148-050FalkTypeGear Drives_Installation Manual.pdf

How to Use This Manual This manual provides detailed instructions on installation and maintenance of gear drives and couplings. Use the table of contents below to locate required information.

CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS

MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE

FREE SERVICE.

Table of Contents Installation Instructions . . . . . . . . . . . . . . . . . . . . Pages 1 & 2

Shaft Connections . . . . . . . . . . . . . . . . . . . . . . . Pages 2 & 3

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

Lubrication Recommendations . . . . . . . . . . . . . Pages 3 thru 7

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . Page 8

Stored and Inactive Gear Drives . . . . . . . . . . . . . . . . . Page 8

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 horsepower, speed and ratio shown on nameplate. Before changing any one of these, submit complete nameplate data and new application conditions to the Factory for correct oil level, parts and application approval.

DISASSEMBLY AND ASSEMBLY — Disassembly & assembly instructions and parts guides are available from the Factory or Rexnord Account Executives. When requesting information, please give complete data from the nameplate on the gear drive; Model, M.O.Number, Date, RPM, and Ratio.

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 (the “Company”) warrants that, for a period of three years from the date of shipment, the product described herein will deliver successfully its rated output as indicated on the nameplate, provided, it is properly installed and maintained, correctly lubricated, and operated in the environment and within the limits of speed, torque or other load conditions for which it was sold. Such product is expressly not warranted against failure or unsatisfactory operation resulting from dynamic vibrations imposed upon it by the drive system in which it is installed unless the nature of such vibrations has been fully defined and expressly accepted in writing by the Company as a condition of operation.

Installation Instructions The following instructions apply to standard Falk™ Type GHB, Y, YB & YBX drives shown above. If a drive is furnished with special features, refer to the supplementary instructions shipped with the drive.

WELDING — Do not weld on the gear drive or accessories without prior approval from Rexnord Industries, LLC. Welding on the drive may cause distortion of the housing or damage to the bearings and gear teeth. Welding without prior approval could void the warranty.

EFFECTS OF SOLAR ENERGY — If the gear drive operates in the sun at ambient temperatures over 100�F(38�C), then special measures should be taken to protect the drive from solar energy.

This protection can consist of a canopy over the drive or reflective paint on the drive. If neither is possible, a heat exchanger or other cooling device may be required to prevent the sump temperature from exceeding the allowable maximum.

HORIZONTAL MOUNTING — Mount gear drive with base horizontal, unless it has been specifically ordered for mounting in another position. If it is necessary to mount the drive in a different position from that for which it was ordered, consult Rexnord for changes necessary to provide proper lubrication.

NON-HORIZONTAL MOUNTING — For gear drives with non-horizontal mounting, including tilted, vertical and wall mounted, refer to instructions provided with the drive for oil levels and bearing lubrication.

Falk™ Enclosed Gear Drives • Installation & Maintenance Instructions

Types GHB, Y, YB, & YBX • Sizes 1080-1195 & 2050-2235 (Page 1 of 8)

Rexnord Industries, LLC, Gear Group 148-050 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131 November 2006

Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.com Supersedes 4-99

Type Y Type YBX

Type YB Type GHB

FOUNDATION, GENERAL — To facilitate oil drainage, elevate the gear drive foundation above the surrounding floor level. If desired, replace the drive oil drain plug with a valve, but provide a guard to protect the valve from accidental opening or breakage.

When an outboard bearing is used, mount drive and outboard bearing on a continuous foundation or bedplate and dowel both in place.

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 3 for coupling alignment instructions.

MOTOR BRACKETS — The weight, location and starting torque of the motor will cause some brackets to deflect downward and to twist. This movement is within allowable engineered limits for motor-drive selections from the Falk™ selection guide. If the customer considers the movement excessive, jackscrew supports for the bracket extension are available from Rexnord. To compensate for deflection caused by heavy motors AND to get CORRECT COUPLING ALIGNMENT, use more shims under the rear motor feet than the front feet.

GEAR DRIVE ALIGNMENT — Align drive with driven equipment by placing broad, flat shims under all mounting pads. 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 3 for coupling alignment.

If equipment is received from Rexnord mounted on a bedplate, the components were accurately aligned at Rexnord 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 Connections WARNING: Provide suitable guards in accordance with OSHA standards.

