Rexnord Industries Falk Series Instruction Manual

INTRODUCTION
This gear drive is furnished with a cooling system to dissipate
the heat generated by the load being transmitted through the
drive. The installation, operation and minor adjustments to this
cooling system is the subject of this manual. For detailed
maintenance instructions and specifications for accessories
such as the oil filter, thermometer, oil relief valve, oil heater,
oil flow indicator, oil pressure gauge, pressure control switch
and warning device, consult the product manufacturer’s
literature.
Falk™ Specifications 146-764 lists part numbers and brief
construction and operation data for the above accessories.
Selection Guide 141-931 gives selection and dimensional
data for Falk™ standard external pump and cooler systems.
When ordering parts, or requesting information, specify the
Falk M.O. number, unit size, H.S. shaft rpm, ratio and date
stamped on the unit nameplate.
CAUTION: Lock out power source and remove all external
loads from unit before servicing unit or accessories.
PIPE CONNECTIONS
Oil line connections are completed at Falk™ for internal and
unit mounted pumps; only the cooler water lines require
connection during installation. For floor-mounted pumps and
coolers, connect oil and water lines after the gear drive has
been installed. Refer to Figures 1 thru 3 and Tables 1 and 2 for
oil and water line connection points and pipe sizes. Always
locate floor mounted pumps BELOW the unit oil level to
maintain a prime and CLOSE to the unit to minimize pipe
lengths.
Connect water inlet line to the tube side of the heat exchanger
and run the discharge line to an OPEN DRAIN to prevent back
pressure. DO NOT use a throttling valve between heat
exchanger and drain.
Equip units with a by-pass valve or an immersion type oil
heater when the ambient temperature is below 50°F(10°C).
Consult Factory for size and type of heater and Specifications
146-764 for wiring diagram.
OIL LEVELS — Prior to filling Type Y and YB reducers, remove
the inspection plate and FLOOD THE OIL TROUGHS to insure
a generous flow of oil to the bearings. For Type YBX, remove
the top plug or sight glass and flood oil passages. This priming
action lubricates and protects the bearings until sufficient oil is
circulated. Fill unit to level marked on the dipstick.
Falk™ Gear Drive Type PC Pump and Cooler •Installation and Maintenance
Types Y, YF, YB, and YBX •All Sizes (Page 1 of 3)
Rexnord Industries, LLC, Gear Group 148-931
3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: [phone] December 1990
Fax: [phone] e-mail: [email protected] web: www.rexnord.com Supersedes 2-71
TABLE1—YandYFDrivePipeSizes – NPT
(Refer to Figures 1 and 2)
DRIVE
SIZE HDD GE JD KD DRIVE
SIZE QDD GE JD KD
2050 .50 . . . . . . 1.00 2120/25 .75 1.00 1.25 1.25
2060 .50 . . . . . . 1.00 2130/35 .75 1.00 1.25 1.25
2070 .50 . . . . . . 1.00 2140/45 1.00 1.00 1.50 1.50
2080 .50 †. . . . . . 1.25 2150/55 1.00 1.25 1.50 1.50
2090 .50 †. . . . . . 1.25 2160/65 1.50 ‡1.25 2.00 2.00
2100 .75 . . . 1.25 1.25 2170/75 1.25 1.25 2.00 2.00
2110 .75 .75 1.25 1.25 2180/85 1.50 ‡1.25 2.00 2.00
2190/95 1.50 ‡1.25 2.00 2.50
HDimensions also apply to YF series drives. For YB and YBX, refer to Factory.
†DD = .75 with 40PC.
‡DD = 1.25 with 50PC.
TABLE 2 — Pump and Cooler Pipe Sizes – NPT
(Refer to Figure 3)
Pump and
Cooler Size GA MB V WD Pump and Cooler Size GA MB V WD
20PC .75 1.00 .50 . . . 50PC 2.00 3.00 1.00 1.25 l
30PC 1.00 1.50 .50 .75 60/61PC 2.00 3.00 1.50 1.50 l
40PC 1.50 2.00 .75 1.00 70PC 2.00 3.00 1.50 2.00
lWD = 2 for Drive Sizes 2180 through 2195.
SINGLE
REDUCTION
DOUBLE
REDUCTION
GE – HOLE
DOUBLE REDUCTION
WD – HOLE
SINGLE REDUCTION
KD – HOLE FOR OIL SUCTION
LINE FROM PUMP
SPLASH LUBRICATION
Figure 1
Figure 2
Figure 2
HEAT
EXCHANGER
MB – OIL
DISCHARGE
PUMP
OIL AND WATER LINE LOCATIONS
JET LUBRICATION
V– OIL
SUCTION GA – WATER
INLET
V– OIL
DISCHARGE GA – WATER
OUTLET
V– OIL
DISCHARGE GA – WATER
INLET
V– OIL
SUCTION
GA – WATER
OUTLET
V– OIL
SUCTION GA – WATER
INLET
V– OIL
DISCHARGE
GA – WATER
OUTLET
SIZES 20 AND 40 PC
SIZES 50 AND 61 PC
SIZES 60, 70, AND 80 PC

