Falk™ Drive One™ Conveyor Drives • Owners Manual

Type D Series • Sizes M1220 thru M1250 (Page 1 of 18)

How to Use This Manual

This manual provides detailed instructions on installation and
maintenance of Falk parallel shaft Type DH and right angle
Type DB gear drives. Use the table of contents below to locate
required information.
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE Type DH Type DB
FREE SERVICE OF YOUR FALK GEAR DRIVE.
installation environment; (III) use for purposes other than those
Table of Contents for which designed, or other abuse or misuse; (IV) unauthorized
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 attachments, modifications or disassembly, or (V) mishandling
Shaft Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 during shipping.
Tightening Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubrication Recommendations. . . . . . . . . . . . . . . . . . . . . 4-7 Installation Instructions
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Stored and Inactive Gear Drives . . . . . . . . . . . . . . . . . . . . . 8 The following instructions apply to standard Falk Type DH & DB
Changing Hand of Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 9 drives. If a drive is furnished with special features, refer to the
APPENDIX supplementary instructions shipped with the drive.
Appendix A: Fixed Torque Arm Installation . . . . . . . . . . . . 11 WELDING — Do not weld on the gear drive or accessories
Appendix B: Swing Base Installation . . . . . . . . . . . . . . . . . 13 without prior approval from the Factory. Welding on the drive
Appendix C: Alignment Free Assembly & Installation . . . 15-16 may cause distortion of the housing or damage to the bearings
Appendix D: Electric Fan Installation & Maintenance . . 17-18 and gear teeth. Welding without prior approval could void the
warranty.
Introduction NOTE: Drives equipped with cooling fans may require removal
of shroud when installing foundation fasteners.
Credit for long service and dependable operation of a gear
drive is often given to the engineers who designed it, or the EFFECTS OF SOLAR ENERGY — If the gear drive operates in
craftsmen who constructed it, or the sales engineer who the sun at ambient temperatures over 38°C (100°F), then special
recommended the type and size. Ultimate credit belongs to the measures should be taken to protect the drive from solar energy.
mechanic on the job who worked to make the foundation rigid This protection can consist of a canopy over the drive or reflective
and level, who accurately aligned the shafts and carefully paint on the drive. If neither is possible, a heat exchanger or other
installed the accessories, and who made sure that the drive cooling device may be required to prevent the sump temperature
received regular lubrication. The details of this important job from exceeding the allowable maximum.
are the subject of this manual. MOUNTING POSITION — Standard mounting positions for
NAMEPLATE — Operate Falk gear drives only at power, speed and types DH & DB are with the input and output shafts horizontal.
ratio shown on the nameplate. Before changing any one of these, Allowable mounting angles for standard oil levels are;
submit complete nameplate data and new application conditions to Bridge Slope
the Factory for correct oil level, parts, and application approval. DH & DB 0° Up & 4° Down ± 1.5°
DISASSEMBLY AND ASSEMBLY — Disassembly & assembly Consult the Factory for other angles.
instructions and parts guides are available from the Factory or If a gear drive is ordered for non-standard mounting positions,
Sale Representatives. When requesting information, please give refer to the instructions provided with the drive for oil levels and
complete data from the nameplate on the gear drive; Model, bearing lubrication. If it is necessary to mount the gear drive in
M.O. Number, Date, RPM, and Ratio. a different position from which it was ordered, refer to the
WARNING: Consult applicable local and national safety codes Factory for required changes to provide proper lubrication.
for proper guarding of rotating members. Lock out power FOUNDATION, GENERAL — To facilitate oil drainage,
source and remove all external loads from drive before elevate the gear drive
servicing drive or accessories. foundation above the
surrounding floor level. If
desired, replace the drive oil
Warranty drain plug with a valve, but
Rexnord Industries, LLC (the “Company”) warrants that Drive provide a guard to protect the
One gear drives (I) conform to Company’s published valve from accidental opening
specifications, and (II) are free from defects of material for three or breakage.
years from the date of shipment.
When an outboard bearing is used, mount drive and outboard
Company does not warrant any non-Company branded bearing on a continuous foundation or bedplate, and dowel
products or components (manufacturer’s warranty applies) or both in place.
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

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 168-054
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 (PN 2128959) June 2006
Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com NEW
Owners Manual • Falk™ Drive One™ Conveyor Drives

(Page 2 of 18) Sizes M1220 thru M1250 • Type D Series

FOUNDATION, STEEL — When mounting gear drive on rotation with a slugging wrench to achieve proper torque. After
structural steel, it is recommended that an engineered design drive is aligned with driven equipment and bolted down, align
be utilized for a pedestal, adapter prime mover to drive input shaft. Refer to Page 3 for coupling
base or bed to provide sufficient alignment.
rigidity, to prevent induced loads from If equipment is received from the Factory mounted on a
distorting the housing and causing bedplate, the components were accurately aligned at the
gear misalignment. In the absence of Factory with the bedplate mounted on a large, flat assembly
an engineered design, it is plate. Shim under the bedplate foot pads until the gear drive is
recommended that a base plate, with level and all feet are in the same plane.
thickness equal to or greater than the
thickness of the drive feet, be securely Continuous Plate
Leveling
bolted to steel supports and extend Reference
under the entire drive as illustrated. Surfaces

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 5 for
coupling alignment instructions.
Shims

Gear Drive Alignment

FOOT MOUNTED DRIVES – Align drive with driven equipment Check high speed shaft coupling alignment. If the coupling is
by placing broad, flat shims under all mounting pads. Jack screw misaligned, the bedplate is shimmed incorrectly. Re-shim
holes are provided by mounting feet to facilitate alignment. See bedplate and recheck high speed coupling alignment. If
Table 8, Page 7 for fastener and wrench sizes. Start at the low speed necessary, realign motor.
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 Shaft Mounted Drives – General
down. Fasten drive to foundation using Class 8.8 fasteners, see Shaft mount drives should never be mounted in a manner that
Table 8 for fastener size. Tighten fasteners to the torque restricts the natural movement of the drive. They should be
specified in Table 1, Page 4. If the required torque is not allowed to move freely with the shaft on which it is mounted.
attainable, the fasteners may be tightened with a pre-torque of Shaft mounted drives should always be used in conjunction with
270 N-m (200 lb-ft), then tightened an additional 60° of a torque reaction arm. See Appendix A for instructions.

OIL FILL HOLE

DIPSTICK
LIFTING LUGS
4 PER SIDE VENT
(8 TOTAL)

DRAIN PLUGS JACKING SCREW HOLES

2 PER END 2 PER SIDE (4 TOTAL)
(4 TOTAL)

168-054 Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492
June 2006 (PN 2128959) 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
 Falk™ Drive One™ Conveyor Drives • Owners Manual

Type D Series • Sizes M1220 thru M1250 (Page 3 of 18)

Shaft Connections SPROCKETS, PULLEYS OR SHEAVES — Mount power

take-offs as close to the gear drive housing as possible to
WARNING: Provide suitable guards in accordance with local
avoid undue bearing load and shaft deflection.
and national standards.
Align the output shaft of the gear drive square and parallel with
COUPLING CONNECTIONS — The performance and life of
the driven shaft by placing a straightedge across the face of the
any coupling depends largely upon how well the coupling is
sprockets or sheaves as illustrated. RIGHT WRONG
installed and serviced. Refer to the coupling manufacturer’s
Check horizontal shaft alignment by
manual for specific instructions.
placing one leg of a square against
CORRECT METHOD the face of the sheave or sprocket
Heat interference fitted with the spirit level on the
hubs, pinions, sprockets or horizontal leg of the square.
pulleys to a maximum of GEAR DRIVE WALL
135°C (275°F) and slide
onto gear drive shaft.