COUPLING CONNECTIONS — The performance and life of any coupling depends largely upon how well the coupling is installed and serviced. Refer to the coupling manufacturer’s manual for specific instructions.

CORRECT METHOD

Heat interference fitted coupling hubs, pinions, sprockets or pulleys to a maximum of 275�F (135�C) and slide onto gear drive shaft.

INCORRECT METHOD

DO NOT drive coupling hub, pinion, sprocket or pulley onto the shaft. An endwise blow on the shaft/coupling may damage gears and bearings.

FALK COUPLINGS™ — (Except fluid type) Detailed installation manuals are available from the Factory, your local Rexnord Account Executive or Distributor—just provide size and type designations stamped on the coupling. For lubricant requirements and a list of typical lubricants meeting Rexnord specifications, refer to appropriate coupling service manual.

Flanged Type Rigid Couplings are typically used on drives with vertical output shafts. The low speed shaft extension ends of the solid vertical shaft drives are drilled and tapped to accommodate coupling keeper plates. Tightening torques for fasteners, including keeper plate fasteners are listed in Table 1, Page 3.

Rexnord Industries, LLC, Gear Group148-050 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131November 2006

Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.comSupersedes 4-99

Installation & Maintenance Instructions • Falk™ Enclosed Gear Drives

(Page 2 of 8) Sizes 1080-1195 & 2050-2235 • Types GHB, Y, YB, & YBX

CONTINUOUS PLATE

LEVELING

REFERENCE

SURFACE

SHIMSSHIMS

— CAUTION —

DO NOT HAMMER

FALK™ FLUID COUPLINGS — Refer to the installation manual furnished with the fluid coupling for installation, alignment and startup instructions.

GAP AND ANGULAR ALIGNMENT — If possible, after mounting coupling hubs, position the driving and driven equipment so that the distance between shaft ends is equal to the coupling gap.

Align the shafts by placing a spacer block, equal in thickness to required gap, between hub faces, as shown above, and also at 90� intervals around the hub. Check with feelers.

OFFSET ALIGNMENT — Align driving and driven shafts so that a straight edge will rest squarely on both couplings hubs as shown to the right and also at 90� intervals. Tighten foundation bolts of the connected equipment and recheck alignment and gap.

SPROCKETS, PULLEYS OR SHEAVES — Mount power take-offs as close to the gear drive housing as possible to avoid undue bearing load and shaft deflection.

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 manufacturers’ specifications. Adjust belts as follows:

The ideal tension is the lowest tension at which the belt will not slip under peak load conditions. Check the belt tension frequently during the first 24 to 48 hours of run-in operation.

Over tightening belts shortens belt and bearing life. Keep belts free from foreign material which may cause slippage. Inspect the V–belt periodically; tighten the belts if they are slipping.

OUTBOARD BEARING — Mount the outboard bearing and gear drive on a common foundation so that they will shift as an assembly if settling should occur. Bring the outboard bearing to the correct horizontal position with broad flat shims under the mounting pad. Align accurately so that the load is equally divided between the two drive bearings and the outboard bearing. Mount a stop bar against the pillow block foot on the load side when large horizontal load components are exerted on the pillow block.

PINION MOUNTING — Mount pinion as close to the unit as possible to avoid undue bearing load and shaft deflection.

Refer to the Factory for pinion alignment instructions.

BACKSTOPS — To prevent damage to backstops due to incorrect motor shaft rotation at start up, couplings are NOT assembled when gear drives are furnished with backstops. After completing the electrical connection, check motor and gear drive shaft rotations. Then complete alignment and assembly of coupling.

Fastener Tightening Torques Use the tightening torque values specified in Table 1, for fastening Falk™ gear drives, motors, keeper plates and accessories to their mounting surfaces with non-lubricated fasteners. DO NOT use these values for “torque locking” fasteners or for fastening components with aluminum feet or with soft gaskets or vibration dampers on the mounting surface. If the tightening torque exceeds the capacity of the torque wrench, use a torque multiplier. Use Grade 5 fasteners for diameters through 1.50", for larger diameter fasteners, use ASTM A-354 Grade BC.

Water Cooling WATER COOLED HEAT EXCHANGERS — Install a shut-off or control valve in the water line to the heat exchanger to regulate the water flow through the exchanger. Also install a water flow gauge between the control valve and the exchanger to determine actual flow rate. Discharge water to an OPEN DRAIN to prevent back pressure.

