Installation & Maintenance, True Torque, Type HFD25, HFDD25, Sizes 370-870, 1420-1760 Brochure

How to Use This ManualFor HFD25 & HFDD25 (Sizes 370, & 1420 thru 1760 and2760), use this manual in conjunction with Disc Couplingmanual 478-210.This manual provides detailed instructions on installation,maintenance and parts identification. Use the following Tableof Contents to locate required information.Table of ContentsGeneral Information . . . . . . . . . . . . . . . . . Page 1Recommended Fluids . . . . . . . . . . . . . . . . Page 1Installation . . . . . . . . . . . . . . . . . . . . . Page 2Orifice Plugs(Sizes 1420 and larger) . . . . . . . . . . . . . . . Page 4Fusible Plugs . . . . . . . . . . . . . . . . . . . . Page 5Startup and Trouble Shooting . . . . . . . . . . . . Page 6Fluid Coupling Data Record . . . . . . . . . . . . . Page 6CAREFULLY FOLLOW THE INSTRUCTIONS IN THISMANUAL FOR OPTIMUM PERFORMANCE AND TROUBLEFREE SERVICE.INTRODUCTIONType HF fluid couplings are designed for horizontal operation.Falk disc couplings provide limited end float, withoutmechanical stops, for most applications where a limited endfloat coupling is required. Refer to Factory for couplingoperation other than horizontal or for restricted limited endfloat requirements.Each fluid coupling is shipped from Falk with an angle finder(P/N 1224653). Simply place the angle finder on the filler plugboss and rotate the coupling to the required fill angle asinstructed in the “Fill Fluid Coupling” section of these instructions.Maximize Performance & LifeThe performance and life of couplings depend largely uponhow you install and maintain them. Before installing couplings,make certain that foundations of equipment to be connectedmeet manufacturers’ requirements. Check for soft foot. The useof stainless steel shims is recommended. Measuringmisalignment and positioning equipment within alignmenttolerances is simplified with an alignment computer. Thesecalculations can also be done graphically or mathematically.It is recommended that final alignment be checked usingeither an alignment computer or graphical analysis. Bothmethods allow the incorporation of “cold offsets”, which willcompensate for shaft position changes due to thermal growth.WARNING: Lock out starting switch of prime mover and removeall external loads from drive before installing or servicingcouplings.WARNING: Opening of drain plugs, filler plugs or meteringorifice seal plugs of a fluid coupling should be done after thecoupling has cooled down. When opening the plugs of a warmor hot fluid coupling is absolutely necessary, place a rag overthe plug/plug hole, and loosen the plug slowly to relieve anyinternal pressure.WARNING: Consult applicable local and national safetycodes for proper guarding of rotating members. Guard mustnot restrict free flow of air, but the portion of the guard in linewith fusible plugs must be solid construction. Observe allsafety rules when installing or servicing couplings.CAUTION: DO NOT PAINT fluid coupling. Painting will reducefluid coupling thermal heat dissipation characteristics.CAUTION: DO NOT spray water on a hot fluid coupling, asthis may result in cracking of aluminum components.IDENTIFICATION:Coupling size and M.O. Number (Mfg Order Number) arestamped on the perimeter of the coupling. Where Falk hasbeen provided application data (HP, speed, start factor, drivenequipment), the coupling will also include an orange label onthe perimeter, indicating the approximate fill quantity in fluidounces, and the correct fill angle. Provide coupling size andM.O. number when ordering spare parts.Disc Coupling — Refer to disc coupling service manual,478-210.Fluid Coupling — Size and Type are stamped on couplingperimeter. Refer to Falk for replacement parts.Keep Records for Future ReferenceFuture maintenance of the fluid coupling can be greatlysimplified by keeping good records. It is strongly suggestedthat the Fluid Coupling Data Record, Table 7, be completedand stored in the maintenance files.RECOMMENDED FLUIDSThe following specifications and fluids listed in Table 1 apply toFalk fluid couplings. Refer to Falk for use of fire resistant fluids.NOTE: Fluids listed are typical products ONLY and should not beconstrued as exclusive recommendations.ISO Viscosity Grade, Petroleum Oils (R & O) . . . . . . . 