Falk UltraMax Type FC, FZ, Sizes 2040-2130 Gear Drives - Rexnord

FalkтДв UltraMax┬о Gear Drives
тАв Installation & Maintenance Instructions
Types FC and FZтАВ тАвтАВ Sizes 2040 thru 2130
(Page 1 of 8)
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 7
Stored and Inactive Gear Drives.................................Page 7
Reliability Package (Lubrication Package)..................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 тАФ 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 & ASSEMBLY тАФ Disassembly and assembly instructions and parts guides are available from the
Factory or Rexnord-Falk Representatives. 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 тАФ Rexnord Industries (the тАЬCompanyтАЭ)
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.
Type FZ
Type FC
Installation Instructions
The following instructions apply to standard Falk Type FC &
FZ drives shown above. If a drive is furnished with special
features, refer to the supplementary instructions shipped
with the drive.
WELDING тАФ Do not weld on the gear drive or accessories
without prior approval from the Factory. 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 тАФ If the gear drive operates in the sun at ambient temperatures over 80┬░F(27┬░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 тАФ 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 the Factory for changes necessary to
provide proper lubrication.
NON-HORIZONTAL MOUNTING тАФ 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.
LIFTING INSTRUCTIONS тАФ Lift UltraMax drives by means
of a sling (with adequate lifting capacity) wrapped around
the high speed and low speed shaft extensions for drive
Sizes 2040 through 2090 and Sizes 2100 through 2130
when equipped with an electric fan. Standard drive Sizes
2100 through 2130 are equipped with lifting lugs welded to
the side of the drive. Refer to Figure 1. When lifting a drive
with a sling, make certain that the shaft extension keyways
do not come in contact with the sling as the sharp corners
could cut the sling.
SLING
LIFTING
LUGS
SIZES 2040 - 2090
SIZES 2100 - 2130
Figure 1
Rexnord Industries, LLC 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131тАГFax: 414-937-4359тАГ www.rexnord.com
318-100
December 2013
Supersedes 12-06
FalkтДв UltraMax┬о Gear Drives
(Page 2 of 8)
тАв Installation & Maintenance Instructions
Types FC and FZтАВ тАвтАВ Sizes 2040 thru 2130
FOUNDATION, GENERAL тАФ To facilitate oil drainage,
elevate the gear drive foundation above the surrounding
floor level. If desired, replace the drives 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 тАФ 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
CONTINUOUS
illustrated.
PLATE
FOUNDATION, CONCRETE тАФ 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.
MOTOR BRACKETS тАФ
Falk motor brackets provide an economical тАЬsoft mountingтАЭ
for standard NEMA T & U frame AC induction type electric
motors. The weight, location, and starting torque of the
motor will cause cantilevered motor brackets to deflect
downward or twist to varying degrees.
The drive/coupling/motor selections found in the Rexnord
selection guide are engineered to be within acceptable
deflection limits as determined by Rexnord. However,
because the bracket is a тАЬsoft motor supportтАЭ, deflection
and vibration magnitude of the bracket may exceed
levels normally considered acceptable for rigidly mounted
machinery.
For applications using other than standard selection guide
drive/coupling/motor selections, the use of a motor plate is
recommended. If a motor bracket is to be used, it becomes
the customerтАЩs responsibility to support the rear of the
motor bracket as necessary to diminish motor bracket
deflection and vibration to within satisfactory levels as
determined by the customer.
When using other than standard T-frame motors refer to
Manual 317-315.
318-100
December 2013
Supersedes 12-06
GEAR DRIVE ALIGNMENT тАФAlign 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 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.
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
PLATE
SHIMS
Shaft Connections
WARNING: Provide suitable guards in accordance with
OSHA standards.
COUPLING CONNECTIONS тАФ The performance and
life of any coupling depends largely upon how well the
coupling is installed and serviced. Refer to the coupling
manufacturerтАЩs 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.
COUPLINGS тАФ Detailed installation
manuals are available from the
Factory, your local Rexnord-Falk
тАФ CAUTION тАФ
Representative or DistributorтАФjust
DO NOT HAMMER
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.
Rexnord Industries, LLC
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131тАГFax: 414-937-4359тАГwww.rexnord.com
FalkтДв UltraMax┬о Gear Drives тАв Installation & Maintenance Instructions
FalkтДв UltraMax┬о Gear Drives тАв Installation & Maintenance Instructions
Types FC and FZтАВ тАвтАВ Sizes 2040 thru 2130
(Page 3 of 8)
Types FC & FZ тАв Sizes 2040 thru 2130
(Page 3 of 7)
Flanged Type Rigid Couplings are typically used on drives
Flanged
Type
Rigidshafts.
Couplings
are speed
typicallyshaft
used extension
on drives
with
vertical
output
The low
with vertical
outputvertical
shafts. The
speed
shaft
extension
ends
ends
of the solid
shaftlow
drives
are
drilled
and tapped
to
keeper
plates.
Tightening
of accommodate
the solid verticalcoupling
shaft drives
are drilled
and
tapped to
torques
for fasteners,
keeper
plate fasteners
accommodate
couplingincluding
keeper plates.
Tightening
torques are
for
listed
in Table
1. keeper plate fasteners are listed in Table 1.
fasteners,
including
GAP &
& ANGULAR
ANGULAR ALIGNMENT
mounting
GAP
ALIGNMENT тАФ
тАФ IfIfpossible,
possible,after
after
mounting
coupling
hubs,
the driven
drivingequipment
and driven
coupling hubs,
position
theposition
driving and
so
equipment
so that
the distance
between shaft ends is equal
that the distance
between
shaft ends
to
coupling
gap. Align
shafts
is the
equal
to the coupling
gap.the
Align
by
spacer ablock,
theplacing
shafts bya placing
spacerequal
block,in
thickness
to required
gap, between
equal in thickness
to required
gap,
hub
faces,
asfaces,
shown
and
between
hub
asabove,
shown above,
also
90┬░
around
the the
hub.
and at
also
at intervals
90┬░ intervals
around
Check
with feelers.
hub. Check
with feelers.
STEELFLEX ILLUSTRATED
┬о
STEELFLEX ILLUSTRATED
OFFSET
ALIGNMENTтАФ
тАФAlign
Align
OFFSET ALIGNMENT
driving
and
driven
shafts
so
that
a
driving and driven shafts so that a
straight
edgewill
willrest
restsquarely
squarely
straight edge
onon
both
hubsasasshown
shown
both couplings
couplings hubs
to to
the
the
right
and
also
at
90┬░
intervals.
right and also at 90┬░ intervals.
Tighten foundation bolts of the
Tighten foundation bolts of the
connected equipment and recheck
connected equipment and recheck
STEELFLEX ILLUSTRATED
alignment and gap.
STEELFLEX ILLUSTRATED
alignment and gap.
SPROCKETS,
PULLEYS
OR
SHEAVES
тАФ Mount
power
SPROCKETS, PULLEYS OR SHEAVES тАФ Mount
power
take-offs as close to the gear drive housing as possible to
take-offs as close to the gear drive housing as possible to
avoid undue bearing load and shaft deflection.
avoid undue bearing load and shaft deflection.
Align
output shaft
shaftofofthe
thegear
gear
drive
square
parallel
Align the
the output
drive
square
andand
parallel
with
with the driven shaft by placing a straightedge across the
the driven shaft by placing a straightedge across the face of the
face of the sprockets or sheaves
RIGHT
WRONG
sprockets or sheaves as illustrated. Check
horizontal shaft
as illustrated. Check horizontal
alignment
by placing
one legone leg
shaft
alignment
by placing
WRONG
RIGHT
of aa square
square against
of
againstthe
theface
face of the
of the sheave
or sprocket
withspirit
sheave
or sprocket
with the
the spirit
level
on the leg of the
level
on the
horizontal
horizontal leg of the square.
square.
GEAR DRIVE WALL
GEAR DRIVE WALL
LEVEL
SQUARE AND
PARALLEL
SQUARE AND
PARALLEL
over
tighten belts
LEVEL
DO NOT
or chains. Adjust to
manufacturersтАЩ specifications. Adjust belts as follows:
DO NOT over tighten belts or chains. Adjust to manufacturersтАЩ
The
ideal tension
is the
lowest
tension at which the belt
specifications.
Adjust
belts
as follows:
will
slip
underispeak
load conditions.
Check
Thenot
ideal
tension
the lowest
tension at which
thethe
beltbelt
will not
tension
frequently
during
the
first
24
to
48
hours
of run-in
slip under peak load conditions. Check the belt tension
operation. Over tightening belts shortens belt and bearing
frequently during the first 24 to 48 hours of run-in operation.
life. Keep belts free from foreign material which may cause
Over tightening belts shortens belt and bearing life. Keep belts
slippage. Inspect the VтАУbelt periodically; tighten the belts if
free from
foreign material which may cause slippage. Inspect
they
are slipping.
the VтАУbelt periodically; tighten the belts if they are slipping.
OUTBOARD BEARING тАФ Mount the outboard bearing and
OUTBOARD BEARING тАФ Mount the outboard bearing and
gear drive on a common foundation so that they will shift
gear drive on a common foundation so that they will shift as an
as an assembly if settling should occur. Bring the outboard
assemblytoif the
settling
should
occur. Bring
the outboard
bearing
bearing
correct
horizontal
position
with broad
flat to
the
correct
horizontal
position
with
broad
flat
shims
under
shims under the mounting pad. Align accurately so thatthe
mounting
Aligndivided
accurately
so that the
equally
divided
the
load ispad.
equally
between
theload
two isdrive
bearings
between
the
two
drive
bearings
and
the
outboard
bearing.
