KTR-SI Compact
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46311 EN
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3
KTR-SI
Compact
Type DK
(ratchet design)
Type SK
(synchronous design)
KTR-SI Compact
KTR-SI Compact with ROTEX® GS coupling
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-01-11 Ka/Su
2023-01-11 Ka
Replacing:
Replaced by:
KTR-N dated 2023-01-05
KTR-SI Compact
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46311 EN
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3
KTR-SI Compact is a torque limiting, backlash-free overload system operating with positive locking. It protects
adjacent components from damage.
In case of overload on the overload system the torque is considerably reduced to a lower residual torque. KTR-SI
Compact is a not load holding overload system.
• 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°.
Table of contents
1
Technical data
3
2
Advice
6
2.1
2.2
2.3
2.4
2.5
2.6
6
6
6
7
7
7
3
4
5
General advice
Safety and advice symbols
General hazard warnings
Intended use
Selection of overload system
Reference to EC Machinery Directive 2006/42/EC
Storage, transport and packaging
8
3.1
3.2
8
8
Storage
Transport and packaging
Assembly
9
4.1 Components of overload systems
4.2 Layering of disk springs
4.3 Advice for finish bore
4.4 Assembly (general)
4.5 Assembly of the KTR-SI Compact overload system (hub type 1.0)
4.6 Assembly of the KTR-SI Compact overload system (hub type 4.5)
4.7 Notes with the use of hollow shafts
4.8 Assembly of KTR-SI Compact with ROTEX® GS coupling
4.9 Disassembly of overload system / replacement of single parts (size 01 to 3)
4.10 Disassembly of overload system / replacement of single parts (size 4)
4.11 Assembly of the overload system
9
11
12
13
13
14
14
15
16
17
18
Adjustment of torque
18
5.1
5.2
5.3
18
20
22
Torque setting - KTR-SI Compact
Replacement of layering of disk springs
Setting diagrammes
6
Assembly of limit switch
24
7
Breakdowns, causes and elimination
25
8
Disposal
26
9
Maintenance and service
26
10
Advices for the use of drive components
27
11
Spares inventory, customer service addresses
27
Please observe protection
note ISO 16016.
Drawn:
Verified:
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Replacing:
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KTR-N
Sheet:
Edition:
KTR-SI Compact
Operating/Assembly instructions
1
46311 EN
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3
Technical data
Hub type 1.0
Illustration 1: KTR-SI Compact size 01 to 3
Illustration 2: KTR-SI Compact size 4
Hub type 4.5 with taper bush
Illustration 3: KTR-SI Compact size 01 to 3
Illustration 4: KTR-SI Compact size 4
Table 1: Technical data and dimensions
Torques in Nm
Bore Ø D
Speed
in rpm
T1
T2
T3
1.0
01
4000
3-14
6-28
13-56
8-20
0
3000
9-35
18-70
40-140
1
2500
19-65
38-130
78-260
2
2000
35-110
80-220
160-440
Size
10-25
(30) 1)
14-30
(35) 1)
18-40
(45) 1)
3
1200
80-210
160-400
320-800
24-50
4
400
230-730
460-1590
960-3100
40-75
Dimensions in mm
L
4.5
10-20
19-25
15-20
19-30
19-30
32-40
32-50
32-50
55-60
50-60
65-80
DA
D4
D5 h5
D7
47
70
56
47
65
48
53
56
85
71
62
80
59
67
100
85
75
95
64
73
115
100
90
110
135
116
100
130
220
160
145H7
186
1.0
4.5
40
75
119
85
86
133.5
138
D8
40.5
42.0
40.5
57.0
57.0
64.0
73.5
73.5
89.0
96.5
123.0
Dimensions in mm
Size
AE
BE
LG
LH1
LH2
L3
L5
01
-
7
7.5
7
12.0
0
-
8
8.0
8
14.0
1
-
9
10.5
9
16.0
2
-
10
12.0
10
17.0
3
-
12
12.0
12
21.0
4
46.5
9
24.0
9
38.5
26
26
31
40
31
29
29
44
54
62
H=
stroke
1.2
L6
L7
L8
L9
ZxM
SW
SW1
5
8
40
46
8 x M5
7
9
14
57
60.0
8 x M6
8
10
16
63
8 x M6
10
7
7
10
10
8
10
10
18
75
4.0
8 x M8
10
10
2.2
-
7
119
66.5
78.5
78.0
125.5
126.0
2.8
2.8
4.0
4.0
3.5
4.0
7
11
42.0
48.0
49.0
8 x M4
7
5.5
7.0
6 x M12
13
13
16
3.5
1.5
1.8
2.0
1) Max. bore with keyway acc. to DIN 6885 sheet 3 (low-rise design) with size 0 = d > 28 mm, with size 1 = d > 32 mm and
with size 2 = d > 42 mm
Please observe protection
note ISO 16016.
