KTR SYNTEX Operating/Mounting Instructions

Below you will find brief information for overload system SYNTEX DK. This overload system with positive locking protects components against destruction. The design DK (ratchet) re-engages after 30° each into the following lock-in position in case of an overload. This document covers technical data, storage hints, general assembly instructions, adjustment of the torque of engagement, assembly of SYNTEX overload system, limit switch operation.

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KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX&reg;
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
1 of 8
7
SYNTEX&reg; design DK
Hub design 1.0
Hub design 4.5
The SYNTEX&reg; is an overload system with positive locking. It protects the following
components against destruction. The design DK (ratchet) re-engages after 30&deg; each into the
following lock-in position in case of an overload.
Table of Contents
1
Technical Data
2
Hints
2.1
2.2
2.3
2.4
General Hints
Safety and Advice Hints
General Hints to Danger
Proper Use
3
Storage
4
Assembly
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Components SYNTEX&reg;-Overload System
Assembly (General)
Adjustment of the Torque of Engagement
Adjustment of the Torque of Engagement after the Disassembly
Assembly SYNTEX&reg;-Overload System
Limit Switch
Spares Inventory, Customer Service Addresses
Please note protection
mark ISO 16016.
Drawn:
Verified:
15.08.13 Kb/Koh
23.08.13 Kb
Replaced for:
Replaced by:
KTR-N valid from 30.06.10
SYNTEX&reg;
Operating-/Assembly Instructions
design DK (ratchet)
KTR Kupplungstechnik
GmbH
D-48407 Rheine
46210 EN
2 of 8
7
KTR-N
sheet:
edition:
1 Technical Data
illustration 1: hub design 1.0
illustration 2: hub design 4.5
Table 1: dimensions
Size
20
25
35
50
Max. finish
bore
DA
d [mm]
20
20
25
25
35
35
50
50
Dimensions [mm]
D2
d1
DN
D3
D1
dL
L
l1
l2
l3
l4
l5
z
71
65
48
54 61,5 4,5
89
81
60
68
80 5,5
110 102 75
78
91 5,5
152 142 105 108 121 6,6
45
50
60
70
8
8
10
12
2
2
2
2
16
17
21
25
6
8
10
13
35
39
42
56
8
8
12
12
H
(stroke)
2
2
2
2
Table 2: dimensions hub design 4.5
Size
l6
9
11
10
12
20
25
35
50
l7
3,5
4,0
4,0
4,0
Dimensions [mm]
l8
23
28
31
37
LG
54
61
70
82
s
3
4
4
6
M
M5
M6
M6
M6
Clamping screws
Number
TA [Nm]
4
8,5
4
14
4
14
4
14
Table 3: technical data
Torques [Nm]
-1
Size
Max. speed [min ]
20
25
35
50
1500
1500
1000
1000
DK1
6 – 20
20 – 60
25 – 80
60 –180
DK2
15 – 30
45 – 90
75 – 150
175 – 300
Table 4: transmittable friction torques of hub design 4.5
Size
20
25
35
50
12
14
15
16
17
Bores and the corresponding transmittable friction torques * TR [Nm]
18
19
20
22
23
24
25
28
30
32
35
38
45
62
72
71
83
81
95
92
107
103
120
115
133
127
148
179
127
196
139
213
152
231
165
207
237
270
323
238
281
40
42
45
48
50
311
343
394
448
486
* fit H7/h6
Please note protection
mark ISO 16016.
Drawn:
Verified:
15.08.13 Kb/Koh
23.08.13 Kb
Replaced for:
Replaced by:
KTR-N valid from 30.06.10
KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX&reg;
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
3 of 8
7
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!
Danger of injury to persons.
!
CAUTION!
Damages on the machine possible.
ATTENTION!
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 &quot;safety first&quot;.
 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&reg; described in here corresponds to the technical status at the time of printing of these mounting
instructions.
Please note protection
mark ISO 16016.
Drawn:
Verified:
15.08.13 Kb/Koh
23.08.13 Kb
Replaced for:
Replaced by:
KTR-N valid from 30.06.10
KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX&reg;
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
4 of 8
7
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
&reg;
The SYNTEX -overload system is delivered in assembled condition.
4.1 Components SYNTEX&reg;-Overload System
Components SYNTEX&reg;-overload system with hub design 1.0
Component
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
3
6
18
Designation
Hub (design 1.0)
Disc spring
Flange ring
Setting ring
Shifting ring
Setting nut
Slide bush
Axial needle spider
Shaft lock washer
Set screw DIN EN ISO 4762
Grub screw DIN EN ISO 4029
Grub screw with tappet DIN EN ISO 4028
