Dodge Fluid Couplings Owner's Manual

Dodge Fluid Couplings are a versatile and reliable power transmission solution, offering key features that enhance performance and productivity in various industrial applications. Their compact design allows for easy installation in confined spaces, while their robust construction ensures durability and longevity even in demanding conditions. These couplings provide smooth power transmission, effectively absorbing shock and vibration, resulting in reduced wear and tear on connected equipment.

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Dodge Fluid Couplings Owner's Manual | Manualzz

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1
DESCRIPTION

A fluid coupling is a hydrokinetic transmission unit comprised of

three main elements:

1.
Driving impeller (pump) mounted on the input shaft.
2.
Driven impeller (turbine) mounted on the output shaft.
3.
Cover, flanged to the output impeller, with an oil-tight seal.
The first two elements can work both as pump and/or turbine.

The impellers perform like a centrifugal pump and a hydraulic

turbine. With an input drive to the pump (e.g., electric motor

or Diesel engine) kinetic energy is imparted to the oil in the

coupling. The oil moves by centrifugal force across the blades of

the turbine towards the outside of the coupling. This absorbs the

kinetic energy and develops a torque which is always equal to

input torque thus causing rotation of the output shaft. The wear

is practically zero since there are no mechanical connections.

Figure 1 shows an example of a fluid coupling and its major

components:

1. Input (motor shaft)

2. Output (driven shaft)

3. Fluid Coupling Unit

4. PARA-FLEX
® PH Style Coupling
C
4


3
1 2

Figure 1 - KCP Fluid Coupling

WARNING: Because of the possible danger to person(s) or property from

accidents which may result from the improper use of products, it is

important that correct procedures be followed. Products must be used

in accordance with the engineering information specified in the catalog.

Proper installation, maintenance and operation procedures must be

observed. The instructions in the instruction manuals must be followed.

Inspections should be made as necessary to assure safe operation

under prevailing conditions. Proper guards and other suitable safety

devices or procedures, as may be desirable, or as may be specified in

safety codes should be provided, and are neither provided by Baldor

Electric Company, nor are the responsibility of Baldor Electric Company.

This unit and its associated equipment must be installed, adjusted and

maintained by qualified personnel who are familiar with the construction

and operation of all equipment in the system and the potential hazards

involved. When risks to persons or property may be involved, a holding

device must be an integral part of the driven equipment beyond the

speed reducer output shaft.

Instruction Manual

FLUID COUPLINGS

These instructions must be read thoroughly before installation or operation.

INSTALLATION / DISASSEMBLY

Model KCP/CKCP:

This coupling contains two sections consisting of a fluid

coupling circuit (the CKCP contains a delay-fill chamber) and

a PARA-FLEX
® coupling consisting of a PARA-FLEX PH high
speed element and PS assembly with TAPER-LOCK
® bushing.
Install in the following sequence:

1. Set the Between Shaft Ends (B.S.E.) Dimension

for the Driver and Driven Equipment (Table 1).

Table 1

Size
Fluid Cplg.
Bore Size

BSE

KCP
CKCP
11
1.625 6.26
1.875
5.64
12
1.625 6.21 8.87
1.875
5.59 8.25
13

1.875
7.46 9.82
2.125
6.83 9.19
2.375
6.21 8.57
15

2.125
9.86 12.54
2.375
9.24 11.92
2.875
7.86 10.54
17

2.375
10.11 13.26
2.875
8.73 11.88
3.375
8.11 11.26
19

2.375
10.11 13.26
2.875
8.73 11.88
3.375
8.11 11.26
21
2.375 11.79 15.73
3.375
10.54 14.48
24

2.875
11.79 15.73
3.375
10.54 14.48
3.875
10.29 14.23
NOTE:
It is necessary to mark the BSE setting on the base
where the motor is mounted. The fluid coupling unit is larger

than necessary between shaft ends and will need to be installed

after marking the setting and then moving the motor back to

allow for adequate room.

Coupling Styles:

KCP: 11-24

CKCP: 12-24

KCM: 7-34

CKCM: 12-34

Sheave Style:

KSD: 7-24
2
To install the KCP and CKCP Fluid Coupling, the motor shaft may need to be threaded. Values are given in Table 2.