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KTR-SI Compact
Operating/Assembly instructions
1
46311 EN
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Technical data
KTR-SI Compact with ROTEX® GS coupling
Hub type 1.0
Hub type 1.0
Hub type 6.0
Illustration 5: KTR-SI Compact (hub type 1.0/1.0)
Hub type 4.5
Illustration 6: KTR-SI Compact (hub type 6.0/4.5)
Table 2: Technical data and dimensions
Torques in Nm
Speed
in rpm]
T1
T2
T3
ROTEX® GS
size
01
0
1
2
3
4
4000
3000
2500
2000
1200
400
3-14
9-35
19-65
35-110
80-210
230-730
6-28
18-70
38-130
80-220
160-400
460-1590
13-56
40-140
78-260
160-440
320-800
960-3100
24
28
38
42
48
75
Size
L
Size
L1
01
1.0/1.0
95.0
6.0/4.5
102.0
1.0/1.0
30
6.0/4.5
30
0
111.5
119.5
35
35
1
138.0
146.0
45
45
2
150.0
159.0
50
50
3
171.0
182.0
56
56
4
283.5
302.5
85
85
Max. finish bore
D
1.0
28
38
45
55
62
80
Dimensions in mm
L2
L3
1.0/1.0
6.0/4.5
1.0/1.0
6.0/4.5
47.0
47.0
40
26
26
56.5
54.5
48
31
40
69.0
67.0
59
31
74.0
73.0
64
29
29
87.0
87.0
75
44
54
158.5
158.5
112
62
D1
6.0 2)
28
38
45
55
62
80
1.0
20
30 1)
35 1)
45 1)
50
75
4.5
25
30
40
50
60
80
DA
DH
E
70
55
18
85
65
20
100
80
24
115
95
26
135
105
28
220
160
40
1) Max. bore with keyway acc. to DIN 6885 sheet 3 (low-rise design) with size 0 = d > 28 mm, with size 1 = d > 32 mm and
with size 2 = d > 42 mm
2) For friction torques see operating/assembly instructions of ROTEX® GS (ROTEX® GS hub type 6.0)
Please observe protection
note ISO 16016.
Drawn:
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KTR-SI Compact
Operating/Assembly instructions
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46311 EN
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Technical data
Table 3: Friction torque and surface pressure of hub type 4.5 (without feather keyway)
Size
Clamping screw SW1
Tightening torque TA in Nm
01
M4
4.6
0
M4
4.6
M6
10
Bore Ø D
Ø10
Ø11
Ø12
Ø14
Ø15
Ø16
Ø18
Ø19
Ø20
Ø22
Ø24
Ø25
65
133
70
118
75
106
90
94
95
86
100
80
115
72
120
68
130
66
140
59
150
53
160
52
Ø28
Ø30
1
2
M6
M5
M6
10
5.9
10
Transmittable friction torque TR in Nm
Surface pressure in N/mm2
M8
28
4
680
121
700
105
740
94
780
89
820
85
870
79
930
74
970
71
1070
43
1160
39
2500
98
2750
89
3000
82
M10
49
120
109
130
104
150
94
160
76
180
77
190
67
210
62
220
62
240
52
260
49
240
88
260
86
290
79
310
71
320
71
360
61
390
57
330
55
360
50
390
46
410
44
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
Ø48
Ø50
550
98
600
90
650
82
690
79
720
75
770
70
820
65
860
63
Ø55
Ø60
3300
67
3600
63
3800
58
4100
55
Ø65
Ø70
Ø75
Ø80
Please observe protection
note ISO 16016.
3
M6
10
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KTR-SI Compact
Operating/Assembly instructions
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KTR-N
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Edition:
46311 EN
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Advice
2.1 General advice
Please read through these operating/assembly instructions carefully before you start up the overload system.
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 overload system. The copyright for these operating/assembly instructions remains with KTR.
2.2 Safety and advice symbols
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.
2.3 General hazard warnings
STOP
With assembly, operation and maintenance of the overload system 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. Make absolutely sure to read through and observe the following safety indications.
• All operations on and with the overload system 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 overload system.
• 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 overload system as long as it is in operation.
