KD2 & KD20 Disc Coupling Installation and Alignment

Instructions
FORM 15-111
APRIL, 2002
®
KOP-FLEX, INC., P.O. BOX 1696, BALTIMORE MARYLAND 21203, 410-768-2000
Emerson Power Transmission
KOP-FLEX CANADA, LTD., 19 METEOR DRIVE, REXDALE, ONTARIO, CANADA M9W-1A3, 416-675-7144

! WARNING
High voltage and rotating parts may cause
serious or fatal injury.
Turn off power to install or service.
Operate with guards in place.
Read and follow all instructions in this manual.

Because of the possible danger to person(s) or property from accidents which may result from the improper use or unapproved modification of the
product, this product must be installed, maintained, and operated in accordance with the procedures, standards and engineering information
specified in the product brochures and illustrations. To assure safe operation, this product should be inspected in accordance with the instructions
described in this form. Proper guards and other suitable safety devices or procedures as may be desirable, or as may be specified in safety codes,
should be installed by the user. Guards and other safety equipment are not provided, nor are they the responsibility of Emerson Power Transmis-
sion.
1.0 General Instructions
FEELER GAUGES
Prior to installation, inspect the coupling for any signs of damage that may
have occured during shipment. Check that all parts are on hand and are as
ordered. SPLIT COLLAR

ONLY BOLTS AND NUTS SUPPLIED BY

KOP-FLEX ARE TO BE USED.

Components should be cradled or supported during handling to avoid dam-

age and should be wrapped for protection. Flanges and pilot surfaces should
be kept free of nicks and burrs.
Read all of the installation instructions and review the procedure before Figure 2. Using Split Collar to Set Advance
the actual coupling installation.
Diametral Taper Rate
2.0 Installation of Coupling Hubs - Keyed Mounting .070
2.1 Check the hub bore and shaft for nicks and burrs, dress if necessary. 1/2"/ft 5/8"/ft
.060 3/4"/ft
Make sure that the bore and shaft are clean.
2.2 For tapered bores, check the fit of the bore to the shaft. 1"/ft
.050
Advance (in.)

2.3 Keys must be precisely fitted to the keyways in the shaft and hub.
Each key should have a tight fit on the sides with a slight clearance on .040 1 1/4"/ft
top. To maintain dynamic balance, the keys should fill the keyways
exactly and not be too short or too long. .030
1 1/2"/ft
2.4 Clean the hub bore and shaft. For straight bores, proceed to step 2.6.
For taper bores, mount the hub handtight on the shaft and lightly rap .020
it with a soft mallet to establish the initial line-to-line fit. This is the
START position. With a depth gauge, measure the amount the hub .010
overhangs the shaft end and record this value. See Figure 1.
.000
DEPTH GAUGE .0000 .0005 .0010 .0015 .0020 .0025 .0030 .0035 .0040

Interference (in.)

Figure 3. Hub Advance vs. Interference Chart

2.6 Heat the hub to expand the bore; DO NOT allow the hub temperature
to exceed 600°F (300°C). DO NOT apply an open flame to any part
of the coupling, an oven is recommended.
To avoid the risk of explosion, fire, or damage to
the coupling and equipment, and/or injury to per-
sonnel, do not use an open flame or oil bath to
Figure 1. Measuring Hub Overhang expand the hub. If heat is used at any time for in-
stallation, DO NOT allow the hub temperature to
exceed 600°F (300°C).
2.7 Place the hub in the proper position on the shaft. Hold the hub in
2.5 Taper Bores Only: A recommended method to measure the hub ad- place as it cools. For taper bores, verify the hub advance (see Fig-
ures 1 and 2) and install the shaft retaining nut. Remove the split
vance is to install a split collar on the shaft, away from the hub by the collar from the shaft.
amount of the specified advance. Use feeler gauges for accurate spac-
ing. See Figure 2. The amount of hub draw is dependent upon the
desired interference and taper angle as specified by the machine manu-
facturer or as given on the coupling drawing. See Figure 3.

™
3.0 Alignment 4.4 Put the center assembly (spacer and rings) between the rigid hubs,
Note: Exact values and procedures for aligning equipment are normally engage the pilot, and install the hub bolts in one hub flange.
specified by the equipment manufacturers. Good initial alignment to
the minimum possible values will promote optimum machinery per- 4.5 Release all the collapsing bolts, and install the hub flange bolts on the
formance and eliminate potential operating problems. After securely second rigid hub flange.
tightening the foundation bolts, the hub separation and alignment 4.6 Torque the hub flange bolts to the value specified in Table 1.
should be rechecked and adjusted if necessary.
The coupling alignment should be checked periodically. Even
when a coupling is well aligned at installation, subsequent settling of
foundations, shifting of equipment, etc., may cause the alignment to Tightening Torque (Lightly Oiled)
Coupling
deteriorate. Size KD2 KD20
ft-lb N-m ft-lb N-m
Offset and Angular Alignment
103 8 10 -- --
3.1 Reverse dial indication or optical methods of alignment (such as la- 153 8 10 -- --
ser) are recommended. A cold alignment and a hot check (with cor- 203, 204 30 40 50 70
rections if necessary) are required. The hub flange OD can be used to 253, 254 30 40 50 70
mount the alignment equipment. The hub flange OD is machined to 303, 304 75 100 110 150
be concentric to the coupling bore and can be used as the reference 353, 354 75 100 150 200
diameter. 403, 404 150 200 270 370
3.2 The maximum recommended operating misalignment is: 453, 454 150 200 270 370
504 -- -- 430 580
0.10 degrees per disc pack
554 -- -- 640 870
(0.0035 in/in TIR equivalent parallel offset)
604 -- -- 640 870
Important: Total misalignment is the combination of equipment par- 705 -- -- 1120 1500
allel offset and angular misalignment. 805 -- -- 1470 2000
905 -- -- 1470 2000
Note that improving the alignment below these values will promote
optimum machinery performance.
Axial Alignment Table 1. Flange Bolt Tightening Torques.
3.3 Align the hubs until they are at the correct hub separation. The hub
separation is measured from the two flange faces, not from the pilot 5.0 Removal
face. 5.1 Disassemble the coupling in the reverse order as per the applicable
Hub Separation = Center Assembly Length assembly procedure.
4.0 Final Assembly 5.2 KEYED HUBS - Install a puller on the hub using the tapped holes
(KD2 and KD20) provided in the hub face. Pull the hub off the shaft.
4.1 After correctly installing both hubs, use the separate collapsing screws 6.0 Disc Pack Replacement
to pull the adapter rings toward the center of the pre-assembled cen- The terminology used to identify parts and the order of assembly may differ
ter section. This is made up of the spacer, two disc packs, and two from one coupling style to another. Follow the instructions which match the
adapter rings. coupling style being installed.
ADAPTER RING COLLAPSING BOLT

KD2 - For KD20 skip to 6.7

DISC PACK
SPACER
6.1 Remove the center assembly in reverse order as per the applicable
assembly procedure. Remove disc pack bolts and nuts.
6.2 Insert the disc pack removal socket into one of the clearance holes in
the spacer flange or ring (Figure 6). Install the removal cap screw and
turn it until it cannot be tightened any more.
Note: The removal socket is supplied as part of the “parts kit”.

DISC PACK
CLEARANCE HOLE
BUSHING
Figure 4. Collapsing center section
4.2 For each side of the center section, insert the collapsing bolts through
the spacer clearance holes into tapped holes in the ring (see Figure 4).
4.3 Tighten them evenly and collapse the disc packs equally, only enough
to allow the center assembly to drop into place (see Figure 5).
CENTER ASSEMBLY

HUB BOLTS
REMOVAL SOCKET REMOVAL SCREW

WASHER
Figure 6. Bolt Disc Pack to Adapter.

6.3 Remove the tool and repeat step 6.2 on all bushings to free the disc
pack from the ring and spacer.

O.D. PILOT

Figure 5. Installing center section.

Disconnect all power before adjusting units

The Emerson logo is a trademark and a service mark of Emerson Electric Co.
© Emerson Power Transmission Manufacturing, L. P. or affiliates 2002. All Rights Reserved.
 6.4 Line up the bushings of the new disc pack with the reamed holes in KD20
the ring, lightly tap on the bushings to start them into the holes. Insert
3 disc pack bolts and nuts with the bolt heads in the ring counterbore 6.7 Remove the center assembly in reverse order as per the applicable
hole, tighten them evenly to pull the bushing into the ring flange (see assembly procedure.
Figure 7).
6.8 Unbolt the adapter ring from the disc pack. Unbolt the disc pack from
the spacer.
DISK PACK NUT
6.9 Clean and deburr all of the coupling parts.
DISK PACK 6.10 Line up the new disc pack between the adapter ring and the spacer.
BUSHING Insert the disc pack bolt into the counterbored hole in the adapter
ring, and through the disc pack.
ADAPTER RING
SPACER 6.11 Make sure that the spacer is properly indexed for the large clear-
ance holes to receive the bolt ends. Place the spacing washer and
disc pack nut on the bolt. Repeat for the other bolts (see Figure 9).
DISC PACK NUT

SPACING WASHER

DISC PACK

ADAPTER RING

SPACER

DISK PACK BOLT

Figure 7. Bolt Disc Pack to Adapter Ring.

