Rexnord Falk Drive One DH, Falk Drive One DB, Falk Drive One DV, Falk Drive One DX Owner's Manual

Falk™ Drive One® Enclosed Gear Drives • Owners Manual

Type D Series • Sizes M1130 thru M1210 (Page 1 of 27)

How to Use This Manual

This manual provides detailed instructions on installation
and maintenance of parallel shaft Type DH, DV and right
angle Type DB, DX gear drives. Use the table of contents
below to locate required information.

CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND
TROUBLE-FREE SERVICE OF YOUR FALK GEAR
DRIVE.

Table of Contents

Installation Instructions.......................... 1-5

Shaft Connections ...............................5

Tightening Torques...............................6

Lubrication Recommendations.................... 6-9

Preventive Maintenance ........................ 9-10

Stored and Inactive Gear Drives ...................11

APPENDIX

Appendix A: Adjustable Torque Arm Installation ...........13

Appendix B: Rod End Adj. Torque Arm Installation ...... 14-15

Appendix C: Swing Base Installation ....................16

Appendix D: Alignment Free Assembly & Installation..... 17-20

Appendix E: Electric Fan Installation & Maintenance ..... 21-22

Appendix F: Cooling Tubes Installation & Maintenance... 23-25

Appendix G: Thrust Plate & Fastener Usage ..............26

Appendix H: Directions For Inverting Drives DH2 & DB3 .....27

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 power,
speed and ratio shown on the nameplate. Before changing
any one of these, submit complete nameplate data and
new application conditions to the Factory for correct oil
level, parts, and application approval.

DISASSEMBLY AND ASSEMBLY — Disassembly &
assembly instructions and parts guides are available from
the Factory or Rexnord 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

Rexnord Industries, LLC (the ”Company”) warrants that
Drive One gear drives (I) conform to Company’s published
specifications, and (II) are free from defects of material for
three years from the date of shipment.

Company does not warrant any non-Company branded
products or components (manufacturer’s warranty applies)
or 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 installation environment; (III) use for purposes other

Type DH

Type DV Type DX

Type DB

than those for which designed, or other abuse or misuse;
(IV) unauthorized attachments, modifications or disassembly,
or (V) mishandling during shipping.

Installation Instructions

The following instructions apply to standard Falk Type DH,
DB, DV & DX drives. 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 Factory. Welding on the
drive may cause distortion of the housing or damage to the
bearings and gear teeth. Welding without prior approval
could void the warranty.

NOTE: Drives equipped with cooling fans may require
removal of shroud when installing foundation fasteners.

EFFECTS OF SOLAR ENERGY — If the gear drive
operates in the sun at ambient temperatures over 38°C
(100°F), 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.

MOUNTING POSITION — Standard mounting positions
for types DH & DB are with the input and output shafts
horizontal and for DV & DX with the output shafts vertical

Allowable mounting angles for standard oil levels are:
Bridge Slope
DH & DB 0° Up & 4° Down ± 1.5°
Consult the Factory for other angles.
If a gear drive is ordered for non-standard mounting

positions, refer to the instructions provided with the drive
for oil levels and bearing lubrication. If it is necessary to
mount the gear drive in a different position from which it
was ordered, refer to the Factory for required changes to
provide proper lubrication.

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.

When an outboard bearing is used, mount drive and
outboard bearing on a continuous foundation or bedplate,
and dowel both in place.

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Telephone: [phone] Fax: [phone] January 2019
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Owners Manual • Falk™ Drive One® Enclosed Gear Drives

(Page 2 of 27) Type D Series • Sizes M1130 thru M1210

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.

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.

Gear Drive Alignment

FOOT-MOUNTED DRIVES – Align drive with driven
equipment by placing broad, flat shims under all mounting
pads. Jack screw holes are provided by mounting feet to
facilitate alignment. See Table 12, page 10 for fastener
and wrench sizes. Start at the low-speed shaft end and
level across the length and then the width of the drive.
Check with a feeler gauge to make certain that all pads are
supported to prevent distortion of housing when drive is
bolted down. After drive is aligned with driven equipment
and bolted down, align prime mover to drive input shaft.
Refer to page 5 for coupling alignment.

JACKING
SCREW HOLES

LIFTING HOLES
2 PER CORNER
(16 TOTAL)

CONTINUOUS PLATE

DIPSTICK/VENT
HOLES

Shaft-Mounted Drives – General

Shaft-mounted drives should never be mounted in a
manner that restricts the natural movement of the drive.
They should be allowed to move freely with the shaft on
which it is mounted. Shaft-mounted drives should always
be used in conjunction with a torque reaction arm. Refer
to Appendixes A, B or C for torque reaction arm mounting
instructions and angular limits. The drive may require
repositioning on the driven shaft after initial installation to
accommodate the location of the foundation anchor and
be within limits specified in Appendix A (fixed torque arm)
or Appendix B (adjustable torque arm).

The tapered bore hollow shaft is designed for use with a TA
Taper® bushing for mounting the drive on a driven shaft
with a straight outside diameter. The taper bushing
assembly is supplied with a thrust plate kit and retention
fastener as standard (usage is optional, shaft cover must
be removed to install thrust plate kit). Refer to data sheet
supplied with the tapered bushing assembly for driven
shaft length, shaft keyway length and driven shaft tapped
hole dimensions if the thrust plate kit with retention
fastener is to be used.

Prior to installing the drive, it is a good idea to check
the driven shaft for proper dimensions. Using Table
1 or 1A, find the driven shaft size for the application.
Verify that dimensions A and B are within the allowable
range. When dimensions are verified, proceed with the
installation. The minimum and maximum driven shaft
engagements, dimension N in Figure 1, are shown in
Table 2. The minimum engagement is necessary for full
bushing engagement, and the maximum (and specified)
engagement is provided for use when the thrust plate kit is
used for added retention capacity and an auxiliary removal
aid (bushing nut normally used for both).

SHIMS

LEVELING
REFERENCE
SURFACES

DRAIN
PLUG

JACKING
SCREW HOLES

If equipment is received from the Factory mounted on
a bedplate, the components were accurately aligned at
the Factory with the bedplate mounted on a large, flat
assembly plate. Shim under the bedplate foot pads until
the gear drive is level and all feet are in the same plane.

Check high-speed shaft coupling alignment. If the
coupling is misaligned, the bedplate is shimmed
incorrectly. Re-shim bedplate and recheck high-speed
coupling alignment. If necessary, realign motor.

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
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(PN 2124650)

Figure 1

KEEP CLOSE

THRUST
PLATE
BORE

INPUT
SHAFT

SHEAVE

N

KEEP CLOSE

BUSHING NUT

DRIVEN SHAFT

BEARING
SUPPORT

Falk™ Drive One® Enclosed Gear Drives • Owners Manual

Type D Series • Sizes M1130 thru M1210 (Page 3 of 27)

Table 1 — Driven Shaft Dimensions – mm

Drive

Size

M1130

M1140

M1150

M1160

M1170

M1180

M1190

M1200

M1210

Shaft Diameter

Tolerance h10

Nominal + – Min Max Min Max

90 0.0 0.140 99.314 99.774 89.860 90.000
85 0.0 0.140 96.814 97.274 84.860 85.000
80 0.0 0.120 94.334 94.774 79.880 80.000
75 0.0 0.120 91.834 92.274 74.880 75.000

100 0.0 0.140 114.362 114.812 99.860 100.000

95 0.0 0.140 111.862 112.312 94.860 95.000
90 0.0 0.140 96.550 97.000 89.860 90.000

120 0.0 0.140 134.334 134.784 119.860 120.000
115 0.0 0.140 131.834 132.284 114.860 115.000
110 0.0 0.140 129.334 129.784 109.860 110.000

135 0.0 0.160 146.674 147.264 134.840 135.000
130 0.0 0.160 144.314 144.784 129.840 130.000
125 0.0 0.160 141.814 142.284 124.840 125.000
120 0.0 0.160 139.334 139.784 119.860 120.000

150 0.0 0.160 164.193 164.773 149.840 150.000
140 0.0 0.160 159.193 159.773 139.840 140.000
130 0.0 0.160 154.293 154.773 129.840 130.000

170 0.0 0.160 184.173 184.763 169.840 170.000
160 0.0 0.160 179.113 179.733 159.840 160.000
150 0.0 0.160 174.113 174.733 149.840 150.000

185 0.0 0.160 201.698 202.303 184.815 185.000
175 0.0 0.160 196.723 197.303 174.840 175.000
170 0.0 0.160 194.223 194.803 169.840 170.000
160 0.0 0.160 189.223 189.803 159.840 160.000

200 0.0 0.185 226.087 226.732 199.815 200.000
190 0.0 0.185 221.087 221.732 189.815 190.000

200 0.0 0.185 226.087 226.732 199.815 200.000
190 0.0 0.185 221.087 221.732 189.815 190.000

A B

Table 1A — Driven Shaft Dimensions – Inches

Drive

Size

M1130

M1140

M1150

M1160

M1170

M1180

M1190

M1200

M1210

Shaft Diameter

Tolerance per AGMA 6109

Nominal + – Min Max Min Max

3.4375 0.0 0.006 3.8580 3.8770 3.4315 3.4375

3.4875 0.0 0.006 3.7331 3.7521 3.1815 3.1875

2.9375 0.0 0.006 3.6081 3.6271 2.9315 2.9375

4.1875 0.0 0.007 4.6278 4.6478 4.1805 4.1875

3.9375 0.0 0.006 4.5028 4.5218 3.9315 3.9375

3.4375 0.0 0.006 4.2528 4.2718 3.4315 3.4375

4.4375 0.0 0.007 5.1450 5.1650 4.4305 4.4375

4.1875 0.0 0.007 5.0200 5.0400 4.1805 4.1875

3.9375 0.0 0.006 4.8950 4.9140 3.9315 3.9375

4.9375 0.0 0.007 5.5920 5.6120 4.9305 4.9375

4.4375 0.0 0.007 5.3420 5.3620 4.4305 4.4375

5.9375 0.0 0.007 6.4855 6.5055 5.9305 5.9375

5.4375 0.0 0.007 6.2349 6.2549 5.4305 5.4375

4.9375 0.0 0.007 5.9856 6.0056 4.9305 4.9375

6.5000 0.0 0.008 7.1590 7.1800 6.4920 6.5000

6.0000 0.0 0.007 6.9106 6.9306 5.9930 6.0000

5.9375 0.0 0.007 6.8794 6.8994 5.9305 5.9375

7.0000 0.0 0.008 7.8045 7.8255 6.9920 7.0000

6.9375 0.0 0.008 7.7725 7.7935 6.9295 6.9375

6.5000 0.0 0.008 7.5539 7.5749 6.4920 6.5000

6.0000 0.0 0.007 7.3055 7.3255 5.9930 6.0000

5.9375 0.0 0.007 7.2743 7.2943 5.9305 5.9375

8.000 0.0 0.008 9.2224 9.2434 7.9920 8.0000

7.500 0.0 0.008 8.8478 8.8688 7.4920 7.5000

8.000 0.0 0.008 9.2224 9.2434 7.9920 8.0000

7.500 0.0 0.008 8.8478 8.8688 7.4920 7.5000

A B

Table 2 — N Dimension

Drive

Size

M1130 285 (11.2) 340 (13.4)
M1140 300 (11.8) 390 (15.4)
M1150 310 (12.2) 410 (15.7)

M1160 330 (13.0) 450 (17.7)
M1170 340 (13.4) 435 (17.1)
M1180 380 (15.0) 515 (20.3)

M1190 395 (15.6) 545 (21.5)
M1200 423 (16.78) 425 (16.84)
M1210 423 (16.78) 425 (16.84)

† The minimum engagement is necessary for full bushing engagement;

the maximum engagement is only if a thrust plate will be employed to
remove the drive from the driven shaft. Shaft engagements include
5 mm (.20 inch) clearance at the bushing nut.