• Please secure the overload system against accidental contact. Provide for the necessary protection devices
and covers.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-01-11 Ka/Su
2023-01-11 Ka
Replacing:
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KTR-SI Compact
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
46311 EN
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Advice
2.4 Intended use
You may only assemble, operate and maintain the overload system if you
• have carefully read through the operating/assembly instructions and understood them
• had technical training
• are authorized by your company
The overload system may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications on the overload system 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 KTR-SI Compact described in here corresponds to the state of the art at the time of printing of these operating/assembly instructions.
2.5 Selection of overload system
!
!
!
For a long-lasting and failure-free operation of the overload system the overload system
(with coupling, where appropriate) must be selected according to the selection instructions
for the particular application (see catalogue drive technology "KTR-SI Compact").
If the operating conditions (performance, speed, modifications on engine and machine)
change, the selection must be reviewed.
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and
is subject to his responsibility.
Please observe the potential operating temperature from -20 °C to +90 °C of KTR-SI Compact.
We recommend to use 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 other components.
As soon as the limit switch or sensor is activated (overload: release of overload system) the
drive should immediately be stopped.
With higher speeds respective braking devices may be necessary.
2.6 Reference to EC Machinery Directive 2006/42/EC
The overload systems supplied by KTR should be considered as components, not machines or partly completed
machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of incorporation. For details about safe assembly, start-up and safe operation refer to the present operating/assembly instructions considering the warnings.
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2023-01-11 Ka
Replacing:
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KTR-SI Compact
Operating/Assembly instructions
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KTR-N
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Edition:
46311 EN
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Storage, transport and packaging
3.1 Storage
The overload systems are supplied in preserved condition and can be stored in a dry and roofed place for 6 - 9
months.
!
Humid storage rooms are not suitable.
Make sure that condensation is not generated. The best relative air humidity is less than
65 %.
3.2 Transport and packaging
!
In order to avoid any injuries and any kind of damage always make use of proper transport
and lifting equipment.
The overload systems/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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2023-01-11 Ka
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KTR-SI Compact
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
46311 EN
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Assembly
The overload system is supplied fully assembled with finish bore (as specified by the customer) and optionally
with the torque set.
4.1 Components of overload systems
Subassembly 1: Components of KTR-SI Compact (hub type 1.0)
Component
1.1
1.2
1.3
1.4
1.6.1
1.6.2
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
Quantity
1
1
1
see table 4
1
1
1 1)
1
1
1
1
1
2
Description
Hub 1.0
Flange ring DK or SK
Shifting ring
Disk springs (set)
Setting nut
Hexagon screw DIN EN ISO 4017 - 12.9
Lock washer
Balls
Groove ball bearing DIN 625
Circlip DIN 471
Supporting disk
Circlip DIN 472
Axial needle bearing
Axial disk
1) Complete set
Illustration 7: KTR-SI Compact size 01 to 3
Illustration 8: KTR-SI Compact size 4
Please observe protection
note ISO 16016.
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Verified:
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2023-01-11 Ka
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KTR-SI Compact
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KTR-N
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Edition:
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Assembly
4.1 Components of overload systems
Subassembly 2: Components of KTR-SI Compact (hub type 4.5 with taper bush)
Component
2.1
2.2
2.3
2.4
2.5.1
2.5.2
2.6.1
2.6.2
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
Quantity
1
1
1
see table 4
1
1
1
1 1)
1
1
1
1
1
2
Description
Hub 4.5
Flange ring DK or SK
Shifting ring
Disk springs (set)
Taper bush
Hexagon screws DIN EN ISO 4017 - 12.9
Setting nut
Hexagon screw DIN EN ISO 4017 - 12.9
Lock washer
Balls
Groove ball bearing DIN 625
Circlip DIN 471
Supporting disk
Circlip DIN 472
Axial needle bearing
Axial disk
1) Complete set
Illustration 9: KTR-SI Compact size 01 to 3
Illustration 10: KTR-SI Compact size 4
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-01-11 Ka/Su
2023-01-11 Ka
Replacing:
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KTR-SI Compact
Operating/Assembly instructions
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KTR-N
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Edition:
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Assembly
4.1 Components of overload systems
Components of KTR-SI Compact with ROTEX® GS coupling
Components/
subassemblies
1/2
3
4
5
6
7
Quantity
1
1
1
1
1)
1
Description
KTR-SI Compact (complete overload system)
ROTEX® GS driving flange
ROTEX® GS spider
ROTEX® GS hub
Cap screws DIN EN ISO 4762 - 12.9
Setscrew DIN EN ISO 4029
1) see number Z in table 1
Illustration 11: KTR-SI Compact with ROTEX® GS
4.2 Layering of disk springs
Layering of disk springs with KTR-SI Compact
Table 4:
Layering of disk springs
T1
Design DK and SK
T2
T3
1x1
1x2
1x4
Illustration
Description
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Assembly
4.3 Advice for finish bore
The maximum permissible bore diameters D (see
table 1 and 2 in chapter 1 - technical data) must not
be exceeded. If these figures are disregarded, the
overload system may tear. Rotating particles may
cause danger to life.
