KTR SYNTEX-NC Series Product guide

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
1 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
SYNTEX®-NC
Backlash-free overload
system
Type DK
(ratchet design)
Type SK
(synchronous design)
SYNTEX®-NC
SYNTEX®-NC with ROTEX®GS
SYNTEX®-NC with TOOLFLEX®

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
2 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
SYNTEX®-NC is a torque limiting, backlash-free overload system operating with positive locking
protecting adjacent components from damage.
In case of overload on the coupling the torque is considerably reduced to a lower residual torque.
SYNTEX®-NC is a not load-holding coupling.
In case of overload type DK (ratchet design) re-engages every 15° with the next following ball
indentation.
In case of overload type SK (synchronous design) re-engages after a rotation of 360°.
1Technical data 3
2Advice 7
2.1 General advice 7
2.2 Safety and advice symbols 7
2.3 General hazard warnings 7
2.4 Intended use 8
2.5 Coupling selection 8
3Storage, transport and packaging 8
3.1 Storage 8
3.2 Transport and packaging 8
4Assembly 9
4.1 Components of the couplings 9
4.2 Advice on remachining 10
4.3 Assembly (general) 10
4.4 Assembly of SYNTEX®-NC (hub design 1.0) 11
4.5 Assembly of SYNTEX®-NC (hub design 6.1) 11
4.6 Notes with the use of hollow shafts 12
4.7 Assembly of SYNTEX®-NC with ROTEX®GS 12
4.8 Assembly of SYNTEX®-NC with TOOLFLEX®13
5Adjustment of torque 14
5.1 Torque setting - SYNTEX®-NC 14
5.2 Replacement of layering of disk springs 16
5.3 Setting diagrammes 18
5.3 Setting diagrammes 19
6Assembly of limit switch 20
7Breakdowns, causes and elimination 21
8Disposal 22
9Maintenance and service 22
10 Notes for using drive components/attachments 23
11 Spares inventory, customer service addresses 23
Table of contents

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
3 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Illustration 1: SYNTEX®-NC
(hub design 1.0)
Illustration 2: SYNTEX®-NC
(hub design 6.1)
Table 1: Technical data and dimensions
Size
Speed
[rpm]
Torques [Nm]
Dimensions [mm]
T1
T2
T3
Max. bore d 1)
D
D1
D2
D3
DA
15
3500
2 - 3.5
3.5 - 7
7 - 14
12
32
33
37
42
42
25
3000
9 - 15
20 - 30
40 - 65
22
42
50
48
56
61
32
3000
25 - 38
50 - 75
100 - 150
30
52
60
60
67
74
42
2500
30 - 65
60 - 135
120 - 265
38
65
72
75
83
90
60
2000
70 - 140
120 - 280
220 - 550
50
90
96
100
113
116
Size
Dimensions [mm]
l1
l2
l3
l4
l5
l6
L
z x dM
H=stroke
15
5.0
7.0
9.2
2
4
18.8
28
12 x M3
0.8
25
5.5
11.5
9.1
2
5
23.9
33
8 x M4
1.2
32
6.0
12.5
9.9
2
5
25.1
35
8 x M4
1.5
42
7.0
16.0
11.2
2
6
31.8
43
8 x M5
1.5
60
8.0
21.0
11.8
2
7
38.2
52
12 x M6
1.8
1) Max. finish bore, feather keyway according to DIN 6885 sheet 3
Table 2: Technical data and dimensions –hub design 6.1
Size
Bore d1
Dimensions [mm]
Weight 2)
[kg]
Mass moment
of inertia 2)
Jtotal [kgm2]
Pilot
bored
Max.
D4
DK
L1
e
M
TA[Nm]
15
7.5
15
40
43.0
38
15
M4
1.7
0.124
2.9 × 10-5
25
9.5
25
55
-
45
21
M6
14
0.282
1.4 × 10-4
32
13.5
32
70
-
53
27
M8
34
0.471
3.5 × 10-4
42
18.5
42
86
91.2
63
33
M10
67
0.815
9.5 × 10-4
60
24.0
60
112
119.4
75
45
M12
115
3.04
5.9 × 10-3
2) With max. finish bore
1 Technical data

