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® GS
ZR1 and ZR2
KTR-N
Sheet:
Edition:
45523 EN
1 of 8
3
Please observe protection
note ISO 16016.
Drawn: 02.01.17 Shg/Rt Replaced for: KTR-N dated 08.09.2014
Verified: 02.01.17 Shg Replaced by:
These mounting instructions are a summary of KTR-N 45510 comprising details about the as-
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 war-
ranty cannot be allowed.
ROTEX® GS
Torsionally flexible intermediate shaft coupling type ZR1 and ZR2
ROTEX® GS, ZR1
ROTEX® GS, ZR2
1 Technical data 2
2 Assembly 3
2.1 Components of the couplings 4
2.2 Assembly of type ZR1 5
2.3 Assembly of type ZR2 5
2.4 Displacements - alignment of the couplings 6
2.5 Critical whirling speed 8
Table of contents
ROTEX® GS
ZR1 and ZR2
KTR-N
Sheet:
Edition:
45523 EN
1 of 8
3
Please observe protection
note ISO 16016.
Drawn: 02.01.17 Shg/Rt Replaced for: KTR-N dated 08.09.2014
Verified: 02.01.17 Shg Replaced by:
These mounting instructions are a summary of KTR-N 45510 comprising details about the as-
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 war-
ranty cannot be allowed.
ROTEX® GS
Torsionally flexible intermediate shaft coupling type ZR1 and ZR2
ROTEX® GS, ZR1
ROTEX® GS, ZR2
1 Technical data 2
2 Assembly 3
2.1 Components of the couplings 4
2.2 Assembly of type ZR1 5
2.3 Assembly of type ZR2 5
2.4 Displacements - alignment of the couplings 6
2.5 Critical whirling speed 8
Table of contents
Summarized assembly instructions
ROTEX® GS
ZR1 and ZR2
KTR-N
Sheet:
Edition:
45523 EN
2 of 8
3
Please observe protection
note ISO 16016.
Drawn: 02.01.17 Shg/Rt Replaced for: KTR-N dated 08.09.2014
Verified: 02.01.17 Shg Replaced by:
Intermediate shaft coupling type ZR1
Illustration 1: ROTEX® GS, type ZR1
Table 1: Dimensions
Size Dimensions [mm]
DH dH L l1; l2 E b s a B
14 30 10.5 35 11 13 10 1.5 2.0 11.5
19 40 18 66 25 16 12 2.0 3.0 14.0
24 55 27 78 30 18 14 2.0 3.0 16.0
28 65 30 90 35 20 15 2.5 4.0 17.5
38 80 38 114 45 24 18 3.0 4.0 21.0
Size
Dimensions [mm]
intermediate pipe
Cap screw
DIN EN ISO 4762
8.8
Tightening
torque
[Nm]
Friction torque
[Nm]
dR LR1 LZR1
14 14x2.5
According to
customer
specification
LR1+22 M3x12 1.34 6.1
19 20x3.0 LR1+50 M6x16 10.5 34
24 25x2.5 LR1+60 M6x20 10.5 45
28 35x4.0 LR1+70 M8x25 25 105
38 40x4.0 LR1+90 M8x30 25 123
Table 2: Torques and finish bores
Size
Spider 1) (component 2)
Rated torque [Nm] Unbo-
red
Finish bore [mm]
hub design
92 Sh A-GS 98 Sh A-GS 64 Sh D-GS 72 Sh D-GS dmin.
1.0
dmax.
1.1, 1.2
dmax.
2.0, 2.1
dmax.
14 7.5 12.5 16.0 - - 5 15 16 16
1.0, 1.1
dmax.
2.5
dmax.
2.6
dmax.
19 12 21 26 - x 6 24 24 24
24 35 60 75 97 2) x 8 28 28 28
28 95 160 200 260 2) x 10 38 38 38
38 190 325 405 525 2) x 12 45 45 45
42 265 450 560 728 2) x 14 55 50 45
48 310 525 655 852 2) x 15 62 55 55
55 410 685 825 1072 2) x 20 74 68 68
65 - 940 3) 1175 - x 22 80 70 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
1 Technical data
ROTEX® GS
ZR1 and ZR2
KTR-N
Sheet:
Edition:
45523 EN
2 of 8
3
Please observe protection
note ISO 16016.