Mount
and the outboard bearing. Mount a stop bar against the
a stop block
bar against
thethe
pillow
block
on the
loadhorizontal
side whenload
pillow
foot on
load
sidefoot
when
large
large horizontal
load
components
exerted
on the pillow block.
components
are
exerted
on theare
pillow
block.
BACKSTOPS тАФ To prevent damage to backstops due to
BACKSTOPS
тАФ shaft
To prevent
damage
to backstops
due to are
incorrect
incorrect
motor
rotation
at start
up, couplings
NOT
motor shaft rotation
at startdrives
up, couplings
are NOTwith
assembled
when
assembled
when gear
are furnished
backstops.
gear drives
are furnished
with backstops.
After completing
the
After
completing
the electrical
connection,
check motor
and
gearconnection,
drive shaftcheck
rotations.
complete
alignment
electrical
motor Then
and gear
drive shaft
rotations.
and
of coupling.
Thenassembly
complete alignment
and assembly of coupling.
Fastener Tightening Torques
Fastener Tightening Torques
Use the tightening torque values specified in Table 1, for
Use the tightening
torque
values
specified
in Table 1, forto
fastening
Falk gear
drives,
motors,
and accessories
fastening
Falk gear
drives, motors,
and accessories
to their DO
their
mounting
surfaces
with non-lubricated
fasteners.
mounting
with non-lubricated
fasteners.fasteners
DO NOTor
use
NOT
use surfaces
these values
for тАЬtorque lockingтАЭ
these
values forcomponents
тАЬtorque lockingтАЭ
or for
fastening
for
fastening
withfasteners
aluminum
feet
or with soft
components
with aluminum
feet or
gaskets or
vibration
gaskets
or vibration
dampers
onwith
thesoft
mounting
surface.
If
dampers
on the torque
mounting
surface.the
If the
tightening
exceeds
the
tightening
exceeds
capacity
of torque
the torque
the capacity
torquemultiplier.
wrench, use
a torque
Usefor
wrench,
useofathe
torque
Use
Grademultiplier.
5 fasteners
diameters
through
for larger
use
Grade 5 fasteners
for1.50",
diameters
throughdiameter
1.50", forfasteners,
larger diameter
ASTM
A-354
GradeA-354
BC. Grade BC.
fasteners,
use ASTM
TABLE 1 тАФ Tightening Torques (lb-ft) ┬▒ 5% тАУ
(DO NOT Lubricate Fasteners)
Thread
Dia-UNC
Metal to
Metal
Metal to
Concrete
Thread
Dia-UNC
Metal to
Metal
Metal to
Concrete
.250-20
.312-18
.375-16
.500-13
.625-11
.750-10
.875-9
1.000-8
1.125-7
7
15
27
67
134
242
395
590
740
6
12
22
54
108
194
315
475
590
1.250-7
1.375-6
1.500-6
1.750-5
2.000-4.5
1060
1360
1840
3900
5900
840
1100
1460
2700
4100
Water Cooling
Water Cooling
WATER COOLED HEAT EXCHANGERS тАФ Install a shut-off or
WATER COOLED HEAT EXCHANGERS тАФInstall a shutcontrol valve in the water line to the heat exchanger to regulate
off or control valve in the water line to the heat exchanger
theregulate
water flow
the exchanger.
Also
install a water
to
thethrough
water flow
through the
exchanger.
Also flow
gauge
between
the
control
valve
and
the
exchanger
to
install a water flow gauge between the control valve and the
determine actual
flow rate.actual
Discharge
to an OPENwater to
exchanger
to determine
flow water
rate. Discharge
DRAIN
to
prevent
back
pressure.
an OPEN DRAIN to prevent back pressure.
Lubrication Recommendations
Lubrication
Recommendations
Carefully follow
onon
thethe
gear
drive
Carefully
follow lubrication
lubricationinstructions
instructions
gear
drive
nameplate, warning
installation
manuals
furnished
nameplate,
warningtags
tagsand
and
installation
manuals
furnished
with the
the gear
geardrive.
drive.
Lubricants listed
manual
areare
typical
ONLY
andand
should
Lubricants
listedininthis
this
manual
typical
ONLY
not be construed
as exclusive
Industrial type
should
not be construed
as recommendations.
exclusive recommendations.
Industrial
based rust
and oxidation
petroleum type
basedpetroleum
rust and oxidation
inhibited
(R & O) gear
inhibited
O) geartype
lubricants
or industrial extreme
type sulphurlubricants (R
or &
industrial
sulphur-phosphorus
phosphorus
pressure
gear lubricants
are the
pressure (EP) extreme
gear lubricants
are (EP)
the recommended
lubricants
recommended
lubricantsoffor
ambient
temperatures
of 15┬░F
for ambient temperatures
15┬░F
to 125┬░F(тАУ9┬░C
to +52┬░C).
to 125┬░F(тАУ9┬░C to +52┬░C).
For drives operating outside the above temperature range refer
For
drives operating
outside
the above
to тАЬSynthetic
LubricantsтАЭ
paragraphs,
Pagetemperature
4. Synthetic
range
refer
to also
тАЬSynthetic
paragraphs, Page 4.
lubricants
can
be usedLubricantsтАЭ
in normal climates.
Synthetic lubricants can also be used in normal climates.
VISCOSITY (IMPORTANT) тАФ The proper grade for R & O, EP,
VISCOSITY (IMPORTANT) тАФ The proper grade forR&O,EP,
or lubricants is found in Table 2, Page 4. Select a lubricant
or lubricants is found in Table 2, Page 4. Select a lubricant
which has a pour point at least 10┬░F (5.5┬░C) below the
which has a pour point at least 10┬░F (5.5┬░C) below the
expected minimum
starting
temperature.
Usable
expected
minimumambient
ambient
starting
temperature.
Usable
temperature
ranges
can
sometimes
be
widened
if
specific
temperature ranges can sometimes be widened
if specific
application conditions
application
conditionsare
areknown.
known.
Rexnord Industries, LLC Rexnord
Industries,
Gear Group
3001
W. Canal
St., LLC,
Milwaukee,
WI 53208-4200 USA
3001
W.
Canal
St.,
Zip
53208-4200,
Milwaukee,тАГ WI
USA Telephone : 414-342-3131
Telephone: 414-342-3131тАГFax: 414-937-4359
www.rexnord.com
Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.com
318-100
318-100
December
2013
December
2006
Supersedes 12-06
Supersedes 05-01
┬о Gear Drives
Installation
& ┬оMaintenance
FalkтДв UltraMax
тДв
тАв Maintenance
Falk
UltraMax
Gear Drives тАвInstructions
Installation &
Instructions
┬о Gear Drives
Installation
& Maintenance
Instructions
тАв FalkтДв UltraMax
thru 2130
(Page 44 of
of 8)
7)
Types
тАв Sizes
(Page
Types FC
and FC
FZтАВ&тАвтАВFZ
Sizes
2040 2040
thru 2130
(Page 4 of 7)
Types FC &
FZ тАв Sizes 2040 thru 2130
TABLE 2 тАФ Viscosity Grade Recommendations H
TABLE 2 тАФ Viscosity Grade Recommendations H
Synthetic Lubricants
R & O or EP Lubricants
Synthetic Lubricants
R & O or EP Lubricants
Cold Climates
Normal Climates тАа
Output
Cold Climates
Normal Climates тАа
тАУ30┬░
to
+10┬░F
тАУ15┬░
to
+50┬░F
15┬░
to
60┬░F
50┬░ to 125┬░F
Output
RPM
тАУ30┬░
to
+10┬░F
тАУ15┬░
to
+50┬░F
15┬░
to
60┬░F
50┬░ to 125┬░F
(тАУ34┬░
тАУ12┬░C)
(тАУ26┬░
to
+10┬░C)
(тАУ9┬░
to
+16┬░C)
(10┬░
52┬░C)
RPM
(тАУ34┬░ to тАУ12┬░C) (тАУ26┬░ to +10┬░C) (тАУ9┬░ to +16┬░C) (10┬░ to 52┬░C)
ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA
ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA
Below 80
32
0S
68
2S
150
4
320
6
80Below
& Above
32
0S
68
2S
150
44
220
56
80
32
0S
68
2S
150
320
80
&
Above
32
0S
68
2S
150
4
220
5
H
When ambient temperatures are higher than 125┬░F (52┬░C), or when drives
H are
When
ambientintemperatures
are higher
than or
125┬░F
or when drives
operating
extremely humid,
chemical,
dust (52┬░C),
laden atmospheres,
it is
are operating in
extremely
humid,
dustfrequently.
laden atmospheres,
it is
recommended
that
the lubricant
bechemical,
changed or
more
See
recommended
that the lubricant be changed more frequently. See
lubricant
changes.
lubricant
changes.
тАа Refer
to Table
3 for proper synthetic lubricant viscosity grades for normal climates.
тАа Refer to Table 3 for proper synthetic lubricant viscosity grades for normal climates.