Lubrication Recommendations Carefully follow lubrication instructions on the gear drive nameplate, warning tags and installation manuals furnished with the gear drive.

Lubricants listed in this manual are typical ONLY and should not be construed as exclusive recommendations. Industrial type petroleum based rust and oxidation inhibited (R & O) gear lubricants or industrial type sulfur-phosphorus extreme pressure (EP) gear lubricants are the recommended lubricants for ambient temperatures of 15�F to 125�F(-9�C to +52�C).

For drives operating outside the above temperature range refer to “Synthetic Lubricants” paragraphs, Page 4. Synthetic lubricants can also be used in normal climates.

Falk™ Enclosed Gear Drives • Installation & Maintenance Instructions

Types GHB, Y, YB, & YBX • Sizes 1080-1195 & 2050-2235 (Page 3 of 8)

Rexnord Industries, LLC, Gear Group 148-050 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131 November 2006

Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.com Supersedes 4-99

TABLE 1 — Tightening Torques – lb-in

DO NOT LUBRICATE FASTENERS

Thread Dia-UNC

Metal to Metal

Metal to Concrete

Thread Dia-UNC

Metal to Metal

Metal to Concrete

.250-20 90 70 1.250-7 12600 10000

.3125-18 185 145 1.375-6 16500 13000

.375-16 330 255 1.500-6 22100 17500

.500-13 825 640 1.750-5 23700 18700

.625-11 1640 1280 2.000-4.5 37000 29000

.750-10 2940 2290 2.250-4.5 52000 41000

.875-9 4560 3750 2.500-4 72000 56000 1.000-8 6800 5600 2.750-4 98000 77000 1.125-7 8900 7000 3.000-4 125000 99000

STEELFLEX ILLUSTRATED

STEELFLEX ILLUSTRATED

RIGHT WRONG

GEAR DRIVE WALL

LEVEL

SQUARE AND

PARALLEL

VISCOSITY (IMPORTANT) — The proper grade for R & O and EP lubricants is found in Table 2. For cold climate conditions refer to Table 4, Page 5 and the “Synthetic Lubricant” paragraphs.

Select a lubricant which has a pour point at least 10�F (5.5�C) below the expected minimum ambient starting temperature.

Usable temperature ranges can sometimes be widened if specific application conditions are known.

If a gear drive operates in a typical indoor environment where the ambient temperature is within 70�F to 125�F (21�C to 52�C), the oil viscosity should be increased one AGMA grade above that shown for the 50�F to 125�F(10�C to 52�C) range.

That is, an AGMA Number 6 or 7 should be substituted for a 5 or 6 respectively, under this ambient condition.

OIL PUMPS — When selecting a lubricant for a gear drive equipped with an oil pump, cold temperature oil viscosity is important. Lubricant viscosity at start-up generally should not exceed 1725 cSt (8,000 SSU). When exceeding this viscosity, pump cavitation is possible, preventing oil circulation. A sump heater may be required or it may be possible to use a lower viscosity oil to minimize pump cavitation, consult the Factory.

Petroleum Based Lubricants R & O GEAR LUBRICANTS (Table 5) — Industrial type petroleum based rust and oxidation inhibited (R & O ) gear lubricants are the most common and readily available general purpose gear lubricants.

EXTREME PRESSURE (EP) LUBRICANTS (Table 3) — For highly loaded gear drives or drives loaded in excess of original estimates, industrial type petroleum extreme pressure lubricants are preferred. The EP lubricants currently recommended are of the sulphur-phosphorus type.

WARNING: EP LUBRICANTS IN FOOD PROCESSING INDUSTRY

— EP lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturers’ approval. Lubricants which meet USDA “H1” classification are suitable for food processing applications.

CAUTION: EP LUBRICANTS & INTERNAL BACKSTOPS — Do not use EP lubricants or lubricants with anti-wear additives or lubricant formulations including sulfur, phosphorus, chlorine, lead derivatives, graphite or molybdenum disulfides in units equipped with internal cartridge type backstops. Some lubricants in Table 5 may contain anti-wear additives. Lubricants in Table 3 do contain several of these additives.