INCORRECT METHOD
LEVEL
DO NOT drive coupling
hub, pinion, sprocket or SQUARE AND
pulley onto the shaft. An PARALLEL
endwise blow on the
shaft/coupling may damage DO NOT over tighten belts or chains. Adjust chains to
– CAUTION –
DO NOT HAMMER gears and bearings. manufacturers’ specifications. Adjust belts as follows:
The ideal tension is the lowest tension at which the belt will not
COUPLINGS — (Except fluid type) Detailed installation slip under peak load conditions. Check the belt tension
manuals are available from the Factory, your local frequently during the first 24 to 48 hours of run-in operation.
Representative or Distributor—just provide size and type Over tightening belts shortens belt and bearing life. Keep belts
designations stamped on the coupling. For lubricant free from foreign material which may cause slippage. Inspect
requirements and a list of typical lubricants meeting the Factory the V–belt periodically; tighten the belts if they are slipping.
specifications, refer to appropriate coupling service manual. OUTBOARD BEARING — Mount the outboard bearing and
FLANGED TYPE RIGID COUPLINGS — These are typically gear drive on a common foundation so that they will shift as an
used on drives with vertical output shafts. The low speed shaft assembly if settling should occur. Bring the outboard bearing to
extension ends of the solid vertical shaft drives are drilled and the correct horizontal position with broad flat shims under the
tapped to accommodate coupling keeper plates. Tightening mounting pad. Align accurately so that the load is equally
torques for fasteners, including keeper plate fasteners are listed divided between the two drive bearings and the outboard
in Table 1, Page 4. bearing. Mount a stop bar against the pillow block foot on the
load side when large horizontal load components are exerted
FLUID COUPLINGS — Refer to the installation manual on the pillow block.
furnished with the fluid coupling for installation and startup
instructions. For Alignment Free Drives, refer to Appendix C. PINION MOUNTING — Mount pinion as close to the drive
as possible to avoid undue bearing load and shaft deflection.
GAP AND ANGULAR ALIGNMENT — If possible, after Refer to the Factory for pinion alignment instructions.
mounting coupling hubs, position the driving and driven
equipment so that the distance NON FALK COUPLINGS — Refer to manufacturers’
between shaft ends is equal to the installation and maintenance instructions.
coupling gap. Align the shafts by BACKSTOPS — To prevent damage to backstops due to incorrect
placing a spacer block, equal in motor shaft rotation at start up, couplings are NOT assembled when
thickness to required gap, between gear drives are furnished with backstops.
hub faces, as shown at right, and After completing electrical connections, check motor and gear
also at 90° intervals around the hub. drive shaft rotations. If rotations are correct, complete
Check with feelers. STEELFLEX ILLUSTRATED
alignment and assembly of coupling.
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 STEELFLEX ILLUSTRATED
alignment and gap.

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 168-054
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 (PN 2128959) June 2006
Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com NEW
Owners Manual • Falk™ Drive One™ Conveyor Drives

(Page 4 of 18) Sizes M1220 thru M1250 • Type D Series

Fastener Tightening Torques Lubrication Recommendations

Use the tightening torque values specified in Table 1 for Carefully follow lubrication instructions on the gear drive
fastening gear drives, motors and accessories to their nameplate, warning tags, and installation manuals furnished
mounting surfaces with un-lubricated fasteners. DO NOT with the gear drive.
use these values for “torque locking” fasteners or for Lubricants listed in this manual are typical ONLY and should
fastening components with aluminum feet or soft gaskets not be construed as exclusive recommendations. Industrial type
or vibration dampeners on the mounting surface. If the petroleum based rust and oxidation inhibited (R & O) gear
tightening torque exceeds the capacity of the torque lubricants or industrial type sulfur-phosphorus extreme pressure
wrench, use a torque multiplier. Use ISO property class (EP) gear lubricants are the recommended lubricants for
ambient temperatures of -9°C to +50°C(15°F to 125°F).
8.8 for metric fasteners. See Table 8, Page 7 for fastener
and wrench size. For drives operating outside the above temperature range refer
to “Synthetic Lubricants” paragraphs. Synthetic lubricants can
also be used in normal climates.
TABLE 1 — Tightening Torques: ±5% VISCOSITY (IMPORTANT) — The proper grade for R & O and
DO NOT Lubricate Fasteners EP lubricants is found in Table 3. For cold climate conditions refer
to Table 5, Page 6 and the “Synthetic Lubricant” paragraphs.
Metric Fasteners – Property Class 8.8
If a gear drive operates in a typical indoor environment where
Fastener Metal to Metal Metal to Concrete the ambient temperature is within 21°C to 52°C(70°F to
Size Nm lb-ft Nm lb-ft 125°F), the oil viscosity could be increased one AGMA grade
M4 x .7 3 2 2 1.5 above that shown for the 10°C to 52°C(50°F to 125°F) range.
M5 x .8 6 5 5 3.5 That is, an AGMA Number 6 or 7 could be substituted for a 5
M6 x 1.0 10 8 8 6 or 6 respectively, under these ambient conditions.
M8 x 1.25 24 18 19 14
M10 x 1.5 50 36 39 29 TABLE 2 — Viscosity Grade
M12 x 1.75 84 62 68 50 Recommendations for Petroleum
M16 x 2 210 156 170 126 Based R & O or EP Lubricants
M20 x 2.5 415 305 330 246
M24 x 3 705 530 570 420 Normal Climates
M30 x 3.5 1 440 1060 1 150 850 -9° to +16°C 10° to 52°C
M36 x 4 2 520 1860 2 030 1500 Output RPM
(15° to 60°F) (50° to 125°F)
M42 x 4.5 4 050 3000 3 250 2400
6 100 4500 4 880 3600 ISO-VG AGMA ISO-VG AGMA
M48 x 5
M56 x 5.5 9 850 7300 7 860 5800 Output RPM Below 80 150 4 320 6
Output RPM 80 & Above 150 4 220 5

Water Cooling
OIL PUMPS — When selecting a lubricant for a gear drive
WATER COOLED HEAT EXCHANGERS — Install a shut-off or
equipped with an oil pump, cold temperature oil viscosity is
control valve in the water line to the heat exchanger to regulate
important. Lubricant viscosity at start-up generally should not
the water flow through the exchanger. Also install a water flow
exceed 1725 cSt (8,000 SSU). When exceeding this viscosity,
gauge between the control valve and the exchanger to
pump cavitation is possible, reducing oil circulation and
determine actual flow rate. Discharge water to an OPEN
possibly damaging the pump. A sump heater may be required
DRAIN to prevent back pressure.
or it may be possible to use a lower viscosity oil to minimize
INTERNAL COOLING TUBES — Refer to Factory. pump cavitation, refer to the Factory.