IfIf a
gear drive
driveoperates
operatesinina atypical
typical
indoor
environment
a gear
indoor
environment
where
where
thedrive
ambient
temperature
isindoor
within
70┬░F (21┬░C
to 125┬░F
If a ambient
gear
operates
inisawithin
typical70┬░F
environment
where
the
temperature
to 125┬░F
to
(21┬░C
to
52┬░C),
the
oil
viscosity
should
be
increased
one
the
ambient
temperature
is
within
70┬░F
to
125┬░F
(21┬░C
to
52┬░C), the oil viscosity should be increased one AGMA grade
AGMA
grade
shown
for the 50┬░F
toAGMA
125┬░F(10┬░C
52┬░C),that
the shown
oil above
viscosity
should
be
increased
one
grade
above
for that
the
50┬░F
to 125┬░F(10┬░C
to
52┬░C)
range.
to
52┬░C)
range.
That
is,
Number
6to
or52┬░C)
7 should
above
shown
for
thean
50┬░F
range.
That
is,that
an
AGMA
Number
6AGMA
orto7125┬░F(10┬░C
should
be substituted
for a 5
be
substituted
for Number
a 5 or 6 6
respectively,
under
this ambient
That
is,
an
AGMA
or
7
should
be
substituted
for a 5
or 6 respectively, under this ambient condition.
condition.
or 6 respectively, under this ambient condition.
OIL PUMPS тАФ When selecting a lubricant for a gear drive
OIL
тАФ When
When selecting
selectinga alubricant
lubricant
a gear
drive
OILPUMPS
PUMPS
тАФ
forfor
a gear
drive
equipped
with
an
oil
pump,
cold
temperature
oil
viscosity
is
equipped
with
an
oil
pump,
cold
temperature
oil
viscosity
equipped with
an oilviscosity
pump, cold
temperature
oil viscosity
is
important.
Lubricant
at start-up
generally
should not
is
important.
Lubricant
viscosity
at
start-up
generally
important.
Lubricant
viscosity
atWhen
start-up
generallythis
should
not
exceed
1725
cSt
(8,000
SSU).
exceeding
viscosity,
should not exceed 1725 cSt (8,000 SSU). When exceeding
exceedcavitation
1725 cStis(8,000
SSU).
When exceeding
this viscosity,
pump
possible,
preventing
oil circulation.
A sump
this
viscosity, pump
cavitation
is possible,
preventing
oil
pump cavitation
is possible,
preventing
oil circulation.
A sump
heater
may
be
required
or
it
may
be
possible
to
use
a
lower
circulation. A sump heater may be required or it may be
heater may
beminimize
required
or
it may
be
a lower
viscosity
oil
cavitation,
refertotouse
Factory.
possible
to to
use
a lowerpump
viscosity
oilpossible
to minimize
pump
viscosity
oil
to
minimize
pump
cavitation,
refer
to
Factory.
cavitation, refer to Factory.
Petroleum Based Lubricants
Based Lubricants
Lubricants
Petroleum
Based
RPetroleum
& O GEAR LUBRICANTS
(Table 6) тАФ Industrial type
R&
&O
O GEAR
GEAR
LUBRICANTS
(Table
6)6)тАФтАФIndustrial
petroleum
based
rust and oxidation
(R & Otype
) type
gear
R
LUBRICANTS
(Tableinhibited
Industrial
petroleumare
based
oxidation
(R &
O ) general
gear
petroleum
based
rustand
and
oxidation
inhibited
(R&O)gear
lubricants
the rust
most
common
andinhibited
readily
available
lubricants
are
the
most
common
and
readily
available
general
lubricants
are
the
most
common
and
readily
available
purpose gear lubricants.
purpose purpose
gear lubricants.
general
gear
lubricants.
EXTREME PRESSURE (EP) LUBRICANTS (Table 4) тАФ For
EXTREME
PRESSURE
(EP)(EP)
4) тАФ
ForтАФ
EXTREME
PRESSURE
LUBRICANTS
(Table
highly
loaded
gear drives
orLUBRICANTS
drives
loaded(Table
in excess
of 4)
original
highly
loaded
geargear
drives
or drives
loaded
inpressure
excess
of
original
For
highly
loaded
or drives
loaded
in excess
estimates,
industrial
typedrives
petroleum
extreme
lubricants
of
original
estimates,
industrial
typeextreme
petroleum
extreme
estimates,
industrial
petroleum
pressure
lubricants
are
preferred.
The EPtype
lubricants
currently
recommended
are of
pressure
lubricants
are
preferred.
The
EP
lubricants
currently
are
preferred.
The
EP
lubricants
currently
recommended
are of
the sulphur-phosphorus type.
recommended
are of the
sulphur-phosphorus type.
the sulphur-phosphorus
type.
WARNING: EP LUBRICANTS IN FOOD PROCESSING INDUSTRY
WARNING:
EP
LUBRICANTS
FOOD
PROCESSING
WARNING:
EPmay
LUBRICANTS
ININ
FOOD
PROCESSING
тАФ
EP lubricants
contain toxic
substances
and shouldINDUSTRY
not be
INDUSTRY
тАФ EP
lubricants
may
contain toxic
substances
тАФ
EP
lubricants
may
contain
toxic
substances
should
not be
used in the food processing industry without theand
lubricant
and
should
not processing
be used inindustry
the food
processing
industry
used
in
the
food
without
the
lubricant
manufacturersтАЩ approval. Lubricants which meet USDA тАЬH1тАЭ
without
the lubricant
manufacturersтАЩ
approval.
Lubricants
manufacturersтАЩ
approval.
Lubricants
which
meetapplications.
USDA
тАЬH1тАЭ
classification
are
suitable
for food processing
which
meet USDA
тАЬH1тАЭ classification
are suitable
for food
classification
are suitable
for food processing
applications.
processing
applications.
CAUTION: EP
LUBRICANTS & INTERNAL BACKSTOPS тАФ Do
CAUTION:
EP LUBRICANTS
& INTERNAL
BACKSTOPS
тАФ or
Do
not
use
EP
lubricants
or lubricants
with anti-wear
additives
CAUTION:
EP
LUBRICANTS
& INTERNAL
BACKSTOPS
not use EP
lubricants
or
lubricants
with anti-wear
additives
or
lubricant
formulations
including
sulfur-phosphorus,
chlorine,
тАФ Do not use EP lubricants or lubricants with anti-wearlead
lubricant formulations
sulfur-phosphorus,
chlorine, lead
derivatives,
orincluding
molybdenum
disulfides in
drives
additives
orgraphite
lubricant
formulations
including
sulfurderivatives,
graphite
orcartridge
molybdenum
disulfides Some
in drives
equipped
with
internal
type
backstops.
phosphorus, chlorine, lead derivatives, graphite orlubricants
equipped with disulfides
internal cartridge
typeequipped
backstops.with
Some
lubricants
molybdenum
in drives
internal
in Table 6 may contain anti-wear additives. Lubricants in Table
cartridge
backstops.
Someadditives.
lubricants
in Tablein6 Table
indo
Table
6 type
may
contain
Lubricants
4may
contain
several
of anti-wear
these
additives.
contain
anti-wear
additives.
Lubricants
in Table 4 do
4 do contain several of these additives.
contain several of these additives.
Synthetic Lubricants
Synthetic
Lubricants
Synthetic
Lubricants
Synthetic
lubricants
of the polyalphaolefin type are
Synthetic lubricants
ofof
the
polyalphaolefin
typetype
are
recommended
for cold
climate
operation, high
temperature
Synthetic
lubricants
the
polyalphaolefin
are
recommended
for
climate
operation,
high
temperature
recommended
forcold
cold
climate
operation,
high
temperature
applications,
extended
temperature
range (all
season)
applications,
extended
temperature
(allintervals.
season)
applications,
extended
temperature
range
(all
season)
operation
and/or
extended
lubricantrange
change
The
operation
and/or
extended
lubricant
change
intervals.
TheThe
operation
and/or
extended
lubricant
change
intervals.
proper viscosity grade of synthetic lubricant is given
in Table
3.
proper viscosity
of of
synthetic
lubricant
is given
in Table
proper
viscositygrade
grade
synthetic
lubricant
is given
in 3.
WARNING:
SYNTHETIC LUBRICANTS IN FOOD PROCESSING
Table 3.
WARNING:
LUBRICANTS
IN FOOD
INDUSTRY
тАФSYNTHETIC
Synthetic lubricants
may contain
toxicPROCESSING
substances
WARNING:
LUBRICANTS
INindustry
FOOD
INDUSTRY
Synthetic
contain
toxic
substances
and
should тАФ
notSYNTHETIC
be used lubricants
in the
foodmay
processing
without the
PROCESSING
INDUSTRY
тАФ
Synthetic
lubricants
may
and
should
not
be
used
in
the
food
processing
industry
lubricant manufacturersтАЩ approval. Lubricants which meetwithout
USDAthe
contain
toxic
substances
and
notwhich
be used
lubricant
manufacturersтАЩ
approval.
Lubricants
meetinUSDA
тАЬH1тАЭ
classification
are suitable
forshould
food
processing
applications.
the
processing
industryforwithout
the lubricant
тАЬH1тАЭfood
classification
are suitable
food processing
applications.
manufacturersтАЩ
approval.
