Rexnord Falk UltraMax Series User manual

How to Use This Manual
The following instructions and recommendations apply to
standard Falk Model PRT backstops, Sizes 20, 60 & 65, when
mounted on UltraMax Drive Sizes 2100 thru 2130F and M2100
thru M2130F.
The backstop’s performance and life depend largely upon how
they are installed and serviced. Drawings are representative of
this series of backstops and may not agree in detail with all
backstop sizes.
When requesting information specify the M.O. number,
backstop size, part number, maximum running rpm, torque
rating and date stamped on the backstop nameplate.
This manual provides detailed instructions on installation,
maintenance and parts identification. Use the following Table of
Contents to locate required information.
Table of Contents
General Information ..............................1
Warranty.......................................1
Safety Codes & General Precautions ...................1
Application Requirements...........................1
Installation- Drives without Shaft Fans ..................2
Installation- Drives with Shaft Fans ....................2
Maintenance....................................3
Service and Removal ..............................3
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE
FREE SERVICE.
Warranty
Rexnord Industries, LLC (the ”Company”) warrants that Ultramax
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 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.
Safety Codes & General Precautions
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.
Application Requirements
BACKSTOP APPLICATION — The backstop is designed to
operate during overrunning within a speed range of 0 to 1800
rpm. The backstop can operate successfully on slope mounted
applications up to a maximum shaft axis tilt of ±6° from
horizontal without shaft modifications; refer to the Factory for
other mountings.
WARNING — DO NOT use Falk PRT type backstop in tandem.
Refer to Factory for all applications involving the need for two or
more backstops in one system.
DO NOT use backstops for systems that are designed for the
handling of people such as elevators, man lifts, ski tows, and ski
lifts.
DO NOT use the backstop as a substitute for a brake.
Rexnord Industries, LLC, Gear Group 318-814
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone] December 2006
Fax: [phone] e-mail: [email protected] web: www.rexnord.com Supersedes 7-2000
Falk™ UltraMax®Gear Drives •External Backstop Installation
Type F •Sizes 2100 thru 2130 (Page 1 of 3)
TABLE 1 — Anchor Bracket Tightening
Torques (w/o Shaft Fan) ±5%
DRIVE SIZE Fastener
Size
SAE
Grade
Torque
(lb-Ft)
Torque
(Nm)
2100-2110 .625-11 5 134 182
2120-2130 .750-10 5 242 328

Installation — Drives Without Shaft Fans
CAUTION: Refer to direction of rotation arrow on backstop.
Before installation make sure that the direction of rotation is
correct. To change the backstop over running direction, rotate
the backstop 180° end for end on shaft. For some
backstop/drive combinations, it will be necessary to have the
torque arm mounted on the outside of the backstop due to
interference with the anchor bracket. Follow specific instructions
found in Manual 568-810 shipped with the backstop. Check
backstop size on nameplate and make certain it is correct.
1. If installing external backstop on drive not previously
supplied with a backstop, a special - long high speed shaft
is required. Refer to drive assembly/disassembly
instructions for installation of high speed shaft.
2. Install anchor bracket if necessary by removing the
appropriate high speed head fasteners to allow anchor
bracket to be centered above the high speed shaft (see
Figures1&2).Mount anchor bracket and insert the longer
fasteners and lock washers that were supplied with the
backstop kit. Tighten fasteners to values shown in Table 1.
3. Clean the backstop bore and the shaft on which the
backstop will be mounted. Make sure the short key is clean
and completely seated in the shaft.
4. Align the hub keyway with the shaft key and slide backstop
onto shaft and anchor bracket torque arm pin. The
backstop must slip onto shaft. DO NOT hammer backstop
onto shaft. There should be clearance between the
backstop anchor lug and torque arm pin as shown in
Figure 3. Position the backstop axially to allow clearance
for the extreme float limits of the shaft, Figure 4.
5. Install spring pins to hold backstop onto torque arm pin.
6. Check free, or overrunning, and locked rotation of
backstop. If satisfactory, stake key (inch series) to through
hardened shaft, Figure 5, or use an anaerobic thread
sealant such as Loctite 242 if shaft is carburized.
Installation — Drives with Shaft Fans
CAUTION: Refer to direction of rotation arrow on backstop.
Before installation make sure that the direction of rotation is
correct. To change the backstop over running direction, rotate
the backstop 180° end for end on shaft. For some
backstop/drive combinations, it will be necessary to have the
torque arm mounted on the outside of the backstop due to
interference with the anchor bracket. Follow specific instructions
found in Manual 568-810 shipped with the backstop. Check
backstop size on nameplate and make certain it is correct.
1. If installing external backstop on drive not previously
supplied with a backstop, a special - long high speed shaft
is required. Refer to drive assembly/disassembly
instructions for installation of high speed shaft.
2. Install anchor bracket if necessary by removing the
appropriate high speed head fasteners as shown in Figures
6 & 7. Mount anchor bracket and insert the longer
fasteners and lock washers that were supplied with the
backstop kit. Tighten fasteners to torque values shown in
Table 2.
WARNING:To meet OSHA requirements, double
reduction drives require a shaft sleeve between the fan
guard and backstop (see Figure 8).
Rexnord Industries, LLC, Gear Group318-814
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]December 2006
Fax: [phone] e-mail: [email protected] web: www.rexnord.comSupersedes 7-2000
External Backstop Installation •Falk™ UltraMax®Gear Drives
(Page 2 of 3) Type F •Sizes 2100 thru 2130
TORQUE
ARM
PIN
CLEARANCE
FIGURE 3
4-FASTENERS
ANCHOR
BRACKET
ANCHOR
BRACKET
2-FASTENERS
CLEARANCE
ANCHOR BRACKET
SPRING PINS
TORQUE ARM
PRT
BACKSTOP
FIGURE 4
FIGURE 1
Sizes 2100- 2130
with #20 PRT Backstops
without shaft fans
FIGURE 2
Sizes 2100- 2130 with
#60 or 65 PRT Backstops
without shaft fans
STAKE
KEY
BACKSTOP
KEY
FIGURE 5