Lubrication Systems
SPLASH LUBRICATED DRIVES — Standard horizontal shaft
type DH & DB drives are splash lubricated. The lubricant is
picked up by the revolving elements and distributed to the
bearings and gear meshes.
OIL PUMP LUBRICATED DRIVES (OPTIONAL) — Standard
horizontal shaft type DH & DB drives can be equipped with an
internal gear driven oil pump. The system consists of an
automatic reversing pump, driving gears and internal
distribution. The system can be used for improved thermal
capacity and lubrications accessories, i.e. filters. The pump
system is rotation independent.

168-054 Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492
June 2006 (PN 2128959) 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
 Falk™ Drive One™ Conveyor Drives • Owners Manual

Type D Series • Sizes M1220 thru M1250 (Page 5 of 18)

Petroleum Based Lubricants TABLE 4 — Extreme Pressure Lubricants †

R & O GEAR LUBRICANTS (Table 3) — Industrial type Maximum Operating Temperature
petroleum based rust and oxidation inhibited (R & O ) gear 93°C(200°F)
lubricants are the most common and readily available general
purpose gear lubricants. Manufacturer Lubricant
EXTREME PRESSURE (EP) LUBRICANTS (Table 4) — For Amoco Oil Co. Permagear/Amogear EP
highly loaded gear drives or drives loaded in excess of original BP Oil Co. Energear EP
estimates, industrial type petroleum extreme pressure lubricants Chevron U.S.A. Inc. Gear Compounds EP
Citgo Petroleum Corp. Citgo EP Compound
are preferred. The EP lubricants currently recommended are of
the sulfur-phosphorus type. Conoco Inc. Gear Oil
WARNING: EP LUBRICANTS IN FOOD PROCESSING Exxon Co. U.S.A. Spartan EP
E.F. Houghton & Co. MP Gear Oil
INDUSTRY — EP lubricants may contain toxic substances and Imperial Oil Ltd. Spartan EP
should not be used in the food processing industry without the
lubricant manufacturers’ approval. Lubricants which meet USDA Kendall Refining Co. Kendall NS-MP
Keystone Div. Pennwalt Corp. Keygear
“H1” classification are suitable for food processing applications. Lyondell Petrochemical (ARCO) Pennant NL
Mobil Oil Corp. Mobilgear
Petro–Canada Products Ultima EP
Synthetic Lubricants
Phillips 66 Co. Philgear
Synthetic lubricants of the polyalphaolefin type are Shell Oil Co. Omala Oil
recommended for cold climate operation, high temperature Shell Canada Limited Omala Oil
applications, extended temperature range (all season) Sun Oil Co. Sunep
operation, and/or extended lubricant change intervals. The Texaco Lubricants Meropa
proper viscosity grade of synthetic lubricant is given in Table 5. Valvoline Oil Co. AGMA EP
Refer to Table 6 for Synthetic lubricants.
† Minimum viscosity index of 90.
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.

TABLE 3 — Petroleum Based R & O Gear Oils † Maximum operating temperature of lubricants 93°C (200°F)
AGMA Viscosity Grade 4 5 6 7
ISO Viscosity Grade 150 220 320 460
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632 1919-2346
Viscosity cSt @ 40°C 135-165 198-242 288-352 414-506
Manufacturer Lubricant Lubricant Lubricant Lubricant
Amoco Oil Co. Amer.Ind. Oil 150 Amer.Ind. Oil 220 Amer. Ind. Oil 320 Amer. Ind. Oil 460
BP Oil Co. ..... Energol HLP-HD 220 ..... .....
Chevron U.S.A., Inc. Machine Oil AW 150 Machine Oil AW 220 Machine Oil AW 320 .....
Citgo Petroleum Corp. Citgo Pacemaker 150 Citgo Pacemaker 220 Citgo Pacemaker 320 Citgo Pacemaker 460
Conoco Inc. Dectol R&O Oil 150 Dectol R&O Oil 220 Dectol R&O Oil 320 Dectol R&O Oil 460
Exxon Company, U.S.A. Teresstic 150 Teresstic 220 Teresstic 320 Teresstic 460
Houghton International, Inc. Hydro–Drive HP 750 Hydro–Drive HP 1000 ..... .....
Imperial Oil Ltd. Teresso 150 Teresso 220 Teresso 320 .....
Kendall Refining Co. Four Seasons AW 150 ..... ...... .....
Keystone Lubricants KLC–40 KLC-50 ..... .....
Lyondell Petrochemical (ARCO) Duro 150 Duro 220 Duro 32 .....
Mobil Oil Corp. DTE Oil Extra Heavy DTE Oil BB DTE Oil AA DTE Oil HH
Pennzoil Products company Pennzbell AW Oil 150 Pennzbell AW Oil 220 Pennzbell AW Oil 320 Pennzbell AW Oil 460
Petro–Canada Products Premium R & O 150 Premium R & O 220 Premium R & O 320 .....
Phillips 66 Co. Magnus Oil 150 Magnus Oil 220 Magnus Oil 320 .....
Shell Oil Co. Morlina 150 Morlina 220 Morlina 320 Morlina 460
Shell Canada Limited Tellus 150 Tellus 220 Tellus 320 .....
Sun Oil Co. Sunvis 9150 Sunvis 9220 ..... .....
Texaco Lubricants 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 150 Unax RX 220 Unax AW 320 Turbine Oil 460
Unocal 76 (West) Turbine Oil 150 Turbine Oil 220 Turbine Oil 320 Turbine Oil 460
Valvoline Oil Co Valvoline AW ISO 150 Valvoline AW ISO 220 Valvoline AW ISO 320 .....
† Minimum viscosity index of 90.

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 168-054
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 (PN 2128959) June 2006
Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com NEW
Owners Manual • Falk™ Drive One™ Conveyor Drives

(Page 6 of 18) Sizes M1220 thru M1250 • Type D Series

TABLE 5 — Viscosity Grade Recommendations for Synthetic Lubricants H

Cold Climates Normal Climates
Output –34° to –12°C –26° to +10°C –18° to +27°C –12° to +52°C –7° to +52°C
RPM (–30° to +10°F) (–15° to +50°F) (0° to +80°F) (+10° to +125°F) (+20° to +125°F)
ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA
Below 80 32 0S 68 2S 150 4S 320 6S 320 6S
80 & Above 32 0S 68 2S 150 4S 220 5S 320 6S
H Refer to Falk for viscosity recommendations when ambient temperatures are below –34°C (–30°F) or above 52°C (125°F).

