FALK Steelflex T35 series Installation & Maintenance

Falk™ Steelflex®Spacer Couplings•Installation & Maintenance

Type T35

Sizes 1020-1140 & 20-140 (Page 1 of 7)

•

How to Use This Manual

This manual provides detailed instructions on maintenance,
lubrication, installation, and parts identification. Use the table
of contents below to locate required information.

Table of Contents

Introduction ...............................Page1

Lube Fittings ...............................Page1

Limited End Float ...........................Page1

Lubrication .............................Pages 1-2

Installation & Alignment Instructions............Pages 2-4

Annual Maintenance, Relube & Disassembly ........Page5

Installation & Alignment Data...................Page6

Parts Identification & Parts Interchangeability ........Page7

CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE
FREE SERVICE.

INTRODUCTION

This manual applies to Sizes 1020T thru 1140T and 20T thru
140T35 standard Falk SteelfIex Spacer Couplings. Unless
otherwise stated, information for Sizes 1020T thru 1140T applies
to Sizes 20T thru 140T respectively, e.g. 1020T = 20T, 1100T =
100T, etc. For couplings furnished with special features, refer to
assembly drawing furnished with coupling for proper assembly
arrangement and any additional installation or maintenance
requirements. The Spacer Assembly permits installation (or
removal, as shown on Page 5) without disturbing connected
equipment. These couplings are designed to operate in either the
horizontal or vertical position without modification. However, for
vertical applications, the cover match mark shown on Page 4 must
be up. Current couplings are supplied with one set of metric cover
fasteners. Older couplings may have inch cover fasteners.

The performance and life of the couplings depend largely upon
how you install and service them.

WARNING: Consult applicable local and national safety
codes for proper guarding of rotating members. Lockout
starting switch of prime mover and remove all external loads from
drive before installing or servicing couplings. Observe all safety
rules when installing or servicing couplings.

WARNING: Mixing grid coupling components from different
manufacturers may cause premature failure and personal or
property damage from flying debris.

LUBE FITTINGS

Cover halves have1/8NPT Iube holes. Use a standard grease
gun and Iube fitting as instructed on Page 5.

Because of its superior lubricating characteristics and low
centrifuge properties, Falk Long Term Grease (LTG) is highly
recommended. Sizes 1020T to 1090T35 are furnished with a
pre-measured amount of LTG grease for each coupling. The
grease can be ordered for larger size couplings.

The use of general purpose grease requires re-lubrication of
the coupling at least every six months. If coupling leaks
grease, is exposed to extreme temperatures, excessive
moisture, experiences frequent reversals or axial movements;
more frequent lubrication may be required.

Long Term Grease (LTG)

The high centrifugal forces encountered in couplings separate the
base oil and thickener of general purpose greases. Heavy
thickener, which has no lubrication qualities, accumulates in the
grid-groove area of Steelflex couplings resulting in premature hub
or grid failure unless periodic lubrication cycles are maintained.

Falk Long Term Grease (LTG) was developed specifically for
couplings. It resists separation of the oil and thickener. The
consistency of Falk LTG changes with operating conditions. As
manufactured, it is an NLG1 # ½ grade. Working of the
lubricant under actual service conditions causes it to become
semifluid while the grease near the seals will set to a heavier
grade, helping to prevent leakage.

LTG is highly resistant to separation, easily out performing all
other lubricants tested. The resistance to separation allows the
lubricant to be used for relatively long periods of time.

Steelflex couplings initially lubricated with LTG will not
require re-lubrication until the connected equipment is
stopped for servicing. If a coupling leaks grease, is exposed
to extreme temperatures, excessive moisture, or experiences
frequent reversals, more frequent lubrication may be required.

Although LTG grease is compatible with most other coupling
greases, the mixing of greases may dilute the benefits of LTG.

USDA Approval

LTG has the United States Department of Agriculture Food Safety
& Inspection Service approval for applications where there is no
possibility of contact with edible products. (H-2 ratings).

CAUTION: Do not use LTG in bearings.