46ISO Viscosity Grade, Synthetic Oils. . . . . . . . . . . . 32Viscosity at 104°F(40°C) — 46 cSt (215 SSU)Viscosity Index — Equal to or greater than 95.Pour Point — Must be 5°F(3°C) lower than minimumambient starting temperature.Rexnord Industries, LLC, Coupling Group 528-2705555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 June 2006Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com Supersedes 7-96Falk™ Fluid Couplings • Installation and Maintenance InstructionsSizes 370, 1420-1760/2760 • Types HFD25 & HFDD25 (Page 1 of 6)PERIMETERFASTENERSHF OUTPUTADAPTERDISC COUPLINGOUTPUT ADAPTERDISC COUPLINGADAPTER BOLT &LOCKNUTDRAIN PLUG284ºF (140ºC)DELAY FILLCHAMBERORIFICE SEALPLUG (1000SERIES ONLY)HF INPUTADAPTERFILL PLUG392ºF (200ºC)Figure 1Flash Point — 400°F(204°C) when using 140°C and/or180°C fusible plugs.Flash Point — 425°F (218°C) when using 200°C fusibleplugs at both fill and drain holes.Specific Gravity — 0.87Antioxidant and Anti-foaming AdditivesAnnual Maintenance1. Check shaft coupling alignment on a regular basis.Excessive misalignment will transfer damaging loads to theconnected equipment and may cause failure.2. An annual check of the coupling and fluid is recommended.For extreme or unusual operating conditions, or when thecoupling is subjected to overheating, check the couplingand fluid more frequently. Overheated fluid which becomesdark in color and gives off a burnt odor, must be changed.Fluid suppliers can test coupling fluid samples periodicallyand recommend economical change periods based on therate of degradation. Continuous operating temperaturemust not exceed 212°F (100°C).3. Check outer blades of discpacks near bushings for fatiguecracks. Discpacks can be checked while coupling is inoperation by using a strobe light. Replace cracked discpacksper disc coupling service manual and recheck alignment. Aslight bowing or “S” like distortion is normal.4. Check tightening torques of all drive bolts.LiftingRemove two perimeter fasteners (metric) approximately 90°apart. Insert threaded rod (Table 2) with washers and nuts,then sling coupling as shown in Figure 2.Key Installation Tips? Do not exceed specified tightening torques for fusibleplugs at fill and drain holes (Step 4D). Excessivetightening may strip aluminum threads.? Mount the fluid coupling as shown in Figure 4, theoutput adapter side of the coupling must be connectedto the driven equipment. Attaching the output adapterside of the fluid coupling to the driver (usually a motor)will result in degraded performance, or in some casesinadequate performance.? After initial installation, store clamping bolts so they areavailable if the fluid coupling should need to beremoved.? Carefully follow the instructions in this manual.INSTALLATIONOnly standard mechanics tools, torque wrenches, feelergauges, straight edges and a bevel protractor with spirit levelor Falk Angle Finder (P/N 1224653) are required to installFalk fluid couplings.Rexnord Industries, LLC, Coupling Group528-2705555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone: 262-796-4060June 2006Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.comSupersedes 7-96Installation and Maintenance Instructions • Falk™ Fluid Couplings(Page 2 of 6) Types HFD25 & HFDD25 • Sizes 370, 1420-1760/2760TABLE 2 — Type HF Perimeter Fastener Size& Tightening Torques/ThreadedRod DiameterCOUPLINGSIZE370 1420 1480 1584 166017602760Torquelb-ft 33 33 33 88 81 140Size(mm) M10 x 80 M10 x 80 M10 x 80 M14 x 100 M14 x 120 M16 x 160ThreadedRod — Dia-in .375 .500 .625Figure 2TABLE 1 — Fluids & Operating TemperaturesPetroleum Oils (R & O)For Ambient Temperatures 20°F to 125°F (-6°C to 52°C)Manufacturer FluidAmoco Oil Company American Industrial Oil 46BP Oil Company HL-C46Chevron Products Company Hydraulic Oil AW 46Exxon Company, USA Teresstic 46Mobil Oil Corporation Mobil Fluid 424Petro-Canada Products Harmony 46Shell Oil Company Turbo T 46Texaco Lubricants Company Rando Oil HD 4676 Lubricants Company 76 Unax AW 46Petroleum Oils (R & O)For Ambient Temperatures -20°F to 125°F (-28°C to 52°C)Manufacturer FluidAmoco Oil Company American Industrial Oil 46Mobil Oil Corporation Mobilfluid 424Synthetic Oils and Synthetic