Bearing and Seal Greases grease. Refer to the preventive maintenance instructions
All drives and some backstops have grease lubricated seals. for greasing instructions.
Some specially mounted drives have grease lubricated GREASE LUBRICATED SEALS — Drive One drives are
bearings. Drives are shipped with NLGI #2 grease in the seal furnished with grease purged seals which minimize the entry of
housing cavities unless otherwise specified. Refer to Table 7 for contaminants into the drive. Drives are shipped with NLGI #2
grease recommendations. grease in the seal housing cavities unless otherwise specified. If
GREASE LUBRICATED BEARINGS — Torque arms with grease could contaminate the product, as in the food and drug
industries, it should be removed. A grease that meets USDA
plain spherical bearings are grease lubricated. These
“H1” classification is suitable for food processing applications.
bearings are lubricated at the Factory with an NLGI#2

TABLE 6 — Synthetic Lubricants – Polyalphaolefin Type H

AGMA
0S 2S 4S 5S 6S 7S
Viscosity Grade
ISO
32 68 150 220 320 460
Viscosity Grade
Viscosity
28.8–35.2 61.2–74.8 135–165 198–242 288–352 414-506
cSt @ 40°C
Viscosity
134–164 284–347 626–765 918–1122 1335–1632 1919-2346
SSU @ 100°F
Manufacturer Lubricant
... ... Clarity Synthetic PM Oil 220 ... ...
Chevron U.S.A., Inc.
... ... Syn. Gear Lube Tegra 150 ‡ Syn. Gear Lube Tegra 220 ‡ Syn. Gear Lube Tegra 320 ‡. Syn. Gear Lube Tegra 460 ‡
Syncon R & O 32 Syncon R & O 68 ... Syncon R & O 220 † ... Syncon R & O 460 †
Conoco, Inc. † ‡
... ... Syncon EP 150 Syncon EP 220 † ‡ Syncon EP 320 † ‡ Syncon EP 460 † ‡
Dryden Oil Co. Drydene SHL Lubricant 32 Drydene SHL Lubricant 68 Drydene SHL Lubricant 150 Drydene SHL Lubricant 220 Drydene SHL Lubricant 320 Drydene SHL Lubricant 460
Teresstic SHP 32 Teresstic SHP 68 Teresstic SHP 150 Teresstic SHP 220 Teresstic SHP 320 Teresstic SHP 460
Exxon Co. U.S.A.
... ... Spartan Synthetic EP 150 ‡ Spartan Synthetic EP 220 ‡ Spartan Synthetic EP 320 ‡ Spartan Synthetic EP 460 ‡
SHC 624 SHC 626 SHC 629 SHC 630 SHC 632 SHC 634
Mobil Oil Corp.
... ... Mobilgear SHC 150 ‡ Mobilgear SHC 220 ‡ Mobilgear SHC 320 ‡ Mobilgear SHC 460 ‡
Pennzgear SHD 32 Pennzgear SHD 68 Pennzgear SHD 150 Pennzgear SHD 220 Pennzgear SHD 320 Pennzgear SHD 460
Pennziol Products Co.
... Super Maxol “S” 68 ‡ Super Maxol “S” 150 ‡ Super Maxol “S” 220 ‡ Super Maxol “S” 320 ‡ Super Maxol “S” 460 ‡
Petro-Canada Products ... ... Super Gear Fluid 150EP ‡ Super Gear Fluid 220EP ‡ Super Gear Fluid 320EP ‡ Super Gear Fluid 460EP ‡
Syndustrial P Oil 32 ... ... ... ... ...
Phillips 66 Company
... Syndustrial EP Oil 68 ‡ Syndustrial EP Oil 150 ‡ Syndustrial EP Oil 220 ‡ Syndustrial EP Oil 320 ‡ Syndustrial EP Oil 460 ‡
... ... ... Hyperia 220 Hyperia 320 Hyperia 460
Shell Oil Co.
... ... ... Hyperia S 220 ‡ Hyperia S 320 ‡ Hyperia S 460 ‡
... ... ... Sunoco Challenge 220 Sunoco Challenge 320 ...
Sun Co.
... ... ... Sunoco Challenge EP 220 ‡ Sunoco Challenge EP 320 ‡ ...
Pinnacle 32 Pinnacle 68 Pinnacle 150 Pinnacle 220 Pinnacle 320 Pinnacle 460
Texaco Lubricants Co.
... ... Pinnacle EP 150 ‡ Pinnacle EP 220 ‡ ... Pinnacle EP 460 ‡
Whitmore Mfg. Co. ... ... Decathlon 4EP ‡ Decathlon 5EP ‡ Decathlon 6EP ‡ Decathlon 7EP ‡
76 Lubricants Company ... ... 76 Triton Syngear 4EP ‡ 76 Triton Syngear 5EP ‡ ... 76 Triton Syngear 7EP ‡
H Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
† Minimum viscosity index of 120.
‡ Extreme Pressure EP lubricant (contains sulphur phosphorus ).

168-054 Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492
June 2006 (PN 2128959) 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
 Falk™ Drive One™ Conveyor Drives • Owners Manual

Type D Series • Sizes M1220 thru M1250 (Page 7 of 18)

TABLE 7 — Greases for Bearings and Seals Preventive Maintenance

–18° to +93°C (0° to 200°F) AFTER FIRST WEEK — Check alignment of total system and
realign where necessary. Also tighten all external bolts and
Manufacturer Lubricant
plugs where necessary. DO NOT readjust the internal gear or
Amoco Oil Co. Amolith Grease No. 2 bearing settings in the drive, these were permanently set at the
BP Oil Co. Energrese LS–EP2 Factory. See Table 8 for fastener and wrench sizes.
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 TABLE 8 — Fastener & Wrench Sizes
E.F. Houghton & Co. Cosmolube 2
Imperial Oil Ltd. Unirex N2L DRIVE SIZE
Fastener
Kendall Refining Co. Multi–Purpose Lithium Grease L421 M1220 M1230 M1240 M1250
Keystone Div. Pennwalt Corp. Zeniplex 2 Foot Screw Size M42 M42 M48 M48
Lyondell Petrochemical (ARCO) Litholine H EP 2 Grease Mounting Wrench Size 65mm 65mm 75mm 75mm
Mobil Oil Corp. Mobilith 22
Mobil Oil Corp Mobilith SHC 460 H Housing Screw Size M12 M12 M12 M12
Petro–Canada Products Multipurpose EP2 Top Plate Wrench Size 18mm 18mm 18mm 18mm
Phillips 66 Co. Philube Blue EP Housing Screw Size M12 M12 M12 M12
Shell Oil Co. Alvania Grease 2 Bottom Wrench Size 18mm 18mm 18mm 18mm
Shell Canada Limited Alvania Grease 2
Sun Oil Co. Ultra Prestige EP2 Inspection Screw Size M8 M8 M8 M8
Texaco Lubricants Premium RB Grease Cover Wrench Size 13mm 13mm 13mm 13mm
Unocal 76 (East & West) Unoba EP2 Screw Size M16 M16 M16 M16
Jackscrews
Valvoline Oil Co. Multilube Lithium EP Grease Wrench Size 24mm 24mm 24mm 24mm
H High performance synthetic alternate. Magnetic Plug Size 1.250 NPT 1.250 NPT 1.250 NPT 1.250 NPT
Drain Plugs Wrench Size 15/16 15/16 15/16 15/16
Plug Size 1.250 NPT 1.250 NPT 1.250 NPT 1.250 NPT
Other Plugs
Oil Levels Sq. Skt. 3/4 3/4 3/4 3/4
TYPES DH & DB — Fill the drive with oil to the level indicated Shaft Fan Screw Size M12 M12 M12 M12
on the oil dipstick. Approximate oil capacities are given on the Shroud Wrench Size 18mm 18mm 18mm 18mm
drive nameplate. Shaft Fan Screw Size M10 M10 M10 M10
Setscrew Hex Size 5mm 5mm 5mm 5mm
The inspection cover is sealed with a non hardening chemical
gasket eliminator. When replacing the inspection cover, run a
bead of Loctite Gasket Sealant #2 (or equivalent) around the AFTER FIRST MONTH — Proceed as follows:
perimeter of the inspection opening, making sure to circle the 1. Operate drive until old sump oil reaches normal operating
fastener holes. temperature. Shut down drive and drain immediately.
DRIVES WITH OIL PUMPS — Occasionally gear drives will be 2. Immediately flush drive with an oil of the same type and
equipped with oil pumps for cooling or special lubrication viscosity grade as the original charge (warmed to
considerations. If a drive is equipped with an oil pump, fill the approximately 38°C (100°F) in cold weather) by rapidly
drive to the level marked on the dipstick. Run the lubrication pouring or pumping a charge equal to 25 - 100% of the
system for several minutes to fill the system components. Verify initial fill volume or until clean oil flows through the drain.
that the pump is circulating oil properly, then recheck oil level. 3. Close the drain and refill the drive to the correct level with
If necessary, add oil to compensate for filter and/or cooler. new oil of the correct type and viscosity.
Before starting the gear drive, rotate the input shaft to check for PERIODICALLY —
obstructions. Then start the drive and allow it to run without
1. Check the oil level of the drive when it is stopped and at
load for several minutes. Shut down and recheck oil level. If
ambient temperature. Add oil if needed. If the oil level is
everything is satisfactory, the drive is ready for operation.
ABOVE the high oil level mark on the dipstick, have the oil
analyzed for water content. Moisture in the oil may indicate
that a seal or the heat exchanger is leaking. If so, replace
the defective part immediately and change the oil. DO
NOT fill above the mark indicated as leakage or undue
heating may result.
2. Check coupling alignment to make certain that foundation
settling has not caused excessive misalignment.
3. If drive is equipped with a fan, periodically clean accumulated
foreign matter from the fan, guard, and deflector.
4. If drive is equipped with a torque arm, check for free
movement.

