Emerson KD20, KD2 User Manual
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
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 Transmission.
1.0 General Instructions
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.
ONLY BOLTS AND NUTS SUPPLIED BY
KOP-FLEX ARE TO BE USED.
Components should be cradled or supported during handling to avoid damage 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
the actual coupling installation.
2.0 Installation of Coupling Hubs - Keyed Mounting
2.1 Check the hub bore and shaft for nicks and burrs, dress if necessary.
Make sure that the bore and shaft are clean.
2.2 For tapered bores, check the fit of the bore to the shaft.
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
top. To maintain dynamic balance, the keys should fill the keyways
exactly and not be too short or too long.
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
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
overhangs the shaft end and record this value. See Figure 1.
DEPTH GAUGE
Figure 1. Measuring Hub Overhang
2.5 Taper Bores Only: A recommended method to measure the hub advance is to install a split collar on the shaft, away from the hub by the
amount of the specified advance. Use feeler gauges for accurate spacing. See Figure 2. The amount of hub draw is dependent upon the
desired interference and taper angle as specified by the machine manufacturer or as given on the coupling drawing. See Figure 3.
Advance (in.)
2.6 Heat the hub to expand the bore; DO NOT allow the hub temperature
2.7 Place the hub in the proper position on the shaft. Hold the hub in
Figure 2. Using Split Collar to Set Advance
.070
.060
.050
.040
.030
.020
.010
.000
.0000 .0005 .0010 .0015 .0020 .0025 .0030 .0035 .0040
Figure 3. Hub Advance vs. Interference Chart
to exceed 600°F (300°C). DO NOT apply an open flame to any par t
of the coupling, an oven is recommended.
place as it cools. For taper bores, verify the hub advance (see Figures 1 and 2) and install the shaft retaining nut. Remove the split
collar from the shaft
®
Emerson Power Transmission
FEELER GAUGES
SPLIT COLLAR
Diametral Taper Rate
1/2"/ft
Interference (in.)
To avoid the risk of explosion, fire, or damage to
the coupling and equipment, and/or injury to personnel, do not use an open flame or oil bath to
expand the hub. If heat is used at any time for installation, DO NOT allow the hub temperature to
exceed 600°F (300°C).
5/8"/ft
3/4"/ft
1"/ft
1 1/4"/ft
1 1/2"/ft
.
™
3.0 Alignment
Note: Exact values and procedures for aligning equipment are normally
specified by the equipment manufacturers. Good initial alignment to
the minimum possible values will promote optimum machinery performance and eliminate potential operating problems. After securely
tightening the foundation bolts, the hub separation and alignment
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
deteriorate.
Offset and Angular Alignment
3.1 Reverse dial indication or optical methods of alignment (such as laser) are recommended. A cold alignment and a hot check (with corrections if necessary) are required. The hub flange OD can be used to
mount the alignment equipment. The hub flange OD is machined to
be concentric to the coupling bore and can be used as the reference
diameter.
3.2 The maximum recommended operating misalignment is:
0.10 degrees per disc pack
(0.0035 in/in TIR equivalent parallel offset)
Important: Total misalignment is the combination of equipment parallel offset
Note that improving the alignment below these values will promote
optimum machinery performance.
and angular misalignment.
Axial Alignment
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
face.
Hub Separation = Center Assembly Length
4.0 Final Assembly
(KD2 and KD20)
4.1 After correctly installing both hubs, use the separate collapsing screws
to pull the adapter rings toward the center of the pre-assembled center section. This is made up of the spacer, two disc packs, and two
adapter rings.
ADAPTER RING
DISC PACK
COLLAPSING BOLT
SPACER
4.4 Put the center assembly (spacer and rings) between the rigid hubs,
engage the pilot, and install the hub bolts in one hub flange.
4.5 Release all the collapsing bolts, and install the hub flange bolts on the
second rigid hub flange.
4.6 Torque the hub flange bolts to the value specified in Table 1.
gnilpuoC
eziS
301801---351801----
402,30203040507
452,35203040507
403,30357001011051
453,35357001051002
404,304051002072073
454,354051002072073
405----034085
455----046078
406----046078
507----02110051
508----07410002
509----07410002
2DK02DK
bl-tfm-Nbl-tfm-N
)deliOylthgiL(euqroTgninethgiT
Table 1. Flange Bolt Tightening Torques.
5.0 Removal
5.1 Disassemble the coupling in the reverse order as per the applicable
assembly procedure.
5.2 KEYED HUBS - Install a puller on the hub using the tapped holes
provided in the hub face. Pull the hub off the shaft.
6.0 Disc Pack Replacement
The terminology used to identify parts and the order of assembly may differ
from one coupling style to another. Follow the instructions which match the
coupling style being installed.
KD2 - For KD20 skip to 6.7
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”.
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
O.D. PILOT
Figure 5. Installing center section.
Disconnect all power before adjusting units
CLEARANCE HOLE
REMOVAL SOCKET
DISC PACK
BUSHING
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.
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.
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