KTR KTR-SI Operating/Mounting Instructions
KTR KTR-SI is a torque limiting overload system that protects adjacent components from damage in case of overload. It offers various types, including DK (ratchet design), SR (synchronous design), FR (idle rotation design), and SGR (fail-safe synchronous design). Each type has specific features and re-engagement mechanisms that can be selected based on the application requirements. KTR-SI is designed for different sizes (0 to 7) and can be combined with a torsionally flexible ROTEX® coupling. This manual explains how to assemble and configure KTR-SI based on the specific type and size chosen.
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KTR-SI
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46310 EN
1 of 22
4
Please observe protection
note ISO 16016.
Drawn: 2023-06-02 Shg/Koh Replacing: KTR-N dated 2017-02-10
Verified: 2023-06-02 Shg Replaced by:
KTR-SI
Type DK
(ratchet design)
Type SR
(synchronous design)
Type FR
(Idle rotation design)
Type SGR
(fail-safe synchronous
design)
KTR-SI size 0 to 5
KTR-SI size 6 to 7
KTR-SI with torsionally flexible ROTEX® coupling
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46310 EN
1 of 22
4
Please observe protection
note ISO 16016.
Drawn: 2023-06-02 Shg/Koh Replacing: KTR-N dated 2017-02-10
Verified: 2023-06-02 Shg Replaced by:
KTR-SI
Type DK
(ratchet design)
Type SR
(synchronous design)
Type FR
(Idle rotation design)
Type SGR
(fail-safe synchronous
design)
KTR-SI size 0 to 5
KTR-SI size 6 to 7
KTR-SI with torsionally flexible ROTEX® coupling
KTR-SI
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46310 EN
2 of 22
4
Please observe protection
note ISO 16016.
Drawn: 2023-06-02 Shg/Koh Replacing: KTR-N dated 2017-02-10
Verified: 2023-06-02 Shg Replaced by:
KTR-SI is a torque limiting overload system with positive locking operation protecting adjacent
components from damage.
• In case of overload type DK (ratchet design) re-engages every 15° with the next following ball indentation.
• In case of overload type SR (synchronous design) re-engages after a rotation of 360°.
• Type FR (idle rotation design) remains separated with overload. The overload system re-engages manually or
via a mechanism with standstill of machine.
• Type SGR (fail-safe synchronous design) is purely intended for torque measurement without any ratchet
operation. In case of overload a signal is generated by a limit switch along with mechanical separation of
driving and driven side = ratching is not possible.
1 Technical data 3
2 Advice 5
2.1 General advice 5
2.2 Safety and advice symbols 5
2.3 General hazard warnings 5
2.4 Intended use 6
2.5 Coupling selection 6
2.6 Reference to EC Machinery Directive 2006/42/EC 6
3 Storage, transport and packaging 6
3.1 Storage 6
3.2 Transport and packaging 6
4 Assembly 7
4.1 Components of the couplings 7
4.2 Layering of disk springs 8
4.3 Advice for finish bore 9
4.4 Assembly (general) 10
4.5 Assembly of the KTR-SI coupling 10
4.6 Assembly of KTR-SI with torsionally flexible ROTEX® coupling 10
4.7 Disassembly of the coupling / replacement of single parts 11
4.8 Assembly of the coupling 12
4.9 Torque setting - KTR-SI size 0 to 5 12
4.10 Torque setting - KTR-SI size 6 to 7 13
4.11 Setting diagrammes - type DK 14
4.12 Setting diagrammes - type SR/SGR 16
4.13 Setting diagrammes - type FR 17
4.14 Advice for the use of drive components 18
4.15 Assembly of limit switch 19
5 Re-engagement of KTR-SI design FR 20
6 Breakdowns, causes and elimination 20
7 Disposal 21
8 Maintenance and service 22
9 Spares inventory, customer service addresses 22
Table of contents
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46310 EN
2 of 22
4
Please observe protection
note ISO 16016.
Drawn: 2023-06-02 Shg/Koh Replacing: KTR-N dated 2017-02-10
Verified: 2023-06-02 Shg Replaced by:
KTR-SI is a torque limiting overload system with positive locking operation protecting adjacent
components from damage.
• In case of overload type DK (ratchet design) re-engages every 15° with the next following ball indentation.
• In case of overload type SR (synchronous design) re-engages after a rotation of 360°.
• Type FR (idle rotation design) remains separated with overload. The overload system re-engages manually or
via a mechanism with standstill of machine.
• Type SGR (fail-safe synchronous design) is purely intended for torque measurement without any ratchet
operation. In case of overload a signal is generated by a limit switch along with mechanical separation of
driving and driven side = ratching is not possible.