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
4 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Illustration 3: SYNTEX®-NC with ROTEX®GS (hub design 2.8, from size 60 - 6.0/6.1)
Illustration 4: SYNTEX®-NC with ROTEX®GS (hub design 2.9, from size 60 1.0/1.0)
Table 3: Dimensions and technical data with ROTEX®GS
Size
ROTEX®GS
size
Speed [rpm]
Torques [Nm]
Max. bore [mm]
T1
T2
T3
d
d1
d2
15
19
3500
2 - 3.5
3.5 - 7
7 - 14
12
15
24
25
24
3000
9 - 15
20 - 30
40 - 65
22
25
32
32
28
3000
25 - 38
50 - 75
100 - 150
30
32
35
42
38
2500
30 - 65
60 - 135
120 - 265
38
42
45
60
48
2000
70 - 140
120 - 280
220 - 550
50
60
55
Size
Dimensions [mm]
D5
DH
DK
DK1
DA
l1
l2
l3
E
15
45
40
-
46.7
42
17
40.0
40
16
25
58
55
-
57.5
61
18
47.5
35.5
18
32
70
65
-
69.0
74
21
55.0
37.0
20
42
88
80
91.2
86.0
90
26
66.0
46.0
24
60
113
105
119.4
-
116
56
83.0
60
28
Size
Dimensions [mm]
e
e1
LG
L1
LG1
M
TA[Nm]
M1
TA1 [Nm]
15
15
15.5
63
38
73.0
M4
1.7
M5
6
25
21
20.0
71.5
45
83.5
M6
14
M6
10
32
27
23.8
78.0
53
96.0
M8
34
M8
25
42
33
30.5
96.0
63
116.0
M10
67
M10
49
60
45
-
144
75
167.0
M12
115
M10
49
1 Technical data

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
5 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Illustration 5: SYNTEX®-NC with TOOLFLEX®
Table 4: Technical data and dimensions with TOOLFLEX®
Size
TOOLFLEX®
size
Speed [rpm]
Torques [Nm]
Max. bore [mm]
T1
T2
T3
d1
d2
15
20
3500
2 - 3.5
3.5 - 7
7 - 14
15
20
25
38
3000
9 - 15
20 - 30
40 - 65
25
38
32
42
3000
25 - 38
50 - 75
100 - 150
32
42
42
45
2500
30 - 65
60 - 135
120 - 265
42
45
60
65
2000
70 - 140
120 - 280
220 - 550
60
65
Size
Dimensions [mm]
D4
DH
DA
DK
DK1
l1
L1
E
15
40
40
52 1)
43
43.5
21.5
38
16.5
25
55
65
61
-
72.6
25.5
45
18.0
32
70
70
74
-
76.1
30.0
53
24.0
42
86
83
90
91.2
89.0
32.0
63
22.5
60
112
125
140 1)
119.4
127.1
45.0
84
36.0
Size
Dimensions [mm]
e
e1
LG
M
TA[Nm]
M1
TA1 [Nm]
15
15
14.5
76
M4
1.7
M5
6
25
21
25.0
88
M6
14
M8
25
32
27
27.0
107
M8
34
M8
25
42
33
30.0
114
M10
67
M10
49
60
45
45.0
165
M12
115
M14
185
1) Outside diameter shifting ring see table 1.
1 Technical data

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
6 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Table 5: Torques and surface pressure –hub design 6.1 (without feather keyway)
Size
15
25
32
42
60
Clamping screw M
M4
M6
M8
M10
M12
Tightening torque TA[Nm]
1.7
14
34
67
115
Bore Ø
Transmittable torque [Nm]
Surface pressure [N/mm2]
8
8
94.5
10
12
30
92
131
11
14
35
90.5
129.5
12
16
42
88
127.5
14
22
55
85
123.5
15
24
62
74
83.5
121
97
16
69
83
119
96
18
48
104
66
94
19
53
114
65
93
20
58
125
149
64.5
92
99
22
69
148
178
63
90
97.5
24
80
116
209
61.5
59.5
96
25
86
125
225
247
61
59
95
113.5
28
153
275
310
57.5
93
113.5
30
172
310
356
56.5
91.5
113.5
32
192
264
405
55.5
68.5
113.5
35
309
485
67
113.5
36
324
513
66.5
113.5
38
356
571
65.5
113.5
40
389
633
64.5
113.5
42
422
394
63.5
63.98
45
452
63.98
48
514
63.98
50
558
63.98
55
674
63.98
60
803
63.98
1 Technical data

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
7 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 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 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.
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 indications.
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 on the coupling.
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

