KTR GEARex FA Manual

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
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
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
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
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
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