Table 2

Size
Fluid Cplg.
Bore Size
Thread for installation Housing Thread
for Dismounting
KCP minimum
rod length
CKCP minimum
rod length
KSD minimum
rod length
Mtr. Shaft
Hole Depth
Mtr. Shaft
Thread Depth

11
1.625
1/2–13

UNC

3/4–10

UNC

12
2.25 1.5
1.875

12
1.625
1.875
12 14 2.25 1.5
13

1.875

7/8–9

UNC

12
15 2.25 1.52.125
2.375

15

2.125

3/4–10

UNC
15 17 20 2.25 1.75
2.375

2.875

17

2.375

2.875

7/8–9

UNC
1-1/4–7
UNC

15
18 23 2.5 2
3.375

19

2.375

15
18 23 2.5 22.875
3.375

21
2.375 17 21 25 2.5 2
3.375

24

2.875

17
21 27 2.5 23.375
3.875

2. Install Fluid Coupling:

Using the threaded bar as shown on Fig. 1, and using two

wrenches (hold wrench “A” and turn wrench “B” to draw the

coupling on to the motor shaft). For a good mounting, make

sure shafts are clean and without burrs, and lubricate the mating

surfaces with oil or antiseizing grease. Note: In case of hot

mounting (not recommended), do not reach a temperature above

195°F, or higher, which causes irrepairable damages to oil seals.

Tighten wrench “B” until the motor shaft end completely slides

onto coupling bore. Tighten the two setscrews on fluid coupling

to lock it in place. Remove the threaded rod.

Important Notice:
Always mount the KCP/CKCP coupling so
that the fluid coupling is mounted on the input (motor) side.

3. Remove Fluid Coupling:

Back off locking screws.

Engage the dismounting threaded bar “C” (this is different from

mounting threaded bar) onto the back of the fluid coupling (Figure

3). Continue with threading of the rod against the motor shaft.

This will cause the fluid coupling body to slide off the motor shaft.

For KSD models provided with collet (sizes 7 through 13) proceed

as follows:

1.
Remove hex head capscrew which retains the collet.
2.
Tap the fluid coupling body with a mallet. The fluid coupling
should break free from the motor shaft.

3.
Remove input shaft and coupling assembly with sheave from
motor shaft adapter. Remove sheave from sheave hub.

4. Assemble PARA-FLEX® Coupling to Fluid Coupling

Unit and Driven Equipment

Connect adapter plate (#4) to fluid coupling unit. For KCP/CKCP

sizes 11 and 12, torque nuts attaching the adapter plate to 216

lb-in. For sizes 13, 15, 17, and 19, torque to 425 lb-in. For sizes

21 and 24, torque to 1,175 lb-in.

Before installing the flexible element, slip bolt ring over flange and

rest it on the shaft. Remove clamp ring screws and internal clamp

ring. Place internal clamp ring inside the element and reassemble

to flange seating the bead of the element on the flange. Tighten

clamp ring screws alternately and evenly and torque to values

shown in column “A” in Table 3. On coupling sizes 15 through 24,

remove external clamp ring and rest it on shaft. Attach the spacer

hub to the clamp ring (external clamp ring for sizes 11-13 and

internal clamp ring for sizes 15-24). Torque to values in Table

3, column “D”. Install TAPER-LOCK bushing into flange. Turn

element on flange and reassemble clamp ring and screws.

Place bolt ring and screws in position. Tighten down screws

through the bolt ring and element through to the fluid coupling

adapter plate. Tighten screws alternately and evenly and torque

to values shown in Table 3, column “B”.

Figure 2

C

Figure 3

4
5 6
8
7
1
3
2

KCP 11-13

4
5 6
1
8
7
3

KCP 15-24

Figure 4
1 FLEXIBLE ELEMENT
2 INTERNAL CLAMP RING

3 EXTERNAL CLAMP RING

4 FLUID COUPLING ADAPTER PLATE

5 BOLT RING

6 DISC ASSEMBLY SCREWS

7 CLAMP RING SCREWS

8 SPACER HUB

NOTES:
FOR SIZES 11–13, IT IS NOT NECESSARY TO THREAD THE SHAFT.
If drilling and tapping the motor shaft, install threaded rod onto motor shaft, install motor shaft key, and follow mounting procedure as given in Step 2.

A
B
3
Table 3

Fluid Coupling

Size
Coupling
Size

Flange

Assembly

Size

Wrench Torque

(lb-in.)

