Steelflex® Couplings • Installation and Maintenance

Type F • Sizes 3 thru 190 (Page 1 of 5)

How To Use This Manual Falk Long Term Grease (LTG) was developed specifically for
couplings. It resists separation of the oil and thickener. The
This manual provides detailed instructions on maintenance,
consistency of Falk LTG changes with operating conditions. As
lubrication, installation, and parts identification. Use the table
manufactured it is an NLGI #1/2 grade. Working of the
of contents below to locate required information.
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.
Table of Contents
LTG is highly resistant to separation, easily outperforming all
Introduction . . . . . . . . . . . . . . . . . . . . . Page 1
other lubricants tested. The resistance to separation allows the
Limited End Float . . . . . . . . . . . . . . . . . . Page 1 lubricant to be used for relatively long periods of time.
Installation & Alignment Data . . . . . . . . . . . . Page 2
Steelflex couplings initially lubricated with LTG will not require
Lubrication . . . . . . . . . . . . . . . . . . . Pages 1-2 re-lubrication until the connected equipment is stopped for
Installation Instructions . . . . . . . . . . . . . . Pages 2-4 servicing. If a coupling leaks grease, is exposed to extreme
Annual Maintenance, Relube & Disassembly . . . . . Page 4 temperatures, excessive moisture, or experiences frequent
Parts Identification & Parts Interchangeability . . . . . Page 5 reversals, more frequent lubrication may be required.
Although LTG grease is compatible with most other coupling
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS greases, the mixing of greases may dilute the benefits of LTG.
MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE
FREE SERVICE. USDA Approval
LTG has the United States Department of Agriculture Food Safety
INTRODUCTION & Inspection Service approval for applications where there is no
This manual applies to Sizes 3F thru 190F Falk SteelfIex possibility of contact with edible products. (H-2 ratings).
Couplings. These couplings are designed to operate in either CAUTION: Do not use LTG in bearings.
the horizontal or vertical position without modification.
CAUTION: Consult applicable local and national safety Specifications — Falk LTG
codes for proper guarding of rotating members. Observe all The values shown are typical and slight variations are permissible.
safety rules when installing or servicing couplings. During
assembly, seal keyways of vertical couplings and oil lubricated AMBIENT TEMPERATURE RANGE — -20°F (-29°C) to 250°F
couplings to prevent leakage. (121°C). Min. Pump = 20° F (-7° C).
MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @
WARNING: Lockout starting switch of prime mover and remove 100°F (38°C).
all external loads from drive before installing or servicing couplings.
THICKENER — Lithium & soap/polymer.
LIMITED END FLOAT CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM
#D4425 (Centrifuge Test) — K36 = 2/24 max., very high
When electric motors, generators, engines, compressors, and resistance to centrifuging.
other machines are fitted with sleeve or straight roller
bearings, limited axial end float kits are recommended for NLGI GRADE (ASTM D-217) — 1/2
protecting the bearings. Falk Steelflex couplings are easily MINIMUM DROPPING POINT — with 60 stroke worked
modified to limit end float; refer to Manual 438-820 for penetration value in the range of 320 to 365 —
instructions. 350°F (177°C) min.
MINIMUM TIMKEN O.K. LOAD — 40 lb.
LUBRICATION ADDITIVES — Rust and oxidation inhibitors that do not
Adequate lubrication is essential for satisfactory operation. corrode steel or swell or deteriorate synthetic seals.
Column 2 provides a list of typical lubricants and specifications for
general purpose and long term greases. Because of its superior Packaging
lubricating characteristics and low centrifuge properties, Falk Long 14 oz (0,4 kg) CARTRIDGES — Individual or case lots of 10 or 60.
Term Grease (LTG) is highly recommended. The use of general
purpose grease requires re-lubrication of the coupling at least 35 lb (16 kg) PAIL, 120 lb (54 kg) KEG & 400 lb (181 kg) DRUMS.
annually.
General Purpose Grease
Long Term Grease (LTG) Annual Lubrication — The following specifications and
The high centrifugal forces encountered in couplings separate lubricants for general purpose grease apply to Falk Steelflex
the base oil and thickener of general purpose greases. Heavy couplings that are lubricated annually and operate within
thickener, which has no lubrication qualities, accumulates ambient temperatures of 0°F to 150°F (-18°C to 66°C). For
in the grid-groove area of Steelflex couplings resulting in temperatures beyond this range (see Table 1), refer to Falk.
premature hub or grid failure unless periodic lubrication cycles If a coupling leaks grease, is exposed to extreme
are maintained. temperatures, excessive moisture, or experiences frequent
reversals, more frequent lubrication may be required.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 438-110

