KD2 & KD20 Disc Coupling
Installation and Alignment
Instructions
FORM 15-111
APRIL, 2002
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KOP-FLEX, INC., P.O. BOX 1696, BALTIMORE MARYLAND 21203, 410-768-2000 |
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Emerson Power Transmission |
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KOP-FLEX CANADA, LTD., 19 METEOR DRIVE, REXDALE, ONTARIO, CANADA M9W-1A3, 416-675-7144 |
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! 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.
1.0General 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.
2.0Installation of Coupling Hubs - Keyed Mounting
2.1Check the hub bore and shaft for nicks and burrs, dress if necessary.
Make sure that the bore and shaft are clean.
2.2For tapered bores, check the fit of the bore to the shaft.
2.3Keys 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.
2.4Clean 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
2.5Taper 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.
FEELER GAUGES
SPLIT COLLAR
Figure 2. Using Split Collar to Set Advance
Diametral Taper Rate
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.070 |
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1/2"/ft |
5/8"/ft |
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.060 |
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3/4"/ft |
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1"/ft |
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.050 |
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(in.) |
.040 |
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1 1/4"/ft |
Advance |
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.030 |
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1 1/2"/ft |
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.020 |
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.010 |
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.000 |
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.0000 |
.0005 |
.0010 |
.0015 |
.0020 |
.0025 |
.0030 |
.0035 |
.0040 |
Interference (in.)
Figure 3. Hub Advance vs. Interference Chart
2.6Heat 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 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).
2.7Place the hub in the proper position on the shaft. Hold the hub in 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.
™
3.0Alignment
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
3.1Reverse 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.
3.2The 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 and angular misalignment.
Note that improving the alignment below these values will promote optimum machinery performance.
Axial Alignment
3.3Align 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
4.0Final Assembly (KD2 and KD20)
4.1After 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 |
COLLAPSING BOLT |
DISC PACK
SPACER
Figure 4. Collapsing center section
4.2For each side of the center section, insert the collapsing bolts through the spacer clearance holes into tapped holes in the ring (see Figure 4).
4.3Tighten 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.
4.4Put the center assembly (spacer and rings) between the rigid hubs, engage the pilot, and install the hub bolts in one hub flange.
4.5Release all the collapsing bolts, and install the hub flange bolts on the second rigid hub flange.
4.6Torque the hub flange bolts to the value specified in Table 1.
Coupling |
Tightening Torque (Lightly Oiled) |
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Size |
KD2 |
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KD20 |
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ft-lb |
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N-m |
ft-lb |
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N-m |
103 |
8 |
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10 |
-- |
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-- |
153 |
8 |
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10 |
-- |
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-- |
203, 204 |
30 |
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40 |
50 |
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70 |
253, 254 |
30 |
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40 |
50 |
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70 |
303, 304 |
75 |
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100 |
110 |
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150 |
353, 354 |
75 |
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100 |
150 |
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200 |
403, 404 |
150 |
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200 |
270 |
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370 |
453, 454 |
150 |
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200 |
270 |
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370 |
504 |
-- |
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-- |
430 |
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580 |
554 |
-- |
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-- |
640 |
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870 |
604 |
-- |
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-- |
640 |
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870 |
705 |
-- |
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-- |
1120 |
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1500 |
805 |
-- |
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-- |
1470 |
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2000 |
905 |
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1470 |
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2000 |
Table 1. Flange Bolt Tightening Torques.
5.0Removal
5.1Disassemble the coupling in the reverse order as per the applicable assembly procedure.
5.2KEYED HUBS - Install a puller on the hub using the tapped holes provided in the hub face. Pull the hub off the shaft.
6.0Disc 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
6.1Remove the center assembly in reverse order as per the applicable assembly procedure. Remove disc pack bolts and nuts.
6.2Insert 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
REMOVAL SOCKET |
REMOVAL SCREW |
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WASHER
Figure 6. Bolt Disc Pack to Adapter.
6.3Remove the tool and repeat step 6.2 on all bushings to free the disc pack from the ring and spacer.
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.
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