Falk® Enclosed Gear Drives • Installation and Maintenance
Type A Series • Sizes 305 thru 585
(Page 1 of 17)
HOW TO USE THIS MANUAL
This manual provides detailed instructions on installation
and maintenance of parallel shaft Types A, AR, AXV and
right angle Types AB, ABR, ABX, and ABRC 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.
Type A
Type AB
TABLE OF CONTENTS
Installation Instructions..........................................Pages 1-3
Shaft Connections.................................................Pages 3-4
Tightening Torques.....................................................Page 5
Installation Instructions..........................................Pages 1-3
Shaft Connections.................................................Pages 3-4
Tightening Torques.....................................................Page 5
Lubricant Recommendations..............................Pages 6-13
Lubricant Selection Process...................................Page 6
Preventative Maintenance......................................Page 8
Lubricant Analysis and Changes...........................Page 8
Stored and Inactive Gear Drives..........................Page 13
Food Grade Lubricants.....................................Pages 14-17
Food Grade Lubricant Selection Process............Page 14
Preventative Maintenance....................................Page 15
Lubricant Analysis and Changes.........................Page 15
Stored and Inactive Gear Drives..........................Page 17
Type AXVD
Type AR
Type ABXU
Type ABR
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 Account Executive. 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
WARRANTY — Rexnord Industries (the “Company”)
warrants that, for a period of three years from the
date of shipment, the product described herein will
deliver successfully its rated output as indicated on
the nameplate, provided, it is properly installed and
maintained, correctly lubricated, and operated in the
environment and within the limits of speed, torque or other
load conditions for which it was sold. Such product is
expressly not warranted against failure or unsatisfactory
operation resulting from dynamic vibrations imposed
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
Type ABRC
upon it by the drive system in which it is installed unless
the nature of such vibrations has been fully defined
and expressly accepted in writing by the Company as a
condition of operation.
INSTALLATION INSTRUCTIONS
The following instructions apply to standard Falk Type A,
AB, AXV, ABX, AR, ABR, & ABRC (Alignment Free) drives.
If a drive is furnished with special features, refer to the
supplementary instructions shipped with the drive.
NOTE: Quadruple Reduction Type “A” Gear Drives:
Removal of backstop and mounting bracket may be
required for adequate clearance when installing foundation
fasteners. Removal of fan assemblies may be required for
adequate clearance when installing foundation fasteners.
WELDING — Do not weld on the gear drive or accessories
without prior approval from Rexnord Industries, LLC.
Welding on the drive may cause distortion of the housing
or damage to the bearings and gear teeth. Welding without
prior approval could void the warranty.
EFFECTS OF SOLAR ENERGY — If the gear drive
operates in the sun at ambient temperatures over
100°F(38°C), then special measures should be taken to
protect the drive from solar energy. This protection can
consist of a canopy over the drive or reflective paint on
the drive. If neither is possible, a heat exchanger or other
cooling device may be required to prevent the sump
temperature from exceeding the allowable maximum.
138-050
June 2015
Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance
(Page 2 of 17)
Type A Series • Sizes 305 thru 585
MOUNTING POSITION — Standard mounting positions
for types A, AB, , and ABX are with the base horizontal, and
for types AR, ABR, and ABRC with the input and output
shafts horizontal. 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 Falk 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.
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
Continuous Plate
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 4 for
coupling alignment instructions.
MOTOR BRACKETS — Falk motor brackets provide an
economical “soft mounting” for standard NEMA and IEC foot
mounted AC induction electric motors. The weight, location,
and starting torque of the motor will cause cantilevered motor
brackets to deflect downward or to twist to varying degrees.
The motor bracket/motor selections are engineered to
be within acceptable deflection limits as determined by
Rexnord.. Because the bracket is a “soft motor support”,
deflection and vibration magnitude of the bracket may
exceed levels normally considered acceptable for rigidly
mounted machinery.
For applications using other than standard selections, use
of a motor plate is recommended. If a motor bracket is to be
used, it becomes the customer’s responsibility to support the
rear of the motor bracket to limit deflection and vibration to
within satisfactory levels as determined by the customer.