STOP
• If the bore of the hub is machined by the customer,
the overload system needs to be disassembled (see
chapter 4.6).
• Axial run-out or concentricity (see illustration 12)
need to be adhered to.
• Please make absolutely sure to observe the figures
for Ø Dmax.
• Carefully align the hubs when the finish bores are
drilled.
Illustration 12: Concentricity and axial runout
The customer bears the sole responsibility for all machining processes performed subsequently on unbored or pilot bored as well as finish machined components and spare parts.
KTR does not assume any warranty claims resulting from insufficient remachining.
!
Table 5: Recommended fit pairs acc. to DIN 748-1
Bore in mm
above
up to
50
50
Shaft tolerance
Bore tolerance
k6
m6
H7
(KTR standard)
If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR standard) with normal operating conditions or ISO P9 with difficult operating conditions (frequently alternating torsional
direction, shock loads, etc.).
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his
responsibility.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-01-11 Ka/Su
2023-01-11 Ka
Replacing:
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KTR-N dated 2023-01-05
KTR-N
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KTR-SI Compact
Operating/Assembly instructions
4
46311 EN
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3
Assembly
4.4 Assembly (general)
We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the KTR-SI Compact overload system respectively ROTEX® GS hub lightly (approx.
80 °C) allows for easier mounting on the shafts.
STOP
Touching the heated overload system, coupling or hub causes burns. Please wear safety
gloves.
With assembly of the overload system it is not allowed to generate any forces (e. g. by hammer blows or mounting equipment) on the flange ring (component 1.2 or 2.2) and groove ball
bearing (component 1.9 or 2.9).
• Make sure the perfect technical condition of the KTR-SI Compact overload system.
• Please only use original KTR components (no purchased parts).
4.5 Assembly of the KTR-SI Compact overload system (hub type 1.0)
• 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).
!
Oils and greases containing molybdenum disulfide or
other high-pressure additives as well as internal lubricants must not be used.
• Mount the KTR-SI Compact flange type (component 1) on the shaft of
the driving or driven side.
• Provide for an end plate to fasten the KTR-SI Compact overload system axially (see illustration 13).
Illustration 13: axial locking
All screw connections must be secured against working loose additionally,
e. g. conglutinating with Loctite (average strength).
Please observe protection
note ISO 16016.
Drawn:
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KTR-SI Compact
Operating/Assembly instructions
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46311 EN
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3
Assembly
4.6 Assembly of the KTR-SI Compact overload system (hub type 4.5)
With the use of hollow shafts please observe chapter 4.7 before assembly of KTR-SI Compact.
• Unscrew the hexagon screws in the taper sleeve (component 2.5.1).
• 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 QuietschEx).
!
Oils and greases containing molybdenum disulfide or other
high-pressure additives as well as internal lubricants must
not be used.
• Mount the KTR-SI Compact flange type (component 2) on the shaft of the
driving or driven side.
• Tighten the hexagon screws (component 2.5.2) in the taper sleeve (component 2.5.1) to the tightening torque TA specified in table 3..
Illustration 14
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).
4.7 Notes with the use of hollow shafts
The power transmission of KTR-SI Compact with hub type 4.5 is frictionally engaged. The necessary surface
pressure is transmitted via the hub 4.5 (component 2.1) resp. taper sleeve (component 2.5.1) and consequently to
the shaft. The torques or surface pressure specified in table 3 have to be considered.
The strength and dimensions of the shafts (specifically hollow shafts) have to be defined such that sufficient safety against plastic deformation is ensured. This may roughly be reviewed as per the following criterion.
For clamping connections with hollow shafts the required internal diameter of the hollow shaft diW is calculated based on the following formula:
d iW d
tiW
Shear stress for solid shaft:
−
diW
d
CW
2 pW
1 − C W
tW
= yield strength of shaft material in N/mm2
= surface pressure of hub/shaft in N/mm2
mm
R p 0 ,2
Shear stress on the internal shaft diameter for hollow
shaft:
Rp0.2
pW
R p 0 ,2 − 2 p W
= − pW
N / mm
2
2
N / mm
2
= internal diameter of hollow shaft in mm
= shaft diameter in mm
= 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.
Please observe protection
note ISO 16016.
