Rexnord Falk Drive One D Series Owner'S Manual Download Page 6

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Oil Levels

TYPES DH & DB —

Fill the drive with oil to the level indicated

on the oil dipstick. Approximate oil capacities are given on the
drive nameplate. Gear drive can be filled through oil fill plug
or inspection cover. Clean area around fill location BEFORE
removing plug or cover to reduce the risk of debris
contaminating the drive. When filling with oil, pour a minimum
of 20 liters (5 gallons) of oil into lubrication pan in the top of
the drive, allow oil to drain from pan before checking level.
Lubricant must be clean to maximize gear and bearing life. It is
recommended to filter new oil when filling or adding oil to the
gear drive.
The inspection cover is sealed with a non hardening chemical
gasket eliminator. When replacing the inspection cover, run a
bead of Loctite Gasket Sealant #2 (or equivalent) around the
perimeter of the inspection opening, making sure to circle the
fastener holes.

DRIVES WITH OIL PUMPS

— Occasionally gear drives will be

equipped with oil pumps for cooling or special lubrication
considerations. If a drive is equipped with an oil pump, fill the
drive to the level marked on the dipstick. Run the lubrication
system for several minutes to fill the system components. Verify
that the pump is circulating oil properly, then recheck oil level.
If necessary, add oil to compensate for filter and/or cooler.
Before starting the gear drive, rotate the input shaft to check for
obstructions. Then start the drive and allow it to run without
load for several minutes. Shut down and recheck oil level. If
everything is satisfactory, the drive is ready for operation.

Preventive Maintenance

AFTER FIRST WEEK —

Check alignment of total system and

realign where necessary. Also tighten all external bolts and
plugs where necessary. DO NOT readjust the internal gear or
bearing settings in the drive, these were permanently set at the
Factory. See Table 7 for fastener and wrench sizes.

AFTER FIRST MONTH —

Proceed as follows:

1. Operate drive until old sump oil reaches normal operating

temperature. Shut down drive and drain immediately.

2. Immediately flush drive with an oil of the same type and

viscosity grade as the original charge (warmed to
approximately 38°C (100°F) in cold weather) by rapidly
pouring or pumping a charge equal to 15 - 25% of the
initial fill volume or until clean oil flows through the drain.

3. Close the drain and refill the drive to the correct level with

new oil of the correct type and viscosity.

PERIODICALLY —

1. Check the oil level of the drive when it is stopped and at

ambient temperature. Add oil if needed. If the oil level is
ABOVE the high oil level mark on the dipstick, have the oil
analyzed for water content. Moisture in the oil may indicate
that a seal or the heat exchanger is leaking. If so, replace
the defective part immediately and change the oil. DO
NOT fill above the mark indicated as leakage or undue
heating may result.

2. Check coupling alignment to make certain that foundation

settling has not caused excessive misalignment.

3. If drive is equipped with a fan, periodically clean accumulated

foreign matter from the fan, guard, and deflector.

4. If drive is equipped with a torque arm, check for free

movement.

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492

168-056

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131

February 2009 (PN 2128959)

Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com

NEW

Owners Manual

•

Falk™ Drive One™ Model C Conveyor Drives

(Page 6 of 16)

Sizes M1220 thru M1250

•

Type D Series

TABLE 7 — Fastener & Wrench Sizes

Fastener

DRIVE SIZE

M1220

M1230

M1240

M1250

Foot

Mounting

Screw Size

M42

M48

Wrench Size

65mm

75mm

Housing

Top Plate

Screw Size

M12

Wrench Size

18mm

Housing

Bottom

Screw Size

M12

Wrench Size

18mm

Inspection

Cover

Screw Size

Wrench Size

13mm

Jackscrews

Screw Size

M16

Wrench Size

24mm

Magnetic

Drain Plugs

Plug Size

1.250 NPT

Wrench Size

15/16

Other Plugs

Plug Size

1.250 NPT

Sq. Skt.

3/4

Shaft Fan

Shroud

Screw Size

M12

Wrench Size

18mm

Shaft Fan

Setscrew

Screw Size

M10

Hex Size

5mm

TABLE 6 —

Lithium Based Greases for
Bearings and Seals

–18° to +93°C (0° to 200°F) ‡

Manufacturer

Lubricant

Amoco Oil Co.

Amolith Grease No.2

BP Oil Co.

Energrease LS EP2

Chevron U.S.A.

Industrial Grease Medium

Citgo Petroleum Corp.

Premium Lithium Grease No. 2

Conoco, Inc.

Multiplex Red

Mobil Oil Corp.

Mobilux EP2

Mobil Oil Corp.

Mobilith SHC 460

Petro-Canada Products

Multipurpose EP2

Phillips 66 Co.

Multiplex Red

Shell Oil Co.

Alvania Grease 2

Shell Canada Ltd

Alvania Grease 2

Texaco Lubricants

Premium RB Grease

High performance synthetic alternate.

‡

For ambient or operating temperatures outside this range, review application
with grease supplier or consult the Factory.

Summary of Contents for Falk Drive One D Series

Page 1: ...imposed by the drive system in which such products are installed unless the nature of such vibrations has been defined and accepted in writing by Company as a condition of operation II failure to provide suitable installation environment III use for purposes other than those for which designed or other abuse or misuse IV unauthorized attachments modifications or disassembly or V mishandling during...

