Disc Couplings • Installation and Maintenance

Type A10 • Sizes 85 thru 8770 (Page 1 of 5)

How To Use This Manual Type A10

This manual provides detailed instructions on installation,
annual maintenance and parts identification. Use the following
Table of Contents to locate required information.

Table of Contents
Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
General Assembly Information . . . . . . . . . . . . . . . . . . Page 1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 2 thru 4
Parts Identification & Order Information . . . . . . . . . . . . Page 5

CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS

MANUAL FOR OPTIMUM PERFORMANCE AND
TROUBLE FREE SERVICE. ANNUAL MAINTENANCE
For extreme or unusual operating conditions, check coupling
INTRODUCTION more frequently.
1. Check alignment per Step 5, Page 4. If operation limits from
This manual applies to standard Type A10 free end float Falk Disc Table 1, Page 3 are exceeded, re-align coupling to
Couplings. Couplings with spacers up to 24" can operate in either installation limits.
the horizontal or vertical position without modification. Falk Disc
Couplings provide limited end float, without mechanical stops, for 2. Check outer blades of discpacks near bushings for fatigue
most applications where a limited end float is required. For cracks. Discpacks can be checked while coupling is in operation
floating shaft or restricted limited end float applications, refer by using a strobe light. Replace cracked discpacks and recheck
to Factory. alignment. A slight bowing or “S” like distortion is normal.
3. Check tightening torques of all drive bolts.
WARNING: Consult applicable local and national safety codes
for proper guarding of rotating members. Observe all safety
rules when installing or servicing couplings. Lockout starting GENERAL ASSEMBLY INFORMATION
switch of prime mover and remove all external loads from drive
before installing or servicing couplings. Standard mechanics tools, torque wrenches, a straight edge and
feeler gauges or dial indicators and brackets and micrometers are
required to install Falk Disc Couplings. For best results use a dial
Maximize Performance & Life indicator to check final alignment and make certain bolts are
The performance and life of couplings depend largely upon tightened to the required elongation or torque listed in Table 1,
how you install and maintain them. Before installing couplings, Page 3. The drive bolts have been factory tightened to the
make certain that foundations of equipment to be connected required elongation indicated in Table 1 and should not be
meet manufacturers’ requirements. Check for soft foot. The use disturbed. Outside micrometer sizes required to measure drive
of stainless steel shims is recommended. Measuring bolt elongation are listed in Table 1, Page 3.
misalignment and positioning equipment within alignment INTERFERENCE FIT HUBS — (See also Step 1, Page 2)
tolerances is simplified with an alignment computer. These Unless otherwise specified, Falk Disc Couplings are furnished
calculations can also be done graphically or mathematically. for an interference fit without set screw. Heat hubs to
It is recommended that final alignment be checked using either 275°F(135°C) using an oven, torch, induction heater or an oil
an alignment computer or graphical analysis. Both methods bath.
allow the incorporation of “cold offsets”, which will
CAUTION: To prevent damage DO NOT heat hubs beyond a
compensate for shaft position changes due to thermal growth.
maximum temperature of 400°F (205°C).

Balanced Couplings When an oxy-acetylene or blow torch is used, use an excess

Balanced couplings are match marked and must be assembled acetylene mixture. Mark hubs near the center of their length in
with mating match marks aligned. several places on hub body with a temperature sensitive
Dynamically balanced couplings crayon, 275°F(135°C) melt temperature. Direct flame towards
have the runout etched at 90° hub bore using constant motion to avoid overheating an area.
intervals around the flange O.D. WARNING: If on oil bath is used, the oil must have a flash
Recheck runouts after coupling is point of 350°F(177°C) or higher. Do not rest hubs on the
mounted. Any wide variation in bottom of the container. Do not use an open flame in a
these readings must be corrected. combustible atmosphere or near combustible materials.
Some possible causes of variation
are burrs on mating components or Heat hubs as instructed above. Mount hubs as quickly as possible
bent shafts. with hub flange face flush with shaft end. Allow hubs to cool
before proceeding. Insert set screws (if required) and tighten.
CLEARANCE FIT HUBS — (See also Step 1, Page 2) Clean all
parts using a non-flammable solvent. Check hubs, shafts and

The Falk Corp., a Sundstrand Company 478-210

P.O. Box 492, Milwaukee, WI 53201 USA November 1997
Telephone: 414-342-3131, Fax: 414-937-4359 Supersedes 6-89
Installation and Maintenance • Disc Couplings
(Page 2 of 5) Type A10 • Sizes 85 thru 8770

