Kop-Flex Series HD, Series H Installation Manual

Series H and

ASHER

GASKET

ACCESSORIES

MALE

END

SIZES 8-30

SIZES 1-7

Series HD Couplings
Installation and Alignment Instructions

F O R M

1912-01E

Revised

June 2016

• 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.

HEX BOLT

O-RING SEAL

SLEEVE

HUBS

PIPE PLUGS

SLEEVE

NUT & LOCKW

KEY

O-RING SEAL

SHAFT

SERIES H

INSTALLATION and ALIGNMENT
INSTRUCTIONS

These instructions generally apply to KOP-FLEX®
Series H and Series HD couplings.

This sheet may be supplemented by Special
Instructions supplied with the coupling for
modifications and variations of these couplings.
For dimensions, ratings, maximum bores,
interference fits, and other technical information,
please refer to Bulletin 2000.

CAUTION: when working on rotating equip­ment. Be sure to lock out the starting switch
of the prime mover so the equipment cannot
be started until work is complete, checked,
and personnel are safely away.

MAINTENANCE and LUBRICATION

Lubricate the Series H and Series HD couplings
only with grease. Use KOP-FLEX

®

KSG coupling
grease or other grease meeting the minimum
specifications shown. Do not use oil in Series H
or HD couplings. Coupling lubrication is critical.
The use of proper and sufficient lubrication
is part of a successful installation. Lubricants
should be checked to see the proper level is
maintained and that the lubricant is free of
contaminates.

In an average industrial application, the coupling
should be checked for lubricant contamination
and replenished with the proper volume every
twelve months.

Conditions such as very slow speed, reversing
drives, high heat and severe environments may
require more frequent lubrication.

RECOMMENDED LUBRICANT

KOP-FLEX

®

KSG Coupling Grease

This grease is specifically compounded for
standard couplings to provide improved
lubrication and resistance to centrifugal
separation. When KSG grease is used,
lubrication intervals may be extended, based
upon operating experience. Balanced couplings
or others operating at speeds above 3500 rpm
can benefit from KHP coupling grease. Both
KSG and KHP coupling greases are available
from Kop-Flex or authorized distributors of Kop­Flex power transmission products.

If the coupling is mounted on a reciprocating
machine, or if recurrent reverse loading is
experienced, a heavy viscous lubricant, similar
to Texaco Crater Compound #0 or Gulf Lubecoat
#0 may be required for damping characteristics.

• Periodic inspections should be performed. Failure to perform proper
maintenance can result in premature product failure and personal
injury.

FEMALE
RABBET

CENTER
FLANGE
GASKET

ALIGNMENT FACE

ALIGNMENT DIAMETER

SLEEVE

HUB

END RING

END FLANGE

GASKET

O-RING SEAL

SEAL GROOVE

FLANGE

ACCESSORIES

END FLANGE

LOCKWASHER FURNISHED THRU SIZE 18

RABBET

CENTER
FLANGE

CENTER
FLANGE

PIPE

PLUG

SERIES HD

OTHER GREASES

Alternate lubricating greases should equal or
exceed the specifications for KOP-FLEX
and KHP coupling greases. (Specification sheet
3532 is available upon request.) Greases other
than KSG or KHP, should meet these minimum
specifications:

Grade: NLGI #1
Base oil Viscosity: Min.:

3000 SSU at 100° F

160 SSU at 210° F
Dropping point, Min.: 190°F
Four Ball Wear, ASTM D-2266:

.500mm Maximum
Base oil content: 87% Minimum
K36 Factor, ASTM D-4425:

KSG: K36 = 8/24 = .33
Required:

Rust and Oxidation Inhibitors

E. P. Additives

The most reliable test of a suitable lubricant
is often the result of user experience and
satisfaction. If a lubricant has been known to
sludge, separate into heavy components or dry
out, consider the use of Kop-Flex greases or
one meeting the minimum specifications.

®

KSG

Preparation:

NOTICE: that the Series H coupling sleeve
has an integral end ring while the Series HD
has a separate, bolted end ring.

Coat the sleeve teeth with coupling grease.
Use a portion of the grease to coat the ‘O’
ring seals and install the seals into the groove
of the Series H Sleeve, or the end ring of the
Series HD coupling.

MAINTENANCE and LUBRICATION

For the Series H, place the coupling sleeves
over the shaft end as shown in cover illustration.

For the Series HD, first place the end ring over
the shaft.

If using a keyed connection apply a suitable
anti-galling compound to the shaft. For keyless
hub-to-shaft connections, follow the equipment
manufacturers instructions.

