FALK MDX SERIES MANUAL
Contents
1. P 4630 324 684 150 220 t Phillips 66 Co Philgear Shell Oil Co Omala Oil Spartan spartan Shell Canada Limited Omala Oil Evon Co USA ones Se Sun Oil Co Sunep EP 150 EP 220 Texaco Lubricants Meropa SHC 624 SHC 626 SHC 629 SHC 630 Mobil Oil Corp Mobil Mobil Unocal 76 East amp West Extra Duty NL Gear Lube ovigeor oongeor Valvoline Oil Co AGMA EP Sc SHC220 Minimum viscosity index of 130 Consult lubricant supplier manufacturer for t With complete application information temperature range can sometimes be extended consult Factory t Extreme Pressure EP lubricants contain phosphorus TABLE 9 Petroleum Based R amp O Gear Oils Maximum operating temperature of lubricants 200 F 93 C AGMA Viscosity Grade 3 4 5 6 7 ISO Viscosity Grade 100 150 220 320 460 Viso cSt 40 C 90 110 135 165 198 242 288 352 414 506 osy SUO 100 F 417 510 626 765 918 1122 1335 1632 1919 2346 Manufacturer Lubricant Lubricant Lubricant Lubricant Lubricant Amoco Oil Co Amer Ind Oil 100 Amer Ind Oil 150 Amer Ind Oil 220 Amer Ind Oil 320 Amer Ind Oil 460 P Oil Co TubinolT 100 Energol HLP HD 220 fee o usse Chevron U S A Inc Machine Oil AW 100 Machine Oil AW 150 Machine Oil AW 220 Machine OAW320 fn Citgo Petroleum Corp Citgo Pacemaker 100 Citgo Pacemaker 150 Citgo Pacemaker 220 Citgo Pacemaker 320 Citgo Pacemaker 460 Cono2. 500 1030682 1800 625 11 UNC 2 75 600 1035682 3000 625 11 UNC 3 75 700 1040682 3000 750 10 UNC 4 00 800 1045682 3000 1 125 7 UNC 4 50 900 1045682 3000 1 125 7 UNC 4 50 The outside diameter of the selected rigid coupling is less than the seal cage register diameter to accommodate pedestal mounting with coupling hub installed t Torque to Table 4 metal to metal values FALK FLUID COUPLINGS Refer to the installation manual furnished with the fluid coupling for installation alignment and startup instructions GAP amp ANGULAR ALIGNMENT If possible after mounting coupling hubs position the driving and driven equipment so that the distance between shaft ends is equal to the coupling gap Align the shafts by placing a spacer block equal in thickness to required gap between hub faces as shown above and also at 90 intervals around the hub Check with feelers STEELFLEX ILLUSTRATED The Falk Corporation PO Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 352 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com 308 050 March 1995 Supersedes 9 90 Installation and Maintenance Instructions e RAM Mixer Drives Sizes 300 thru 900 Types MDX MDXQ MDXT MDH amp MDHQ Page 4 of 8 a good name in industry OFFSET ALIGNMENT Align driving and driven shafts so that a straight edge will rest squarely on both couplings hubs as shown to the
3. W Canal St Zip 53208 4200 Milwaukee Wl USA Telephone 414 342 3131 Supersedes 9 90 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com a good name in industry RAM Mixer Drives Installation and Maintenance Instructions Types MDX MDXQ MDXT MDH amp MDHQ e Sizes 300 thru 900 Page 7 of 8 Lubricant Changes OIL ANALYSIS REPORT Checking oil condition at regular intervals is recommended In the absence of more specific limits the guidelines listed below may be used to indicate when to change oil 1 Water content is greater than 0 05 500 ppm 2 Iron content exceeds 150 ppm 3 Silicon dust dirt exceeds 25 ppm 4 Viscosity changes more than 1596 PETROLEUM LUBRICANTS For normal operating conditions change gear oils every 6 months or 2500 operating hours whichever occurs first If the drive is operated in an area where temperatures vary with the seasons change the oil viscosity grade to suit the temperature refer to Table 5 on Page 4 Lubricant suppliers can test oil from the drive periodically and recommend economical change schedules SYNTHETIC LUBRICANTS Synthetic lube change intervals can be extended to 8000 10 000 hours depending upon operating temperatures and lubricant contamination Laboratory analysis is recommended for optimum lubricant life and gear drive performance Change lube with change in ambient temperature if required Refer to Table 8 on Page 6 Lubr
