KTR ROTEX GS ZR1 and ZR2 Operating/Mounting Instructions

KTR ROTEX GS ZR1 and ZR2 are torsionally flexible intermediate shaft couplings designed for various applications. These couplings offer reliable performance, ease of assembly, and efficient operation. They are particularly well-suited for applications where misalignment between shafts can occur, providing smooth and controlled power transmission. The provided instructions aim to guide you through the assembly and disassembly of these couplings.

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Summarized assembly instructions
ROTEX&reg; GS
ZR1 and ZR2

KTR-N
Sheet:
Edition:
45523 EN
1 of 8
3
These mounting instructions are a summary of KTR-N 45510 comprising details about the as&reg;
sembly/disassembly of the intermediate shaft coupling ROTEX GS ZR1 and ZR2 only. Please
refer to the instructions KTR-N 45510 for general advice as well as advice on safety and danger
before starting up the coupling. According to EU standard (2014/34/EU), legal claims for warranty cannot be allowed.
ROTEX&reg; GS
Torsionally flexible intermediate shaft coupling type ZR1 and ZR2
&reg;
ROTEX GS, ZR1
&reg;
ROTEX GS, ZR2
Table of contents
1
Technical data
2
2
Assembly
3
2.1
2.2
2.3
2.4
2.5
4
5
5
6
8
Components of the couplings
Assembly of type ZR1
Assembly of type ZR2
Displacements - alignment of the couplings
Critical whirling speed
Please observe protection
note ISO 16016.
Drawn:
Verified:
02.01.17 Shg/Rt
02.01.17 Shg
Replaced for:
Replaced by:
KTR-N dated 08.09.2014
Summarized assembly instructions
ROTEX&reg; GS
ZR1 and ZR2
1
KTR-N
Sheet:
Edition:
45523 EN
2 of 8
3
s
1.5
2.0
2.0
2.5
3.0
a
2.0
3.0
3.0
4.0
4.0
Technical data
Intermediate shaft coupling type ZR1
Illustration 1: ROTEX&reg; GS, type ZR1
Table 1: Dimensions
Size
14
19
24
28
38
DH
30
40
55
65
80
Size
14
19
24
28
38
dR
14x2.5
20x3.0
25x2.5
35x4.0
40x4.0
dH
10.5
18
27
30
38
L
35
66
78
90
114
l 1; l 2
11
25
30
35
45
Dimensions [mm]
intermediate pipe
LR1
Dimensions [mm]
E
13
16
18
20
24
Cap screw
DIN EN ISO 4762
8.8
M3x12
M6x16
M6x20
M8x25
M8x30
LZR1
LR1+22
LR1+50
LR1+60
LR1+70
LR1+90
According to
customer
specification
b
10
12
14
15
18
Tightening
torque
[Nm]
1.34
10.5
10.5
25
25
B
11.5
14.0
16.0