Place keys in shaft keyways with a snug side­to-side fit, and slight clearance top to bottom.
Clean the shaft and HUB. Straight bored hubs
may be coated with a suitable anti-galling
lubricant. Taper bored hubs must be installed
without lubricant.

Expand HUB in an oven until the bore is
substantially larger than the shaft diameter.
Straight bored hubs are normally bored for an
interference fit of approximately 0.0005 in/in of
shaft diameter. For most values of interference,
this will require a hub temperature of about
3000F (150°C). NEVER EXCEED 600°F (300°C).

WARNING! To avoid the risk of explosion,
fire, damage to coupling and equipment, and/
or injury to personnel, do not use an open
flame or oil bath to expand the hub.

Remove HUB from oven and position quickly on
shaft, with hub end flush with shaft end.

For normal applications, hubs are mounted with
teeth away from end of shaft.

The Series H and HD couplings can accomodate
increase hub separation by reverse mounting
one, or both of the hubs. (See dimensions CI
and CW in Table I and Table II.) Make sure the
hub is mounted with the teeth in the correct
location.

Properly orienting the hubs, slip them over
the shafts and keys. Hub faces are normally
mounted flush with the shaft end.

On bolted end ring couplings such as the Series
HD, the sleeves are bolted to the end rings after
placing the gasket between the flanges.

MAINTENANCE and LUBRICATION

Select the unheated taper bored hub. Mount
the hub hand tight on its shaft and lightly rap it
with a soft mallet to establish the initial line-to­line fit. Draw the hub up an additional Distance
to obtain the desired interference fit for the
connection. In some cases the hub may require
heating to achieve desired fit.

(The required amount of axial movement is
dependent upon the bore diameter and taper
angle.)

Install the hub retention means (locknut, etc.)
provided with the shaft, and securely lock the
retainer into place. For most installations, the
hub face will project lightly beyond the shaft end
after hub pull-up.

CHECK ANGULAR ALIGNMENT

For normal hub separation, use a feeler gauge
at 4 points 90° apart, or for best accuracy, a dial
indicator.

Position machines to obtain best alignment.
Normal variation should not exceed .001 inches
(0.025mm) times coupling size. Maintain correct
hub separation referring to the “C” dimension
shown in tabulations on page 4.

For Greater hub separation than standard (such
as spacer and floating shaft couplings), use
micrometers or other suitable alignment fixtures
to span the separation and measure the four 90°
points.

Note: For maximum coupling life, the
Instrument Method of coupling alignment is
recommended.

Attach a dial indicator bracket to one hub with
dial indicator probe contacting the opposite
hub’s alignment surface. Rotate the hub ON
WHICH THE DIAL INDICATOR IS ATTACHED,
and take readings at 4 points 900 apart. The
offset (TIR) should be less than .002 inches
times the coupling size. For greater hub
separation than (such as spacer or floating
shaft couplings) use suitable fixtures to span
the separation and measure the four 90°
points. Shim either machine until best possible
alignment is obtained.

Recheck angular alignment and hub separation.

OFFSET ALIGNMENT
VISUAL METHOD

Shim one machine and align shafts using a
straight edge until it appears to be at right
angles to the shafts. Repeat at three additional
points 90° apart.

Recheck angular alignment and hub separation.

COUPLING ASSEMBLY

Check to insure the center flange gasket (or
O-ring) is not damaged. Clean the flange faces
and place the gasket in place. For spacer
couplings or other arrangements, a gasket must
be placed between each set of flanges.

Draw flanges together, positioning lube holes
90° apart.

Align the gasket with the flange bolt holes,
insert the fitted bolts, lockwashers and nuts.
Tighten all fasteners to the torque value shown
on page 4.

n.

Remove two fittings 1800 apart. Rotate the
coupling to place the bottom hole 450 off
horizontal. Pump lubricant into the top hole
until excess appears at the bottom hole.
Sufficient lubricant has now been added. (Hand
packing of grease in each half of the coupling is
recommended.)

Do not attempt to fill the coupling without
venting the interior; and air lock can result in
incomplete filling or in damage to the ‘O’ ring
seal.

After lubrication, tighten lube plugs to the
specified torque value shown on page 4.

Note: Spacer; limited end float; floating shaft
couplings, and some other styles, require each
end to be separately lubricated. Do not fill
the interior of spacer coupling arrangements.
Lubricant capacities for each size and coupling
style are given on page 4. One-half this amount
should be placed in each coupling half.