Synthetic Lubricants Synthetic lubricants of the polyalphaolefin type are recommended for cold climate operation, high temperature applications, extended temperature range (all season) operation and/or extended lubricant change intervals. The proper viscosity grade of synthetic lubricant is given in Table 4.

WARNING: SYNTHETIC LUBRICANTS IN FOOD PROCESSING

INDUSTRY — Synthetic lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturers’ approval. Lubricants which meet USDA “H1” classification are suitable for food processing applications.

CAUTION: SYNTHETIC LUBRICANTS & INTERNAL BACKSTOPS

— Synthetic lubricants may be used in gear drives with internal backstops operating only in cold temperatures -30� to +50�F (-34� to +10�C). Mobil SHC 624 and SHC 626 provide proper backstop action under these conditions. Other synthetic lubricants may also be acceptable. DO NOT use synthetic lubricants in units with backstops operating in ambient temperatures above 50�F (10�C).

Oil Levels Prior to filling gear drives, remove the inspection cover and flood the oil troughs with a generous flow of oil to the bearings. Fill the drive with oil to the level indicated on the oil dipstick. Approximate oil capacities are given on the drive nameplate.

Lubricant Changes OIL ANALYSIS REPORT— Checking oil condition at regular intervals is recommended. In the absence of more specific limits, the guidelines listed below may be used to indicate when to change oil:

1. Water content is greater than 0.05% (500 ppm).

2. Iron content exceeds 150 ppm.

3. Silicon (dust/dirt) exceeds 25 ppm.

4. Viscosity changes more than 15%.

PETROLEUM LUBRICANTS — For normal operating conditions, change gear oils every 6 months or 2500 operating hours, whichever occurs first. If the drive is operated in an area where temperatures vary with the seasons, change the oil viscosity grade to suit the temperature, refer to Table 2.

Lubricant suppliers can test oil from the drive periodically and recommend economical change schedules.

SYNTHETIC LUBRICANTS — Synthetic lube change intervals can be extended to 8000-10,000 hours depending upon operating temperatures and lubricant contamination.

Laboratory analysis is recommended for optimum lubricant life and gear drive performance. Change lube with change in ambient temperature, if required. Refer to Table 4.

Rexnord Industries, LLC, Gear Group148-050 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131November 2006

Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.comSupersedes 4-99

Installation & Maintenance Instructions • Falk™ Enclosed Gear Drives

(Page 4 of 8) Sizes 1080-1195 & 2050-2235 • Types GHB, Y, YB, & YBX

TABLE 2 — Viscosity Grade Recommendations for R & O or EP Lubricants

Output RPM

Normal Climates

15� to 60�F (-9� to +16�C)

50� to 125�F (10� to 52�C)

ISO-VG AGMA ISO-VG AGMA

Output RPM Below 80 150 4 320 6 Output RPM 80 & Above 150 4 220 5

Falk™ Enclosed Gear Drives • Installation & Maintenance Instructions

Types GHB, Y, YB, & YBX • Sizes 1080-1195 & 2050-2235 (Page 5 of 8)

Rexnord Industries, LLC, Gear Group 148-050 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131 November 2006

Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.com Supersedes 4-99

TABLE 5 — Petroleum Based R & O Gear Oils (Maximum operating temperature of lubricants 200�F (93�C)

AGMA Viscosity Grade 1 2 3 4 5 6 7

ISO Viscosity Grade 46 68 100 150 220 320 460

Viscosity cSt @ 40�C 41.4-50.6 61.2-74.8 90-110 135-165 198-242 288-352 414-506

SSU @ 100�F 193-235 284-347 417-510 626-765 918-1122 1335-1632 1919-2346

Manufacturer Lubricant Lubricant Lubricant Lubricant Lubricant Lubricant Lubricant

Amoco Oil Co. Amer. Ind. Oil 46 Amer. Ind. Oil 68 Amer. Ind. Oil 100 Amer. Ind. Oil 150 Amer. Ind. Oil 220 Amer. Ind. Oil 320 Amer. Ind. Oil 460 BP Oil Co. Turbinol T-46 Turbinol T-68 Turbinol T-100 . . . . Energol HLP-HD 220

Chevron U.S.A., Inc. Hydraulic Oil AW 46 Hydraulic Oil AW 68 Machine Oil AW 100 Machine Oil AW 150 Machine Oil AW 220 Machine Oil AW 320