Lubricants& which
meetBACKSTOPS
USDA
CAUTION:
SYNTHETIC
LUBRICANTS
INTERNAL
CAUTION:
SYNTHETIC
LUBRICANTS
&gear
INTERNAL
BACKSTOPS
тАЬH1тАЭ
classification
aremay
suitable
forinfood
processing
тАФ
Synthetic
lubricants
be used
drives with
internal
тАФ Synthetic
lubricants
may
in gear drives
internal
applications.
backstops
operating
only
in be
coldused
temperatures
тАУ30┬░with
to +50┬░F
backstops
operating
only
in
cold
temperatures
тАУ30┬░
to
+50┬░F
(тАУ34┬░
to +10┬░C).
Mobil SHC
624 and SHC
626 provide proper
CAUTION:
SYNTHETIC
LUBRICANTS
& INTERNAL
(тАУ34┬░ to +10┬░C).
Mobil
SHC
624 and SHC
626
provide proper
backstop
actionтАФunder
these
conditions.
Other
BACKSTOPS
Synthetic
lubricants
may
besynthetic
used in
backstop action
under
these
conditions. Other
synthetic
lubricants
may
also
be
acceptable.
gear drives with internal backstops operating only in cold
lubricants may also be acceptable.
temperatures тАУ30┬░ to +50┬░F (тАУ34┬░ to +10┬░C). Mobil SHC
624 and
SHC 626 provide proper backstop action under
Oil
Levels
Oil Levels
these
conditions. Other synthetic lubricants may also be
Fill the drive with oil to the level indicated on the oil dipstick.
acceptable.
Fill the drive with
oil to the are
levelgiven
indicated
the oil
dipstick.
Approximate
oil capacities
on theondrive
nameplate
Approximate
oilPage
capacities
are given on the drive nameplate
and
in
Table
8,
7.
Oil
Levels
and in Table 8, Page 7.
Fill the drive with oil to the level indicated on the oil
Lubricant
Changes
dipstick. Approximate
oil capacities are given on the drive
Lubricant
Changes
nameplate
and
in Table тАФ
8, Checking
Page 7. oil condition at regular
OIL
ANALYSIS
REPORT
OIL ANALYSIS
REPORT тАФ
oil of
condition
at regular
intervals
is recommended.
In Checking
the absence
more specific
intervals
is
recommended.
In
the
absence
of
more
specific
limits,
the guidelines
listed below may be used to indicate when
Lubricant
Changes
limits,
the guidelines
listed below may be used to indicate when
to
change
oil: REPORT
OIL
ANALYSIS
тАФ Checking oil condition at
to change oil:
regular
recommended.
In (500
the absence
1.
Waterintervals
content isisgreater
than 0.05%
ppm). of more
1. Waterlimits,
content
is guidelines
greater thanlisted
0.05%
(500may
ppm).
specific
the
below
be used to
2.
Iron content exceeds
150 ppm.
indicate
when to
change
oil:ppm.
2. Iron content
exceeds
150
3. Silicon (dust/dirt) exceeds 25 ppm.
1.
is greater
0.05% (500 ppm).
3. Water
Siliconcontent
(dust/dirt)
exceeds than
25 ppm.
4. Viscosity changes more than 15%.
2.
content
exceeds
4. Iron
Viscosity
changes
more150
thanppm.
15%.
PETROLEUM LUBRICANTS тАФ For normal operating
3.
Silicon (dust/dirt)
exceeds
ppm.
PETROLEUM
LUBRICANTS
тАФ25
For6
normal
conditions,
change
gear oils every
monthsoperating
or 2500 operating
4.
Viscosity
changes
more
than
15%.
conditions,
change
gear
oils
every
6 months
orfrequently
2500 operating
hours, whichever occurs first. Change
oil more
when
hours,
whichever
occurs
first.
Change
oil
more
frequently
when
PETROLEUM
LUBRICANTS
тАФ
For
normal
operating
gear drives operate in extremely humid, chemical or dust laden
gear drives operate
in
extremely
chemical
or dust
laden
conditions,
change
gear
oilsRevery
6 months
or 2500
atmospheres.
In these
cases,
& humid,
O and
EP lubricants
should
atmospheres.
In these
R & or
O 1500
and
lubricants
operating
whichever
occurs
first.EP
Change
oil should
be
changedhours,
every
3 to cases,
4 months
to
2000 hours.
If the
be
changed
every
3
to
4
months
or
1500
to
2000
hours.
If the
more
frequently
when
gear
drives
operate
in
extremely
drive is operated in an area where temperatures vary with the
humid,
chemical
oran
dust
laden
atmospheres.
Invary
these
drive is operated
in
where
temperatures
with the
seasons,
change the
oilarea
viscosity
grade
to suit the
temperature,
cases,R&Oand
should
be
changed
every
seasons,
change
thelubricants
oil viscosity
grade
to test
suit
the
temperature,
refer
to Table
2. EP
Lubricant
suppliers
can
oil from
the 3 to
4
months
or 1500
to 2000
hours.
If economical
the
is operated
refer
to
Table
2. Lubricant
suppliers
candrive
test oil
from the in
drive
periodically
and
recommend
an
area
where temperatures vary with the seasons, change
drive
periodically
change
schedules.and recommend economical
the
oil viscosity
grade to suit the temperature, refer to Table
change
schedules.
2. Lubricant suppliers can test oil from the drive periodically
and recommend economical change schedules.
TABLE 3 тАФ Viscosity Grade Recommendations for Synthetic Lubricants H
TABLE 3 тАФ Viscosity Grade Recommendations for Synthetic Lubricants H
Output
Output
RPM
RPM
Below 80
80Below
& Above
80
80 & Above
H
Cold Climates
Cold Climates
тАУ30┬░ to +10┬░F
тАУ15┬░ to +50┬░F
тАУ30┬░ to +10┬░F
тАУ15┬░ to
to +10┬░C)
+50┬░F
(тАУ34┬░
тАУ12┬░C)
(тАУ26┬░
(тАУ34┬░ to тАУ12┬░C)
(тАУ26┬░ to +10┬░C)
ISO-VG
AGMA
ISO-VG
AGMA
ISO-VG
AGMA
ISO-VG
AGMA
32
0S
68
2S
32
0S
68
2S
32
0S
68
2S
32
0S
68
2S
0┬░ to +80┬░F
0┬░ toto+80┬░F
(тАУ18┬░
+27┬░C)
(тАУ18┬░ to +27┬░C)
ISO-VG
AGMA
ISO-VG
AGMA
150
4S
150
4S
150
4S
150
4S
Normal Climates
Normal Climates
+10┬░ to +125┬░F
+10┬░ to
to +52┬░C)
+125┬░F
(тАУ12┬░
(тАУ12┬░ to +52┬░C)
ISO-VG
AGMA
ISO-VG
AGMA
320
6S
220
5S
320
6S
220
5S
Refer to Factory for viscosity recommendations when ambient temperatures are below тАУ30┬░F (тАУ34┬░C) or above 125┬░F (52┬░C).
+20┬░ to +125┬░F
+20┬░
+125┬░F
(тАУ7┬░ toto+52┬░C)
(тАУ7┬░ to +52┬░C)
ISO-VG
AGMA
ISO-VG
AGMA
320
6S
320
6S
320
6S
320
6S
H Refer to Factory for viscosity recommendations when ambient temperatures are below тАУ30┬░F (тАУ34┬░C) or above 125┬░F (52┬░C).
318-100
318-100
318-100
December
2006
December
2013
December 2006
Supersedes
05-01
Supersedes
12-06
Supersedes 05-01
Rexnord Industries, LLC, Gear Group
Rexnord Industries,
LLC
Gear Group
3001 W. Canal St., Zip 53208-4200, Milwaukee,Rexnord
WI USAIndustries,
Telephone:LLC,
414-342-3131
3001 W.
Canal St.,WIMilwaukee,
WI 53208-4200
USA
3001 W. CanalFax:
St., 414-937-4359
Zip 53208-4200,
Milwaukee,
USA Telephone:
414-342-3131
e-mail:
info@rexnord.com
web: www.rexnord.com
Telephone:
414-342-3131
414-937-4359
тАГwww.rexnord.com
Fax:
414-937-4359
e-mail:тАГFax:
info@rexnord.com
web:
www.rexnord.com
тДв
┬о
┬о Gear
UltraMax
Gear
Drives
Installation&&Maintenance
Maintenance Instructions
Instructions
FalkтДвFalk
UltraMax
Drives
тАв тАвInstallation
Types
FC and
FZтАВ тАв2040
тАВ Sizesthru
20402130
thru 2130
Types FC
& FZ
тАв Sizes
тАа тАа
TABLE
Pressure
Lubricants
TABLE 44тАФ
тАФExtreme
Extreme
Pressure
Lubricants
Maximum
Temperature
Maximum Operating
Operating Temperature
200┬░F(93┬░C)
200┬░F(93┬░C)
Manufacturer
Manufacturer
Amoco Oil Co.
Amoco
Oil Co.
BP
Oil Co.
BP Oil Co.
Chevron
U.S.A. Inc.
Chevron
U.S.A. Inc.
Citgo
Petroleum
Corp.
Citgo Petroleum Corp.
Conoco Inc.
ConocoCo.
Inc.U.S.A.
Exxon
Exxon
Co. U.S.A.
E.F
. Houghton
& Co.
E.F. Houghton
& Co.
Imperial
Oil Ltd.
Imperial Oil Ltd.
Kendall Refining Co.
