Rexnord Falk MCF 1135 Installation & Maintenance

Falk® Rigid Moment Couplings • Installation & Maintenance

Type MCF • Size 1135 (Page 1 of 4)

How to Use This Manual

This manual provides detailed instructions on installation,
removal, maintenance, and part descriptions. Use the table
of contents below to locate required information.

Table of Contents

Introduction ................................Page 1

Installation ...........................Pages 1 thru 3

Removal ...................................Page 3

Annual Maintenance .........................Page 4

Part Descriptions ...........................Page 4

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

Introduction

This manual applies to Type MCF rigid moment couplings,
size 1135. The couplings are designed to shaft mount
a gear drive to a shaft. The couplings will generally be
mounted horizontally but they can be mounted vertically
as well. MCF couplings are available with interference fit
hubs with key (Type 2), keyless interference fit hubs with
hydraulic removal (Type 6), or a combination of Type 2 and
Type 6 hubs. See Figure 1.

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

WARNING: 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.

WARNING: Do not service the coupling without
first completely reading installation, alignment, and
maintenance instructions. The compressive fit between
the shaft and hub provides both support for the drive
assembly and transmits the torque. Failure to achieve
correct fit between the shaft and hub, and between the two
hubs, can result in damage to the system components and
has the potential to cause serious injury to personnel in the
immediate vicinity.

WARNING: Visual movement of the drive and assembly
is normal. The movement is due to shaft and coupling
connection runout. DO NOT restrain this movement; to do
so will adversely load the reducer low-speed shaft and the
connected shaft, and may result in shaft or hub failures.

HEX SOCKET
PIPE PLUG

PREVAILING
TORQUE
LOCKNUT

INTERFERENCE
FIT HUB WITH KEY

Figure 1 — TYPE 2 FEMALE HUB & TYPE 6 MALE HUB

HEX HEAD
CAP SCREW

KEYLESS
FIT HUB

5. If a key seat is present in the driven shaft, the edges of the
key seat should be broken with a file and free of burrs.

6. Mount hubs on shafts.
a. Clean all parts. Heat hub to between 450°F (232°C)

and 500°F (260°C) using an oven, torch, or an

induction heater.
WARNING: Do not use an oil bath to heat hub.
When an oxy-acetylene or blow torch is used, use an

excess acetylene mixture. Mark hub near the center

of its length in several places on hub body with

temperature-sensitive crayons, one 450°F (232°C)

and one 500°F (260°C) melt temperature. Direct

flame toward hub bore using constant motion to

avoid overheating an area.
b. Mount hub flush with face of shaft. Allow hub to cool

before proceeding. Refer to Figure 4.

IMPORTANT

CAREFULLY CLEAN

SHAFT & HUB BORE

& KEEP FREE OF

ANY GREASE

HUB

DEGREASE
FAC E

Installation

1. Thoroughly clean, degrease, and dry coupling hub
flange mounting faces, drive and driven shafts. Clean
with a non-flammable solvent. See Figure 2.

2. Check both shafts for runout to ensure shafts are not
bent. Refer to Figure 4.

3. Shaft ends must be chamfered to provide a lead for hub
mounting.

4. Shafts and bores must be free of burrs. Any rust or
corrosion in the interference area must be removed
before assembly.

Rexnord CP3-006
5555 S. Moorland Rd., New Berlin, WI 53151-7953 February 2015
Telephone: [phone] Fax: [phone] www.rexnord.com NEW

Figure 2

Installation & Maintenance • Falk Rigid Moment Couplings

(Page 2 of 4) Type MCF • Size 1135

SHAFT END
FLUSH WITH
FACE OF HUB

SHAFT NOT FLUSH
WITH END OF HUB

CORRECT

Figure 3

INCORRECT

c. Check that the hub is correctly positioned on the

shaft, then using dial indicators, check hub runout
as illustrated in Figure 4. Checking the hub runout
ensures correctness of hub mounting and will reduce
drive movement. Make sure runout values do not
exceed limits listed in Table 1. If runout is excessive,
remove hub following the removal instructions, and
carefuly remount the hub to the shaft.

INDICATOR #2

Table 2 — Flange Fastener Tightening

COUPLING

SIZE

1135 MCF 2.500 - 4 UNC x 11.00 12745 9400

Flange Fastener Size

Grade 8

(Inch)

9. Fasten the torque arm to the bed frame per gear drive
instructions and remove the lifting equipment. Rexnord
recommends that a loose, unrestraining safety sling
be attached to the bedplate and support structure to
support the drive in case of an emergency.