138-050
June 2015
Supersedes 01-10
GEAR DRIVE ALIGNMENT
FOOT MOUNTED DRIVES – Align drive with driven
equipment by placing broad, flat shims under all mounting
pads. Start at the low speed shaft end and level across
the length and then the width of the drive. Check with a
feeler gauge to make certain that all pads are supported
to prevent distortion of housing when drive is bolted down.
After drive is aligned with driven equipment and bolted
down, align prime mover to drive input shaft. Refer to Page
4 for coupling alignment.
If equipment is received from Rexnord 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.
SHAFT MOUNTED DRIVES — Shaft mounted drive
alignment occurs when the gear drive is attached to
the driven shaft. The standard hollow low speed shaft
is connected to the driven shaft with a shrink disc
connection. Solid low speed shafts are typically connected
with an MCF moment type coupling. Refer to the Shaft
Connection section for coupling installation.
Leveling
Reference
Surfaces
Shims
There may be some visible movement of the drive
while operating due to shaft and coupling . Torque arm
assemblies must be aligned such that the gear drive
movement is not restricted during operation. Refer to
torque arm instructions on Page 3.
The Alignment Free drive flange motor adapter provides
registration for the motor which eliminates the adjustments
normally required for high speed coupling alignment.
TORQUE ARMS
The torque arm connects a shaft mounted gearbox to
the foundation. In static condition, it helps to support the
weight of the gearbox/motor assembly. In the dynamic
condition, it supports the weight and also transmits the
torque reaction to the foundation. The torque arm may
be loaded in compression or tension. Maximum torque
arm loads should be considered when designing the
foundation for the torque arm anchor.
TORQUE ARM ASSEMBLY — The torque arm
components are to be assembled according to the
following illustration. A plain spherical bearing is fitted
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
are to be assembled according to the following illustration. A
CORRECT METHOD
plain spherical bearing is fitted into the gearbox
or
Sizes 305 thru 585
(Page 3fitted
of 11)
Typehousing
A Series
•
Heat interference
bedplate. A pin engages the spherical bearing and connects
it
Falk® Enclosed
Gear Drives • Installation
and
Maintenance
hubs,
pinions,
sprockets
or
to the torque arm. Spacers center the bearing on the pin. The
pulleys to a maximum of
pin is retained by a snap ring. A similar connection isType
made A Series • Sizes 305 thru 585
(Page
3 slide
of 17)
TORQUE ARM ASSEMBLY — The torque arm components
275°F (135°C)
and
between the torque arm and anchor bracket. In operation, the
are to be assembled according to the following illustration. A
onto
gear
drive
shaft.
CORRECT METHOD
torque arm is to be perpendicular to the edge of the gear
plain spherical bearing is fitted into the gearbox housing or
drive.
Heat interference fitted
bedplate.
A pin engages
theor
spherical
bearing
connects it
into
the gearbox
housing
bedplate.
A pinand
engages
INCORRECT
METHODor
hubs,
pinions, sprockets
INCORRECT
METHOD
Warning:
Angular
misalignment
of
the
torque
arm
may
restrict
tothe
thespherical
torque arm.
Spacers
the bearing
the pin.
The
bearing
andcenter
connects
it to theontorque
arm.
DO NOT
drive
coupling
pulleys
to
a
maximum
of
gear
drivecenter
gear
movement
and
cause
excessive
loading
pin
is retained
by drive
athe
snap
ring. Aonsimilar
connection
is retained
made
DO NOT
drive
coupling
Spacers
bearing
the pin.
The
pin is
hub,
pinion,
sprocket
275°F
(135°C)
and
slide
on
the
low
speed
shaft
and
driven
equipment.
between
the ring.
torque
anchor bracket.
In operation,
the
hub,
pinion,
sprocket
or
by a snap
A arm
similar connection
is made
between the
or
pulley
onto
the
shaft.
onto
gear
drive
shaft.
TORQUE
ARM
MOVEMENT
— to
Movement
drive
torque
arm
to be
perpendicular
edge of
of the
the
gear
pulley
onto
the
shaft.
torque
armis
and
anchor
bracket.