5. Attach torque arms to the anchor bracket. Tighten locknut
until there is zero clearance between the torque arms and
the anchor bracket lug. Then back off locknut one and
one-half turns. Lay torque arms to the left side for CCW
high speed shaft rotation, or to the right side for CW shaft
rotation (see Figures6&7).
6. Clean the backstop bore and the shaft on which the
backstop will be mounted. Make sure the shaft key is clean
and completely seated in the shaft.
7. Align the hub keyway with the shaft key and slide backstop
onto shaft. The backstop must slip onto shaft. DO NOT
hammer backstop onto shaft.
8. Insert bushing into backstop lug and fasten backstop to the
torque arms. Tighten the locknut until there is zero
clearance between the torque arms and the bushing, then
back off 60°.
9. Position backstop axially on the shaft to allow for equal
clearance at the torque arm as shown in Figure 8.
10. Check free and locked rotation of backstop. If satisfactory,
stake key (inch series) to through hardened shaft, Figure 5,
or use an anaerobic thread sealant such as Loctite 242 if
shaft is carburized.
Maintenance
Refer to Manual 568-810 shipped with each backstop for
proper maintenance schedule and lubrication intervals.
The backstops do have grease-purged cavities which minimize
the entry of taconite and other abrasive dusts into the backstop.
When PRT backstops are furnished assembled to an UltraMax
drive, the grease-purge cavity will be filled with NLGI #2
bearing grease, unless specifically ordered otherwise.
WARNING: If application is in the food or drug industry where
grease could contaminate the product, the backstop should be
ordered special — lubricated with a grease that meets USDA
“HI” classification.
To make use of this feature, pump NLGI #2 (worked
penetration at 60 strokes, 265-295) bearing grease into the
seal housing cavity through the grease fitting. Periodically
(monthly) depending upon the frequency and degree of
contamination, purge contaminated grease from by pumping
fresh bearing grease through the cover or torque arm until it
flows out along the shaft. It is important to rotate the shaft while
greasing cavity to prevent excessive pressure. Wipe off purged
grease.
Service and Removal
WARNING: DO NOT attempt to service or remove backstops
before locking out power source and removing load. Replace
damaged backstops with a new Falk tested backstop.
Backstop should be removed from the shaft by applying
force to the hub of the backstop only.
Rexnord Industries, LLC, Gear Group 318-814
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone] December 2006
Fax: [phone] e-mail: [email protected] web: www.rexnord.com Supersedes 7-2000
Falk™ UltraMax®Gear Drives •External Backstop Installation
Type F •Sizes 2100 thru 2130 (Page 3 of 3)
TABLE 2 — Anchor Bracket Tightening Torque
(with Shaft Fan) ±5%
DRIVE SIZE Fastener Size SAE Grade Torque
(lb-Ft)
Torque
(Nm)
2100-2110 F2
w/ #60 BACKSTOP .625-11 8 190 257
2100-2110 F2 & F3
w/ #20 BACKSTOP .625-11 5 134 182
2120-2130 F2
w/ #60 or 65 BACKSTOP .750-10 8 345 467
2120-2130 F2 & F3
w/ #20 BACKSTOP .750-10 5 242 328
TORQUE ARM LOCATION
FOR CCW ROTATION OF
H.S. SHAFT
TORQUE ARM LOCATIO
N
FORCWROTATIONOF
H.S. SHAFT
FIGURE 6
All Drives with #20 PRT backstop & 2100F2 with #60 PRT backstop
TORQUE ARM LOCATION
FOR CCW ROTATION OF
H.S. SHAFT
TORQUE ARM LOCATIO
N
FORCWROTATIONOF
H.S. SHAFT
OSHA SLEEVE
FAN GUARD
BACKSTOP
2 TORQUE ARMS
ANCHOR BRACKET
CLEARANCE
CLEARANCE
FIGURE 8
FIGURE 7
2110F2, 2120F2, & 2130F2 with #60 or 65 PRT backstop