Falk® Continuous Sleeve Gear Couplings • Installation and Maintenance
Types GC02/05
• Sizes 1010 thru 1035 (Page 1 of 7)
How To Use This Manual
This manual provides detailed instructions on installation,
maintenance and parts identification for Falk Lifelign
couplings, Types GC02 & 05. Use the table of contents
below to locate required information.
Installation & Alignment Instructions
Annual Maintenance & Disassembly
Installation & Alignment Data
Parts Identification & Parts Interchangeability
...................Pages 3-5
................Pages 4 & 5
...................................Page 6
........ Page 7
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND
TROUBLE FREE SERVICE.
INTRODUCTION
This manual applies to standard coupling Types GC02 & 05.
For couplings furnished with special features, refer to assembly drawing furnished with coupling for proper assembly
arrangement and any additional installation or maintenance
requirements. These couplings are designed to operate in
either the horizontal or vertical position without modification.
However, for vertical operation, assemble Type GC02 cou
pling so retainer ring is up on the high side. For Type GC05
the addition of an elastomer gap disc is required in the lower
coupling.
IMPORTANT: When gear couplings are mounted on a horizon
tal floating shaft, use a gap disc in coupling sizes indicated.
Where limited end float is required or where sleeve bearing
motors are used, consult the Factory.
CAUTION: Consult applicable local and national safety codes
for proper guarding of rotating members. Observe all safety
rules when installing or servicing couplings.
WARNING: Lockout starting switch of prime mover and remove
all external loads from drive before installing or servicing
couplings.
LUBE FITTINGS
Sleeves have 1/8 NPT lube holes for sizes 1010GC thru
1035GC. Use a standard grease gun and lube fittings.
Type GC02 Type GC05
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).
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 tooth mesh area of gear couplings resulting in premature
mesh 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 NLGI #1/2 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 allow the
lubricant to be used for relatively long periods of time.
Although LTG grease is compatible with most other coupling
greases, the mixing of greases may dilute the benefits of LTG.
CAUTION: Do not use LTG in bearings. Do not use LTG for
low speed applications. Refer to Table 4 for coupling speed
range of LTG grease.
Packaging
14 oz. (0,4 Kg) CARTRIDGES — Individual or case lots of 10
or 30.
35 lb. (16 Kg) PAILS, 120 lb. (54 Kg) KEG & 400 lb. DRUMS.
LUBRICATION
Adequate lubrication is essential for satisfactory operation. Because of its superior lubricating characteristics and low centrifuge
properties, Falk Long Term Grease (LTG) is highly recommended.
Gear couplings initially lubricated with Falk Long Term Grease
(LTG) will not require re-lubrication for up to three years.
The use of general purpose grease requires re-lubrication
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.
Rexnord 458-120
5555 S. Moorland Rd., New Berlin, WI 53151-7953 January 2005
Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com Supersedes 06-01
Specifications — Falk LTG (Long Term Grease)
TEMPERATURE RANGE — –20°F (–29°C) to 250°F (121°C).
Minimum pump = 20°F (–7°C).
MINIMUM BASE OIL VISCOSITY — 3300SSU (715cSt) @ 100°F
#D4425–84 (Centrifuge Test) — K36 = 2/24 max., 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 @ 77°F (25°C).
Falk Continuous Sleeve Gear Couplings • Installation and Maintenance
(Page 2 of 7) Types GC02/05
• Sizes 1010 thru 1035
DROPPING POINT — 350°F (177°C) minimum.
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.
General Purpose Grease
Bi-annual Lubrication — The following specifications and
lubricants for general purpose grease apply to gear couplings
that are lubricated bi-annually and operate within ambient tem
peratures of –30°F (–34°C) to 200°F (93°C). For temperatures
beyond this range, consult the Factory. For normal service, use
a NLGI #1 extreme pressure (EP) grease EXCEPT when the
coupling speed is less than the minimum specified in Table 4,
Page 6. At these lower speeds, use a NLGI #0 extreme pressure
(EP) grease. When one or more gear couplings in an application
require NLGI #0 grease, the same grease may be used in all of
the couplings. DO NOT use cup grease.