Inthe
operation,
thegear
torque
An
endwise
blow
on An
whileisoperating
is natural. The
due gear
to shaft
and
drive.
endwise
blow on the
arm
to be perpendicular
to movement
the edge ofis the
drive.
the
shaft/coupling
may
– CAUTION –
coupling Angular
runouts. misalignment
The standard of
torque
arm isarm
designed
to
shaft/coupling
may
damage
gears
and
INCORRECT
METHOD
–
CAUTION
–
Warning:
the
torque
may
restrict
WARNING:
Angular
misalignment
of the
torque
DO NOT HAMMER
accommodate
this movement.
Itand
allows
theexcessive
gearboxarm
to move
damage gears and
bearings.
DO NOT HAMMER
gear
geargear
drive
movement
cause
loading
DO
NOT drive coupling
maydrive
restrict
drive
gear drive
movement
and cause
bearings.
on
the low speed
shaft
equipment.
excessive
loading
onand
the driven
low speed
shaft and driven
hub, pinion, sprocket or
equipment.
TORQUE
ARM MOVEMENT
— Movement
of the gear drive
onto theaxial
shaft. An
FLANGED MOTOR ADAPTERSpulley
— Accurate
SPACER
(4)
FLANGED MOTOR
ADAPTERS
Accurate
axial
positioning
while
operating
natural. The movement
is due
shaft
and
endwise
blow
on the
positioning
of the coupling
hub —
on
the motor
shaft
is
TORQUE
ARMis MOVEMENT
— Movement
oftothe
gear
–of
CAUTION
–
the coupling
hub proper
on the motor
shaft
is required
to ensure
coupling
runouts.
The
standard
torque
arm
is
designed
to
shaft/coupling
may
required
to
ensure
coupling
gap.
To
establish
drive while operating is natural. The
movement
TORQUE
ARM (1) is due to
DO
NOTcoupling
HAMMERgap. To establishdamage
proper
theshaft,
correct
overhang
accommodate
this movement.
It allows
the gearbox
to
move
gears
and on the
the
correct
overhang on the motor
measurements
shaft and coupling
runouts. The
standard
torque
arm
is
TORQUE
motor
shaft, measurements
are1 required.
Refer
to Figure
bearings.
are
required.
Refer
to
Figure
below.
First
measure
the1
designed to accommodate this movement. It allows
the
ARM PIN (2)
below.
First
measure
the
distance
from
the
motor
mounting
distance from the motor mounting face of the motor to the
SPACER (4)
face of
of the
the motor
motor to the(A).
end Then
of themeasure
motor shaft (A).
Then
end
FLANGED
MOTORshaft
ADAPTERS
— Accurate the
axialdistance
positioning
TUBE
FITTING
(2)
EXTERNAL
measure
the distance
fromface
the motor
mounting
face oftothe
from
the
motor
mounting
of
the
motor
adapter
of the coupling hub on the motor shaft is required to ensure
RETAINING RING (2)
motor
adapter
the drive
face of
the(B).
gearRefer
drive hub
Refer to
the
face
of theto
gear
hub
the(B).
coupling
TORQUE ARM (1)
proper
coupling
gap.
To establish
the correcttooverhang
on the
the
coupling
installation
and
maintenance
instructions
to
installation
and
maintenance
instructions
to
determine
TORQUE
motor shaft, measurements are required. Refer to Figure 1
the
desired
coupling
gap.
The
coupling
overhang
is
determine
the
desired
coupling
gap.
The
coupling
overhang
is
ARM PIN (2)
RADIAL SPHERICAL
below. First measure the distance from the motor mounting
determined
from the
thefollowing
followingequation:
equation:
determined from
PIPE PLUG
BEARING (2)
face of the motor to the end of the motor shaft (A). Then
SQUARE HEAD (2)
TUBE FITTING (2)
EXTERNAL
measure Overhang=A+Gap-B
the distance from the motor mounting face of the
Overhang = A + Gap - B
ANCHOR
RETAINING RING (2)
motor
adapter
to the
face of the
gear
drivevalue,
hub (B). Refer
to
IfIf the
calculated
overhang
positive
motor
BRACKET (1)
the calculated
overhang
isisa apositive
value, thethe
motor
shaft
the
coupling
installation
andhub
maintenance
instructions to
shaft
extends
beyond
the
by
that
amount.