LIMITED END FLOAT

When electric motors, generators, and other machines are
fitted with sleeve or straight roller bearings, limited axial end
float kits are recommended for protecting the bearings. Falk
Steelflex couplings are easily modified to limit end float; refer
to Manual 428-820 for instructions.

LUBRICATION

Adequate lubrication is essential for satisfactory operation.

Rexnord Industries, LLC, Coupling Group 428-312
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone] April 2005
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Specifications — Falk LTG

The values shown are typical and slight variations are
permissible.

AMBIENT TEMPERATURE RANGE — –20°F (–29°C) to
250°F (121°C). Min. Pump = 20°F (–7°C)

MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @
100°F (38°C)

THICKENER — Lithium & soap/polymer.

Installation & Maintenance

Falk™ Steelflex

•

®

Spacer Couplings

(Page 2 of 7) Sizes 1020-1140 & 20-140

CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM
#D4425-84 Centrifuge Test — K36 = 2/24 maximum, very
high resistance to centrifuging.

NLGI GRADE (ASTM D-217) —

1

/

2

CONSISTENCY (ASTM D-217) — 60 stroke worked penetration
value in the range of 315 to 360 measured at 77°F (25°C)

MINIMUM DROPPING POINT — 350°F (177°C) min.
MINIMUM TIMKEN EP O.K. LOAD — 40 lbs (18 kg).
ADDITIVES — Rust and oxidation inhibitors that do not

corrode steel or swell or deteriorate synthetic seals.

Packaging

14 oz. CARTRIDGES — For use in standard industrial
lubrication guns.

35 lb. PAILS — Ideal for larger size couplings or many
smaller sizes.

120 lb. KEG — For plants with many small couplings or large
size couplings. Best for hand packing.

400 lb. DRUMS — For plants with a pressurized lubrication
system.

CASE LOTS — 10 Pak – 14 oz. cartridges, 30 – 14 oz.
cartridges.

TABLE 1 — General Purpose Greases

Ambient Temperature

Range

Manufacturer Lubricant

Amoco Oil Co. Amolith Grease #2 Amolith Grease #2
BP Oil Co. Energrease LS-EP2 Energrease LS-EP1
Chevron U.S.A. Inc. Dura-Lith EP2 Dura-Lith EP1
Citgo Petroleum Corp. Premium Lithium Grease EP2 Premium Lithium Grease EP1
Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2

Exxon Company, USA Unirex EP2 Unirex EP2
E.F. Houghton & Co. Cosmolube 2 Cosmolube 1
Imperial Oil Ltd. Unirex EP2 Unirex EP2
Kendall Refining Co. Lithium Grease L421 Lithium Grease L421

Keystone Div. (Pennwalt) 81 EP- 2 81 EP-1
Lyondell Petrochemical

(ARCO)
Mobil Oil Corp. Mobilux EP111 Mobilith AW1
Petro-Canada Products Mult ipurpose EP2 Multipurpose EP1

Phillips 66 Co. Philube Blue EP Philube Blue EP
Shell Oil Co. Alvania Grease 2 Alvania Grease 2
Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2
Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EP

Texaco Lubricants Starplex HD2 Multifak EP2
Unocal 76 (East & West) Unoba EP2 Unoba EP2
Valvoline Oil Co. Multilube Lithium EP Grease . . .

H

Grease application or re-lubrication should be done at temperatures above
20°F (-7°C). If grease must be applied below 20°F (-7°C), consult the
Factory.

†

Lubricants listed may not be suitable for use in the food processing industry;
check with lube manufacturer for approved lubricants.

INSTALLATION OF TYPE T35 STEELFLEX

General Purpose Grease

ANNUAL LUBRICATION — The following specifications and
lubricants for general purpose grease apply to Falk Steelflex
couplings that are lubricated annually and operate within
ambient temperatures of 0° to 150°F (–18° to 66°C). For
temperatures beyond this range (See Table 1), consult the Factory.

If a coupling leaks grease, is exposed to extreme
temperatures, excessive moisture or experiences frequent
reversals, more frequent lubrication may be required.