†

Minimum

mm (Inches)

Maximum

mm (Inches)

TAPER BUSHING — With the driven shaft keyway at the
12 o’clock position, slide bushing assembly onto the driven
shaft, nut end first, and position the keyway slot over the
shaft keyway. The bushing may have to be opened slightly
to assist in installation. Insert a screwdriver into the slot
in the bushing and very lightly pry open until the bushing
slides onto the shaft. Insert the drive key furnished with
the bushing into the shaft keyway. On drives using the
thrust plate kit, slide the bushing assembly onto the driven
shaft until final position (end of driven shaft open ended
keyway).

Installation of Shaft-Mounted Drives
Sizes M1130 - M1190

1. On drives using the thrust plate kit, remove the hollow
low speed shaft cover. Before lifting the drive into
position, rotate the high-speed shaft until the hollow
shaft keyway will be in position to line-up with the driven
shaft key.

2. Lift the drive into position and slide onto the driven
shaft taking care that the driven shaft key seats into the
hollow shaft keyway. DO NOT hammer or use excessive
force.

3. Thread the bushing nut onto the hollow shaft one to two
turns.

NOTE: The bushing nut threads have been coated with
an anti-seize compound at the Factory. This compound
should not be removed. Before re-installing a previously
used nut, recoat the nut threads only with an anti-seize
compound.

NOTE: In extremely severe or corrosive environments,
additonal anti-seize compound MUST be applied to the
threads of the TA bushing nut.

WARNING: DO NOT apply anti-seize or lubricant
to bushing or shaft surfaces. Use of anti-seize may
prevent secure connection of the drive to the shaft and
cause the drive to move.

See Table 12 for nut setscrew and wrench sizes.
a. PREFERRED METHOD — Use a spanner, chain

or pipe wrench to tighten the bushing nut to the

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Owners Manual • Falk™ Drive One® Enclosed Gear Drives

DO NOT apply ANTI-SEIZE

(Page 4 of 27) Type D Series • Sizes M1130 thru M1210

on these areas.

Table 3 — Wrench Type and Bushing Nut

Tightening Torque

Drive

Size

M1130 81858 474B 380 (280)
M1140 81858 474B 450 (332)
M1150 81858 474B 450 (332)

M1160 92685
M1170 92685
M1180 92685
M1190 92685

★ These are chain wrenches where standard spanner wrenches are not available.

GearWrench Williams

Ridgid Tool Williams

Wrenches

«
«
«
«

CT-15
CT-15
CT-15
CT-15

«
«
«
«

Table 3A — Equivalent Tightening Torque

Drive

Size

M1130 380 (280) 80-100 (180-220) 460-610 (1.5-2)
M1140 450 (332) 80-100 (180-220) 610-915 (2-3)
M1150 450 (332) 80-100 (180-220) 610-915 (2-3)

M1160 520 (384) 80-100 (180-220) 610-915 (2-3)
M1170 630 (465) 80-100 (180-220) 915-1220 (3-4)
M1180 770 (568) 80-100 (180-220) 915-1220 (3-4)
M1190 900 (664) 80-100 (180-220) 1220-1525 (4-5)

‡ If a torque wrench is not available, the torque can be approximated by

applying the given weight at the given distance from the nut.

b. OPTIONAL TA BUSHING NUT TIGHTENING —

Required Torque

Nm (lb-ft)

Person’s Weight

kg (lbs)

torque value indicated in Table 3. If the required
torque cannot be measured, an approximation can
be made using Table 3A. The full weight should be
applied to the wrench handle in a horizontal position.
For example, to achieve the required tightening
torque for an M1180 bushing nut a 85 kg person
would have to apply all of his/her weight to a wrench
handle 950 mm from the nut, (a 190 lb. person
would have to apply all his/her weight to a wrench
handle 3 feet from the nut). Apply Loctite® 243 or
equivalent to threads of the setscrew. Tighten the
setscrew to 10 Nm (90 lb-in). For drives subjected to
vibratory conditions, refer to Step c.

When the required tightening torque of the TA
bushing nut can not be measured at the low-speed
shaft, the torque-multiplying characteristic of the
drive can be utilized. Rotating the high-speed
shaft of the drive while holding the TA bushing nut
stationary will allow a large torque to be reached. Fix
the TA bushing nut by securing a spanner, chain or
pipe wrench to the nut. Allow the wrench to contact
a surface that will hold the force when tightening.

WARNING: Make sure the wrench will not slip and
cause damage or injury.

Determine the proper rotation of the high-speed
shaft to achieve tightening of the stationary nut. If
the drive is equipped with a backstop, verify that
the backstop will allow the necessary rotation, or
remove the backstop. Find the torque to apply to the

Nut

Tightening Torque

Nm (lb-ft)

520 (384)
630 (465)
770 (568)
900 (664)

‡

Length of Handle

mm (ft)

high-speed shaft by dividing the tightening torque
indicated in Table 3 by the drive’s ratio (Torque ÷
Ratio). Apply the calculated torque to the high­speed shaft or coupling using a spanner, chain or
pipe wrench. Be careful not to damage the usable
length of the high-speed shaft. Remove the fixed
wrench from the TA bushing nut and reassemble the
backstop if necessary.

WARNING: Never use the prime mover to produce
the required torque. This could result in severe
personal injury or damage.

Apply Loctite 243 or equivalent to threads of
setscrew. Tighten the setscrew to 10 Nm (90 lb-in)
on the bushing nut. For drives subjected to vibratory
conditions refer to Step c.

c. DRIVES SUBJECTED TO VIBRATORY

CONDITIONS — Extra precautions should be
taken for drives subjected to vibratory conditions.
With the nut of the TA bushing tightened to the
specified torque, locate the setscrew hole in the
nut of the bushing assembly. Using a 6 mm (15/64
inch) diameter drill, create a dimple in the outside
diameter of the bushing flange by drilling through
the setscrew hole in the nut. Apply Loctite 243 or
equivalent to threads of setscrew and tighten into
bushing nut.

d. DRIVES USING THRUST PLATE KIT — Install

thrust plate and thrust plate retaining ring in hollow
shaft. Coat four to five engaging threads of retention
fastener with Loctite 222 or equivalent (low-strength)
thread locking compound and thread into driven
shaft end until snug tight. Reinstall shaft cover.

Removal of Shaft-Mounted Drives
Sizes M1130 - M1190

WARNING: Lock out power source and remove all external
loads from drive before servicing drive or accessories.

1. Drain the lubricant from the drive.

2. Remove safety guards and belts (if so equipped).

Remove hollow shaft cover if thrust plate kit is used.

3. Remove motor and motor mount (if so equipped).

4. Remove backstop (if so equipped).

WARNING: Drive must be supported during removal
process. Use a sling and take up the slack before
proceeding.

5. Remove the setscrew(s) on the bushing nut, which

is located at the output end of the hollow shaft. On
drives using the thrust plate kit, remove the driven shaft
retention fastener.

6. Use a spanner, pipe or chain wrench to loosen

the bushing nut. Initially the nut will freely rotate
counterclockwise approximately 180° as the nut moves
from the locked position to the removal position. At this
point, anticipate resistance which indicates unseating
of the bushing. Continue to rotate the nut until it is free
from the hollow shaft. If unable to release the drive from
the driven shaft with the bushing nut, the thrust plate
kit using a backing bolt (threaded into the driven shaft
tapped hole) and removal bolt (threaded into the thrust
plate tapped hole) may be used to release the drive
from the driven shaft. Refer to Appendix G for backing
and removal bolt sizes (user supplied). To use, remove

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
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(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Owners Manual

Type D Series • Sizes M1130 thru M1210 (Page 5 of 27)

thrust plate retaining ring and thrust plate, install backing
bolt, and reinstall thrust plate with retaining ring. Remove
bushing nut retaining ring. Install removal bolt in thrust
plate and tighten against backing bolt to release drive
from driven shaft (insert screwdriver in thrust plate key
slot to engage hollow shaft keyway to prevent thrust plate
rotation while tightening removal bolt).

7. Prepare drive for lifting by disconnecting the torque arm.

8. Slide the drive from the bushing. The bushing can be
left in place or removed as required. If bushing will not
slide off the shaft, insert a small prybar into the split of
the bushing and pry the split open slightly to loosen the
bushing and remove from the shaft.

Bushing

Size

190-200 mm M30 x 3.5 x 200 mm 1355 (1000) M24 x 3 x 45 mm

7.50-8.00 inch 1.500-6UNC x 7.50 inch 1125 (830) 1.250-7UNC x 3.00 inch

Removal Bolt Size &

Minimum Length

Max Tightening

Torque

Nm (lb-ft)

Backing Bolt Size

& Max Length

Taper Bushing – Sizes M1200 & M1210

Driven shafts are retained on M1200 & M1210 drives with
a thrust plate and three cap screw arrangement. With
the driven shaft keyway at the 12 o’clock position, slide
bushing onto the driven shaft, flange end first, and position
the keyway slot over the shaft keyway. The bushing may
have to be opened slightly to assist in installation. Insert a
screwdriver into the slot in the bushing and very lightly pry
open until the bushing slides onto the shaft. Insert the drive
key furnished with the bushing into the shaft keyway.

Installation of Shaft-Mounted Drives
Sizes M1200 M1210

1. Before lifting the drive into position, rotate the high­speed shaft until the hollow shaft keyway will be in
position to line-up with the driven shaft key.

2. Lift the drive into position and slide onto the drive shaft
taking care that the driven shaft key seats into the hollow
shaft keyway. DO NOT hammer or use excessive force.

3. Align three holes in hollow shaft thrust plate with tapped
holes in end of driven shaft. Insert fasteners through
thrust plate and engage tapped holes in driven shaft
one to two turns by hand to ensure that fasteners are
not cross-threaded.

4. Tighten fasteners to the torque vales (± 10%) listed below:
M24 x 3 – 640 Nm (470 lb-ft) for metric-based bushing

bores.

1.250-7UNC – 1400 Nm (1060 lb-ft) for inch-based
bushing bores.

5. Re-install low-speed shaft cover.

Removal of Shaft-Mounted Drives
Sizes M1200 & M1210

1. Remove low-speed shaft cover.

2. Remove three thrust plate fasteners, retaining ring and
thrust plate from the hollow shaft.

3. Select the backing bolts from the table above and install
them into the three threaded holes in the end of the
driven shaft. The head of the backing bolts provides a
working surface for the removal bolts.

4. Re-insert the thrust plate and retaining ring into the hollow
shaft and select the removal bolts from the table above.

5. Thread three removal bolts into the thrust plate until they
contact the backing bolt heads.

6. Tighten the removal bolts equally in stages to the torque
indicated in the table above. After torquing the bolts, as
instructed, strike the bolts sharpy with a hammer and re­torque the bolts if separation of the drive from the driven
shaft did not occur. Repeat this procedure, re-torquing
the bolts after each blow, until separation occurs.

7. Prepare drive for lifting by disconnecting the torque arm.

8. Slide the drive from the bushing. The bushing can be
left in place or removed as required. If bushing will not
slide off the shaft, insert a small prybar into the split of
the bushing and pry the split open slightly to loosen the
bushing and remove from the shaft.

Shaft Connections

WARNING: Provide suitable guards in accordance with
local and national standards.

COUPLING CONNECTIONS — The performance and
life of any coupling depends 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 hubs,
pinions, sprockets or pulleys to
a maximum of 135°C (275°F)
and slide onto gear drive shaft.

