Rexnord Falk MCF 1135 Maintenance and service guide

Falk®Rigid Moment Couplings •Installation & Maintenance
Type MCF •Size 1135 (Page 1 of 4)
Rexnord CP3-006
5555 S. Moorland Rd., New Berlin, WI 53151-7953 February 2015
Telephone: [phone] Fax: [phone] www.rexnord.com NEW
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.
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.
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.
PREVAILING
TORQUE
LOCKNUT
HEX SOCKET
PIPE PLUG
HEX HEAD
CAP SCREW
KEYLESS
FIT HUB
INTERFERENCE
FIT HUB WITH KEY
Figure 1 — TYPE 2 FEMALE HUB & TYPE 6 MALE HUB
IMPORTANT
CAREFULLY CLEAN
SHAFT & HUB BORE
& KEEP FREE OF
ANY GREASE HUB
DEGREASE
FAC E
Figure 2

Installation & Maintenance • Falk Rigid Moment Couplings
(Page 2 of 4) Type MCF •Size 1135
CP3-006 Rexnord
February 2015 5555 S. Moorland Rd., New Berlin, WI 53151-7953
NEW Telephone: [phone] Fax: [phone] www.rexnord.com
SHAFT END
FLUSH WITH
FACE OF HUB
SHAFT NOT FLUSH
WITH END OF HUB
CORRECT 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 #3
INDICATOR #2
INDICATOR #1
Figure 3
Figure 4
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.
Table 2 — Flange Fastener Tightening
COUPLING
SIZE
Flange Fastener Size
Grade 8
(Inch)
Flange Fastener Tightening
Torque Tolerance 5%
(Nm) (lb-ft)
1135 MCF 2.500 - 4 UNC x 11.00 12745 9400
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.
DIAL
INDICATOR
DIAL
INDICATOR
REVERSE DIAL INDICATOR METHOD
Figure 5
Table 1 — Maximum Runouts (TIR) for Dial
Indicators – Inch (mm)
All
Sizes
#1 #2 #3
.001 (0.025) .003 (0.076) .003 (0.076)

Falk®Rigid Moment Couplings •Installation & Maintenance
Type MCF •Size 1135 (Page 3 of 4)
Rexnord CP3-006
5555 S. Moorland Rd., New Berlin, WI 53151-7953 February 2015
Telephone: [phone] Fax: [phone] www.rexnord.com NEW
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 4 — Type 6 Hub Removal Pressure
COUPLING
SIZE
Maximum Recommended Pressure At Hub Bore
When Dismounting Hub
(MPa) (psi)
1135 MCF 138 - 152 20,000 - 22,000
Table 3 — Type 2 & Type 6 Hub Puller Bolt
COUPLING
SIZE
Flange Face Puller Bolt Holes
UNC Tap (2 x Dia Deep)
BC - Inch (mm) UNC Tap (4 @ 180°)
1135 MCF 25.00 (635) 2.000 - 4.5UNC
METAL CABLE SLINGS
TO SUPPORT HUB
AND PULLER
TORCH
COUPLING
HUB
TORCH
SHAFT
BAR
STOCK
HAND PUMP OR
HYDRAULIC PUMP
GAUGE
WITH OR
WITHOUT
ADJUSTING
SCREW
ALLOR STEEL
PLATE
HYDRAULIC
CYLINDER
Figure 6 — BASIC TYPE 2 HUB REMOVAL EQUIPMENT

Installation & Maintenance • Falk Rigid Moment Couplings
(Page 4 of 4) Type MCF •Size 1135
CP3-006 Rexnord
February 2015 5555 S. Moorland Rd., New Berlin, WI 53151-7953
NEW Telephone: [phone] Fax: [phone] www.rexnord.com
1
2
3
4
5
6
Annual Maintenance
Whenever the equipment is down for general maintenance
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 part number.
COUPLING HUB
SHAFT
LOW PRESSURE
HIGH PRESSURE
PUMP VALVES
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.
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)
MCF COUPLING SHOWN WITH A TYPE 6 MALE JUB &
A TYPE 2 FEMALE HUB