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 168-054
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 (PN 2128959) June 2006
Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com NEW
Owners Manual • Falk™ Drive One™ Conveyor Drives

(Page 8 of 18) Sizes M1220 thru M1250 • Type D Series

Lubricant Changes CAUTION: Rapid greasing with a power grease gun can force
grease inward past the seals causing seal leaks.
OIL ANALYSIS REPORT— Checking oil condition at regular
intervals is recommended. In the absence of more specific GREASE LUBRICATED BEARINGS (Torque Arm) — Most
limits, the guidelines listed below may be used to indicate when shaft mounted drives have a grease lubricated bearings in the
to change oil: torque arm. Grease bearings during oil changes or at intervals
of every 6 months or 2500 hours of operation whichever is
1. Water content is greater than 500 ppm (0.05%). less.
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm. Stored & Inactive Gear Drives
4. Viscosity changes more than 15%. Each gear drive is protected with a rust preventative that will
PETROLEUM LUBRICANTS — For normal operating conditions, protect parts against rust for a period of 4 months in an
change gear oils every 6 months or 2500 operating hours, outdoor shelter or 12 months in a dry building after shipment
whichever occurs first. Change oil more frequently when gear drives from the Factory.
operate in extremely humid, chemical or dust laden atmospheres. In If a gear drive is to be stored, or is inactive after installation
these cases, R & O and EP lubricants should be changed every 3 to beyond the above periods, drain oil from housing and spray all
4 months or 1500 to 2000 hours. If the drive is operated in an area internal parts with a rust preventative oil that is soluble in
where the temperatures vary with seasons, change oil viscosity grade lubricating oil or add “Motorstor”™ vapor phase rust inhibitor
to suit temperature. Lubricant suppliers can test oil periodically and at the rate of 1.05 liters per cubic meter (one ounce per cubic
recommend economical change intervals. foot) of internal drive space (5% of sump capacity). Refer to
SYNTHETIC LUBRICANTS — Synthetic lube change intervals can Table 9 for Motorstor quantities. Rotate the shafts several times
be extended to 8000 - 10,000 hours depending upon operating by hand. Before operating, drives which have been stored or
temperatures and lubricant contamination. Change oil more inactive must be filled to the proper level with oil meeting the
frequently when gear drives operate in extremely humid, chemical specifications given in this manual. Refer to Manual 128-014
or dust laden atmospheres. In these cases, synthetic lubricants for “Start-up after Storage” instructions.
should be changed every 4 to 6 months or 4000 to 6000 hours.
Laboratory analysis is recommended for optimum lubricant life
and gear drive performance. Change lube with change in TABLE 9 — Motorstor/VCI–10 H
ambient temperature, if required. Refer to Table 6 for synthetic (Add to stored or inactive drives)
lubricant viscosity recommendations.
Motorstor
GREASE LUBRICATED SEALS — Depending on the frequency DRIVE SIZE
Milliliters Per Drive Ounces Per Drive
and degree of contamination (at least every six months or when
changing oil in the drive), purge contaminated grease from M1220 - M1230 440 15
M1240 - M1250 590 20
seals by slowly pumping fresh grease, WITH A HAND GREASE
H Product of Daubert Chemical Company, Chicago, IL.
GUN, through the seal cavity until fresh grease flows out along
the shaft. Wipe off purged grease. Refer to Table 7 for NLGI
#2 greases. Some of these greases are of the IP type and may Periodically inspect stored or inactive gear drives and spray or
contain toxic substances not allowed in the food processing add rust inhibitor every six months, or more often if necessary.
industry. A grease that meets the USDA “H1” classification is Indoor dry storage is recommended.
suitable for food processing applications.
Gear drives ordered for extended storage can be treated at the
Factory with a special preservative and sealed to rust-proof
CAST IN OIL TROUGH parts for periods longer than those cited previously.
The vented dipstick should be replaced with a plug (vented
dipstick should be attached to gear drive for future use) so that
OIL TO BEARING the protective rust inhibiting atmosphere is sealed inside the
GREASE drive. Install vented dipstick when preparing drive for operation.
FITTING
GREASE

LIP SEAL

OPTIONAL SECOND
LIP SEAL LOCATION

RADIAL BEARING
BUSH SEAL
GREASE
CAVITY

GREASE PURGE
COVER BUILT-IN
OIL DAM

DRAINBACK
PASSAGE

168-054 Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492
June 2006 (PN 2128959) 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
 Falk™ Drive One™ Conveyor Drives • Owners Manual

Type D Series • Sizes M1220 thru M1250 (Page 9 of 18)

