Falk™ Gear Drive Type PC Pump and Cooler • Installation and Maintenance
Types Y, YF, YB, and YBX • All Sizes (Page 1 of 3)
INTRODUCTION Falk™ Specifications 146-764 lists part numbers and brief
construction and operation data for the above accessories.
This gear drive is furnished with a cooling system to dissipate
Selection Guide 141-931 gives selection and dimensional
the heat generated by the load being transmitted through the
data for Falk™ standard external pump and cooler systems.
drive. The installation, operation and minor adjustments to this
cooling system is the subject of this manual. For detailed When ordering parts, or requesting information, specify the
maintenance instructions and specifications for accessories Falk M.O. number, unit size, H.S. shaft rpm, ratio and date
such as the oil filter, thermometer, oil relief valve, oil heater, stamped on the unit nameplate.
oil flow indicator, oil pressure gauge, pressure control switch CAUTION: Lock out power source and remove all external
and warning device, consult the product manufacturer’s loads from unit before servicing unit or accessories.
literature.
PIPE CONNECTIONS
SPLASH LUBRICATION Oil line connections are completed at Falk™ for internal and
unit mounted pumps; only the cooler water lines require
connection during installation. For floor-mounted pumps and
coolers, connect oil and water lines after the gear drive has
been installed. Refer to Figures 1 thru 3 and Tables 1 and 2 for
oil and water line connection points and pipe sizes. Always
locate floor mounted pumps BELOW the unit oil level to
maintain a prime and CLOSE to the unit to minimize pipe
lengths.
Connect water inlet line to the tube side of the heat exchanger
and run the discharge line to an OPEN DRAIN to prevent back
pressure. DO NOT use a throttling valve between heat
Figure 1
exchanger and drain.
JET LUBRICATION Equip units with a by-pass valve or an immersion type oil
heater when the ambient temperature is below 50°F(10°C).
WD – HOLE Consult Factory for size and type of heater and Specifications
SINGLE REDUCTION 146-764 for wiring diagram.
OIL LEVELS — Prior to filling Type Y and YB reducers, remove
the inspection plate and FLOOD THE OIL TROUGHS to insure
a generous flow of oil to the bearings. For Type YBX, remove
SINGLE DOUBLE GE – HOLE the top plug or sight glass and flood oil passages. This priming
REDUCTION REDUCTION DOUBLE REDUCTION action lubricates and protects the bearings until sufficient oil is
circulated. Fill unit to level marked on the dipstick.
Figure 2 KD – HOLE FOR OIL SUCTION
LINE FROM PUMP
OIL AND WATER LINE LOCATIONS
HEAT V – OIL GA – WATER TABLE 1 — Y and YF Drive Pipe Sizes – NPT
SUCTION
EXCHANGER INLET (Refer to Figures 1 and 2)
DRIVE DRIVE
SIZE H DD GE JD KD SIZE Q DD GE JD KD
MB – OIL
DISCHARGE
V – OIL GA – WATER
2050 .50 ... ... 1.00 2120/25 .75 1.00 1.25 1.25
DISCHARGE OUTLET 2060 .50 ... ... 1.00 2130/35 .75 1.00 1.25 1.25
2070 .50 ... ... 1.00 2140/45 1.00 1.00 1.50 1.50
SIZES 20 AND 40 PC 2080 .50 † ... ... 1.25 2150/55 1.00 1.25 1.50 1.50
2090 .50 † ... ... 1.25 2160/65 1.50 ‡ 1.25 2.00 2.00
V – OIL 2100 .75 ... 1.25 1.25 2170/75 1.25 1.25 2.00 2.00
SUCTION GA – WATER
INLET 2110 .75 .75 1.25 1.25 2180/85 1.50 ‡ 1.25 2.00 2.00
PUMP 2190/95 1.50 ‡ 1.25 2.00 2.50
H Dimensions also apply to YF series drives. For YB and YBX, refer to Factory.
† DD = .75 with 40PC.
V – OIL GA – WATER ‡ DD = 1.25 with 50PC.
DISCHARGE OUTLET
SIZES 50 AND 61 PC
V – OIL GA – WATER TABLE 2 — Pump and Cooler Pipe Sizes – NPT
DISCHARGE INLET (Refer to Figure 3)
Pump and Pump and
GA MB V WD Cooler GA MB V WD
Cooler Size Size
20PC .75 1.00 .50 ... 50PC 2.00 3.00 1.00 1.25 l
V – OIL GA – WATER 30PC 1.00 1.50 .50 .75 60/61PC 2.00 3.00 1.50 1.50 l
SUCTION OUTLET
Figure 2 40PC 1.50 2.00 .75 1.00 70PC 2.00 3.00 1.50 2.00
SIZES 60, 70, AND 80 PC l WD = 2 for Drive Sizes 2180 through 2195.
Rexnord Industries, LLC, Gear Group 148-931
3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131 December 1990
Fax: 414-937-4359 e-mail:
[email protected] web: www.rexnord.com Supersedes 2-71
Installation and Maintenance • Falk™ Gear Drive Type PC Pump and Cooler
(Page 2 of 3) All Sizes • Types Y, YF, YB, and YBX
BEFORE STARTING — Rotate the external pump shaft by The minimum value of the range is for clean water at a
hand to prime the pump. Start the pump motor and check for minimum velocity to prevent fouling of the tube bundle. For
oil flow thru the oil sight or in the oil troughs. If oil is not brackish water, a flow rate of 2 times the minimum value is
circulating, reverse the motor shaft rotation and recheck. required to prevent suspended solids from settling. The
Internal pumps on YBX units do not require priming, but check maximum value of the range is based on a maximum velocity
for oil flow through the oil sight after the unit has been started. to avoid erosion of the tube bundle.
