KTR GEARex FA Operating & Assembly Instructions
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KTR GEARex FA Operating & Assembly Instructions

All-steel gear couplings
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FA, FB, FAB, DA, DB and DAB along with their combinations
Type FA
Type DA
Type FH
Please observe protection
note ISO 16016.
GEARex
Operating/Assembly instructions
GEARex
All-steel gear couplings type:
according to directive 2014/34/EU
FH, DH, FR and DR along with combinations
for finish bored, pilot bored and unbored couplings
Type DH
Drawn:
2019-09-19 Pz/Wb
Verified:
2019-09-19 Pz
®
®
Type FB
Type DB
Type FR
Replacing:
Replaced by:
KTR-N
40310 EN
Sheet:
1 of 36
Edition:
15
Type FAB
Type DAB
Type DR
KTR-N dated 2017-01-02

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Summary of Contents for KTR GEARex FA

  • Page 1 FH, DH, FR and DR along with combinations for finish bored, pilot bored and unbored couplings Type FH Type DH Type FR Type DR Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 2: Table Of Contents

    Standard values for circumferential backlash Standard values of wear Cleaning of the coupling Replacement of coupling Disassembly of the coupling Disposal Spares inventory, customer service addresses Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 3 10.2 Inspection intervals for couplings in potentially explosive atmospheres 10.3 marking of coupling for potentially explosive atmospheres 10.4 EU Certificate of conformity Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 4: Technical Data

    3) Hub lengthened max. l 4) Maximum torque of the coupling T = rated torque of the coupling T K max K rated Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 5 2) Grease feeding for each coupling half 3) Maximum torque of the coupling T = rated torque of the coupling T Kmax. K rated Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 6 4) Maximum torque of the coupling T = rated torque of the coupling T Kmax. K rated 5) Number for each coupling half Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 7 2) Grease feeding for each coupling half 3) Maximum torque of the coupling T = rated torque of the coupling T Kmax. K rated Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 8: Advice

    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. 2.2 Safety and advice symbols This symbol indicates notes which may contribute to...

  • Page 9: Intended Use

    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.

  • Page 10: Storage, Transport And Packaging

    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. 3.2 Storage of O-rings Proper storage conditions increase the service life of O-rings.

  • Page 11: Components Of The Couplings

    1) With size 10 cap screws DIN 7984 - 8.8 ® Illustration 11: GEARex type FA ® Illustration 12: GEARex type FB ® Illustration 13: GEARex type FAB Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 12 O-ring - material 70 NBR ® Illustration 14: GEARex type DA ® Illustration 15: GEARex type DB ® Illustration 16: GEARex type DAB Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 13 Cover see table 10 Cap screws DIN EN ISO 4762 O-ring - material 70 NBR Spacer ® Illustration 18: GEARex type DH Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 14 10 Cap screws DIN EN ISO 4762 O-ring - material 70 NBR Flange hub ® Illustration 20: GEARex type DR Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 15: Advice For Finish Bore

    (see illustration 21 to 25 and table 9 and 10). • If any other shaft-hub-connections (e. g. clamping elements, spline, taper bores, etc.) are to be used, please consult with KTR. Illustration 21: Clamping/sealing surfaces of types: FA, FAB and FR...

  • Page 16: Assembly Of The Coupling (General)

    The customer bears the sole responsibility for all machining processes performed subsequently on unbored or pilot bored as well as finish machined coupling components and spare parts. KTR does not assume any warranty claims resulting from insufficient remachining. KTR supplies unbored or pilot bored coupling components and spare parts only upon explicit request of the customer.

  • Page 17: Assembly Of The Types Fa, Fb, Fab, Fh And Fr

    With each reassembly of the coupling we recommend to replace the flat gasket (component 5) and the dowel screws (component 3) as well as nuts (component 4). Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz...

