Falk
®
Continuous Sleeve Gear Couplings
•
Installation and Maintenance
Types GC02/05
•
Sizes 1010 thru 1035
(Page 1 of 7)
How To Use This Manual
This manual provides detailed instructions on installation,
maintenance and parts identification for Falk Lifelign
®
gear
couplings, Types GC02 & 05. Use the table of contents
below to locate required information.
Table of Contents
Introduction...............................................................Page 1
Lube Fittings
.............................................................Page 1
Lubrication ..........................................................Pages 1-2
Installation & Alignment Instructions
...................Pages 3-5
Annual Maintenance & Disassembly
................Pages 4 & 5
Installation & Alignment Data
...................................Page 6
Parts Identification & Parts Interchangeability
........ Page 7
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND
TROUBLE FREE SERVICE.
INTRODUCTION
This manual applies to standard coupling Types GC02 & 05.
For couplings furnished with special features, refer to as-
sembly drawing furnished with coupling for proper assembly
arrangement and any additional installation or maintenance
requirements. These couplings are designed to operate in
either the horizontal or vertical position without modification.
However, for vertical operation, assemble Type GC02 cou-
pling so retainer ring is up on the high side. For Type GC05
the addition of an elastomer gap disc is required in the lower
coupling.
IMPORTANT: When gear couplings are mounted on a horizon-
tal floating shaft, use a gap disc in coupling sizes indicated.
Where limited end float is required or where sleeve bearing
motors are used, consult the Factory.
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
/
8
NPT lube holes for sizes 1010GC thru
1035GC. Use a standard grease gun and lube fittings.
LUBRICATION
Adequate lubrication is essential for satisfactory operation. Be-
cause of its superior lubricating characteristics and low centrifuge
properties, Falk Long Term Grease (LTG) is highly recommended.
Gear couplings initially lubricated with Falk Long Term Grease
(LTG) will not require re-lubrication for up to three years.
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 Safe-
ty & 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. 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
semifluid, while the grease near 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 allow the
lubricant to be used for relatively long periods of time.
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.
Packaging
14 oz. (0,4 Kg) CARTRIDGES — Individual or case lots of 10
or 30.
35 lb. (16 Kg) PAILS, 120 lb. (54 Kg) KEG & 400 lb. DRUMS.
Sp
e
cifications — Falk LTG (Long Term Grease)
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).
Rexnord
458-120
5555 S. Moorland Rd., New Berlin, WI 53151-7953
January 2005
Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com
Supersedes 06-01
Type GC02
Type GC05
