 1)

10

26

50

43

105

3

21

12

89

107

98

55

67

111

84

74

52

0.02

15

26

64

50

115

3

15

9

103

115

109

59

87

152

107

84

68

0.04

20

31

80

62

130

3

31

17

127

155

141

79

108

178

130

104

85

0.08

25

38

98

76

150

5

29

17

157

181

169

93

130

213

158

123

110

0.12

30

44.5

112

90

170

5

33

19

185

213

199

109

153

240

182

148

130

0.18

35

46

133

105

185

6

40

23

216

250

233

128

180

280

214

172

150

0.22

40

52

158

120

215

6

42

24

246

282

264

144

214

318

250

192

175

0.35

45

80

172

135

245

8

50

29

278

320

299

164

233

347

274

216

190

0.45

50

80

192

150

295

8

56

32

308

356

332

182

260

390

309

241

220

0.70

55

90

210

175

300

8

70

39

358

420

389

214

283

425.5

334

275

250

0.90

60

100

232

190

305

8

84

46

388

464

426

236

312

457

365.5

316

265

1.15

70

100

276

220

310

10

76

43

450

516

483

263

371

527

425

360

300

1.50

Table 2: Technical data - FA, FB and FAB

Size

Torque 4) [Nm]

Max. speed

[rpm]

Weight with max. bore [kg]

Mass moment of

inertia with max.

bore [kgm2]

Dowel screws (10.9)/nuts

TKN

(42 CrMo4)

Sleeve

Hub

Total

z

M

TA[Nm]

10

930

1580

8500

0.75

0.55

2.73

0.00436

6

M6

15

2000

3300

6400

1.88

1.12

6.38

0.01894

8

M8

36

20

3500

6300

5400

2.60

2.09

9.94

0.04000

6

M10

72

25

6500

11000

4500

4.43

3.56

16.83

0.09749

6

M12

125

30

10000

17400

4000

5.83

6.18

25.21

0.18080

8

M12

125

35

17000

28800

3500

9.71

9.87

41.25

0.41419

8

M14

200

40

28500

48500

3100

11.88

16.07

58.14

0.75535

8

M14

200

45

37000

62000

3000

15.72

21.42

77.08

1.17590

10

M14

200

50

51000

86000

2500

25.66

29.59

114.40

2.24991

8

M18

430

55

65000

110000

2300

31.52

40.30

150.41

3.45102

14

M18

430

60

85000

145000

2100

32.82

52.96

177.44

4.16734

14

M18

430

70

135000

240000

1850

43.52

85.77

268.20

9.32429

16

M20

610

1) Space required to align the coupling and replace the gasket

2) Grease feeding for each coupling half

3) Hub lengthened max. l1, l2

4) Maximum torque of the coupling TK max = rated torque of the coupling TK rated x 2

1 Technical data

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

5 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

Illustration 4: Type DA

Illustration 5: Type DB

Illustration 6: Type DAB

Table 3: Dimensions - DA, DB and DAB

Size

Pilot

bore

Max.

finish

bore

d1, d2

Dimensions [mm]

Grease

feeding

2)

[dm3]

l1, l2

EDA

EDB

EDAB

LDA

LDB

LDAB

L3

D

DA1

DA2

F 1)

d3 1)

