KOP-FLEX

Installation and Alignment Instructions

for

KS Disc Couplings

WARNING: Because of the possible danger to person(s) or property from accidents which
may result form 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 by KOP-FLEX, nor are the responsibility of KOP-FLEX.

Form 39-901
December 1995
 Installation and Alignment Instructions
for the KS Disc Coupling

Contents
1.0 General Instructions
2.0 Installation Of Coupling Rigid Hubs
3.0 Alignment
4.0 Final Assembly
5.0 Removal
6.0 General Recommendations

1.0 General Instructions

The KOP-FLEX KS disc coupling is normally dynamically balanced. When balanced, it
must be assembled with all parts in the positions specified by the match marks on the
coupling.

Each coupling assembly has a unique serial number marked on it. Make sure that the
serial numbers match exactly on components used for a complete coupling.

The flange bolts and nuts are individually weight balanced for balanced couplings so that
any nut may be used on any bolt. WARNING: ONLY BOLTS AND NUTS SUPPLIED
BY KOP-FLEX ARE TO BE USED.

When dynamically balanced, KOP-FLEX KS disc couplings are supplied in factory pre-
assembled units. It is not necessary for normal installation or removal to disassemble the
disc pack/flange assemblies or tighten or loosen the disc pack bolts and nuts. The disc
pack bolts and nuts may be removed to replace the disc pack assembly if desired,
however, this may affect the original balance quality of the coupling.

Prior to installation, inspect the coupling for any signs of damage 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 and rabbets should be kept free of nicks and burrs.

The disc pack/flange assemblies may be made rigid during manufacturing by shipping
screws (see figure 1). The red locking screws (set screws) hold the disc pack in the
neutral position. The yellow collapsing screws (socket head capscrews) lock the disc
pack/assembly in place. DO NOT REMOVE OR LOOSEN THESE SCREWS UNTIL
INSTRUCTED.

Read all of the installation instructions and review the procedure before the actual
coupling installation.

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 Figure 1. KS Center Subassembly

2.0 Installation Of Coupling Rigid Hubs (If Supplied)

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.

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2.2 For taper 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. Mount the hub hand-tight 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 2.

Figure 2. Measuring Hub Overhang

2.5 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 3. 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 4.

Figure 3. Using Split Collar to Set Advance

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 Diametral Taper Rate
.070
1/2"/ft 5/8"/ft
.060 3/4"/ft
1"/ft
.050
Advance (in.)
.040 1 1/4"/ft

.030
1 1/2"/ft
.020

.010

.000
.0000 .0005 .0010 .0015 .0020 .0025 .0030 .0035 .0040

Interference (in.)

Figure 4. Hub Advance vs. Interference Chart

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 flame to any part of the coupling, an
oven is recommended.

WARNING: 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).

2.7 Place 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 figure 1) and install the shaft
retaining nut. Remove the split collar from the shaft.

Hydraulic (Keyless) Mounting

CAUTION: Specific instructions for hydraulic mounting of coupling hubs are given by
the manufacturers of the connected equipment. The following general
instructions on mounting are given for reference. Make sure that the
equipment manufacturer's instructions are supplied and are followed.

2.8 Check the hub bore and shaft for nicks and burrs, dress if necessary. Make sure
that the bore and shaft are clean.

2.9 Check the fit of the bore to the shaft, at least 85% contact is required. Make sure
there are no O-rings or backup rings in the oil seal grooves. DO NOT lap the hub
on the shaft to obtain the required contact, use special gauges. Record the
position of the hub on the shaft as the "start" position for advancing.

2.10 Clean the hub bore and shaft and install the O-rings and backup rings (if used).

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 2.11 Place the hub on the shaft and install the necessary hydraulic mounting
equipment.

2.12 Place the hub in the "start" position and inject oil to pressurize the bore and
expand the hub. Check for leaks.

2.13 Push the hub onto the shaft to the specified advance. Keep the proper pressure in
the bore, it should not be necessary to exceed 30,000 psi. DO NOT exceed the
maximum allowable assembly pressure specified on the coupling general
arrangement drawing or on the equipment manufacturer’s installation
instructions.

2.14 Release the bore pressure slowly and allow some time for the oil to drain from the
bore. Leave the pusher in place to hold the hub in position.

2.15 Remove the hub pusher after the bore oil has drained and verify the correct
advance of the hub on the shaft. Install the shaft nut (if used) and lock in place.

CAUTION: If sufficient time is not allowed for the oil to drain from the bore, the hub
could move off the shaft with great force when the pusher is removed.
Make sure proper safety procedures are followed.

3.0 Alignment
Note: Exact values and procedures for aligning equipment are normally specified 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 operating problems.

Offset And Angular Misalignment

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 rigid hub OD can be used to mount the alignment equipment.
The hub OD is machined to be concentric to the coupling bore and can be used as
the reference diameter.

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3.2 The maximum recommended operating misalignment is:
0.10 degrees per disc pack
(0.0035 in/in TIR parallel offset)
Note that improving the alignment below these values will promote optimum
machinery performance.

Axial Misalignment
3.3 Measure the flange gap where the center section is to be installed. This is
dimension L1 in figure 5. The nominal flange to flange dimension is given on the
coupling drawing.

Figure 5. Axial Misalignment Measurements

3.4 Before removing the shipping screws, measure the overall center section length
(face of flange to face of flange). This is dimension L2 in figure 5.

3.5 Compare the measured dimensions. The difference between measurements is the
amount of shim to be installed between the flanges.
Shim needed = L1 - L2

Caution: In general, each coupling is supplied with (2) shim packs. The coupling is
designed to use one full shim pack when the actual shaft separation equals
the design shaft separation to allow a plus or minus axial adjustment. DO
NOT add the equivalent of more than one pack at any flange
connection. If shims from a second pack are required, add them to the
opposite flange.

