Rexnord Falk Steelflex T10 Maintenance and service guide

Falk®Steelflex®Couplings •Installation & Maintenance
Type T10 •Sizes 1020–1140 & 20–140 (Page 1 of 8)
Rexnord 428-110
5555 S. Moorland Rd., New Berlin, WI 53151-7953 May 2004
Telephone: [phone] Fax: [phone] www.rexnord.com Supersedes 2-03
How To Use This Manual
This manual provides detailed instructions on maintenance,
lubrication, installation, and parts identification. Use the
table of contents below to locate required information.
Table of Contents
Introduction ................................................................ Page 1
Lube Fittings............................... ................................ Page 1
Limited End Float ....................................................... Page 1
Lubrication ............................................................ Pages 1-2
Installation & Alignment Instructions ..................... Pages 2-4
Annual Maintenance, Relube & Disassembly ............ Page 4
Installation & Alignment Data ..................................... Page 5
Parts Identification & Parts Interchangeability ........... Page 6
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND
TROUBLE FREE SERVICE.
INTRODUCTION
This manual applies to Sizes 1020T thru 1140T and 20T
thru 140T10 Falk SteelfIex Tapered Grid Couplings. Unless
otherwise stated, information for Sizes 1020T thru 1140T
applies to Sizes 20T thru 140T respectively, e.g. 1020T =
20T, 1100T = 100T, etc. These couplings are designed to
operate in either the horizontal or vertical position without
modification. Beginning in year 1994 through 2003, these
couplings were being suppliedwithone setofinchseries
fasteners and one set of Metric fasteners. Beginning in
year 2004 only Metric fasteners are being supplied. Refer
to Page 6 for part interchangeability.
The performance and life of the couplings depend largely
upon how you install and service them.
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
Cover halves have1/8 NPT Iube holes. Use a standard
grease gun and Iube fitting as instructed on Page 4.
LIMITED END FLOAT
When electric motors, generators, engines, compressors
and other machines are fitted with sleeve or straight roller
bearings, limited axial end float kits are recommended for
protecting the bearings. Falk Steelflex couplings are easily
modified to limit end float; refer to Manual 428-820 for
instructions.
LUBRICATION
Adequate lubrication is essential for satisfactory
operation. Page 2 provides a list of typical lubricants
and specifications for general purpose and long term
greases. Because of its superior lubricating characteristics
and low centrifuge properties, Falk Long Term Grease
(LTG) is highly recommended. Sizes 1020T to 1090T10
are furnished with a pre-measured amount of grease for
each coupling. The grease can be ordered for larger size
couplings.
The use of general purpose grease requires re-lubrication
of the coupling at least annually.
TYPE T10 STEELFLEX COUPLING
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 grid-groove area of Steelflex
couplings resulting in premature hub or grid 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 semifluidwhile thegreasenear 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
allows the lubricant to be used for relatively long periods of
time.
Steelflex couplings initially lubricated with LTG will not
require re-lubrication until the connected equipment
is stopped for servicing. If a coupling leaks grease, is
exposed to extreme temperatures, excessive moisture, or
experiences frequent reversals, more frequent lubrication
may be required.
Although LTG grease is compatible with most other
coupling greases, the mixing of greases may dilute the
benefits of LTG.
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).
CAUTION: Do not use LTG in bearings.

Falk Steelflex Couplings •Installation & Maintenance
(Page 2 of 6) Type T10 •Sizes 1020–1140 & 20–140
428-110 Rexnord
May 2004 5555 S. Moorland Rd., New Berlin, WI 53151-7953
Supersedes 2-03 Telephone: [phone] Fax: [phone] www.rexnord.com
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). Min. Pump = 20° F (-7° C).
MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @
100°F (38°C).
THICKENER — Lithium & soap/polymer.
CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM
#D4425 (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 at
77°F (25°C)
MINIMUM DROPPING POINT — 350°F (177°C) minimum
MINIMUM TIMKEN O.K. LOAD — 40 lbs.
ADDITIVES — Rust and oxidation inhibitors that do not
corrode steel or swell or deteriorate synthetic seals.
Packaging
14 oz. (0,4 kg ) CARTRIDGES — Individual or case lots of
10 or 30.
35 lb. (16 kg )PAIL, 120 lb. (54 kg ) KEG & 400 lb. (181 kg)
DRUMS.
General Purpose Grease
Annual Lubrication — The following specifications and
lubricants for general purpose grease apply to Falk
Steelflex couplings that are lubricated annually and operate
within ambient temperatures of 0°F to 150°F (-18°C to
66°C). For temperatures beyond this range (see Table 1),
consult the Factory.