Citgo Petroleum Corp. Citgo Pacemaker 46 Citgo Pacemaker 68 Citgo Pacemaker 100 Citgo Pacemaker 150 Citgo Pacemaker 220 Citgo Pacemaker 320 Citgo Pacemaker 460

Conoco Inc. Dectol R & O Oil 46 Dectol R & O Oil 68 Dectol R & O Oil 100 Dectol R & O Oil 150 Dectol R & O Oil 220 Dectol R & O Oil 320 Dectol R & O Oil 460 Exxon Co., U.S.A. Teresstic 46 Teresstic 68 Teresstic 100 Teresstic 150 Teresstic 220 Teresstic 320 Teresstic 460 Houghton International Inc. Hydro-Drive HP-200 Hydro-Drive HP-300 Hydro-Drive HP-500 Hydro-Drive HP-750 Hydro-Drive HP-1000

Imperial Oil Ltd. Teresso 46 Teresso 68 Teresso 100 Teresso 150 Teresso 220 Teresso 320

Kendall Refining Co. Kenoil R & O AW 46 Kenoil R & O AW 68 Kenoil R & O AW 100 Four Seasons AW 150

Keystone Lubricants KLC-15 KLC-20 KLC-30 KLC-40 KLC-50

Lyondell Petrochemical (ARCO) Duro 46 Duro 68 Duro 100 Duro 150 Duro 220 Duro 320

Mobil Oil Corp. DTE Oil Medium DTE Oil Heavy Medium DTE Oil Heavy DTE Oil Extra Heavy DTE Oil BB DTE Oil AA DTE Oil HH

Petro-Canada Prod. Harmony 46 Harmony 68 Harmony 100 Harmony 150 or150D Harmony 220 Harmony 320

Phillips 66 Co. Magnus Oil 46 Magnus Oil 68 Magnus Oil 100 Magnus Oil 150 Magnus Oil 220 Magnus Oil 320

Shell Oil Co. Turbo T46 Turbo T68 Morlina 100 Morlina 150 Morlina 220 Morlina 320 Morlina 460 Shell Canada Ltd. Tellus 46 Tellus 68 Tellus 100 Tellus 150 Tellus 220 Tellus 320

Texaco Lubricants Regal Oil R & O 46 Regal Oil R & O 68 Regal Oil R & O 100 Regal Oil R & O 150 Regal Oil R & O 220 Regal Oil R & O 320 Regal Oil R & O 460 Unocal 76 (East) Unax RX 46 Unax RX 68 Unax RX 100 Unax RX 150 Unax RX 220 Unax AW 320 Turbine Oil 460 Unocal 76 (West) Turbine Oil 46 Turbine Oil 68 Turbine Oil 100 Turbine Oil 150 Turbine Oil 220 Turbine Oil 320 Turbine Oil 460 Valvoline Oil Co. Valvoline AW ISO 46 Valvoline AW ISO 68 Valvoline AW ISO 100 Valvoline AW ISO 150 Valvoline AW ISO 220 Valvoline AW ISO 320

TABLE 3 — Extreme Pressure Lubricants Maximum Operating Temperature 200�F (93�C)

Manufacturer Lubricant

Amoco Oil Co. Permagear/Amogear EP BP Oil Co. Energear EP Chevron U.S.A. Inc. Gear Compounds EP Citgo Petroleum Corp. Citgo EP Compound

Conoco Inc. Gear Oil Exxon Co. U.S.A. Spartan EP E.F. Houghton & Co. MP Gear Oil Imperial Oil Ltd. Spartan EP

Kendall Refining Co. Kendall NS-MP Keystone Div., Pennwalt Corp. Keygear Lyondell Petrochemical (ARCO) Pennant NL Mobil Oil Corp. Mobilgear

Petro-Canada Products Ultima EP Phillips 66 Co. Philgear Shell Oil Co. Omala Oil Shell Canada Limited Omala Oil

Sun Oil Co. Sunep Texaco Lubricants Meropa Unocal 76 (East & West) Extra Duty NL Gear Lube Valvoline Oil Co. AGMA EP

TABLE 4 — Polyalphaolefin Type Synthetic Lubricants †

AGMA Viscosity Grade . . . 2 4 5 6

ISO Viscosity Grade 32 68 150 220 320

Viscosity cSt @ 40�C 28.8–35.2 61.2–74.8 135–165 198–242 288–352

SSU @ 100�F 135–164 284–347 626–765 918–1122 1335–1632

Ambient Temperature Range� F ‡

– 30 to +10

– 15 to + 50

0 to + 80

+10 to +125

+ 20 to +125

Manufacturer Lubricant

Chevron U.S.A., Inc Syn. Gear Lube Tegra

220 •

Conoco, Inc. Syncon 32 Syncon 68

CPI Engineering Services, Inc.