Specifications — General Purpose
Coupling Lubricants

The values shown are typical and slight variations are
permissible.

DROPPING POINT — 300°F (149°C) or higher.
CONSISTENCY — NLGI No. 2 with 60 stroke worked

penetration value in the range of 250 to 300.
SEPARATION AND RESISTANCE — Low oil separation rate

and high resistance to separation from centrifuging.
LIQUID CONSTITUENT — Possess good lubricating properties,

equivalent to a high quality, well refined petroleum oil.
INACTIVE — Must not corrode steel or cause swelling or

deterioration of synthetic seals.
CLEAN — Free from foreign inclusions.

General Purpose Greases Meeting
Rexnord Specifications

Lubricants listed in Table 1 are typical products only and
should not be construed as exclusive recommendations.

TAPERED GRID COUPLINGS

Installation

Only standard mechanics tools, wrenches, a straight edge and
feeler gauges are required to install Falk Steelflex couplings.
Clean all parts using a non-flammable solvent. Check hubs,
shafts and keyways for burrs. Coupling Sizes 1020T thru
1090T are generally furnished for CLEARANCE FIT with
setscrew over the keyway. Sizes 1100T and larger are
furnished for an INTERFERENCE FIT without a setscrew.

CLEARANCE FIT HUBS — Do not heat clearance fit hubs.
Install keys, mount hubs flush with shaft ends or as otherwise
specified and tighten setscrews.

INTERFERENCE FIT HUBS — Furnished without setscrews.
Heat hubs to 275°F (135°C) using an oven, torch, induction
heater or an oil bath. To prevent seal damage DO NOT heat
hubs beyond a maximum temperature of 400°F (205°C).

When an oxy-acetylene or blow torch is used, use an excess
acetylene mixture. Mark hubs near the center of their length in
several places on hub body with a temperature sensitive
crayon, 275°F (135°C) melt temperature. Direct flame towards
hub bore using constant motion to avoid overheating an area.

WARNING: If an oil bath is used, the oil must have a flash
point of 350°F (177°C) or higher. Do not rest hubs on the
bottom of the container. Do not use an open flame in a
combustible atmosphere or near combustible materials.

Heat hubs as instructed above. Mount hubs as quickly as possible
with hub face flush with shaft end. Allow hubs to cool before
proceeding. Insert setscrews (if required) and tighten.
Maximize Performance & Life
The performance and life of couplings depend largely upon
how you install and maintain them. Before installing
couplings, make certain that foundations of equipment to be

Type T35

•

H

0°F to 150°F

(-18°C to 66°C)

†

Litholine H EP 2 Grease Litholine H EP 2 Grease

-30°F to 100°F
(-34°C to 38°C)

†

Lubricant

Rexnord Industries, LLC, Coupling Group428-312

5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone]April 2005

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Falk™ Steelflex®Spacer Couplings•Installation & Maintenance

Type T35

connected meet manufacturers’ requirements. Check for soft
foot. The use of stainless steel shims is recommended.
Measuring misalignment and positioning equipment within
alignment tolerances is simplified with an alignment computer.
These calculations can also be done graphically or
mathematically.

Alignment is shown using spacer bar and straight edge. This
practice has proven to be adequate for many industrial
applications. However, for superior final alignment, the use of
dial indicators (see Manual 458-834 for instructions), lasers,
alignment computers or graphical analysis is recommended.

Sizes 1020-1140 & 20-140 (Page 3 of 7)

•

Installation of Spacer Assembly

1— Mount Seal & Hubs

3 — Gap & Angular Alignment

Use a spacer bar equal in thickness to the gap specified in
Table 2 on Page 6. Insert bar, as shown above, to same depth
at 90° intervals and measure clearance between bar and hub
face with feelers. The difference in minimum and maximum
measurements must not exceed the ANGULAR installation
limits specified in Table 2 on Page 6.

4 — Offset Alignment

Lock out starting switch of prime mover. Lightly coat seal with
grease and place on shaft before mounting T-Hub. Heat
interference fit hubs as previously instructed. Mount hubs on their
respective shafts so that hub face is flush with the end of the shaft
unless otherwise indicated. Allow hub to cool. Seal keyway of
T-Hub to prevent leakage. Tighten setscrew when furnished.