4. furnished with special features refer to the supplementary instructions shipped with the drive The MDX Mixer is a right angle drive with vertical or horizontal output shaft designed primarily for mixer service The basic drive is designed for pedestal mounting but may be furnished with a Falk mounted bolt on adapter base or with an independently supported output stub shaft and pedestal base MDXT The standard drive may be furnished with a solid output shaft or hollow output shaft A low speed shaft drywell feature is standard on vertical drives with either solid shaft extension down and with hollow shaft and may be furnished as an option on solid shaft extension up drives Upper low speed bearings of all vertical drives and lower low speed bearings of drives with drywells are grease lubricated The MDXT drive is furnished with an output stub shaft independently supported by spherical roller bearings in externally mounted upper and lower bearing members upper bearing cage and pedestal base The output shaft is flexible coupling connected to the drive hollow shaft and the drive foundation is integral with the pedestal base The standard MDXT output shaft is furnished with an integral coupling flange The low speed shaft extension ends of solid shaft drives are drilled and tapped 2 holes for thrust coupling keeper plates refer to Shaft Connections on Page 3 MOUNTING CAUTION Mount drive only in the position for which it was
5. ordered i e horizontal base for MDX or horizontal low speed shaft for MDH If it is necessary to mount the drive in a different position from that for which it was ordered consult The Falk Corporation for changes necessary to provide proper lubrication The Falk Corporation PO Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 352 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com 308 050 March 1995 Supersedes 9 90 Installation and Maintenance Instructions e RAM Mixer Drives Sizes 300 thru 900 Types MDX MDXQ MDXT MDH amp MDHQ Page 2 of 8 a good name in industry The basic RAM drive is designed for pedestal mounting customer supplied with a bolt circle on the housing underside that is concentric about the low speed shaft The lower low speed seal cage or end cover has a close tolerance machined outside register diameter for accurate positioning of the drive on the pedestal Refer to Table 1 for housing mounting bolt circle data The Falk supplied adapter base optional is registered on the lower L S seal cage or end cover and uses the same bolting as used for customer pedestal mounting The MDXT drive with an independently supported output shaft is supplied with a pedestal base which has a unique foundation bolt pattern 22 5 SIZES 300 amp 400 7 15 SIZES 500 900 TABLE 1 Unit Housing to Pedestal Adapter Base Bolting Da
6. DA H1 classification is suitable for food processing applications GREASE LUBRICATED BEARINGS All upper low speed shaft bearings and the lower low speed shaft bearings of drives with drywell are grease lubricated in addition the output shaft bearings of MDXT drives are grease lubricated When changing oil in the drive grease bearings with a NLGI 2 bearing grease selected from Table 10 Regrease these bearings as part of the standard maintenance program Where process requirements permit regreasing output shaft bearings of MDXT drives with a NLGI 2 EP Extreme Pressure TABLE 10 Greases for Grease Lubricated Bearings amp Grease Purged Seals 0 to 200 F 18 to 93 C Manufacturer Lubricant Amoco Oil Co Amolith Grease No 2 P Oil Co nergrease LS EP2 Chevron U S A Inc ndustrial Grease Medium Citgo Petroleum Corp remium Lithium Grease No 2 Conoco Inc P Conolith Grease No 2 xxon Company U S A Unirex N2 F Houghton amp Co Cosmolube 2 mperial Oil Ltd Unirex N2 Kendall Refining Co Multi Purpose Lithium Grease L421 Keystone Div Pennwalt Corp Zeniplex 2 yondell Petrochemical ARCO itholine H EP 2 Grease Mobil Oil Corp Mobilith 22 Mobil Oil Corp Mobilith SHC 460 etro Canada Products Multipurpose EP2 hillips 66 Co hilube Blue EP Shell Oil Co Alvania Grease 2 Shell Canada Limited Alvania Grease 2 Sun Oil Co Ultra Prestige EP2 Texaco Lubricants