Drawn: 02.01.17 Shg/Rt Replaced for: KTR-N dated 08.09.2014
Verified: 02.01.17 Shg Replaced by:
Intermediate shaft coupling type ZR1
Illustration 1: ROTEX® GS, type ZR1
Table 1: Dimensions
Size Dimensions [mm]
DH dH L l1; l2 E b s a B
14 30 10.5 35 11 13 10 1.5 2.0 11.5
19 40 18 66 25 16 12 2.0 3.0 14.0
24 55 27 78 30 18 14 2.0 3.0 16.0
28 65 30 90 35 20 15 2.5 4.0 17.5
38 80 38 114 45 24 18 3.0 4.0 21.0
Size
Dimensions [mm]
intermediate pipe
Cap screw
DIN EN ISO 4762
8.8
Tightening
torque
[Nm]
Friction torque
[Nm]
dR LR1 LZR1
14 14x2.5
According to
customer
specification
LR1+22 M3x12 1.34 6.1
19 20x3.0 LR1+50 M6x16 10.5 34
24 25x2.5 LR1+60 M6x20 10.5 45
28 35x4.0 LR1+70 M8x25 25 105
38 40x4.0 LR1+90 M8x30 25 123
Table 2: Torques and finish bores
Size
Spider 1) (component 2)
Rated torque [Nm] Unbo-
red
Finish bore [mm]
hub design
92 Sh A-GS 98 Sh A-GS 64 Sh D-GS 72 Sh D-GS dmin.
1.0
dmax.
1.1, 1.2
dmax.
2.0, 2.1
dmax.
14 7.5 12.5 16.0 - - 5 15 16 16
1.0, 1.1
dmax.
2.5
dmax.
2.6
dmax.
19 12 21 26 - x 6 24 24 24
24 35 60 75 97 2) x 8 28 28 28
28 95 160 200 260 2) x 10 38 38 38
38 190 325 405 525 2) x 12 45 45 45
42 265 450 560 728 2) x 14 55 50 45
48 310 525 655 852 2) x 15 62 55 55
55 410 685 825 1072 2) x 20 74 68 68
65 - 940 3) 1175 - x 22 80 70 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
1 Technical data
Summarized assembly instructions
ROTEX® GS
ZR1 and ZR2
KTR-N
Sheet:
Edition:
45523 EN
3 of 8
3
Please observe protection
note ISO 16016.
Drawn: 02.01.17 Shg/Rt Replaced for: KTR-N dated 08.09.2014
Verified: 02.01.17 Shg Replaced by:
Intermediate shaft coupling type ZR2
Illustration 2: ROTEX® GS, type ZR2
Table 3: Dimensions
Size Dimensions [mm]
DH D dH L l1; l2 E b s a B
14 30 – 10.5 35 11 13 10 1.5 2.0 11.5
19 40 – 18 66 25 16 12 2.0 3.0 14.0
24 55 – 27 78 30 18 14 2.0 3.0 16.0
28 65 – 30 90 35 20 15 2.5 4.0 17.5
38 80 – 38 114 45 24 18 3.0 4.0 21.0
42 95 85 46 126 50 26 20 3.0 4.0 23.0
48 105 95 51 140 56 28 21 3.5 4.0 24.5
55 120 110 60 160 65 30 22 4.0 4.5 26.0
65 135 115 68 185 75 35 26 4.5 4.5 30.5
Size
Dimensions [mm]
intermediate pipe Clamping set KTR 250
dR LR2 LZR2 Size dxD
Cap screw
DIN EN ISO 4762
12.9
Tightening
torque
[Nm]
Friction torque
[Nm]
14 10x2.0
According
to customer
specification
LR2+22 10x16 M4x10 5.2 46
19 12x2.0 LR2+50 12x18 M4x10 5.2 55
24 20x3.0 LR2+60 20x28 M6x18 17 222
28 25x2.5 LR2+70 25x34 M6x18 17 277
38 32x3.5 LR2+90 32x43 M6x18 17 689
42 40x4.0 LR2+100 40x53 M6x18 17 886
48 45x4.0 LR2+112 45x59 M8x22 41 1842
55 55x4.0 LR2+130 55x71 M8x22 41 2815
65 60x4.0 LR2+150 60x77 M8x22 41 3070
The coupling is generally supplied in individual parts. Before starting with the assembly, please inspect the cou-
pling 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.
1 Technical data
2 Assembly
ROTEX® GS
ZR1 and ZR2
KTR-N
Sheet:
Edition:
45523 EN
3 of 8
3
Please observe protection
note ISO 16016.