Kendall Refining
Co.
Keystone
Div. Pennwalt
Corp.
Keystone Petrochemical
Div. Pennwalt Corp.
Lyondell
(ARCO)
Lyondell
(ARCO)
Mobil
OilPetrochemical
Corp.
Mobil Oil Corp.Products
PetroтАУCanada
PetroтАУCanada Products
Phillips 66 Co.
PhillipsOil66Co.
Co.
Shell
Shell Oil
Co. Limited
Shell
Canada
ShellOil
Canada
Sun
Co. Limited
Sun Oil Lubricants
Co.
Texaco
Texaco Lubricants
Valvoline Oil Co.
Valvoline Oil Co.
тАаMinimum viscosity index of 90.
тАа Minimum viscosity index of 90.
Lubricant
Lubricant
Permagear/Amogear EP
Permagear/Amogear
EP
Energear
EP
Energear
EP
Gear
Compounds
EP
Gear Compounds
EP
Citgo
EP Compound
Citgo EP Compound
Gear Oil
Gear OilEP
Spartan
Spartan
MP
GearEPOil
MP GearEP
Oil
Spartan
Spartan EP
Kendall NS-MP
Kendall NS-MP
Keygear
Keygear NL
Pennant
Pennant NL
Mobilgear
Mobilgear
Ultima
EP
Ultima EP
Philgear
PhilgearOil
Omala
Omala Oil
Oil
Omala
Omala Oil
Sunep
Sunep
Meropa
Meropa
AGMA EP
AGMA EP
SYNTHETIC LUBRICANTS тАФ Synthetic lube change inSYNTHETIC
LUBRICANTS
Synthetic lube
change
intervals
tervals
can be
extended toтАФ
8000-10,000
hours
depending
can be
extendedtemperatures
to 8000-10,000
depending
upon
upon
operating
andhours
lubricant
contamination.
Change
more frequently
when gear
drives operate
in
operatingoiltemperatures
and lubricant
contamination.
Change
extremely
humid, chemical
dust laden
oil more frequently
when gearordrives
operateatmospheres.
in extremely In
these
synthetic
should beInchanged
every
humid,cases
chemical
or dustlubricants
laden atmospheres.
these cases
4synthetic
to 6 months
or 4,000
to be
6,000
hours.every
Laboratory
analysis
lubricants
should
changed
4 to 6 months
or
is4,000
recommended
for optimum
lubricant
and gear drivefor
to 6,000 hours.
Laboratory
analysislife
is recommended
performance.
Change
lube
withdrive
change
in ambient
temoptimum lubricant
life and
gear
performance.
Change
perature,
if
required.
Refer
to
Table
5.
lube with change in ambient temperature, if required. Refer to
Table 5.
Lubrication Systems
SPLASH
LUBRICATED
DRIVES тАФ Standard Type FC
Lubrication
Systems
&SPLASH
FZ gearLUBRICATED
drives are splash
lubricated.
TheType
lubricant
is gear
DRIVES
тАФ Standard
FC & FZ
picked up by the revolving elements and distributed to all
drives are splash lubricated. The lubricant is picked up by the
bearings and gear meshes.
revolving elements and distributed to all bearings and
gear meshes.
OIL
тАФ Occasionally
Occasionallygear
geardrives
drives
are
equipped
OIL PUMPS
PUMPS тАФ
are
equipped
withwith
oil
oil
pumps,
either
for special
lubrication
considerations
pumps,
either
for special
lubrication
considerations
or for or
for
external
cooling.
When
so equipped, run the lubrication
external
cooling.
When
so equipped,
system
for
several
minutes
fill the
run the lubrication system fortoseveral
DIPDIP
system
Verify
that the
STICK
STICK
minutescomponents.
to fill the system
components.
pump
is circulating
properly then
Verify that
the pump oil
is circulating
oil
recheck the oil level.
properly then recheck the oil level.
Before starting the gear drive, rotate
Before
starting
gear drive,
rotate
the
input
shaft the
by hand
to check
for
the input
shaft by Then
hand start
to check
any
obstruction.
the for
drive
any allow
obstruction.
Then
start the
drive
and
it to run
without
a load
for
Shut down
andseveral
allow itminutes.
to run without
a loadand
for
recheck
oil level.Shut
Adddown
oil toand
compenseveral minutes.
sate
for cooler,
recheck
oil level.filter,
Addetc.,
oil tooil capacities.
If everything
is satisfactory,
the
compensate
for cooler,
filter, etc., oil
STAND
STAND
drive
is ready
for operation.
capacities.
If everything
is satisfactory,
PIPE
PIPE
the drive is ready for operation.
(Page5 5ofof7)
8)
(Page
TABLE 5 тАФ Synthetic Lubricants тАУ
Polyalphaolefin Type H
AGMA Viscosity Grade
0S
2S
ISO Viscosity Grade
32
68
Viscosity SSU @ 100┬░F 134тАУ164 284тАУ347
4S
150
626тАУ765
Viscosity cSt @ 40┬░C 28.8тАУ35.2 61.2тАУ74.8 135тАУ165
Manufacturer
...
...
...
...
...
...
Syncon 32
Dryden Oil Co.
Exxon Co. U.S.A.
Mobil Oil Corp.
Pennziol Products Co.
Petro-Canada Products
Shell Oil Co.
Syncon 68
...
Syncon
...
...
EP 68 тАб
Drydene SHL Drydene SHL Drydene SHL
Lubricant 32 Lubricant 68 Lubricant 150
Teresstic
Teresstic
Teresstic
SHP 32
SHP 68
SHP 150
Spartan
...
...
Synthetic
EP 150 тАб
SHC 624
SHC 626
SHC 629
Mobilgear
...
...
SHC 150 тАб
Pennzgear Pennzgear Pennzgear
SHD 32
SHD 68
SHD 150
Super Maxol
Super
Maxol
...
тАЬSтАЭ 150 тАб
тАЬSтАЭ 68 тАб
Super
Gear
...
...
Fluid 150EP тАб
...
...
...
...
...
...
...
...
...
...
...
...
Sun Co.
Texaco Lubricants Co.
Whitmore Mfg. Co.
6S
220
320
918тАУ1122 1335тАУ1632
198тАУ242
288тАУ352
Lubricant
Chevron U.S.A., Inc.
Conoco, Inc.
5S
Pinnacle 32 Pinnacle 68 Pinnacle 150
Pinnacle
...
...
EP 150 тАб
Decathlon
...
...
4EP тАб
Clarity Synthetic
...
PM Oil 220
Syn. Gear
...
Lube Tegra
220 тАб
...
...
Syncon
...
EP 220 тАб
Drydene SHL Drydene SHL
Lubricant 220 Lubricant 320
Teresstic
Teresstic
SHP 220
SHP 320
Spartan
Spartan
Synthetic
Synthetic
тАб
EP 220
EP 320 тАб
SHC 630
SHC 632
Mobilgear
Mobilgear
SHC 220 тАб
SHC 320 тАб
Pennzgear
Pennzgear
SHD 220
SHD 320
Super Maxol Super Maxol
тАЬSтАЭ 220 тАб
тАЬSтАЭ 320 тАб
Super Gear
Super Gear
Fluid 220EP тАб Fluid 320EP тАб
Hyperia 220 Hyperia 320
Hyperia S220 тАб Hyperia S320 тАб
Sunoco
Sunoco
Challenge 220 Challenge 320
Sunoco
Sunoco
Challenge
Challenge
EP 220 тАб
EP 220 тАб
Pinnacle 220 Pinnacle 320
Pinnacle
...
EP 220 тАб
Decathlon
Decathlon
5EP тАб
6EP тАб
H Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for
maximum operating temperature.
тАб Extreme Pressure EP lubricant (contains sulphur phosphorus ).
CAUTION:
fordrives
drivesthat
that
use
pumps
CAUTION:Refer
Refer to
to Factory
Factory for
use
pumps
to to
distribute
lubricantswith
withtemperatures
temperatures
below
30┬░F(-1┬░C).
distribute lubricants
below
30┬░F(-1┬░C).
Rexnord
Industries,LLC,
LLCGear
Rexnord Industries,
Group
3001
WI 53208-4200
3001W.
W.Canal
CanalSt.,
St.,Milwaukee,
Zip 53208-4200,
Milwaukee,USA
WI USA Telephone : 414-342-3131
Telephone:
414-342-3131
тАГFax:
414-937-4359web:
тАГ www.rexnord.com
Fax: 414-937-4359
e-mail:
info@rexnord.com
www.rexnord.com
318-100
318-100
December
2013
December 2006
Supersedes
12-06
Supersedes 05-01
FalkтДв UltraMax┬о Gear Drives
(Page 6 of 8)
тАв Installation & Maintenance Instructions
Types FC and FZтАВ тАвтАВ Sizes 2040 thru 2130
TABLE 6 тАФ Petroleum Based R&O Gear Oils тАа Maximum operating temperature of lubricants 200┬░F (93┬░C)
AGMA Viscosity Grade
ISO Viscosity Grade
Viscosity SSU @ 100┬░F
Viscosity cSt @ 40┬░C
Manufacturer
Amoco Oil Co.
BP Oil Co.
Chevron U.S.A., Inc.
Citgo Petroleum Corp.
Conoco Inc.
Exxon Company, U.S.A.
Houghton International, Inc.