extends beyond the hub by that amount.
determine the desired coupling gap. The coupling overhang is
RADIAL SPHERICAL
NOTE:
couplings
where
the
couplinggap
gapdoes
doesnot
notoccur
NOTE: For
Forfrom
couplings
where the
coupling
determined
the following
equation:
PIPE PLUG
BEARING (2)
occur
theofend
the hub,
motoranhub,
an additional
adjustment
at the at
end
the of
motor
additional
adjustment
must be
SQUARE HEAD (2)
must
made.
See dimension
C in Figure 1 below.
made.be
See
dimension
C in
Figure
Overhang
=A+
Gap
- B 1 below.
ANCHOR
slightly with the driven shaft. This prevents transmitting
If the calculated overhang isFLANGE
a positive value, the motor shaft
unnecessary additional loads to the driven shaftBRACKET
through(1)the
MOTOR
extends beyond the hub by that
amount.
gearbox. DO NOT restrain free movement of the gear drive,
ADAPTER
to do so will adversely load the low speed shaft and driven
NOTE: For couplings where the coupling gap does not occur
shaft and may result in shaft or hub failure. Recheck torque
at the end of the motor
hub, an additional adjustment must be
MOTOR
MOUNTING
arm movement
during
regular
maintenance
intervals.
made.
See
dimension
C
in Figure 1 below.
gearbox
to
move
slightly
with
the
driven
shaft.
This
prevents
slightly with the driven shaft. This prevents transmitting
FACE
transmittingadditional
unnecessary
loads
to through
the driven
FLANGE
unnecessary
loadsadditional
to the driven
shaft
the
MOTOR
shaft through
the restrain
gearbox.
DO
NOT restrain
movement
gearbox.
DO NOT
free
movement
of thefree
gear
drive,
ADAPTER
Shaft
Connections
of
the
gear
drive,
to
do
so
will
adversely
load
the
low
C
toWARNING:
do so will adversely suitable
load the low speed
shaft and driven
in accordance
withor
local
speed shaft Provide
and driven shaftguards
and may
result in shaft
MOTOR
shaft
and
may
result
in
shaft
or
hub
failure.
Recheck
torque
MOTOR
and national
standards.
hub
failure. Recheck
torque arm movement during regular
MOUNTING
arm
movement during regular maintenance intervals.
maintenance
FACE
SHRINK DISCintervals.
CONNECTIONS — Shrink disc assemblies
used on hollow low speed shafts and on some MCF coupling
Shaft
Connections
hubs require
special installation procedures. Refer to the
SHAFT
CONNECTIONS
C
COUPLING HUBS
following Falk™
bulletins
for guards
detailedininstructions:
WARNING:
Provide
suitable
with with
local
A
B
WARNING: Provide
suitable
guardsaccordance
in accordance
MOTOR
and
national
standards.
OVERHANG
Figure 1
local and national standards.
Shrink Discs . . . . . . . . 138-850
SHRINK
DISC
CONNECTIONS
—
Shrink
disc
assemblies
SHRINK
DISC
CONNECTIONS
disc assemblies
MCF
couplings
. . . . . .—. Shrink
458-862
FALK™ COUPLINGS — (Except fluid type) Detailed
used
onon
hollow
lowlow
speed
shafts
and and
on some
MCFMCF
coupling
FALK COUPLINGS — (Except fluid type) Detailed
used
hollow
speed
shafts
on some
installation manuals are available from Rexnord, your local
hubs
requirehubs
special
installation
procedures.
to the
installation manuals are available from Rexnord, your local
coupling
require
special
installationRefer
procedures.
Rexnord Account
oror
Distributor—just
provide
size
COUPLING
CONNECTIONS
—
The
performance
and
life
COUPLING HUBS
following
Falk™
bulletins
for
detailed
instructions:
Rexnord
AccountExecutive
Distributor—just
provide
Refer to the following Falk bulletins for detailed instructions:
AExecutive
B
and
type
designations
stamped
on
the
coupling.