Changing Hand of Drive Position drive top side up. Install dipstick fitting in housing on
side opposite the low speed gear. Assemble AirMax assembly
Right/Left Hand Spare — A Drive One Conveyor Drive can
fitting in housing on gear side. Reposition magnetic drain
be used in a right hand or left hand application with a single
plugs such that they will be in the oil sump. Coat pipe threads
low speed shaft extension and minimal change-over effort. The
with Loctite Pipe Joint Compound or equivalent prior to
Conveyor Drive housing top and bottom halves are identical
installation.
and therefore can be mounted on either end. Internal
lubrication troughs and oil passage function in either position Drives with an Internal Lubrication Pump — When
as well. Changing the drive from one hand to the other simply changing the hand of a drive with an internal lubrication pump,
requires repositioning of the top and bottom plate, magnetic the pump must be moved to the cross-bar of what will be the
drain plugs, dipstick and breather. bottom of the housing. All previous instructions for changing
hands must be followed. In addition, to remove the oil pan,
To change hands of the drive, begin by cleaning the outside of
remove the fitting holding the fill tube into the oil pan. Remove
the housing to prevent contamination of internal components
the two fasteners mounting the pump bracket to the cross-bar
and drain the oil. With inspection cover up, remove the AirMax
and any shims that are used.
breather and dipstick pipe fittings from the housing. Remove
the top cover of the drive, threaded jacking holes are provide Prepare the pump for mounting on the opposite cross-bar by
to break loose the sealant if required, (eyebolts threaded into loosening the compression nut on the fittings securing the
jacking holes can be used for lifting). Remove internal oil suction and output tubes to the pump. The tubes must remain
distribution pan if present, (See additional instructions below if in the same port on the pump. Rotate the output tube 180°
drive is equipped with an internal lubrication pump). Rotate the and tighten compression nut. The suction tube should be
drive 180° so the bottom plate is now up. Remove the bottom rotated such that is will be approximately 10-20mm
plate, jacking holes are also provided. (0.375-0.750 inches) off the bottom of the drive sump. Position
the pump in the housing. Align the pump gearset with a
Prepare top and bottom plate for reassembly by removing old
straight edge. The pump gearset back lash should be set
sealant. Loctite Chisel Gasket Remover or equivalent can be
between 0.15-0.56mm (0.006-0.022 inches) by adding or
used to aid in the removal of sealant. CAUTION: Gasket
removing shim beneath the pump bracket.
Remover can soften and remove paint. Prepare the housing
surface in the same manner. Apply Loctite Activator 7649 or After proper gear alignment and backlash is achieved, apply
equivalent to the mating surfaces of the top plate and housing Loctite 242 threadlocker or equivalent to the threads of the
and allow to dry. Position the oil distribution pan in housing (if pump mounting fasteners. Tighten fasteners to 85 Nm (62
required) with large opening over the low speed gear. The tabs lb-ft) and re-check alignment and backlash. When installing
of the pan reside in the pockets of the housing and is secured the oil pan, position pump output tube through coupling in
by the cover plate. Apply a continuous bead of Loctite 515 pan. Install fitting to secure output tube. Continue with
Gasket Eliminator or equivalent to the housing mating surface instructions as mentioned previously.
to the inside of the bolt pattern. Assemble top plate to housing
with the inspection cover over the low speed gear. Tighten
fasteners to 85 N-m (62 lb-ft).
Remove pipe plugs from new dipstick and breather location.
Rotate the drive 180° so the newly assembled top plate is
down. Clean and prepare housing surface as previously
mentioned for top plate. Apply a continuous bead of Loctite
515 Gasket Eliminator or equivalent to the housing mating
surface to the inside of the bolt pattern. Assemble bottom plate
to housing and tighten fasteners to 85 N-m (62 lb-ft). Install
previously remove pipe plugs into old dipstick and breather
location. Coat pipe threads with Loctite Pipe Joint Compound
or equivalent prior to installation.

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 168-054
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 (PN 2128959) June 2006
Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com NEW
Appendix A • Falk™ Drive One™ Conveyor Drives

(Page 10 of 18) Sizes M1220 thru M1250 • Type D Series

This Page Intentionally Left Blank

168-054 Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492
June 2006 (PN 2128959) 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
 Falk™ Drive One™ Conveyor Drives • Appendix A

Type D Series • Sizes M1220 thru M1250 (Page 11 of 18)

Fixed Torque Arm Installation

Introduction Installation
The Drive One spherical bearing link style torque arm is 1. Position the drive on the driven equipment shaft such that
available for all shaft mounted Drive One Large Conveyor the torque arm link is centered in the mounting clevis.
Drive Sizes, both parallel shaft Type DH and right angle Type Ideally, the clevis mounting holes should be added to the
DB. It is used to support the drive when mounted in a standard structure after the drive has been secured to the driven
horizontal position. The torque arm accessory is suitable for use equipment.
on swing bases, bedplates, Alignment Free or mounted directly NOTE: Do not fasten the torque arm to the support
to the drive. The torque arm requires mounting holes in the structure at this time.
driven equipment support structure to provide for attachment. 2. Secure the drive to the driven equipment via the rigid
The customer is responsible for determining the structural coupling connection.
integrity of their support member. 3. Mount the clevis to the drive or drive system. Locate the
position of the clevis to be mounted to the support
Mounting structure. Match drill the mounting holes for M24 Cl. 8.8
or 1 inch Grade 5 fasteners or better.
It is natural for the drive system to move during operation. This
movement is due to runout from the driven equipment shaft 4. (IF REQUIRED) Mount plain spherical bearings into link.
and gear drive low speed shaft. Plain spherical bearings and a Secure bearings with retainer plate and cap screws. Apply
link are used to provide a resilient mounting support that Loctite 242 Threadlocker or equivalent to fastener threads
accommodates the motion of the drive. To allow for maximum prior to installation.
movement, the torque arm should be perpendicular to the 5. Install pin through one lug of clevis mounted to drive.
supports and centered in the mounting clevis. Restricting the Position spacer, then link (with spherical bearings previously
drive’s motion will result in premature failure of the drive or installed) and finally second spacer on pin. Finish
driven equipment. positioning pin within clevis. Install retaining rings to each
side of pin to retain pin. Refer to Figure 1.
6. Install pin in clevis mounted to supporting structure in a
MOUNTING SPACER (4)
Figure 1 CLEVIS (2) similar manner. The drive may need to be rotated about
the low speed shaft to install second pin. If the drive has a
backstop, it may be necessary to disconnect the backstop
to rotate the drive. Refer to the backstop instructions for
removal.
PIN
7 Verify the torque arm link is centered in the clevis and is not
restricting motion of the drive.

PLAIN SPHERICAL
BEARING (2) RETAINING
PLATE (2)

PIN

RETAINING
RING (4)

CAPSCREW (6)
EVEN GAP

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 168-054
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 (PN 2128959) June 2006
Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com NEW
Appendix B • Falk™ Drive One™ Conveyor Drives

(Page 12 of 18) Sizes M1220 thru M1250 • Type D Series

This Page Intentionally Left Blank

168-054 Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492
June 2006 (PN 2128959) 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
 Falk™ Drive One™ Conveyor Drives • Appendix B

Type D Series • Sizes M1220 thru M1250 (Page 13 of 18)

Swing Base Installation

Introduction
The Drive One Swing Base is a welded steel structure designed
to support a motor and a right angle Type DB, shaft mounted STEP
BLOCK
drive. The swing base itself is a length of square cross-sectional
tubing with plates welded to it for the motor and drive. The
motor and drive plates are machined and are supported by
gussets for additional strength. A torque arm attaches to the
tube section near the motor end of the swing base.

MOTOR PLATE

COUPLING GUARD PLATE Coupling Guard

DRIVE PLATES
The coupling guard must be trimmed in order to fit the height
and shaft extension requirements. Refer to the coupling guard
installation manual for instructions on trimming the guard. After
the guard has been trimmed holes can be drilled in the
coupling guard plate on the swing base. The guard can then
be bolted down to the plate.
GUSSET
TUBE SECTION LIFTING LUG
TORQUE ARM 2 PER SIDE (4 TOTAL)
MOUNTING Lifting the Swing Base Assembly
Supporting the Swing Base After the drive, motor, and coupling have been mounted to the
swing base, the completed assembly can be lifted into position
The torque arm connection lug prevents the swing base from for installation on the driven shaft. The motor eyebolt and the
lying flat on the ground; therefore, a supporting structure is lifting holes on the drive housing can be used as cable
required for mounting the gear drive and motor to the swing attachment points. The motor eyebolt is strongest when the
base. This structure is typically built from wood and is unique to cable pull is vertical. To insure that cable pull on the motor
each swing base. All gussets have a 19 mm (0.75 inch) eyebolt is vertical, use of a spreader bar is recommended. See
diameter hole for securing the swing base to the supporting the sketch below. To ensure safety, chains or a sling should be
structure. placed behind the torque arm connection.