1 Technical data 3
2 Advice 5
2.1 General advice 5
2.2 Safety and advice symbols 5
2.3 General hazard warnings 5
2.4 Intended use 6
2.5 Coupling selection 6
2.6 Reference to EC Machinery Directive 2006/42/EC 6
3 Storage, transport and packaging 6
3.1 Storage 6
3.2 Transport and packaging 6
4 Assembly 7
4.1 Components of the couplings 7
4.2 Layering of disk springs 8
4.3 Advice for finish bore 9
4.4 Assembly (general) 10
4.5 Assembly of the KTR-SI coupling 10
4.6 Assembly of KTR-SI with torsionally flexible ROTEX® coupling 10
4.7 Disassembly of the coupling / replacement of single parts 11
4.8 Assembly of the coupling 12
4.9 Torque setting - KTR-SI size 0 to 5 12
4.10 Torque setting - KTR-SI size 6 to 7 13
4.11 Setting diagrammes - type DK 14
4.12 Setting diagrammes - type SR/SGR 16
4.13 Setting diagrammes - type FR 17
4.14 Advice for the use of drive components 18
4.15 Assembly of limit switch 19
5 Re-engagement of KTR-SI design FR 20
6 Breakdowns, causes and elimination 20
7 Disposal 21
8 Maintenance and service 22
9 Spares inventory, customer service addresses 22
Table of contents
KTR-SI
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46310 EN
3 of 22
4
Please observe protection
note ISO 16016.
Drawn: 2023-06-02 Shg/Koh Replacing: KTR-N dated 2017-02-10
Verified: 2023-06-02 Shg Replaced by:
Illustration 1: KTR-SI type FT Illustration 2: KTR-SI type KT Illustration 3: KTR-SI type LT
Table 1: Dimensions and weights
Size
Dimensions [mm]
Bore d d1 D D1 D2 DA l1 l2 l3 l4
Pilot bore Max.
0 7 20 41.0 28 38 48 55 4.0 6.5 3.0 7.5
1 10 25 60.0 38 50 70 82 4.0 8.0 6.0 11.5
2 14 35 78.0 52 60 89 100 5.0 10.0 5.0 12.0
3 18 45 90.5 65 80 105 120 5.0 12.0 8.5 21.0
4 24 55 105.0 78 100 125 146 6.5 15.0 11.0 27.0
5 30 65 120.5 90 120 155 176 6.5 17.0 12.0 33.0
6 40 80 136.0 108 130 160 200 7.0 20.0 14.0 39.0
7 50 100 168.0 135 160 200 240 8.0 25.0 15.0 46.0
Size
Dimensions [mm] Weight with
max. bore
[kg]
l5 l6 l7 l8 L L1 L2 z SW
0 9 8 27.5 - 38.5 51.0 66.0 6 x M5 - 0.41
1 9 10 33.0 - 52.0 70.0 85.0 6 x M5 - 1.30
2 9 12 39.0 - 61.0 78.0 100.0 6 x M6 - 2.27
3 10 12 47.0 - 78.0 96.0 125.0 6 x M8 - 3.88
4 9 16 52.5 - 100.0 124.5 152.5 6 x M10 2) - 8.34
5 9 18 57.5 - 113.5 140.0 171.0 6 x M12 2) - 13.51
6 9 20 64.0 15 119.0 150.0 183.0 6 x M12 2) 30 21
7 9 25 72.0 21 141.0 175.0 213.0 6 x M16 2) 24 37
1) Dimensions H=stroke see table 9
2) Type T4 SR and SGR: tightening torques according to 12.9
Table 2: Torques
Size
Torques [Nm]
Type DK Type SR and SGR Type FR
T1 T2 T3 T4 T1 T2 T3 T4 T1 T2 T3 nmax. 3)
[rpm]
0 2.5-5 5-20 - 20-40 5-10 10-40 - - 5-10 10-20 20-40 6000
1 6-12 12-25 25-55 55-100 12-25 25-50 50-100 - 12-25 25-50 50-100 5000
2 12-25 25-50 50-120 120-200 25-50 50-100 100-200 - 25-50 50-100 100-200 4000
3 25-50 50-100 100-250 200-450 50-100 100-200 200-450 - 50-100 100-200 200-450 3500
4 50-100 100-200 200-500 500-1000 100-200 200-400 400-800 800-2000 100-200 200-400 400-800 3000
5 85-250 230-600 300-1000 600-2000 170-450 350-900 600-1800 1200-3400 170-450 350-900 600-1800 2300
6 180-480 360-960 720-1950 1600-3300 300-750 600-1500 1200-3000 2900-5800 - - - -
7 250-520 500-1050 1000-2100 2000-3600 550-1100 1100-2200 2200-4400 3000-8200 - - - -
3) Only valid for type FR
1 Technical data
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46310 EN
3 of 22
4
Please observe protection
note ISO 16016.