For
lubricant
of any coupling depends largely upon how well the coupling is
size and typeOVERHANG
designations stamped on the coupling.
Figure
1
requirements
and a list of typical
meeting
Rexnord
installed
and Discs
serviced.
For
lubricant requirements
and alubricants
list of typical
lubricants
Shrink
. . Refer
. . .to. the
. .coupling
138-850manufacturer’s
Shrink
Discs
........138-850
specifications,
refer
to
appropriate
coupling
service
manual.
manual
for
specific
instructions.
meeting
Rexnord
specifications,
refer
to
appropriate
MCF couplings . . . . . . . 458-862
FALK™ COUPLINGS — (Except fluid type) Detailed
coupling
service
manual.
Flanged Type
Rigid
Couplings
typically
usedyour
on drives
MCF couplings .......458-862
installation
manuals
are
availableare
from
Rexnord,
local with
vertical Account
output
The
low
speed
extension
ends
of the
Rexnord
Executive
or Distributor—just
provide
Flanged
Typeshafts.
Rigid
Couplings
areshaft
typically
used
onsize
COUPLING CONNECTIONS — The performance and life
solid
vertical
shaft
drives
are
drilled
and
tapped
to
accommodate
and
type
designations
stamped
on
the
coupling.
For
lubricant
drives with vertical output shafts. The low speed shaft
Thehow
performance
and is
ofCOUPLING
any couplingCONNECTIONS
depends largely —
upon
well the coupling
coupling keeper
torques
fasteners,
requirements
and plates.
a list
typical
lubricants
meeting
Rexnord
extension
ends
of
theofTightening
solid
vertical
shaftfor
drives
are
drilled
life of any
largely
uponmanufacturer’s
how well the
installed
andcoupling
serviced.depends
Refer to the
coupling
including
keeper
plate
fasteners
are
listed
in
Table
1,
Page 5.
specifications,
refer
to
appropriate
coupling
service
manual.
and
tapped
to
accommodate
coupling
keeper
plates.
coupling
installed
and serviced. Refer to the coupling
manual
for is
specific
instructions.
Tightening
for fasteners,
including
keeper
plate
manufacturer’s manual
Flanged
Typetorques
Rigid Couplings
are typically
used
on drives
with
fasteners
areshafts.
listedThe
in Table
1, Page
for specific instructions.
vertical
output
low speed
shaft5.extension ends of the
Rexnord Industries,
LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 solid
138-050
vertical
shaft
drives are drilled
and tapped
to accommodate
FALK
FLUID
COUPLINGS
— Refer
to the installation
CORRECT
METHOD
Telephone:
414-342-3131
2010
manual keeper
furnished
with
the Falk torques
fluid coupling
for January
installation
coupling
plates.
Tightening
for fasteners,
Heat
interference
fitted Fax: 414-937-4359
e-mail:pinions,
info@rexnord.com
web: www.rexnord.com
and startup
instructions.
including
keeper
plate fasteners are listed in Table Supersedes
1, Page 5. 11-09
hubs,
sprockets
or pulleys to a maximum
Type ABRC — The Alignment Free flange motor adapter
of 275°F (135°C) and
has two side inspection openings. On solid shaft gear
slide onto gear drive
drives, the opening opposite the low speed shaft
extension
Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200
138-050
shaft.
Telephone: 414-342-3131 Fax: 414-937-4359
e-mail: info@rexnord.com web: www.rexnord.com
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
January 2010
Supersedes 11-09
138-050
June 2015
Supersedes 01-10
® ™FLUID COUPLINGS — Refer to the installation
DO NOT over tighten belts or chains. Adjust chains to
FALK
Falk
Enclosed Gear Drives • Installation and Maintenance
Installation
and
Maintenance
Enclosed Gear
Drives specifications. Adjust belts as follows:
manufacturers’
manual furnished
with
the Falk fluid coupling
for installation
• Falk™
and startup
instructions.