Imperial Oil Ltd.
Kendall Refining Co.
Keystone Lubricants
Lyondell Petrochemical
(ARCO)
Mobil Oil Corp.
Pennzoil Products Co.
PetroтАУCanada Products
Phillips 66 Co.
Shell Oil Co.
Shell Canada Limited
Sun Oil Co.
Texaco Lubricants
Unocal 76 (East)
Unocal 76 (West)
Valvoline Oil Co
4
150
626-765
135-165
Lubricant
Amer.Ind. Oil 150
.....
Machine Oil AW 150
Citgo Pacemaker 150
Dectol R&O Oil 150
Teresstic 150
HydroтАУDrive HP 750
Teresso 150
5
220
918-1122
198-242
Lubricant
Amer.Ind. Oil 220
Energol HLP-HD 220
Machine Oil AW 220
Citgo Pacemaker 220
Dectol R&O Oil 220
Teresstic 220
HydroтАУDrive HP 1000
Teresso 220
6
320
1335-1632
288-352
Lubricant
Amer. Ind. Oil 320
.....
Machine Oil AW 320
Citgo Pacemaker 320
Dectol R&O Oil 320
Teresstic 320
.....
Teresso 320
Four Seasons AW 150
KLCтАУ40
Duro 150
DTE Oil Extra Heavy
Pennzbell AW Oil 150
PremiumR&O150
.....
KLC-50
Duro 220
DTE Oil BB
Pennzbell AW Oil 220
PremiumR&O220
Duro 320
DTE Oil AA
Pennzbell AW Oil 320
PremiumR&O320
.....
.....
.....
DTE Oil HH
Pennzbell AW Oil 460
.....
Magnus Oil 150
Morlina 150
Tellus 150
Sunvis 9150
Regal Oil R&O 150
Unax RX 150
Turbine Oil 150
Valvoline AW ISO 150
Magnus Oil 220
Morlina 220
Tellus 220
Sunvis 9220
Regal Oil R&O 220
Unax RX 220
Turbine Oil 220
Valvoline AW ISO 220
Magnus Oil 320
Morlina 320
Tellus 320
.....
Regal Oil R&O 320
Unax AW 320
Turbine Oil 320
Valvoline AW ISO 320
.....
Morlina 460
.....
.....
Regal Oil R&O 460
Turbine Oil 460
Turbine Oil 460
.....
.....
.....
7
460
1919-2346
414-506
Lubricant
Amer. Ind. Oil 460
.....
.....
Citgo Pacemaker 460
Dectol R&O Oil 460
Teresstic 460
..........
тАаMinimum viscosity index of 90.
TABLE 7 тАФ Greases for Grease Lubricated
Bearings & Grease Purged Seals
0┬░ to 200┬░F(-18┬░ to +93┬░C)
Manufacturer
Lubricant
Amoco Oil Co.
BP Oil Co.
Chevron U.S.A., Inc.
Citgo Petroleum Corp.
Amolith Grease No. 2
Energrease LSтАУEP2
Industrial Grease Medium
Premium Lithium Grease No. 2
Conoco Inc.
Exxon Company, U.S.A.
E.F. Houghton & Co.
Imperial Oil Ltd.
EP Conolith Grease No. 2
Unirex N2
Cosmolube 2
Unirex N2L
Kendall Refining Co.
Keystone Div. Pennwalt Corp. MultiтАУPurpose Lithium Grease
L421
Lyondell Petrochemical
Zeniplex 2
(ARCO)
Litholine H EP 2 Grease
Mobil Oil Corp.
Mobilith 22
Mobil Oil Corp
Mobilith SHC 460┬а
PetroтАУCanada Products
Multipurpose EP2
Phillips 66 Co.
Shell Oil Co.
Shell Canada Limited
Sun Oil Co.
Texaco Lubricants
Philube Blue EP
Alvania Grease 2
Alvania Grease 2
Ultra Prestige EP2
Premium RB Grease
Unocal 76 (East & West)
Valvoline Oil Co.
Unoba EP2
Multilube Lithium EP Grease
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 тАЬH1тАЭ classification is suitable
for food processing applications.
GREASE LUBRICATED SEALS тАФ Most gear drives and external 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. If grease could
contaminate the product, as in the food and drug industries, it
should be removed. A grease that meets USDA тАЬH1тАЭ 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.
TYPICAL BEARING & SEAL ASSEMBLIES
FOR GREASING
SEAL
┬аHigh performance synthetic alternate.
Bearing & Seal Greases
All Type FC & FZ gear drives have grease purged seals,
and some specially mounted gear drives have one or more
grease lubricated bearings. Whenever changing oil in the
drive, grease the bearings where appropriate and purge the
seals with one of the NLGI #2 greases listed in Table 7.
318-100
December 2013
Supersedes 12-06
OIL LUBRICATED BEARINGS
Rexnord Industries, LLC
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131тАГFax: 414-937-4359тАГwww.rexnord.com
тДв
┬о
┬о Gear
FalkтДвFalk
UltraMax
Drives
UltraMax
Gear
Drives
Maintenance Instructions
Instructions
тАв Installation
тАв Installation&&Maintenance
┬о Gear
FalkтДвFC
UltraMax
Drives
Installation
& Maintenance
Instructions
тАв2130
Types
FZтАВ 2040
2040
thru
2130
(Page
8)
тАвтАВ Sizes
Types
& FZFCтАвand
Sizes
thru
(Page
7 7ofof7)
Types FC & FZ тАв Sizes 2040 thru 2130
TABLE 8 тАФ Types FC & FZ
Approx. Oil Capacities H тАФ Gallons
TABLE 8 тАФ Types FC & FZ
Standard
Types FZ & FC тАУ Horizontal
H тАФ Gallons
DRIVE
Approx.
OilтАУ Capacities
H
SIZE
Double
Triple
Quadruple
Standard тАУ Types FZ & FC тАУ Horizontal
DRIVE
2040
2.4
2.4
2.4
SIZE
Double
Triple
Quadruple
2050
3.5
3.5
3.5
2060
4.4
4.8
4.8
2040
2.4
2.4
2.4
2050
3.5
3.5
3.5
2070
6.5
7.0
7.0
2060
4.4
4.8
4.8
2080
9.0
10.0
10.0
2090
14.0
15.5
15.5
2070
6.5
7.0
7.0
2080
9.0
10.0
10.0
2100
20.0
21.0
21.0
2090
14.0
15.5
15.5
2110
27.0
30.0
30.0
2120
36.0
39.0
39.0
2100
20.0
21.0
21.0
2130
48.0
54.0
54.0
2110
27.0
30.0
30.0
2120 are approximate.
36.0 Exact quantities 39.0
39.0 speed.
Oil capacities
vary with ratio and input
48.0 on the dipstick.54.0
54.0
Always2130
fill drive to level indicated
H Oil capacities are approximate. Exact quantities vary with ratio and input speed.
Always fill drive
to level indicated
on theтАФ
dipstick.
BACKSTOP
EQUIPPED
DRIVES
Sizes
20402040
thru thru
2090,
BACKSTOP
EQUIPPED
DRIVES
тАФ Sizes
Types FC
& FZFC
drives,
an internal/cartridge
type backstop
2090,
Types
& FZuse
drives,
use an internal/cartridge
type
BACKSTOP
EQUIPPED
DRIVES50%
тАФ
Sizes
2040
thru
2090,
which
is continuously
lubricated.
or more
of
the or
backstop
backstop
which
is continuously
lubricated.
50%
more is
Types
&
use anSizes
internal/cartridge
type
backstop
of
the FC
backstop
in2100
oil at thru
all times.
Sizes
2100
immersed
in FZ
oil drives,
atisallimmersed
times.
2130,
Types
FC &
which
is continuously
lubricated.
50%
or
of
the
backstop is
thru
2130,
Types
& FZ drives,
use
amore
self
contained,
FZ
drives,
use
a selfFC
contained,
wedge
ramp
type,
externally
immersed
in oil
at all
times.
Sizes
2100 thru
2130,
wedge
ramp
type,
externally
mounted
backstop
which
mounted
backstop
which
is prelubricated
and
sealedTypes
at FC &
FZprelubricated
drives,The
use external
a self
rampdo
type,
externally
is
andcontained,
sealed
atwedge
assembly.
The
external
assembly.
backstops
(Type PRT)
require
mounted backstop
which
is require
prelubricated
and sealed
at
backstops
(Type PRT)
do
additional
lubrication
additional
lubrication
at specific
intervals.
Refer
to
Manual
assembly.
The
external
backstops
(Typealso
PRT)
do require
at
specific
intervals.
Refer
to Manual
568-810
for
details.
568-810
for
details.
These
backstops
contain
grease
These
backstops
also
grease
seals. See
additional
lubrication
atcontain
specific on
intervals.
to Manual
purgeable
seals.
See
paragraph
Page purgeable
6,Refer
for grease
paragraph
on
Page
6,
for
grease
lubricated
seals.
568-810
for
details.
These
backstops
also
contain
grease
lubricated seals.
purgeable seals. See paragraph on Page 6, for grease
Preventive
Maintenance
lubricated seals.
Preventive
AFTER
FIRSTMaintenance
WEEK тАФ Check alignment of the total
AFTER FIRST
WEEK тАФ
Check
alignment Also,
of thetighten
total system
system
and realign
where
necessary.
all and
Preventive
Maintenance
realign where
tighten
all external
external
boltsnecessary.
and plugsAlso,
where
necessary.