keyways for burrs. Do not heat clearance fit hubs. Install keys, mount 2 — Check Angular Alignment
hubs with flange face flush with shaft ends or as otherwise specified Take readings with an inside micrometer at 90° intervals between
and tighten set screws. flange faces. If a dial indicator is used compensate for sag and
attach it on one shaft and rotate the hub 360° while taking
readings on the flange face as shown. Do not exceed installation
INSTALLATION ANGULAR limit specified in Table 1, Page 3. When using a dial
1 — Mount Hubs indicator the best results are achieved by rotating both driver and
Lock out starting switch of prime mover. Check shafts, hub driven shafts together.
bores and keyways for burrs or nicks. Make certain key slides
CAUTION: Dial indicator face readings should not be used on
easily in shaft and hub keyways. (NOTE: Not all keys are
journal bearing equipment due to the liberal end float inherent
square. Certain bore conditions require rectangular keys and in such a design.
these keys may be furnished with the coupling.) Heat hubs as
instructed on Page 1. Mount hubs as quickly as possible with 3 — Check Parallel Offset Alignment
hub flange face flush with shaft end or as otherwise specified. Lay a straight edge squarely across the top of the flanges of
Allow hubs to cool before proceeding. Insert set screws (if both shaft hubs as shown and also at a point 90° away. Check
required) and tighten. Position equipment for approximate clearance with feelers. Multiply this clearance by two (2). This
distance between shaft ends (BE) with minimum angular and value must not exceed the installation PARALLEL OFFSET as
offset alignment. The BE dimension equals X plus two times the calculated in Table 1, Page 3. If a dial indicator is used,
GAP listed in Table 1, Page 3 plus the length of the spacer compensate for sag and attach it on one shaft and rotate the
furnished. hub 360° while taking readings on the other hub male register
outside diameter. Do not exceed the installation PARALLEL
OFFSET limits as calculated in Table 1, Page 3.

BE = X + 2 Gaps + Spacer Length

4 — Install Spacer, Discpacks and Adapter Assembly

After tightening foundation fasteners, recheck alignment and BE
dimension. Check hubs and adapter mounting surfaces for nicks
and burrs and remove with a minimum of material removal.

478-210 The Falk Corp., a Sundstrand Company

November 1997 P.O. Box 492, Milwaukee, WI 53201 USA
Supersedes 6-89 Telephone: 414-342-3131, Fax: 414-937-4359
Disc Couplings • Installation and Maintenance
Type A10 • Sizes 85 thru 8770 (Page 3 of 5)

A. Sizes 85FD06-1700FD06 — Insert installation/removal bolts adapter toward the spacer and allow the spacer assembly to
provided through clearance holes in spacer and into tapped clear the register on the adapter hubs.
holes in adapters. See Table 2. Assemble all fasteners to a C. Place compressed assembly into position. If additional
“finger tight” condition. Then tighten each fastener in both compression is required, tighten each installation/removal
flanges an additional 1 1/2 turns from the finger tight position. bolt on each end an additional 1/2 turn. Align match marks
This will draw the adapters towards the spacer and allow the on flange O.D. if present.
spacer assembly to clear the registers on the adapter hubs.
D. Dip adapter bolt threads in SAE 30 oil and insert bolts with
lockwashers through hub flange holes and engage tapped holes
in each adapter. REMOVE ALL INSTALLATION/REMOVAL
BOLTS FROM BOTH FLANGES and put in a safe place for
future use should center section assembly require removal.
Tighten adapter bolts to the recommended torque as given
in Table 1.

B. Sizes 2500FD08-8770FD08 — Assemble compression cap

and installation/removal bolt on to each main element bolt end
which protrudes through the large holes in each flange of the
spacer. Position compression cap legs such that they do not
cover any portion of the large holes. Tighten installation/removal
bolts to a finger tight condition. Continue until all compression
caps are in position. Then tighten all compression cap
installation/removal bolts an additional 1 1/2 turns drawing the

TABLE 1 — Installation and Alignment Data – Inches

Installation Operation – Max Adpt. Bolt Drive Bolt
BE Axial l Outside
SIZE Gap X Tolerance Angular H (TIR) † Float Tightening Tightening Drive Bolt Micrometer
Angular (TIR)
† Torque – Torque – Elongation
± Max.-Min. Parallel Offset ‡ (TIR) Max.-Min. Max. ± Size – in
lb-ft Oiled lb-ft Oiled
85FD .405 1.04 .015 .015 .0030 X (BE – 1.445) .030 .106 6.7 21 .0025-.0030 1-2
190FD .495 1.36 .015 .017 .0030 X (BE – 1.855) .034 .121 6.7 54 .0035-.0045 1-2
340FD .525 1.50 .015 .020 .0030 X (BE – 2.025) .040 .139 15.7 84 .0035-.0045 2-3
625FD .600 1.90 .015 .022 .0030 X (BE – 2.500) .044 .150 28 169 .0050-.0060 2-3
1080FD .675 2.20 .015 .026 .0030 X (BE – 2.875) .052 .160 74 289 .0060-.0070 3-4
1700FD .750 2.60 .015 .030 .0030 X (BE – 3.350) .060 .212 74 460 .0065-.0075 3-4
2500FD .895 2.46 .015 .023 .0020 X (BE – 3.355) .046 .170 137 466 .0070-.0080 3-4
3160FD .851 2.92 .015 .025 .0020 X (BE – 3.771) .050 .196 137 466 .0065-.0075 4-5
4630FD .851 3.28 .015 .028 .0020 X (BE – 4.131) .056 .231 237 688 .0065-.0075 4-5
6470FD 1.060 3.78 .015 .031 .0020 X (BE – 4.840) .062 .243 137 973 .0090-.0100 5-6
8770FD 1.095 4.44 .015 .034 .0020 X (BE – 5.535) .068 .255 137 1333 .0110-.0120 5-6
★ BE maximum minus BE minimum from Step 2.
† GAP maximum minus GAP minimum from Step 5.
‡ EXAMPLE: A Size 85FD06A 10 with 5" BE. Installation Parallel Offset (TIR) = .0030 x (5 - 1.445) = .011" TIR.
l Values are for installation without misalignment.