7. DHQ e Sizes 300 thru 900 Page 3 of 8 ax zn 10 MAX 7117 10 MAX gi e J 10 MAX 10 MAX FOR HORIZONTAL OUTPUT SHAFT TABLE 2 Load Reaction Through Tie Rod Unit Size Load Ibs 300 5000 400 7000 500 9000 600 10000 700 14000 800 17000 900 17000 MOTOR BRACKETS The weight location and starting torque of the motor will cause some brackets to deflect downward and to twist This movement is within allowable engineered limits for motor drive selections from the Falk bulletin If the customer considers the movement excessive jackscrew supports for the bracket extension are available from Falk To compensate for deflection caused by heavy motors AND to get CORRECT COUPLING ALIGNMENT use more shims under the rear motor feet than the front feet Motors and other components mounted on motor plates or motor brackets may become misaligned during shipment ALWAYS check alignment after installation Refer to Shaft Connections for coupling alignment instructions Shaft Connections WARNING Provide suitable guards in accordance with OSHA standards SHRINK DISC CONNECTIONS Shrink disc assemblies used on drives with a horizontal and hollow low speed shaft require special installation procedures and have metric fasteners Refer to the supplementary instructions supplied with the shrink disc assembly COUPLING CONNECTIONS The performance and life of any coupling depe
8. 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 COUPLINGS Lubricate Falk Steelflex couplings in accordance with instructions in Manual 428 010 and Falk Gear couplings in accordance with instructions in Manual 458 010 Preventive Maintenance AFTER FIRST WEEK Check alignment of the total system and realign where necessary Also tighten all external bolts and plugs where necessary DO NOT readjust the internal gear or bearing settings in the drive these were permanently set at the Factory AFTER FIRST MONTH S SERVICE Proceed as follows 1 Operate drive until old sump oil reaches normal operating temperature Shut the drive down and drain immediately 2 Immediately flush drive with an oil of the same type and viscosity grade as the original charge warmed to approximately 100 F 38 C in cold weather Rapidly pour or pump a charge equal to 25 100 of the initial fill volume through the drive or until clean oil flows through the drain 3 Close the drain and refill the drive to the correct level with new or reclaimed oil of the correct type and viscosity If determined to be in good condition by the supplier reclaimed oil may be reused if it is filtered through a 40 micron or finer filter PERIODICALLY Carefully check the oil level of the drive
9. a good name in industry RAM Mixer Drives Installation and Maintenance Instructions Types MDX MDXQ MDXT MDH amp MDHQ e Sizes 300 thru 900 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 s anaana aana Pages 1 thru 3 Shaft G nnectionsc s csse Pad ES Pages 3 amp 4 Tightening lorques i 52i RIXA E Page 4 Lubrication Recommendations Pages 4 thru 8 Preventive Maintenance llle Page 8 Stored amp Inactive Gear Drives 205 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 Operate Falk gear drives only at horsepower speed and ratio shown on nameplate Before changing any one of these submit co
10. al steel mounting pads into the mounting base as illustrated rather than grouting the drive directly into the concrete FOUNDATION STEEL 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 illustrated Refer to Fastener Tightening Torques on Page 4 GEAR DRIVE ALIGNMENT Align 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 moke 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 Falk mounted on a bedplate the components were accurately aligned at Falk 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 L
11. co Inc ecol R amp O Oil 100 Dectol R amp O Oil 150 ectol R amp O Oil 220 ecol R amp O Oil 320 Dectol R amp O Oil 460 xxon Company U S A Teresstic 100 Teresstic 150 Teresstic 220 Teresstic 320 Teresstic 460 Houghton International Inc Hydro Drive HP 500 Hydro Drive HP 750 Hydro Drive HP1000 uuu osse mperial Oil Ltd Teresso 100 Teresso 150 Teresso 220 ereso320 Kendall Refining Co Kenoil R amp O AW 100 FourSeasonsAW150 fe fee Keystone Lubricants KLC 30 KLC 40 KESO 777 qp Eee o d ome yondell Petrochemical ARCO uro 100 Duro 150 uro 220 uo3200 aa Mobil Oil Corp TE Oil Heavy DTE Oil Extra Heavy TE Oil BB TE Oil AA DTE Oil HH etro Conada Products Harmony 100 Harmony 150 or 150D Harmony 220 Hamoy320 hillips 66 Co Magnus Oil 100 Magnus Oil 150 Magnus Oil 220 Magnus 01320 Shell Oil Co Morlina 100 Morlina 150 Morlina 220 Morlina 320 Morlina 460 Shell Canada Limited Tellus 100 Tellus 150 Tellus 220 Tellus320 Texaco Lubricants egal Oil R amp O 100 Regal Oil R amp O 150 egal Oil R amp O 220 egal Oil R amp O 320 Regal Oil R amp O 460 Unocal 76 East Unax RX 100 Unax RX 150 Unax RX 220 Unax AW320 Turbine Oil 460 Unocal 76 West Turbine Oil 100 Turbine Oil 150 Turbine Oil 220 Turbine Oil 320 Turbine Oil 460 Valvoline Oil Co Valvoline AW ISO 100 Valvoline AW ISO 150 Valvoline AW ISO 220 ValvolineAWISO320 308 050 The Falk Corporation P O Box 492 Zip 53201 0492 March 1995 3001