DO bolts
NOT and
AFTERwhere
FIRST
WEEK тАФ
Check
alignment
of
total
system
and
readjust
the necessary.
internal
gear
or
bearing
settings
in the
drive,
plugs
DO
NOT
readjust
thethe
internal
gear
or
realign
where
necessary.
Also,
tighten
all
external
bolts
and
these
were
permanently
set
at
the
Factory.
bearing settings in the drive, these were permanently set at
plugs
where necessary. DO NOT readjust the internal gear or
the
Factory.
AFTER
FIRST MONTHтАЩS SERVICE тАФ Proceed as follows:
bearing settings in the drive, these were permanently set at
AFTER
FIRST
MONTHтАЩS SERVICE тАФ Proceed as follows:
1.
Operate
the Factory.drive until old sump oil reaches normal
temperature.
Shutoil
thereaches
drive down
and
drain
1. operating
Operate drive
until old sump
normal
operating
AFTER FIRST MONTHтАЩS SERVICE тАФ Proceed as follows:
immediately.
temperature. Shut the drive down and drain immediately.
1. Operate drive until old sump oil reaches normal operating
2. Immediately
Immediately flush
drive with
anan
oil of of
thethe
same typetype
and
2.
with
temperature.flush
Shut drive
the drive
downoiland
drainsame
immediately.
viscosity
gradegrade
as the as
original
charge (warmed
to
and
viscosity
the original
charge (warmed
to
2. approximately
Immediately flush
drive
with an
oilcold
ofweather).
the
sameRapidly
type
and
100┬░F
(38┬░C)
weather).
Rapidly
approximately
100┬░F
(38┬░C)
inincold
pour or
viscosity
grade aas
the original
charge
(warmed
tothe
pour
ora pump
charge
equal
to of
25-100%
initial fill
pump
charge
equal
to 25-100%
the
initialoffill
volume
approximately
100┬░F
(38┬░C)
cold
weather).
Rapidly
pour or
volume
through
the
drive
orinuntil
clean
oil flows
through
the drive
or until
clean
oil
flows
through
thethrough
drain.
pump
a charge equal to 25-100% of the initial fill volume
the
drain.
3. Close the drain and refill the drive to the correct level with
through the drive or until clean oil flows through the drain.
3. Close
drain and
drivetype
to the
level
new orthe
reclaimed
oil refill
of thethe
correct
andcorrect
viscosity.
If
3. with
Close
theordrain
refill
drivecorrect
tobythe
level with
new
reclaimed
oilthe
of the
type
and
determined
to
beand
in good
condition
thecorrect
supplier,
new or reclaimed
oil of
the
correct
type condition
and
viscosity.
If
viscosity.
Ifoildetermined
to be
by
the
reclaimed
may be
reused
if itinisgood
filtered
through
a 40
determined
to be
in oil
good
condition
by the
supplier,
may
be reused
if itsupplier,
is filtered
micron
orreclaimed
finer
filter.
through
a 40
finer iffilter.
reclaimed
oil micron
may be or
reused
it is filtered through a 40
PERIODICALLY тАФ Carefully check the oil level of the drive
micron or finer filter.
PERIODICALLY
Carefully
check
the oil level
the
when it is stoppedтАФ
and
at ambient
temperature,
addofoil
if drive
PERIODICALLY
Carefully
check
oillevel
levelmark
of the
when
it isIf stopped
and
ambient
temperature,
add
oil if
needed.
the oil тАФ
level
is at
ABOVE
the the
high
ondrive
the
when it ishave
and
at
temperature,
oil on
if inthe
needed.
Ifstopped
thethe
oiloil
level
is ambient
ABOVE
the high
leveladd
mark
dipstick,
analyzed
for water
content.
Moisture
needed.
Ifhave
the
oil
isthe
ABOVE
thewater
high level
on
dipstick,
thelevel
oil
analyzed
content.
Moisture
the
oil may
indicate
that
heatfor
exchanger
or amark
seal
is the
dipstick,
the oil analyzed
water
content. Moisture
in
the oilIfhave
may
indicate
that
thefor
heat
exchanger
or aand
sealin
leaking.
so, replace
the
defective
part
immediately
is
leaking.
If
so,
replace
the
defective
part
immediately
the
oil
may
indicate
that
the
heat
exchanger
or
a
seal
is
change the oil. DO NOT fill above mark indicated as leakage
and
change
oil.
fill above
mark indicated
leaking.
Ifheating
so,the
replace
theNOT
defective
part immediately
and as to
or
undue
mayDO
result.
Also
check
coupling
alignment
leakage
or
undue
heating
may
result.
Also
check
coupling
change
the
oil.
DO
NOT
fill
above
mark
indicated
as
leakage
make certain that foundation settling has not caused excessive
alignment
to makemay
certain
that
foundation
settling
has not to
or
undue
heating
result.
Also
check
coupling
alignment
misalignment. If drive is equipped with a fan, periodically clean
caused
excessive
misalignment.
If drive
is caused
equipped
with a
make certain
that foundation
settling
has fan
not
excessive
accumulated
foreign
matter
from
the fan,
guard
fan,
periodically
clean
accumulated
foreign
matterand
fromclean
the
misalignment.
If
drive
is
equipped
with
a
fan,
periodically
deflector
to allow
adequate
airtoflow.
fan,
fan
guard
and
deflector
allow
adequate
air
flow.
accumulated foreign matter from the fan, fan guard and
LUBRICANT CHANGES
тАФ Refer
to Page 4.
LUBRICANT
CHANGES
Refer
deflector to allow
adequateтАФair
flow.to Page 4.
LUBRICANT CHANGES тАФ Refer to Page 4.
(Page 7 of 7)
SEAL
тАФтАФ
Refer
to Page
6. 6.
SEALGREASES
GREASES
Refer
to Page
Stored
& Inactive
SEAL GREASES
тАФ ReferGear
to PageDrives
6.
Stored & Inactive Gear Drives
NEW DRIVES WHICH HAVE NOT BEEN OPERATED
NEW DRIVES WHICH HAVE NOT BEEN OPERATED тАФ Each
тАФ
Each gear
drive has Gear
been spin
tested with a rust
Stored
& Inactive
Drives
gear
drive hasoil
been
tested
with
a rust parts
preventative
oilrust
that
preventative
thatspin
willHAVE
protect
internal
against
NEW
DRIVES
WHICH
NOT
OPERATED
тАФ Each
will
protect
internal
parts against
rust BEEN
for ashelter
period
of 412months
for
a
period
of
4
months
in
an
outdoor
for
months
gear
drive hasshelter
been spin
tested
with ina arust
oil that
in
an
outdoor
forshipment
12
months
drypreventative
building after
in
a protect
dry
building
after
from
the
Factory.
will
internal
parts
against
rust
for
a
period
of
4
months
shipment from the Factory.
Ifin aandrive
is to shelter
be stored
or months
inactiveinbeyond
the above
outdoor
for 12
a dry building
after
Ifperiods:
a drive is to be stored or inactive beyond the above periods:
shipment from the Factory.
1.
Spray all
internal
parts
with
preventative
oil thatthat
is is
1.
internal
parts
witha arust
rust
preventative
If aSpray
drive all
is to
be stored
or inactive
beyond
the aboveoilperiods:
soluble in
amounts
of
soluble
in lubricating
lubricatingoiloilororadd
addrecommended
recommended
amounts
1. of
Spray
all internal
with
a
rust
preventative
oil
thatshown
is
тАЬMotorstorтАЭ
тДв vapor
phase
rust
inhibitor
oil asoil
shown
in
тАЬMotorstorтАЭ
тДв parts
vapor
phase
rust
inhibitor
as
soluble
Table
9. in
in
Table
9.lubricating oil or add recommended amounts of
тАЬMotorstorтАЭ тДв vapor phase rust inhibitor oil as shown in
2.
Seal
air
vent
and the area around the dipstick immediately
2. Seal
Tableair9.vent and the area around the dipstick with pressure with
sensitive
tape. sensitive tape.
immediately
pressure
2. Seal air vent and the area around the dipstick immediately
SHUT
DOWN
OF
DRIVES
WHICH
SHUT
DRIVES
WHICHHAVE
HAVEBEEN
BEEN
withDOWN
pressureOF
sensitive
tape.
OPERATED
тАФтАФIf Ifa a
drive
is to
bebe
stored
or inactive
for more
OPERATED
drive
is
to
stored
or
inactive
for more
SHUT DOWN
OF DRIVES WHICH HAVE BEEN
than
than two
twomonths:
months:
OPERATED тАФ If a drive is to be stored or inactive for more
1.
Drain oil
oil from
from
anyany
attached
cooling
1.
Drain
from the
thedrive
driveand
andwater
water
from
attached
than
two months:
system. Check
for Check
damageforif damage
water wasifpresent
thepresent
drive.
cooling
system.
water in
was
1. Drain oil from the drive and water from any attached cooling
thethe
drive.
2. in
Add
recommended amounts of тАЬMotorstorтАЭ as shown in
system. Check for damage if water was present in the drive.
Tablethe
9.