2 — Mount Half Spacer

SEAL

Wrap tape over grid grooves and carefully stretch and roll the
seal over hub teeth into position. Remove tape. Carefully
position half spacer on register of shaft hub and fasten parts
together. Torque fasteners to specifications in Table 2 on Page

6. Position drives for approximate distance between shaft ends
with minimum angular and offset misalignment.

Align so that a straight edge rests squarely (or within the limits
specified in Table 2, Page 6) on both hubs as shown above
and also at 90° intervals. Check with feelers. The clearance
must not exceed the PARALLEL OFFSET installation limits
specified in Table 2 on Page 6. Tighten all foundation bolts
and repeat Steps 3 and 4. Realign coupling if necessary.

Rexnord Industries, LLC, Coupling Group 428-312
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone] April 2005
Fax: [phone] e-mail: [e-mail] web: www.rexnord.com Supersedes 4-99

Installation & Maintenance

Falk™ Steelflex

•

®

Spacer Couplings

(Page 4 of 7) Sizes 1020-1140 & 20-140

5 — Insert Grid

Pack gap and grooves with lubricant before inserting grid.
When grids are furnished in two segments, install them so that
all cut ends extend in the same direction (as detailed in the
inset picture above). This will assure correct grid contact with
the non-rotating lug in the cover and permit cover installation.
Spread the grid slightly to pass over the coupling teeth and
then seat with a soft mallet.

Pack the spaces between and around the grid with as much
lubricant as possible and wipe off excess flush with top of grid.
Position seals on hubs to line up with grooves in cover.
Position gaskets on flange of lower cover half and assemble
covers so that the match marks are on the same side (see
below left). If shafts are not level (horizontal) or coupling is to
be used vertically, assemble cover halves with the lug and
match mark

UP or on the high side. Push gaskets in until they stop against
the seals and secure cover halves with fasteners, tighten to
torque specified in Table 2 on Page 6. Make sure gaskets stay
in position during tightening of fasteners. CAUTION: Make
certain lube plugs are installed before operating.

Type T35

•

MATCH MARK

VERTICAL COUPLINGS

LUG UP

6 — Pack with Grease & Assemble Covers

MATCH MARK

MATCH MARK

Rexnord Industries, LLC, Coupling Group428-312

5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone]April 2005

Fax: [phone] e-mail: [e-mail] web: www.rexnord.comSupersedes 4-99

Falk™ Steelflex®Spacer Couplings•Installation & Maintenance

Type T35

Sizes 1020-1140 & 20-140 (Page 5 of 7)

•

ANNUAL MAINTENANCE

For extreme or unusual operating conditions, check coupling
more frequently.

1. Check tightening torques of all fasteners.

2. Inspect seal ring and gasket to determine if replacement is
required; if leaking grease, replace.

3. When connected equipment is serviced, disassemble,
clean grease from coupling, inspect for wear, and replace
worn parts. Check alignment per steps on Page 3. Install
coupling per this manual using new gaskets and seals.

Periodic Lubrication

Removal & Installation of Spacer Assembly

Remove Spacer Hub

Remove all but two fasteners opposite each other. Loosen these
about one-quarter inch and tap them with a mallet to disengage
spacer from the shaft hub. Remove fasteners and spacer.

Insert Spacer Hub

The required frequency of lubrication is directly related to the type
of lubricant chosen and the operating conditions. Steelflex
couplings lubricated with common industrial lubricants, such as
those shown in Table 1, should be re-lubed annually. The use of
Falk Long Term Grease (LTG) will allow relube intervals to be
extended beyond five years. When relubing, remove both lube
plugs and insert lube fitting. Fill with recommended lubricant until
an excess appears at the opposite hole. CAUTION: Make

certain all plugs have been inserted after lubricating.