If a coupling leaks grease, is exposed to extreme
temperatures, excessive moisture or experiences frequent
reversals, more frequent lubrication may be required.
Specifications — General Purpose Coupling
Lubricants
The values shown are typical and slight variations are
permissible.
DROPPING POINT — 300°F (149°C) or higher.
CONSISTENCY — NLGI No. 2 with 60 stroke worked
penetration value in the range of 250 to 300.
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.
INACTIVE — Must not corrode steel or cause swelling or
deterioration of synthetic seals.
CLEAN — Free from foreign inclusions.
General Purpose Greases Meeting Rexnord
Specifications
Lubricants listed below are typical products only and
should not be construed as exclusive recommendations.
TABLE 1 — General Purpose Greases 
Ambient Temperature
Range
0°F to 150°F
(-18°C to 66°C)
-30°F to 100°F
(-34°C to 38°C)
Manufacturer Lubricant Lubricant 
Amoco Oil Co. Amolith Grease #2 Amolith Grease #2
BP Oil Co. Energrease LS-EP2 Energrease LS-EP1
Chevron U.S.A., Inc. Dura-Lith EP2 Dura-Lith EP1
Citgo Petroleum Corp Premium Lithium Grease EP2 Premium Lithium Grease EP1
Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2
Exxon Company, U.S.A.. Unirex EP2 Unirex EP2
E.F. Houghton & Co. Cosmolube 2 Cosmolube 1
Imperial Oil Ltd. Unirex EP2 Unirex EP2
Kendall Refining Co. Lithium Grease L421 Lithium Grease L421
Keystone Div. (Pennwalt) 81 EP-2 81 EP-1
Lyondell Petrochemical
(ARCO) Litholine H EP 2 Grease Litholine Complex EP1
Mobil Oil Corp.. Mobilux EP111 Mobilith AW1
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
Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2
Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EP
Texaco Lubricants Starplex HD2 Multifak EP2
Unocal 76 (East & West) Unoba EP2 Unoba EP2
Valvoline Oil Co. Multilube Lithium EP Grease ...
★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 Factory.
†Lubricants listed may not be suitable for use in the food processing
industry; check with lube manufacturer for approved lubricants.
INSTALLATION OF TYPE T10
STEELFLEX GRID COUPLINGS
Installation
Only standard mechanics tools, wrenches, a straight edge
and feeler gauges are required to install Falk Steelflex
couplings. Coupling Sizes 1020T thru 1090T are generally
furnished for CLEARANCE FIT with setscrew over the
keyway. Sizes 1100T and larger are furnished for an
INTERFERENCE FIT without a setscrew.
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.
INTERFERENCE FIT HUBS — Furnished without setscrews.
Heat hubs to a maximum of 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).
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.


Falk Steelflex Couplings •Installation & Maintenance
Type T10 •Sizes 1020–1140 & 20–140 (Page 3 of 8)
Rexnord 428-110
5555 S. Moorland Rd., New Berlin, WI 53151-7953 May 2004
Telephone: [phone] Fax: [phone] www.rexnord.com Supersedes 2-03
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.
Heat hubs as instructed above. Mount hubs as quickly as
possible with hub face flush with shaft end. Allow hubs to
cool before proceeding. Insert setscrews (if required) and
tighten.
Maximize Performance And 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.
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.
1— Mount Seals And Hubs
MOUNT
SEAL
FIRST
Lock out starting switch of prime mover. Clean all metal
parts using a non-flammable solvent. Lightly coat seals with
grease and place on shafts BEFORE mounting hubs. Heat
interference fit hubs as previously instructed. Seal keyways
to prevent leakage. Mount hubs on their respective shafts
so the hub face is flush with the end of its shaft unless
otherwise indicated. Tighten setscrews when furnished.
2 — Gap and Angular Alignment
Use a spacer bar equal in thickness to the gap specified
in Table 2, Page 5. Insert bar as shown below left, 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 ANGULAR
installation limits specified in Table 2.
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 PARALLEL OFFSET installation limits
specified in Table 2. Tighten all foundation bolts and repeat
Steps 2 and 3. Realign coupling if necessary.
4 — Insert Grid
Pack gap and grooves with specified lubricant before
inserting grid. When grids are furnished in two or more
segments, install
them so that all cut ends extend in the same direction
(as detailed in the exploded view picture above); this will
assure correct grid contact with non-rotating pin in cover
halves. Spread the grid slightly to pass over the coupling
teeth and seat with a soft mallet.