17.5
21.0
Friction torque
[Nm]
6.1
34
45
105
123
Table 2: Torques and finish bores
1)
Spider (component 2)
Rated torque [Nm]
Size
92 Sh A-GS 98 Sh A-GS 64 Sh D-GS 72 Sh D-GS
Unbored
dmin.
14
7.5
12.5
16.0
-
-
5
19
24
28
38
42
48
55
65
12
35
95
190
265
310
410
-
21
60
160
325
450
525
685
3)
940
26
75
200
405
560
655
825
1175
2)
97
2)
260
2)
525
2)
728
2)
852
2)
1072
-
x
x
x
x
x
x
x
x
6
8
10
12
14
15
20
22
Finish bore [mm]
hub design
1.1, 1.2
1.0
dmax.
dmax.
2.0, 2.1
dmax.
15
1.0, 1.1
dmax.
24
28
38
45
55
62
74
80
16
2.6
dmax.
24
28
38
45
45
55
68
70
16
2.5
dmax.
24
28
38
45
50
55
68
70
1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2; except for clamping hubs types 2.0, 2.5
2) When using the spider 72 Sh D, we recommend to use hubs made of steel.
3) Figures for spider 95 Sh A-GS
Please observe protection
note ISO 16016.
Drawn:
Verified:
02.01.17 Shg/Rt
02.01.17 Shg
Replaced for:
Replaced by:
KTR-N dated 08.09.2014
Summarized assembly instructions
ROTEX&reg; GS
ZR1 and ZR2
1
KTR-N
Sheet:
Edition:
45523 EN
3 of 8
3
Technical data
Intermediate shaft coupling type ZR2
Illustration 2: ROTEX&reg; GS, type ZR2
Table 3: Dimensions
Size
DH
30
40
55
65
80
95
105
120
135
14
19
24
28
38
42
48
55
65
D
–
–
–
–
–
85
95
110
115
dH
10.5
18
27
30
38
46
51
60
68
L
35
66
78
90
114
126
140
160
185
Dimensions [mm]
l 1; l 2
E
11
13
25
16
30
18
35
20
45
24
50
26
56
28
65
30
75
35
Dimensions [mm]
intermediate pipe
14
19
24
28
38
42
48
55
65
2
10x2.0
12x2.0
20x3.0
25x2.5
32x3.5
40x4.0
45x4.0
55x4.0
60x4.0
s
1.5
2.0
2.0
2.5
3.0
3.0
3.5
4.0
4.5
a
2.0
3.0
3.0
4.0
4.0
4.0
4.0
4.5
4.5
B
11.5
14.0
16.0
17.5
21.0
23.0
24.5
26.0
30.5
Clamping set KTR 250
Size
dR
b
10
12
14
15
18
20
21
22
26
LR2
LZR2
Size dxD
According
to customer
specification
LR2+22
LR2+50
LR2+60
LR2+70
LR2+90
LR2+100
LR2+112
LR2+130
LR2+150
10x16
12x18
20x28
25x34
32x43
40x53
45x59
55x71
60x77
Cap screw
DIN EN ISO 4762
12.9
M4x10
M4x10
M6x18
M6x18
M6x18
M6x18
M8x22
M8x22
M8x22
Tightening
torque
[Nm]
5.2
5.2
17
17
17
17
41
41
41
Friction torque
[Nm]
46
55
222
277
689
886
1842
2815
3070
Assembly
The coupling is generally supplied in individual parts. Before starting with the assembly, please inspect the coupling for completeness and dimensional accuracy.