20

31

80

62

3

31

17

133

155

144

79

108

187

146

105

85

0.08

25

38

98

76

5

29

17

157

181

169

93

130

220

172

115

105

0.12

30

44.5

112

90

5

33

19

185

213

199

109

153

248

182

140

120

0.18

35

46

133

105

6

40

23

216

250

233

128

180

285

214

165

145

0.22

40

52

158

120

6

42

24

246

282

264

144

214

335

250

180

160

0.35

45

80

172

135

8

50

29

278

320

299

164

233

358

294

195

185

0.45

50

80

192

150

8

56

32

388

356

332

182

260

390

309

215

205

0.70

55

90

210

175

8

70

39

358

420

389

214

283

425.5

348

240

220

0.90

60

100

232

190

8

84

46

388

464

426

236

312

457

380

260

245

1.15

70

100

276

220

10

76

43

450

516

483

263

371

527

445

300

290

1.50

80

140

300

280

10

50

30

570

610

590

310

394

545

475

340

310

2.50

85

160

325

292

13

53

33

597

637

617

325

430

585

515

352

330

3.00

90

180

350

305

13

83

48

623

693

658

353

464

640

560

365

360

4.00

100

220

390

330

13

93

53

673

753

713

383

512

690

612

390

400

5.00

110

220

420

350

20

296

158

720

996

858

508

560

765

665

410

420

6.00

120

260

450

420

25

421

223

864

1261

1063

643

608

825

720

480

470

7.50

130

300

500

440

25

415

220

905

1295

1100

660

684

950

805

520

9.00

140

380

550

460

20

430

225

940

1350

1145

685

750

1020

875

570

590

12.00

150

460

630

520

30

460

245

1070

1500

1285

765

850

1140

975

630

670

15.00

Table 4: Technical data - DA, DB and DAB

Size

Torque 3) [Nm]

Max. speed

[rpm]

Weight with max. bore [kg]

Mass moment of

inertia with max.

bore [kgm2]

Dowel screws (10.9)/nuts

TKN

(42 CrMo4)

Sleeve

Hub

Total

z

M

TA[Nm]

20

3500

6300

5400

3.6

2.1

12.8

0.056

6

M10

72

25

6500

11000

4500

5.5

3.5

20.3

0.125

6

M12

125

30

10000

17400

4000

6.8

6.2

28.9

0.220

8

M12

125

35

17000

28800

3500

11.2

9.8

46.6

0.488

8

M14

200

40

28500

48500

3100

16.3

15.9

70.9

1.011

8

M14

200

45

37000

62000

3000

20.2

21.4

90.7

1.482

10

M14

200

50

51000

86000

2500

27.2

29.5

124

2.474

8

M18

430

55

65000

110000

2300

40

175

4.047

14

M18

430

60

85000

145000

2100

32

53

185

4.810

14

M18

430

70

135000

240000

1850

44

85

280

9.907

16

M20

610

80

175000

300000

1750

64

117

362

14.214

18

M20

610

85

225000

380000

1650

75

148

446

20.320

20

M20

610

90

290000

500000

1550

101

183

568

31.036

20

M24

1000

100

380000

650000

1500

117

232

698

45.358

24

M24

1000

110

480000

820000

1250

140

295

940

73.880

20

M30

1700

120

620000

1050000

1150

188

430

1312

118.40

24

M30

1700

130

-

1450000

1000

319

603

1954

226.732

20

M36

2800

140

-

1950000

950

373

758

2391

328.567

24

M36

2800

150

-

2750000

850

475

983

3069

540.298

30

M36

2800

1) Space required to align the coupling and replace the gasket

2) Grease feeding for each coupling half

3) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2

1 Technical data

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

6 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

Type FH

(size 10 to 70)

Type DH

(size. 80 to 150)

Illustration 7

Illustration 8: type FH / DH

Table 5: Dimensions - FH and DH

Size

Pilot

bore

Max.

finish

bore

d1, d2

Dimensions [mm]

Grease

feeding 2)

[dm3]

l1, l2

Hub lengthened

max. l1, l2

D

DA1 3)

DA2 3)

LH

L3FH

L3DH

EH

F 1)

d3 1)

10

26

50

43

105

67

111

84

LH= EH+ l1+ l2

According to customer specification

74

52

0.02

15

26

64

50

115

87

152

107

84

68

0.04

20

31

80

62

130

108

178

130

104

85

0.08

25

38

98

76

150

130

213

158

123

110

0.12

30

44.5

112

90

170

153

240

182

148

130

0.18

35

46

133

105

185

180

280

214

172

150

0.22

40

52

158

120

215

214

318

250

192

175

0.35

45

80

172

135

245

233

347

274

216

190

0.45

50

80

192

150

295

260

390

309

241

220

0.70

55

90

210

175

300

283

425.5

334

275

250

0.90

60

100

232

190

305

312

457

365.5

316

265

1.15

70

100

276

220

310

371

527

425

360

300

1.50

80

140

300

280

-

394

545

475

340

310

2.50

85

160

325

292

-

430

585

515

352

330

3.00

90

180

350

305

-

464

640

560

365

360

4.00

100

220

390

330

-

512

690

612

390

400

5.00

110

220

420

350

-

560

765

665

410

420

6.00

120

260

450

420

-

608

825

720

480

470

7.50

130

300

500

440

-

684

950

805

520

9.00

140

380

550

460

-

750

1020

875

570

590

12.00

150

460

630

520

-

850

1140

975

630

670

15.00

Table 6: Technical data - FH and DH

Size

Torque 4) [Nm]