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
8 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 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
had technical training
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 SYNTEX®-NC described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
!
To review the coupling selection please consult with KTR.
The couplings are supplied in preserved condition and can be stored at a dry and covered place for 6 - 9 months.
!
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less
than 65 %.
!
In order to avoid any injuries and any kind of damage please 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.
2 Advice
2.4 Intended use
2.5 Coupling selection
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
9 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
The coupling is supplied fully assembled (as specified by the buyer) and optionally with the torque set.
Component assembly 1: Components of SYNTEX®-NC (hub design 1.0)
Component
Quantity
Description
Illustration 6: SYNTEX®-NC (hub design 1.0)
1.1
1
Hub 1.0
1.2
1
Flange ring DK or SK
1.3
1
Shifting ring
1.4
see table
9
Disk springs (set)
1.5
1
Setting nut with cap screw
DIN EN ISO 4762 - 12.9
1.6
1 1)
Balls
1.7
1
Groove ball bearing
DIN 625
1.8
1
Circlip
1) Complete set
Component assembly 2: Components of SYNTEX®-NC (hub design 6.1)
Component
Quantity
Description
Illustration 7: SYNTEX®-NC (hub design 6.1)
2.1
1
Clamping ring hub
design 6.1
2.2
1
Flange ring DK or SK
2.3
1
Shifting ring
2.4
see table
9
Disk springs (set)
2.5
1
Setting nut with cap screw
DIN EN ISO 4762 - 12.9
2.6
1 1)
Balls
2.7
1
Groove ball bearing
DIN 625
2.8
1
Circlip
2.9
1
Clamping ring
2.10
1
Clamping screw
DIN EN ISO 4762 - 12.9
1) Complete set
Components of SYNTEX®-NC with ROTEX®GS
Component/
component
assembly
Quantity
Description
Illustration 8: SYNTEX®-NC with ROTEX®GS
1/2
1
SYNTEX®-NC
(complete coupling)
3
1
ROTEX®GS driving
flange
4
1
ROTEX®GS spider
5
1
ROTEX®GS clamping
hub
6
1)
Cap screws
DIN EN ISO 4762 - 12.9
1) see quantity in table 1
4 Assembly
4.1 Components of the couplings

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
10 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Components of SYNTEX®-NC with TOOLFLEX®
Component/
component
assembly
Quantity
Description
Illustration 9: SYNTEX®-NC with TOOLFLEX®
7
1
SYNTEX®-NC
(complete coupling)
!
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.

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the SYNTEX®-NC (hub design 1.0) lightly (approx. 80 °C) allows for an easier
mounting on the shafts.
STOP
Touching the heated coupling or clamping hub causes burns.
Please wear safety gloves.
Please make sure the perfect technical condition of the SYNTEX®-NC overload system.
Please only use original KTR components (no purchased parts).
4 Assembly
4.1 Components of the couplings
4.2 Advice on remachining
4.3 Assembly (general)

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
11 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Clean the hub bore and shaft and review for dimensional
accuracy, afterwards lubricate with a thin-fluid oil (e. g. Castrol
4 in 1 or Klüber Quietsch-Ex).
Illustration 10: axial locking
!
Oils and greases containing molybdenum disulfide
or other high-pressure additives as well as internal
lubricants must not be used.
Mount the SYNTEX®-NC (component assembly 1) on the shaft of
the driving or driven side.
Please provide for an end plate to fasten the SYNTEX®-NC axially
(see illustration 9).

We recommend to secure all screw connections against working loose additionally,
e. g. conglutinating with Loctite (average strength).

With the use of hollow shafts please observe chapter 4.6 before assembly of SYNTEX®-NC.
Unscrew the clamping screw (component 2.10) in the clamping
ring (component 2.9).
Clean the hub bore and shaft and review for dimensional
accuracy, afterwards lubricate with a thin-fluid oil (e. g. Castrol
4 in 1 or Klüber Quietsch-Ex).
Illustration 11: Assembly of SYNTEX®-NC
(hub design 6.1)
!
Oils and greases containing molybdenum disulfide
or other high-pressure additives as well as internal
lubricants must not be used.
Mount the SYNTEX®-NC (component assembly 2) on the shaft of
the driving or driven side.
Tighten the clamping screw to the tightening torque TAspecified in
table 2.

If the assembly is repeated the bore of the hub and shaft have to be cleaned and afterwards
lubricated with a thin-fluid oil (e. g. Castrol 4 in 1 or Klüber Quietsch-Ex).