If coupling leaks grease, is exposed to extreme temperatures,
excessive moisture or experiences frequent reversals or axial
movements; more frequent lubrication may be required.
Lubricants listed in Tables 1,2&3are typical products only and
should not be construed as exclusive recommendations.
Specifications — General Purpose
Coupling Lubricants
COUPLING SPEED RANGE — See Table 4.
TEMPERATURE RANGE — –30°F to +200°F(–34°C to +93°C)
WORKED PENETRATION AT 77°F(25°C) —
NLGI #1 ........310-340 (See Table 1)
NLGI #0 ........355-385 (See Table 2)
DROPPING POINT — 300°F(149°C) or higher
TEXTURE — Smooth or fibrous
MINIMUM TIMKEN O.K. LOAD — 30 lbs.
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 with EP additives.
INACTIVE — Must not corrode steel or cause swelling or
deterioration of synthetic seals.
Oil Lubrication
EP oils may be a more effective lubricant than grease when
the required coupling speed is one half of the minimum speed
range of NLGI #1 grease listed in Table 4 (Minimum rpm ÷ 2).
Oil lubricated couplings must be sealed to prevent leakage, i.e.
keyways, etc. Couplings must be drained and refilled with new
oil every six months for operating temperatures up to 160°F
(71°C) and every three months for couplings operating at tem
peratures of 160°F (71°C) up to 200°F (93°C). For temperatures
beyond this range, consult the Factory. The minimum operating
temperature must not be lower than the pour point of the oil.
The specified amount of grease listed in Table 4, Page 6, is in
ounces and also applies to the volume of oil.
-
-
Specifications
Type: Mild EP gear oil that meets AGMA Speci-
fications 250.04.
Grade: AGMA #8EP (ISO VG 680).
Viscosity: 612-748 cSt @ 104°F (40°C).
Pour Point: 20°F (–7°C) Maximum.
Must not corrode steel or swell or deteriorate synthetic seals.
TABLE 1 — NLGI #1 Grease
ManufacturerLubricant
Amoco Oil Co.
BP Oil Co.
Chevron U.S.A., Inc.
Citgo Petroleum Cor p
Conoco Inc.
Exxon Company, U.S.A.
Imperial Oil Ltd.
Kendall Refining Co.
Keystone Div., Pennwalt Corp.
Lyondell Lubricants
Mobil Oil Cor p.
Petro-Canada Products
Phillips 66 Co.
Shell Oil Co.
Shell Canada Ltd.
Sun Oil Co.
Texaco Lubricants
Unocal 76 (East & West)
Rykon Grease #1 EP
Energrease LS-EP1
Dura-Lith EP1
Premium Lithium Grease EP1
EP Conolith Grease #1
Lidok EP1
Ronex EP1
Lithium Grease L-416
Zeniplex-1
Litholine Complex EP1
Mobilux EP1
Multipurpose EP1
Philube Blue EP
Alvania EP Grease 1
Alvania Grease EP1
Sun Prestige 741 EP
Multifak EP1
Unoba EP1
Rykon Premium Grease 0
EP Energrease LS-EP 0
Dura-Lith EP 0
Premium Lithium Grease EP 0
EP Conolith Grease #0
Lidok EP 0
Unirex EP 0
Lithium Grease L-406
Zeniplex-0
Mobilux EP 0
Multipurpose Lotemp EP Grease
Philube Blue EP
Alvania EP Grease RO
Alvania Grease EPW
Sun Prestige 740 EP
Multifak EP 0
Unoba EP 0
TABLE 3 — Oil Lubricants
ManufacturerLubricant
Amoco
Chevron, U.S.A.
Exxon Co., U.S.A.
Gulf Oil Co.
Mobil Oil Co.
Shell Oil Co.
Texaco Inc.
Union Oil Co. of Calif.