A
(lb-in.)
B
(lb-in.)
D
E
Steel

Flanges
Iron
Flanges

11
KCP/CKCP PH 96 PX 80 290 290 300 300 0.025
12
KCP/CKCP PH 116 PX 100 480 480 360 300 0.030
13
KCP/CKCP PH 131 PX 110 480 480 420 300 0.035
15, 17, 19
KCP/CKCP PH 172 PX 140 1150 1080 600 720 0.045
21, 24
KCP/CKCP PH 192 PX 160 1150 2160 780 1296 0.050
5. Check Shaft Alignment of High Speed PARAFLEX
®
Coupling

BOLT RING
INDICATOR FOR
CHECKING PARALLEL
ALIGNMENT
INDICATOR FOR
CHECKING ANGULAR
ALIGNMENT

Although shafts may be perfectly aligned at installation, some

parallel and angular misalignment usually develops in usage

because of shifting of the driving and driven units. Check both

parallel and angular alignments by mounting indicators near the

O.D. of the flange as shown in the graphic above and rotate the

coupling through 360°. For a good installation, neither indicator

reading should exceed the value shown in Table 3, column “E”.

Both alignments should be rechecked after any repositioning.

INSTALLATION:

Model KSD:

This fluid coupling is to be installed on the end of a drive shaft

with a sheave mounted on the fluid coupling.

Sizes 7 through 13 are provided with an adapter collet. Install

in the following sequence:

1.
Install key flush with end of drive shaft.
2.
Install sheave to fluid coupling hub, torque bushing capscrews
properly (see recommended bolt torques listed).

3.
Install coupling assembly on drive shaft, (it may be necessary
to free the slotted adapter by pushing on loosened center

capscrew). Make sure slotted adapter does not ride up on any

radius or shoulder on the drive shaft. Note: Shaft must protrude

into slotted adapter 2.50 inches minimum.

4.
Torque retaining collet capscrew.
CAUTION: The fluid coupling is installed on the end of a

shaft and it is essential that a guard be provided.

Sizes 15 through 24 are provided without collet. Install in the

following sequence:

1.
To install KSD or CKSD fluid coupling, the motor shaft may
need to be threaded. Values are given in Table 2.

2.
Fit fluid coupling on motor shaft by using a threaded bar as
shown on Figure 2 and using two wrenches (hold wrench “A”

and turn wrench “B” to draw the coupling on the motor shaft).

3
. After fitting, lock it down using the fixing bolt. The fixing bolt
thread must be the same as the thread for installation as given

in Table 2.

Table 4 - Recommended

Tightening Torque for Fixing Bolt

Size
Torque (Max.)
¾–10 UNC
3000 lb-in.
7/8–9 UNC
4200 lb-in.
For good mounting, make sure shafts are clean

and without burrs, and lubricate the mating

surfaces with oil or antiseizing grease.

Figure 6

Figure 5
For REMOVAL: Refer to section 3 on page 2.
Model KCM, CKCM:

This coupling is a complete unit and is to be installed between

two halves of a double engagement gear tooth flexible coupling.

The gear coupling halves need to have a shrouded bolt design,

not the exposed bolt version. Install in the following sequence:

1.
Set between shaft spacing for driver and driven equipment per
chart below.

2.
Install gear coupling half to each shaft.
3.
Align shafts to within 0.030 total indicator reading.
4.
Install fluid coupling.
5.
Torque coupling bolts to recommended installation torque as
shown in gear coupling instruction manual.

Figure 7

Table 6 - BSE Spacing for KCM/CKCM

Couplings

Size

KCM

Centre

Distance

CKCM

Center

Distance

Gear

Coupling

Size

7
5.63 201
8
5.83 201
9
7.09 201½
11
7.44 201½
12
7.91 10.55 201½
13
8.31 11.28 201½
15
10.04 13.15 202½
17
10.04 13.27 202½
19
10.04 13.27 202½
21
12.78 16.80 202½
24
12.78 16.80 202½
27
14.70 20.96 203½
29
15.84 22.10 203½
34
18.79 25.21 204
NOTE:
The input side
flange on the fluid

coupling has clearance

holes for the gear coupling

bolts and the output

side flange is threaded.

The fluid coupling unit

is supplied with two

accessory kits. These

kits include bolts, nuts,

lockwashers, and gaskets.

Table 5 - Recommended Tightening

Torque for Bolt-On Sheaves

Qty
Size Torque
12
M10 360 lb-in.
8
M14 720 lb-in.
World Headquarters
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895

Dodge Product Support

6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433

www.baldor.com

© Baldor Electric Company

MN4051 (Replaces 499440)

All Rights Reserved. Printed in USA.

5/10 Printshop 500
*4051-0510*
OPERATION AND MAINTENANCE

1.
Start motor several times to check the coupling
performance. Maximum temperature should not

exceed 195°F. For higher temperatures, contact

Baldor Electric, Dodge Engineering, Greenville,

SC.