All screw connections must be secured against working loose additionally, e. g.
conglutinating with Loctite (average strength).
4 Assembly
4.4 Assembly of SYNTEX®-NC (hub design 1.0)
4.5 Assembly of SYNTEX®-NC (hub design 6.1)

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
12 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
The power transmission of SYNTEX®-NC with hub design 6.1 is frictionally engaged. The necessary surface
pressure is transmitted via the clamping ring to the clamping ring hub and consequently to the shaft. The torques
or surface pressure specified in table 5 have to be considered.
The stiffness and dimensions of the shafts (here specifically hollow shafts) have to be selected in a way that
sufficient safety against plastic deformation is ensured. This may roughly be reviewed as per the following
criterion.
With clamping connections with hollow shafts the
internal diameter of the hollow shaft diW required is
calculated based on the following formula:
 
mm
Rp2R
dd 2,0p
W2,0p
iW


Shear stress on the internal shaft diameter for hollow
shaft:
 
2
2
W
W
tiW mm/N
C1 p2 


Shear stress for solid shaft:
 
2
WtW mm/Np
Rp0.2
= yield strength of shaft material [N/mm2]
diW
= internal diameter of hollow shaft [mm]
pW
= surface pressure of hub/shaft [N/mm2]
d
= shaft diameter [mm]
CW
= diW / d
The strength required is not provided if the hollow shaft bore is bigger than the max. internal bore calculated or if
the shear stress exceeds the yield strength of the material.
For a detailed calculation please contact KTR.
Mount the SYNTEX®-NC on the shaft of the driving or
driven side each depending on the hub design as per
chapter 4.4 or 4.5, respectively.
Clean the hub bore of the ROTEX®GS clamping hub
(component 5) and review for dimensional accuracy,
afterwards lubricate with a thin-fluid oil (e. g. Castrol
4 in 1 or Klüber Quietsch-Ex).
Illustration 12: SYNTEX®-NC with ROTEX®GS
!
Oils and greases containing molybdenum
disulfide or other high-pressure additives
as well as internal lubricants must not be
used.
Mount the ROTEX®GS clamping hub on the shaft of the driving or driven side.
Tighten the cap screws of the ROTEX®GS clamping hub to the tightening torques TA1 specified in table 3.
Hand-tighten the ROTEX®GS driving flange (component 3) with the SYNTEX®-NC coupling for the time being.
Tighten the cap screws (component 6, see illustration 11) crosswise to the tightening torques TAspecified in
table 6.
Insert the ROTEX®GS spider (component 4) into the cam section of the ROTEX®GS clamping hub.
4 Assembly
4.6 Notes with the use of hollow shafts
4.7 Assembly of SYNTEX®-NC with ROTEX®GS

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
13 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Shift the power packs in axial direction until the distance
dimension E is achieved (see illustration 12, table 3).
If the power packs are already firmly assembled, shifting
the hubs axially on the shafts allows for adjusting the
distance dimension E.
Illustration 13: Assembly of coupling
!
With the assembly please make sure that
the distance dimension E (see table 3) is
observed so that the coupling components
are not in contact with each other during
the operation.
Disregarding this advice may cause
damage to the coupling.

All screw connections must be secured against working loose additionally,
e. g. conglutinating with Loctite (average strength).
Table 6: Cap screws DIN EN ISO 4762
Size
15
25
32
42
60
Screw dimension dM
M3
M4
M4
M5
M6
Tightening torque TA[Nm]
1.7
2.8
4.1
8.1
14

Please consider our operating/assembly instructions KTR-N 45510 additionally when using
the ROTEX®GS coupling.
Clean the hub bore and shaft and review for dimensional
accuracy, afterwards lubricate with a thin-fluid oil (e. g. Castrol
4 in 1 or Klüber Quietsch-Ex).
Illustration 14: SYNTEX®-NC with TOOLFLEX®
!
Oils and greases containing molybdenum disulfide
or other high-pressure additives as well as internal
lubricants must not be used.
Unscrew the clamping screws of TOOLFLEX®.
Insert the shaft end of the driving machine in the coupling half of
TOOLFLEX®.
Secure the clamping hub by tightening the clamping screws at the
tightening torques TA1 specified in table 4.
Insert the shaft end of the driven machine in the coupling half of SYNTEX®-NC.
Shift the power packs in axial direction until the distance dimension LGis achieved (see illustration 13, table 4).
Secure the clamping ring hub of SYNTEX®-NC by tightening the clamping screws at the tightening torques TA
specified in table 4.
4 Assembly
4.7 Assembly of SYNTEX®-NC with ROTEX®GS
4.8 Assembly of SYNTEX®-NC with TOOLFLEX®

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
14 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:

All screw connections must be secured against working loose additionally,
e. g. conglutinating with Loctite (average strength).