Drawn:
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KTR-SI Compact
Operating/Assembly instructions
4
46311 EN
15 of 27
3
Assembly
4.8 Assembly of KTR-SI Compact with ROTEX® GS coupling
Please consider our operating/assembly instructions KTR-N 45510 additionally when using
the ROTEX® GS coupling.
• Mount the KTR-SI Compact overload system (subassembly 1
or 2) on the shaft of the driving or driven side depending on
the hub type as per chapter 4.5 resp. 4.6.
• Clean the hub bore and shaft of the ROTEX® GS hub (component 5) and review for dimensional accuracy, afterwards
lubricate with a thin oil (e. g. Castrol 4 in 1 or Klüber
Quietsch-Ex).
!
Oils and greases containing molybdenum disulfide or other high-pressure additives as well as
internal lubricants must not be used.
Illustration 15: KTR-SI Compact with
ROTEX® GS coupling
• Mount the ROTEX® GS hub (component 5) on the shaft of the driving or driven side.
• Hand-tighten the ROTEX® GS driving flange (component 3) with the KTR-SI Compact overload system (subassembly 1 or 2) first.
• Tighten the cap screws (component 6) crosswise to the tightening torques TA specified in table 6.
• Insert the ROTEX® GS spider (component 4) into the cam section of the ROTEX® GS hub (component 5).
• Shift the power packs in axial direction until the distance dimension E has been achieved (see illustration 16).
• If the power packs are already firmly assembled, shifting the
hubs axially on the shafts allows for setting the distance dimension E.
• Fasten the ROTEX® GS hub (component 5) by tightening
the setscrew DIN EN ISO 4029 with a cup point (tightening
torques TA see KTR-N 45510).
!
With the assembly make sure that the distance
dimension E (see table 2) is observed so that
the components are not in contact with each
other during the operation.
Disregarding this advice may cause damage to
the overload system resp. coupling.
Illustration 16: Assembly of overload system with 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 (component 6)
Size
Screw size M
Tightening torque TA in Nm
Please observe protection
note ISO 16016.
01
M4
2.8
Drawn:
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0
M5
5.5
1
M6
9.6
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2
M6
14
Replacing:
Replaced by:
3
M8
34
4
M12
115
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Assembly
4.9 Disassembly of overload system / replacement of single parts (size 01 to 3)
Applies with hub type 4.5 only:
• Unscrew and remove the hexagon screws (component 2.5.2) from the taper sleeve (component
2.5.1).
• Screw the 4-off hexagon screws (component
2.5.2) into the tapped holes of the taper sleeve
(component 2.5.1) and lever the taper sleeve
from the hub 4.5 (component 2.1) by tightening
the hexagon screws. Afterwards remove the hexagon screws from the taper sleeve.
Illustration 17: KTR-SI Compact (hub type 4.5)
Illustration 18: KTR-SI Compact (hub type 1.0)
Continuation of disassembly with all hub types:
• Unscrew the hexagon screw (component 1.6.2 resp. 2.6.2) from the setting nut (component 1.6.1 resp. 2.6.1),
afterwards disassemble the setting nut.
• Remove the locking washer (component 1.7 or 2.7) from the hub (component 1.1 or 2.1).
• Remove the disk springs (component 1.4 or 2.4) and the shifting ring (component 1.3 or 2.3).
Please note the disk spring layer for the assembly.
Please note that the balls (component 1.8 or 2.8) can be omitted when removing the shifting
ring (component 1.3 or 2.3).
• Remove the circlip (component 1.10 or 2.10) from the hub.
• Disassemble the deep groove ball bearing (component 1.9 or 2.9) by means of a suitable puller.
• Remove the flange ring (component 1.2 or 2.2) from the hub (component 1.1 or 2.1).
Please observe protection
note ISO 16016.
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Assembly
4.10 Disassembly of overload system / replacement of single parts (size 4)
Applies with hub type 4.5 only:
• Unscrew and remove the hexagon screws (component 2.5.2) from the taper sleeve (component 2.5.1).
• Screw the 4-off hexagon screws (component 2.5.2) into the tapped holes of the taper sleeve (component
2.5.1) and lever the taper sleeve from the hub 4.5 (component 2.1) by tightening the hexagon screws. Afterwards remove the hexagon screws from the taper sleeve.
Illustration 19: KTR-SI Compact (hub type 4.5)
Illustration 20: KTR-SI Compact (hub type 1.0)
Continuation of disassembly with all hub types:
• Unscrew the hexagon screw (component 1.6.2 resp. 2.6.2) from the setting nut (component 1.6.1 resp. 2.6.1),
afterwards disassemble the setting nut.