High oil operating temperature can be caused by:

a) Insufficient oil filling.

b) Absorbed power is higher than the motor

rated power.

c) High ambient temperature.

d) Too frequent starts.

e) Long starting time.

f) Inadequate air ventilation to allow cooling

of the coupling. If coupling is operating in a

restricted space, adequate ventilation

apertures should be provided.

2.
After the first 20 days of operation, check the
filling (this must be carried out with cold oil).

Also, check the motor and driven machine’s

fixing bolt.

3.
Coupling is supplied with fusible plug at 290°F
(250°F, 350°F, or 390°F upon request). It is

suggested that these alternative fusible plugs

should be considered for belt conveyors,

crushers, mills, mixers, etc. where continual

overload conditions can occur. If the fusible plug

blows at regular intervals in normal service, then

re-check a) through f) above.

4.
Oil should be replaced after 4,000 hours
operation.

FILLING INSTRUCTIONS

Series KCP, KSD, KCM:

Fluid couplings are not filled at the factory and thus a correct

filling procedure is necessary:

1.
With the fluid coupling mounted in a horizontal plane, turn the
coupling so the X mark which is cast into the housing is at the

top (maximum filling) which will ensure the filler/level plug item

13, is in the correct angular position as shown in Figure 8.

2.
Fill with oil until it overflows out of the filler hole. During filling,
rock the coupling gently on its axis to ensure all excess air is

vented from the circuit. Table 7 shows various oil quantities for

different fillings. The filling procedure for these intermediate

fills is the same as outlined above, in each case the number

must be at the top of the unit.

3.
To ensure no oil leaks from coupling during its operation, use
thread sealant on filler plug thread.

4.
The different filling X-1-2-3-4 can be selected at the users
discretion to obtain a better performance from the coupling.

With X fill (maximum), the fluid coupling will operate with

minimal slip and maximum efficiency. The ratio starting

torque/nominal torque will be at maximum. By decreasing the

coupling’s oil filling (1-2-3-4), the contrary occurs.

5.
High values of slip decrease the unit’s efficiency and will
cause the oil to overheat.

6.
Fluid recommendations are indicated in Table 9.
7
. For vertical mounted applications, fills are indicated in Table 7.
Series CKCP, CKSD, CKCM:

Fluid coupling CK series (with delayed fill chamber) is used to

limit the starting torque/nominal torque ratio to 1.4. The starting

torque limitation can be obtained by reducing the oil quantity in

the working circuit (filling 2-3-4) without increasing the slip value

at rated speed. For each given size, see Table 7 or 8 for proper

filling position.

After filling the coupling, start the motor and check to make sure

the fluid coupling operates properly. After approximately 100

hours, stop the motor and check the alignment and tightness of

the screws.
Table 7 - K... Series Oil Qty. U.S. Gal.
K…
X 1 2 3 4
6
.132 .126 .120 .112 .103
7
.243 .227 .211 .192 .171
8
.338 .314 .290 .264 .237
9
.515 .480 .446 .409 .369
11
.727 .673 .620 .554 .488
12
1.083 1.023 .944 .858 .766
13
1.374 1.281 1.175 1.070 .951
15
2.020 1.889 1.743 1.585 1.426
17
3.090 2.879 2.642 2.404 2.166
19
3.750 3.513 3.249 2.959 2.642
21
5.020 4.702 4.332 3.963 3.566
24
7.500 7.001 6.499 5.970 5.416
27
11.090 10.300 9.511 8.850 8.322
29
14.533 13.47 12.417 11.624 10.964
Table 8 - CK … Series

Oil Qty. U.S. Gal.

CK …
2 3 4
11
.885 .805 .726
12
1.268 1.109 .951
13
1.532 1.373 1.241
15
2.272 2.034 1.690
17
3.593 3.381 3.091
19
4.306 4.015 3.698
21
6.076 5.627 5.099
24
8.243 7.556 6.869
27
13.21 12.28 11.36
29
16.64 15.58 14.26
Table 9 - Fluid Recommendation

Coupling Operating

Temperature

Above 160ºF
Below 160ºF
SAE 10 W

Non-Detergent

SAE 5 W

Non-Detergent

For fluids (F) with specitic gravity (S.G.)

Other than fluid (G) with S.G. .88 at 60°F

HP. fluid (F) = H.P. fluid (G) × S.G. fluid (G)
S.G. fluid (F)

Figure 8

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