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 December 2002
Fax: 414-937-4359 e-mail: [email protected] web: www.falkcorp.com Supersedes 10-90
Installation and Maintenance • Steelflex Couplings ®

(Page 2 of 5) Type F • Sizes 3 thru 190 a good name in industry

Specifications — General Purpose Coupling TABLE 1 — General Purpose Greases

Lubricants Ambient Temperature 0°F to 150°F -30°F to 100°F
The values shown are typical and slight variations are Range (-18°C to 66°C) (-34°C to 38°C)
permissible. Manufacturer Lubricant † Lubricant †
DROPPING POINT — 300°F (149°C) or higher. Amoco Oil Co. Amolith Grease #2 Amolith Grease #2
BP Oil Co. Energrease LS-EP2 Energrease LS-EP1
CONSISTENCY — NLGI No. 2 with 60 stroke worked Chevron U.S.A. Inc. Dura-Lith EP2 Dura-Lith EP1
penetration value in the range of 250 to 300. Citgo Petroleum Corp. Premium Lithium Grease EP2 Premium Lithium Grease EP1
Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2
SEPARATION AND RESISTANCE — Low oil separation rate Exxon Company, USA Unirex EP2 Unirex EP2
and high resistance to separation from centrifuging. E.F. Houghton & Co. Cosmolube 2 Cosmolube 1
Imperial Oil Ltd. Unirex EP2 Unirex EP2
LIQUID CONSTITUENT — Possess good lubricating properties Kendall Refining Co. Lithium Grease L421 Lithium Grease L421
equivalent to a high quality, well refined petroleum oil. Keystone Div. (Pennwalt) 81 EP-2 81 EP-1
Lyondell Petrochemical Litholine H EP 2 Grease Litholine H EP 2 Grease
INACTIVE — Must not corrode steel or cause swelling or
(ARCO)
deterioration of synthetic seals. Mobil Oil Corp. Mobilux EP111 Mobilith AW1
CLEAN — Free from foreign inclusions. Petro-Canada Products Multipurpose EP2 Multipurpose EP1
Phillips 66 Co. Philube Blue EP Philube Blue EP
Shell Oil Co. Alvania Grease 2 Alvania Grease 2
General Purpose Greases Meeting Falk Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2
Specifications Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EP
Texaco Lubricants Starplex HD2 Multifak EP2
Lubricants listed below are typical products only and should Unocal 76 (East & West) Unoba EP2 Unoba EP2
not be construed as exclusive recommendations. 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 Falk Corporation.
† Lubricants listed may not be suitable for use in the food processing industry; check
with lube manufacturer for approved lubricants.