2.
amountsofofтАЬMotorstorтАЭ
тАЬMotorstorтАЭ
shown
2. Add
Add the recommended
recommended amounts
as as
shown
in
3. in
Seal
the drive
completely be tightening all gauges and
Table
Table 9. 9.
plugs. Seal air vents and the area around the dipstick with
3.
drive
completelybe
betightening
tightening
gauges
3. Seal
Seal the
the sensitive
drive completely
allall
gauges
andand
pressure
tape.
plugs.
air vents
ventsand
andthe
thearea
areaaround
around
dipstick
plugs. Seal
Seal air
thethe
dipstick
with
4. with
Pack pressure
grease around
the shafts near the contact seals and
sensitive
pressure sensitive
tape. tape.
into the seal retainers, then tape the shaft areas near the
4.
around
theshafts
shafts
near
contact
seals
4. Pack
Pack grease
grease
around
the
thethe
contact
seals
and
seals
and
wrap
tape against
thenear
seals.
and
the seal
retainers,
thenthe
tape
theareas
shaftnear
areas
into into
the seal
retainers,
then tape
shaft
the
5. near
For external
surfaces,wrap
inspect
and protectthe
scratched
tape
seals. surfaces
sealsthe
andseals
wrap and
tape against
theagainst
seals.
as required.
5.
surfaces,inspect
inspect
and
protect
scratched
5. For
Forexternal
external surfaces,
and
protect
scratched
surfaces
6. surfaces
If the driveas
is stored outdoors, position it on blocks. Build a
as required. required.
frame around it if possible and cover it with a tarpaulin left
6.
drive
stored
position
itblocks.
on
6. Ifopen
If the
the on
drive
stored
outdoors,
position
it onuse
Buildcover.
aBuild
theisis
bottom
foroutdoors,
ventilation.
Do not
a blocks.
plastic
aframe
frame
around
if possible
and cover
a tarpaulin
around
it ifitpossible
and cover
it with ita with
tarpaulin
left
7. left
Inspect
theon
drive
three
and addnot
vapor
open
the every
bottom
for months
ventilation.
usephase
acover.
open
on the
bottom
for ventilation.
Do notDo
use a plastic
rust inhibitor
plastic
cover.as outlined in paragraph 2.
7. Inspect the drive every three months and add vapor phase
7. Inspect
the drive
every three
months 2.
and add vapor
rust inhibitor
as outlined
in paragraph
phase rust inhibitor as outlined in paragraph 2.
TABLE 9 тАФ Recommended Quantity of
Motorstor to Add to Stored or
TABLE 9 тАФ Inactive
Recommended
Drives Quantity of
Motorstor to Add to Stored or
DRIVE Inactive
SIZE
Drives Motorstor Ounces Per Drive
2040 thru 2060
1
DRIVE
Motorstor Ounces
2070SIZE
2 Per Drive
2080
31
2040 thru 2060
2090
42
2070
2100
63
2080
2110
84
2090
2120
106
2100
2130
148
2110
10 known as
Product of Daubert2120
Chemical Company, Chicago, IL . (Formerly
2130
14
тАЬNucle OilтАЭ).
Product
of Daubert
Daubert
Chemical
Company,
Chicago,
. (Formerly
known
Product of
Chemical
Company,
Chicago,
IL .IL(Formerly
known
as as
START-UP
AFTER
STORAGE
тАЬNucle
тАЬNucle OilтАЭ).
OilтАЭ).
1.
Remove all
tape applied
in storage preparation.
START-UP
AFTER
STORAGE
START-UP AFTER
STORAGE
2.
Drain
all
moisture
that
may
accumulated
in the sump
1.
appliedininhave
storage
preparation.
1. Remove
Remove all
all tape
tape applied
storage
preparation.
and thoroughly check for damage.
2.
may have
haveaccumulated
accumulatedininthe
the
2. Drain
Drainall
allmoisture
moisture that
that may
sump
3. sump
Fill the and
cooling
system (ifcheck
applicable)
and check for leaks.
thoroughly
for damage.
and thoroughly
check for damage.
4.
Fill the drive
to the
proper
with oil meeting
3. Fill
cooling
system
(if level
applicable)
and check for
3. leaks.
Fill the cooling system (if applicable) and check for leaks.
specifications given in the Lubrication Recommendation
4. Fill
Fillthe
the drive
drive to
to the
the proper
Section.
4.
properlevel
levelwith
withoiloilmeeting
meeting specificaspecifications
given
in
the
Lubrication
Recommendation
tions given in the Lubrication Recommendation
Section.
Section.
Rexnord Industries,
Group
Rexnord
Industries,LLC,
LLCGear
3001 W.
W. Canal
Canal St.,
St., Milwaukee,
Zip 53208-4200,
Milwaukee,USA
WI USA
Telephone : 414-342-3131
3001
WI 53208-4200
Rexnord
Industries,
LLC,
Gear
Group
Fax:
414-937-4359
e-mail:
info@rexnord.com
web:
www.rexnord.com
Telephone:
414-342-3131
тАГFax:
414-937-4359
тАГ www.rexnord.com
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131
Fax: 414-937-4359 e-mail: info@rexnord.com web: www.rexnord.com
318-100
318-100
December 2006
December
2013
318-100
Supersedes
05-01
Supersedes
12-06
December 2006
Supersedes 05-01
FalkтДв UltraMax┬о Gear Drives
(Page 8 of 8)
тАв Installation & Maintenance Instructions
Types FC and FZтАВ тАвтАВ Sizes 2040 thru 2130
Reliability Package (Lubrication Package)
permanently attached to the gearbox with drive screws,
at the same level as the label, to indicate the oil level if
anything were to happen to the static oil level label.
Introduction
The UltraMax Reliability Package includes an enhanced
desiccant and particulate filter, Viton seals, oil level sight
glass, oil sample port, and quick disconnects for oil
return and suction lines. The Reliability Package will come
preassembled from the Factory, with the exception of
AirMax Plus breather mounted to the gearbox.
Installation and Maintenance Instructions
AirMax Plus тАУ Remove the pipe plug from the gearbox
as depicted in the illustration above. Screw the breather
onto the gearbox. For detailed breather installation and
maintenance instructions, refer to the literature included
with the AirMax Plus breather (GR3-002). For all Falk
UltraMax drive sizes, remove two (2) red plastic pipe plugs
from the bottom air vents located 180┬░ apart. Falk AirMax
Plus breathers have visual indication when they need to be
changed. As the breather functions, the silica gel material
changes color from blue to pink as it absorbs moisture.
When all the material has turned pink in color, it is time
to replace the breather. Life of breather is dependent on
operating conditions and ambient conditions (humidity).
Breather should be changed every twelve (12) months
regardless of color.
Oil Levels тАУ Fill drive to the height located on the oil level
sight glass with approved lubricant [refer to Page 3 for
Lubrication Recommendations; DO NOT USE GMAX 6000
or other types of polyalkylene glycol (PAG) lubricants
which are incompatible with the polycarbonate sight glass].
The oil level sight glass is intended to be used when the
gearbox is not running; in the static condition. Therefore,
the sight glass contains a label that indicates that the oil
level is a static oil level. (oil levels tend to fluctuate based
on oil churning and are dependent on speed and direction
of rotation; for continuous direction, and continuous speed
applications it is recommended that the oil level sight glass
be marked once steady state operating conditions have
been reached). There is a secondary nameplate that is
318-100
December 2013
Supersedes 12-06
Oil Sampling тАУ The oil sampling port that is included allows
users to easily draw oil samples for lubrication analysis.
Refer to the Oil Analysis Report section (Page 4) of this
document for detailed recommendations on oil content.
The oil sample port has a screw on cover that needs to be
unscrewed in order to access the valve to the sampling
port. The valve can then be actuated by screwing on
the threaded oil sample port adapter included in our Oil
Sample Kit (sold separately; see Table A1). The sampling
bottle is composed of PET (polyethylene terephthalate)
which is compatible with most industrial lubricants;
however, user should confirm compatibility prior to use.
It should be noted that the cleanliness of the bottle can
greatly affect the results of an oil sample analysis; therefore
user is cautioned to use care to avoid contamination of
the sample. The oil sample should be taken shortly after
the unit has been shut down to ensure the oil is properly
mixed. It is important to initially purge some oil from the oil
sampling port and discard this purge, prior to collecting the
sample. Be sure to check the oil level in the drive after the
sample has been collected (additional oil may need to be
added to ensure proper level).
Oil Change and/or Oil Filtering тАУ Quick couplers are
provided to allow users to easily filter and/or change oil
in the gear drive. The 0.75тАЭ male quick couplers that are
supplied meet the dimensional requirements of ISO 7241-1
Series B for the most widely used Industrial Interchange.
Male coupler fittings are installed on the gearbox
requiring female coupler fittings on the oil suction and
return lines. Refer to Page 7 for Preventative Maintenance
recommendations (oil change intervals).
TABLE A1 тАФ Sample Port Adapter, Sampling Kit and
Breathers for use by Maintenance Professionals
Usage
Part
Part Number
ALL SIZES
Oil Sampling Kit
(includes oil sample port
adapter, case of
12 sample bottles,
vacuum pump, 20тАЩ of
tubing, and labels)
10097025
2040F TO
2070F
AirMax Plus HG-1
Breather
10097978
2080F TO
2130F
AirMax Plus HG-8
Breather
10096606
Rexnord Industries, LLC
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131тАГFax: 414-937-4359тАГwww.rexnord.com

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