KTR SYNTEX Hub design 1.0 Manual

KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX®
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
1 of 8
6
Gezeichnet: 30.06.10 Li/Lm Ersatz für: KTR-N vom 17.03.10Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.10 Li Ersetzt durch:
SYNTEX®design DK
Hub design 1.0 Hub design 4.5
The SYNTEX®is an overload system with positive locking. It protects the following
components against destruction. The design DK (ratchet) re-engages after 30° each into the
following lock-in position in case of an overload.
Table of Contents
1 Technical Data
2 Hints
2.1 General Hints
2.2 Safety and Advice Hints
2.3 General Hints to Danger
2.4 Proper Use
3 Storage
4 Assembly
4.1 Components SYNTEX®-Overload System
4.2 Assembly (General)
4.3 Adjustment of the Torque of Engagement
4.4 Adjustment of the Torque of Engagement after the Disassembly
4.5 Assembly SYNTEX®-Overload System
4.6 Limit Switch
4.7 Spares Inventory, Customer Service Addresses

KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX®
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
2 of 8
6
Gezeichnet: 30.06.10 Li/Lm Ersatz für: KTR-N vom 17.03.10Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.10 Li Ersetzt durch:
1 Technical Data
picture 1: hub design 1.0 picture 2: hub design 4.5
Table 1: dimensions
Dimensions [mm]
Size
Max. finish
bore
d [mm] DAD
2d 1D ND 3D 1d LL l1l 2l 3l 4l 5z H
(stroke)
20 20 20 71 65 48 54 61,5 4,5 45 8 2 16 6 35 8 2
25 25 25 89 81 60 68 80 5,5 50 8 2 17 8 39 8 2
35 35 35 110 102 75 78 91 5,5 60 10 2 21 10 42 12 2
50 50 50 152 142 105 108 121 6,6 70 12 2 25 13 56 12 2
Table 2: dimensions hub design 4.5
Dimensions [mm] Clamping screws
Size l6l
7l 8L Gs M Number TA[Nm]
20 9 3,5 23 54 3 M5 4 8,5
25 11 4,0 28 61 4 M6 4 14
35 10 4,0 31 70 4 M6 4 14
50 12 4,0 37 82 6 M6 4 14
Table 3: technical data
Torques [Nm]
Size Max. speed [min-1] DK1 DK2
20 1500 6 – 20 15 – 30
25 1500 20 – 60 45 – 90
35 1000 25 – 80 75 – 150
50 1000 60 –180 175 – 300
Table 4: transmittable friction torques of hub design 4.5
Bores and the corresponding transmittable friction torques * TR[Nm]
Size 12 14 15 16 17 18 19 20 22 23 24 25 28 30 32 35 38 40 42 45 48 50
20 45 62 71 81 92 103 115 127
25 72 83 95 107 120 133 148 179 196 213 231
35 127 139 152 165 207 237 270 323
50 238 281 311 343 394 448 486
* fit H7/h6

KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX®
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
3 of 8
6
Gezeichnet: 30.06.10 Li/Lm Ersatz für: KTR-N vom 17.03.10Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.10 Li Ersetzt durch:
2 Hints
2.1 General Hints
Please read through these mounting instructions carefully before you set the coupling into operation.
Please pay special attention to the safety instructions!
The mounting instructions are part of your product. Please keep them carefully and close to the coupling.
The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.
2.2 Safety and Advice Hints
STOP
DANGER! Dangerofinjurytopersons.
! CAUTION! Damagesonthemachinepossible.
)A TTENTION! Pointing to important items.
2.3 General Hints of Danger
STOP
DANGER!
With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is protected against unintentional engagement. You can be seriously hurt
by rotating parts. Please make absolutely sure to read through and observe the following
safety instructions.
•All operations on and with the coupling have to be performed taking into account "safety first".
•Please make sure to disengage the power pack before you perform your work.
•Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement
or removing the fuse for current supply.
•Do not touch the operation area of the coupling as long as it is in operation.
•Please protect the coupling against unintentional touch. Please provide for the necessary protection devices
and caps.
2.4 Proper Use
You may only assemble, operate and maintain the coupling if you
•carefully read through the mounting instructions and understood them
•had technical training
•are authorized to do so by your company
The coupling may only be used in accordance with the technical data. Unauthorized modifications on the coupling
design are not admissible. We do not take any warranty for resulting damages. To further develop the product we
reserve the right for technical modifications.
The SYNTEX®described in here corresponds to the technical status at the time of printing of these mounting
instructions.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX®
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
4 of 8
6
Gezeichnet: 30.06.10 Li/Lm Ersatz für: KTR-N vom 17.03.10Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.10 Li Ersetzt durch:
3 Storage
The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for
6 - 9 months.
!
CAUTION!
Humid storage rooms are not suitable.
Please make sure that there is no condensation. The best relative air humidity is under 65%.
4 Assembly
The SYNTEX®-overload system is delivered in assembled condition.
4.1 Components SYNTEX®-Overload System
Components SYNTEX®-overload system with hub design 1.0
Component Quantity Designation
1 1 Hub (design 1.0)
2 1 Disc spring
3 1 Flange ring
4 1 Setting ring
5 1 Shifting ring
6 1 Setting nut
7 1 Slide bush
8 1 Axial needle spider
9 1 Shaft lock washer
10 1 Set screw DIN EN ISO 4762
11 1 Grub screw DIN EN ISO 4029
12 1 Grub screw with tappet DIN EN ISO 4028
13 3 Half length reserve taper grooved dowel pin DIN EN ISO 8741
14 6 Round head grooved pin DIN EN ISO 8746
15 18 Ball DIN 5401
picture 3: SYNTEX®DK hub design 1.0

KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX®
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
5 of 8
6
Gezeichnet: 30.06.10 Li/Lm Ersatz für: KTR-N vom 17.03.10Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.10 Li Ersetzt durch:
4 Assembly
4.1 Components SYNTEX®-Overload System
Components SYNTEX®-overload system with hub design 4.5
Component Quantity Designation
1.1 1 Hub (design 4.5)
1.2 1 Clamping bush
1.3 4 Clamping screws DIN EN ISO 4017
2 1 Disc spring
3 1 Flange ring
4 1 Setting ring
5 1 Shifting ring
6 1 Setting nut
7 1 Slide bush
8 1 Axial needle spider
9 1 Shaft lock washer
10 1 Set screw DIN EN ISO 4762
11 1 Grub screw with tappet DIN EN ISO 4028
12 3 Half length reserve taper grooved dowel pin DIN EN ISO 8741
13 6 Round head grooved pin DIN EN ISO 8746
14 18 Ball DIN 5401
picture 4: SYNTEX®DK hub design 4.5
4.2 Assembly (General)
)ATTENTION!
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
•Please make sure the perfect technical condition of the SYNTEX®-overload system.
•Before assembly and operation please check whether it is necessary to clean the components.
•Lubricate the balls (e. g. Klüber-Microlube GL 263).
•Please only use original components.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX®
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
6 of 8
6
Gezeichnet: 30.06.10 Li/Lm Ersatz für: KTR-N vom 17.03.10Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.10 Li Ersetzt durch:
4 Assembly
4.3 Adjustment of Torque of Engagement
•Fix the hub against twisting.
•Unscrew the set screw in the setting nut.
•Rotate the setting nut (clockwise for higher torque of engagement, anticlockwise for lower torque of
engagement) to the desired twisting angle with a sickle spanner (see table of torque of engagement).
!
CAUTION!
The SYNTEX®-overload system must not exceed the max. torque of engagement!
•When the desired torque of engagement is adjusted, fix the setting nut by screwing down the set screw on the
threaded portion of the hub.
Table of torque of engagement:
Torque of engagement [Nm]
Size 20 Size 25 Size 35 Size 50
Twisting angle
setting nut Spring
DK1
Spring
DK2
Spring
DK1
Spring
DK2
Spring
DK1
Spring
DK2
Spring
DK1
Spring
DK2
30° 5
60° 7 20 25 57
90° 8 15 23 28 65
120° 9 17 25 32 73
150° 11 20 29 35 80
180° 13 23 33 46 38 88
210° 15 25 37 52 40 78 95
240° 17 27 41 58 45 86 100
270° 18 29 45 64 49 93 110
300° 20 30 49 70 53 100 118
330° 52 76 57 108 126 175
360° 55 82 61 115 134 188
390° 58 86 66 122 142 200
420° 60 90 71 129 150 212
450° 74 136 157 225
480° 77 143 165 237
510° 80 150 172 250
540° 180 262
570° 275
600° 288
630° 300
SYNTEX®
size
Hinged hook wrench
with tappet
20 Ø35 - 60 x 5
25 Ø60 - 90 x 6
35 Ø60 - 90 x 6
picture 5: hinged hook wrench 50 Ø90 - 155 x 8

KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX®
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
7 of 8
6
Gezeichnet: 30.06.10 Li/Lm Ersatz für: KTR-N vom 17.03.10Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.10 Li Ersetzt durch:
4 Assembly
4.4 Adjustment of the Torque of Engagement after the Disassembly
•Insert the balls with grease (e. g. Klüber - Microlube GL 263) into the pocket hole bores of the hub (12 balls)
and of the flange ring (6 balls).
•Put the disc spring with the concave side onto the flange ring, whereby the balls must engage into the disc
spring bores (please observe partition).
•Push the flange ring with the disc spring onto the hub and align the flange marking (bore) with the external
keyway of the hub.
•Check the correct position of all balls in the bores.
•Push on the axial needle bearing.
•Push on the setting ring, the large external chamfer is directed to the hub thread.
•Put the shifting ring with the keyways on the face into the correct position to the round head grooved pins and
put it onto the setting ring (please observe partition). Furthermore the pins grip from the setting ring into the
axial keyways of the shifting ring.
•Check the function of the shifting ring (axial stroke ≥2mm).
•Push the shaft lock washer onto the setting ring and into the shifting ring.
•Tighten the setting nut with the set screw clockwise and handset up to the limit stop.
•Adjust the desired torque of engagement by twisting the setting nut clockwise with a sickle spanner (see table
of torque of engagement).
•The setting nut must be secured by tightening the set screw.
picture 6

KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX®
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
8 of 8
6
Gezeichnet: 30.06.10 Li/Lm Ersatz für: KTR-N vom 17.03.10Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.10 Li Ersetzt durch:
4 Assembly
4.5 Assembly SYNTEX®-Overload System
Feather key connection
For the axial fixing of the SYNTEX®- overload system with cylindrical finish bore (standard: ISO fit - H7) and
feather key (standard: DIN 6885, page 1 - JS9), there are the following possibilities:
1. Tighten the grub screw on the feather key or the shaft.
2. Secure the hub with an end plate and a screw. The grub screw must be removed.
Clamping set connection
Please ask for the special mounting instruction for the respective clamping set.
Please consider the assembly situation.
Hub design 4.5
Tighten all pressure screws successively in several rotations until all screws have reached the full tightening
torque (see table 1).
4.6 Limit Switch
Operation
The axial thrust of the shifting ring arising in the event of overload operates a mechanical limit switch or an
inductive sensor. Consequently a control operation is performed to disengage the drive.
Assembly
The sensor has to be mounted in a solid device in order to ensure a smooth operation. The sensor should be
protected against dirt and potential mechanical disorders.
Adjustment
When the overload coupling slips, the shifting ring makes an axial thrust of about 2 mm. The sensor or limit
switch, respectively, has to be mounted within this shifting range. In order to adapt the mechanical limit switch
and the shifting process to the machine, the limit switch has to be adjusted accordingly. For that purpose the
shifting process can be regulated after opening the cover plate on the tappet.
!
CAUTION!
Before delivery of the machine please make absolutely sure to check the operation of the
limit switch. Please also note the operating instructions for the sensor or limit switch,
respectively. The axial thrust of the hub must not be obstructed by other components.
4.7 Spares Inventory, Customer Service Addresses
A basic requirement to guarantee the operational readiness of the coupling is a stock of the most important spare
parts on site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage
under www.ktr.com.