Permagear EP 160
NL Gear Compound 680
Spartan EP680
EP Lubricant HD 680
Mobilgear 636
Omala Oil 680
Meropa 680
Extra Duty NL Gear Lube 8EP
458-120 Rexnord
January 2005 5555 S. Moorland Rd., New Berlin, WI 53151-7953
Supersedes 06-01 Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com
Lubricants listed may not be suitable for use in the food processing
industry; check with lube manufacturer for approved lubricants.
Falk Continuous Sleeve Gear Couplings • Installation and Maintenance
Only standard mechanics tools, spacer bar, feeler gauge,
straight edge and a dial indicator are required to install Falk gear
couplings. Clean all parts using a non-flammable solvent. Check
hubs, shafts and keyways for burrs. DO NOT heat clearance fit
hubs. Use a lubricant that meets the specifications on Page 1
or 2. Pack sleeve teeth with grease and lightly coat seals with
grease BEFORE assembly. The required amount of grease is
listed in Table 4.
Interference Fit Hubs —
Unless otherwise specified, gear couplings
are furnished for an interference fit without setscrews. Heat hubs
to 275°F(135°C) using an oven, torch, induction heater or an oil
bath.
CAUTION: 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.
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 connected
meet manufacturers’ requirements. Check for soft foot. The use
stainless steel shims is recommended. Measuring misalignment
of
and positioning equipment within alignment tolerances is simplified
with an alignment computer. These calculations can also be done
graphically or mathematically, and allow the incorporation of “cold
offsets”, which will compensate for shaft position changes due to
thermal growth.
1 — Mount Hubs, Sleeve, Seals & Retainer Ring
Place the sleeve WITH seal ring in sleeve seal groove on shaft
BEFORE mounting flex hub #1. Mount flex hub #1 onto shaft,
as shown above, so that the face is flush with the end of the
shaft. Place retainer ring and proper size seal onto other shaft
end. Mount flex hub #2, as shown, so that the face is flush with
the end of the shaft. Allow hubs to cool before proceeding.
Seal keyways to prevent leakage. Install seal in flex hub #2
seal groove. Inser t setscrews (if required) and tighten. Position
equipment in approximate alignment with approximate hub
gap specified in Table 4 on Page 6.
ALWAYS MEASURE
TO SAME DEPTH
GAP
2 — Gap & Angular Alignment
Use a spacer bar equal in thickness to gap specified in Table
4. Insert bar, as shown above, to same depth at 90° intervals
and measure clearance between bar and hub face with feel
ers. The difference in minimum and maximum measurements
must not exceed the INSTALLATION ANGULAR limit speci
fied in Table 4.
-
-
BI-ANNUAL MAINTENANCE
Re-lubricate coupling if using general purpose greases. If
coupling leaks grease, is exposed to extreme temperatures,
excessive moisture or frequent rever sals; more frequent
lubrication may be required.
TYPE GC02 HORIZONTAL
COUPLING INSTALLATION
NOTE: SHORTER SHANK
TOWARD GAP END
NOTE:
SLEEVE
SEAL END
Rexnord 458-120
5555 S. Moorland Rd., New Berlin, WI 53151-7953 January 2005
Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com Supersedes 06-01
FLEX HUB #1 FLEX HUB #2
NOTE:
FLUSH HERE
RETAINER
RING
SEAL IN
GROOVE
3 — Offset Alignment
Align so that a straight edge rests squarely on both hubs as
shown above and also at 90° inter vals. Check with feelers. The
clearance should not exceed the INSTALLATION OFFSET limit
specified in Table 4. Tighten foundation bolts and repeat Steps
2 and 3. Realign coupling if necessary. Use a dial indicator if
hub extension is too short for accurate use of a straight edge.
Refer to Step 4 on Page 5 for procedure.
Falk Continuous Sleeve Gear Couplings • Installation and Maintenance
Remove pipe plugs from sleeve if present. Slide sleeve to
engage hub #2. Separate coils of retainer ring and insert ring
end into sleeve retainer ring groove. Keep the coils separated
and spiral turn each progressively into the groove until the ring
snaps into place. Check ring for proper seating.
