Rexnord Falk GL32 Maintenance and service guide

How To Use This Manual
This manual provides detailed instructions on installation,
maintenance and parts identification. Use the table of contents
below to locate required information.
Table of Contents
Introduction .....................Page1
Lube Fittings .....................Page1
Lubrication ....................Pages 1-3
Balanced Couplings .................Page4
Installation & Alignment Instructions ........Pages 4-5
Annual Maintenance .................Page5
Installation & Alignment Data .............Page6
Parts Identification & Parts Interchangeability .... Page7-8
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND TROU-
BLE FREE SERVICE.
INTRODUCTION
This manual applies to standard coupling Types GL32 with
exposed bolts. For couplings furnished with special features,
refer to assembly drawing furnished with coupling for proper
assembly arrangement and any additional installation or
maintenance requirements. Type GL32 couplings are
recommended for applications that require axial hub
movement and are designed for horizontal operations. Refer to
Factory for vertical applications.
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 1/8NPT lube holes for sizes 1010G thru 1035G,
and 1/4NPT for sizes 1040G thru 1070G. Use a standard
grease gun and lube fittings.
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.
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.
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 and is
an extreme pressure grease.
Gear couplings initially lubricated with Falk Long Term Grease
(LTG) will not require re-lubrication for up to three years.
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.
Rexnord Industries, LLC, Coupling Group 458-730
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone] September 1996 (.PDF Revision)
Fax: [phone] e-mail: [email protected] web: www.rexnord.com Supersedes 4-96
Falk™ Double Engagement Gear Couplings •Installation & Maintenance
Type GL32 •Sizes 1010 thru 1070 (Page 1 of 8)
Type GL32

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). Minimum pump = 20°F (–7°C).
MINIMUM BASE OIL VISCOSITY — 3300SSU (715cSt) @
100°F (38°C).
THICKENER — Lithium soap/polymer.
CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM
#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).
MINIMUM 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.
Packaging
14 oz. (.4 Kg) CARTRIDGES — For use in standard industrial
lubrication guns.
CASELOTS—10 – 14 oz. cartridges, 60 – 14 oz. cartridges.
35 lb. (16 Kg)PAILS — Ideal for larger size couplings or
many smaller sizes.
120 lb. (54 Kg) 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.
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
temperatures 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&3onPage3aretypical products
only and should not be construed as exclusive recommendations.
Specifications — General Purpose
Coupling Lubricants
The values shown are typical and slight variations are permissible.
DROPPING POINT — 300°F (149°C) or higher.
CONSISTENCY — See Table 1 or 2 on Page 3.
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.
CLEAN — Free from foreign inclusions.
Rexnord Industries, LLC, Coupling Group458-730
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone]September 1996 (.PDF Revision)
Fax: [phone] e-mail: [email protected] web: www.rexnord.comSupersedes 4-96
Installation & Maintenance •Falk™ Double Engagement Gear Couplings
(Page 2 of 8) Type GL32 •Sizes 1010 thru 1070