10. Using dial indicators per Figure 5, measure assembly

runout on driving and driven shafts. Runout values
should be within 0.005” (0.127 mm) TIR (total indicator
reading) to minimize drive movement. See Table 1.

11. Run the drive for a short period of time, and then

shut off and lockout motor. Recheck all fasteners for
specified torque.

12. The coupling installation is now complete.

WARNING: Install the warning nameplate supplied

with the coupling on the coupling guard or on some
other support structure near the coupling.

Flange Fastener Tightening

Torque Tolerance 5%

(Nm) (lb-ft)

INDICATOR #1

INDICATOR #3

Figure 4

Table 1 — Maximum Runouts (TIR) for Dial

Indicators – Inch (mm)

All

Sizes

7. With suitable lifting equipment, move the drive/motor
assembly into position, approximately parallel and in
line with the driven shaft using hub flanges as a guide.
Align fastener holes, and install and hand tighten one
flange fastener. Align hub registers and flange fastener
holes. Install all flange bolts finger tight.

8. Use a precision torque wrench and equally tighten all
opposing fasteners while allowing the drive assembly to
move as required to draw the flanges together (flexible
support). Continue tightening until flanges are mated
and all flange fasteners are torqued to values specified
in Table 2.

#1 #2 #3

.001 (0.025) .003 (0.076) .003 (0.076)

Figure 5

DIAL
INDICATOR

DIAL
INDICATOR

REVERSE DIAL INDICATOR METHOD

CP3-006 Rexnord

February 2015 5555 S. Moorland Rd., New Berlin, WI 53151-7953
NEW Telephone: [phone] Fax: [phone] www.rexnord.com

Falk® Rigid Moment Couplings • Installation & Maintenance

Type MCF • Size 1135 (Page 3 of 4)

Coupling Disconnection

WARNING: Do not disconnect torque arm or tie rod until
the low-speed coupling is completely disconnected.

1. With suitable equipment, remove the weight of the
drive assembly from the coupling and driven shafts. It
is necessary to make fine adjustments of position at
each of the bedplate lugs. The lifting slings should have
appropriate provisions for adjustment.

2. Lift the drive by the lifting lugs in the bedplate or wrap
slings around the assembly when a bedplate is not
used. Balance loads so drive is level and will not swing
down when the coupling is disconnected.

3. Loosen flange fasteners in sequence until all fasteners
have at least a 0.125” (3.175 mm) clearance under
the fastener heads. Remove all but one fastener near
the top of the flange. Separate the two flanges using
four 1/2–13UNC fasteners (not supplied with coupling)
inserted in the four jackscrew holes in the male register
flange. Continue backing off the last flange fastener as
the flanges are separated. When completely separated,
adjust the weight of the drive assembly until the weight
is off the last fastener. Carefully remove the last fastener.

4. Adjust the drive assembly position until all the weight of
the assembly is balanced. When the tie rod is no longer
bearing any of the weight, disconnect the tie rod. Slowly
lower the assembly to the ground.

Hub Removal

1. Type 2 Hubs
a. Thoroughly clean hubs of grease and solvents to

avoid combustion when heat is applied.

b. Assemble puller as shown in Figure 6. Check to

make sure puller has enough stroke to pull the hub
off. Be sure to adequately support both the hub and
puller assembly using metal cable slings. Reference
Table 3 for the hub puller bolt hole mounting pattern.

c. Heat the hub evenly with a rosebud torch to

approximately 400° to 500°F (204° to 260°C) while
applying pressure to the puller. The temperature may
be measured with a heat-sensitive crayon. Apply
puller pressure until the hub clears the shaft.

2. Type 6 Hubs
a. Mount a hydraulic hub puller (see Figure 7) on the

end of the hub with a pressure rod against the shaft
end. Reference Table 3 for the hub puller bolt hole
mounting pattern. The puller must have an axial
travel equal to or greater than the hub-to-shaft bore
length. Be sure to adequately support both the hub
and puller assembly using metal cable slings.

b. Mount the hydraulic expansion fittings to the hub

and high-pressure hydraulic pump. Pressurize the
hub-to-shaft interface until oil is oozing out between
bore and shaft, or to the removal pressure called
out in Table 4. Apply axial removal force at the same
time as pressurizing the hub. Shut off pressure (item
8 of Figure 7) prior to the groove being exposed
beyond the shaft end.