INCORRECT METHOD

DO NOT drive coupling hub,
pinion, sprocket or pulley onto
the shaft. An endwise blow

– CAUTION –
DO NOT HAMMER

FALK COUPLINGS — (Except fluid type) Detailed

installation manuals are available from the Factory, your
local Rexnord representative or distributor — just provide
size and type designations stamped on the coupling.
For lubricant requirements and a list of typical lubricants
meeting Rexnord specifications, refer to appropriate
coupling service manual.

FALK FLANGED TYPE RIGID COUPLINGS — These are
typically used on drives with vertical output shafts. The
low-speed shaft extension ends of the solid vertical shaft
drives are drilled and tapped to accommodate coupling
keeper plates. Tightening torques for fastener, including
keeper plate fasteners are listed in Table 4, page 6.

FALK FLUID COUPLINGS — Refer to the installation
manual furnished with the Falk fluid coupling for installation
and startup instructions. For Alignment-Free drives, refer to
Appendix D.

GAP AND 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 at right, and
also at 90° intervals around the hub.
Check with feelers.

on the shaft/coupling may
damage gears and bearings.

Steelflex® Illustrated

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
e-mail: [e-mail] web: www.rexnord.com Supersedes 04-11

(PN 2124650)

Owners Manual • Falk™ Drive One® Enclosed Gear Drives

(Page 6 of 27) Type D Series • Sizes M1130 thru M1210

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.
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 shaft by placing a straightedge across the
face of the sprockets or sheaves as illustrated.
Check horizontal shaft alignment
by placing one leg of a square

RIGHT

WRONG

against the face of the sheave or
sprocket with the spirit level on the
horizontal leg of the square.

GEAR DRIVE WALL

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.

OUTBOARD BEARING — Mount the outboard bearing and
gear drive on a common foundation so that they will shift
as an assembly if settling should occur. Bring the outboard
bearing to the correct horizontal position with broad flat
shims under the mounting pad. Align accurately so that
the load is equally divided between the two drive bearings
and the outboard bearing. Mount a stop bar against the
pillow block foot on the load side when large horizontal load
components are exerted on the pillow block.

PINION MOUNTING — Mount pinion as close to the
drive as possible to avoid undue bearing load and shaft
deflection. Refer to the Factory for pinion alignment
instructions.

NON FALK COUPLINGS — Refer to manufacturers’
installation and maintenance instructions.

BACKSTOPS — To prevent damage to backstops due to
incorrect motor shaft rotation at start up, couplings are NOT
assembled when gear drives are furnished with backstops.

After completing electrical connections, check motor and
gear drive shaft rotations. If rotations are correct, complete
alignment and assembly of coupling.

Fastener Tightening Torques

Use the tightening torque values specified in Table 4 for
fastening Falk gear drives, motors and accessories to their
mounting surfaces with un-lubricated fasteners. DO NOT use
these values for “torque locking” fasteners or for fastening
components with aluminum feet or soft gaskets or vibration
dampeners on the mounting surface. If the tightening torque
exceeds the capacity of the torque wrench, use a torque
multiplier. Use ISO property class 8.8 for metric fasteners. See
Table 12 for fastener and wrench size.

Table 4 — Tightening Torques: ±5%

DO NOT Lubricate Fasteners

Metric Fasteners – Property Class 8.8

Fastener

Size

M4 x .7 3 2 2 1.5
M5 x .8 6 5 5 3.5
M6 x 1.0 10 8 8 6
M8 x 1.25 24 18 19 14

M10 x 1.5 50 36 39 29
M12 x 1.75 84 62 68 50
M16 x 2 210 156 170 126
M20 x 2.5 415 305 330 246
M24 x 3 705 530 570 420

M30 x 3.5 1 440 1060 1 150 850
M36 x 4 2 520 1860 2 030 1500
M42 x 4.5 4 050 3000 3 250 2400
M48 x 5 6 100 4500 4 880 3600
M56 x 5.5 9 850 7300 7 860 5800

Metal to Metal Metal to Concrete

Nm lb-ft Nm lb-ft

Water Cooling

WATER COOLED HEAT EXCHANGERS — Install a shut­off 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.

INTERNAL COOLING TUBES — Refer to Appendix E for
installation, operation, and maintenance of internal cooling
tubes.

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 — Types DV and DX
are equipped with an external oil pump to provide oil
to the upper bearings and gear meshes. The system is
composed of an electric motor-driven gear pump and
an internal distribution network with relief valve (set at
30 psi). The pump system may be furnished with a 50 or
60Hz, 3-phase electrical motors based on the selection.
Refer to the pump motor nameplate and Table 5 for
electrical requirements. Wire the motor for correct rotation
as indicated by the rotation arrow. Optional accessories
include an oil filter and flow indicator with switch. The flow
indicator has a single pole, double throw switch rated at
15A, 125V/7A, 250V maximum. Connect the flow indicator
switch with the prime mover control circuitry to prevent
drive operation without the lubrication system.

Other types of gear drives may also be equipped with oil
pumps for special lubrication considerations or external
cooling.

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
Supersedes 04-11 e-mail: [e-mail] web: www.rexnord.com

(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Owners Manual

Type D Series • Sizes M1130 thru M1210 (Page 7 of 27)

Table 5 — Oil Pump Electrical Specifications

Drive Size M1130 Thru M1210

Power 1.12 kw 1.5 hp

Cycles, Hz 50 60

RPM 1425 1750

Voltage 220/380/440 208/230/460

Table 6 — Viscosity Grade

Recommendations for Petroleum –
Based R & O or EP Lubricants

Normal Climates

Output RPM

Output RPM Below 80 150 4 320 6

Output RPM 80 & Above 150 4 220 5

-9° to +16°C

(15° to 60°F)

ISO-VG AGMA ISO-VG AGMA

10° to 52°C

(50° to 125°F)

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 & O) gear lubricants or industrial type sulfur­phosphorus extreme pressure (EP) gear lubricants are the
recommended lubricants for ambient temperatures of -9°C
to +50°C (15°F to 125°F).

For drives operating outside the above temperature range,
refer to “Synthetic Lubricants” paragraphs. Synthetic
lubricants can also be used in normal climates.

Table 8 — Extreme Pressure Lubricants †

(Maximum Operating Temperature
93°C(200°F)

Manufacturer Lubricant

Amoco Oil Co.
BP Oil Co.
Chevron U.S.A. Inc.
Citgo Petroleum Corp.

Conoco Inc.
Exxon Co. U.S.A.
E.F. Houghton & Co.
Imperial Oil Ltd.

Kendall Refining Co.
Keystone Div. Pennwalt Corp.
Lyondell Petrochemical (ARCO)
Mobil Oil Corp.
Petro–Canada Products

Phillips 66 Co.
Shell Oil Co.
Shell Canada Limited
Sun Oil Co.
Texaco Lubricants

Valvoline Oil Co. AGMA EP

† Minimum viscosity index of 90.

VISCOSITY (IMPORTANT) — The proper grade for R &
O and EP lubricants is found in Table 7. For cold climate
conditions refer to Table 9, page 8 and the “Synthetic
Lubricant” paragraphs.

If a gear drive operates in a typical indoor environment
where the ambient temperature is within 21°C to 52°C (70°F
to 125°F), the oil viscosity could be increased one AGMA
grade above that shown for the 10°C to 52°C (50°F to 125°F)
range. That is, an AGMA Number 6 or 7 could be substituted
for a 5 or 6 respectively, under these ambient conditions.

Permagear/Amogear EP
Energear EP
Gear Compounds EP
Citgo EP Compound

Gear Oil
Spartan EP
MP Gear Oil
Spartan EP

Kendall NS-MP
Keygear
Pennant NL
Mobilgear
Ultima EP

Philgear
Omala Oil
Omala Oil
Sunep
Meropa

Table 7 — 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.
BP Oil Co.
Chevron U.S.A., Inc.
Citgo Petroleum Corp.

Conoco Inc.
Exxon Company, U.S.A.
Houghton International, Inc.
Imperial Oil Ltd.

Kendall Refining Co.
Keystone Lubricants
Lyondell Petrochemical (ARCO)
Mobil Oil Corp.
Pennzoil Products company
Petro–Canada Products

Phillips 66 Co.
Shell Oil Co.
Shell Canada Limited
Sun Oil Co.
Texaco Lubricants

Unocal 76 (East)
Unocal 76 (West)
Valvoline Oil Co

† Minimum viscosity index of 90.

Amer.Ind. Oil 150

. . . . .

Machine Oil AW 150
Citgo Pacemaker 150

Dectol R&O Oil 150
Teresstic 150
Hydro–Drive HP 750
Teresso 150

Four Seasons AW 150
KLC–40
Duro 150
DTE Oil Extra Heavy
Pennzbell AW Oil 150
Premium R & O 150

Magnus Oil 150
Morlina 150
Tellus 150
Sunvis 9150
Regal Oil R&O 150

Unax RX 150
Turbine Oil 150
Valvoline AW ISO 150

Amer.Ind. Oil 220
Energol HLP-HD 220
Machine Oil AW 220
Citgo Pacemaker 220

Dectol R&O Oil 220
Teresstic 220
Hydro–Drive HP 1000
Teresso 220

. . . . .

KLC-50
Duro 220
DTE Oil BB
Pennzbell AW Oil 220
Premium R & O 220

Magnus Oil 220
Morlina 220
Tellus 220
Sunvis 9220
Regal Oil R&O 220

Unax RX 220
Turbine Oil 220
Valvoline AW ISO 220

Amer. Ind. Oil 320

. . . . .

Machine Oil AW 320
Citgo Pacemaker 320

Dectol R&O Oil 320
Teresstic 320

. . . . .

Teresso 320

. . . . . .

. . . . .

Duro 32
DTE Oil AA
Pennzbell AW Oil 320
Premium R & O 320

Magnus Oil 320
Morlina 320
Tellus 320

. . . . .

Regal Oil R&O 320

Unax AW 320
Turbine Oil 320
Valvoline AW ISO 320

Amer. Ind. Oil 460

. . . . .

. . . . .

Citgo Pacemaker 460

Dectol R&O Oil 460
Teresstic 460

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

DTE Oil HH
Pennzbell AW Oil 460

. . . . .

. . . . .

Morlina 460

. . . . .

. . . . .

Regal Oil R&O 460

Turbine Oil 460
Turbine Oil 460

. . . . .

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
e-mail: [e-mail] web: www.rexnord.com Supersedes 04-11

(PN 2124650)

Owners Manual • Falk™ Drive One® Enclosed Gear Drives

(Page 8 of 27) Type D Series • Sizes M1130 thru M1210

Table 9 — Viscosity Grade Recommendations for Synthetic Lubricants

«

Cold Climates Normal Climates

Output

RPM

–34° to –12°C

(–30° to +10°F)

–26° to +10°C

(–15° to +50°F)

–18° to +27°C

(0° to +80°F)

–12° to +52°C

(+10° to +125°F)

–7° to +52°C

(+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

★ Refer to the Factory for viscosity recommendations when ambient temperatures are below –34°C (–30°F) or above 52°C (125°F).

OIL PUMPS — When selecting a lubricant for a gear drive
equipped with an oil pump, cold temperature oil viscosity
is important. Lubricant viscosity at start-up generally
should not exceed 1725 cSt (8,000 SSU). When exceeding
this viscosity, pump cavitation is possible, reducing oil
circulation and possibly damaging the pump. A sump
heater may be required or it may be possible to use a
lower viscosity oil to minimize pump cavitation. Refer to the
Factory.

Petroleum-Based Lubricants

R & O GEAR LUBRICANTS (Table 7) — Industrial type

EP LUBRICANTS (Table 8) — For highly loaded gear

drives or drives loaded in excess of original estimates,
industrial-type petroleum EP lubricants are preferred. The
EP lubricants currently recommended are of the sulfur­phosphorus type.