Drawn: 2023-06-02 Shg/Koh Replacing: KTR-N dated 2017-02-10
Verified: 2023-06-02 Shg Replaced by:
Illustration 1: KTR-SI type FT Illustration 2: KTR-SI type KT Illustration 3: KTR-SI type LT
Table 1: Dimensions and weights
Size
Dimensions [mm]
Bore d d1 D D1 D2 DA l1 l2 l3 l4
Pilot bore Max.
0 7 20 41.0 28 38 48 55 4.0 6.5 3.0 7.5
1 10 25 60.0 38 50 70 82 4.0 8.0 6.0 11.5
2 14 35 78.0 52 60 89 100 5.0 10.0 5.0 12.0
3 18 45 90.5 65 80 105 120 5.0 12.0 8.5 21.0
4 24 55 105.0 78 100 125 146 6.5 15.0 11.0 27.0
5 30 65 120.5 90 120 155 176 6.5 17.0 12.0 33.0
6 40 80 136.0 108 130 160 200 7.0 20.0 14.0 39.0
7 50 100 168.0 135 160 200 240 8.0 25.0 15.0 46.0
Size
Dimensions [mm] Weight with
max. bore
[kg]
l5 l6 l7 l8 L L1 L2 z SW
0 9 8 27.5 - 38.5 51.0 66.0 6 x M5 - 0.41
1 9 10 33.0 - 52.0 70.0 85.0 6 x M5 - 1.30
2 9 12 39.0 - 61.0 78.0 100.0 6 x M6 - 2.27
3 10 12 47.0 - 78.0 96.0 125.0 6 x M8 - 3.88
4 9 16 52.5 - 100.0 124.5 152.5 6 x M10 2) - 8.34
5 9 18 57.5 - 113.5 140.0 171.0 6 x M12 2) - 13.51
6 9 20 64.0 15 119.0 150.0 183.0 6 x M12 2) 30 21
7 9 25 72.0 21 141.0 175.0 213.0 6 x M16 2) 24 37
1) Dimensions H=stroke see table 9
2) Type T4 SR and SGR: tightening torques according to 12.9
Table 2: Torques
Size
Torques [Nm]
Type DK Type SR and SGR Type FR
T1 T2 T3 T4 T1 T2 T3 T4 T1 T2 T3 nmax. 3)
[rpm]
0 2.5-5 5-20 - 20-40 5-10 10-40 - - 5-10 10-20 20-40 6000
1 6-12 12-25 25-55 55-100 12-25 25-50 50-100 - 12-25 25-50 50-100 5000
2 12-25 25-50 50-120 120-200 25-50 50-100 100-200 - 25-50 50-100 100-200 4000
3 25-50 50-100 100-250 200-450 50-100 100-200 200-450 - 50-100 100-200 200-450 3500
4 50-100 100-200 200-500 500-1000 100-200 200-400 400-800 800-2000 100-200 200-400 400-800 3000
5 85-250 230-600 300-1000 600-2000 170-450 350-900 600-1800 1200-3400 170-450 350-900 600-1800 2300
6 180-480 360-960 720-1950 1600-3300 300-750 600-1500 1200-3000 2900-5800 - - - -
7 250-520 500-1050 1000-2100 2000-3600 550-1100 1100-2200 2200-4400 3000-8200 - - - -
3) Only valid for type FR
1 Technical data
KTR-SI
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46310 EN
4 of 22
4
Please observe protection
note ISO 16016.