Fill with recommended grease until an excess appears at the
open hole; then insert plug.CAUTION: Make certain all lube
plugs are inserted after lubricating.
OFFSET MISALIGNMENT ANGULAR MISALIGNMENT
ANNUAL MAINTENANCE
For extreme or unusual operating conditions, check coupling
more frequently.
1
.
The alignment can be checked without disassembling the coupling
as shown in the above illustrations. Mount dial indicator on hub or
shaft and indicate surface shown by rotating shafts with coupling.
The offset TIR value divided by 2, must not exceed the offset
operating limit shown in Table 4. The angular TIR value, must
not exceed the angular operating limit shown in Table 4. Realign
equipment to within the installation limits if either operating limit
value is exceeded.
2. Inspect seal ring to determine if replacement is required.
3. Re-lubricate coupling if using general purpose grease.
DISASSEMBLY
Locate the radius removal notch on face of retainer ring. With screw
driver or similar tool, pry end of ring down and out of groove. Wedge
tool behind notch and pry ring from sleeve using spiral motion. Slide
sleeve off hubs.
NOTE:
SLEEVE
SEAL END
FLEX HUB #1 PILOT
NOTE:
FLUSH HERE
HUB
SEAL IN
GROOVE
1 — Mount Hubs, Sleeve, Seals & Retainer Ring
Place the sleeve WITH seal ring in sleeve seal groove on shaft
BEFORE mounting flex hub #1. Mount flex hub #1 onto shaft,
as shown above, so that the face is flush with the end of the
shaft. Place retainer ring and proper size seal onto other shaft
end. Mount pilot hub, as shown above, so that the face is flush
with the end of the shaft. Allow hubs to cool before proceed
ing. Seal keyways to prevent leakage. Install seal in pilot hub
seal groove. Inser t setscrews (if required) and tighten. NOTE:
Pilot hub or flex hub #1 (as illustrated below) can be mounted
on floating shaft.
V-BLOCKS
2 — Position First Drive & Floating Shaft
drive most difficult to move to true level and bolt it in place. Set
the floating shaft on V-blocks. Then align the floating shaft to
the fixed drive.
TO SAME DEPTH
ALWAYS MEASURE
V-BLOCKS
GAP
-
Set the
458-120 Rexnord
January 2005 5555 S. Moorland Rd., New Berlin, WI 53151-7953
Supersedes 06-01 Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com
3 — Gap & Angular Alignment
Use a spacer bar equal in thickness to gap specified in Table 4.
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 INSTALLATION ANGULAR limit specified in Table 4.
Falk Continuous Sleeve Gear Couplings • Installation and Maintenance
Types GC02/05
V-BLOCKS
• Sizes 1010 thru 1035 (Page 5 of 7)
4 — Offset Alignment
Mount dial indicator on hub or shaft and indicate surface shown
by rotating hub with indicator. The offset TIR value divided by
2, must not exceed the INSTALLATION OFFSET limit specified
in Table 4. For optional straight edge method, refer to Step 3 on
Page 3. Rest straight edge on pilot hub tooth tip and check with
feelers at flex hub #1 tooth tip at 90° intervals.
V-BLOCKS
X X
ANNUAL MAINTENANCE
For extreme or unusual operating conditions, check coupling
more frequently.
1. The alignment can be checked without disassembling the
coupling as shown in the above illustration. Measure dis
tance “X” using a depth MIC. The difference in minimum
and maximum measurements taken at each coupling
end, must not exceed the angular operating limit shown
in Table
4. Realign equipment to within the installation limit if the
operating limit is exceeded.
2. Inspect seal ring to determine if replacement is required.
3. Re-lubricate coupling if using general purpose grease.
-
DISASSEMBLY
Safely support floating shaft. Locate the radius removal notch
on face of retainer ring. With screw driver or similar tool,
pry end of ring down and out of groove. Wedge tool behind
notch and pry ring from sleeve using spiral motion. Slide
sleeve off hubs.