WARNING: EP 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.

petroleum-based rust and oxidation inhibited (R & O) gear
lubricants are the most common and readily available
general purpose gear lubricants.

Table 10 —Synthetic Lubricants – Polyalphaolefin Type

AGMA

Viscosity Grade

ISO

Viscosity Grade

Viscosity

cSt @ 40°C

Viscosity

SSU @ 100°F

Manufacturer Lubricant

Chevron U.S.A., Inc.

Conoco, Inc.

Dryden Oil Co.

Exxon Co. U.S.A.

Mobil Oil Corp.

Pennziol Products Co.

Petro-Canada Products

Phillips 66 Company

Shell Oil Co.

Sun Co.

Texaco Lubricants Co.

Whitmore Mfg. Co.

76 Lubricants Company

★ Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
† Minimum viscosity index of 120.
‡ EP lubricant (contains sulphur phosphorus).

0S 2S 4S 5S 6S 7S

32 68 150 220 320 460

28.8-35.2 61.2-74.8 135-165 198-242 288-352 414-506

134-164 284-347 626-765 918-1122 1335-1632 1919-2346

. . . . . . Clarity Synthetic PM Oil 220 . . . . . .

. . . . . . 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 EP 150

Drydene SHL Lubricant 32 Dr ydene SHL Lubricant 68 Drydene SHL Lubricant 150 Drydene SHL Lubricant 220 Dr ydene 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

. . . . . . 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

. . . . . . Mobilgear SHC 150

Pennzgear SHD 32 Pennzgear SHD 68 Pennzgear SHD 150 Pennzgear SHD 220 Pennzgear SHD 320 Pennzgear SHD 460

. . . Super Maxol “S” 68 ‡Super Maxol “S” 150

. . . . . . Super Gear Fluid 150EP ‡Super Gear Fluid 220EP ‡Super Gear Fluid 320EP ‡Super Gear Fluid 460EP

Syndustrial P Oil 32 . . . . . . . . . . . . . . .

. . . 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

. . . . . . . . . Hyperia S 220

. . . . . . . . . Sunoco Challenge 220 Sunoco Challenge 320 . . .

. . . . . . . . . Sunoco Challenge EP 220 ‡Sunoco Challenge EP 320

Pinnacle 32 Pinnacle 68 Pinnacle 150 Pinnacle 220 Pinnacle 320 Pinnacle 460

. . . . . . Pinnacle EP 150

. . . . . . Decathlon 4EP

. . . . . . 76 Triton Syngear 4EP ‡76 Triton Syngear 5EP

«

†

† ‡

‡

‡

Syncon EP 220

‡

Mobilgear SHC 220

‡

Super Maxol “S” 220 ‡Super Maxol “S” 320

Pinnacle EP 220

Decathlon 5EP

† ‡

‡

‡

‡

‡

‡

. . . Syncon R & O 460

Syncon EP 320

Mobilgear SHC 320

Hyperia S 320

Decathlon 6EP

† ‡

‡

Mobilgear SHC 460

‡

Super Maxol “S” 460

‡

‡

. . . Pinnacle EP 460

‡

. . . 76 Triton Syngear 7EP

Syncon EP 460

Hyperia S 460

. . .

Decathlon 7EP

‡

†

† ‡

‡

‡

‡

‡

‡

‡

‡

‡

‡

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
Supersedes 04-11 e-mail: [e-mail] web: www.rexnord.com

(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Owners Manual

Type D Series • Sizes M1130 thru M1210 (Page 9 of 27)

Table 11 — Greases for Bearings and Seals

–18° to +93°C (0° to 200°F)

Manufacturer Lubricant

Amoco Oil Co.
BP Oil Co.
Chevron U.S.A., Inc.
Citgo Petroleum Corp.

Conoco Inc.
Exxon Company, U.S.A.
E.F. Houghton & Co.
Imperial Oil Ltd.

Kendall Refining Co.
Keystone Div. Pennwalt Corp.
Lyondell Petrochemical (ARCO)
Mobil Oil Corp.
Mobil Oil Corp
Petro–Canada Products

Phillips 66 Co.
Shell Oil Co.
Shell Canada Limited
Sun Oil Co.
Texaco Lubricants

Unocal 76 (East & West)
Valvoline Oil Co.

★ High performance synthetic alternate.

Amolith Grease No. 2
Energrese LS–EP2
Industrial Grease Medium
Premium Lithium Grease No. 2

EP Conolith Grease No. 2
Unirex N2
Cosmolube 2
Unirex N2L

Multi–Purpose Lithium Grease L421
Zeniplex 2
Litholine H EP 2 Grease
Mobilith 22
Mobilith SHC 460 «
Multipurpose EP2

Philube Blue EP
Alvania Grease 2
Alvania Grease 2
Ultra Prestige EP2
Premium RB Grease

Unoba EP2
Multilube Lithium EP Grease

CAUTION: LUBRICANTS & INTERNAL BACKSTOPS —
Do not use lubricants with anti-wear additives or lubricant
formulations including PTFE (Teflon), lead derivatives,
graphite or molybdenum disulfide in drives equipped with
backstops. Some lubricants in Table 8 may contain several
of these additives.

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 9. Refer to Table 10 for Synthetic lubricants.

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.

Bearing and Seal Greases

All drives and some backstops have grease-lubricated
seals. Some vertical shaft and specially mounted drives
have grease-lubricated bearings. Drives are shipped with
NLGI #2 grease in the seal housing cavities unless otherwise
specified. Refer to Table 11 for grease recommendations.

GREASE-LUBRICATED BEARINGS — Vertical shaft
drives with drywells have grease-lubricated lower low­speed bearings. These bearings are lubricated at the
Factory with an NLGI#2 grease. Refer to the preventive
maintenance instructions for greasing instructions.

GREASE-LUBRICATED SEALS — Drive One drives are
furnished with grease purged seals which minimize the
entry of contaminants into the drive. 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.

Oil Levels

TYPES DH & DB — Fill the drive with oil to the level
indicated on the oil dipstick. Approximate oil capacities are
given on the drive nameplate.

The inspection cover is sealed with a non hardening
chemical gasket eliminator. When replacing the inspection
cover, run a bead of Loctite 515 Gasket Eliminator «
(or equivalent) around the perimeter of the inspection
opening, making sure to circle the fastener holes.

★ Product of Henkel Corp., Rocky Hill, CT.

DRIVES WITH OIL PUMPS — Types DV, DX, and
occasionally other types of gear drives will be equipped
with oil pumps for cooling or special lubrication
considerations. If a drive is equipped with an oil pump,
fill the drive to the level marked on the dipstick. Run the
lubrication system for several minutes to fill the system
components. Verify that the pump is circulating oil properly,
then recheck oil level. If necessary, add oil to compensate
for filter and/or cooler.

Before starting the gear drive, rotate the input shaft to
check for obstructions. Then start the drive and allow it
to run without load for several minutes. Shut down and
recheck oil level. If everything is satisfactory, the drive is
ready for operation.

Preventive Maintenance

AFTER FIRST WEEK — Check alignment of 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. See Table 12 for fastener
and wrench sizes.

AFTER FIRST MONTH — Proceed as follows:

1. Operate drive until old sump oil reaches normal
operating temperature. Shut down drive and drain
immediately.

2. Immediately flush drive with an oil of the same type
and viscosity grade as the original charge (warmed to
approximately 38°C (100°F) in cold weather) by rapidly
pouring or pumping a charge equal to 25 - 100% of the
initial fill volume or until clean oil flows through the drain.

3. Close the drain and refill the drive to the correct level
with new oil of the correct type and viscosity.

PERIODICALLY —

1. Check the oil level of the drive when it is stopped and at
ambient temperature. Add oil if needed. If the oil level is
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, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
e-mail: [e-mail] web: www.rexnord.com Supersedes 04-11

(PN 2124650)

Owners Manual • Falk™ Drive One® Enclosed Gear Drives

(Page 10 of 27) Type D Series • Sizes M1130 thru M1210

Table 12 — Fastener & Wrench Sizes

Bushing

Nut

Bushing

Nut

Setscrew

Inspection

Cover

Jackscrews

Magnetic

Drain Plugs

Other Plugs

Torque

Arm

Grease

Purge
Cover

Shaft Fan

Shroud

Shaft Fan
Setscrew

Fastener

Diameter

Circumference

Screw Size M8 M8 M8 M8 M8 M8 M8 . . . . . .

Hex Size 4mm 4mm 4mm 4mm 4mm 4mm 4mm . . . . . .

Screw Size M12 M12 M12 M12 M12 M12 M12 M12 M12

Wrench Size 19mm 19mm 19mm 19mm 19mm 19mm 19mm 19mm 19mm

Screw Size M12 M16 M16 M20 M20 M24 M24 M24 M24

Wrench Size 19mm 24mm 24mm 30mm 30mm 36mm 36mm 36mm 36mm

Plug Size 3/4 BSPT 3/4 BSPT 3/4 BSPT 3/4 BSPT 1.0 BSPT 1.0 BSPT 1.0 BSPT 1.0 BSPT 1.0 BSPT

Wrench Size 14mm 14mm 14mm 14mm 19mm 19mm 19mm 14mm 14mm

Plug Size 3/4 BSPT 3/4 BSPT 3/4 BSPT 3/4 BSPT 1.0 BSPT 1.0 BSPT 1.0 BSPT 1.0 BSPT 1.0 BSPT
Hex Size 12mm 12mm 12mm 12mm 17mm 17mm 17mm 17mm 17mm

Nut Size M30 M30 M36 M36 M36 M36 M48 M48 M48

Wrench Size 46mm 46mm 55mm 55mm 55mm 55mm 75mm 75mm 75mm

Screw Size M6/M8 M6/M8 M6/M8 M6/M8 M6/M8 M8 M8 M8 M8

Wrench Size 10mm/13mm 10mm/13mm 10mm/13mm 10mm/13mm 10mm/13mm 13mm 13mm 13mm 13mm

Screw Size M8 M8 M8 M8 M8 M8 M8 M12 M12

Wrench Size 13mm 13mm 13mm 13mm 13mm 13mm 13mm 18mm 18mm

Screw Size M6/M8 M6/M8 M6/M8 M8 M8 M8 M8 M10 M10

Hex Size 3mm/4mm 3mm/4mm 3mm/4mm 4mm 4mm 4mm 4mm 5mm 5mm

M1130 M1140 M1150 M1160 M1170 M1180 M1190 M1200 M1210

185mm

7.3”

581mm

22.9”

205mm

8.1”

644mm

25.4”

225mm

8.9”

709mm

27.9”

240mm

9.4”

754mm

29.7”

DRIVE SIZE

260mm

10.2”

817mm

32.2”

280mm

11.0”

880mm

34.6”

295mm

11.6”

927mm

36.5”

. . . . . .

. . . . . .

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 500 ppm (0.05%).

2. Iron content exceeds 150 ppm.

3. Silicon (dust/dirt) exceeds 25 ppm.

4. Viscosity changes more than 15%.
PETROLEUM LUBRICANTS — For normal operating

conditions, change gear oils every six months or 2500
operating hours, whichever occurs first. Change oil more
frequently when gear drives operate in extremely humid,
chemical or dust laden atmospheres. In these cases, R
& O and EP lubricants should be changed every 3 to 4
months or 1500 to 2000 hours. If the drive is operated in
an area where the temperatures vary with seasons, change
oil viscosity grade to suit temperature. Lubricant suppliers
can test oil periodically and recommend economical
change intervals.