Falk™Steelflex®Couplings •Installation & Maintenance
(Page 4 of 6) Type T10 •Sizes 1020–1140 & 20–140
428-110 Rexnord
May 2004 5555 S. Moorland Rd., New Berlin, WI 53151-7953
Supersedes 2-03 Telephone: [phone] Fax: [phone] www.rexnord.com
5— Pack With Grease And Assemble Covers
MATCH MARK
MATCH MARK
Pack the spaces between and around the grid with as
much lubricant as possible and wipe off excess flush with
top of grid. Position seals on hubs to line up with grooves
in cover. Position gaskets on flange of lower cover half
and assemble covers so that the match marks are on the
same side (see above). If shafts are not level (horizontal)
or coupling is to be used vertically, assemble cover halves
with the lug and match mark UP or on the high side. Push
gaskets in until they stop against the seals and secure
cover halves with fasteners, tighten to torque specified
in Table 2. Make sure gaskets stay in position during
tightening of fasteners.
MATCH MARKLUG UP
VERTICAL COUPLINGS
CAUTION: Make certain lube plugs are installed before
operating.
CAUTION:
ANNUAL MAINTENANCE
For extreme or unusual operating conditions, check
coupling more frequently.
1. Check alignment per steps on Page 3. If the maximum
op-erating misalignment limits are exceeded, realign the
cou-pling to the recommended installation limits. See
Table 2 for installation and operating alignment limits.
2. Check tightening torques of all fasteners.
3. Inspect seal ring and gasket to determine if
replacement is required. If leaking grease, replace.
4. When connected equipment is serviced, disassemble
the coupling and inspect for wear. Replace worn parts.
Clean grease from coupling and repack with new
grease. Install coupling using new gasket as instructed
in this manual.
Periodic Lubrication
The required frequency of lubrication is directly related to
the type of lubricant chosen, and the operating conditions.
Steelflex couplings lubricated with common industrial
lubricants, such as those shown in Table 1, should be
relubed annually. The use of Falk Long Term Grease (LTG)
will allow relube intervals to be extended to beyond five
years. When relubing, remove both lube plugs and insert
lube fitting. Fill with recommended lubricant until an excess
appears at the opposite hole.
CAUTION: Make certain all plugs have been inserted after
lubricating.
Coupling Disassembly And Grid Removal
Whenever it is necessary to disconnect the coupling,
remove the cover halves and grid. A round rod or
screwdriver that will 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.

Falk Steelflex Couplings •Installation & Maintenance
Type T10 •Sizes 1020–1140 & 20–140 (Page 5 of 8)
Rexnord 428-110
5555 S. Moorland Rd., New Berlin, WI 53151-7953 May 2004
Telephone: [phone] Fax: [phone] www.rexnord.com Supersedes 2-03
TYPE T COUPLING INSTALLATION &
ALIGNMENT DATA
Maximum life and minimum maintenance for the coupling
and connected machinery will result if couplings are
accurately aligned. Coupling life expectancy between initial
alignment and maximum operating limits is a function of
load, speed and lubrication. Maximum operating values
listed in Table 2 are based on cataloged allowable rpm.
Values listed are based upon the use of the gaps listed,
standard coupling components, standard assemblies and
cataloged allowable speeds.
Values may be combined for an installation or operating
condition.
Example: 1060T max. operating misalignment is .016"
parallel plus .018" angular.
NOTE: For applications requiring greater misalignment,
refer application details to the Factory.
Angular misalignment is dimension X minus Y as illustrated
below. Parallel misalignment is distance P between the hub
center lines as illustrated below.
End float (with zero angular and parallel misalignment)
is the axial movement of the hubs(s) within the cover(s)
measured from “0” gap.