12. eveling Surface 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 HORIZONTAL OUTPUT SHAFT When the drive is mounted for horizontal output the torque reaction can be transmitted through the adapter base pedestal tie rod or a combination thereof The Falk tie rod may be mounted above or below the drive and its angular position may vary as shown For other positions refer to the factory If it is necessary to shorten the tie rod cut off the excess from either threaded end The support to which the clevis bracket is to be fastened must sustain the torque reaction shown in Table 2 Use Grade 5 fasteners to anchor the clevis bracket tighten to torques specified in Fastener Tightening Torques on Page 4 Bolt the tie rod to both the clevis bracket and the drive anchor bracket and tighten bolts until seated against the brackets DO NOT bend the brackets Clearance between the clevis brackets and tie rod is required 308 050 March 1995 Supersedes 9 90 The Falk Corporation P O Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com a good name in industry RAM Mixer Drives Installation and Maintenance Instructions Types MDX MDXQ MDXT MDH amp M
13. haft deflection Refer to the Factory for pinion alignment instructions Fastener Tightening Torques Use the tightening torque values specified in Table 4 for fastening Falk gear drives motors keeper plates and accessories to their mounting surfaces with non lubricated fasteners DO NOT use these values for torque locking fasteners or for fastening components with aluminum feet or with soft gaskets or vibration dampers on the mounting surface If the tightening torque exceeds the capacity of the torque wrench use a torque multiplier Use Grade 5 fasteners for diameters through 1 50 for larger diameter fasteners use ASTM A 354 Grade BC TABLE 4 Tightening Torques Ib in 5 DO NOT Lubricate Fasteners Metal to Concrete Thread Metal to Thread Dia UNC Concrete Dia UNC Lubrication Recommendations Carefully follow lubrication instructions on the gear drive nameplate warning tags and installation manuals furnished with the gear drive Lubricants listed in this manual are typical ONLY and should not be construed as exclusive recommendations Industrial type petroleum based rust and oxidation inhibited R amp O gear lubricants or industrial type sulfur phosphorus extreme pressure EP gear lubricants are the recommended lubricants for ambient temperatures of 15 F to 125 F 9 C to 52 C For drives operating outside the above temperature range refer to Synthetic Lubricants paragrap
14. hs Page 5 Synthetic lubricants can also be used in normal climates VISCOSITY IMPORTANT The proper grade for R amp O and EP lubricants is found in Table 5 For cold climate conditions refer to Table 8 Page 6 and the Synthetic Lubricant paragraphs Select a lubricant which has a pour point at least 10 F 5 5 C below the expected minimum ambient starting temperature Usable temperature ranges can sometimes be widened if specific application conditions are known If a gear drive operates in a typical indoor environment where the ambient temperature is within 70 F to 125 F 21 C to 52 C the oil viscosity should be increased one AGMA grade above that shown for the 50 F to 125 F 10 C to 52 C range That is an AGMA Number 6 or 7 should be substituted for a 5 or 6 respectively under this ambient condition TABLE 5 Viscosity Grade Recommendations for R amp O or EP Lubricants Normal Climates 15 to 60 F 50 to 125 F Output RPM 9 to 16 C 10 to 52 C ISO VG AGMA ISO VG AGMA Output RPM Below 80 150 4 320 6 Output RPM 80 amp Above 150 4 220 5 308 050 March 1995 Supersedes 9 90 The Falk Corporation P O Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com a good name in industry RAM Mixer Drives Installation and Maintenance Instruct