SYNTHETIC LUBRICANTS — Synthetic lube change
intervals can be extended to 8000 - 10,000 hours
depending upon operating temperatures and lubricant
contamination. Change oil more frequently when gear
drives operate in extremely humid, chemical or dust-laden
atmospheres. In these cases, synthetic lubricants 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 ambient temperature, if required. Refer to Table 9 for
synthetic lubricant viscosity recommendations.

GREASE-LUBRICATED SEALS — Depending on the
frequency and degree of contamination (at least every

six months or when changing oil in the drive), purge
contaminated grease from seals by slowly pumping fresh
grease, WITH A HAND GREASE GUN, through the seal
cavity until fresh grease flows out along the shaft. Wipe
off purged grease. Refer to Table 11 for NLGI #2 greases.
Some of these greases are of the IP type and may contain
toxic substances not allowed in the food processing
industry. A grease that meets the USDA “H1” classification
is suitable for food processing applications.

CAUTION: Rapid greasing with a power grease gun can
force grease inward past the seals causing seal leaks.

GREASE LUBRICATED BEARINGS (TYPES DV AND DX)
— Most vertical low-speed shaft drives have a grease­lubricated lower low-speed bearing. Grease bearings
during oil changes or at intervals of every 6 months or
2500 hours of operation whichever is less.

VERTICAL SHAFT DRIVES — Remove the pressure relief
plug before greasing. Pump grease into bearing cage until
fresh grease appears at the plug. Replace the pressure
relief plug when finished. See figure below.

Refer to Table 11 for NLGI #2 greases. Some of these
greases are of the EP type and may contain toxic
substances not allowed in the food processing industry. A
grease that meets the USDA “H1” classification is suitable
for food processing applications.

M

Q

L

Q

M

EE

BEARING
GREASE
FITTING

RELIEF
PLUG

CC

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
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(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Owners Manual

Type D Series • Sizes M1130 thru M1210 (Page 11 of 27)

Stored & Inactive Gear Drives

Each gear drive is protected with a rust preventative 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 preventative oil that is
soluble in lubricating oil or add Motorstor™ vapor phase
rust inhibitor at the rate of 1.05 liters per cubic meter (one
ounce per cubic foot) of internal drive space (5% of sump
capacity). Refer to Table 13 for Motorstor quantities. 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 specifications given in
this manual. Refer to Manual 128-014 for “Start-up after
Storage” instructions.

Table 13 — Motorstor/VCI–10

(Add to stored or inactive drives)

DRIVE SIZE

M1130 45 1.5
M1140 & M1150 60 2
M1160 & M1170 120 4
M1180 & M1190 180 6
M1200 & M1210 235 10

★ Product of Daubert Chemical Company, Chicago, IL.

Milliliters Per Drive Ounces Per Drive

«

Motorstor

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 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 the protective rust inhibiting atmosphere
is sealed inside the drive. Install vented dipstick when
preparing drive for operation.

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
e-mail: [e-mail] web: www.rexnord.com Supersedes 04-11

(PN 2124650)

Owners Manual • Falk™ Drive One® Enclosed Gear Drives

(Page 12 of 27) Type D Series • Sizes M1130 thru M1210

THIS PAGE INTENTIONALLY LEFT BLANK

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
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(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Appendix A

Type D Series • Sizes M1130 thru M1210 (Page 13 of 27)

Adjustable Torque Arm Installation

Introduction

The Drive One adjustable tie rod style torque arm is
available for all shaft-mounted Drive One sizes, parallel
shaft Type DH only. It is used to support the drive when
mounted in a standard horizontal position. Refer to the
Factory for other positions. The torque arm is mounted
directly to the drive with an anchor bracket. The torque
arm requires mounting holes in the driven equipment
support structure to provide for clevis bracket attachment.
The customer is responsible for determining the structural
integrity of their support member.

Mounting

It is natural for the drive system to move during operation.
This movement is due to run out from the driven equipment
shaft and gear drive low-speed shaft. Clearance in the
torque arm assembly will accommodate the motion of the
drive. To allow for the movement, the torque arm should
be centered at its attachment point on the drive system
and also centered in the clevis bracket on the support
member. Over-tightening or failure to center the torque
arm in the mounting will restrict the drive’s motion and will
result in premature failure of the drive or driven equipment.
The torque arm should be perpendicular to the support
structure ± 2° when looking at the end of the drive. See
Figure 1.

ANCHOR
BRACKET

90°±2°

CLEVIS
BRACKET

Figure 1

Installation

1. Position the drive on the driven equipment shaft such
that the torque arm is perpendicular and centered in
the clevis mounted to the supporting structure and at its
attachment point on the drive system. Ideally, the clevis
bracket should be added to the structure after the drive
has been secured to the driven equipment.

NOTE: Do not fasten the torque to the support structure
at this time.

2. Secure the drive to the driven equipment via the TA
bushing or rigid coupling connection.

3. Check that the torque arm remains perpendicular and
centered in the clevis if mounted. If the torque arm is
not perpendicular and centered, reposition the drive on
the driven equipment shaft. If the clevis bracket is not
mounted, position and mount at this time.

3°

HIGH-SPEED SHAFT

3°

Figure 2

CLEVIS BRACKET

ANCHOR
BRACKET

TORQUE ARM
ASSEMBLY

30° MAX

30° MAX

4. The exact position of the torque arm may vary within
the range shown in Figure 2. For torque arm mountings
other than shown, refer to the Factory. If it is necessary
to shorten the torque arm assembly, cut the excess from
either tie rod end on Sizes M1130 through M1190 only.

Table 1 — Load Reaction Through Tie Rod

‡

Drive

Size

M1130 42700 9600
M1140 54500 12300
M1150 69500 15600

M1160 92300 20800
M1170 126000 25300
M1180 130000 29200

M1190 160200 36000
M1200 170300 38300
M1210 202900 45600

‡ Load includes moment due to motor and motor mount with torque arm at

maximum angle.

N lb

Load

5. The support to which the clevis bracket is mounted
must sustain the load from the torque reaction shown in
Table 1. The maximum load reaction through the torque
arm occurs when the torque arm is located in the
extreme off angle position. Use Class 8.8 fasteners to
anchor the clevis bracket. Refer to Table 2 for fastener
size and tightening torque.

Table 2 — Tie Rod Clevis Bracket Fastener

Tightening Torque

Drive

Size

M1130-M1140 M20 x 2.5 415 (305) 330 (246)
M1150-M1160 M24 x 3.0 705 (530) 570 (420)
M1170-M1210 M30 X 3.5 1440 (1060) 1150 (850)

† Class 8.8 fasteners required.

Fastener

†

Size

6. Bolt the torque arm to both the clevis bracket and the
drive anchor bracket and tighten the bolts until seated
against the brackets. DO NOT bend the bracket as
clearance between the clevis brackets and tie rod is
necessary.

Tightening Torque - Nm (lb-ft)

Steel Foundation Concrete Foundation

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
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(PN 2124650)

Appendix B • Falk™ Drive One® Enclosed Gear Drives

(Page 14 of 27) Type D Series • Sizes M1130 thru M1210

Rod End Adjustable Torque Arm Installation

Introduction

The Drive One rod end type adjustable torque arm is
available for all shaft-mounted Drive One sizes, both
parallel shaft Type DH and right angle Type DB. It is
used to support the drive when mounted in a standard
horizontal position; other positions may be available
(consult Factory). The torque arm accessory is suitable
for use on swing bases, bedplates, or mounted directly
to the drive. Three styles of rod end torque arms are
available: (1) Standard style for swingbase or bedplate
mounting, (2) Clevis style for mounting directly to the drive
foot, (3) Turnbuckle style for greater length and adjustment.
The torque arm requires mounting holes in the driven
equipment support structure to provide for attachment.
The customer is responsible for determining the structural
integrity of their support member.

Mounting

It is natural for the drive system to move during operation.
This movement is due to runout from the driven equipment
shaft, gear drive low-speed shaft and the connection of
the two. Rod ends containing plain spherical bearings
form a link to provide a resilient mounting support
that accommodates the motion of the drive. To allow
for maximum movement, the torque arm must be
perpendicular to the supports and rod ends centered
in the mounting anchor bracket. Restricting the drive’s
motion in any way may result in premature failure of the
drive or driven equipment.

Installaton

1. Position the drive on the driven equipment shaft such
that the torque arm link is centered in the anchor
bracket. Ideally, the anchor bracket mounting holes
should be added to the structure after the drive has
been secured to the driven equipment.

NOTE: Do not fasten the torque arm to the support
structure at this time.

2. Secure the drive to the driven equipment via the TA
Bushing, shrink disc or rigid coupling connection.

3. Mount the anchor bracket or clevis to the drive or drive
system if not already done. Locate the position of the
anchor bracket to be mounted to the support structure.
Match drill the mounting holes for M20 Cl. 8.8 or 0.75
inch Grade 5 fasteners or better. Lock washers and flat
washers are also required.

NOTE: Torque arm must be vertical (± 1°) in both
directions after installation.

4. (IF REQUIRED) Assemble rod end components to create
a link. A combination of male/female rod ends, clevis/
male rod end or turnbuckle/male rod ends are required
dependent on torque arm style. All styles require jam
nuts to lock linkage. Refer to Figures 1 thru 3.

NOTE: Rod ends must be assembled such that the
relative position of one rod end head to the other is
parallel. Loosen locknut and adjust if necessary. See
Figure 4.

5. For Standard and Turnbuckle style torque arm, install
pin through one lug of anchor bracket mounted to drive.
Position spacer, then rod end and finally second spacer
on pin. Finish positioning pin within anchor bracket.
Install retaining ring to secure the pin. See Figure 1
or 3. For Clevis style torque arm, install crowned pin
through clevis and drive foot. Secure pin with retaining
ring. See Figure 2.

6. Install pin in anchor bracket mounted to supporting
structure with spacers in a 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.

7. If the drive system is not horizontal, the rod end linkage
can be adjusted (within the limits indicated in the
catalog or certified print) to level the drive.

8. Verify the torque arm link is centered in the anchor
bracket and is not restricting motion of the drive.

9. Some rod ends may be provided with grease fittings
for lubricating. Grease rod end at every scheduled
maintenance or at least every six months. See Table 11
for approved greases.

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
Supersedes 04-11 e-mail: [e-mail] web: www.rexnord.com

(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Appendix B

Type D Series • Sizes M1130 thru M1210 (Page 15 of 27)

Figure 1

Figure 3

ANCHOR
BRACKET

RETAINING
RING

SPACER

SPACER

RETAINING
RING

ANCHOR
BRACKET

ANCHOR
BRACKET

RETAINING
RING

SPACER

ROD END

MOUNTING HARDWARE
(PROVIDED)

TORQUE
ARM PIN

ROD END
(MALE)

JAM NUT

ROD END
(FEMALE)

TORQUE
ARM PIN

MOUNTING HARDWARE
(SUPPLIED BY CUSTOMER)

MOUNTING HARDWARE
(PROVIDED)

TORQUE
ARM PIN

JAM NUT

TURNBUCKLE

Figure 2

Figure 4

RETAINING

RING

JAM NUT

SPACER

RETAINING
RING

MOUNTING HARDWARE

(SUPPLIED BY CUSTOMER)

ROD END

HEAD

JAM NUT

CROWNED

TORQUE

ARM PIN

CLEVIS

ROD END

TORQUE

ARM PIN

ANCHOR
BRACKET

ROD END
SPACER

RETAINING
RING

ANCHOR
BRACKET

JAM NUT

TORQUE
ARM PIN

MOUNTING HARDWARE
(SUPPLIED BY CUSTOMER)

CORRECT
LINK ASSEMBLY ­ROD END HEADS

PARALLEL

ROD END

HEAD

INCORRECT
LINK ASSEMBLY ­ROD END HEADS

NOT PARALLEL

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
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(PN 2124650)

Appendix C • Falk™ Drive One® Enclosed Gear Drives

(Page 16 of 27) Type D Series • Sizes M1130 thru M1210

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 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 not
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.