Dowel screws (10.9)/nuts

TKN

TKN (42 CrMo4)

z 5)

M

TA[Nm]

10

930

1580

6

M6

15

2000

3300

8

M8

36

20

3500

6300

6

M10

72

25

6500

11000

6

M12

125

30

10000

17400

8

M12

125

35

17000

28800

8

M14

200

40

28500

48500

8

M14

200

45

37000

62000

10

M14

200

50

51000

86000

8

M18

430

55

65000

110000

14

M18

430

60

85000

145000

14

M18

430

70

135000

240000

16

M20

610

80

175000

300000

18

M20

610

85

225000

380000

20

M20

610

90

290000

500000

20

M24

1000

100

380000

650000

24

M24

1000

110

480000

820000

20

M30

1700

120

620000

1050000

24

M30

1700

130

-

1450000

20

M36

2800

140

-

1950000

24

M36

2800

150

-

2750000

30

M36

2800

1) Space required to align the coupling and replace the gasket

2) Grease feeding for each coupling half

3) For dimensions of type F see table 1; type D see table 3

4) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2

5) Number for each coupling half

1 Technical data

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

7 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

Type FR

(size 10 to 70)

Type DR

(size. 80 to 150)

Illustration 9

Illustration 10: Type FR / DR

Table 7: Dimensions - FR and DR

Size

Max. finish bore

Dimensions [mm]

Grease

feeding 2)

[dm3]

d1

d4

l1, l2

Hub

lengthened

max. l1, l2

D

DA1

DA2

DF

LR

F 1)

d3 1)

10

50

60

43

105

67

111

84

88

74

52

0.02

15

64

78

50

115

87

152

107

103

84

68

0.04

20

80

95

62

130

108

178

130

127

104

85

0.08

25

98

115

76

150

130

213

158

157

123

110

0.12

30

112

135

90

170

153

240

182

185

148

130

0.18

35

133

155

105

185

180

280

214

216

172

150

0.22

40

158

185

120

215

214

318

250

244

192

175

0.35

45

172

200

135

245

233

347

274

276

216

190

0.45

50

192

225

150

295

260

390

309

305

241

220

0.70

55

210

245

175

300

283

425.5

334

356

275

250

0.90

60

232

265

190

305

312

457

365.5

386

316

265

1.15

70

276

310

220

310

371

527

425

450

360

300

1.50

80

300

340

280

-

394

545

475

462

570

340

310

2.50

85

325

370

292

-

430

585

515

500

597

352

330

3.00

90

350

400

305

-

464

640

560

546

623

365

360

4.00

100

390

440

330

-

512

690

612

594

673

390

400

5.00

110

420

480

350

-

560

765

665

647

710

410

420

6.00

120

450

520

420

-

608

825

720

700

852

480

470

7.50

130

500

560

440

-

684

950

805

760

890

520

9.00

140

550

610

460

-

750

1020

875

835

930

570

590

12.00

150

630

690

520

-

850

1140

975

935

1055

630

670

15.00

Table 8: Technical data - FR and DR

Size

Torque 3) [Nm]

Dowel screws (10.9)/nuts

TKN

TKN (42 CrMo4)

z

M

TA[Nm]

10

930

1580

6

M6

15

2000

3300

8

M8

36

20

3500

6300

6

M10

72

25

6500

11000

6

M12

125

30

10000

17400

8

M12

125

35

17000

28800

8

M14

200

40

28500

48500

8

M14

200

45

37000

62000

10

M14

200

50

51000

86000

8

M18

430

55

65000

110000

14

M18

430

60

85000

145000

14

M18

430

70

135000

240000

16

M20

610

80

175000

300000

18

M20

610

85

225000

380000

20

M20

610

90

290000

500000

20

M24

1000

100

380000

650000

24

M24

1000

110

480000

820000

20

M30

1700

120

620000

1050000

24

M30

1700

130

-

1450000

20

M36

2800

140

-

1950000

24

M36

2800

150

-

2750000

30

M36

2800

1) Space required to align the coupling and replace the gasket

2) Grease feeding for each coupling half

3) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2

1 Technical data

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

8 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

Please read through these operating/assembly instructions carefully before you start up the coupling.

Please pay special attention to the safety instructions!

The GEARex®coupling is suitable and approved for the use in potentially explosive atmospheres.

When using the coupling in potentially explosive atmospheres, observe the special advice and

instructions regarding safety in enclosure A.