The Falk Corp., a Sundstrand Company 478-210

P.O. Box 492, Milwaukee, WI 53201 USA November 1997
Telephone: 414-342-3131, Fax: 414-937-4359 Supersedes 6-89
Installation and Maintenance • Disc Couplings
(Page 4 of 5) Type A10 • Sizes 85 thru 8770

5. Final Alignment — Attach dial indicator to hub as shown 6. Discpack Replacement — Should discpacks require
and take 360° readings as close to spacer flange outside replacement, it is recommended that new drive bolts,
diameter as possible. Alternate method is to measure the overload washers and locknuts also be obtained. If center
difference in minimum and maximum gap between adapter assembly was balanced (with match marks), return entire
flange and spacer flange on both ends of the coupling. Do center assembly to Factory for reassembly and balancing.
not exceed the installation ANGULAR limits specified in A. Remove old discpacks from adapters and spacer and
Table 1. Refer to the Factory for a more accurate alignment discard.
using the Reverse Dial Indicator Method.
B. Install overload washers onto half of the new drive bolts
provided and dip threads of ALL drive bolts in SAE 30 or
equivalent oil. Insert drive bolts with overload washers
through alternate holes in each discpack and through the
small holes in each end of the spacer and install nuts until
bolts protrude through nut. DO NO FULLY TIGHTEN.
C. Insert the remaining drive bolts from the counterbore side of
each adapter through the three small non-threaded holes
and through the remaining holes in each discpack. These
bolts should now be protruding through the large holes in
each flange of the spacer. Install the remaining overload
washers and nuts onto these bolts. All nuts should be on the
spacer side and all bolt heads located in the adapter.
D. Tightening of all drive bolts should be done with the center
component assembly in a horizontal position. The most
reliable method of tightening drive bolts is achieved using
Drive Bolt Elongation. Measure the length of the #1 drive
bolt with an outside micrometer and record. Hold the drive
bolt head and tighten the nut to the tightening torque listed
in Table 1. Recheck drive bolt length. Subtract the first
reading from the second reading. Compare the difference
to the elongation listed in Table 1. If required, increase or
decrease tightening to achieve proper elongation. Repeat
this procedure for each drive bolt in cylinder head fashion
illustrated below.

DRIVE BOLT TIGHTENING PATTERN

TABLE 2 — Installation/Removal Bolts

SIZE Quantity Bolt Size
85FD 6 .3125-18UNC x 1.000
190FD 6 .3125-18UNC x 1.000
340FD 6 .2500-20UNC x 1.500
625FD 6 .3125-18UNC x 1.500
1080FD 6 .3750-16UNC x 1.750
1700FD 6 .3750-16UNC x 1.750
2500FD 8† .2500-20UNC x 0.500
3160FD 8† .2500-20UNC x 0.500
4630FD 8† .3750-16UNC x 0.625
6470FD 8† .3750-16UNC x 0.625
8770FD 8† .3750-16UNC x 0.625
† Bolts to be used with compression caps originally furnished with coupling.

478-210 The Falk Corp., a Sundstrand Company

November 1997 P.O. Box 492, Milwaukee, WI 53201 USA
Supersedes 6-89 Telephone: 414-342-3131, Fax: 414-937-4359
Disc Couplings • Installation and Maintenance
Type A10 • Sizes 85 thru 8770 (Page 5 of 5)

PARTS IDENTIFICATION ORDER INFORMATION

All coupling parts have identifying part numbers. When ordering 1. Identify part(s) required by name below.
parts, always specify SIZE and TYPE shown on the hub and the 2. Furnish the following information.
part number on the spacer and adapters. For couplings with EXAMPLE:
special length spacers, furnish M.O. Number, “CL” dimension and Coupling Size: 85FD
drawing number stamped on the spacer. The decimal bore size is Hub Type: A
stamped on the hub face opposite the flange. Bore: 3.250
Keyway: .875 X .438
Spacers: Size or Part Number
Adapters: Part Number
Discpacks: Part Number
3. Price parts from Price List 472-110 and appropriate
discount sheet.

PART NUMBER LOCATION

The Falk Corp., a Sundstrand Company 478-210

P.O. Box 492, Milwaukee, WI 53201 USA November 1997
Telephone: 414-342-3131, Fax: 414-937-4359 Supersedes 6-89