Coupling Disassembly & Grid Removal

Whenever it is necessary to disconnect the coupling, remove
the cover halves and grid. A round rod or screwdriver that will
conveniently fit into the open loop ends of the grid is required.
Begin at the open end of the grid section and insert the rod or
screwdriver into the loop ends. Use the teeth adjacent to each
loop as a fulcrum and pry the grid out radially in even,
gradual stages, proceeding alternately from side to side.

Insert fasteners as shown — do not allow them to protrude
beyond flange face. Insert spacer between hubs. Carefully
engage the hub register and then alternately tighten fasteners.
Torque to specifications in Table 2 on Page 6.

Rexnord Industries, LLC, Coupling Group 428-312
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone] April 2005
Fax: [phone] e-mail: [e-mail] web: www.rexnord.com Supersedes 4-99

Installation & Maintenance

Falk™ Steelflex

•

®

Spacer Couplings

(Page 6 of 7) Sizes 1020-1140 & 20-140

INSTALLATION & ALIGNMENT DATA

Maximum life and minimum maintenance for the coupling
and connected machinery will result if couplings are
accurately aligned. Coupling life expectancy between initial
alignment and maximum operating limits is a function of
load, speed and lubrication.

Values listed are based upon the use of standard
coupling components, standard assemblies and
cataloged allowable speeds.

Values may be combined for an installation or operating condition.
Example: 1060T max. operating misalignment is .016"

parallel plus .018" angular.
NOTE: For applications requiring greater misalignment, refer

application details to the Factory.
Angular misalignment is dimension X minus Y as illustrated

below.
Parallel misalignment is distance P between the hub center

lines as illustrated below.

Type T35

•

End float (with zero angular and parallel misalignment) is the
axial movement of the hubs(s) within the cover(s) measured
from “O” gap.

ANGULAR MISALIGNMENT

Y

X

PARALLEL OFFSET MISALIGNMENT

P

P

END FLOAT

FF

GAP

TABLE 2 — Misalignment & End Float

Installation Limits Operating Limits

Max

mm

Hub Gap

± 10%

Inch mm

Parallel

Offset-P

SIZE

Max

MaxmmMax

Inch

1020T .006 0.15 .003 0.08 .125 3 .012 0.30 .010 0.25 .210 5.33 100 11.3 120 4500 .06 0.03
1030T .006 0.15 .003 0.08 .125 3 .012 0.30 .012 0.30 .198 5.03 100 11.3 120 4500 .09 0.04
1040T .006 0.15 .003 0.08 .125 3 .012 0.30 .013 0.33 .211 5.36 100 11.3 120 4500 .12 0.05
1050T .008 0.20 .004 0.10 .125 3 .016 0.41 .016 0.41 .212 5.38 200 22.6 250 4500 .15 0.07
1060T .008 0.20 .005 0.13 .125 3 .016 0.41 .018 0.46 .258 6.55 200 23.6 440 4350 .19 0.09

1070T .008 0.20 .005 0.13 .125 3 .016 0.41 .020 0.51 .259 6.58 200 23.6 440 4125 .25 0.11
1080T .008 0.20 .006 0.15 .125 3 .016 0.41 .024 0.61 .288 7.32 200 23.6 825 3600 .38 0.17
1090T .008 0.20 .007 0.18 .125 3 .016 0.41 .028 0.71 .286 7.26 200 23.6 1640 3600 .56 0.25
1100T .010 0.25 .008 0.20 .188 5 .020 0.51 .033 0.84 .429 10.90 312 35 2940 2440 .94 0.43
1110T .010 0.25 .009 0.23 .188 5 .020 0.51 .036 0.91 .429 10.90 312 35 2940 2250 1.1 0.51

1120T .011 0.28 .010 0.25 .250 6 .022 0.56 .040 1.02 .556 14.12 650 73 4560 2025 1.6 0.74
1130T .011 0.28 .012 0.30 .250 6 .022 0.56 .047 1.19 .551 14.00 650 73 6800 1800 2.0 0.91
1140T .011 0.28 .013 0.33 .250 6 .022 0.56 .053 1.35 .571 14.50 650 73 8900 1650 2.5 1.14