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 temperatures 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 then the pour point of the oil. The specified amount of
grease listed in Table 4, Page 6, is in pounds and also applies
to the volume of oil in pints.
Specifications
Type: Mild EP gear oil that meets AGMA Specifications 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.
Rexnord Industries, LLC, Coupling Group 458-730
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone] September 1996 (.PDF Revision)
Fax: [phone] e-mail: [email protected] web: www.rexnord.com Supersedes 4-96
Falk™ Double Engagement Gear Couplings •Installation & Maintenance
Type GL32 •Sizes 1010 thru 1070 (Page 3 of 8)
TABLE 1 — NLGI #1 Grease
Coupling speed range....................SeeTable 4
Temperature range ....–30°F to +200°F (–34°C to +93°C)
Worked penetration at 77°F (25°C) ............310-340
Dropping point................300°F (149°C) or higher
Texture ..........................Smooth or fibrous
Minimum Timken EP O.K. load ...........30lbs. (14kg)
Does not corrode steel or swell or deteriorate synthetic seals.
Manufacturer Lubricant H
Amoco Oil Co. Rykon Grease #1 EP
BP Oil Co. Energrease LS-EP1
Chevron U.S.A., Inc. Dura-Lith EP1
Citgo Petroleum Corp Premium Lithium Grease EP1
Conoco Inc. EP Conolith Grease #1
Exon Company, U.S.A.. Lidok EP1
Imperial Oil Ltd. Ronek EP1
Kendall Refining Co. Lithium Grease L-416
Keystone Div., Pennwalt Corp. Zeniplex-1
Lyondell Lubricants Litholine Complex EP1
Mobil Oil Corp.. Mobilux EP1
Petro-Canada Products Multipurpose EP1
Phillips 66 Co. Philube Blue EP
Shell Oil Co. Alvania EP Grease 1
Shell Canada Ltd. Alvania Grease EP1
Sun Oil Co. Sun Prestige 741 EP
Texaco Lubricants Multifak EP1
Unocal 76 (East & West) Unoba EP1
HLubricants listed may not be suitable for use in the food processing industry;
check with lube manufacturer for approved lubricants.
TABLE 2 — NLGI #0 EP Grease
Coupling speed range....................SeeTable 4
Temperature range ....–30°F to +200°F (–34°C to +93°C)
Worked penetration at 77°F (25°C) ............310-340
Dropping point................300°F (149°C) or higher
Texture ..........................Smooth or fibrous
Minimum Timken EP O.K. load............30lbs. (14kg)
Does not corrode steel or swell or deteriorate synthetic seals.
Manufacturer Lubricant H
Amoco Oil Co. Rykon Premium Grease 0 EP
BP Oil Co. Energrease LS-EP 0
Chevron U.S.A., Inc. Dura-Lith EP 0
Citgo Petroleum Corp Premium Lithium Grease EP 0
Conoco Inc. EP Conolith Grease #0
Exon Company, U.S.A.. Lidok EP 0
Kendall Refining Co. Lithium Grease L-406
Keystone Div., Pennwalt Corp. Zeniplex-0
Mobil Oil Corp.. Mobilux EP 0
Petro-Canada Products Multipurpose Lotemp EP Grease
Phillips 66 Co. Philube Blue EP
Shell Oil Co. Alvania EP Grease RO
Shell Canada Ltd. Alvania Grease EPW
Sun Oil Co. Sun Prestige 740 EP
Texaco Lubricants Multifak EP 0
Unocal 76 (East & West) Unoba EP 0
HLubricants listed may not be suitable for use in the food processing industry;
check with lube manufacturer for approved lubricants.
TABLE 3 — Oil Lubricants
Manufacturer Lubricant H
Amoco Permagear EP 160
Chevron, U.S.A. NL Gear Compound 680
Exxon Co., U.S.A. Spartan EP680
Gulf Oil Co. EP Lubricant HD 680
Mobil Oil Co. Mobilgear 636
Shell Oil Co. Omala Oil 680
Texaco Inc. Meropa 680
Union Oil Co. of Calif. Extra Duty NL Gear Lube 8EP
HLubricants listed may not be suitable for use in the food processing industry;
check with lube manufacturer for approved lubricants.

TYPE GL HORIZONTAL COUPLING
INSTALLATION
Only standard mechanics tools, torque wrenches, dial
indicator and feeler gauges are required to install 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 2 or 3. Pack sleeve teeth with grease and lightly coat
seals with grease BEFORE assembly. The required amount of
grease is listed in Table 4, Page 6. Make certain flange
fasteners are tightened to the required torque listed in Table 4,
Page 6.
Interference Fit Hubs — Unless otherwise specified, gear
couplings are furnished for an interference fit without set screws.
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).
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 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.
Balanced Couplings
The fasteners provided are
matched sets and must not be
mixed or substituted. Balanced
couplings are match marked
and must be assembled with
mating match marks aligned.
Component parts of assembly
balanced couplings must not be replaced without re-balancing
the complete assembly.
1 — Determine Coupling Assembly Number
Measure flex hub dimension ZG or ZGL, as shown in drawings
on Page 7. Compare the results with the values listed in Table
4 and compare coupling parts provided to the part
identification drawings on Page 7 to determine if coupling is a
GL32-1, GL32-2, or GL32-4. NOTE: GL32-4 couplings are
provided with short tooth sleeves and gap discs.
2 — Mount Flanged Sleeve, Seal & Hubs
Place the flanged sleeves WITH seal rings on shafts BEFORE
mounting hubs.
IMPORTANT: Mount hubs as shown above with SHORT shank,
DIM. ZG or ZGL in Table 4 on Page 6, toward gap. Mount hubs
so that each face is flush with the end of its shaft. Allow hubs to
cool before proceeding. Seal keyways to prevent leakage. Insert
set screws (if required) and tighten. Position equipment in
approximate alignment with approximate hub gap.
3 — Determine Distance Between Hub Ends
Accurately measure spacer length as shown above. To
determine minimum hub gap dimension, add the spacer
length measured, plus the minimum “X” dimension listed in
Table 4 on Page 6. To determine maximum hub gap
dimension, add the spacer length measured, plus the
maximum “X” dimension listed in Table 4 on Page 6.
4 — Gap & Angular Alignment
Adjust gap to any value between minimum and maximum
value calculated in Step 3. Axial movement must never exceed
the minimum and maximum gap values. Temporarily secure
the floating shaft or shafts at their required positions. Use an
inside micrometer as shown above and at 90° intervals to
measure the distance between hubs. The difference in
minimum and maximum measurements should not exceed the
installation ANGULAR limit specified in Table 4 on Page 6.
Rexnord Industries, LLC, Coupling Group458-730
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone]September 1996 (.PDF Revision)
Fax: [phone] e-mail: [email protected] web: www.rexnord.comSupersedes 4-96
Installation & Maintenance •Falk™ Double Engagement Gear Couplings
(Page 4 of 8) Type GL32 •Sizes 1010 thru 1070
A1 A1 A1 A1 B1 B1 B1 B1
NOTE: SHORTER SHANK
TOWARD GAP END.
NOTE:
FLUSH HERE
SPACER LENGTH