15. ication Systems SPLASH LUBRICATED UNITS Standard MDX drives are splash lubricated The lubricant is picked up by the revolving elements and distributed to all bearings except the L S shaft bearings and gear meshes UNITS WITH WATER COOLED HEAT EXCHANGERS Install a shut off or control valve in the water line TO the heat exchanger to regulate the water flow through the exchanger Also install a water flow gauge between the control valve and the exchanger to determine actual flow rate Discharge water to an OPEN DRAIN to prevent back pressure If drive is equipped with an external pump check immediately after starting to see that pump is circulating oil properly NON STANDARD MOUNTING For drives with non standard mounting including tilted refer to instructions provided with the drive for oil levels and bearing lubrication Bearing amp Seal Greases All MDX drives have one or two grease lubricated low speed shaft bearings and all drives have a grease purged high speed shaft oil seal All MDXT drives have four grease lubricated low speed shaft bearings 2 drive 2 output shaft the drive upper low speed grease fitting is accessed by removal of the labeled inspection cover Whenever changing oil in the drive regrease bearings and seal with one of the NLGI 2 greases listed in Table 10 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 US
16. ions Petroleum Based Lubricants R amp O GEAR LUBRICANTS Table 9 Industrial type petroleum based rust and oxidation inhibited R amp O gear lubricants are the most common and readily available general purpose gear lubricants EXTREME PRESSURE EP LUBRICANTS Table 7 For highly loaded gear drives or drives loaded in excess of original estimates industrial type petroleum extreme pressure lubricants are preferred The EP lubricants currently recommended are of the sulphur phosphorus type WARNING FP LUBRICANTS IN FOOD PROCESSING INDUSTRY EP 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 Synthetic Lubricants Synthetic lubricants of the polyalphaolefin type are recommended for cold climate operation high temperature applications extended temperature range all season operation and or extended lubricant change intervals The proper viscosity grade of synthetic lubricant is given in Table 8 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 Oil Levels Fill
17. lephone 414 352 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com 308 050 March 1995 Supersedes 9 90 Page 6 of 8 Installation and Maintenance Instructions e RAM Mixer Drives Sizes 300 thru 900 Types MDX MDXQ MDXT MDH amp MDHQ a good name in industry TABLE 7 Extreme Pressure Lubricants Maximum Operating Temperature TABLE 8 Polyalphaolefin Type Synthetic Lubricants 200 F 93 C AGMA Viscosity Grade es 2 4 5 Manufacturer Lubricant ISO Viscosity Grade 32 68 150 220 i TEN cSt 40 C 28 8 35 2 61 2 74 8 135 165 198 242 M ee B iscoslly SU 100 F 135 164 284 347 626 765 918 1122 Chevron U S A Inc Gear Compounds EP Ambient Temperature 30 to 10 F 15 to 50 F 0 to 80 F 4 10 to 125 F Citgo Petroleum Corp Citgo EP Compound Range t 3 to 12 C 26 to 10 C 18 to 27 C 12 to 52 C Conoco Inc Gear Oil Manufacturer Lubricant Exxon Co U S A Spartan E E F Houghton amp Co MP Gear Oil Chevron USA Inc Ad Imperial Oil Ltd Spartan E Tegra 220 Kendall Refining Co Kendall NS MP Conoco Inc Syncon 32 Syncon 68 e e Keystone Div Pennwalt Corp Keygear ALIN ALIN ALIN ALIN Lyondell Petrochemical ARCO Pennant NL 0 Ls d i e p M k mat Mobil Oil Corp Mobilgear CPI Engineering Petro Canada Products Ultima EP Services Inc CP 4630 CP 4630 CP 4630
18. mplete nameplate data and new application conditions to the Factory for correct oil level parts and application approval DISASSEMBLY amp ASSEMBLY Disassembly amp assembly instructions and parts guides are available from the Factory or 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 The Falk Corporation the Company warrants that for a period of one year 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 Installation Instructions The following instructions apply to all standard Falk Type MDX and MDH gear drives If a drive is
19. nds largely upon how well the coupling is installed and serviced Refer to the coupling manufacturer s 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 CAUTION DO NOT HAMMER Ns ee a FALK COUPLINGS Except fluid type Detailed installation manuals are available from the Factory your local Falk Representative or Distributor just provide size and type designations stamped on the coupling For lubricant requirements and a list of typical lubricants meeting Falk specifications refer to appropriate coupling service manual FLANGED TYPE RIGID COUPLINGS are typically used on drives with vertical output shafts The low speed shaft extension ends of the solid shaft drives are drilled and tapped to accommodate coupling keeper plates Tightening torques for fasteners including keeper plate fasteners are listed in Table 3 TABLE 3 Rigid Coupling Selection amp Keeper Plate Fastener Data Rigid Coupling Flange Keeper Plate Fastener Data t Drive C gie Fastener i oupling Tighteni Ize Size H ightening Size Bolt Circle Torque Ih in 300 1020682 900 500 13 UNC 2 00 400 1025682 1800 500 13 UNC 2 50