SPREADER BAR

WOODEN SUPPORTING
STRUCTURE VERTICAL
CABLE PULL

Mounting Gear Drive to Swing Base

It is standard procedure to mount the drive to the swing base at
the Factory. These instructions are to be followed when field
mounting of the drive to the swing base is required. Use of
broad, flat shims between the gear drive and mounting plate
are recommended to prevent distortion of the housing when the
drive is bolted down. Jacking screw holes are provided in gear LOCATE SAFETY
drive housing to aid in fixing the shims. Begin at the low speed CHAINS/SLING HERE
shaft end and level across the length and then the width of the
gear drive. Use a feeler gauge to insure that all pads are Mounting Swing Base Assembly to Driven
supported. Bolt down the drive to the torque specified in Table
1, Page 4.
Equipment
Mount the gear drive to the driven shaft (See Page 2). Secure
the torque arm to the foundation per the instructions in
Mounting Motor and Coupling Alignment Appendix A.
Shims are provided for motor mounting. Holes must be drilled
into the swing base motor plate for mounting of the motor. Step
blocks are also provided for some small frame motors. Use a
feeler gauge to ensure that all motor pads are firmly seated.
Motor mounting needs to be done in conjunction with coupling
alignment to control angular and offset misalignment. Refer to
the coupling manufacturer’s manual for specific instructions.
Bolt down the motor to the torque specified in Table 1, Page 4.

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 168-054
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 (PN 2128959) June 2006
Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com NEW
Appendix C • Falk™ Drive One™ Conveyor Drives

(Page 14 of 18) Sizes M1220 & M1230 • Type D Series

This Page Intentionally Left Blank

168-054 Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492
June 2006 (PN 2128959) 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
 Falk™ Drive One™ Conveyor Drives • Appendix C

Type D Series • Sizes M1220 & M1230 (Page 15 of 18)

Alignment Free Assembly and Installation

Introduction Assemble the mounting shroud and fan guard inside the bell
The Alignment Free Drive design consists of a shaft mounted housing. Mounting shroud and fan guard cannot be
drive, bell housing, motor adapter plate, torque arm, motor assembled outside the bell housing. Install all fasteners loosely
and coupling. When assembled, the bell housing, motor to ensure all fastener holes are aligned. When all fasteners
adapter, and motor locate off registers, resulting in alignment are loosely installed, tighten starting with the mounting shroud
of the motor and gear drive shafts. Therefore, no additional to bell housing fasteners and finish with the fan guard fasteners.
alignment is required for the high-speed coupling. Rotate the high speed shaft by hand to verify there is no
interference between the fan and guard.

Assembly Instructions
Fluid Coupling
The bell housing is fastened to the drive’s high speed end using
cap screws in tapped holes on that face, (see Table 1 for size Location of the fluid coupling on the high speed shaft of the
and torque). The bell housing will locate on the bevel head of drive is determined by the provided shaft spacer. Install the fluid
the drive. Read instructions provided with high speed coupling coupling on the high-speed shaft of the gear drive per fluid
prior to assembly. coupling instructions.
Once the fluid coupling is installed, the motor adapter plate
can be mounted to the bell housing, also being located by a
TABLE 1 — Tightening Torques register. Measurements must be taken to accurately position the
motor half of the coupling hub on the motor shaft. First,
DRIVE Bolt Tightening Torque measure the distance from the motor mounting face to the end
SIZE Size N-m lb-ft of the motor shaft, (A). Then measure the distance from the
M1220 M24 725 535 motor adapter plate face to the hub on the fluid coupling, (B).
M1230 M24 725 535 Finally measure the distance from the hub flange to the hub
end, (C). The desired gap can be found in Table 3, based on
coupling size.
Shaft Fan (Optional)
A shaft fan is provided on the high speed shaft for drive
requiring a shaft fan. The fan must be assembled to the drive TABLE 3 — Coupling Gap
prior to mounting any type of coupling. Assemble the fan to Gap
the hub, apply Loctite 242 threadlocker or equivalent to the Fluid Coupling Tschan Hub
Size Size mm Inch
fasteners and tighten. Caution: over-tightening can crack the
fan. Position the fan on the high speed shaft to the position 1480HFDD 260 7.5 0.295
indicated in Table 2 (See Figure 1). Apply Loctite 242 1584HFDD 300 8.4 0.331
1660HFDD 360 9.0 0.354
threadlocker or equivalent to the set screw and tighten.

Calculate the hub protrusion:

TABLE 2 — Fan Hub Location Protrusion = (A + Gap) – (B + C)
DRIVE Shaft Protrusion If the calculated protrusion is a negative value, the hub
SIZE mm Inch overhangs the shaft by that amount. (Figure 2)
M1220 205 8.07
M1230 205 8.07
MOTOR MOTOR
MOTOR MOUNTNG ADAPTER BELL
FACE PLATE HOUSING DRIVE
FAN MOUNTING
FIGURE 1 GUARD SHROUD FAN COUPLING
DRIVE HUBS

C B SHAFT
PROTRUSION SPACER
FIGURE 2 A

SHAFT FAN HUB

PROTRUSION

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 168-054
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 (PN 2128959) June 2006
Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com NEW
Appendix C • Falk™ Drive One™ Conveyor Drives

(Page 16 of 18) Sizes M1220 & M1230 • Type D Series

Once the hub is correctly located on the motor shaft, the motor Lifting the Alignment Free Drive
can be mounted to the motor adapter plate. The hubs will be
Lifting points are provided on the corners of the motor side of
aligned and come together to the proper gap. To fill the fluid
the bell housing, see Figure 4. Lift by these and the provisions
coupling to the proper oil level, align the mark on the
provided on the drive housing itself to maneuver the drive. DO
perimeter of the fluid coupling with the mark in the center of
NOT lift by the motor lifting eye.
the inspection window on the bell housing on the side opposite
the low speed shaft extension. To locate the correct mark on the
fluid coupling, begin by aligning the fill hole of the fluid LIFT POINTS
coupling with the mark in the inspection window. For fill angles
less than 90°, rotate the fill plug upward until the marks line up.
For fill angles greater than 90°, rotate the fill plug downward
until the marks line up. When the proper marks are in-line, fill
the fluid coupling with recommended fluid until fluid appears at
the lip of the fill hole.

Close Coupling
If the drive requires a shaft fan, assemble prior to installing FIGURE 4
coupling.
Mount the motor to the motor adapter plate on the bell
housing before installing the coupling. Once the motor is Mounting the Drive
secured, measure the distance (D) between the end of the Mount the Alignment Free Drive to the driven equipment per
motor shaft and the high speed shaft of the drive, see Figure 3. Page 2. The torque arm must be located on the extension side
Subtract the distance (D) from the length of the spacer coupling of the drive at the foot as shown in Figure 5. Connect the
(BE). Then divide this value in half to find the overhang of each torque arm to the foundation per the torque arm installation
hub. [Overhang + (BE – D)/2] The overhang will be negative, instructions.
this is the amount each hub overhangs the shaft. Once the
overhang is determined, install the hubs according to the
instructions provided with the coupling. Install the spacer
sections and verify the gap is correct. If not, readjust the hub on
the motor shaft. If the coupling is furnished with an interference
fit, readjustment will not be possible, take extra care in making
measurements. After the proper gap is set, finish installing the
coupling per the instructions.