CP–4620–

CP–4620–

CP–4620–

CP–4620–

CP–4630–

32 •

CP–4630–

68 •

CP–4630–

150 •

CP–4630–

220 •

Exxon Co. U.S.A Spartan Synthetic

EP 150 •

Spartan Synthetic

EP 220 •

Spartan Synthetic

EP 320 •

Mobil Oil Corp.

SHC 624 SHC 626 SHC 629 SHC 630 SHC 632

Mobilgear

SHC 150

Mobilgear

SHC 220 •

Mobilgear

SHC 320 •

† Minimum viscosity index of 130 (consult lubricant supplier/manufacturer for maximum operating temperature). Vixcosity grade selections are not applicable to semi-high speed and high speed drives.

‡ With complete application information, temperature range can sometimes be extended, consult Factory.

• Extreme pressure EP lubricants (contains sulphur phosphorus).

Lubrication Systems SPLASH LUBRICATED UNITS — Standard Type GHB, Y, YB & YBX drives are splash lubricated. The lubricant is picked up by the revolving elements and distributed to all bearings and gear meshes.

OIL PUMPS — Occasionally gear drives are equipped with oil pumps, either for special lubrication considerations or for external cooling. When so equipped, run the lubrication system for several minutes to fill the system components.

Verify that the pump is circulating oil properly then recheck the oil level.

Before starting the gear drive, rotate the input shaft by hand to check for any obstruction. Then start the drive and allow it to run without a load for several minutes. Shut down and recheck oil level. Add oil to compensate for cooler, filter, etc., oil capacities. If everything is satisfactory, the drive is ready for operation.

CAUTION: Consult the Factory for drives that use pumps to distribute lubricants with temperatures below 30�F(-1�C).

Bearing & Seal Greases Some gear drives have one or more grease lubricated bearings and grease purged seals. Whenever changing oil in the drive, grease the bearings and purge the seals with one of the NLGI #2 greases listed in Table 6.

Some of these greases are of the EP type and may contain toxic substances not allowed in the food processing industry. A grease that meets the USDA “H1” classification is suitable for food processing applications.

GREASE LUBRICATED BEARINGS — Remove pressure relief plug when greasing bearing on vertical hollow shaft drives.

Pump grease into bearing cage until it appears at the plug.

Replace pressure relief plug.

GREASE LUBRICATED SEALS — Most gear drives and backstops are furnished with grease purged seals which minimize the entry of contaminants and abrasive dusts into the drive or backstop. Gear drives and backstops are shipped with NLGI #2 grease in the seal housing cavities unless otherwise specified. If grease could contaminate the product, as in the food and drug industries, it should be removed. A grease that meets USDA “H1” classification is suitable for food processing applications.

Periodically (at least every six months) depending upon the frequency and degree of contamination, purge contaminated grease from seals by slowly pumping fresh bearing grease thru the seal, WITH A HAND GREASE GUN, until fresh grease flows out along the shaft. Wipe off purged grease.

CAUTION: Rapid regreasing with a power grease gun can force grease inward past the seals and plug the oil drain back system causing seal leaks.

BACKSTOP EQUIPPED DRIVES — Type “Y”, gear drives, use a self contained, pawl type, backstop externally mounted on an intermediate shaft. The backstop is furnished filled with grease suitable for operation in an ambient temperature range of -20�F to +125�F(-29�C to +52�C). Relubricate the backstop every 3 months (2 weeks in severe operating condition). To relubricate, select and clean one grease fitting and pump grease into the backstop until fresh grease appears at both seals. Refer to the backstop manufacturer’s service manual (supplied with the drive) for detailed maintenance instructions and recommended greases.

DO NOT use greases with molybdenum disulfide or other EP additives.