With vertical assembly of the intermediate shaft couplings a special distance washer of KTR
has to be inserted between the coupling hub at the bottom and the spider at the bottom.
Please observe protection
note ISO 16016.
Drawn:
Verified:
02.01.17 Shg/Rt
02.01.17 Shg
Replaced for:
Replaced by:
KTR-N dated 08.09.2014
Summarized assembly instructions
ROTEX&reg; GS
ZR1 and ZR2
2
KTR-N
Sheet:
Edition:
45523 EN
4 of 8
3
Assembly
2.1 Components of the couplings
Components of ROTEX&reg; GS, intermediate shaft coupling type ZR1
Component
1
2
Quantity
2
2
3
4
5
6
1
2
2
Description
Hub (design 1.0, 1.1, 1.2, 2.0, 2.1, 2.5, 2.6, 2.8, 2.9, 6.0, 6.0 steel or 6.0 light)
Spider
Setscrew DIN EN ISO 4029 (for hub design 1.0 or 1.1)
Cap screw DIN EN ISO 4762 (for hub design 2.0, 2.1, 2.5, 2.6, 2.8, 2.9, 6.0, 6.0
steel or 6.0 light)
Intermediate pipe
ZR clamping hub
Cap screw DIN EN ISO 4762
Illustration 3: ROTEX&reg; GS ZR1, size 14 - 38
Components of ROTEX&reg; GS, intermediate shaft coupling type ZR2
Component
1
2
Quantity
2
2
3
4
5
6
1
2
2
Description
Hub (design 1.0, 1.1, 1.2, 2.0, 2.1, 2.5, 2.6, 2.8, 2.9, 6.0, 6.0 steel or 6.0 light)
Spider
Setscrew DIN EN ISO 4029 (for hub design 1.0 or 1.1)
Cap screw DIN EN ISO 4762 (for hub design 2.0, 2.1, 2.5, 2.6, 2.8, 2.9, 6.0, 6.0
steel or 6.0 light)
Intermediate shaft or intermediate pipe with spigot
Hub type 4.2
&reg;
CLAMPEX KTR 250
Illustration 4: ROTEX&reg; GS ZR2, size 14 - 65
Please observe protection
note ISO 16016.
Drawn:
Verified:
02.01.17 Shg/Rt
02.01.17 Shg
Replaced for:
Replaced by:
KTR-N dated 08.09.2014
Summarized assembly instructions
ROTEX&reg; GS
ZR1 and ZR2
2
KTR-N
Sheet:
Edition:
45523 EN
5 of 8
3
Assembly
2.2 Assembly of type ZR1
 Mount the hubs on the shaft of driving and driven side. For hints regarding assembly of the hubs please refer
to KTR-N 45510. The dimension between the cam ground and the cam ground of the hubs should correspond
to the shaft distance dimension LR1.
 Insert the spiders into the hubs.
 Shift the ZR clamping hubs onto the intermediate pipe in a way that the jaws do not protude over the pipe.
Here the jaws of the two ZR clamping hubs should be flush. If necessary, the outside diameter of the pipe
should be remachined.
 Insert the intermediate pipe along with the ZR clamping hubs between the driving and driven side and consequently between the hubs with the spiders (see illustration 5).
 The distance dimension E (table 1) can be set by shifting the ZR clamping hubs axially on the pipe (see illustration 6).
 Fasten the ZR clamping hubs on the pipe by tightening the cap screws DIN EN ISO 4762 at the tightening
torques TA specifed in table 1.
 Fasten the hubs by tightening the setscrews DIN EN ISO 4029 at the tightening torques TA mentioned in KTRN 45510.
Illustration 5: Assembly of type ZR1
Illustration 6: Assembly of type ZR1
2.3 Assembly of type ZR2
 Mount the hubs on the shaft of driving and driven side. For hints regarding assembly of the hubs please refer
to KTR-N 45510. The dimensions between the cam ground and the cam ground of the hubs should correspond to the shaft distance dimension LR2.
 Insert the spiders into the hubs.
 Insert the clamping sets KTR 250 into the hubs to match type 4.2.
 Insert the hub type 4.2 along with the clamping set KTR 250 onto the intermediate shaft in a way that the jaws
do not protude over the shaft. Here the jaws of the two hubs type 4.2 should be flush.
PLEASE NOTE: In case of a long shaft distance dimension an intermediate shaft is not concerned, but an
intermediate pipe with spigot. Being pressed into the pipe, the spigots need to be flush.
 Insert the intermediate shaft between the driving and driven side and consequently between the hubs with the
spiders (see illustration 7).
 The distance dimension E (table 3) can be set by shifting the hub 4.2 axially along with the clamping set
(see picture 8).
 Fasten the hubs type 4.2 and the clamping set on the intermediate shaft by tightening the cap screws
DIN EN ISO 4762 at the tightening torques T A mentioned in table 3.
 Fasten the hubs by tightening the setscrews DIN EN ISO 4029 at the tightening torques TA mentioned in
KTR-N 45510.
Please observe protection
note ISO 16016.
Drawn:
Verified:
02.01.17 Shg/Rt
02.01.17 Shg
Replaced for:
Replaced by:
KTR-N dated 08.09.2014
Summarized assembly instructions
ROTEX&reg; GS
ZR1 and ZR2
2
KTR-N
Sheet:
Edition:
45523 EN
6 of 8
3
Assembly
2.3 Assembly of type ZR2
Illustration 7: Assembly of type ZR2
Illustration 8: Assembly of type ZR2