STEP
BLOCK

MOTOR PLATE

TORQUE ARM
CONNECTION LUG

TUBE
SECTION

GUSSET

DRIVE PLATE

Supporting the Swing Base

The torque arm connection lug prevents the swing base
from lying flat on the ground; therefore, a supporting
structure is required for mounting the gear drive and motor
to the swing base. This structure is typically built from
wood and is unique to each swing base. All gussets have
a 19 mm (0.75 inch) diameter hole for securing the swing
base to the supporting structure.

WOODEN SUPPORTING

STRUCTURE

Mounting Gear Drive to Swing Base

It is Rexnord’s 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 drive
housing to aid in fixing the shims. Begin at the low-speed
shaft end and level across the length and then the width of
the gear drive. Use a feeler gauge to ensure that all pads
are supported. Bolt down the drive to the torque specified
in Table 4, page 6.

Mounting Motor and Coupling Alignment

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 4, page 6.

Coupling Guard

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.

Lifting the Swing Base Assembly

After the drive, motor, and coupling have been mounted
to the swing base, the completed assembly can be lifted
into position for installation on the driven shaft. The motor
eyebolt and the lifting holes on the drive housing can
be used as cable attachment points. The motor eyebolt
is strongest when the cable pull is vertical. To ensure
that cable pull on the motor eyebolt is vertical, use of a
spreader bar is recommended. See the sketch below. To
ensure safety, chains or a sling should be placed behind
the torque arm connection.

SPREADER BAR

VERTICAL
CABLE PULL

LOCATE SAFETY
CHAINS/SLING HERE

Mounting Swing Base Assembly to Driven
Equipment

Mount the gear drive to the driven shaft (see page

3). Secure the torque arm to the foundation per the
instructions in Appendix A.

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
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(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Appendix D

Type D Series • Sizes M1130 thru M1210 (Page 17 of 27)

Alignment-Free Assembly and Installation – Welded Design

Introduction

The Alignment-Free drive design consists of a shaft­mounted drive, bell housing, motor adapter plate, torque
arm, motor and coupling. When assembled, the bell
housing, motor adapter, and motor locate off registers,
resulting in alignment of the motor and gear drive shafts.
Therefore, no additional alignment is required for the high­speed coupling.

Assembly Instructions

The bell housing is fastened to the drive’s high-speed end
using cap screws through the four mounting holes on that
face (see Table 1 for size and torque). The bell housing will
locate on the bevel head of the drive. Read instructions
provided with high-speed coupling prior to assembly.

Table 1 — Tightening Torques

Drive

Size

M1150 M24 725 535
M1160 M24 725 535
M1170 M30 1450 1070

M1180 M30 1450 1070
M1190 M36 2530 1866
M1200 M36 2530 1866
M1210 M36 2530 1866

Bolt
Size

Tightening Torque

N-m lb-ft

Fluid Coupling

Location of the fluid coupling on the high-speed shaft of
the drive is determined by the provided shaft spacer. Install
the fluid coupling on the high-speed shaft of the gear drive
per fluid coupling instructions. If a shaft fan is required,
remove every other of the twelve delay fill chamber
fasteners. Install the fan adapter ring to the fluid coupling
using the long socket head cap screws provided. Place a
mounting post between the delay fill chamber flange and
the adapter ring as shown in Figure 1. After all fasteners
and mounting posts are installed, tighten cap screws to
the torque specified in Table 2. Install the six fan segments
to the outer bolt circle of the adapter ring. See Table 2 for
tightening torque.

Figure 1

FAN

ADAPTER

RING

LONG

CAP SCREW

Once the fluid coupling is installed, the motor adapter plate
can be mounted to the bell housing, also being located
by a register. Measurements must be taken to accurately
position the motor half of the coupling hub on the motor

FAN

SEGMENT

MOUNTING

POST

DRIVE

Table 2 — Fan Mounting Tightening Torques

Fastener
Location

1420HFDD M12 80 59
1480HFDD M12 80 59
1584HFDD M14 130 96

Fan Segment M8 20 15

‡

Fan Hub

‡ For close coupling only.

Fastener

Size

M6 10 7.5

shaft. First, measure the distance from the motor mounting
face to the end of the motor shaft (A). Then measure the
distance from the motor adapter plate face to the hub on
the fluid coupling (B). 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.

Tightening Torque

Nm ft-lb

Table 3 — Coupling Gap

Fluid Coupling

Size

370HFDD 200 6.5 0.256
1420HFDD 230 7.5 0.295
1480HFDD 260 7.5 0.295
1584HFDD 300 8.4 0.331
1660HFDD 360 9.0 0.354

Calculate the hub protrusion:
Protrusion = (A + Gap) – (B + C)
If the calculated protrusion is a negative value, the hub

overhangs the shaft by that amount (Figure 2).

MOTOR

Figure 2

Once the hub is correctly located on the motor shaft, the
motor can be mounted to the motor adapter plate. The
hubs will be aligned and come together to the proper gap.
To fill the fluid coupling to the proper oil level, align the
mark on the perimeter of the fluid coupling with the mark
in the center of the inspection window on the bell housing
on the side opposite the TA bushing nut or shaft extension.
To locate the correct mark on the fluid coupling, begin by
aligning the fill hole of the fluid 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.

MOTOR

MOUNTING

FACE

COUPLING

C

A

Tschan Hub

Size

HUBS

PROTRUSION

MOTOR

ADAPTER

PLATE

B

mm Inch

BELL

HOUSING

DRIVE

SHAFT
SPACER

Gap

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
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(PN 2124650)

Appendix D • Falk™ Drive One® Enclosed Gear Drives

(Page 18 of 27) Type D Series • Sizes M1130 thru M1210

Close Coupling

If the drive requires a shaft fan, mount the fan hub on
the high-speed shaft of the gear drive. See Figure 3. See
Table 4 for shaft protrusion based on drive size. Apply
Loctite 242 or equivalent to hub setscrews and tighten into
hub. Mount the fan adapter ring to the fan hub. Install six
fan segments to the outer bolt circle on the adapter ring
to complete the fan. See Table 2 for fastener tightening
torque.

Figure 3

FAN

SEGMENT

FAN

ADAPTER

RING

SHAFT

PROTRUSION

FAN
HUB

DRIVE

Table 4 — Fan Hub Location

Drive

Size

M1150 105 4.13
M1160 110 4.33
M1170 115 4.53

M1180 125 4.92
M1190 130 5.12
M1200 178 7.01
M1210 178 7.01

Mount the motor to the motor adapter plate on the bell
housing before installing the coupling. Once the motor is
secured, measure the distance (D) between the end of
the motor shaft and the high-speed shaft of the drive. See
Figure 4. Subtract the distance (D) from the length of the
spacer coupling (BE). Then divide this value in half to find
the overhang of each hub [Overhang + (BE – D)/2]. The
overhang will be negative. 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.

Shaft Protrusion

mm

Inch

MOTOR

Figure 4

MOTOR

ADAPTER

PLATE

ONERHANG

BELL

HOUSING

D

DRIVE

ONERHANG

Lifting the Alignment Free Drive

Lifting points are provided on the corners of the motor
side of the bell housing. See Figure 5. Lift by these and
the provisions provided on the drive housing itself to
maneuver the drive. DO NOT lift by the motor lifting eye.

LIFT POINTS

Figure 5

Mounting the Drive

Mount the Alignment-Free drive to the driven equipment
per Page 3. The torque arm must be located on the TA
bushing nut side (hollow shaft) or the extension side (solid
shaft) of the drive at the foot as shown in Figure 6. Connect
the torque arm to the foundation per the torque arm
installation instructions.

TA BUSHING
NUT SIDE OR
EXTENSION SIDE

Figure 6

TORQUE ARM LOCATON AT
DRIVE FOOT ON BUSHING
NUT SIDE OR EXTENSION SIDE

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
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(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Appendix D

Type D Series • Sizes M1130 thru M1210 (Page 19 of 27)

Alignment-Free Assembly and Installation – Cast Design

Introduction

The Alignment-Free drive design consists of a shaft­mounted gear drive, bell housing, torque arm, motor and
coupling. When assembled, the gear drive, bell housing
and motor locate off registers, resulting in alignment of the
shafts. Therefore, no additional alignment is required for
the high-speed coupling.

Assembly Instructions

The bell housing is fastened to the gear drive’s high-speed
end using capscrews through the four mounting holes on
that face with a nut and lock washer (see Table 1 for size
and torque). Apply Loctite #242 or equivalent to mounting
fastener threads. The bell housing will locate on the bevel
head of the gear drive. Read instructions provided with
high-speed coupling prior to assembly.

Table 1 — Tightening Torques

Drive

Size

M1140 M24 780 570
M1150 M24 780 570
M1160 M24 780 570
M1170 M30 1540 1140

M1180 M30 1540 1140
M1190 M36 2720 2000
M1200 M36 2720 2000
M1210 M36 2720 2000

Bolt
Size

Tightening Torque

Nm lb-ft

FAN HUB
POSITION

SET SCREW

Figure 1

to be notched to allow clearance for the bell housing to
drive mounting fasteners. Rotate fan to ensure clearance,
and reposition fan hub if necessary. Split fan guard may
be removed or installed without disrupting high-speed
coupling. See Figure 2.

MOUNTING RAILS

FAN GUARD

FAN

FAN HUB

MOUNTING PLATE

FAN COWLING WITH
EXPANDED METAL

High-Speed Shaft Fan

High-speed shaft fan is standard on all Drive One
Alignment-Free drives. Fan size and position is dependent
on bell housing casting and high-speed coupling, not
drive size. Assemble fan to fan hub, apply Loctite #242 or
equivalent to fastener threads and tighten.

CAUTION: Do not over-tighten fasteners into plastic fan as
fan may crack.

Mount the fan hub on the gear drive high-speed shaft
such that the set screw hole in the hub is towards the end
of the shaft. Locate the hub axially at the values listed in
Table 2. Dimensions listed are from the inside face of the

Table 2 — Fan Hub Location

Coupling Size

1420 D011723 130 5.12
1480 D011724 125 4.92
1584 D011725 115 4.53
1660 D011726 142 5.59

Spacer Coupling D011723 130 5.12
Spacer Coupling

✱ Casting number located on inside sidewall of bell housing.

Bell Housing

Casting Number

D011725 115 4.53

✱

bell housing to the far side of the hub. See Figure 1. Apply
Loctite #242 or equivalent to threads of the set screw and
tighten over key to secure hub in position. Fan hub must be
installed prior to installing high-speed coupling hub.

Assemble fan shroud mounting rails to bell housing.
Assemble fan cowling with expanded metal guard to back
of fan shroud/plates on same fasteners. Mount fan shroud
assembly to mounting rails. The cowling may require

Hub Location

mm inch

Figure 2

Fluid Coupling

The fluid coupling can be installed/removed without
removing the motor (see fluid coupling instructions for
procedure). Mount the coupling hubs to the drive high­speed shaft and the motor shaft. Hubs are to be mounted
flush with the end of the shafts (coupling hubs may be
furnished with an interference fit). Mount the motor to the
bell housing, apply Loctite #242 or equivalent fastener
threads and tighten to proper torque. Install fluid coupling
per coupling instructions.

To fill the fluid coupling to the proper oil level, install
the small top cover on the bell housing. Rotate the fluid
coupling such that the fill hole is up and fill with the
approximate quantity of oil (see coupling instructions for oil
type and quantity). Rotate the coupling in either direction
to align the mark on the perimeter of the fluid coupling with
the mark in the center of the cover on the bell housing. A
container should be placed to catch any excess oil that
may spill from the fill hole. If oil drains from the fill hole,
allow all excess to drain to achieve the proper fill level. If
no oil drains when marks are aligned, rotate coupling back
and add more oil. Repeat process until excess oil drains
and proper fill level is achieved.

