Falk
®
CT-Series Gear Drives • Operation and Maintenance
Sizes 2160 thru 2400
(Page 1 of 7)
Rexnord
GR3-014
3001 W. Canal St., Milwaukee, WI 53208-4200
January 2017
Telephone: 414-937-4359 Fax: 414-937-4359 www.rexnord.com
NEW
How to Use this Manual
This manual provides detailed instructions on installation
and maintenance of Falk CT-Series gear drive. Use the
table of contents below to locate required information.
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND
TROUBLE-FREE SERVICE OF YOUR FALK GEAR DRIVE.
TABLE OF CONTENTS
1. Introduction .....................................................................1
2. General Notes and Safety Instructions............................1
3. Transport and Storage.....................................................2
4. Installation .......................................................................3
5. Shaft Connections ...........................................................5
6. Lubrication .......................................................................5
7. Preparation For Test Run .................................................5
8. Maintenance ....................................................................6
1. INTRODUCTION
Credit for long service and dependable operation of a
gear drive is often given to the engineers who designed it,
or the craftsmen who constructed it, or the sales engineer
who recommended the type and size. Ultimate credit
belongs to the mechanic on the job who worked to make
the foundation rigid and level, who accurately aligned the
shafts and carefully installed the accessories, and who
made sure that the drive received regular lubrication. The
details of this important job are the subject of this manual.
NAMEPLATE
— Operate Falk gear drives only at power,
speed and ratio shown on the nameplate. Before changing
any one of these, submit complete nameplate data and
new application conditions to Factory for correct oil level,
parts, and application approval.
LUBRICATION
— Lubrication of gears and bearings is
entirely self-contained by splash. In general oil grade to be
used is ISO-VG 320. Oil thrower on input shaft produces
positive splash which in turn, ensures continuous
circulation of oil to top bearings through channels.
WARNING:
Consult applicable local and national safety
codes for proper guarding of rotating members. Lock out
power source and remove all external loads from drive
before servicing drive or accessories.
WARRANTY
— Rexnord Industries, LLC (the ”Company”)
warrants that Falk V-Class
™
gear drives (I) conform to
Company’s published specifications, and (II) are free from
defects of material for two 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 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 shipping.
QUALIFIED PERSONNEL
— The product or system
to which these instructions relate may be handled only
by persons qualified for the work concerned and in
accordance with the instructions relating to the work
concerned, particularly the safety and warning notes
contained in those instructions. Qualified personnel must
be specially trained and have the experience necessary to
recognize risks associated with these products or systems
and to avoid possible hazards.
2. GENERAL NOTES AND SAFETY
INSTRUCTIONS
The proper working of a gear unit not only depends on
the good design, the use of good material and good
workmanship but also on careful installation, proper
lubrication and proper working conditions. Hence, it is
of utmost importance to see that the installation of the
gear box is one according to the instructions given in this
manual to ensure proper working of the gear box and to
ensure a long and trouble free service.
This manual should be kept with the person in-charge
who handles the installation & operation. They should
thoroughly study and understand the instructions
given in this manual. Precisely following of this manual
will give trouble free working of the Gear unit. In the
interest of future development, we reserve the right to
introduce modifications to the individual subassemblies &
accessories, which, while retaining the essential features,
can be regarded as desirable to increase their efficiency,
reliability and safety.
2.1 INSTRUCTIONS FOR LONG STORAGE OF GEAR
UNITS
Following instructions for the long time storage of the
gear units is of extreme importance as violation of
which can lead to the premature failure.
Long time storage of a gear unit can be due to:
2.1.1
Unit is not in action, however, installed in the place
2.1.2
Unit is kept in store and waiting for its use.
OR
2.1.3
The unit is installed but not in action:
When the gear unit is installed in the system
but is out of action, a quantity of oil must be
added to exceed maximum level by 30 mm to
50 mm. Special attentions should be given to
the condition of the oil. Old oil, which may form
a deposit or be acidic, should be removed.
The gears should be turned slowly by hand at
intervals, in order to ensure the oil is distributed
over all parts in contact. Wherever grease nipples
are provided, add grease through grease nipples.
2.1.4
The unit is to be stored for a long time:
When the unit is to be stored for a long time, it
should be run for 5 minutes after filling with rust
protective oil. The level of the oil should be about
30 mm to 50 mm higher than the normal oil level.
All the parts having been thoroughly coated with
oil, the protective fluid can be drained and kept
for other similar operations.
The inspection covers and the drain plugs should
be completely sealed. On starting up the speed
reducer, no special precaution need be taken