Transmission FluidsFor Ambient Temperatures -40°F to 125°F (-40°C to 52°C)Manufacturer FluidConoco Incorporated Syncon R&O 32Exxon Company, USA Teresstic SHP 32Mobil Oil Corporation SHC 624Texaco Lubricants Company Pinnacle 32Mobil Oil Corp. Synthetic ATFChevron Synthetic All Weather THFCitgo Transgard Fluid 250Automatic Transmission Fluids (Dexron or Mercon Oils, etc.)For Ambient Temperatures -40°F to 125°F (-40°C to 52°C)NOTICE: Automatic Transmission Fluids below can onlybe used with two 140°C fusible plugsMobil Multi-purpose ATFTexaco (Havoline) Mercon/Dexron-III or ATFCitgo Transgard ATF,Type FATF Type A and Type Dexron II, llD, llE, lll, Mercon M-891205 and M-921253The discpack drive bolts have been Factory tightened to therequired elongation indicated in Manual 478-210.INTERFERENCE FIT HUBS — Unless otherwise specified,Falk disc couplings are furnished for an interference fit withoutset screw. Heat hubs to a maximum 275°F (135°C) using anoven, torch, induction heater or an oil bath.When an oxy-acetylene or blow torch is used, use an excessacetylene mixture, as well as a rose bud tip. Mark hubs nearthe center of their length in several places on hub body with atemperature sensitive crayon, 275°F (135°C) melttemperature. Direct flame towards hub bore using constantmotion to avoid overheating an area.WARNING: If an oil bath is used, the oil must have a flashpoint of 350°F (177°C) or higher. Do not rest hubs on thebottom of the container. Do not use an open flame in acombustible atmosphere or near combustible materials.CLEARANCE FIT HUBS — Clean all parts using anon-flammable solvent. Check hubs, shafts and keyways forburrs. Do not heat clearance fit hubs. Install keys, mount hubswith flange face flush with shaft end or as otherwise specifiedand tighten set screws.1. Install Type FD Shaft Hubs (A-Hubs)A. Lock out starting switch of prime mover.B. Determine required distance between shaft ends (BE)from Table 3.C. Install Type FD shaft hubs (A-Hubs) on the driving shaftand driven shaft, and align the disc coupling A-Hubs perinstructions found in the disc coupling service manual.2. Install Type HFD25 or HFDD25 Fluid CouplingA. The fluid coupling is shipped with input and outputadapters, discpacks and coupling adapters assembledas shown in Figure 1, Page 1.B. Remove clamping bolts and plastic spacer tubes on bothends between coupling adapter and input/outputadapter, see Figure 3a. Properly discard spacer tubeswhile keeping the clamping bolts for use in the followingsteps.See Table 3 for clamping bolt size and number.CAUTION: Plastic spacer tubes must be removed fromcoupling at time of installation.C. Re-insert clamping bolts on both ends between couplingadapter and input/output adapter as shown in Fig. 3b.D. Evenly tighten bolts 1 1/2 turns from “Finger Tight” tocompress discpacks. DO NOT OVER TIGHTEN.Discpacks are now modestly compressed to aid thesubsequent assembly process.E. Position fluid coupling assembly between disc couplinghubs as close to the centerline as possible, Figure 4.F. With fluid coupling suspended from the sling, align theholes of the disc coupling A-Hubs with the holes in theadapters, and insert the adapter bolts on both sides(Figure 3c).G. Slowly remove clamping bolts between couplingadapters and input/output adapters to decompress thediscpacks. Make sure disc coupling A-Hubs areproperly seated in adapter registers (see Figure 3c).Store clamping bolts so they are available if the fluidcoupling should need to be removed.Rexnord Industries, LLC, Coupling Group 528-2705555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 June 2006Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com Supersedes 7-96Falk™ Fluid Couplings • Installation and Maintenance InstructionsSizes 370, 1420-1760/2760 • Types HFD25 & HFDD25 (Page 3 of 6)CLAMPINGBOLTCOUPLINGADAPTERINPUT OROUTPUTADAPTERINPUT OROUTPUTADAPTERCLAMPINGBOLTPLASTICSPACERTUBECOUPLINGADAPTERDISC COUPLINGADAPTER BOLT& LOCKNUTA-HUBFigure 3bFigure 3aTABLE 3 — Disc Coupling Clamp Bolt SizeFLUIDCOUPLINGSIZEDISCCOUPLINGSIZEBE Disc CouplingAdapter BoltTighteningTorque lb-ftClamping BoltNo.