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
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(PN 2124650)

Appendix D • Falk™ Drive One® Enclosed Gear Drives

(Page 20 of 27) Type D Series • Sizes M1130 thru M1210

Close Coupling

Mount the coupling hubs to the drive high-speed shaft and
motor shaft. Hubs are to be mounted flush with the end of
the shafts unless otherwise noted (coupling hubs may be
furnished with an interference fit). Mount the motor to the
bell housing, apply Loctite #242 or equivalent to fastener
threads and tighten to proper torque. Install high-speed
coupling per coupling instructions.

Guards and Covers

Install bell housing covers (top and bottom). Install air
deflectors on the top, bottom and both sides of the gear
drive. The bends of the deflectors are perforated to allow
positioning of the deflectors. Air deflectors should be
positioned approximately 25 mm (1 inch) from the nearest
housing surface by bending deflector towards or away
from the drive.

Torque Arm

The carriage, adjusting rod, brackets and support bar are
furnished pre-assembled from the Factory. Assemble the
rod ends with heads perpendicular to each other (90°) as
shown in Figure 3. Rod end threads must be engaged a
minimum of one times thread diameter. Attach female rod
end to carriage with pin. Place a spacer on each side of
the rod end. Secure pin with locking plate. Carriage may
be adjusted from center to either far end of the housing

Figure 3

CARRIAGE
PIN

SPACER

SECTON A-A

FEMALE
ROD END

MALE
ROD END

THREADED
ADJUSTING ROD

BRACKET

ADJUSTING
SCREW

LOCKING
PLATE

to facilitate installation of pin. Ensure that adjusting rod
locking plate is NOT installed at this time as it will prevent
adjustment of the torque arm assembly. Assemble anchor
bracket to male rod end with a spacer on each side and
secure with pin and retaining ring.

Lifting the Alignment-Free Drive

Lifting points are provided on the corners of the motor
end of the bell housing. See Figure 4. Lift by these and the
provisions provided on the drive housing itself to maneuver
the drive. DO NOT lift by the motor lifting eye.

Mounting the Drive

Mount the Alignment-Free drive to the driven equipment
per Pages 2 and 3 of this manual. With Alignment-Free
drive assembly supported, rotate adjusting screw to
move torque arm to desired position and to line up with
foundation. Torque Arm must be perpendicular in both
directions (± 1°). Adjust screw if not. Install locking plate
to lock the adjusting screw (plate can be installed on either
side). Remove support from drive and secure anchor
bracket to foundation. Use M24 Class 8.8 (1 inch Grade

5) or better fasteners with lock and flat washers to mount
anchor bracket. Slots are provided such that torque arm
can be mounted perpendicular.

CAUTION: Do NOT adjust torque arm screw after support
is removed and torque arm is under any load.

CARRIAGE

MOUNTING
HARDWARE
(SUPPLIED BY
CUSTOMER)

JAM NUT

PIN

A

A

PIN LOCKING
PLATE

BRACKET

SUPPORT BAR

RETAINING
RING

SPACER

ANCHOR
BRACKET

Figure 4

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January 2019 Telephone: [phone] Fax: [phone]
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(PN 2124650)

LIFT POINTS

Falk™ Drive One® Enclosed Gear Drives • Appendix E

Type D Series • Sizes M1130 thru M1210 (Page 21 of 27)

Electric Fan Installation & Maintenance

Installation

The installation and troubleshooting of electric cooling fans
are to be carried out by a qualified electrician according
to the applicable local, state, province and federal codes.
Inspect for any damage that may have occurred during
transit. Check all bolts, screws, set screws, etc. Retighten
as required. Before installing, rotate the blade to be sure it
does not rub. Adjust if necessary. Before installation, read
the entire manual carefully.

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

Warning: To reduce the risk of fire, electric shock, or
personal injury, observe the following:

1. Use this electric fan only in the manner intended by
the manufacturer. If you have any questions, contact
Factory.

2. Before servicing or cleaning the fan, switch the power
off at the service panel and lock out to prevent the
power from being switched on accidentally.

3. Follow all local electrical and safety codes, as well as
the National Electrical Code (NEC) and Occupational
Safety and Health Act (OSHA).

4. Fan motor must be securely and adequately grounded.

5. All working parts should be grounded.

6. When cleaning electrical equipment always use an
approved cleaning agent. See CLEANING in NOTES
section, page 22.

7. For general ventilation and cooling use only. Do not
use if hazardous or explosive materials and vapors are
present.

Guidelines For Installation

Before connecting the electric fan, check if the information
on the fan motor name plate is in accordance with the
actual main supply voltage, phase and frequency.

Warning: To reduce the risk of fire, electric shock, or
personal injury, observe the following:

1. Switch off the main power supply and lock out before
installing, servicing or making connections to the fan.

2. Installation work and electrical wiring must be done by
a 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.

SINGLE PHASE

TYPE - E

CAPACITOR

THERMAL
PROTECTON

SINGLE PHASE

TYPE - D

250V
10A
COS ψ=1

THERMAL
PROTECTION

250V
10A
COS ψ=1

Figure 1

B3

B3

OPTION

B3

B3

OPTION

1 PHASE 220V - 50Hz
1 PHASE 220V - 50Hz

1 PHASE 110V - 60Hz
1 PHASE 220V - 60Hz
1 PHASE 240V - 60Hz

L

3 PHASE

3 PHASE 220/380V - 50Hz
3 PHASE 230/400V - 50Hz
3 PHASE 240/415V - 50Hz

3 PHASE 220/380V - 60Hz
3 PHASE 208/360V - 60Hz
3 PHASE 265/460V - 60Hz

L1

L1

L2

L2

N (L2)

L3

L3

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
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Appendix E • Falk™ Drive One® Enclosed Gear Drives

(Page 22 of 27) Type D Series • Sizes M1130 thru M1210

7. A temperature switch is provided to control oil sump
temperature. See Figure 2 for proposed wiring.
There are 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 motor starter relay
(consult applicable local and national electrical codes).
The high circuit is provided to operate either a high
temperature alarm or main motor shutdown.

PROPOSED TEMPERATURE SWITCH WIRING

L

 AC RATING - INDUCTIVE LOAD - 50% PF
DC RATING - INDUCTIVE LOAD - L/R = 0.26

VOLTS

125
250
480

 MAXIMUM CONTINUOUS CURRENT

∗∗ Reference only.

Figure 2

DIAGRAM FOR ELECTRIC FANS

1

932716 - NEMA 4 & 13

PURPLE

BROWN

CUSTOMER WIRING
AND COMPONENTS

AC

CONTROL VOLTAGE

SWITCH

FALK PART NO.

SET AT 140°F

SET AT 210°F

AMP

15
15
15

DC

VOLTS

6-12 **

24 **
125
250

RED

BLUE

(60°C)

YELLOW

ORANGE

(100°C)

LOW CIRCUIT

START FAN

MS

MOTOR

HIGH CIRCUIT

ALARM OR MAIN MOTOR

CIRCUIT

MS = MOTOR STARTER

AMP

15

5

0.05

0.03

10. Remove proper condensation plug. See Figure 3
below. Do not discard. Plug is to be used during
cleaning.

Mounting Positions

For Position

A & B

Remove Plug 1

POSITION A

L

2

1

For Position

Remove Plug 2

POSITION B

1

C

copper or brass

fastening materials

POSITION C

2

Note: Never use

Figure 3

NOTES:
AIR SUPPLY AND TEMPERATURE — Sufficient air supply

over the motor must be assured in all circumstances.
Limits of operating ambient temperature are 14°F to 113°F
(–10°C to 45°C).

RESTRICTION ON USE — Fan blade material
is Polypropylene which is unsuitable and/or not
recommended for certain chemicals. The following is a
partial list of unsuitable chemicals for guideline purposes.

Chloro-Sulphonic Acid Nitric Acid Chloroform

Mixture of HNO3-HCL Esters 1:2 Trichloroethylene

Mixture of HNO3-H2SO4 Benzene Trichloroethylene

Sulfuric Acid, fuming Gasoline Diethyl Ether

Carbon Tetrachloride Toluene Chlorine, Liquid

Chlorobenzene Xylene

CLEANING — When cleaning fan, both condensation
holes (Figure 3, Items 1 and 2) are to be temporarily
plugged. If this 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.

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
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(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Appendix F

Type D Series • Sizes M1130 thru M1210 (Page 23 of 27)

Internal Cooling Tubes Installation & Maintenance

Cooling Tube Description

The internal cooling tube accessory is a network of finned
cooling tubes. Factory-installed in the base of a drive
housing, for heat removal. The cooling tubes operate
submerged in the oil of the drive sump. The revolving
elements provide the necessary oil flow around the
cooling tubes for efficient heat transfer. No oil pumps are
required. The external requirement for the cooling tube
system is a clean water hookup supplying a flow rate of 2
gallons (8 liters) per minute at a maximum temperature of
90°F (32°C). An inlet water temperature of 70°F (21°C) is
required to obtain the system catalog thermal power rating
with a sump oil temperature of 200°F (93°C).

The number of cooling tubes required varies with drive
size, type and number of reductions. Cooling tubes are
connected in series to maintain the optimum water flow
velocity in the tubes with the specified water flow rate of 2
to 5 gallons (8 to 19 liters) per minute. Note: A typical Falk
PC cooling assembly requires between 2 to 70 gallons (8
to 265 liters) of water per minute, depending upon PC size
and cooling requirements.

All cooling tube system connections are made outside of
the housing to eliminate the possibility of water leakage
into the drive sump. Seal rings are used at all connections
for ease of disassembly and reassembly. The standard
cooling tubes are 90/10 copper nickel alloy with aluminum
fins. Cooling tube connections are cadmium-plated mild
steel with “Buna-N” seal rings.

Water connections are .500”-14 NPT fittings located at
the high-speed end. The water outlet is located on the
high-speed end of the drive. The water inlet connection is
a straight fitting located on the lowest cooling tube in the
drive.

The water outlet connection is a right angle fitting (faced
up) located on the uppermost tube in the drive. The
cooling tube system connections are selected and located
so that the cooling system is always full of water during
operation for maximum heat transfer. The water inlet and
outlet connections may be moved to the opposite end of
the drive by removing the water inlet, outlet and all “loop
end” fitting assemblies and by reinstalling them on the
same tubes at the opposite end of the drive. Refer to the
Maintenance Instructions on page 24 and Figures 7 & 8 on
page 25 for disassembly and reassembly.

Installation & Operation

1. Connect the .500”-14 NPT straight water inlet fitting to
a source of clean, fresh water. Water must be regulated
to a minimum of 2 gallons (8 liters) per minute and must
not exceed 90°F (32°C).

2. Connect the .500”-14 NPT right angle water outlet fitting
(faced up) to an open drain. Do not pressurize the
cooling tube system. The turned up water outlet fitting
ensures that the system is always full of water during
operation.

3. Control water flow rate to between 2 and 5 gallons (8
and 19 liters) per minute to minimize fouling at low flow
rates or tube erosion at high flow rates. The water flow
rate may be reduced to 1 gallon (4 liters) per minute
if clean, fresh (drinking quality) water is used and the
sump oil temperature can be maintained within the
maximum limit of 200°F (93°C).

4. For shutdowns at ambient temperatures less than 32°F
(0°C), drain the cooling tube system by removing the
“loop end” assemblies on the end of the drive opposite
the water inlet. Refer to Figure 8 on page 25 for typical
assemblies and record location of assemblies for
reinstallation purposes.