Rexnord Industries, LLC, Gear Group148-050 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131November 2006

Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.comSupersedes 4-99

Installation & Maintenance Instructions • Falk™ Enclosed Gear Drives

(Page 6 of 8) Sizes 1080-1195 & 2050-2235 • Types GHB, Y, YB, & YBX

TABLE 6 — Greases for Grease Lubricated Bearings & Grease Purged Seals (0� to 200�F (–18� to +93�C)

Manufacturer Lubricant

Amoco Oil Co. Amolith Grease No. 2 BP Oil Co. Energrease LS-EP2 Chevron U.S.A., Inc. Industrial Grease Medium Citgo Petroleum Corp. Premium Lithium Grease No. 2

Conoco Inc. EP Conolith Grease No. 2 Exxon Company, U.S.A. Unirex N2 E.F. Houghton & Co. Cosmolube 2 Imperial Oil Ltd. Unirex N2L

Kendoll Refining Co. Multi-Purpose Lithium Grease L421 Keystone Div., Penwalt Corp. Zeniplex 2 Lyondell Petrochemical (ARCO) Litholine H EP 2 Grease Mobil Oil Corp. Mobilith 22

Mobil Oil Corp. Mobilith SHC 460 H Petro-Canada Products Mulipurpose EP2 Phillips 66 Co. Philube Blue EP Shell Oil Co. Alvania Grease 2

Shell Canada Limited Alvania Grease 2 Sun Oil Co. Ultra Prestige EP2 Texaco Lubricants Premium RB Grease

Unocal 76 (East & West) Unoba EP2 Valvoline Oil Co. Multilube Lithium EP Grease

� High performance synthetic alternate.

Dipstick

TYPICAL SEAL ASSEMBLIES

FOR

GREASING

SEAL

SEAL

COVER

SEAL GAGE PLUG

BASE PLUG

BUSH

SEAL

SEAL

DRAIN

CAVITY

FOR

GREASING

SEAL

SEAL

COVER

BASE PLUG

BUSH

SEAL

SEAL

DRAIN

CAVITY

Falk™ Enclosed Gear Drives • Installation & Maintenance Instructions

Types GHB, Y, YB, & YBX • Sizes 1080-1195 & 2050-2235 (Page 7 of 8)

Rexnord Industries, LLC, Gear Group 148-050 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131 November 2006

Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.com Supersedes 4-99

TABLE 7 — Viscosity Recommendations �

Drive Description Classification

Symbol (Drive Type)

Drive Size

Synthetic Lubricants R & O Petroleum Oils

Cold Climates Normal Climates

–30� to +10�F (–34� to –12�C)

–15� to +50�F (–26� to +10�C)

15� to 60�F (–9� to +16�C)

50� to 125�F (10� to 52�C)

IS0-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA

Parallel Shaft and Horizontal Right Angle

Roller Bearings

Fabricated Steel Housings

Y1 50-135, 2050-2135 32 . . . 68 2 100 3 220 5

YF1 1080-1135 32 . . . 68 2 100 3 220 5

Y1 140-195, 2140-2165 32 . . . 68 2 150 4 220 5

YF1 1140-1195 32 . . . 68 2 150 4 220 5

Y2 & YB2 50-195 32 . . . 68 2 150 4 220 5

Y2 & YB2 2050-2245 32 . . . 68 2 150 4 220 5

Y3, YB3 & 4 50-135, 2050-2135 32 . . . 68 2 150 4 220 5

Y3, YB3 & 4 140-195, 2140-2245 32 . . . 68 2 220 5 320 6

Vertical Right Angle

Fabricated Steel Housings

YBX2 50-135, 2070-2135 32 . . . 68 2 100 3 220 5

YBX3 50-135, 2070-2135 32 . . . 68 2 150 4 220 5

YBX2 140-195, 2140-2195 32 . . . 68 2 150 4 220 5

YBX3 140-195, 2140-2195 32 . . . 68 2 220 5 320 6

Parallel Shaft

Sleeve and Roller Bearings

Cast Iron Housings

GHC, GHF

GDA, GDF

GRA, GRF

6-9

10-13

Right Angle

Horizontal and Vertical

Cast Iron Housings

2000 GHB1 2050-2120 32 . . . 68 2 100 3 220 5

GHB

GDB

GRB

3-5 6-9

10-12

GDX 4, 5 32 . . . 68 2 100 3 220 5

GDX, GRX 6-12 32 . . . 68 2 150 4 220 5

Parallel Shaft Semi-High Speed ‡

Sleeve, Roller and Ball Bearings

YHF1

YH1

YH2

1080-1135 2050-2125 2050-2175

GHCH

GHCH

6-13

Parallel Shaft High Speed ‡

Sleeve Bearings YQA, YPA All Sizes 32 . . . 68 2 46 † 1 † 68 2

� Consult Factory for viscosity recommendations when ambient temperatures are higher than 125�F(52�C), or when drives are operating in extremely humid, chemical, or dust laden atmospheres.