• Remove the axial washers (component 1.14 or 2.14), the axial needle bearing (component 1.13 or 2.13) and
the safety disk (component 1.7 or 2.7) from the hub (component 1.1 or 2.1).
• Remove the disk springs (component 1.4 or 2.4) and the shifting ring (component 1.3 or 2.3).
Please note the disk spring layer for the assembly.
Please note that the balls (component 1.8 or 2.8) can be omitted when removing the shifting
ring (component 1.3 or 2.3).
• Remove the locking rings (component 1.10 and 1.12 resp. 2.10 and 2.12) and support disk (component 1.11
resp. 2.11) from the hub (component 1.1 resp. 2.1).
• Disassemble the deep groove ball bearing (component 1.9 or 2.9) by means of a suitable puller.
• Remove the flange ring (component 1.2 or 2.2) from the hub (component 1.1 or 2.1).
Please observe protection
note ISO 16016.
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Assembly
4.11 Assembly of the overload system
The assembly is done in reverse order with the disassembly (see chapter 4.9 and 4.10). For that purpose observe
the exploded-view drawings illustration 17 to 20. Components lubricated by the manufacturer may have to be relubricated.
!
5
Greasing by usual greases has to be done.
Please note the disk spring layer for the assembly as per chapter 4.2.
Adjustment of torque
If the torque pre-set cannot be modified by the customer any more, the hexagon screw
(component 1.6.2 or 2.6.2) of the setting nut (component 1.6.1 or 2.6.1) has to be removed
and coated with Loctite (average strength). Afterwards tighten the hexagon screw at the
tightening torque TA specified in table 7.
5.1 Torque setting - KTR-SI Compact
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 4 each depending on the setting
range (chapter 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.
• Unscrew the hexagon screws (see illustration 21) in the taper
bush (component 2.5.1).
• Unscrew the locking screw in the setting nut (component
2.7).
• Choose any reference point of the setting nut (component
1.6.1 or 2.6.1) versus a scale mark of the shifting ring (component 1.3 or 2.3).
• Insert the face spanner of table 8 into the respective bores of
the setting nut (component 1.6.1 resp. 2.6.1) resp. one of the
hook spanners into one of the keyways intended (see illustration 24).
• Turn the setting nut by the number of notches while respecting the torsional direction (see chapter 5.3).
Please observe protection
note ISO 16016.
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Illustration 21
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46311 EN
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Adjustment of torque
5.1 Torque setting - KTR-SI Compact
With torque setting please note the setting diagrammes of the respective sizes (see chapter
5.3).
• Make sure that the tapped hole in the setting nut (component 1.6.1 resp. 2.6.1) is centered towards a through
hole in the locking washer (component 1.7 resp. 2.7).
• Having set the torque fasten the setting nut (component 1.6.1 resp. 2.6.1) against working loose via the hexagon screw (component 1.6.2 resp. 2.6.2).
• Remove the torque figure entered from the label.
• Mark the overload system with the new torque pre-set.
Table 7: Hexagon screw DIN EN ISO 4017 (component 1.6.2 or 2.6.2)
Size
Screw size of width across flats
Tightening torque TA in Nm
01
M4
4.1
0
M4
4.1
1
M45
8.1
2
M6
14
3
M6
14
4
M8
34
All screw connections must be secured against working loose additionally,
e. g. conglutinating with Loctite (average strength).
Please bear in mind that setting the torque beyond the torque range (see chapter 5.1) may
result in misoperation and damage of the overload system.
!
In order to ensure optimum torque setting, KTR-SI Compact should be inspected after initial
disengagement processes and reset, if necessary.
If KTR-SI Compact was set to the requested torque as per the present 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
Jointed pin wrench
Jointed face wrench
Ø60-90x5
Ø40-80x5
Ø90-155x6
Ø80-125x6
Ø155-230x8
Ø125-200x8
Size
01
0
1
2
3
4
Ø65-70
Ø80-90
Ø98-105
Ø120-130
Ø205-220
Please observe protection
note ISO 16016.
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Adjustment of torque
5.2 Replacement of layering of disk springs
!
If torque setting is beyond the requested torque range as per chapter 1, the overload system
can be reset to the requested torque by adapting the disk spring layering.
We recommend to have the modification and resetting of the overload system performed by
KTR's qualified staff.
Driving components falling down may cause injury to persons or damage on the machine.
Secure the driving components during disassembly.
Illustration 22: Example - KTR-SI Compact 4 (hub type 1.0)
Illustration 23: Example - Assembly of KTR-SI Compact 4
• Disassemble the overload system from the machine and mount it onto a suitable auxiliary shaft.