BEFORE STARTING — Rotate the external pump shaft by
hand to prime the pump. Start the pump motor and check for
oil flow thru the oil sight or in the oil troughs. If oil is not
circulating, reverse the motor shaft rotation and recheck.
Internal pumps on YBX units do not require priming, but check
for oil flow through the oil sight after the unit has been started.
RECHECK OIL LEVEL — After operating the unit for 2 or 3
minutes, shut down and immediately recheck the oil level
before oil lines drain. This reading will indicate the true
operating oil level. Add oil, if necessary, to raise level to the
“full” mark on the dipstick.
JET SPRAYS — Drives equipped with this system may be
identified by the oil piping shown in Figure 2. A jet of oil is
directed to the H.S. shaft bearings, while a spray of oil
lubricates the H.S pinion.
Check to see that an even spray of oil emerges from the nozzles
onto the pinion and that oil is flowing through the H.S bearings. If
not, disassemble the clogged portion and clean the oil passages
with a wire. Flush thoroughly to remove any contaminant.
Oil must be free of lint or any contamination that may clog the
lubrication nozzles or oil passages.
WATER FLOW — Be sure that all parts of the system are
clean and that the exchanger is full of fluid. Maintain the
specified rate of oil and water flow. Avoid excessive flow of
cooling water since this may cause tube failure through
erosion and may decrease cooling efficiency.
Add antifreeze per manufacturer’s specification to closed
water supply systems. However, note that antifreeze reduces
the rate of heat dissipation.
The additional thermal horsepower capacity provided by the
cooler is based on a 1:1 oil/water flow rate, a 55°F(31°C)
inlet temperature difference between oil and water,
90°F(32°C) inlet water temperature and maximum inlet water
pressure of 50 psig.
Adjust the water flow rate within the flow range shown on the
cooler or unit water circulation plate to maintain a reducer
operating temperature range of 140° to 160°F(60° to 71°C).
The minimum value of the range is for clean water at a
minimum velocity to prevent fouling of the tube bundle. For
brackish water, a flow rate of 2 times the minimum value is
required to prevent suspended solids from settling. The
maximum value of the range is based on a maximum velocity
to avoid erosion of the tube bundle.
MAINTENANCE
HEAT EXCHANGER — It is important that the inside parts are
kept clean. Inspect the exchanger periodically and clean
thoroughly. Inspect all tubes carefully for possible corrosion or
foreign material. Bleed the oil side of the cooler periodically if
air tends to collect in the system.
For open systems, drain vertical coolers by removing the two
zinc anodes and loosening the bottom bonnet. Disconnect and
drain the lines on horizontal open systems. Blow out all lines.
Heat exchangers are equipped with zinc anodes to minimize
galvanic corrosion. Inspect after first month of service and
periodically thereafter, depending on the severity of corrosion.
If 50% of the anode is used up, replace it.
Check the reducer oil level periodically. If it is ABOVE the
high level mark on the dipstick, have the oil analyzed for
water content. Moisture or water in the oil may indicate
that the heat exchanger is leaking. If so, replace the
exchanger immediately and change the oil.
EXTERNAL PUMP —Correct shaft alignment is essential;
check with a straightedge across the flanges of the coupling,
or use a feeler gauge between the faces of the coupling
halves at 90° intervals. The pump is a positive displacement
rotary type with a mechanical seal. Refer to manufacturer for
detailed maintenance.
INTERNAL PUMP — The lubricating pump on the 2000YBX2
exchanger cooled units is a positive displacement rotary type
manufactured at Falk. If maintenance is required, refer to the
Factory for detailed instructions.
OIL FILTER —If the filter is a Purolator, cleaning of the
element is accomplished by rotating the hand wheel several
turns once a week. Remove the filtering element and scrub
with a fiber bristle and a non caustic solvent at oil change
intervals. Flush out housing with solvent. If the filter is a
Marvel, follow the above element cleaning procedure, and
when reassembling, be sure that the “O” ring is properly
seated in the head groove.
JET LUBRICATION SYSTEM DISASSEMBLY —Disconnect
piping and remove the housing end covers. The oil manifold
with spray nozzles is attached to one end cover and will pull
free from the opposite cover. Refer to Figure 4.
JET LUBRICATION SYSTEM ASSEMBLY —Install all new
end cover gaskets. Align the nozzles in a horizontal plane
facing the centerline of H.S. pinion as shown in Figure 4.
MERCOID PRESSURE CONTROL SWITCH — The mercoid
switch is a sealed unit and should not be serviced. There is a
double adjustment for setting both “on” and “off” operating points.
RELIEF VALVE — This valve is pre-set at the factory and
normally does not require adjustment. However, rotating the
adjusting screw clockwise will reduce the opening pressure.
Accessories such as flow indicator, pressure gauges,
thermometers, heaters and pressure controls are sealed units.
If a malfunction occurs, return the sealed unit directly to the
manufacturer for repair or replacement.
Installation and Maintenance •Falk™ Gear Drive Type PC Pump and Cooler
(Page 2 of 3) All Sizes •Types Y, YF, YB, and YBX
Rexnord Industries, LLC, Gear Group148-931
3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: [phone]December 1990
Fax: [phone] e-mail: [email protected] web: www.rexnord.comSupersedes 2-71

ACCESSORIES
The drawing below illustrates the general location of the
various accessories that may be used with the pump and
cooler system.
Falk™ Gear Drive Type PC Pump and Cooler •Installation and Maintenance
Types Y, YF, YB, and YBX •All Sizes (Page 3 of 3)
Rexnord Industries, LLC, Gear Group 148-931
3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: [phone] December 1990
Fax: [phone] e-mail: [email protected] web: www.rexnord.com Supersedes 2-71