5 — Position Second Drive
Position and align second drive to the floating shaft per
Steps 3 & 4. DO NOT move the floating shaft. Bolt drive in
place and recheck alignment & gap. Realign if necessary.
6 —Insert Gap Discs, Assemble Sleeves,
Retainer Rings & Lubricate
Remove pipe plugs from sleeve if present. Insert gap discs
between hub faces for Sizes 1025GC thru 1035GC. Slide
sleeve to engage pilot hub. Separate coils of retainer ring
and insert ring end into sleeve retainer ring groove. Keep the
coils separated and spiral turn each progressively into the
groove until the ring snaps into place. Repeat procedure for
other coupling end. Check ring for proper seating. Remove
V-blocks supports.
Fill with recommended grease until an excess appears at
the open hole; then insert plug. Continue procedure for other
coupling end.CAUTION: Make certain all lube plugs are
inserted after lubricating.
Rexnord 458-120
5555 S. Moorland Rd., New Berlin, WI 53151-7953 January 2005
Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com Supersedes 06-01
Falk Continuous Sleeve Gear Couplings • Installation and Maintenance
TABLE 4 — Installation & Alignment Data For Types GC02 & 05— Dimensions
Inches (Metric – mm)
COUPLING SIZE1010G1015G1020G1025G1030G1035G
Gap ±10%G02 & 05
Offset Max
Installation LimitsG02 & 05
Angular Max
Offset Max
Operating Limits
†G02
Angular Max
Operating Limits
Per Cplg
Coupling Speed
Range (rpm)
†
G02&05
G05Angular Max
NLGI #0 Grease-Max.
Falk LTG &
NLGl #1 Grease
‡530043003700330029002600
Min1030700550460380330
Allow.530043003700330029002600
G02
Grease - ounces
(g)
Refer to Selection Guide for maximum bores and Manual 427-108 for reboring instr uctions.
†
Flexible couplings are designed to accommodate changes in operating conditions. Coupling life expectancy between initial alignment and maximum operating limits
is a function of load, speed and lubrication. Application requirements in excess of
‡Couplings with NLGI #0 grease may be operated at any speed between zero and the maximum shown.
G05
.125
(3)
.0015
(.0381)
.003
(.0762)
.005
(.127)
.035
(.889)
.035
(.889)
.4
(11.3)
.3
(8.50)
3/4° misalignment per flex-half coupling should be referred to Factory for review.
.125
(3)
.0015
(.0381)
.007
(.178)
.008
(.203)
.045
(1.14)
.045
(1.14)
1.0
(28.3)
.7
(19.8)
.125
(3)
.0015
(.0381)
.009
(.229)
.009
(.229)
.054
(1.37)
.054
(1.37)
1.5
(42.5)
1.1
(31.2)
.188
(5)
.002
(.0508)
.011
(.279)
.012
(.305)
.067
(1.70)
.067
(1.70)
2.3
(65.2)
1.8
(51.0)
.188
(5)
.002
(.0508)
.013
(.330)
.014
(.356)
.079
(2.01)
.079
(2.01)
3.3
(93.6)
2.6
(73.7)
.250
(6)
.003
(.0762)
.013
(.330)
.016
(.406)
.092
(2.34)
.092
(2.34)
4.3
(122)
3.4
(96.4)
458-120 Rexnord
January 2005 5555 S. Moorland Rd., New Berlin, WI 53151-7953
Supersedes 06-01 Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com
Falk Continuous Sleeve Gear Couplings • Installation and Maintenance
Coupling parts have identifying size and part numbers as illustrated below. When ordering parts, always
SPECIFY SIZE, TYPE, HUB BORE, KEYWAY and PART
NUMBER found on each item.
Contact your Rexnord Distributor or Rexnord for price
and availability.
Rexnord 458-120
5555 S. Moorland Rd., New Berlin, WI 53151-7953 January 2005
Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com Supersedes 06-01
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