(Page
4 of 17)
Type A Series • Sizes 305 thru
The585
ideal tension is the lowest tension at which the belt will not
A Series
(Page
of 11)
Sizes
305
thru has
585 • Type
slip under
peak load conditions. Check the belt tension
Type 4
ABRC
— The Alignment Free flange
motor
adapter
two side inspection openings. On solid shaft gear drives, the
opening
oppositetothe
low speed
extension
hasofbeen
has
been marked
indicate
the shaft
vertical
midpoint
the
FALK
™FLUID
COUPLINGS
—drives,
Refer
tothe
the
installation
marked
to indicate
the vertical
midpoint
of
the adapter.
On
adapter.
On
hollow
shaft
gear
opening
on the
manual
furnished
with
the
Falk
fluidhas
coupling
installation
hollow
shaft
gear
drives,
thedrive
opening
on thefor
shrink
disk
shrink
disk
side
of
the
gear
been
marked
to side of
and
instructions.
thestartup
gear
drive
has been
marked
to indicate
vertical
indicate
the
vertical
midpoint
of the
adapter.the
These
marks
midpoint
the
These
are
used
tofluid
establish
are
used
toof
establish
the proper
fill
angle
for
the
Type
ABRC
—
Theadapter.
Alignment
Freemarks
flange
motor
adapter
has the
proper
fill
angle
for
the
fluid
coupling.
coupling.
two side inspection openings. On solid shaft gear drives, the
opening
opposite
the
low speed
shaft extension
beenwith
The
fluid
coupling
outside
diameter
has been
marked
The
fluid
coupling
outside
diameter
has
beenhas
marked
withtwo
marked
to indicate
themarks.
vertical
midpoint
of thefilladapter.
On
separate
match
marks.
TheThe
recommended
can
obtained
two
separate
match
recommended
fill be
can
be
hollow
shaft
gear
the
opening
on
shrink
disk
side with
of
by lining
up
the drives,
correct
match
mark
onthe
the
fluid
obtained
by
lining
up the
correct
match
mark
oncoupling
the fluid
coupling
with
theinspection
mark marked
in the
inspection
opening
and filling
the
gear
drive
has
been
to indicate
the vertical
the
mark
in the
opening
and filling
the fluid
thecoupling
fluid coupling
fluid
appears
the
the
fill the
midpoint
ofuntil
the adapter.
These
marks
used
toofestablish
fluiduntil
appears
at
the lip are
ofatthe
fillliphole.
To determine
hole.
Tofilldetermine
the
correct
mark on
theby
fluid
coupling
proper
angle
foronthe
the correct
mark
thefluid
fluidcoupling.
coupling
begin
aligning
the fill
begin
by
aligning
themark
fill hole
with
the
markFor
inwith
the
hole
with
the match
in the
inspection
opening.
fill two
The
fluid
coupling
outside
diameter
has match
been
marked
inspection
fill angles
lessupward
than 90°,
rotate
the
angles match
lessopening.
than
90°,For
rotate
the fill plug
tillbe
the
match
separate
marks.
The recommended
fill can
obtained
fillmarks
plug upward
till the
matchgreater
marksthan
line 90°,
up. For
fill the
angles
line
up.
For
fill
angles
rotate
fill
plug
by
liningthan
up the
correct match
on
the fluid coupling
with
greater
90°,
fillmark
plug
downward
till the match
downward
till
therotate
match the
marks
lineand
up.
the
mark
in
the
inspection
opening
filling
the
fluid
marks line up.
coupling
until fluid
appearsALIGNMENT
at the lip of the—fillIfhole.
To determine
GAP AND
ANGULAR
possible,
after
GAP
ANDmark
ANGULAR
ALIGNMENT
—driving
Ifbypossible,
after
the
correct
on thehubs,
fluid
coupling
begin
aligning
the
fill
mounting
coupling
position the
and driven
mounting
coupling
hubs,
the driving
hole
with the
match
in position
the inspection
opening.
Fordriven
equipment
so thatmark
the distance
between
shaft and
ends
isfillequal to
equipment
so that
distance
angles
less than
90°,the
rotate
plug upward till the match
the coupling
gap.
