Installation & Operating Manual (IOM)

GEAR FLEX Coupling

RGD/RGS Series

RGD Series

RGS Series

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/02-09/20

Pune, 411014, INDIA
Installation & Operating Manual /GEAR-FLEX/RGD/RGS

INDEX

Page No

1. Introduction & General Guidelines 02

2. Before installation information 02

3. Installation Information 03

3.1 Hub Mounting 03

3.2 Shaft Alignment 04

3.3 Final Assembly 06

4. Disassembly/ Replacement 06

5. Safety,General Hazard & Environment 07

6. Inspection & Periodic Maintenance 08

7. Spares Management & Complaint Handling 09

8. Breakdown & Trouble-shooting 11

9. Marking Details 12

10. Declaration of comformity 13

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 1 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
1. Introduction & General Guidelines
• RGD/RGS type gear coupling are designed as per API standard and certified by ATEX (explosion
protection) to transmit power and torque between drive and driven shaft.
• This manual will help you to install and maintain gear coupling before installing/disassembling of
coupling. It is advisable to read the manual carefully before starting the work. These special
designs are always provided with general assembly drawing which provides detail information of
the design and connected equipments.
• Symbol description :
Caution person may get injured

Damage the product

Pay attention

Potentially explosive warning

2. Before installation information

• RGD/RGS couplings are delivered by RTPL as assembled condition which consists components
from 1 to 8 as shown in fig. 1.

Sr.No Component Qty.

1 Coupling Bolt Refer GA Drawing
2 Sleeve 02
3 Driving Hub 01
4 Gasket 01
5 Driven Hub 01
6 Spring Washer Refer GA Drawing
7 Hex Nut Refer GA Drawing
8 O-Ring 02

Fig. 1 PART LIST

• Inspect coupling assembly for visible damage, if you found contact RATHI.
• Disassemble the coupling by removing nuts & bolts. Clean all the parts carefully.

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 2 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
3. Installation Information
• Ensure the system is disconnected from electrical connection and other possible energy
transmission before starting the work.
3.1 Finish Bore Instruction (Fig. 2)
• Hub finish bores machined by customer with reference
to outside diameter.
• Finish bore strictly done within specified
limit (H7, Js9 ).
• Maintain face run-out and concentricity as per below table.
Outside diameter Face run-out/
(mm) Concentricity
Fig.2 Finish bore
(mm)
10-180 0.04
180-400 0.08
400-630 0.1

• Provide set screw at distance L ( L = LTB /2). If it is not possible, suitable distance nearer to
midpoint of the length through bore (LTB) is provided.
3.2 Hub Mounting.
• Clean protective coatings/lubricants from bores & keyways.
• Remove coupling bolt (1) and separate hubs from transmission unit (fig.3).
• Slide the sleeve having internal teeth with rubber o-ring on shafts.(Fig 3)
• Mount the hubs having external teeth on their respective shafts flushed with the faces of
hubs as shown in Fig. 3.
• Hubs and Sleeves must be supported during installation to avoid accidental damage.

Fig.3 Hub mounting

• Assemble key(s) on to the shaft.

• Set screws to be removed from hub, if it comes through the keyway or hub bore.
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
• Mount hubs over the shaft by maintaining gap ‘G’ as mentioned in table 2 by using a spacer
bar equal in thickness to the required gap.(Fig.4)
• For spacer type, set the equipment at a distance equal to DBSE by using vernier calliper as
shown in fig. 5

Fig. 4 HUB Mounting Fig. 5 HUB mounting for spacer coupling

• Tighten the set screw.

3.3 Shaft Alignment
• In order to achieve optimum service life of the coupling, shafts must be aligned.
• Initial misalignment should not be more than 25 % of maximum misalignment
(Refer Table 1).
Table 1 : Method of misalignment

Method Parallel/Radial Angular (X)

Using straight edge

1
• Check the parallel/radial alignment with the help of straight edge resting
squarely on both the hubs at 4 places 90° apart.
• Check the angular misalignment with the help of slip gauges by inserting in
the gap at 4 places 90° apart.The difference in max. & min. gap will be the
Total Indicated Reading (TIR).
• Angular misalignment( X)in mm is half the Total Indicated Reading (TIR).