FF
GAP
Y
X
P
P
ANGULAR MISALIGNMENT PARALLEL OFFSET MISALIGNMENT END FLOAT
TABLE 2 — Misalignment & End Float
Size
Installation Limits Operating Limits Cover Fastener
Tightening
Torque Values
Inch or
Metric Series
Fasteners
Allow
Speed
(rpm)
Lube Wt
Parallel
Offset-P
Angular
(x-y)
Hub Gap
10%
Parallel
Offset-P
Angular
(x-y)
End Float
Physical Limit
(Min) 2 x F
Max
Inch
Max
mm
Max
Inch
Max
mm
Max
Inch
Max
mm
Max
Inch
Max
mm
Max
Inch
Max
mm Inch mm (lb-in) (Nm) lb kg
1020T
1030T
1040T
1050T
1060T
1070T
1080T
1090T
1100T
1110T
1120T
1130T
1140T
.006
.006
.006
.008
.008
.008
.008
.008
.010
.010
.011
.011
.011
0,15
0,15
0,15
0,20
0,20
0,20
0,20
0,20
0,25
0,25
0,28
0,28
0,28
.003
.003
.003
.004
.005
.005
.006
.007
.008
.009
.010
.012
.013
0,08
0,08
0,08
0,10
0,13
0,13
0,15
0,18
0,20
0,23
0,25
0,30
0,33
.125
.125
.125
.125
.125
.125
.125
.125
.188
.188
.250
.250
.250
3
3
3
3
3
3
3
3
5
5
6
6
6
.012
.012
.012
.016
.016
.016
.016
.016
.020
.020
.022
.022
.022
0,30
0,30
0,30
0,41
0,41
0,41
0,41
0,41
0,51
0,51
0,56
0,56
0,56
.010
.012
.013
.016
.018
.020
.024
.028
.033
.036
.040
.047
.053
0,25
0,30
0,33
0,41
0,46
0,51
0,61
0,71
0,84
0,91
1,02
1,19
1,35
.210
.198
.211
.212
.258
.259
.288
.286
.429
.429
.556
.551
.571
5,33
5,03
5,36
5,38
6,55
6,58
7,32
7,26
10,90
10,90
14,12
14,00
14,50
100
100
100
200
200
200
200
200
312
312
650
650
650
11,3
11,3
11,3
22,6
22,6
22,6
22,6
22,6
35
35
73
73
73
4500
4500
4500
4500
4350
4125
3600
3600
2440
2250
2025
1800
1650
.06
.09
.12
.15
.19
.25
.38
.56
.94
1.1
1.6
2.0
2.5
0,03
0,04
0,05
0,07
0,09
0,11
0,17
0,25
0,43
0,51
0,74
0,91
1,14
TABLE 3 — Coupling Cover Fastener Identification
Size Inch Series Fasteners Metric Fasteners
Old Style New Style
1020-1070T10 SAE Grade 8 SAE Grade 8
1
0.9
Property Class 10.9
1080-1090T10 SAE Grade 8 SAE Grade 8
1
0.9
Property Class 10.9
1100-1140T10 SAE Grade 5 SAE Grade 5
8.
8
Property Class 8.8
★Older style covers, Sizes 1020T10 thru 1070T10 must utilize socket head cap screws and locknuts held by the cover.


Falk Steelflex Couplings •Installation & Maintenance
(Page 6 of 6) Type T10 •Sizes 1020–1140 & 20–140
428-110 Rexnord
May 2004 5555 S. Moorland Rd., New Berlin, WI 53151-7953
Supersedes 2-03 Telephone: [phone] Fax: [phone] www.rexnord.com
PARTS IDENTIFICATION
All coupling parts have identifying part numbers as shown
below. Parts 3 and 4 (Hubs and Grids), are the same for
both
Type T10 and T20 couplings. All other coupling parts are
unique to
Type T10. When ordering parts, always SPECIFY SIZE and
TYPE shown on the COVER.
PARTS INTERCHANGEABILITY
Parts are interchangeable between Sizes 20T and 1020T,
30T and 1030T, etc. except as noted.
GRIDS — Size 1020T thru 1140T Steelflex couplings use
blue or non-painted grids. Older models, 20T thru 140T, use
orange grids.
CAUTION: Blue or non-painted grids may be used in all
applications, but DO NOT substitute orange grids for blue
or nonpainted.
CAUTION: COVERS — DO NOT mix cover halves of
different designs. Sizes 1020T thru 1070T10 covers have
been manufactured in several different two-rib designs and
80T thru 140T covers have been manufactured with two
and three ribs.
HARDWARE — Older style covers, Sizes 1020T10 thru
1070T10, utilized socket head cap screws with captured
locknuts. The new style covers use hex head cap screws
(either inch or metric from year 1994 through 2003 and only
Metric beginning in 2004). Specify the style cover when
ordering replacement parts.
PART NUMBER LOCATION
(1.) SEAL
(3.) HUB
SIZE &
PART
NUMBER
SIZE, PART
NUMBER &
BORE
SIZE
PART NUMBER
(4.) GRID
(5.) GASKET
(7.)
(2.) COVER
(6.)
1030 B10T
COUPLING
SIZE
PRODUCT
CLASSIFICATION
SIZE
PART NUMBER
TYPE MODEL
PART DESCRIPTION
1. Seal (T10)
2. Cover (T10)
3. Hub (Specify bore and keyway)
4. Grid
5. Gasket (T10)
6. Metric Fasteners (T10).
7. Lube Plug
ORDER INFORMATION
1. Identify part(s) required by name
above.
2. Furnish the following information.
EXAMPLE:
Coupling Size: 1030
Coupling Type: T10 Model: B
Bore: 1.375
Keyway: .375 x .187
3. Contact your Rexnord
DistributororRexnord for price and
availability.