• Unscrew the hexagon screw (component 1.6.2 resp. 2.6.2) in the setting nut (component 1.6.1 resp. 2.6.1). Do
not fully unscrew the hexagon screw.
• Turn back the setting nut (component 1.6.1 resp. 2.6.1) by means of a mounting key (see table 8) until the disk
springs (component 1.4 resp. 2.4) are fully released.
• Remove the setting nut (component 1.6.1 resp. 2.6.1) and the locking washer (component 1.7 resp. 2.7) from
the hub (component 1.1 resp. 2.1).
• Adjust the disk spring layering as per table 4 (see chapter 4.2) to the requested torque (see chapter 1).
• First mount the locking washer (component 1.7 resp. 2.7), afterwards the setting nut (component 1.6.1 resp.
2.6.1) onto the hub (component 1.1 resp. 2.1).
• Insert the face spanner from table 8 respectively one of the hook spanners into the respective bores of the setting nut (component 1.6.1 resp. 2.6.1).
Please observe protection
note ISO 16016.
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2023-01-11 Ka
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KTR-N
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46311 EN
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Adjustment of torque
5.2 Replacement of layering of disk springs
• Tighten the setting nut (component 1.6.1 resp. 2.6.1) until it
cannot be tightened any more. Afterwards turn back the setting nut by one notch.
• The torque pre-set corresponds to the minimum release torque now.
• Twist the setting nut counterclockwise (component 1.6.1
resp. 2.6.1) by the number of notches.
The disk springs (component 1.4 or 2.4) are
operated in the negative sector of the characteristic curve. Tightening the setting nut (component 1.6.1 or 2.6.1) causes a reduced release torque. The release torque is increased
by untightening the setting nut.
Illustration 24: Notches of setting nut
With torque setting please note the setting diagrammes of the respective sizes (see chapter 5.3).
• Make sure that the tapped hole in the setting nut (component 1.6.1 resp. 2.6.1) is centered towards a through hole in
the locking washer (component 1.7 resp. 2.7).
• Having set the torque fasten the setting nut (component
1.6.1 resp. 2.6.1) against working loose via the hexagon
screw (component 1.6.2 resp. 2.6.2).
• Mark the overload system with the new torque set.
• Disassemble the overload system from the auxiliary shaft.
!
Illustration 25: Spring characteristic
Driving components falling down may cause injury to persons or damage on the machine.
Secure the driving components during disassembly.
In order to ensure optimum torque setting, KTR-SI Compact should be inspected after initial
disengagement processes and reset, if necessary.
If KTR-SI Compact 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).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-01-11 Ka/Su
2023-01-11 Ka
Replacing:
Replaced by:
KTR-N dated 2023-01-05
KTR-SI Compact
Operating/Assembly instructions
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KTR-N
Sheet:
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46311 EN
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Adjustment of torque
5.3 Setting diagrammes
Diagramme 1: KTR-SI Compact 01
Diagramme 2: KTR-SI Compact 0
Diagramme 3: KTR-SI Compact 1
Please observe protection
note ISO 16016.
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KTR-N
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Adjustment of torque
5.3 Setting diagrammes
Diagramme 4: KTR-SI Compact 2
Diagramme 5: KTR-SI Compact 3
Diagramme 6: KTR-SI Compact 4
Please observe protection
note ISO 16016.
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KTR-SI Compact
Operating/Assembly instructions
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46311 EN
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3
Assembly of limit switch
If the torque set is exceeded, the overload system disengages with the shifting ring being moved back axially by
dimension H (see table 9).
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 KTR-SI Compact such that signal recording of the disengagement process is ensured.
Table 9: Position of limit switch
Size
01
0
1
2
3
4
LH1
7
8
9
10
12
9 1)
Dimensions in mm
LH2
DA
12.0
70
14.0
85
16.0
100
17.0
115
21.0
135
38.5
220
H = stroke
1.2
1.5
1.8
2.0
2.2
3.5
1) Width of keyway (see illustration 2)
Illustration 26: Mechanical limit switch
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 smooth operation. The sensor should be protected
from dirt and potential mechanical failure.
!
We recommend to use 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 other components.
As soon as the limit switch or sensor is activated (overload: release of overload system) the
drive should immediately be stopped.
With higher speeds respective braking devices may be necessary.
Please observe protection
note ISO 16016.
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Breakdowns, causes and elimination
The below-mentioned failures can result in a use of the KTR-SI Compact overload system other than intended. In
addition to the specifications given in these operating/assembly instructions make sure to avoid such failures.
