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Rexnord Falk Drive One DB, Owner'S Manual, Page: 2 / 27

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Rexnord Falk Drive One DB Owner'S Manual Download Page 2

Owners Manual 

•

 Falk

™

 Drive One

®

 Enclosed Gear Drives

(Page 2 of 27) 

Type D Series 

•

 Sizes M1130 thru M1210

168-050

 

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 

Telephone: 414-342-3131 Fax: 414-937-4359

Supersedes 04-11 

e-mail: [email protected] web: www.rexnord.com

(PN 2124650)

FOUNDATION, STEEL

 — When mounting gear drive on 

structural steel, it is recommended that an engineered 

design be utilized for a pedestal, 

adapter base or bed to provide 

sufficient rigidity, to prevent 

induced loads from distorting 

the housing and causing gear 

misalignment. In the absence 

of  an engineered design, it is 

recommended that a base plate, 

with thickness equal to or greater 

than the thickness of  the drive 

feet, be securely bolted to steel supports and extend 

under the entire drive as illustrated.

FOUNDATION, CONCRETE

 — If  a concrete foundation is 

used, allow the concrete to set firmly before bolting down 

the gear drive. For the 

best type of  mounting, 

grout structural steel 

mounting pads into 

the mounting base, as 

illustrated, rather than 

grouting the drive directly into the concrete.
Motors and other components mounted on motor plates or 

motor brackets may become misaligned during shipment. 

ALWAYS check alignment after installation. Refer to page 5 

for coupling alignment instructions.

Gear Drive Alignment

FOOT-MOUNTED DRIVES

 – Align drive with driven 

equipment by placing broad, flat shims under all mounting 

pads. Jack screw holes are provided by mounting feet to 

facilitate alignment. See Table 12, page 10 for fastener 

and wrench sizes. Start at the low-speed shaft end and 

level across the length and then the width of  the drive. 

Check with a feeler gauge to make certain that all pads are 

supported to prevent distortion of  housing when drive is 

bolted down. After drive is aligned with driven equipment 

and bolted down, align prime mover to drive input shaft. 

Refer to page 5 for coupling alignment.

CONTINUOUS PLATE

LIFTING HOLES

2 PER CORNER

(16 TOTAL)

JACKING

SCREW HOLES

DIPSTICK/VENT

HOLES

JACKING

SCREW HOLES

DRAIN

PLUG

If  equipment is received from the Factory mounted on 

a bedplate, the components were accurately aligned at 

the Factory with the bedplate mounted on a large, flat 

assembly plate. Shim under the bedplate foot pads until 

the gear drive is level and all feet are in the same plane.
Check high-speed shaft coupling alignment. If  the 

coupling is misaligned, the bedplate is shimmed 

incorrectly. Re-shim bedplate and recheck high-speed 

coupling alignment. If  necessary, realign motor.

Shaft-Mounted Drives – General

Shaft-mounted drives should never be mounted in a 

manner that restricts the natural movement of  the drive. 

They should be allowed to move freely with the shaft on 

which it is mounted. Shaft-mounted drives should always 

be used in conjunction with a torque reaction arm. Refer 

to Appendixes A, B or C for torque reaction arm mounting 

instructions and angular limits. The drive may require 

repositioning on the driven shaft after initial installation to 

accommodate the location of  the foundation anchor and 

be within limits specified in Appendix A (fixed torque arm) 

or Appendix B (adjustable torque arm).
The  tapered  bore  hollow  shaft  is  designed  for  use  with  a  TA                                                                                                                                               

Taper

®

 bushing for mounting the drive on a driven shaft 

with a straight outside diameter. The taper bushing 

assembly is supplied with a thrust plate kit and retention 

fastener as standard (usage is optional, shaft cover must 

be removed to install thrust plate kit). Refer to data sheet 

supplied with the tapered bushing assembly for driven 

shaft length, shaft keyway length and driven shaft tapped 

hole dimensions if  the thrust plate kit with retention 

fastener is to be used.
Prior to installing the drive, it is a good idea to check 

the driven shaft for proper dimensions. Using Table 

1 or 1A, find the driven shaft size for the application. 