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 4 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
Table 2 : Misalignment & Tightening Torque

PERMISSIBLE MAXIMUM MISALIGNMENTS

GREASE
GAP 'G' TIGHT. QTY.(Kg)
COUPLING ANGULAR AXIAL (mm) BOLT BOLT
PARALLEL STD. (mm) TORQUE
SIZE SIZE GRADE
PER /RADIAL (Nm)
‘X' 'P' (mm)
GEAR RGD RGS RGD RGS RGD RGS
(mm)
MESH
10 1.2 0.6 3 4 1/4” 8.8 11 0.03 0.02
15 1.6 0.8 3 4 3/8” 8.8 38 0.06 0.03
20 2 1 ± 0.5 ± 0.25 3 4 1/2” 8.8 91 0.17 0.09
25 2.4 1.2 5 5 5/8” 8.8 186 0.23 0.12
30 2.8 1.4 5 5 5/8” 8.8 186 0.34 0.17
35 3.2 1.7 6 6 3/4” 8.8 331 0.45 0.23
40 3.6 2 6 8 3/4” 8.8 331 0.79 0.40
45 4 2.1 ±1 ± 0.5 8 8 3/4” 8.8 331 1.08 0.54
± 1.5º
50 4.4 2.6 8 9 7/8” 8.8 532 1.59 0.80
55 4.8 2.9 8 9 7/8” 8.8 532 1.93 0.97
60 5.2 3.2 8 9.5 7/8” 8.8 532 3.46 1.73
70 6 3.7 9 11 1” 8.8 798 6.35 3.18
±2 ±1
80 6.8 4.2 10 13 M24 8.8 673 9.60 4.80
90 7.6 4.8 13 15 M30 8.8 1338 13.3 6.65
100 8.4 5.5 13 16 M30 8.8 1338 17.3 8.65
±3 ± 1.5
110 9.2 6.2 13 16 M36 8.8 2339 22.9 11.5

• Half Flexible Gear Couplings (RGS) cannot accommodate parallel misalignment.

• Gap ’G’ in the above table is given when angular & axial misalignments are zero.
• All misalignments cannot be taken by coupling at a time.

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 5 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
3.4 Final Assembly
• Insert the gasket between the sleeve flanges.
position the flanged sleeves with lubrication plugs.
• Insert the bolts thru flange holes. Also place the washer
& nuts on bolts and tightening the bolts.
• Assemble only with the help of the fasteners supplied
with the coupling.
• Fill with recommended grease (RSG with reqd. qty.) for lubrication.
• For grease quantity for respective coupling size, refer table 2.
• Use Loctite to prevent the loosening of threads, if required. Fig.5 Plug details

• Customer must provide required safety guards, RTPL does not supply safety guards or
shields.

4. Disssembly/ Replacement

Fig. 6.

• Disengaged sleeve by removing coupling bolts (1) from sleeve.

• Remove the hub from shaft and assemble new hub on shaft.
• Ensure hubs have been mounted as shown in fig.3,to maintain correct Gap 'G'.
• Repeat step of section 3.4.

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 6 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
5. Safety General Hazard & Environment
5.1 Safety General Hazard
• Proper care and safety must be taken care before work started.
• The relevant safety and environmental regulations must be complied during installation,
commissioning, operation, assembly, disassembly and maintenance.
• Coupling must be maintained and/or repaired in the presence of skilled or qulified
persons for particular work.
• During installation or maintenance ensure the drive unit is cut off from the power supply
and caution notice should be display on switch.
• Immediate stop the drive unit if anything abnormalities observed on coupling (e.g. cracks,
chips, wear, noise or deformation)
• Check all the bolts are tightened as per torque specified in the manual or as specified in the GA
drawing.
• The supplied coupling may have to rotate at high speed, it is most important to guard the area
in compliance to ATEX and various other local applicable standards.
• This coupling is complied as per ATEX requirement. Please check the suitability of hazardous
environment at the time of selection of the coupling or during installation of the coupling.
• All spare parts are to be purchased from manufacturer or authorised dealer only.
If the coupling is to be used below ground in potentially explosive areas, the
coupling, must be provided with a robust casing to avoid the risk of ignition from e.g.
friction, impact or friction sparks.
The depositing of heavy metal oxides (rust) on the coupling must be avoided by the
casing or other suitable precautions.