Please consider our operating/assembly instructions KTR-N 45810 additionally when using
the TOOLFLEX®coupling.

KTR supplies the torque limiter pre-set to each approx. 75 % of the maximum torque of the
respective disk spring layering in case that SYNTEX®-NC is ordered without torque setting
by the customer.

If the torque pre-set cannot be modified by the customer any more, the screw of the setting
nut (component 1.5 or 2.5) has to be removed and coated with Loctite (average strength).
Afterwards tighten the screw at the tightening torque TA specified in table 2.
Modifying the torque pre-set (release torque)

The right disk spring layering is a pre-condition to perform a correct torque adjusting.
Please use the respective disk spring layering as per table 9 each depending on the setting
range (chapter 1).
Release the cap screw in the setting nut (component 1.5
or 2.5) by a maximum of one rotation.
Specify the torque pre-set (see step 1 in illustration 14).
Mark the torque pre-set on the label (see step 2 in
illustration 14).
Set a reference mark on the setting nut (see step 3 in
illustration 14).
Illustration 15
4 Assembly
4.8 Assembly of SYNTEX®-NC with TOOLFLEX®
5 Adjustment of torque
5.1 Torque setting - SYNTEX®-NC

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
15 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Rotate the setting nut by the requested number of
notches (see step 1 and 2 in illustration 15) by means of
a hook spanner (see table 8).
Illustration 16

With torque setting please note the setting
diagrammes of the respective sizes (see
chapter 5.3).
Remove the torque value from the label (see step 3 in
illustration 15).
Mark the coupling with the new torque pre-set (see
step 1 in illustration 16).
Remove the reference mark from the setting nut (see
step 2 in illustration 16).
Remove the cap screw from the setting nut.
Coat the cap screw with Loctite (average strength).
Afterwards screw in the cap screw and tighten at the
tightening torque TAspecified in table 7.
Illustration 17

All screw connections must be secured against working loose additionally,
e. g. conglutinating with Loctite (average strength).
Table 7: Cap screws DIN EN ISO 4762
Size
15
25
32
42
60
Screw size
M3
M3
M3
M3
M4
Tightening torque TA[Nm]
1.2
1.2
1.2
1.2
2.8
!
Please bear in mind that setting the torque beyond the torque range (see chapter 1) may
result in misoperation and damage of the coupling.

In order to ensure an optimum torque setting, SYNTEX®-NC should be inspected after initial
disengagement processes and reset, if necessary.

If SYNTEX®-NC was pre-set only or set to the requested torque as per these
operating/assembly instructions, the torque should be considered as a reference value only.
For accurate torque setting we would recommend to inspect the torque by means of a
suitable measuring system and reset, if necessary.

We basically recommend to perform torque setting on KTR's test benches in order to
ensure the optimum accuracy of torque setting.
Table 8: Tools for torque setting
Hook spanner
DIN 1810-A
Size
Hook spanner
10
Ø34-36
25
Ø45-50
32
Ø58-62
42
Ø68-75
60
Ø95-100
5 Adjustment of torque
5.1 Torque setting - SYNTEX®-NC

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
16 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:

If torque setting is beyond the requested torque range as per chapter 1, the coupling can be
reset to the requested torque by adapting the disk spring layering.
We recommend to have the modification and resetting of the coupling performed by KTR's
qualified staff.
STOP
Driving components falling down may cause injury to persons or damage on the machine.
Secure the driving components during disassembly.
Release the clamping screw (component 2.10) of the clamping ring (component 2.9).
[Applies with hub design 6.1 only]
Illustration 18: Example - Assembly of SYNTEX®-NC (hub design 6.1)
Disassemble the coupling from the machine and mount it onto a suitable auxiliary shaft.
Release the cap screw in the setting nut (component 1.5 or 2.5). Do not fully unscrew the cap screw.
Turn back the setting nut by means of a hook spanner (see illustration 17 and table 8) until the disk springs are
fully released.
Remove the clamping ring (component 2.9) from the clamping ring hub (component 2.1).
[Applies with hub design 6.1 only]
Remove the setting nut from the hub (component 1.1) or clamping ring hub (component 2.1), respectively.
Adjust the disk spring layering as per table 9 to the requested torque (see chapter 1).
Table 9: Layering of disk springs
Layering of disk springs
Design DK and SK
T1
T2
T3
Illustration
Designation
1x1
1x2
1x4
5 Adjustment of torque
5.2 Replacement of layering of disk springs