† Lubricant inlet temperature to gear drive must not exceed 100�F(38�C) when using an AGMA No. 1 oil (193 to 235 SSU at 104�F; 41.5-50.6 cSt at 40�C) in a pressure lubrication system.

‡ Consult Factory before substituting higher viscosity grades from those indicated in Table 7 above.

Preventive Maintenance AFTER FIRST WEEK — Check alignment of the 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.

OIL FILTER SERVICE — Record oil pressure at oil filter indicating gauge with drive at operating temperature, with fresh oil. Replace oil filter when oil pressure INCREASE reaches 10 psi with drive at operating temperature. Replacement filter elements (Falk™ Part No. 2906540, Gresen K-22002 or equivalent 30 micron) are available from the Factory.

AFTER FIRST MONTH’S SERVICE — Proceed as follows:

1. Operate drive until old sump oil reaches normal operating temperature. Shut the drive down and drain immediately.

2. Immediately flush drive with an oil of the same type and viscosity grade as the original charge (warmed to approximately 100�F (38�C) in cold weather). Rapidly pour or pump a charge equal to 25-100% of the initial fill volume through the drive or until clean oil flows through the drain.

3. Close the drain and refill the drive to the correct level with new or reclaimed oil of the correct type and viscosity. If determined to be in good condition by the supplier, reclaimed oil may be reused if it is filtered through a 40 micron or finer filter.

PERIODICALLY — Carefully 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 level mark on the dipstick, have the oil analyzed for water content. Moisture in the oil may indicate that the heat exchanger or a seal is leaking. If so, replace the defective part immediately and change the oil. DO NOT fill above mark indicated as leakage or undue heating may result. Also check coupling alignment to make certain that foundation settling has not caused excessive misalignment. If drive is equipped with a fan, periodically clean accumulated foreign matter from the fan, fan guard and deflector to allow adequate air flow.

LUBRICANT CHANGES — Refer to Page 4.

BEARING & SEAL GREASES — Refer to Page 6.

Stored & Inactive Gear Drives Each gear drive is protected with rust preventive that will protect parts against rust for a period of 4 months in an outdoor shelter or 12 months in a dry building after shipment from the Factory.

If a gear drive is to be stored, or is inactive after installation beyond the above periods, drain oil from housing and spray all internal parts with a rust preventive oil that is soluble in lubricating oil or add “Motorstor” ™vapor phase rust inhibitor at the rate of one ounce per cubic foot of internal drive space (or 5% of sump capacity) and 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 necessary.

Indoor dry storage is recommended.

Gear drives ordered for extended storage can be treated at the Factory with a special preservative and sealed to rust-proof parts for periods longer than those cited previously.

The vent cap and vented dipstick should be replaced with a plug (vented dipstick and vent cap assembly should be attached to gear drive for future use) so that the protective rust inhibiting atmosphere is sealed inside the drive. Install vent cap and vented dipstick when preparing drive for operation.

Rexnord Industries, LLC, Gear Group148-050 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131November 2006

Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.comSupersedes 4-99

Installation & Maintenance Instructions • Falk™ Enclosed Gear Drives

(Page 8 of 8) Sizes 1080-1195 & 2050-2235 • Types GHB, Y, YB, & YBX

Motorstor ™/VCI–10 (Add to Stored or Inactive Units)

Drive Type Drive Size Motorstor™ Ounces Per Drive

All Types and

2000 GHB

1080-1090, 2050-2090 2 1100-1135, 2100-2135 6 1140-1145, 2140-2145 10 1150-1165, 2150-2165 20 1170-1195, 2170-2195 45

2200-2235 130

Product of Daubert Chemical Company, Chicago, IL .