5 — Offset Alignment
Align so that a straight edge rests squarely on both hubs as
shown above and also at 90° intervals. Check with feelers. The
clearance should not exceed the INSTALLATION OFFSET limit
specified in Table 1. Tighten foundation bolts and repeat Steps
4 and 5. Realign coupling if necessary. Use a dial indicator if
hub extension is too short for accurate use of a straight edge.
6 — Insert Center Plates Into Spacer &
Assemble Coupling
Position Center Plate in both ends of spacer counterbore. If
Center Plate diameter is stepped, assemble small diameter
side into spacer. Position spacer (with Center Plates) between
hubs. (For GL32-4, insert the gap disc between each hub and
spacer). Insert gasket at each flange connection and assemble
sleeves to spacer. Use only the fasteners furnished with
the coupling.
IMPORTANT: Tighten fasteners to torque specified in Table 4
on Page 6.
7 — Lubricate
Insert a lube fitting into one lube hole and remove opposite
plug for venting. Fill to ONE-HALF of the amount of lubricant
specified in Table 1. REPEAT the procedure for other half
coupling and then INSERT ALL LUBE PLUGS. IMPORTANT:
Over lubrication may restrict the sliding action of the coupling.
BI-ANNUAL MAINTENANCE
Re-lubricate coupling if using general purpose greases. If
coupling leaks grease, is exposed to extreme temperatures,
excessive moisture or frequent reversals; frequent lubrication
may be required.
ANNUAL MAINTENANCE
For extreme or unusual operating conditions, check coupling
more frequently.
1. Check alignment per Steps 4 and 5, Pages 4 and 5. If the
maximum operating misalignment values are exceeded,
realign the coupling to the recommended installation
values. See Table 4, Page 6, for installation and maximum
operating misalignment values.
2. Check tightening torques of all fasteners.
3. Inspect seal ring and gasket to determine if
replacement is required.
4. Re-lubricate coupling if using general purpose grease.
Rexnord Industries, LLC, Coupling Group 458-730
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone] September 1996 (.PDF Revision)
Fax: [phone] e-mail: [email protected] web: www.rexnord.com Supersedes 4-96
Falk™ Double Engagement Gear Couplings •Installation & Maintenance
Type GL32 •Sizes 1010 thru 1070 (Page 5 of 8)
CENTER
PLATES
LUBRICATE BOTH SLEEVES
LUBE HOLE LOCATIONS VARY
WITH COUPLING SIZE.