TABLE 2 — Installation & Alignment Data Q

Cover Fastener
Installation n Operating
Approximate Hub Gap Tightening
Grid Alignment Alignment
Lubricant "10% Torque Values
Allow. Limits Limits
Inch Series
CPLG
Speed
SIZE No.
rpm No. Offset Offset Angular Angular Offset Offset Angular Angular
Segments
lb kg Inch mm of Max Max Max Max Max Max Max Max lb-in Nm
Per
Layers Inch mm Inch mm Inch mm Inch mm
Layer
3 6000 .063 0,03 .125 3 1 1 .004 0,10 .003 0,08 .008 0,20 .008 0,20 100 11,3
4 6000 .094 0,04 .125 3 1 1 .005 0,13 .003 0,08 .010 0,25 .009 0,23 100 11,3
5 6000 .125 0,06 .125 3 1 1 .005 0,13 .003 0,08 .010 0,25 .010 0,25 100 11,3
6 6000 .188 0,09 .125 3 1 1 .005 0,13 .004 0,10 .010 0,25 .012 0,31 100 11,3
7 6000 .188 0,09 .125 3 1 2 .005 0,13 .005 0,13 .010 0,25 .014 0,36 100 11,3
8 5000 .313 0,14 .125 3 1 2 .007 0,18 .005 0,13 .015 0,38 .016 0,41 200 22,6
9 4500 .375 0,17 .125 3 1 2 .007 0,18 .006 0,15 .015 0,38 .018 0,46 200 22,6
10 3750 .375 0,17 .188 5 1 2 .010 0,25 .007 0,18 .020 0,51 .020 0,51 200 22,6
11 3600 .500 0,23 .188 5 1 2 .010 0,25 .007 0,18 .020 0,51 .022 0,56 200 22,6
12 3600 .625 0,28 .188 5 2 2 .010 0,25 .008 0,20 .020 0,51 .024 0,61 200 22,6
13 2700 .750 0,34 .188 5 2 2 .010 0,25 .009 0,23 .020 0,51 .028 0,71 200 22,6
14 2500 1.500 0,68 .250 6 2 2 .011 0,28 .010 0,25 .022 0,56 .031 0,79 350 39,5
15 2400 1.500 0,68 .250 6 2 2 .011 0,28 .011 0,28 .022 0,56 .032 0,81 280 31,6
16 2300 2.0000 0,91 .250 6 2 2 .011 0,28 .012 0,31 .022 0,56 .036 0,91 280 31,6
17 2200 2.750 1,25 .250 6 2 2 .011 0,28 .014 0,36 .022 0,56 .041 1,04 280 31,6
18 2100 3.250 1,47 .250 6 2 3 .011 0,28 .015 0,38 .022 0,56 .046 1,17 570 64,4
190 2000 8.000 3,63 .250 6 2 4 .011 0,28 .017 0,43 .022 0,56 .051 1,30 570 64,4
Q Refer to Selection Guide for maximum bores and Engineering Sheet 427-108 for re-boring instructions
n Flexible couplings are designed to accommodate changes in operating conditions. Coupling life expectancy between initial alignment and operating alignment limits
is a function of load, speed and lubrication. Application requirements in excess of the operating alignment limits shown, must be referred to Falk for review.

438-110 The Falk Corporation, P.O. Box 492, Zip 53201-0492

December 2002 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 10-90 Fax: 414-937-4359 e-mail: [email protected] web: www.falkcorp.com
 Steelflex® Couplings • Installation and Maintenance
®

Type F • Sizes 3 thru 190 (Page 3 of 5)

INSTALLATION OF TYPE F
STEELFLEX 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.
CLEARANCE FIT HUBS — Clean all parts using a
non-flammable solvent. Check hubs, shafts, and keyways for
burrs. Do not heat clearance fit hubs. Install keys, mount hubs
with flange face flush with shaft ends or as otherwise specified
and tighten setscrews. 1— Mount Cover, Seal Ring & Hub on Shaft
INTERFERENCE FIT HUBS — Furnished without setscrews. Heat Lightly coat seals with grease and install in covers. Place covers
hubs to 275°F (135°C) using an oven, torch, induction heater, or on shafts BEFORE mounting hubs. Mount hubs on shafts with
an oil bath. To prevent seal damage, DO NOT heat hubs beyond a hub faces flush with shaft ends. Seal keyways. Tighten set screws
maximum temperature of 400°F (205°C). when furnished.
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
2 — Gap & Angular Alignment
how you install and maintain them. Before installing couplings,
make certain that foundations of equipment to be connected Use a spacer bar equal in thickness to the gap specified in
meet manufacturers’ requirements. Check for soft foot. The use Table 2, Page 2. Insert bar as shown above, to same depth at
of stainless steel shims is recommended. Measuring 90° intervals and measure clearance between bar and hub
misalignment and positioning equipment within alignment face with feelers. The difference in minimum and maximum
tolerances is simplified with an alignment computer. These measurements must not exceed the ANGULAR installation
calculations can also be done graphically or mathematically. limits specified in Table 2.
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.