Angular

(x-y)

Inch

Parallel

Offset-P

Max
Inch

Angular

(x-y)

MaxmmMax

Inch

Max

mm

End Float

Physical Limit

(Min)2xF

Inch mm

Fastener Tightening

Torque Values

Cover Flange

In. Series
Fasteners

(lb-in)

Metric

Fasteners

(Nm)

In. Series
Fasteners

(lb-in)

Allow

Speed

(rpm)

Lube Wt

lb kg

TABLE 3 — Coupling Cover Fastener Identification

SIZE

1020-1070T10

1080-1090T10

1100-1140T10

H

Older style covers, Sizes 1020T10 thru 1070T10 must utilize socket head cap screws and locknuts held by the cover.

Old Style New Style

SAE Grade 8

SAE Grade 8

SAE Grade 5

Inch Series Fasteners

H

5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone]April 2005

SAE Grade 8

SAE Grade 8

SAE Grade 5

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METRIC FASTENERS

Property Class 10.9

Property Class 10.9

Property Class 8.8

Rexnord Industries, LLC, Coupling Group428-312

Falk™ Steelflex®Spacer Couplings•Installation & Maintenance

Type T35

Sizes 1020-1140 & 20-140 (Page 7 of 7)

•

PARTS IDENTIFICATION

All coupling parts have identifying part numbers as shown
below. Parts are interchangeable between the 10 series and
1000 series spacer couplings. However, to utilize the higher
1000 series ratings, the 1000T — Blue Grid, Spacer Hubs,
Shaft Hubs and Hardware must be used. When ordering parts,
always SPECIFY SIZE and TYPE.

PARTS INTERCHANGEABILITY

Parts are interchangeable between Sizes 1020T and 20T,
1030T and 30T, etc. except as noted.

GRIDS — Size 1020T thru 1140T Steelflex couplings use blue
grids. Older models, 20T thru 140T, use orange grids.

MATCH MARK

MUST BE UP

FOR VERTICAL

APPLICATIONS

2

1

5

4

22

9

10

8

CAUTION: Blue grids may be used in all applications, but DO
NOT substitute orange grids for blue.

COVERS — CAUTION: DO NOT mix cover halves of different
designs. Sizes 1020T thru 1070T10 covers have been
manufactured in several different two-rib designs and 80T thru
140T covers have been manufactured with two and three ribs.

HARDWARE — Older style covers, Sizes 1020T10 thru
1070T10, utilized socket head cap screws with captured
locknuts. The new style covers use metric hex head cap screws
and unrestrained locknuts.

7

PART DESCRIPTION

1. Seal (T10)

6

1

2. Cover (T10)

3. T Hub

4. Grid

5. Gasket (T10)

6. Fasteners (T10)

7. Lube Plug

8. T31 Spacer Hub (Specify Length)

22

3

9. Shaft Hub

10. Flange Fastener

22. Setscrew (Size 1020T thru
1090T)

SHAFT HUB

SIZE, PART NUMBER
AND BORE

SPACER HUB

SIZE AND
PART NUMBER

PART NUMBER

SEAL

SIZE AND
PART NUMBER

SIZE

COVER

GRID

GASKET

SIZE

PART NUMBER

6

1030 T 10

COUPLING

SIZE

PRODUCT

CLASSIFICATION

T HUB

TYPE

MODEL

SEAL

SIZE AND
PART NUMBER

SIZE, PART NUMBER
AND BORE

ORDER INFORMATION

1. Identify part(s) required by

B

name above.

2. Furnish the following
information.

EXAMPLE:

Coupling Size: 1030
Coupling Type: T35
T Hub Bore: 1.375
T Hub Keyway: .312 x
.156
Shaft Hub Bore: 1.625
Shaft Hub Keyway: .375
x .188

Distance Between Shaft
Ends (BE): 3.5

3. Price parts from appropriate

Price List and discount sheet.

Rexnord Industries, LLC, Coupling Group 428-312
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone] April 2005
Fax: [phone] e-mail: [e-mail] web: www.rexnord.com Supersedes 4-99