Verify that dimensions A and B are within the allowable 

range. When dimensions are verified, proceed with the 

installation. The minimum and maximum driven shaft 

engagements, dimension N in Figure 1, are shown in 

Table 2. The minimum engagement is necessary for full 

bushing engagement, and the maximum (and specified) 

engagement is provided for use when the thrust plate kit is 

used for added retention capacity and an auxiliary removal 

aid (bushing nut normally used for both).

LEVELING

REFERENCE

SURFACES

SHIMS

KEEP CLOSE

KEEP CLOSE

BUSHING NUT

DRIVEN SHAFT

BEARING

SUPPORT

THRUST

PLATE

BORE

INPUT

SHAFT

SHEAVE

N

Figure 1

Summary of Contents for Falk Drive One DB

Page 1: ...s LLC the Company warrants that Drive One gear drives I conform to Company s published specifications and II are free from defects of material for three years from the date of shipment Company does not warrant any non Company branded products or components manufacturer s warranty applies or any defects in damage to or failure of products caused by I dynamic vibrations imposed by the drive system i...

Page 2: ...ately aligned at the Factory with the bedplate mounted on a large flat assembly plate Shim under the bedplate foot pads until the gear drive is level and all feet are in the same plane Check high speed shaft coupling alignment If the coupling is misaligned the bedplate is shimmed incorrectly Re shim bedplate and recheck high speed coupling alignment If necessary realign motor Shaft Mounted Drives ...

Page 3: ...0 110 0 0 0 140 129 334 129 784 109 860 110 000 M1160 135 0 0 0 160 146 674 147 264 134 840 135 000 130 0 0 0 160 144 314 144 784 129 840 130 000 125 0 0 0 160 141 814 142 284 124 840 125 000 120 0 0 0 160 139 334 139 784 119 860 120 000 M1170 150 0 0 0 160 164 193 164 773 149 840 150 000 140 0 0 0 160 159 193 159 773 139 840 140 000 130 0 0 0 160 154 293 154 773 129 840 130 000 M1180 170 0 0 0 16...

Page 4: ...distance from the nut DO NOT apply ANTI SEIZE on these areas high speed shaft by dividing the tightening torque indicated in Table 3 by the drive s ratio Torque Ratio Apply the calculated torque to the high speed shaft or coupling using a spanner chain or pipe wrench Be careful not to damage the usable length of the high speed shaft Remove the fixed wrench from the TA bushing nut and reassemble th...

Page 5: ... ring and thrust plate from the hollow shaft 3 Select the backing bolts from the table above and install them into the three threaded holes in the end of the driven shaft The head of the backing bolts provides a working surface for the removal bolts 4 Re insert the thrust plate and retaining ring into the hollow shaft and select the removal bolts from the table above 5 Thread three removal bolts i...

Page 6: ...gnment and assembly of coupling Steelflex Illustrated RIGHT WRONG LEVEL GEAR DRIVE WALL SQUARE AND PARALLEL Fastener Tightening Torques Use the tightening torque values specified in Table 4 for fastening Falk gear drives motors and accessories to their mounting surfaces with un lubricated fasteners DO NOT use these values for torque locking fasteners or for fastening components with aluminum feet ...

Page 7: ... HP 750 Teresso 150 Dectol R O Oil 220 Teresstic 220 Hydro Drive HP 1000 Teresso 220 Dectol R O Oil 320 Teresstic 320 Teresso 320 Dectol R O Oil 460 Teresstic 460 Kendall Refining Co Keystone Lubricants Lyondell Petrochemical ARCO Mobil Oil Corp Pennzoil Products company Petro Canada Products Four Seasons AW 150 KLC 40 Duro 150 DTE Oil Extra Heavy Pennzbell AW Oil 150 Premium R O 150 KLC 50 Duro 2...