– Size(Grade 5 or Better)See Figure 3HFD25 HFDD25370 190 15.60 16.98 12 (6) .3125-18UNC x 1.375?1420 190 17.12 20.23 12 (6) .3125-18UNC x 1.375?1480 340 19.50 22.92 25 (6) .3750-20UNC x 1.750 †1584 625 22.18 26.00 43 (6) .3125-18UNC x 2.000 †1660 1080 25.25 29.58 103 (6) .3750-16UNC x 2.250 †1760/2760 1700 28.88 33.72 103 (6) .3750-16UNC x 2.500 †? Socket head cap screws.† Hex head cap screws.Figure 3cFigure 4H. Install locknuts and tighten bolts/locknuts on outputside first according to the required adapter bolttightening torque specified in Table 3. Repeat for inputside.CAUTION: Clamping bolts must be removed fromcoupling before operation.I. Reinstall perimeter fasteners and washers. Tighten totorque specified in Table 2, Page 2J. Recheck final alignment per disc coupling servicemanual.3. Fill Fluid CouplingA. Rotate fluid coupling until fill plug is on top and removethe fill plug, (both fill and drain plugs have metricthreads). See Figure 1, Page 1. NOTE: Coupling canbe filled through either the fill or the drain plugs.B. Fill with the required amount of fluid. Fill information isfound on the orange label that is affixed to the couplingperimeter. Where no orange label is present, refer tofluid coupling Selection Guide 521-110 for fill data.Fluid must meet the specifications listed in Table 1.Do not remove orange fluid fill label that is affixed tothe coupling perimeter. In cases where no orange labelis affixed, a blank label is furnished. Fill out the blankorange label once proper fill date has beendetermined, then affix that label to the coupling.C. Before reinstalling fill plug, check fill angle as describedin the following step. Also, heed fill plug tighteninginstructions, Step 4D.4. Check Fill AngleA. Refer to fluid fill label described in previous step forrequired fill angle.B. Use either a Falk Angle Finder or a bevel protractorwith spirit level set for the required fill angle, and placeit on flat boss of filler hole as shown in Figure 5.C. Slowly rotate fluid coupling until the required fill angleis achieved, Figure 6. Fluid must appear at the lip ofthe hole. Add or drain fluid until level is correct. Figure7 shows fill angle examples.D. Reinstall fill plug with seal ring and tighten to requiretorque: Sizes 370-1660, 33 lb-ft (44.75 Nm); Sizes1760/2760, 59lb-ft (80.00 Nm). DO NOT EXCEEDSPECIFIED TIGHTENING TORQUE, as aluminumthreads may strip.5. Orifice Plugs (Sizes 1420 through 1760 and 2760 ,Types HFD & HFDD only)The 1000 Series fluid couplings contain 3 orifice plugs (metricthreaded) located near the outer part of the casing. They arelocated behind three metric hex socket seal plugs (see Figure8). The function of these orifice plugs is to meter the fluidexiting from the delay fill chamber into the working circuit ofthe fluid coupling. These plugs are initially furnished with a2.5mm hole (Sizes 1420-1660HF) and 3.5mm on Sizes 1760and 2760, which results in acceptable starting times for mostapplications. Should the application require increased orreduced starting times, refer to Table 4 for other orifice holesizes and their estimated effect on starting time. Theseestimates are based on the change in flow rate for the fluid toexit the delay fill chamber. Couplings are furnished with aspare set of orifice plugs (undrilled).CAUTION: Increasing the starting time can result inoverheating the fluid coupling and blowing the fusible plugs.Refer to Table 5 for orifice, seal plugs sizes, tightening torques,and required metric hex “Allen” wrench sizes. Apply anti-seizecompound to the orifice plugs prior to their assembly. This willassist in the event of future removal. Typical compounds (orequal) are as follows:Loctite™ Anti-Seize Thread Compound #767Dow Corning 1000 High Temperature Anti-Seize PasteRexnord Industries, LLC, Coupling Group528-2705555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone: 262-796-4060June 2006Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.comSupersedes 7-96Installation and Maintenance Instructions • Falk™ Fluid Couplings(Page 4 of 6) Types HFD25 & HFDD25 • Sizes 370, 1420-1760/2760Figure 6FILL ANGLEFigure 50°0°0°0°100°FILLANGLEOF50°50°HIGHLEVELOF FILL LOW LEVELOF FILLFILL ANGLEOF100°Figure 76. Fusible PlugsA. Fusible plugs in the fill or drain holes have solder cores thatmelt at the temperatures shown in Figure 1, Page 1. Oneextra 284°F (140°C) plug is furnished with