FALK Ultramite UB Installation & Maintenance Instructions Manual

®
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

Drive Assembly Instructions . . . . . . . . . . . . . . . . . . Page 2
Fastener Tightening Torques . . . . . . . . . . . . . . . . . Page 5
Shaft Connections . . . . . . . . . . . . . . . . . . . . . . . . Page 5
Retaining Methods for Shaft Mounted Drives . . . . . Page 6
Installation & Removal of TA Taper Bushing . . . . . . . . Page 6
Installation & Removal of Shrink Discs. . . . . . . . . . Pages 7-8
Lubrication Recommendations
Extreme Pressure (EP) Lubricants . . . . . . . . . . . . . . Page 8
Oil Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
Mounting Positions . . . . . . . . . . . . . . . . . . . . . . . Page 10
Lubricant Changes . . . . . . . . . . . . . . . . . . . . . . . Page 11
Preventive Maintenance . . . . . . . . . . . . . . . . . . . Page 11
Bearing Greases . . . . . . . . . . . . . . . . . . . . . . . . Page 11
Stored and Inactive Gear Drives . . . . . . . . . . . . . Page 12
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 lubrication at prescribed intervals. 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 and in the mounting
position for which it was ordered. Before changing any one of
these, submit complete nameplate data and new application
conditions to the Factory for correct oil level, parts and
application approval.
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.
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
Ultramite ®
Type UB
. . . . . . . . . . . . . . . Page 8
Installation & Maintenance Instructions
•
Sizes 03 thru 12
•
TYPE UB
General Information
The following instructions apply to standard Falk Type UB drives
shown above. If a drive is furnished with special features, refer to
the supplementary instructions shipped with the drive.
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 100°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, refer to Falk.
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, 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.
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 may become
misaligned during shipment.
ALWAYS check alignment
after installation.
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 make
certain that all pads are supported to prevent distortion of
housing when drive is bolted down. After drive is aligned with
driven equipment and bolted down, align prime mover to drive
input shaft. Refer to Pages 5 and 6
Check high speed shaft coupling alignment. If the coupling is
misaligned, the drive is shimmed incorrectly. Re-shim drive and
recheck high speed coupling alignment. If necessary, realign
motor.
(Page 1 of 12)
for coupling alignment.
288-400
November 2002
Supersedes 10-98