Half length reserve taper grooved dowel pin DIN EN ISO 8741
Round head grooved pin DIN EN ISO 8746
Ball DIN 5401
&reg;
illustration 3: SYNTEX DK hub design 1.0
Please note protection
mark ISO 16016.
Drawn:
Verified:
15.08.13 Kb/Koh
23.08.13 Kb
Replaced for:
Replaced by:
KTR-N valid from 30.06.10
KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX&reg;
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
5 of 8
7
4 Assembly
4.1 Components SYNTEX&reg;-Overload System
Components SYNTEX&reg;-overload system with hub design 4.5
Component
1.1
1.2
1.3
2
3
4
5
6
7
8
9
10
11
12
13
14
Quantity
1
1
4
1
1
1
1
1
1
1
1
1
1
3
6
18
Designation
Hub (design 4.5)
Clamping bush
Clamping screws DIN EN ISO 4017
Disc spring
Flange ring
Setting ring
Shifting ring
Setting nut
Slide bush
Axial needle spider
Shaft lock washer
Set screw DIN EN ISO 4762
Grub screw with tappet DIN EN ISO 4028
Half length reserve taper grooved dowel pin DIN EN ISO 8741
Round head grooved pin DIN EN ISO 8746
Ball DIN 5401
&reg;
illustration 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.
&reg;
 Before assembly and operation please check whether it is necessary to clean the components.
 Lubricate the balls (e. g. Kl&uuml;ber-Microlube GL 263).
 Please only use original components.
Please note protection
mark ISO 16016.
Drawn:
Verified:
15.08.13 Kb/Koh
23.08.13 Kb
Replaced for:
Replaced by:
KTR-N valid from 30.06.10
KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX&reg;
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
6 of 8
7
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&reg;-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:
Twisting angle
setting nut
30&deg;
60&deg;
90&deg;
120&deg;
150&deg;
180&deg;
210&deg;
240&deg;
270&deg;
300&deg;
330&deg;
360&deg;
390&deg;
420&deg;
450&deg;
480&deg;
510&deg;
540&deg;
570&deg;
600&deg;
630&deg;
Torque of engagement [Nm]
Size 25
Size 35
Spring
Spring
Spring
Spring
DK1
DK2
DK1
DK2
Size 20
Spring
Spring
DK1
DK2
5
7
8
15
9
17
11
20
13
23
15
25
17
27
18
29
20
30
20
23
25
29
33
37
41
45
49
52
55
58
60
illustration 5: hinged hook wrench
Please note protection
mark ISO 16016.
Drawn:
Verified:
15.08.13 Kb/Koh
23.08.13 Kb
46
52
58
64
70
76
82
86
90
25
28
32
35
38
40
45
49
53
57
61
66
71
74
77
80
SYNTEX&reg;
size
20
25
35
50
Replaced for:
Replaced by:
78
86
93
100
108
115
122
129
136
143
150
Size 50
Spring
Spring
DK1
DK2
57
65
73
80
88
95
100
110
118
126
134
142
150
157
165
172
180
175
188
200
212
225
237
250
262
275
288
300
Hinged hook wrench
with tappet
&Oslash;35 - 60 x 5
&Oslash;60 - 90 x 6
&Oslash;60 - 90 x 6
&Oslash;90 - 155 x 8
KTR-N valid from 30.06.10
KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX&reg;
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
7 of 8
7
4 Assembly
4.4 Adjustment of the Torque of Engagement after the Disassembly
 Insert the balls with grease (e. g. Kl&uuml;ber - 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.
illustration 6
Please note protection
mark ISO 16016.
Drawn:
Verified:
15.08.13 Kb/Koh
23.08.13 Kb
Replaced for:
Replaced by:
KTR-N valid from 30.06.10
KTR Kupplungstechnik
GmbH
D-48407 Rheine
SYNTEX&reg;
Operating-/Assembly Instructions
design DK (ratchet)
KTR-N
sheet:
edition:
46210 EN
8 of 8
7
4 Assembly
4.5 Assembly SYNTEX&reg;-Overload System
Feather key connection
&reg;
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.
Please note protection
mark ISO 16016.
Drawn:
Verified:
15.08.13 Kb/Koh
23.08.13 Kb
Replaced for:
Replaced by:
KTR-N valid from 30.06.10
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Key features

overload protection
positive locking
ratchet design
adjustable torque
limit switch integration

Frequently asked questions

The SYNTEX DK overload system is designed to protect components against destruction in case of an overload. It features a ratchet mechanism that re-engages after 30° each into the following lock-in position.

You can adjust the torque of engagement by rotating the setting nut clockwise for higher torque or counterclockwise for lower torque. Refer to the table of torque of engagement for specific values based on the size of your system.

The limit switch is activated by the axial thrust of the shifting ring during an overload event. This triggers a control operation to disengage the drive.