Rexnord Industries, LLC, Coupling Group458-730
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone]September 1996 (.PDF Revision)
Fax: [phone] e-mail: [email protected] web: www.rexnord.comSupersedes 4-96
Installation & Maintenance •Falk™ Double Engagement Gear Couplings
(Page 6 of 8) Type GL32 •Sizes 1010 thru 1070
TABLE 4 — Installation and Alignment Data H(Dimensions-Inches)
COUPLING SIZE 1010 1015 1020 1025 1030 1035 1040 1045 1050 1055 1060 1070
Dimensions ZG .586 .500 .700 .860 .960 1.060 1.080 1.240 1.370 1.290 1.670 1.960
ZGL .000 .000 .000 .000 .250 .250 .250 .250 .360 .500 .500 .530
“X”
Min GL32-1 & 2 .32 .32 .32 .38 .38 .48 .60 .66 .74 .74 .86 1.06
GL32- 4 .25 .55 .27 .85 .87 1.32 1.86 1.88 2.40 3.64 3.08 3.82
Max GL32-1 & 4 .42 1.14 1.06 1.34 1.78 2.42 3.14 3.40 4.04 5.30 5.04 5.94
GL32-2 1.60 2.14 2.46 3.06 3.20 4.04 4.80 5.38 6.06 6.88 7.38 8.80
Installation Limits Offset Max .001 Per inch of hub separation
Angular Max .006 .007 .009 .011 .013 .015 .018 .020 .022 .024 .026 .031
Operating Limits †Offset Max .004 Per inch of hub separation
Angular Max .024 .030 .036 .045 .052 .061 .072 .081 .087 .096 .105 .122
Coupling Speed
Range — (rpm)
LTG &
NLGl #1
Grease
Min ‡1030 700 550 460 380 330 290 250 230 210 190 160
Allow 7000 5500 4600 4000 3600 3100 2800 2600 2400 2200 2100 1800
Grease - pounds .05 .08 .14 .25 .40 .60 1.00 1.12 2.00 2.50 3.50 4.80
Flange Bolt Torque — lb-in. 108 372 900 1800 1800 3000 3000 3000 3000 3000 3000 3000
HRefer to Selection Guide for maximum bores and Engineering Manual 427-108 for re-boring instructions.
†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. Limits shown are extremes and should not be combined. Application requirements in excess of 1/4° misalignment per flex-half
coupling should be referred to Factory for review.
‡NLGl #0 grease must be used when speeds are below minimum shown.

PARTS IDENTIFICATION
Coupling parts have identifying size and part numbers as
illustrated below. When ordering parts, always specify SIZE and
TYPE, hub bore & keyway and part number found on each item.
Rexnord Industries, LLC, Coupling Group 458-730
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone] September 1996 (.PDF Revision)
Fax: [phone] e-mail: [email protected] web: www.rexnord.com Supersedes 4-96
Falk™ Double Engagement Gear Couplings •Installation & Maintenance
Type GL32 •Sizes 1010 thru 1070 (Page 7 of 8)
1. Seal Ring 3A. GL Flex Hub 4. Sleeve Gasket 11. Spacer
2A. GL Flanged Sleeve 3B. GL Flex Hub – 2 5. Lube Plug 17. Center Plate
( Long tooth) 6. Sleeve Fasteners 19. GL – 4 Gap Disc ‡
24. G Flanged Sleeve
(Short tooth)
‡Are not required for Sizes 1010 and 1020GL.
3A 12A
6
2A 13A
GL32-1 6
11
ZG
4
5
ZG
45
17 17
3B 12A
6
2A 13B
GL32-2 6
11
ZGL
4
5
ZGL
45
17 17
3A
124 6
3A
1
24
6
11
GL32-4
ZG
17
19
4
5
ZG
17
19
4
5
ZG
17
19
4
5

PART NUMBER LOCATION
Rexnord Industries, LLC, Coupling Group458-730
5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : [phone]September 1996 (.PDF Revision)
Fax: [phone] e-mail: [email protected] web: www.rexnord.comSupersedes 4-96
Installation & Maintenance •Falk™ Double Engagement Gear Couplings
(Page 8 of 8) Type GL32 •Sizes 1010 thru 1070
SLEEVE SLEEVE
FLEX HUB FLEX HUB
GAP
DISC GAP
DISC
CENTER
PLATE
CENTER
PLATE
SPACER
SIZE, BORE &
PART NUMBER
(EITHER LOCATION)
GASKETGASKET
COUPLING
SIZE PRODUCT
CLASSIFICATION
1015 GL 20
TYPE
L
U
B
E
F
A
L
K
1
0
1
5
G
L
2
0
F
A
L
K
1
0
1
5
G
G
A
P
E
N
D
F
A
L
K
1
0
1
5
G
2
3
7
30
7
44
6
7
1
l
U
B
E
F
A
L
K
1
0
1
5
G
L
2
0
F
A
L
K
1
0
1
5
G
2
.
3
7
0
7
4
4
67
1
ORDER INFORMATION
1. Identify part(s) required by name from above.
2. Furnish the following information:
EXAMPLE:
Coupling Size: 1050
Coupling Type: GL32-1
Flex Hub:
Bore: 6.750
Keyway: 1.750 x .750
3. Price parts from Price List 452-110 and appropriate
discount sheet.