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
17 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Screw the setting nut onto the hub or clamping ring hub and hand-tighten it.
Hand-tighten the cap screw in the setting nut. Afterwards turn back the cap screw by half a rotation.
Mount the clamping ring onto the clamping ring hub. [Applies with hub design 6.1 only]

With the assembly please make sure that the
balancing bores of the clamping ring
(component 2.9) point towards the disk
spring(s).
Illustration 19: Notches of setting nut
Screw in the setting nut by means of a hook spanner (see
illustration 17 and table 8) until it cannot be turned any
more. Afterwards turn back the setting nut by one notch
(see illustration 19).
The torque pre-set corresponds to the minimum release
torque (see illustration 20) now.
Set the torque required as described in chapter 5.1.

The disk springs are operated in the negative
sector of the characteristic curve. Tightening
the setting nut causes a reduced release
torque. The release torque is increased by
untightening the setting nut.
Illustration 20: Spring characteristic
Remove the cap screw from the setting nut and paint with
Loctite (average strength). Afterwards screw in the cap
screw and tighten at the tightening torque TAspecified in
table 7.
Unscrew the clamping screw of the clamping ring.
[Applies with hub design 6.1 only]
Disassemble the coupling from the auxiliary shaft.
!
Please bear in mind that setting the torque beyond the torque range (see chapter 1) may
result in misoperation and damage of the coupling.

In order to ensure an optimum torque setting, SYNTEX®-NC should be inspected after initial
disengagement processes and reset, if necessary.

If SYNTEX®-NC was pre-set only or set to the requested torque as per these
operating/assembly instructions, the torque should be considered as a reference value only.
For accurate torque setting we would recommend to inspect the torque by means of a
suitable measuring system and reset, if necessary.

We basically recommend to perform torque setting on KTR's test benches in order to
ensure the optimum accuracy of torque setting.

All screw connections must be secured against working loose additionally, e. g.
conglutinating with Loctite (average strength).
5 Adjustment of torque
5.2 Replacement of layering of disk springs

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
18 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Diagramme 1: SYNTEX®-NC size 15
Diagramme 2: SYNTEX®-NC size 25
Diagramme 3: SYNTEX®-NC size 32
5 Adjustment of torque
5.3 Setting diagrammes

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
19 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Diagramme 4: SYNTEX®-NC size 42
Diagramme 5: SYNTEX®-NC size 60
5 Adjustment of torque
5.3 Setting diagrammes
T3

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
20 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
If the torque set is exceeded, the coupling disengages with the shifting ring being moved back axially by
dimension H (see table 10).
The sensor or limit switch has to be mounted such that signal recording is ensured in this shifting range.
The sensor or limit switch has to be aligned versus SYNTEX®-NC such that signal recording of the
disengagement process is ensured.
Illustration 21: Mechanical limit switch
Table 10: Position of limit switch
Size
Dimensions [mm]
l2
l3
ØDA
H=stroke
15
7.0
9.2
42
0.8
25
11.5
9.1
61
1.2
32
12.5
9.9
74
1.5
42
16.0
11.2
90
1.5
60
21.0
11.8
116
1.8
Function
The axial stroke of the shifting ring generated with overload may activate a mechanical limit switch or an inductive
sensor. As a result a control signal is generated which can be evaluated for disengaging the drive.
Assembly
The sensor needs to be mounted in a solid device to ensure a smooth operation. The sensor should be protected
from dirt and potential mechanical faults.
!
We recommend using a limit switch!
Please absolutely observe the operation of the limit switch before the machine is supplied.
Please also observe the operating instructions for the sensor or limit switch, respectively.
The axial stroke of the shifting ring must not be blocked by any other components.
As soon as the limit switch or sensor is activated (overload: release of overload coupling)
the drive should immediately be stopped.
With higher speeds respective braking devices may be necessary.
6 Assembly of limit switch