RECHECK OIL LEVEL — After operating the unit for 2 or 3
minutes, shut down and immediately recheck the oil level MAINTENANCE
before oil lines drain. This reading will indicate the true
operating oil level. Add oil, if necessary, to raise level to the HEAT EXCHANGER — It is important that the inside parts are
“full” mark on the dipstick. kept clean. Inspect the exchanger periodically and clean
thoroughly. Inspect all tubes carefully for possible corrosion or
JET SPRAYS — Drives equipped with this system may be
foreign material. Bleed the oil side of the cooler periodically if
identified by the oil piping shown in Figure 2. A jet of oil is
air tends to collect in the system.
directed to the H.S. shaft bearings, while a spray of oil
lubricates the H.S pinion. For open systems, drain vertical coolers by removing the two
zinc anodes and loosening the bottom bonnet. Disconnect and
Check to see that an even spray of oil emerges from the nozzles
drain the lines on horizontal open systems. Blow out all lines.
onto the pinion and that oil is flowing through the H.S bearings. If
not, disassemble the clogged portion and clean the oil passages Heat exchangers are equipped with zinc anodes to minimize
with a wire. Flush thoroughly to remove any contaminant. galvanic corrosion. Inspect after first month of service and
periodically thereafter, depending on the severity of corrosion.
Oil must be free of lint or any contamination that may clog the
If 50% of the anode is used up, replace it.
lubrication nozzles or oil passages.
Check the reducer oil level periodically. If it is ABOVE the
high level mark on the dipstick, have the oil analyzed for
water content. Moisture or water in the oil may indicate
that the heat exchanger is leaking. If so, replace the
exchanger immediately and change the oil.
EXTERNAL PUMP — Correct shaft alignment is essential;
check with a straightedge across the flanges of the coupling,
or use a feeler gauge between the faces of the coupling
halves at 90° intervals. The pump is a positive displacement
rotary type with a mechanical seal. Refer to manufacturer for
detailed maintenance.
INTERNAL PUMP — The lubricating pump on the 2000YBX2
exchanger cooled units is a positive displacement rotary type
manufactured at Falk. If maintenance is required, refer to the
Factory for detailed instructions.
OIL FILTER — If the filter is a Purolator, cleaning of the
element is accomplished by rotating the hand wheel several
turns once a week. Remove the filtering element and scrub
with a fiber bristle and a non caustic solvent at oil change
intervals. Flush out housing with solvent. If the filter is a
Marvel, follow the above element cleaning procedure, and
when reassembling, be sure that the “O” ring is properly
seated in the head groove.
JET LUBRICATION SYSTEM DISASSEMBLY — Disconnect
WATER FLOW — Be sure that all parts of the system are piping and remove the housing end covers. The oil manifold
clean and that the exchanger is full of fluid. Maintain the with spray nozzles is attached to one end cover and will pull
specified rate of oil and water flow. Avoid excessive flow of free from the opposite cover. Refer to Figure 4.
cooling water since this may cause tube failure through JET LUBRICATION SYSTEM ASSEMBLY — Install all new
erosion and may decrease cooling efficiency. end cover gaskets. Align the nozzles in a horizontal plane
Add antifreeze per manufacturer’s specification to closed facing the centerline of H.S. pinion as shown in Figure 4.
water supply systems. However, note that antifreeze reduces MERCOID PRESSURE CONTROL SWITCH — The mercoid
the rate of heat dissipation. switch is a sealed unit and should not be serviced. There is a
The additional thermal horsepower capacity provided by the double adjustment for setting both “on” and “off” operating points.
cooler is based on a 1:1 oil/water flow rate, a 55°F(31°C) RELIEF VALVE — This valve is pre-set at the factory and
inlet temperature difference between oil and water, normally does not require adjustment. However, rotating the
90°F(32°C) inlet water temperature and maximum inlet water adjusting screw clockwise will reduce the opening pressure.
pressure of 50 psig.
Accessories such as flow indicator, pressure gauges,
Adjust the water flow rate within the flow range shown on the thermometers, heaters and pressure controls are sealed units.
cooler or unit water circulation plate to maintain a reducer If a malfunction occurs, return the sealed unit directly to the
operating temperature range of 140° to 160°F(60° to 71°C). manufacturer for repair or replacement.
148-931 Rexnord Industries, LLC, Gear Group
December 1990 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131
Supersedes 2-71 Fax: 414-937-4359 e-mail:
[email protected] web: www.rexnord.com
Falk™ Gear Drive Type PC Pump and Cooler • Installation and Maintenance
Types Y, YF, YB, and YBX • All Sizes (Page 3 of 3)
ACCESSORIES
The drawing below illustrates the general location of the
various accessories that may be used with the pump and
cooler system.
Rexnord Industries, LLC, Gear Group 148-931
3001 W. Canal St., Milwaukee, WI 53208-4200 USA Telephone: 414-342-3131 December 1990
Fax: 414-937-4359 e-mail:
[email protected] web: www.rexnord.com Supersedes 2-71