Drawn: 2023-06-02 Shg/Koh Replacing: KTR-N dated 2017-02-10
Verified: 2023-06-02 Shg Replaced by:
Illustration 4: KTR-SI with torsionally flexible ROTEX® coupling
Table 3: Dimensions
Size ROTEX®
size
Dimensions [mm] Cap screws
DIN EN ISO 4762 - 12.9Max. bore dH DH DA l9 l10 E L LG
d d2 M x l TA [Nm]
0 19 20 25 18 40 55 25 22.0 16 38.5 85.5 M5 x 10 2) 5.5
28 40 30 65 35 28.5 20 102.0
1 24 25 35 27 55 82 30 24.0 18 52.0 106.0 M5 x 12 8.1
38 48 38 80 45 32.5 24 129.5 M5 x 10
2 28 35 40 30 65 100 35 28.0 20 61.0 124.0 M6 x 16 14
48 62 51 105 56 38.0 28 155.0 M6 x 12
3 38 45 48 38 80 120 45 32.0 24 78.0 155.0 M8 x 18 34
55 74 60 120 65 43.0 30 186.0 M8 x 16
4 48 55 62 51 105 146 56 38.0 28 100.0 194.0 M10 x 20 67
75 95 80 160 85 56.5 40 241.5
5 55 65 75 60 120 176 65 44.0 30 113.5 222.5 M12 x 30 115
90 110 100 200 100 62.0 45 275.5 M12 x 20
6 100 80 115 113 225 200 110 72.0 50 119.0 301.0 M12 x 30 115
7 110 100 125 127 255 240 120 78.0 55 141.0 339.0 M16 x 35 290
1) Dimensions H=stroke see table 9
2) DIN 6912 - 8.8
Table 4: Torques
ROTEX® torque [Nm]
98 ShA
ROTEX® size
19 24 28 38 48 55 75 90 100 110
TKN 17 60 160 325 525 685 1920 3600 4950 7200
TKmax. 34 120 320 650 1050 1370 3840 7200 9900 14400
1 Technical data
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46310 EN
4 of 22
4
Please observe protection
note ISO 16016.
Drawn: 2023-06-02 Shg/Koh Replacing: KTR-N dated 2017-02-10
Verified: 2023-06-02 Shg Replaced by:
Illustration 4: KTR-SI with torsionally flexible ROTEX® coupling
Table 3: Dimensions
Size ROTEX®
size
Dimensions [mm] Cap screws
DIN EN ISO 4762 - 12.9Max. bore dH DH DA l9 l10 E L LG
d d2 M x l TA [Nm]
0 19 20 25 18 40 55 25 22.0 16 38.5 85.5 M5 x 10 2) 5.5
28 40 30 65 35 28.5 20 102.0
1 24 25 35 27 55 82 30 24.0 18 52.0 106.0 M5 x 12 8.1
38 48 38 80 45 32.5 24 129.5 M5 x 10
2 28 35 40 30 65 100 35 28.0 20 61.0 124.0 M6 x 16 14
48 62 51 105 56 38.0 28 155.0 M6 x 12
3 38 45 48 38 80 120 45 32.0 24 78.0 155.0 M8 x 18 34
55 74 60 120 65 43.0 30 186.0 M8 x 16
4 48 55 62 51 105 146 56 38.0 28 100.0 194.0 M10 x 20 67
75 95 80 160 85 56.5 40 241.5
5 55 65 75 60 120 176 65 44.0 30 113.5 222.5 M12 x 30 115
90 110 100 200 100 62.0 45 275.5 M12 x 20
6 100 80 115 113 225 200 110 72.0 50 119.0 301.0 M12 x 30 115
7 110 100 125 127 255 240 120 78.0 55 141.0 339.0 M16 x 35 290
1) Dimensions H=stroke see table 9
2) DIN 6912 - 8.8
Table 4: Torques
ROTEX® torque [Nm]
98 ShA
ROTEX® size
19 24 28 38 48 55 75 90 100 110
TKN 17 60 160 325 525 685 1920 3600 4950 7200
TKmax. 34 120 320 650 1050 1370 3840 7200 9900 14400
1 Technical data
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Key Features
- Torque limiting overload system
- Positive locking operation
- Various types (DK, SR, FR, SGR)
- Torsionally flexible ROTEX® coupling
- Different sizes (0 to 7)
- Detailed assembly instructions
Related manuals
Frequently Answers and Questions
What does a torque limiting overload system do?
A torque limiting overload system, like the KTR-SI, is designed to protect machinery from damage caused by overloads. It does this by limiting the maximum amount of torque that can be transmitted through the system. When the torque exceeds the limit, the system activates to prevent further damage.
What are the different types of KTR-SI systems and how do they differ?
The KTR-SI comes in four types: DK (ratchet design), SR (synchronous design), FR (idle rotation design), and SGR (fail-safe synchronous design). The primary difference between these lies in their re-engagement mechanism. The DK type re-engages every 15° with the next following ball indentation, SR re-engages after a rotation of 360°, FR remains separated with overload and requires manual re-engagement, and SGR is purely for torque measurement with a mechanical separation in overload.
What are the instructions for the assembly of the KTR-SI coupling?
The assembly process depends on the specific size of the KTR-SI. You can find detailed instructions on assembling the KTR-SI coupling, including the different components and steps, in chapter 4 of the viewed document.
Can I use a ROTEX® coupling with KTR-SI?
Yes, you can. Chapter 4 of the viewed document describes the assembly process for combining the KTR-SI with a torsionally flexible ROTEX® coupling.
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