2.4 Displacements - alignment of the couplings
The displacement figures specified in table 4 provide for sufficient safety to compensate for external influences
like, for example, thermal expansion or foundation settling.
In order to ensure a long service life of the coupling, the shaft ends have to be accurately
aligned.
Please absolutely observe the displacement figures specified (see table 4). If the figures are
exceeded, the coupling will be damaged.
The more accurate the alignment of the coupling, the longer is its service life.
!
Please note:
 The displacement figures specified in table 4 are maximum figures which must not arise in parallel. If radial
and angular displacements arise at the same time, the permissible displacement values may only be used
proportionally.
 Please inspect with a dial gauge, ruler or feeler whether the permissible displacement figures specified in table
4 can be observed.
Angular displacements
Radial displacements
Axial displacements
Kr = (LZR - 2 • l1 - E) • tan α
Lmax = L + Ka
Illustration 9: Displacements
Please observe protection
note ISO 16016.
Drawn:
Verified:
02.01.17 Shg/Rt
02.01.17 Shg
Replaced for:
Replaced by:
KTR-N dated 08.09.2014
Summarized assembly instructions
ROTEX&reg; GS
ZR1 and ZR2
2
KTR-N
Sheet:
Edition:
45523 EN
7 of 8
3
Assembly
2.4 Displacements - alignment of the couplings
Examples of the displacement combinations specified in illustration 10:
Illustration 10:
Combinations of
displacement
Example 1:
Kr = 30%
Kw = 70%
Example 2:
Kr = 60%
Kw = 40%
Ktotal = Kr + Kw  100 %
Table 4: Displacement figures – Intermediate shaft coupling
Size
Max. axial
displacement
Ka [mm]
14
19
24
28
38
42
48
55
65
+1.0 / -1.0
+1.2 / -1.0
+1.4 / -1.0
+1.5 / -1.4
+1.8 / -1.4
+2.0 / -2.0
+2.1 / -2.0
+2.2 / -2.0
+2.6 / -2.0
92
ShA-GS
16.8
16.3
16.1
15.9
15.5
15.3
15.0
14.7
-
Max. radial displacement
1)
Kr [mm]
98
64
ShA-GS
ShD-GS
15.2
13.5
14.7
13.0
14.5
12.9
14.3
12.7
13.9
12.4
13.7
12.2
13.5
12.0
13.2
11.7
12.8
11.4
72
ShD-GS
11.3
11.1
10.8
10.7
10.5
10.3
-
Max. angular displacement
Kw [degree]
92
98
64
72
ShA-GS
ShA-GS
ShD-GS
ShD-GS
1.0
0.9
0.8
1.0
0.9
0.8
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
0.9
0.8
-
1) Referring to an overall coupling length of LZR = 1000 mm.
&reg;
The permissible displacement figures of the flexible ROTEX GS couplings specified are general standard values taking into
account the load of the coupling up to the rated torque TKN of the coupling and an ambient temperature of + 30 &deg;C.
Please observe protection
note ISO 16016.
Drawn:
Verified:
02.01.17 Shg/Rt
02.01.17 Shg
Replaced for:
Replaced by:
KTR-N dated 08.09.2014
Summarized assembly instructions
ROTEX&reg; GS
ZR1 and ZR2
2
KTR-N
Sheet:
Edition:
45523 EN
8 of 8
3
Assembly
2.5 Critical whirling speed
Please observe the critical whirling speed of the coupling.
Illustration 11:
Critical whirling
speed of type ZR1
Example ZR1:
Pipe diameter &Oslash;20x3,0
Speed 800 rpm
Max. permissible shaft distance
dimension 1600 mm
Illustration 12:
Critical whirling
speed of type ZR2
Example ZR2:
Pipe diameter &Oslash;20x3,0
Speed 800 rpm
Max. permissible shaft distance
dimension 1600 mm
Please observe protection
note ISO 16016.
Drawn:
Verified:
02.01.17 Shg/Rt
02.01.17 Shg
Replaced for:
Replaced by:
KTR-N dated 08.09.2014
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Key features

Torsionally flexible
Easy assembly
Intermediate shaft coupling
Misalignment compensation
Reliable performance
High torque capacity
Compact design
Suitable for various applications

Frequently asked questions

The manual describes two main types of ROTEX GS couplings: ZR1 and ZR2. Both types are torsionally flexible intermediate shaft couplings, but their assembly and specific features differ. Refer to the manual for detailed instructions on each type.

Accurate shaft alignment is crucial for the longevity of the coupling. The manual provides specific displacement figures (radial, angular, and axial) to be observed when aligning the shafts. Ensure that the displacement values are not exceeded in parallel, or proportionally if present simultaneously. Use a dial gauge, ruler, or feeler gauge to check for compliance with the specified values.

The manual emphasizes the importance of considering the critical whirling speed of the coupling. The critical whirling speed is affected by factors like the pipe diameter and the shaft distance dimension. You should consult the manual for specific examples and considerations regarding the critical whirling speed for your application.