Kop-Flex KD1, KD10 Installation Manual
KD1 and KD10 Disc Coupling
Installation and Alignment
Instructions
F O R M
22-001E
Revised
August 2015
• Read and follow all instructions carefully.
• Disconnect and lock-out power before installation and maintenance.
Working on or near energized equipment can result in severe injury or death.
• Do not operate equipment without guards in place. Exposed equipment can
result in severe injury or death.
1.0 General Instructions
Prior to installation, inspect the coupling for any signs of damage
that may have occurred during shipment. Check that all parts
are on hand and are as ordered. Components should be cradled
or supported during handling to avoid damage and should be
wrapped for protection. Flanges should be kept free of nicks and
burrs. Read all of the installation instructions and review the procedure before the actual coupling installation.
WARNING! Only bolts and nuts supplied by Kop-Flex are to be used.
2.0 Installation of Coupling Hubs - Keyed Mounting
Make sure the base of the housing and the support surfaces are
clean and free from burrs. If the housing elevation is adjusted with
shims these must cover the entire contact area between the housing and the support surface.
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 t of the bore to the shaft.
2.3 Keys must be precisely tted to the keyways in the shaft
and hub. Each key should have a tight t on the sides with a
slight clearance on top. To maintain dynamic balance, the keys
should ll the keyways exactly and not be too short or too long.
• Periodic inspections should be performed. Failure to perform proper maintenance
can result in premature product failure and personal injury.
2.5 Tapered 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 speci ed advance. Use
feeler gauges for accurate spacing. See Figure 2. The amount
of hub advance is dependent upon the desired interference
and taper angle as speci ed by the machine manufacturer or
as given on the coupling drawing. See Figure 3.
2.4 Clean the hub bore and shaft. For straight bores, proceed
to step 2.6. For tapered bores, mount the hub hand-tight on
the shaft and lightly rap it with a soft mallet to establish the
initial line-to-line t. 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.
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
fl ame to any part of the coupling, an oven is recommended.
2.7 Place the hub in the proper position on the shaft. Hold the
hub in place as it cools. For tapered bores, verify the hub advance (see Figures 1 and 2) and install the shaft retaining nut.
Remove the split collar from the shaft.
3.0 Initial Assembly
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.
KD1 - For KD10 skip to 3.5
3.1 Line up the disc pack bushings with the reamed holes in
the hub. Lightly tap on the bushings to start them in the reamed
holes (See Figure 4).
3.2 Insert three disc pack bolts from the disc pack side, through
the three bushings that are lightly tapped into the reamed holes.
Assemble with lock-nuts and tighten them evenly and in successive steps until they are tightened to the speci ed value in Table
1.
3.3 Position the adapter ring over the hub so that the spacer pilot
and counterbored holes are on the face opposite the disc pack.
(see Figure 4).
3.4 Install the disc pack bolts and nuts with the bolt heads in the
ring. Torque the fasteners evenly and in successive steps to the
values in Table 1.
KD10 - For KD1 skip to 4.0
3.5 The disc packs are packaged as two halves; one left hand
(yellow mark) and one right hand pack (white mark). One left half
and one right half must be put together to make one complete
disc pack. For replacements, slide one half through the gap
between the hubs followed by the other half.
3.6 Place the two halves on the hub, press together and reassemble the complete disc pack (see Figure 5).
3.7 Position the adapter ring over the hub so that the spacer pilot
and counterbored holes are on the face opposite the disc pack.
(see Figure 6). Make sure to align reamed holes with larger
clearance holes in mating part.
3.8 Install the disc pack bolts and nuts with the bolt heads in the
ring. Torque all disc pack bolts to the values speci ed in Table 1.
4.0 Alignment
Note:Exact values and procedures for aligning equipment are nor-
mally speci ed by the equipment manufacturers.
The amounts given below represent values that would provide excellent coupling performance in operation.
Good initial alignment to the minimum possible values will promote
optimum machinery performance and eliminate potential operat-
ing 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.
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