The operating/assembly instructions are part of your product. Please store them carefully and close to the

coupling. The copyright for these operating/assembly instructions remains with KTR.

Warning of potentially explosive

atmospheres

This symbol indicates notes which may contribute to

preventing bodily injuries or serious bodily injuries that

may result in death caused by explosion.

STOP

Warning of personal injury

This symbol indicates notes which may contribute to

preventing bodily injuries or serious bodily injuries that

may result in death.

!

Warning of product damages

This symbol indicates notes which may contribute to

preventing material or machine damage.



General advice

This symbol indicates notes which may contribute to

preventing adverse results or conditions.

Warning of hot surfaces

This symbol indicates notes which may contribute to

preventing burns with hot surfaces resulting in light to

serious bodily injuries.

STOP

With assembly, operation and maintenance of the coupling it has to be made sure that the

entire drive train is secured against accidental switch-on. You may be seriously hurt by

rotating parts. Please make absolutely sure to read through and observe the following

safety notes.

•All operations on and with the coupling have to be performed taking into account "safety first".

•Please make sure to switch off the power pack before you perform your work.

•Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on

or removing the fuse for current supply.

•Do not reach into the operating area of the coupling as long as it is in operation.

•Please secure the coupling against accidental contact. Please provide for the necessary protection devices

and covers.

2 Advice

2.1 General advice

2.2 Safety and advice symbols

2.3 General hazard warnings

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

9 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

You may only assemble, operate and maintain the coupling if you

•have carefully read through the operating/assembly instructions and understood them

•are technically qualified and specifically trained (e. g. safety, environment, logistics)

•are authorized by your company

The coupling may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications

on the coupling design are not admissible. We will not assume liability for any damage that may arise. In the

interest of further development we reserve the right for technical modifications.

The GEARex®described in here corresponds to the technical status at the time of printing of these

operating/assembly instructions.

!

For a long-lasting and failure-free operation of the coupling it must be selected according to

the selection instructions for the particular application (see catalogue drive technology

"GEARex®").

If the operating conditions (performance, speed, modifications on engine and machine)

change, the coupling selection must be reviewed.

The transmittable torque of the shaft-hub-connection must be reviewed by the customer and

is subject to his responsibility.

For drives subject to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to

perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations

are e. g. drives with piston pumps, piston compressors etc. If requested, KTR will perform the coupling selection

and the torsional vibration calculation.

The couplings supplied by KTR should be considered as components, not machines or partly completed

machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a

declaration of incorporation. For details about safe assembly, start-up and safe operation refer to the present

operating/assembly instructions considering the warnings.

2 Advice

2.4 Intended use

2.5 Coupling selection

2.6 Reference to EC Machinery Directive 2006/42/EC

GEARex®

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

40310 EN

10 of 36

15

Please observe protection

note ISO 16016.

Drawn:

2019-09-19 Pz/Wb

Replacing:

KTR-N dated 2017-01-02

Verified:

2019-09-19 Pz

Replaced by:

Unless explicitly ordered differently, the coupling is supplied with preservation and may be stored in a dry and

roofed place for a period of up to 3 months.

In case of a longer storage period please consult with KTR.

Proper storage conditions increase the service life of O-rings. For the storage of O-rings basically DIN 7716

(standards for storage, maintenance and cleaning of rubber products) or ISO 2230 (rubber products - standards

for storage) applies.

The physical characteristics and period of operation may be subject to negative influences like, as an example,

light, heat, moisture, oxygen, ozone, etc.

In general the optimum storage condition is said to be welded in polyethylene bags with temperatures between

+5 °C to +20 °C.

!

The O-rings (component 8) must not be stored being mounted to the hubs (component 1).



The storage space should be dry and free from dust. The O-rings (component 8) must not be

stored together with chemicals, solvents, fuels, acids, etc.

!

In order to avoid any injuries and any kind of damage always make use of proper transport

and lifting equipment.

The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise

contractually agreed, packaging will follow the in-house packaging specifications of KTR.



Observe the manufacturer’s instructions regarding the use of solvents.

STOP

Driving components falling down may cause injury to persons or damage on the machine.

Secure the driving components with assembly or disassembly.

3 Storage, transport and packaging

3.1 Storage of the coupling

3.2 Storage of O-rings

3.3 Transport and packaging

4 Assembly

KTR GEARex FA Handbuch

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