each coupling.B. If solder in fusible plug melts due to overheating fromstalling or overloading, refer to Table 6, Page 6 andcorrect the cause of overheating.CAUTION: DO NOT replace fusible plugs with solid plugs.Use of solid plugs can result in coupling failure fromoverheating unless used in conjunction with a thermal tripswitch. Refer to Falk for thermal trip switch feature.C. Replace fusible plug as instructed in Step 4D.D. Refill coupling with clean fluid as instructed in Steps 3 and 4.Rexnord Industries, LLC, Coupling Group 528-2705555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 June 2006Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com Supersedes 7-96Falk™ Fluid Couplings • Installation and Maintenance InstructionsSizes 370, 1420-1760/2760 • Types HFD25 & HFDD25 (Page 5 of 6)TABLE 5 — Orifice & Seal Plug Sizes – mmCPLG. SIZEOrifice Plug DIN 906 Seal Plug DIN 908 Seal WasherDIN 7603Type “A”CopperThreadSizeHex KeySizeThreadSizeHex KeySize1420 1/8R BSPT 5 mm 18 x 1.5 mm 10 mm 18 x 22 x 1.5 mm1480 1/4R BSPT 6 mm 18 x 1.5 mm 10 mm 18 x 22 x 1.5 mm1584 3/8R BSPT 8 mm 22 x 1.5 mm 12 mm 22 x 27 x 1.5 mm1660 3/8R BSPT 8 mm 22 x 1.5 mm 12 mm 22 x 27 x 1.5 mm1760/2760 1/2R BSPT 10 mm 27 x 2.0 mm 17 mm 27 x 32 x 2.0 mmTABLE 4 — Fluid Coupling Starting TimesOrifice Hole DiameterEstimated Starting Time – % of Original1420HF – 1660HF 1760HF/2760HF3/64" (0.0469) 440 8601/16" (0.0625) 250 4905/64" (0.0781) 160 3103/32" (0.0937) 110 2202.5mm (0.0984) 100 2007/64" (0.1094) 80 1601/8" (0.1250) 60 1203.5mm (0.1380) 50 1005/32" (0.1562) 40 803/16" (0.1875) 30 50ORIFICE PLUGSEAL WASHERSEALPLUGFigure 8Rexnord Industries, LLC, Coupling Group528-2705555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone: 262-796-4060June 2006Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.comSupersedes 7-96Installation and Maintenance Instructions • Falk™ Fluid Couplings(Page 6 of 6) Types HFD25 & HFDD25 • Sizes 370, 1420-1760/2760TABLE 6 — Startup & Trouble ShootingProblem Possible Cause SolutionDriven shaft fails to reach specified speed.Drive motor defective orincorrectly connected.Check motor connection, speed, amperagedraw and power draw.Driven machine jammed. Check driven machine and remove jam.Power consumption exceeds couplingcapacity at specified fill angle.?Coupling over or under filled. Re-check fill angle per Step 4.Coupling leaking.Correct source of leakage and re-check fillangle per Step 4.Size 1420HFD, HFDD, and larger – Orificeplug hole plugged.Clean orifice plug hole or use larger hole.Fusible plugs melt.Coupling under filled. Re-check fill angle per Step 4.Size 1420HFD, HFDD, and larger – Orificeplug hole too small or plugged.Enlarge orifice hole size (See Table 4 forestimatedstart time reduction) or clean plugged holes.Coupling leaking.Correct source of leakage and re-check fillangle per Step 4.Driven machine jammed. Check driven machine and remove jam.Power consumption exceeds couplingcapacity at specified fill angle.?Coupling vibration exceeds acceptable limits.Incorrect shaft coupling alignment.Re-align per instructions in shaft couplingservice manual.Incorrect shaft coupling alignment dueto thermal growth.Check “HOT” alignment and adjust tocompensate for thermal growth.Worn shaft coupling parts.Correct cause of wear and replace wornparts.Loose foundation, shaft coupling oradapter fasteners.Check and tighten fasteners accordingly.Damaged fluid coupling bearing.Return fluid coupling to Factory forbearing replacement.? Increase fluid fill by decreasing fill angle in 5° increments to a minimum of 50° for HFD or 60° for HFDD. If drive shaft still does not reach specified speed, refer to Falk.TABLE 7 — Fluid Coupling Data RecordEquipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor/Brake Hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . @ . . . . . . . . . Input RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fluid Coupling Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fill Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . Degrees. Fill Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl. Oz.Fluid Used (Mfg & Fluid Designation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Falk M.O. Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . .