INSTRUCTION MANUAL FOR FORM 499698

WALDRON ®

Gear Couplings
Sizes: 1 1/8 & 1 5/8PL; 1 1/2 thru 4P
1 1/8 & 1 5/8 PLR; 1 1/2 & 2 PR
PRE-ASSEMBLY INSPECTION

CAUTION
If assembled
incorrectly,
equipment failure
and personal
injury may result.

All parts should be examined for any damage during ship- shaft separation, etc. All parts must be clean and free of any
ping and handling. Measurements should be taken to verify foreign materials before attempting assembly.
correctness of parts to meet application requirements such
as hub and shaft fits,
INSTALLATION
1. Install keys in respective shafts. Keys should fit shaft .0 1 5
keyseats with a tight fit on the sides and slight clearance .0 1 4
over the key. Coat the shafts with a suitable anti-galling .0 1 3 E E
.0 1 2 4 00 f G
lubricant. Use plastic oil sealing compound around keys
.0 11
to prevent loss of lubricant. Follow machinery manufactur- 3 30 f
.0 1 0
Interference Fit

ers recommendations for preparation, mounting and .0 0 9

dismounting of keyless hub to shaft fits. 300 f
.0 0 8 PL, P
.0 0 7
2. Slide one snap ring and then one seal over each shaft. .0 0 6 2 70 f
Be sure that embossed metal ring in the seal is facing .0 0 5 2 40 f
toward the shaft end. (Reference Figure 2) .0 0 4
E E
.0 0 3 210 f G
3. Mount hubs with short end in board. .0 0 2
Straight Bore Hubs: Hub bores must be expanded prior .0 0 1 18 0 f
to mounting. Heat hubs in either an oil bath or oven until
bores are larger than shaft diameter (Reference Table I 0 1" 2" 3 " 4" 5" 6" 7" 8" 9" 10"
and Figure 1). Bore Dia. PLR, PR
Figure 1 - Temperature Chart FIGURE 2 —
CAUTION Never apply an open flame to hub
teeth.
Table 1 - Interference Fit Limitations
Mount so that end of hub is flush with end of shaft.
(Interference Per Inch Max.)
Type of Fit
4. Coat hub teeth and sleeve teeth with coupling grease.
Keyless Keyed
Slide sleeve over hub mounted on longest shaft exten-
sion. Move sleeve as far back as possible in order to .00125" .00075" PL, P Seal
expose short end of hub for alignment. Important: On PLR and PR coupling applications be sure the
set screw hole in the sleeve is toward the rigid hub.

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Emerson Power Transmission

KOP-FLEX, INC., P.O. BOX 1696, BALTIMORE MARYLAND 21203, 410-768-2000
KOP-FLEX CANADA, LTD., 19 METEOR DRIVE, REXDALE, ONTARIO, CANADA M9W-1A3, 416-675-7144

Instruction Manual 499698

POWERLIGN® , , and KOP-FLEX®, are registered trademarks of Kop-Flex, Inc. 7/23/97
© Emerson Power Transmission Manufacturing, L. P. 1998. All Rights Reserved.
 ALIGNMENT

5. Although the shafts may be perfectly aligned at installation they

should be realigned after mounting of couplings. Position machines, Dual indicator (Angular)
referencing to shaft separation dimension “G”in Table 2. Align
couplings per following methods:
Angular Alignment- (Parallel Offset)
A. Instrument method, the most accurate, is recommended. Attach dial
base to one of the hubs and the indicator needle against the face of
the other hub. Rotate both hubs 3600 , taking indicator readings at
four points 900 apart. Adjust machines until all four readings are iden-
tical, referring to figure 4 for maximum angular misalignment. Relo-
cate the dial base to the opposite hub and repeat the procedure.

B. Feeler gage may be used when dial indicator is unavailable or shaft

separation is too small. Check with feeler gage at four points 90 0 Hub A Hub B
apart. Adjust machines until all four readings are identical. Refer to G
Figure 4 for maximum angular misalignment.
Figure 3 — Alignment

Parallel Offset Alignment-

D. Again the dial indicator is recommended as being most accurate. Attach E. A straight edge and feeler gage may be used as shown
dial base to one hub and set dial indicator button in contact with sur- if dial indicator is not available. Adjust machines until
face (O.D.) of opposite hub as shown. Rotate hub on which indicator is straight edge appears to be at right angle to shafts and
mounted 3600 , taking indicator readings at four points 900 apart. Ad- rests squarely on both hubs. Repeat procedure at three
just machines until all four readings are identical, referring to Figure 4 additional points 900 apart. Recheck angular alignment.
for maximum misalignment. Relocate dial base to opposite hub and
repeat the procedure. Recheck angular alignment.
F. Couplings with floating shafts have a greater hub
separation than shown in Table 4. Refer to application for
shaft separation and use either a dial indicator or straight
edge per instruction in 4D or 4E. Recheck alignment after
a few hours of operation to insure proper alignment at
operating temperatures.

Note: Use this graph

as a guide during instal-
PL/PR P/PR lation. Coupling wear is
Coupling Size related to misalignment,
11/8 15/8 11/2 2 231/2 3 31/2 4 .010 therefore, to achieve
Amt. of Lube maximum coupling life,
Req'd. to fill .27 .27 .88 1.4 2.5 3.3 5.5 6.9 .008 misalignment must be
D IA. R .O . (T.I.R .)

minimized.
Coupling*(oz.)
.006 3 1 /2 P
Min. Speed for
Grease 2 1 /2 P
575 510 463 411 380 348 321 301 .004
Lubrication 4 P
1 1/2 P
(R.P.M.) 3 P
.002 2 P
"G" 1 1 /8 a
1
/8" 1
/8" 1
/8" 1
/8" 3
/16" 3
/16" 1
/4" /4"
1
(B.S.E.) 1 5 /8 P L

.000 .002 .004 .006 .008 .010

* Amount by volume.
▲ Couplings operating below these speeds should use a grease FA CE R.O . (T.I.R .)
having an NLGI rating of “0” or “00”. Figure 4 — Limits of Misalignment

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© Emerson Power Transmission Manufacturing, L. P. 1998. All Rights Reserved.

 ASSEMBLY

6. Coat hub teeth and body, as well as inside of sleeve with 8. Remove the two lube plugs, located 180 0 apart, and fill
coupling grease. Slide the sleeve over both hubs, making coupling with recommended amount of coupling grease
sure that the gear teeth mesh properly and are fully (reference Table 2). Replace lube plugs and tighten
engaged. Insert dog point set screw on types PLR & PR. securely.
Be sure that set screw is seated properly.

7. Apply small amount of grease on seals and hubs so seals

will slide easily over hub surfaces. Install the seals in the
sleeves, insuring that they are not crimped or rolled over.
Lock in place with retaining ring. Retaining ring MUST be
properly seated in the groove in the sleeve.

MAINTENANCE

Following an initial break-in period of about 3 million revolutions (80 hr @ During relubricatiion cycle or at least yearly, whichever
600 rpm) it is recommended that the coupling be completely flushed and comes first, the coupling should be disassembled and
relubricated. Thereafter, a regular relubrication schedule should be main- thoroughly cleaned of all old grease. Remove and
tained. Each application should be evaluated based on its environment and visually inspect all parts; gear teeth for sighs of abnormal
operating condition to determine a relubrication interval. For average in- stress and wear, the seals and gaskets for any cracks or
dustrial operating conditions, relubrication every 6 months should suffice breaks. All bolts should fit snugly and locknuts should
with periodic visual inspections to insure that neither the quality nor the tighten securely.
supply (due to leakage) of the lubricant has deteriorated to an unaccept-
able level. Any parts showing signs of wear or damage should be
replaced. These parts are available for purchase by
Many lubricants will perform satisfactorily under average industrial operat- referencing the coupling, size, type and bolting style.
ing conditions. As long as the temperature range of the application is within Hubs and sleeves should be replaced as half couplings
the limits shown for the lubricant and the coupling speed is above the whenever possible.
minimum speed for grease lubrication shown in Table 2. Although some
lubricants will maintain their lubricity at elevated temperatures, the thermal
limit of the coupling is 250 0F. For applications where coupling is exposed to
sustained temperatures above 2500F, consult factory. For low speed op-
eration (below min. speed for grease lubrication, Table 2), use a grease
having an NLGI rating of “0” or “00.” Lubricants required for severe oper-
ating conditions should be referred to a lubrication manufacturers repre-
sentative for recommendations.

RECOMMENDED LUBRICANT
KOP-FLEX® KSG Coupling Grease
This grease is specifically compounded for standard couplings to provide improved (Specification sheet 3532 is available upon request.)
lubrication and resistance to centrifugal separation. When KSG grease is used, Greases other than KSG or KHP, should meet these
lubrication intervals may be extended, based upon operating experience. Bal- minimum specifications:
anced couplings or others operating at speeds above 3500 rpm can benefit from Grade: NLGI #1
Base oil Viscosity: Min.: 3000 SSU at 1000F
KOP-FLEX® KHP coupling grease. Both KSG and KHP coupling greases are
160 SSU at 2100F
available from KOP-FLEX® or authorized distributors of Kop-Flex power transmis- Dropping Point, Min.: 1900F
sion products. Four Ball Wear, ASTM D-2266: .500mm Maximum
Base oil content: 87% Minimum
If the coupling is mounted on a reciprocating machine, or if recurrent reverse load-
K36 Factor, ASTM D-4425: KSG: K36 = 8/24 = .33
ing is experienced, a heavy viscous lubricant similar to Texaco Crater Compound Required: Rust and Oxidation Inhibitors
#0 or Gulf Lubecoat #0 may be required for damping characteristics. E.P. Address
OTHER GREASES The most reliable test of a suitable lubricant is often the
result of user experience and satisfaction. If a lubricant
Alternate lubricating greases should equal or exceed the specifications for KOP- has been known to sludge, separate into heavy compo-
FLEX® KSG and KHP coupling greases. nents or dry out, consider the use of KOP-FLEX® greases
or one meeting the minimum specifications.

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© Emerson Power Transmission Manufacturing, L. P. 1998. All Rights Reserved.

 PARTS REPLACEMENT

2
SN AP R IN G
4 3
PIP E PL U G 6 SE AL
1 HUB
SL EE VE
6
3 HUB
SE AL 2
SN AP R IN G
2
SN AP R IN G 4
PIP E PL U G 3
7 SE AL
1 HUB
SL EE VE
6
3 HUB
SE AL
2
SN AP R IN G 5
SE TS C R EW

Number
Ref. Required
Name of Part
No.
PL,P PLR, PR
1 Sleeve Assy* 1 1
2 Snap Ring 2 2
3 Coupling Seal 2 2
4 Pipe Plug 2 2
5 Set Screw - 1
6 Gear Hub 2 1
7 Rigid Hub - 1

*Assembly Includes Parts Listed Immediately Below. Important Safety Instructions

Before start-up . . . for reasons of safety and
to extend shaft coupling life, follow these
requirements.
1. Coupling guards protect personnel. ALL
COUPLINGS MUST BE COVERED WITH A
GUARD AS PER OSHA REQUIREMENTS.
2. Recheck alignment after all foundation bolts
and mechanical connections are tightened.
TABLE 5 3. Make sure all fasteners are properly installed
Recommended Spare Parts for Powerlign Couplings and tightened.
4. Take the time to double check your work.
RETAINING 5. Only authorized Kop-Flex replacement parts
COUPLING PIPE SET are to be used.
SEALS (SNAP)
SIZE PLUGS SCREWS*
RINGS 6. Call Kop-Flex for any clarification or
questions.
1-1/8 PL 149185 149389 149354 149483
1-5/8 PL 149186 149390 149354 149483
1-1/2 P 149222 149393 149354 149483
2P 149223 149396 149354 149483
2-1/2 P 149224 149402 149354
3P 149225 149407 149354
3-1/2 P 149226 149412 149354
4P 149227 149415 149354
*For PLR & PR Couplings Only.
▲ Consult Factory Set Screw Size. KOP-FLEX, INC.
EMERSON POWER TRANSMISSION
P. O. Box 1696
Form 499698 7/23/97 Baltimore, MD 21203-1696
Printed in U.S.A.
© Emerson Power Transmission Manufacturing, L. P. 1998. All Rights Reserved.