  • Page 18: Assembly Of Types Da, Db, Dab, Dh And Dr

    • Secure the hubs (component 1) axially by tightening the setscrews DIN EN ISO 4029 by means of a cup point (tightening torque T see table 10), an end plate or by shrinking. Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 19 Number z (type [Nm] Number z [Nm] Number z [Nm] 1000 1000 1700 1700 2800 2800 2800 1) See illustration 23 to 25 Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 20: Displacements - Alignment Of The Couplings

    The displacement figures specified in table 11 are maximum figures which must not arise in parallel. If radial and angular displacement arises at the same time, these values must be reduced (see illustration 28). Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz...

  • Page 21: Start-Up And Lubrication

    If the couplings are used in mining (equipment group l M2), the cover must not be made of light metal. In addition, it must be resistant to higher mechanical loads than with use as equipment of equipment group ll. Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 22: Types Of Grease Recommended

    Painting or coating of the sleeve is generally not admitted. 5.2 Types of grease recommended Only those greases recommended by KTR may be used. Claims to warranty caused by the use of unrecommended greases are disregarded by KTR. Manufacturer of grease 1) 2)

  • Page 23: Grease Feeding

    1) Grease feeding for each coupling half  With the vertical type see dimensional drawing for grease filling or consult with KTR. The upper half must be fully filled with grease. In case if a dimensional drawing was prepared for the coupling, the dimensions specified have to be primarily observed.

  • Page 24: Breakdowns, Causes And Elimination

    • Tightening torques have been fallen below/exceeded. • Components are mixed up by mistake/assembled incorrectly. • No original KTR components (purchased parts) are used. • Old/already worn out coupling components stored for too long are used. • Maintenance intervals are not observed.
  • Page 25 4) Eliminate negative influences on the O-rings of ozone, too high 5) Replace O-rings ambient temperatures 6) Filling of lubricating grease Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 26 E of the coupling) 4) Assemble, align and lubricate the new coupling components as per ® GEARex operating/mounting instructions Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 27: Maintenance And Service

    The coupling has to be inspected after approx. 200 operating hours or every month at the maximum.  Lubricants of various types and manufacturers must not be mixed! Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 28: Replacement Of Sealing Elements

    • Lightly grease the sealing surfaces and insert new flat gasket (component 5). Afterwards inspect the alignment and, if necessary, re-align and assemble. • Perform grease feeding as per chapter 5.4. Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 29: Standard Values For Circumferential Backlash

    • Turn the hub (component 1) in the direction of drive and measure the circumferential backlash S • When reaching the circumferential backlash S the coupling must be replaced. Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 30: Standard Values Of Wear

    Circumferential backlash S Circumferential backlash S [mm] [mm] max. max. Size Size (limits of wear for each hub) (limits of wear for each hub) Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...

  • Page 31: Cleaning Of The Coupling

    • A reassembly has to be performed as per chapters 4 and 5. Components that are damaged or worn off have to be replaced! Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz...

  • Page 32: Disposal

    We recommend to store major spare parts on site to ensure the readiness for use of the machine in case if a coupling fails. Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at www.ktr.com.
  • Page 33 Equipment group I of category M2 (coupling is not approved/not suitable for equipment group M1). Permissible ambient temperature -30 °C to +90 °C. Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 34 , the respective coupling half max. (hub and sleeve) must be replaced immediately, irrespective of the inspection intervals. ® Illustration 34: GEARex coupling Drawn: 2019-09-19 Pz/Wb Replacing: KTR-N dated 2017-01-02 Please observe protection note ISO 16016. Verified: 2019-09-19 Pz Replaced by:...
  • Page 35 The marking with explosion group lIlC includes the explosion groups lIlA and lIlB. If the symbol was punched in addition to marking , the coupling component was supplied by KTR as an unbored or pilot bored version (see chapter 4.2 of the present operating/assembly instructions). Drawn:...
  • Page 36 10.4 EU Certificate of conformity EU Certificate of conformity corresponding to EU directive 2014/34/EU dated 26 February 2014 and to the legal regulations The manufacturer - KTR Systems GmbH, D-48432 Rheine - states that the ® GEARex All-steel gear couplings in an explosion-proof design described in these operating/assembly instructions are devices corresponding to article 2, 1.

This manual is also suitable for:

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