DISC PACK BOLT
6.5 Line up the bushings with the spacer reamed holes, lightly tap the
bushings to start them in the holes. Install and tighten 3 disc pack Figure 9. Bolt Disc Pack to Adapter Ring.
bolts and nuts with bolt heads in the ring (see Figure 8).
6.12 Place a spacing washer over a disc pack bolt. Insert the bolt through
DISK PACK BOLT the large hole in the adapter ring and through the disc pack bushing
and reamed hole in the spacer. Place the disc pack nut on the bolt.
ADAPTER RING Repeat for the other bolts (see Figure 10).
DISC PACK ADAPTER RING
SPACING WASHER
BUSHING
DISC PACK
SPACER DISC PACK NUT

SPACER

DISC PACK NUT

Figure 8. Bolt Disc Pack to Spacer. DISC PACK BOLT

6.6 Torque all disc pack fasteners evenly and in successive steps to the Figure 10. Bolt Disc Pack to Spacer.
value specified in Table 2. 6.13 Torque all disc pack fasteners evenly in successive steps to the
value specified in Table 2.
Tightening Torque (Lightly Oiled)
Coupling KD2 KD20 7.0 Dynamic Balance
Size
ft-lb N-m ft-lb N-m Balanced parts will be marked with the letter “B.” The couplings may be
103 8 10 -- -- component balanced (hubs and center assembly) with no match marks, or
153 30 40 -- --
assembly balanced as a complete coupling with match marks of the hub to
203, 204 50 70 55 75
253, 254 75 100 55 75 ring connections. If the coupling is supplied with match marks, it must be
303, 304 120 160 115 160 assembled with the match marks in line.
353, 354 190 260 175 240
403, 404 290 390 280 380
Note: For balanced couplings, disconnecting the disc packs from the cen-
453, 454 320 430 280 380 ter assemblies disturbs the balance of the coupling. When disc packs
504 -- -- 420 570 are replaced in balanced couplings, the couplings must be balanced
554 -- -- 730 1000 before placing back in operation.
604 -- -- 1020 1400
705 -- -- 1800 2450 8.0 Finish Boring and Keyways
805 -- -- 2300 3100 Coupling hubs are often furnished with a “rough stock bore.” This rough
905 -- -- 2300 3100 bore is not necessarily concentric to other hub diameters. To prepare for
Table 2. Disc Pack Bolt Tightening Torques. boring, set-up and indicate the hub as shown in Figure 11.

Disconnect all power before adjusting units

© Emerson Power Transmission Manufacturing, L. P. or affiliates 2002. All Rights Reserved.

9.0 Bore Sizing and Recommended Fit 10.0 Keyways
The finish bore size should be based on the actual measured shaft dimen- Keyways should be cut to give a tight fit on the sides and slight clearance
sion, regardless of whether straight or taper shaft. For keyed shafts, a light over the key. Keyways should not have sharp corners. Refer to published
interference fit based on a nominal interference rate of 0.0005 inch per inch AGMA standards for specific dimensioning of coupling bores and keyways.
of shaft diameter is suggested, or refer to published AGMA standards. Do
not exceed an interference fit of 0.001 inch/inch of shaft diameter. If other 11.0 General Recommendations
than a light interference fit is desired, consult the published AGMA boring 11.1 KOP-FLEX KD2 and KD20 disc couplings are designed to operate for
and keyway standards. extended periods without the need for lubrication or maintenance. Visual
inspection of the disc packs is sufficient to assess the operational condition
For Straight Bores, the rigid hub diameter should be chucked in the bor- of the coupling.
ing lathe and dial indicated as shown of Figure 11. For Taper Bores, chuck
and indicate as shown on Figure 11. Machine the counterbore and SKIM A 11.2 All machinery should be monitored to detect unusual or changing vi-
REFERENCE DIAMETER on the hub body. Then chuck the hub as shown bration levels. KOP-FLEX KD2 and KD20 couplings, under normal condi-
on Figure 12, and indicate using the reference diameter before final boring. tions, have no wearing parts and will retain their original balance quality.
Run-outs should be as near zero as possible. It is essential that the fin- Any change in vibration levels should be investigated and remedial action
ished bore be concentric with the two indicating surfaces. should be taken immediately.

REFERENCE
DIAMETER

Figure 11 Figure 12

5 YEAR WARRANTY REGISTRATION CARD

Name (Last, First)

Title:

Company Name:

Location:

Phone:

APPLICATION DATA

Coupling Type:

HP:

RPM:

Application:

Shaft Size(s): Driving: Driven:

Distance Between Shaft Ends

Plant Identification Pump # Motor #

Send Warranty Card To: Attention Marketing Department

KOP-FLEX, Inc.
Mail to: P. O. Box 1696 or Fax to: 410-787-8424
Baltimore, MD 21203-1696

Important Safety Instructions

Before start-up . . . for reasons of safety and to extend shaft coupling life,
follow these requirements. ®

1. Coupling guards protect personnel. Emerson Power Transmission

ALL COUPLINGS MUST BE COVERED WITH A GUARD AS PER OSHA REQUIREMENTS.
2. Recheck alignment after all foundation bolts and mechanical connections are tightened. P. O. Box 1696
3. Make sure all fasteners are properly installed and tightened. Baltimore, MD 21203-1696
4. Take the time to double check your work.
5. Only authorized KOP-FLEX replacement parts are to be used. www.emerson-ept.com
6. Call KOP-FLEX for any clarification or questions.

© Emerson Power Transmission Manufacturing, L. P. or affiliates 2002. All Rights Reserved.