Page 8: ... AGMA Viscosity Grade 0S 2S 4S 5S 6S 7S ISO Viscosity Grade 32 68 150 220 320 460 Viscosity cSt 40 C 28 8 35 2 61 2 74 8 135 165 198 242 288 352 414 506 Viscosity SSU 100 F 134 164 284 347 626 765 918 1122 1335 1632 1919 2346 Manufacturer Lubricant Chevron U S A Inc Clarity Synthetic PM Oil 220 Syn Gear Lube Tegra 150 Syn Gear Lube Tegra 220 Syn Gear Lube Tegra 320 Syn Gear Lube Tegra 460 Conoco I...

Page 9: ...iderations 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 star...

Page 10: ... the food processing industry A grease that meets the USDA H1 classification is suitable for food processing applications CAUTION Rapid greasing with a power grease gun can force grease inward past the seals causing seal leaks GREASE LUBRICATED BEARINGS TYPES DV AND DX Most vertical low speed shaft drives have a grease lubricated lower low speed bearing Grease bearings during oil changes or at int...

Page 11: ...torstor quantities Rotate the shafts several times by hand Before operating drives which have been stored or inactive must be filled to the proper level with oil meeting the specifications given in this manual Refer to Manual 128 014 for Start up after Storage instructions Periodically inspect stored or inactive gear drives and spray or add rust inhibitor every six months or more often if necessar...

Page 12: ...ype D Series Sizes M1130 thru M1210 168 050 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 January 2019 Telephone 414 342 3131 Fax 414 937 4359 Supersedes 04 11 e mail info rexnord com web www rexnord com PN 2124650 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 13: ...racket should be added to the structure after the drive has been secured to the driven equipment NOTE Do not fasten the torque to the support structure at this time 2 Secure the drive to the driven equipment via the TA bushing or rigid coupling connection 3 Check that the torque arm remains perpendicular and centered in the clevis if mounted If the torque arm is not perpendicular and centered repo...

Page 14: ...to the driven equipment NOTE Do not fasten the torque arm to the support structure at this time 2 Secure the drive to the driven equipment via the TA Bushing shrink disc or rigid coupling connection 3 Mount the anchor bracket or clevis to the drive or drive system if not already done Locate the position of the anchor bracket to be mounted to the support structure Match drill the mounting holes for...

Page 15: ...IN ROD END MALE ROD END FEMALE TORQUE ARM PIN MOUNTING HARDWARE SUPPLIED BY CUSTOMER Figure 1 ANCHOR BRACKET RETAINING RING SPACER ROD END ROD END SPACER RETAINING RING ANCHOR BRACKET MOUNTING HARDWARE PROVIDED TORQUE ARM PIN JAM NUT TURNBUCKLE JAM NUT TORQUE ARM PIN MOUNTING HARDWARE SUPPLIED BY CUSTOMER Figure 3 CROWNED TORQUE ARM PIN CLEVIS ROD END ANCHOR BRACKET RETAINING RING JAM NUT TORQUE A...

Page 16: ...g screw holes are provided in gear drive housing to aid in fixing the shims Begin at the low speed shaft end and level across the length and then the width of the gear drive Use a feeler gauge to ensure that all pads are supported Bolt down the drive to the torque specified in Table 4 page 6 Mounting Motor and Coupling Alignment Shims are provided for motor mounting Holes must be drilled into the ...

Page 17: ...nstall the fluid coupling on the high speed shaft of the gear drive per fluid coupling instructions If a shaft fan is required remove every other of the twelve delay fill chamber fasteners Install the fan adapter ring to the fluid coupling using the long socket head cap screws provided Place a mounting post between the delay fill chamber flange and the adapter ring as shown in Figure 1 After all f...

Page 18: ...te on the bell housing before installing the coupling Once the motor is secured measure the distance D between the end of the motor shaft and the high speed shaft of the drive See Figure 4 Subtract the distance D from the length of the spacer coupling BE Then divide this value in half to find the overhang of each hub Overhang BE D 2 The overhang will be negative This is the amount each hub overhan...