MOTOR TORQUE ARM LOCATION

ADAPTER BELL ON EXTENSION SIDE
MOTOR PLATE HOUSING FIGURE 5
DRIVE

OVERHANG OVERHANG

FIGURE 3 D

168-054 Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492
June 2006 (PN 2128959) 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com
 Falk™ Drive One™ Conveyor Drives • Appendix D

Type D Series • Sizes M1220 thru M1250 (Page 17 of 18)

Electric Fan Installation & Maintenance

Installation FIGURE 1
The installation and troubleshooting of electric cooling fans are
to be carried out by a qualified electrician according to the SINGLE PHASE 1 PHASE 220V - 50Hz
1 PHASE 240V - 50Hz
applicable local, state, province and federal codes. Inspect for
any damage that may have occurred during transit. Check all
TYPE - E 1 PHASE 110V - 60Hz
1 PHASE 220V - 60Hz
bolts, screws, set screws, etc. Re-tighten as required. Before 1 PHASE 240V - 60Hz
installing, rotate the blade to be sure it does not rub. Adjust if
necessary. Before installation, read the entire manual carefully.
CAPACITOR
This guide is pertinent only to electric fans furnished by the
Factory and manufactured by Multifan Inc. (can be verified
from nameplate on the electric fan). In the event the electric fan
furnished by the Factory is of a special nature (manufactured by
an alternate fan manufacturer), please contact the Factory for
appropriate electric fan installation and maintenance
instructions.

General Safety Information

THERMAL
Warning: To reduce the risk of fire, electric shock, or personal PROTECTION
injury, observe the following:
L N(L2)
1. Use this electric fan only in the manner intended by the
manufacture. If you have any questions, contact the Factory.
2. Before servicing or cleaning the fan, switch the power off at
the service panel and lock out to prevent the power from
THREE PHASE 3 PHASE
being switched on accidentally. TYPE - D 3 PHASE 220/380V - 50Hz
3. Follow all local electrical and safety codes, as well as the 3 PHASE 230/400V - 50Hz
3 PHASE 240/415V - 50Hz
National Electrical Code (NEC) and Occupational Safety
and Health Act (OSHA). 3 PHASE 220/380V - 60Hz
3 PHASE 208/360V - 60Hz
4. Fan motor must be securely and adequately grounded. 3 PHASE 265/460V - 60Hz

5. All working parts should be grounded.

6. When cleaning electrical equipment always use an
approved cleaning agent. See CLEANING in NOTES B3
section, Page 18.
7. For general ventilation and cooling use only. DO NOT use
if hazardous or explosive materials and vapors are present. 250V B3
10A
COS =1
OPTION
Guidelines For Installation L1 L2 L3
THERMAL
Before connecting the electric fan, check if the information on PROTECTION
the fan motor name plate is in accordance with the actual main
supply voltage, phase and frequency. B3
Warning: To reduce the risk of fire, electric shock, or personal
injury, observe the following:
B3
1. Switch off the main power supply and lock out before 250V
installing, servicing or making connections to the fan. 10A
COS =1
2. Installation work and electrical wiring must be done by a OPTION
L1 L2 L3
qualified person(s) in accordance with all applicable codes
and standards, including fire-rated construction.
3. The fan should be securely mounted. Recheck the mounting
hardware and tighten as necessary.
4. The fan motor must always be grounded. The installation of
a motor protection switch is recommended. See Figure 1
for wiring diagrams.
5. Mount the motor guard if removed. The motor guard must
be installed at all times during operation to prevent injury
to personnel by rotating fan blade.
6. Use liquid tight electrical fittings and conduit.

Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492 168-054
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 (PN 2128959) June 2006
Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com NEW
Appendix D • Falk™ Drive One™ Conveyor Drives

(Page 18 of 18) Sizes M1220 thru M1250 • Type D Series

7. A temperature switch is provided to control oil sump 10. Remove proper condensation plug. See Figure 3 below.
temperature. See Figure 2 for proposed wiring. There are Do not discard. Plug is to be used during cleaning.
two separate circuits in the temperature switch. The low
circuit is to operate the electric fan. It is recommended the
fan motor be operated by the temperature switch through a FIGURE 3
motor starter relay (consult applicable local and national
electrical codes). The high circuit is provided to operate Mounting Positions
either a high temperature alarm or main motor shutdown. For Position For Position Note: Never use
A&B C copper or brass
Remove Plug 1 Remove Plug 2 fastening materials
FIGURE 2
POSITION A
POSITION B POSITION C
PROPOSED TEMPERATURE SWITCH WIRING
DIAGRAM FOR ELECTRIC FANS 1
L1 L2
CONTROL VOLTAGE
2
SWITCH 1
FALK PART NO.
932716 - NEMA 4 & 13
LOW CIRCUIT

RED START FAN

PURPLE MS
MOTOR
BLUE NOTES:
AIR SUPPLY AND TEMPERATURE — Sufficient air supply over
SET AT 140°F
the motor must be assured in all circumstances. Limits of
(60°C) operating ambient temperature are 14°F to 113°F (–10°C to
HIGH CIRCUIT
45°C).
YELLOW
BROWN
RESTRICTION ON USE — Fan blade material is
ORANGE Polypropylene which is unsuitable and/or not recommended for
certain chemicals. The following is a partial list of unsuitable
ALARM OR MAIN MOTOR
CIRCUIT chemicals for guideline purposes.
SET AT 210°F
(100°C)

Chloro-Sulphonic Acid Nitric Acid Chloroform

CUSTOMER WIRING MS = MOTOR STARTER
Mixture of HNO3-HCL Esters 1:2 Dichloroethylene
AND COMPONENTS Mixture of HNO3-H2SO4 Benzene Trichloroethylene
Sulfuric Acid, fuming Gasoline Diethyl Ether
AC RATING - INDUCTIVE LOAD - 50% PF Carbon Tetrachloride Toluene Chlorine, Liquid
DC RATING - INDUCTIVE LOAD - L/R = 0.26 Chlorobenzene Xylene
AC DC
VOLTS AMP VOLTS AMP
125 15 6-12 15
250 15 24 5
480 15 125 0.05
250 0.03 CLEANING — When cleaning fan, both condensation holes
MAXIMUM CONTINUOUS CURRENT (Figure 3, Items 1 and 2) are to be temporarily plugged. If this
Reference only. is not done, guarantee is void. When cleaning electrical
equipment, always use an approved cleaning agent.

8. Connect power to the motor using an approved wiring

method. See Figure 1 for connection diagrams.
9. Before starting the fan, double-check to ensure there are
no obstructions that could interfere with proper fan
operation and airflow. Verify proper fan rotation, resulting
in air flow directed at the adjacent face of the gear drive.

168-054 Rexnord Industries, LLC, Geared Products, P.O. Box 492, Zip 53201-0492
June 2006 (PN 2128959) 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
NEW Fax: 414-937-4359 e-mail: [email protected] web: www.rexnord.com