5.2 Environment
• Our products are complying with EMS standard ISO 14001:2015, any instruction which are
impermissible according to standard are not followed.

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 7 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
6. Inspection & Periodic Maintenance
• The gear coupling can be monitored under running condition as well as under idle condition.
• Inspect the coupling once in 6 months in idle condition or whenever it is taken for periodic
maintenance.
• After tightening the sleeves (2),fill the specified amount of grease (refer table 2) from lubrication
hole (fig.5) with the help of grease gun.
• Ensure recommended quantity of grease has been filled, such that sleeve and hub teeth are
completely covered.
• It is recommended to check below parameters,
- Vibration and noise
- Grease/Oil leakage
- Damages on gear teeth
- Damages and deterioration of `O'-ring
- Deterioration of grease.
• Carry out below steps during first grease change which should take place within 3 months in
operation,
- Dismantle the coupling and clean thoroughly to remove used grease,abrasive powder.
- Reassemble the coupling.
- Fill the required quantity of grease again for lubrication.
• It is recommended that grease to be renewed at 2 years interval
• In case of high ambient temperature, frequent overloaded condition, frequent reverse operation,
large parallel misalignment and angular misalignment, ensure that the checking intervals are
shortened.
7. Spare Management & Complaint Handling
7.1 Spare management
• We recommend to store spare items as given below, inorder to have continuos operation and
to reduce down time due to failures.
• Spare component list.(Fig.1)
Components/ Quantity
Sr.No. Part descriptions
part No. (No.)
1 Coupling bolt 01 Refer GA drawing
2 Sleeve 02 02
3 Driving Hub 03 01
4 Driven hub 05 01
5 Hex Nut 07 Refer GA Drawing
6 O-Ring 08 02

7.2 Complaint Handling

• In case of any failure,for proper root cause, fill up Product Performance Datasheet (PPDS) and
provide us alongwith images/videos.

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 8 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
• Product Performance datasheet(PPDS)

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 9 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 10 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
8. Breakdown & Trouble Shooting
• The coupling must run with low vibration and noise during operation. any abnormal behaviour
may damage the product or drive unit.
• Following are some possible causes of failure with corrective actions

SR. PROBABLE CORRECTIVE

FAILURE MODE
NO. CAUSES ACTIONS

Worn out Gear teeth Replace the coupling

Excessive
1
misalignments.
Shaft bearing failure Realign the coupling

Excessive starts and

Use coupling with
Premature wear of stops
2 heat treatment on
Gear Teeth
teeth
High peak load

Refill the grease up to

3 Noise during running No lubrication -
required limit
Refill the grease up to
required limit.
No lubrication
4 Heat Generation -
Refer maintenance
Poor lubrication
guidelines for
lubrication frequency
Ensure proper sealing
5 Grease leakage Improper sealing to avoid grease -
leakage
Loose hubs on shaft Torsional shock Find & eliminate
6 -
with sheared keys. overload causes of overload.
Severe corrosion on Apply anticorrosive
7 Chemical attack -
outer surface coating on coupling (*)

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 11 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
9. Marking Details
• The ATEX marking for RGD coupling will be given on outer surface or front side (Fig. 7).
• Example :

Fig.7. Marking example

• ATEX Punching sample

RATHI GEAR-FLEX 129 RGD-25 32 II 2GD -20°C +120ºC

• Where,
1. Manufacturing code e.g. 129 for December 2019
2. Product code e.g. RGD - 25
3. Finish bore size code e.g. 32
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX
10. Declaration of Conformity

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 13 of 14
Installation & Operating Manual /GEAR-FLEX/RGD/RGS
GO TO INDEX

RATHI TRANSPOWER PVT.LTD. Gaia Apex,S No 33/2D,Viman Nagar R-II-D-03/03-10/21

Pune, 411014 Page 14 of 14