Page 19: ...N Do not over tighten fasteners into plastic fan as fan may crack Mount the fan hub on the gear drive high speed shaft such that the set screw hole in the hub is towards the end of the shaft Locate the hub axially at the values listed in Table 2 Dimensions listed are from the inside face of the bell housing to the far side of the hub See Figure 1 Apply Loctite 242 or equivalent to threads of the s...

Page 20: ...ate Carriage may be adjusted from center to either far end of the housing to facilitate installation of pin Ensure that adjusting rod locking plate is NOT installed at this time as it will prevent adjustment of the torque arm assembly Assemble anchor bracket to male rod end with a spacer on each side and secure with pin and retaining ring Lifting the Alignment Free Drive Lifting points are provide...

Page 21: ...s the National Electrical Code NEC and Occupational Safety and Health Act OSHA 4 Fan motor must be securely and adequately grounded 5 All working parts should be grounded 6 When cleaning electrical equipment always use an approved cleaning agent See CLEANING in NOTES section page 22 7 For general ventilation and cooling use only Do not use if hazardous or explosive materials and vapors are present...

Page 22: ...2 POSITION A POSITION B POSITION C 1 1 2 Mounting Positions For Position A B Remove Plug 1 For Position C Remove Plug 2 Note Never use copper or brass fastening materials Figure 3 8 Connect power to the motor using an approved wiring method See Figure 1 for connection diagrams 9 Before starting the fan double check to ensure there are no obstructions that could interfere with proper fan operation ...

Page 23: ... cadmium plated mild steel with Buna N seal rings Water connections are 500 14 NPT fittings located at the high speed end The water outlet is located on the high speed end of the drive The water inlet connection is a straight fitting located on the lowest cooling tube in the drive The water outlet connection is a right angle fitting faced up located on the uppermost tube in the drive The cooling t...

Page 24: ...d by flushing with commercially available cleaning compounds such as Oakite or Dowell The commercially available cleaning compounds are corrosive and must be used in accordance with their manufacturer s recommendations Cleaning may also be accomplished by means of a rod or wire brush Remove the tube end seal ring fittings Figures 7 8 on page 25 and pass a 500 12 mm diameter rod or wire brush throu...

Page 25: ... installed in series with a ball valve to limit maximum water flow Refer to Figure 6 for recommended plumbing diagram The water flow control valve will control water flow rates to less than 2 gallons 8 liters per minute however the cooling tubes will be subject to increased fouling and may require cleaning at more frequent intervals WATER SUPPLY 2 GPM MIN 8 LITERS PER MIN 90 F 32 C MAX TEMP WATER ...

Page 26: ... 00 M20 x 2 5 x 40 750 10 x 1 50 M24 x 3 x 70 M24 x 3 x 70 341 13 43 284 11 18 M1140 M24 x 3 x 90 1 000 8UNC x 3 50 M24 x 3 x 45 1 00 8 x 2 00 M30 x 3 5 x 80 M30 x 3 5 x 80 386 15 20 319 12 55 M1150 M24 x 3 x 90 1 000 8UNC x 3 50 M24 x 3 x 45 1 00 8 x 2 00 M30 x 3 5 x 80 M30 x 3 5 x 80 406 15 98 334 13 15 M1160 M24 x 3 x 90 1 000 8UNC x 3 50 M24 x 3 x 45 1 00 8 x 2 00 M30 x 3 5 x 80 M30 x 3 5 x 80...

Page 27: ...G 1 EACH END SEALED WITH LOCTITE PIPE JOINT COMPOUND 30557 P N D004945 1B SQUARE HEAD MAGNETIC DRAIN PLUG 1 EACH END SEALED WITH LOCTITE PIPE JOINT COMJPOUND 30557 P N D004945 5B INSPECTION COVER IF COVER WAS REMOVED APPLY A CONTINOUOUS BEAD OF LOCTITE 515 GASKET ELIMINATOR P N 99409561 OR EQUIVALENT TO HOUSING INSPECTION COVER BOLTING SURFACE MAKE SURE THAT THE BEAD IS LOCATED INSIDE THE BOLT PAT...

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