The errors listed can only be clues to search for the failures. When searching for the failure the adjacent components must generally be considered.
General failures with improper use:
•
•
•
•
•
•
•
•
•
Important data for the selection of the overload system are not forwarded.
The calculation of the shaft-hub-connection was disregarded.
Components with damage occurred during transport are assembled.
If the heated hubs are assembled, the permissible temperature is exceeded.
The clearance of the components to be assembled is not coordinated with one another.
Tightening torques are fallen below/exceeded.
Components are mixed up by mistake/assembled incorrectly.
No original KTR components (purchased parts) are used.
Maintenance intervals are not observed.
Breakdowns
Different operating
noise and/or vibrations occuring
Causes
Elimination
Screws working loose
Setting nut has worked loose
Torque is not set
The overload system
releases undefinedly
Torque set incorrectly
Setting nut has worked loose
Wear
Torque is no longer
transmitted
Setting nut has worked loose
Wear
The torque of KTR SI
Compact with
ROTEX® GS
is no longer transmitted
ROTEX® GS
ROTEX® GS driving flange has
worked loose
1) Set the unit out of operation
2) Inspect tightening torque of screws.
3) Inspect torque setting.
4) If you cannot find out the cause of the failure, return the overload system to KTR for inspection
1) Set the unit out of operation
2) Adjust torque
3) If you cannot find out the cause of the failure, return the overload system to KTR for inspection
1) Set the unit out of operation
2) Send the overload system to KTR for inspection/repair
1) Set the unit out of operation
2) Reset the release torque
3) Tighten and fasten hexagon screw of setting nut
1) Set the unit out of operation
2) Send the overload system to KTR for inspection/repair
1) Set the unit out of operation
2) Tighten the fastening screws
Please consider our operating/assembly instructions KTR-N 45510 additionally when using the ROTEX® GS coupling.
See chapter 6 Breakdowns, causes and elimination
Please observe protection
note ISO 16016.
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Disposal
In respect of environmental protection we would ask you to dispose of the packaging resp. products on termination of their service life in accordance with the legal regulations resp. standards that apply.
• Metal
Any metal components have to be cleaned and disposed of by scrap metal.
• Nylon materials
Nylon materials have to be collected and disposed of by a waste disposal company.
• Greases/oils
Greases and oils have to be collected and disposed of by a waste disposal company.
9
Maintenance and service
KTR-SI Compact is a low-maintenance overload system. We recommend to perform a visual inspection on the
overload system at least once a year. Please pay special attention to the condition, alignment and screw
connection of the overload system and the condition of the spider.
The KTR-SI Compact overload system is finish bored and provided with grease filling. With normal drive conditions this grease filling is sufficient during the overall service life. In case of extreme drive conditions or heavy dirt,
respectively, the KTR-SI Compact has to be regularly inspected for its operation.
!
!
In case of overload the drive should be stopped by return.
Having started up the overload system the tightening torques of the screws have to be inspected during the usual inspection intervals.
Please consider our operating/assembly instructions KTR-N 45510 additionally when using
the ROTEX® GS coupling.
Please observe protection
note ISO 16016.
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Verified:
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2023-01-11 Ka
Replacing:
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KTR-SI Compact
Operating/Assembly instructions
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KTR-N
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Edition:
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Advices for the use of drive components
• Insert the drive element such as belt pulleys or gear wheels
with the centering (H7 fit) on the deep groove ball bearing
(component 1.9 or 2.9).
• Design the deep groove ball bearing (component 1.9 or 2.9)
as a fixed bearing.
• Screw the drive component to the flange ring (component
1.2 or 2.2).
!
With the asssembly the maximum depth of engagement LG (see table 1, illustration 27)
needs to be observed.
The customer needs to select the screw
connection for transmitting the torque.
Illustration 27
The pitch line of radial forces Fr arising has to lead through the center of the bearing (see
illustration 27).
The radial and axial forces passed into the bearing of the overload system must not exceed
the maximum permissible figures (see table 10).
Table 10: Max. bearing load
Size
Axial force in N
Radial force in N
11
01
670
670
0
980
980
1
1460
1460
2
2480
2480
3
4300
4300
4
7200
7200
Spares inventory, customer service addresses
A basic requirement to ensure the readiness for use of the overload system 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 at
www.ktr.com.
KTR does not assume any liability or warranty for the use of spare parts and accessories
which are not provided by KTR and for the damages which may incur as a result.
KTR Systems GmbH
Carl-Zeiss-Str. 25
D-48432 Rheine
Phone: +49 5971 798-0
E-mail: [email protected]
Please observe protection
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">