3.6 When thermal growth is specified for certain applications, a pre-stretch value may
be given. This is the axial distance the center section will be stretched at
installation to accommodate axial thermal growth of the shaft ends towards each

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 other. For this situation, subtract the pre-stretch value from the amount of shim
calculated in step 3.5.
Shim needed = L1 - L2 - pre-stretch

Caution: In some rare cases, the pre-stretch will need to be added, such as when the
equipment shaft ends grow away from each other as they reach operating
temperature.

4.0 Final Assembly

NOTE: KOP-FLEX KS disc couplings are designed with fitted rabbets which must be pressed or
lightly tapped together. DO NOT use excessive force.

The proper tightening torque for the flange fasteners is given in table 1. The tightening
torque for the disc pack fasteners is listed in table 2 in the event field replacement of the
disc pack is required. For normal installation, the disc pack fasteners do not need to be
tightened or loosened.

4.1 Remove the red locking screws and tighten the yellow screws. This collapses the
disc pack and pulls the center section together to allow clearance for the hub
flange rabbets. Tighten the screws progressively and in small increments; DO
NOT tighten them one at a time.

4.2 Place the coupling center section between the two rigid hubs and line up the
match marks. Make sure the identifying letters or numbers with the match marks
are the same.

4.3 Release the collapsing screws; this must be done progressively and in small
increments. DO NOT loosen them one at a time. Store the yellow collapsing
screws for future use.

4.4 Line up the match marks exactly and push the center section and mounting
flanges together. Install the flange bolts and nuts in the direction as shown on the
coupling general arrangement drawing (see note 4.0). Tighten to the value given
on the general arrangement drawing or in table 1 below.

4.5 Recheck the coupling alignment after the machinery has reached a stable
operating temperature and correct if necessary.

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 Coupling Nut Tightening Torque Tightening Torque
Size Size (dry) (lubed)*
ft-lb N-m ft-lb N-m
103 1/4-28 11 15 9 12
153 1/4-28 11 15 9 12
204 1/4-28 11 15 9 12
254 5/16-24 20 27 18 24
304 5/16-24 20 27 18 24
354 3/8-24 31 42 28 38
404 3/8-24 31 42 28 38
454 1/2-20 75 102 60 81
504 1/2-20 75 102 60 81
554 5/8-18 150 203 120 163
604 5/8-18 150 203 120 163
705 5/8-18 150 203 120 163
805 3/4-16 280 380 210 285
905 7/8-14 450 610 330 447
* Light Machine Oil

Table 1. Flange Nut Tightening Torques

Coupling Nut Tightening Torque Tightening Torque

Size Size (dry) (lubed)*
ft-lb N-m ft-lb N-m
103 5/16-18 10 14 7 9
153 7/16-20 27 37 20 27
204 1/2-20 55 75 45 61
254 1/2-20 55 75 45 61
304 5/8-18 115 156 90 122
354 3/4-16 175 237 140 190
404 7/8-14 280 380 220 298
454 7/8-14 280 380 220 298
504 1"-12 420 570 330 447
554 1 1/8-12 730 990 580 786
604 1 1/4-12 1020 1380 810 1100
705 1 1/2-12 1800 2440 1440 1950
805 1 3/4-12 2300 3120 1840 2500
905 1 3/4-12 2300 3120 1840 2500
* Light Machine Oil

Table 2. Disc Pack Nut Tightening Torques

5.0 Removal
5.1 Remove the flange bolts and nuts and break the flanges apart using the jacking
screw holes located between the bolt holes. Be sure to support the spacer
assembly.

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 5.2 Install the yellow collapsing screws in the clearance holes in the spacer disc
flange and tighten them to collapse the disc pack. The collapsing screws must be
tightened progressively and in small increments: DO NOT tighten them one at a
time. This operation will pull the center section away from the mounting flange
and allow the rabbets to clear so that the center section can be removed.

5.3 KEYED - Install a puller on the hub using the tapped holes provided in the hub
face. Pull the hub off the shaft.

5.4 HYDRAULIC - Install the hydraulic equipment and remove the hub from the
shaft, reversing the installation procedure.

6.0 General Recommendations

6.1 KOP-FLEX KS disc couplings are designed to operate for extended periods
without the need for lubrication or maintenance. Visual inspection of the disc
packs is sufficient to assess the operational condition of the coupling.

6.2 All machinery should be monitored to detect unusual or changing vibration levels.
The KOP-FLEX KS coupling, under normal operation conditions, has no wearing
parts and will retain its original balance quality. Any change in vibration levels
should be investigated and remedial action should be taken immediately.

6.3 A serial number is marked on the coupling. It is required for accurate

identification and is sufficient for ordering an exact duplicate of the coupling or
its components.

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Important Instructions Before Each Start-up:

1. WARNING: Coupling guards protect personnel. ALL COUPLINGS MUST BE

COVERED WITH A GUARD AS PER OSHA REQUIREMENTS. Safety guards are
not included with this product and should be separately installed by the user.

2. Recheck alignment after all foundation bolts and mechanical connections are tightened.

3. Make sure all fasteners are properly installed and tightened.

4. Take the time to double check your work.

5. Only authorized Kop-Flex replacement parts are to be used.

6. Call Kop-Flex for any clarifications or questions.

7. CAUTION: The self-locking nuts on the flange bolts should be replaced after they
have been assembled and removed from the bolts FIVE (5) times.

8. WARNING: Repair or replacement of Kop-Flex disc couplings is restricted to Kop-

Flex authorized facilities, unless under specific instructions given by Kop-Flex.

Kop-Flex, Inc.
P.O. Box 1696
Baltimore, Maryland 21203
410-768-2000

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