Page 2: ...astener size Tighten fasteners to the torque specified in Table 1 Page 4 If the required torque is not attainable the fasteners may be tightened with a pre torque of 270 N m 200 lb ft then tightened an additional 60 of rotation with a slugging wrench to achieve proper torque After drive is aligned with driven equipment and bolted down align prime mover to drive input shaft Refer to Page 3 for coup...

Page 3: ...eflection Align the output shaft of the gear drive square and parallel with the driven shaft by placing a straightedge across the face of the sprockets or sheaves as illustrated Check horizontal shaft alignment by placing one leg of a square against the face of the sheave or sprocket with the spirit level on the horizontal leg of the square DO NOT over tighten belts or chains Adjust chains to manu...

Page 4: ... used only after approval from Factory Failure to use an approved lubricant voids warranty For drives operating outside the above temperature range refer to the Synthetic EP Lubricants section Synthetic lubricants can also be used in normal climates WARNING EP LUBRICANTS IN FOOD PROCESSING INDUSTRY EP lubricants may contain toxic substances and should not be used in the food processing industry wi...

Page 5: ...DA or NSF H 1 classification Consult the Factory Rexnord Industries LLC Geared Products P O Box 492 Zip 53201 0492 168 056 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 PN 2128959 February 2009 Fax 414 937 4359 e mail info rexnord com web www rexnord com NEW Falk Drive One Model C Conveyor Drives Owners Manual Type D Series Sizes M1220 thru M1250 Page 5 of 16 TABLE 3 Visco...

Page 6: ... level with new oil of the correct type and viscosity PERIODICALLY 1 Check the oil level of the drive when it is stopped and at ambient temperature Add oil if needed If the oil level is ABOVE the high oil level mark on the dipstick have the oil analyzed for water content Moisture in the oil may indicate that a seal or the heat exchanger is leaking If so replace the defective part immediately and c...

Page 7: ...using seal leaks GREASE LUBRICATED BEARINGS Torque Arm Most shaft mounted drives have a grease lubricated bearings in the torque arm Grease bearings during oil changes or at intervals of every 6 months or 2500 hours of operation whichever is less Stored Inactive Gear Drives Each gear drive is protected with a rust preventative that will protect parts against rust for a period of 4 months in an out...

Page 8: ...e 515 Gasket Eliminator or equivalent to the housing mating surface to the inside of the bolt pattern Assemble bottom plate to housing and tighten fasteners to 85 N m 62 lb ft Install previously remove pipe plugs into old dipstick and breather location Coat pipe threads with Loctite Pipe Joint Compound or equivalent prior to installation Position drive top side up Install dipstick fitting in housi...

Page 9: ... structure at this time 2 Secure the drive to the driven equipment via the rigid coupling connection 3 Mount the clevis to the drive or drive system Locate the position of the clevis to be mounted to the support structure Match drill the mounting holes for M24 Cl 8 8 or 1 inch Grade 5 fasteners or better 4 IF REQUIRED Mount plain spherical bearings into link Secure bearings with retainer plate and...

Page 10: ... gauge to ensure that all motor pads are firmly seated Motor mounting needs to be done in conjunction with coupling alignment to control angular and offset misalignment Refer to the coupling manufacturer s manual for specific instructions Bolt down the motor to the torque specified in Table 1 Page 4 Coupling Guard The coupling guard must be trimmed in order to fit the height and shaft extension re...

Page 11: ...luid Coupling Location of the fluid coupling on the high speed shaft of the drive is determined by the provided shaft spacer Install the fluid coupling on the high speed shaft of the gear drive per fluid coupling instructions Once the fluid coupling is installed the motor adapter plate can be mounted to the bell housing also being located by a register Measurements must be taken to accurately posi...

Page 12: ...e this is the amount each hub overhangs the shaft Once the overhang is determined install the hubs according to the instructions provided with the coupling Install the spacer sections and verify the gap is correct If not readjust the hub on the motor shaft If the coupling is furnished with an interference fit readjustment will not be possible take extra care in making measurements After the proper...

Page 13: ... installed removed without removing the motor see fluid coupling instructions for procedure Mount the coupling hubs to the drive high speed shaft and the motor shaft Hubs are to be mounted flush with the end of the shafts coupling hubs may be furnished with an interference fit Mount the motor to the bell housing apply Loctite 242 or equivalent fastener threads and tighten to proper torque Install ...

Page 14: ...the drive housing itself to maneuver the drive DO NOT lift by the motor lifting eye Mounting the Drive Mount the Alignment Free Drive to the driven equipment per Pages 1 and 2 of this manual With Alignment Free drive assembly supported rotate adjusting screw to move torque arm to desired position and to line up with foundation Torque Arm must be perpendicular in both directions 1 adjust screw if n...

Page 15: ...nd cooling use only DO NOT use if hazardous or explosive materials and vapors are present Guidelines For Installation Before connecting the electric fan check if the information on the fan motor name plate is in accordance with the actual main supply voltage phase and frequency Warning To reduce the risk of fire electric shock or personal injury observe the following 1 Switch off the main power su...

Page 16: ...hen cleaning fan both condensation holes Figure 3 Items 1 and 2 are to be temporarily plugged If this is not done guarantee is void When cleaning electrical equipment always use an approved cleaning agent Rexnord Industries LLC Geared Products P O Box 492 Zip 53201 0492 168 056 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 February 2009 PN 2128959 Fax 414 937 4359 e mail i...

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