20. remium RB Grease Unocal 76 East amp West Unoba EP2 Valvoline Oil Co Multilube Lithium EP Grease High performance synthetic alternate TABLE 11 L S Shaft Bearing Regreasing Capacity Ounces t Drive Bearing Solid Shaft Hollow MDXT Size Location Ext Down Ext Up Shaft Stub Shaft 3 3 3 2 Upper 300 el 3 3t 3 2 3 3 3 2 Upper 400 ower 3 5i 3 2 4 4 4 3 Upper 500 ower 3 5t 3 3 4 4 4 4 Upper 600 DUET 3 6t 3 4 6 6 6 6 Upper 700 ower 5 t 5 5 12 12 12 12 Upper 800 Tel 10 6t 10 8 12 12 12 12 Upper 900 ower 10 6t 10 8 t The quantities of grease in ounces listed in the table are for relubrication of the bearings which have been originally packed with grease in assembly and are an approximate guide The actual requirements are dependent upon load speed and operating conditions and can only be determined from experience of the equipment operator t These bearings are normally oil lubricated Quantity listed is for grease lubrication option grease is recommended Remove pressure relief plugs while regreasing MDXT output shaft bearings then replace The MDXT drive upper low speed shaft bearing grease fitting is accessed by removing the upper bearing cage inspection cover Before installing a drive note the location of all of the bearing grease fittings and grease labels for future maintenance reference Note that some fittings may be ABOVE the oil level line and o
21. right and also at 90 intervals Tighten foundation bolts of the connected equipment and recheck alignment and gap The Steelfex coupling STEELFLEX ILLUSTRATED at the upper end of the MDXT output shaft is self aligning and is lubricated with LTG Long Term Grease at the Factory SPROCKETS PULLEYS OR SHEAVES Mount power take offs as close to the gear drive housing as possible to avoid undue bearing load and shaft deflection Align the output shaft of the gear drive square and parallel with the driven shatt by placing a straightedge across the face of the sprockets or sheaves as illustrated Check horizontal shaft RIGHT WRONG alignment by placing one xp qe im leg of a square against bx 7 the face of the sheave or GEAR DRIVE WALL sprocket with the spirit level on the horizontal leg of the square LEVEL SQUARE AND PARALLEL DO NOT over tighten belts or chains Adjust chains to manufacturers specifications Adjust belts as follows The ideal tension is the lowest tension at which the belt will not slip under peak load conditions Check the belt tension frequently during the first 24 to 48 hours of run in operation Over tightening belts shortens belt and bearing life Keep belts free from foreign material which may cause slippage Inspect the V belt periodically tighten the belts if they are slipping PINION MOUNTING Mount pinion as close to the drive as possible to avoid undue bearing load and s
22. specifications given in this manual Periodically inspect stored or inactive gear drives and spray or add rust inhibitor every six months or more often if necessary Indoor dry storage is recommended Gear drives ordered for extended storage can be treated at the Factory with a special preservative and sealed to rust proof paris for periods longer than those cited previously The vent cap and vented dipstick should be replaced with a plug vented dipstick and vent cap assembly should be attached to gear drive for future use so that the protective rust inhibiting atmosphere is sealed inside the drive Install vent cap and vented dipstick when preparing drive for operation Motorstor VCI 10 Add to Stored or Inactive Units Unit Size Motorstor Ounces Per Unit 300 amp 400 1 500 amp 600 2 700 3 800 amp 900 5 Product of Daubert Chemical Company Chicago IL Formerly known as Nucle Cil 308 050 March 1995 Supersedes 9 90 The Falk Corporation P O Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com
23. ta UnitSize Quantity Fastener Size Bolt Circle Kogistor n Thad Doth 300 8 500 13 UNC 11 50 8 500 Dn 400 8 625 1 UNC 12 00 9 500 90 500 12 625 11 UNC 13 00 10 250 90 600 12 625 11 UNC 15 00 11 500 1 12 700 12 750 10 UNC 17 00 13 000 1 12 800 12 875 9 UNC 20 00 15 000 1 12 900 12 875 9 UNC 20 00 15 000 1 12 WELDING Do not weld on the gear drive or accessories without prior approval from The Falk Corporation 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 If the gear drive operates in the sun at ambient temperatures over 1 OO F 38 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 FOUNDATION GENERAL To facilitate oil drainage elevate the gear drive foundation above the surrounding floor level If desired replace the drive oil drain plug with a valve but provide a guard to protect the valve from accidental opening or breakage 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 structur
24. the drive with oil to the level indicated on the oil level dipstick Approximate oil capacities for ordering oil are listed in Table 6 Before starting if conditions permit rotate the input shaft by hand to check for any obstruction Then start the drive and allow it to run without a load for several minutes Shut down and recheck oil level Add oil to compensate for cooler filter etc oil capacities If everything is satisfactory the drive is ready for operation TABLE 6 Approximate Oil Capacity Gallons Type MDH Type Figure 1 Figure 2 Double Triple amp Quad All Reductions Drive Size Types MDX MDXQ MDXT MDH amp MDHQ Sizes 300 thru 900 Page 5 of 8 MDH N LN Z1 FIGURE 1 FIGURE 2 H S SHAFT ABOVE L S L S SHAFT ABOVE H S SHAFT CENTERLINE SHAFT CENTERLINE OIL FILL VENTED DIPSTICK L S BEARING MDX GREASE FITTINGS OIL DRAIN NOTE OIL FILL AND DIPSTICK POSITIONS REVERSED ON SIZES 800 amp 900 MDH DRAIN PLUG REDUCER LS SHAFT BEARING GREASE INSIDE INSPECTION COVER OUTPUT STUB SHAFT BEARING GREASE GREASE lt FITTING UPPER BEARING CAGE VENTED DIPSTICK MDXT REDUCER LS SHAFT BEARING GREASE OUTPUT STUB SHAFT BEARING GREASE IL DRAIN ore Fd GREASE VENT PLUG INSPECTION HOLE OUTPUT STUB SHAFT The Falk Corporation PO Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Te
25. thers BELOW If a grease fitting will become inaccessible atter the drive is installed replace the fitting with a pipe extension and the fitting so that the grease fitting will be in an accessible location after the drive is installed The Falk Corporation PO Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 352 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com 308 050 March 1995 Supersedes 9 90 Installation and Maintenance Instructions e RAM Mixer Drives Sizes 300 thru 900 e Types MDX MDXQ MDXT MDH amp MDHQ Page 8 of 8 a good name in industry RO FOR GREASING ap Boh GREASE LUBRICATED SEALS Most gear drives are furnished with grease purged seals on the H S shaft which minimize the entry of contaminants and abrasive dusts into the drive or backstop Gear drives are shipped with NLGI 2 grease in the seal housing cavities unless otherwise specified If grease could contaminate the product as in the food and drug industries it should be removed A grease that meets USDA H1 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 through the seal WITH A HAND GREASE
26. when it is stopped and at ambient temperature add oil if needed If the oil level is ABOVE the high level mark on the dipstick have the oil analyzed for water content Moisture in the oil may indicate that the heat exchanger or a seal is leaking If so replace the defective part immediately and change the oil DO NOT fill above mark indicated as leakage or undue heating may result Also check coupling alignment to make certain that foundation settling has not caused excessive misalignment If drive is equipped with a fan periodically clean accumulated foreign matter from the fan fan guard and deflector to allow adequate air flow LUBRICANT CHANGES Refer to Page 7 BEARING amp SEAL GREASES Refer to Page 7 Stored amp Inactive Gear Drives Each gear drive is protected with rust preventive that will protect parts against rust for a period of 4 months in an outdoor shelter or 12 months in a dry building after shipment from the Factory If a gear drive is to be stored or is inactive after installation beyond the above periods drain oil from housing and spray all internal parts with a rust preventive oil that is soluble in lubricating oil or add Motorstor vapor phase rust inhibitor at the rate of one ounce per cubic foot of internal drive space or 596 of sump capacity and rotate the shafts several times by hand Before operating drives which have been stored or inactive must be filled to the proper level with oil meeting the
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