Drawn: 02.01.17 Shg/Rt Replaced for: KTR-N dated 08.09.2014
Verified: 02.01.17 Shg Replaced by:
Intermediate shaft coupling type ZR2
Illustration 2: ROTEX® GS, type ZR2
Table 3: Dimensions
Size Dimensions [mm]
DH D dH L l1; l2 E b s a B
14 30 – 10.5 35 11 13 10 1.5 2.0 11.5
19 40 – 18 66 25 16 12 2.0 3.0 14.0
24 55 – 27 78 30 18 14 2.0 3.0 16.0
28 65 – 30 90 35 20 15 2.5 4.0 17.5
38 80 – 38 114 45 24 18 3.0 4.0 21.0
42 95 85 46 126 50 26 20 3.0 4.0 23.0
48 105 95 51 140 56 28 21 3.5 4.0 24.5
55 120 110 60 160 65 30 22 4.0 4.5 26.0
65 135 115 68 185 75 35 26 4.5 4.5 30.5
Size
Dimensions [mm]
intermediate pipe Clamping set KTR 250
dR LR2 LZR2 Size dxD
Cap screw
DIN EN ISO 4762
12.9
Tightening
torque
[Nm]
Friction torque
[Nm]
14 10x2.0
According
to customer
specification
LR2+22 10x16 M4x10 5.2 46
19 12x2.0 LR2+50 12x18 M4x10 5.2 55
24 20x3.0 LR2+60 20x28 M6x18 17 222
28 25x2.5 LR2+70 25x34 M6x18 17 277
38 32x3.5 LR2+90 32x43 M6x18 17 689
42 40x4.0 LR2+100 40x53 M6x18 17 886
48 45x4.0 LR2+112 45x59 M8x22 41 1842
55 55x4.0 LR2+130 55x71 M8x22 41 2815
65 60x4.0 LR2+150 60x77 M8x22 41 3070
The coupling is generally supplied in individual parts. Before starting with the assembly, please inspect the cou-
pling 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.
1 Technical data
2 Assembly
Summarized assembly instructions
ROTEX® GS
ZR1 and ZR2
KTR-N
Sheet:
Edition:
45523 EN
4 of 8
3
Please observe protection
note ISO 16016.
Drawn: 02.01.17 Shg/Rt Replaced for: KTR-N dated 08.09.2014
Verified: 02.01.17 Shg Replaced by:
Components of ROTEX® GS, intermediate shaft coupling type ZR1
Component Quantity Description
1 2 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)
2 2 Spider
3
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)
4 1 Intermediate pipe
5 2 ZR clamping hub
6 2 Cap screw DIN EN ISO 4762
Illustration 3: ROTEX® GS ZR1, size 14 - 38
Components of ROTEX® GS, intermediate shaft coupling type ZR2
Component Quantity Description
1 2 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)
2 2 Spider
3
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)
4 1 Intermediate shaft or intermediate pipe with spigot
5 2 Hub type 4.2
6 2 CLAMPEX® KTR 250
Illustration 4: ROTEX® GS ZR2, size 14 - 65
2 Assembly
2.1 Components of the couplings
ROTEX® GS
ZR1 and ZR2
KTR-N
Sheet:
Edition:
45523 EN
4 of 8
3
Please observe protection
note ISO 16016.
Drawn: 02.01.17 Shg/Rt Replaced for: KTR-N dated 08.09.2014
Verified: 02.01.17 Shg Replaced by:
Components of ROTEX® GS, intermediate shaft coupling type ZR1
Component Quantity Description
1 2 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)
2 2 Spider
3
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)
4 1 Intermediate pipe
5 2 ZR clamping hub
6 2 Cap screw DIN EN ISO 4762
Illustration 3: ROTEX® GS ZR1, size 14 - 38
Components of ROTEX® GS, intermediate shaft coupling type ZR2
Component Quantity Description
1 2 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)
2 2 Spider
3
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)
4 1 Intermediate shaft or intermediate pipe with spigot
5 2 Hub type 4.2
6 2 CLAMPEX® KTR 250
Illustration 4: ROTEX® GS ZR2, size 14 - 65
2 Assembly
2.1 Components of the couplings
5
6
7
8
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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
Related manuals
Frequently Answers and Questions
What are the types of ROTEX GS couplings offered?
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.
How do I align the ROTEX GS coupling during assembly?
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.
What is the critical whirling speed of the ROTEX GS coupling?
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.
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