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
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Appendix F • Falk™ Drive One® Enclosed Gear Drives

(Page 24 of 27) Type D Series • Sizes M1130 thru M1210

Assembly of Seal Ring Fittings

Note: For disassembly of seal ring fittings, reverse the
steps of the following assembly procedure.

1. Figure 1 — Deburr tube end to prevent cutting the
rubber seal ring during assembly.

2. Figure 2 — Slide nut and tapered split ring on tube. The
large end of the tapered split ring must face the fitting
body.

3. Figure 3 — Lubricate the rubber seal ring. Insert the
tube into the fitting body past the rubber seal ring.

4. Figure 4 — Slide the tapered split ring against the
fitting body. Lubricate O.D. of tapered split ring with #2
bearing grease.

5. Figure 5 — Assemble nut to fitting and tighten hand
tight. Turn nut with a wrench one turn or until the
tapered split ring is flush with the end of the nut.

TUBE

Figure 1

DEBURRED END

Figure 2

Figure 3

Figure 4

BODY

RUBBER SEAL RING

BODY

TAPERED
SPLIT RING

TEFLON BACK-UP RING

TAPERED SPLIT RING

NUT

Maintenance Instructions

The cooling tube system is designed to be removed
from the drive housing without disturbing the drive or
its foundation, provided sufficient room is available at
either end of the housing for tube withdrawal. All tube
connections are outside the drive and are of the seal ring
type for ease of maintenance and reusability.

Light coatings of sludge or scale will cause a reduction in
heat transfer capacity of the system. Therefore, periodic
cleaning of the system may be required to restore the heat
transfer capacity.

The cooling tube system may be cleaned by flushing
with commercially available cleaning compounds
such as Oakite or Dowell. The commercially available
cleaning compounds are corrosive and must be used in
accordance with their manufacturer’s recommendations.
Cleaning may also be accomplished by means of a rod or
wire brush. Remove the tube end seal ring fittings (Figures
7 & 8 on page 25) and pass a .500” (12 mm) diameter rod
or wire brush through the tubes to remove the scale. Tube
I.D. is .527” (13.39 mm). After cleaning all tubes, reinstall
the tube end seal ring fittings.

The outside of the cooling tubes (aluminum fins) may
be cleaned by removing the tubes from the housing and
cleaning with steam or a suitable solvent. To remove the
tubes from the housing, remove all seal ring fittings from
the tubes. Remove the 1.250-11 NPT x .750-14 NPT pipe
bushings from one end of the drive. A special deep well,
thin wall socket (1.812 hex by 7” deep) may be required to
remove and reinstall the pipe bushings.

CAUTION: Take care not to damage cooling tube ends
during disassembly, cleaning and reassembly.

Withdraw the tubes from the housing through the 1.250-11
NPT holes using a .375” (10 mm) diameter rod through the
tube as a disassembly and reassembly aid. After cleaning,
reinstall the tubes in the drive. Coat pipe bushing threads
with thread sealant and reinstall the pipe bushings and
tube fittings in the reverse order of disassembly. Install
the loop end assemblies in the same positions as before
disassembly.

See left for seal ring fitting assembly procedures. Seal ring
fittings use standard No. 114 (.625 I.D. x .812 O.D. x .094
W) Buna-N seal rings if replacements are required.

TIGHTEN NUT
UNTIL FLUSH

Figure 5

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Falk™ Drive One® Enclosed Gear Drives • Appendix F

Type D Series • Sizes M1130 thru M1210 (Page 25 of 27)

Accessories

A sump temperature sensing water flow controller and
sump temperature indicator (thermometer) are available
accessories for the internal cooling tube system. It is
recommended that a thermometer be used with a water
flow controller. Additional holes in the housing are required
for these accessories and should be referred to the
Factory at the time of order.

Water Flow Control Valve

A water flow control valve is recommended where the
availability or cost of water is at a premium or where
automatic water shutoff or constant temperature is desired.
The standard water flow control valve is an adjustable,
capillary-type, temperature sensing, flow modulating valve.
The flow control valve should be installed in series with a
ball valve to limit maximum water flow. Refer to Figure 6 for
recommended plumbing diagram. The water flow control
valve will control water flow rates to less than 2 gallons
(8 liters) per minute, however, the cooling tubes will be
subject to increased fouling and may require cleaning at
more frequent intervals.

WATER SUPPLY (2 GPM MIN. [8 LITERS PER MIN.], 90°F [32°C] MAX. TEMP.)

WATER OUTLET
(DISCHARGE INTO
OPEN DRAIN)

Cooling Tube Inlet &
Outlet Connection Assemblies

WATER OUTLET (.500 - 14 NPT)

4

3

4

3

Figure 7

7

WATER INLET (.500 - 14 NPT)

9

Cooling Tube Loop End
Connection Assemblies

TAPERED SPLIT RING
REMOVED FROM NUT

6

2

3

4

1

2

1

2

1

2

BALL VALVE
(ADJUST MAX.
WATER FLOW
RATE WITH FLOW
CONTROL OPEN)

Figure 6

WATER INLET

WATER FLOW CONTROLLER
(WITH SENSOR BULB & CAPILLARY)

FLEXIBLE WATER INLET LINE

THERMOMETER

Thermometer

The standard thermometer is a bimetallic, dial-type
instrument.

2

TAPERED SPLIT RING & NUT
REPLACED WITH JAM NUT

6

8

66

2

Figure 8

3

45

6

2

8

2

 Drive Housing Wall
 Cooling Tube

 Pipe Bushing (1.250 x 7.50)
 Male Connector (Lenz 100-10-12)
 Special “Lenz” Elbow Fitting (Falk Part #1199037)
 Union Elbow (Lenz 500-10)
 Female Elbow (Lenz 450-10)
 Tubing (.625 O.D.)
 Female Connector (Lenz 250-10)

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
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(PN 2124650)

Appendix G • Falk™ Drive One® Enclosed Gear Drives

(Page 26 of 27) Type D Series • Sizes M1130 thru M1210

Thrust Plate & Fastener Usage

Thrust plate usage is optional. To use, remove hollow shaft
cover from gear drive. Slide bushing with shaft key onto
driven shaft near final position (shaft length “N” - 5 mm or

0.20 in.) and slide gear drive onto driven shaft. Tighten

bushing nut to specified torque. Verify location of drive on
driven shaft to be within angular limits of the drive torque
arm. Install thrust plate and thrust plate retaining ring. Coat
four or five engaging threads of the retention fastener with
a low-strength thread locking compound and install snug
tight. Install hollow shaft cover.

Table 1 — Metric & Inch Bore Bushings

Drive

Size

M1130 M20 x 2.5 x 75 .750-10UNC x 3.00 M20 x 2.5 x 40 .750-10 x 1.50 M24 x 3 x 70 M24 x 3 x 70 341 13.43 284 11.18
M1140 M24 x 3 x 90 1.000-8UNC x 3.50 M24 x 3 x 45 1.00-8 x 2.00 M30 x 3.5 x 80 M30 x 3.5 x 80 386 15.20 319 12.55
M1150 M24 x 3 x 90 1.000-8UNC x 3.50 M24 x 3 x 45 1.00-8 x 2.00 M30 x 3.5 x 80 M30 x 3.5 x 80 406 15.98 334 13.15

M1160 M24 x 3 x 90 1.000-8UNC x 3.50 M24 x 3 x 45 1.00-8 x 2.00 M30 x 3.5 x 80 M30 x 3.5 x 80 454 17.87 407 16.02
M1170 M30 x 3.5 x 100 1.125-7UNC x 3.75 M30 x 3.5 x 60 1.125-7 x 2.25 M36 x 4 x 90 M36 x 4 x 90 436 17.17 392 15.44
M1180 M30 x 3.5 x 100 1.125-7UNC x 3.75 M30 x 3.5 x 60 1.125-7 x 2.25 M36 x 4 x 90 M36 x 4 x 90 503 19.80 450 17.72
M1190 M30 x 3.5 x 100 1.125-7UNC x 3.75 M30 x 3.5 x 60 1.125-7 x 2.25 M36 x 4 x 90 M36 x 4 x 90 549 21.61 502 19.76

★ Retention fastener is factory-supplied (Grade 8.8 metric & Grade 5 inch).
† Backing and removal bolts are user-supplied (Removal bolt Grade 8.8 minimum).
‡ Shaft length (N) and Keyway (L) are required when using thrust plate and supplied retention fastener.

Retention Fastener

mm Inch mm Inch mm Inch mm Inch mm Inch

«

Backing Bolt

†

Removal Bolt

†

Shaft Length (N)

‡

Keyway (L)

‡

N

5 mm, 0.20 INCHES

L

KEY

THREADED HOLE

BACKING BOLT WITH FLAT WASHER(S)

AUXILIARY RELEASE SYSTEM - USER-PROVIDED WHEN REQUIRED
LOOSEN BUSHING NUT AND REMOVE NUT RETAINING RING BEFORE USING
ADD FLAT WASHERS AT BACKING BOLT IF NEEDED

RETENTION FASTENER

REMOVAL BOLT

168-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200

January 2019 Telephone: [phone] Fax: [phone]
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(PN 2124650)

Falk™ Drive One® Enclosed Gear Drives • Appendix H

Type D Series • Sizes M1130 thru M1210 (Page 27 of 27)

Directions for Inverting Drives DH2 & DB3

5A - INSPECTION COVER

 4A - HEX SOCKET PIPE PLUG

 3B - DIPSTICK IN HOLE OPPOSITE

LOW-SPEED GEAR LOCATION

 3A - DIPSTICK IN HOLE OPPOSITE
LOW-SPEED GEAR LOCATION

• 2A - HEX SOCKET PIPE PLUG
1 - EACH END

• 1A - SQUARE HEAD MAGNETIC DRAIN PLUG
1 - EACH END

STANDARD MOUNT
(INSPECTION COVER UP)

• 2B - HEX SOCKET PIPE PLUG
1 - EACH END
SEALED WITH LOCTITE PIPE JOINT
COMPOUND #30557 (P/N D004945)

• 1B - SQUARE HEAD MAGNETIC DRAIN PLUG
1 - EACH END
SEALED WITH LOCTITE PIPE JOINT
COMJPOUND #30557 (P/N D004945)

5B - INSPECTION COVER
IF COVER WAS REMOVED, APPLY A CONTINOUOUS BEAD OF
LOCTITE 515 GASKET ELIMINATOR (P/N 99409561) OR EQUIVALENT
TO HOUSING INSPECTION COVER BOLTING SURFACE. MAKE
SURE THAT THE BEAD IS LOCATED INSIDE THE BOLT PATTERN
AND CIRCLES EACH BOLT HOLE. INSTALL INSPECTION COVER
AND TIGHTEN FASTENERS TO 85 Nm (63 lb-ft).

• RELOCATE MAGNETIC DRAIN PLUGS (BOTH ENDS) FROM
1A TO 1B AND SWITCH THE SOCKET HEAD PLUGS
FROM 2A TO 2B.

 RELOCATE THE DIPSTICK FROM 3A TO 3B AND SWITCH
THE SOCKET HEAD PLUGS FROM 4A TO 4B.
BE SURE TO LOCATE THE DIPSTICK ON THE OPPOSITE
SIDE FROM THE LOW-SPEED GEAR TO AVOID INTERFERENCE.

 4B - HEX SOCKET PIPE PLUG
SEALED WITH LOCTITE PIPE JOINT
COMPOUND #30557 (P/N D004945)

INVERTED MOUNT
(INSPECTION COVER DOWN)

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 168-050
Telephone: [phone] Fax: [phone] January 2019
e-mail: [e-mail] web: www.rexnord.com Supersedes 04-11

(PN 2124650)