Table 3 — Type 2 & Type 6 Hub Puller Bolt

COUPLING

SIZE

1135 MCF 25.00 (635) 2.000 - 4.5UNC

Flange Face Puller Bolt Holes

UNC Tap (2 x Dia Deep)

BC - Inch (mm) UNC Tap (4 @ 180°)

Table 4 — Type 6 Hub Removal Pressure

COUPLING

SIZE

1135 MCF 138 - 152 20,000 - 22,000

ALLOR STEEL
PLATE

WITH OR
WITHOUT
ADJUSTING
SCREW

GAUGE

Figure 6 — BASIC TYPE 2 HUB REMOVAL EQUIPMENT

Maximum Recommended Pressure At Hub Bore

HYDRAULIC
CYLINDER

When Dismounting Hub

(MPa) (psi)

METAL CABLE SLINGS
TO SUPPORT HUB
AND PULLER

SHAFT

BAR
STOCK

HAND PUMP OR
HYDRAULIC PUMP

TORCH

COUPLING
HUB

TORCH

Rexnord CP3-006
5555 S. Moorland Rd., New Berlin, WI 53151-7953 February 2015
Telephone: [phone] Fax: [phone] www.rexnord.com NEW

Installation & Maintenance • Falk Rigid Moment Couplings

(Page 4 of 4) Type MCF • Size 1135

Annual Maintenance

Whenever the equipment is down for general maintenance

COUPLING HUB

SHAFT

or service, recheck the tightening torque of flange
fasteners. Tighten fasteners if necessary. For extreme
or unusual operating conditions, check coupling more
frequently.

Part Descriptions

Part descriptions are shown below. In addition, all coupling
parts have identifying part numbers. When ordering parts,
always SPECIFY SIZE and TYPE of hub, and par t number.

MCF COUPLING SHOWN WITH A TYPE 6 MALE JUB &
A TYPE 2 FEMALE HUB

LOW PRESSURE

PUMP VALVES

3

6

1

2

HIGH PRESSURE

Figure 7 — BASIC TYPE 6 HUB REMOVAL EQUIPMENT

(1) Hydraulic hub puller. This is a hydraulic ram that is

threaded into the puller plate (9).

(2) Low-pressure pump. The pump should have a 5000

psi (34.5 MPa) maximum pressure rating.

(3) Low-pressure gauge. The gauge should have a large

enough face for accurate readings, with a maximum
pressure rating of psi 5000 psi (34.5 MPa).

(4) Low-pressure flex line and fittings. At 5000 psi

(34.5 MPa), this line can be flexible, which makes
it more convenient when hooking up the system.
Appropriate end fittings and a gauge mounting
snubber are also needed.

(5) High-pressure pump. The pump should have a

40,000 psi (276 MPa) maximum pressure rating.

(6) High-pressure gauge. The gauge should have a

large enough face for accurate readings, with a
maximum pressure rating of 40,000 psi (276 MPa).

(7) Rigid high-pressure line and fittings. At 40,000

psi (276 MPa), a rigid steel, high-pressure line with
special high-pressure connectors are mandatory.
A high-pressure tee and at least 2 high-pressure
elbows are needed to mount the gauge and for
routing the line.

(8) High-pressure valve. This valve is used to shut the

pressure off at this end of the hub as it comes off
the shaft.

(9) Puller plate. This plate is threaded in the center to

accept the hydraulic ram. It also has holes drilled in
it to line up with the tapped puller holes in the hub
(See Table 3).

(10) Puller rods. These rods are usually threaded full

length. They connect the hub to the puller plate
(Reference Table 3 for thread size).

(11) Nuts. These nuts position the puller plate.

4

5

PART DESCRIPTIONS

1. Male Pilot Hub (Type 6)

2. Female Pilot Hub (Type 2)

3. Flange Bolt (Hex Head Cap Screw Grade 8)

4. Flange Nut (Locknut)

5. Hub Puller Bolt Holes

6. Socket Head Plug (BSP, not NPT)

CP3-006 Rexnord

February 2015 5555 S. Moorland Rd., New Berlin, WI 53151-7953
NEW Telephone: [phone] Fax: [phone] www.rexnord.com