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

The Falk Corporation, P.O. Box 492, Zip 53201-0492 438-110

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 December 2002
Fax: 414-937-4359 e-mail: [email protected] web: www.falkcorp.com Supersedes 10-90
Installation and Maintenance • Steelflex Couplings
®

(Page 4 of 5) Type F • Sizes 3 thru 190

Pack the spaces between and around the grid with as much
lubricant as possible. Scrape or wipe excess lubricant off flush
with top of grid. Lightly oil seal rings to facilitate the sliding of
covers onto the hubs.

4 — Insert Gasket & Lubricate

After coupling is aligned, carefully insert the gasket between
hubs and hang it on either hub. Do not damage gasket. Next
force as much lubricant as possible into the gap and grid
grooves. Refer to Page 1 for lubrication specifications. 7 — Assemble Covers
Assemble covers so that lubrication fittings or NPT holes are
180° apart and align covers to prevent wobble. Tighten cover
bolts and check seals for proper seating.

5 — Insert Grid
When grids are furnished in two or more segments, install
them so that all cut ends extend in the same direction (as 8 — Lubricate Every 12 Months
detailed in the exploded view pictured above); this will assure
correct gird contact with non-rotating pin in cover halves. For couplings with permanent Alemite fittings, insert a smooth
Coupling Sizes 3 to 11 have a single layer grid which is feeler gauge (.010) under seal 180° from fitting to vent cover.
painted gray. Sizes 12 thru 190 have a two layer grid; the Use Alemite gun nozzle Z-737. For others, remove both lube
inner layer is painted gray and stamped “IN”; the outer layer plugs and insert your lube fitting. Lubricate couplings until
is painted yellow and stamped “OUT.” Spread the gird slightly grease flows through the vent or other opening. Then INSTALL
to pass over the coupling teeth and seat with a soft mallet. LUBE PLUGS.

6 — Pack with Lubricant

438-110 The Falk Corporation, P.O. Box 492, Zip 53201-0492

December 2002 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 10-90 Fax: 414-937-4359 e-mail: [email protected] web: www.falkcorp.com
 Steelflex® Couplings • Installation and Maintenance
®

Type F • Sizes 3 thru 190 (Page 5 of 5)

ANNUAL MAINTENANCE Periodic Lubrication

For extreme or unusual operating conditions, check coupling The required frequency of lubrication is directly related to the type
more frequently. of lubricant chosen, and the operating conditions. Steelflex
1. Check alignment per steps on Page 3. If the maximum couplings lubricated with common industrial lubricants, such as
operating misalignment limits are exceeded, realign the those shown in Table 1, should be relubed annually. The use of
coupling to the recommended installation limits. See Table Falk Long Term Grease (LTG) will allow relube intervals to be
2 for installation and operating alignment limits. extended to beyond five years. When relubing, remove both lube
plugs and insert lube fitting. Fill with recommended lubricant until
2. Check tightening torques of all fasteners. an excess appears at the opposite hole. CAUTION: Make
3. Inspect seal ring and gasket to determine if replacement is certain all plugs have been inserted after lubricating.
required. If leaking grease, replace.
4. When connected equipment is serviced, disassemble the Coupling Disassembly & Grid Removal
coupling and inspect for wear. Replace worn parts. Clean Whenever it is necessary to disconnect the coupling, remove
grease from coupling and repack with new grease. Install the cover halves and grid. A round rod or screwdriver that will
coupling using new gasket as instructed in this manual. 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.

PARTS IDENTIFICATION
All coupling parts have identifying part numbers. When
ordering parts, always specify hub bores and keyways, and
state coupling size as stamped on the cover and hub.

1. Seal Ring
2. Half Cover
1 7 2 3 4 3 5 2 1
SIZE 3. Hub (Specify bore &
SIZE &
PART Keyway)
NUMBER
4. Grid
INNER layer stamped
“IN”
OUTER layer grid end
tips painted yellow,
SIZE, PART NUMBER stamped “OUT”
& BORE
5. Gasket
6. Cap Screws & Nut
6

The Falk Corporation, P.O. Box 492, Zip 53201-0492 438-110

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 December 2002
Fax: 414-937-4359 e-mail: [email protected] web: www.falkcorp.com Supersedes 10-90