Align
the fill
shafts
between
shaft
ends
is
equal
to the
marks
line up.aFor
fill angles
greater
than
by placing
spacer
block,
equal
in 90°, rotate the fill plug
coupling gap.
Align
the
shafts
downward
match
marks
linebyup.
thicknesstilltothe
required
gap, between
placing a spacer block, equal in
hubAND
faces,
as
shown gap,
at
right,
and — If possible, after
GAP
ANGULAR
ALIGNMENT
thickness
to
required
between
also
at 90°
around
the
mounting
coupling
hubs,
position
hub
faces,
asintervals
shown
at
right,
andthe driving and driven
hub.
with the
feelers.
equipment
that
distancethe
between
also
at Check
90°so
intervals
around
hub. shaft ends is equal to
the
coupling
gap. Align the
OFFSET
—shafts
Align
Check
withALIGNMENT
feelers.
Steelflex Illustrated
by
placingand
a spacer
driving
drivenblock,
shafts
so
thatina
OFFSET
ALIGNMENT
—equal
Align
thickness
toedge
required
gap,
between
straight
will rest
squarely
driving
and
driven
shafts
so thatona
hub
faces,
as shown
at as
right,
andto
both
couplings
shown
straight
edge
willhubs
rest
squarely
on
also
90° and
intervals
around
the to
theatcouplings
right
also
atas
90°shown
intervals.
both
hubs
hub.
Check
with
feelers.
foundation
of the
theTighten
right
and
also
at bolts
90° intervals.
connected
equipment
and
recheck
Tighten
foundation
bolts
of
the
OFFSET
ALIGNMENT
—
Align
Steelflex Illustrated
alignment
and gap.
connected
equipment
recheck
driving
and driven
shaftsand
so that
a
alignment
and
gap.
straight
edge willPULLEYS
rest squarely
SPROCKETS,
OR on
Steelflex Illustrated
both
couplings
as power
shown
SHEAVES
—hubs
Mount
SPROCKETS,
PULLEYS
ORto
the
right and—
at 90°
intervals.
take-offs
asalso
close
topower
the
gear
drive as close to the gear
SHEAVES
Mount
take-offs
Tighten
foundation
boltstoofavoid
the
housing
as possible
undue
bearing
loadload
andand
shaft
drive
housing
as possible
to avoid
undue
bearing
connected
equipment and recheck
deflection.
shaft
deflection.
alignment
and
gap.
Align
theoutput
output
shaftofofthe
the gear
gear drive
drive square
square and
Align
the
shaft
andparallel
parallel
SPROCKETS,
PULLEYS
with
thedriven
driven
shaftby
byOR
placing aa straightedge
straightedge
across
with
the
shaft
placing
acrossthe face
Steelflex Illustrated
SHEAVES
Mount
the sprockets
or power
sheaves
as illustrated.Check
horizontal
theofface
of—the
sprockets
or sheaves
as illustrated.Check
take-offs
asshaft
close
to placing
the gear
drive
horizontal
alignment
byone
placing
shaft alignment
by
leg one leg of a square
against
the
face
of the
sheave
or sprocket
with
spirit
housing
as possible
tothe
avoid
bearing
loadthe
and
shaft
of a square
against
face undue
WRONG
RIGHT
level
on sheave
the horizontal
leg of
the square.
deflection.
of the
or sprocket
with
theNOT
spirit
leveltighten
on theofbelts
Align
the
output
shaft
the gear
drive square
parallel
DO
over
or chains.
Adjust and
chains
to
horizontal
legshaft
of the
manufacturers’
specifications.
belts as
follows:
with
the driven
by square.
placing aAdjust
straightedge
across
the face
of
theideal
sprockets
or is
sheaves
as illustrated.Check
horizontal
The
tension
the lowest
tension at which
the belt
shaft
alignment
by placing
one leg
will not
slip under
peak load
GEAR DRIVE WALL
of
a square against
the belt
face tension
WRONG
RIGHT
conditions.
Check the
of
the sheave
or sprocket
frequently
during
the firstwith
24 to 48
the
spirit
onoperation.
the
hours
of level
run-in
Over
horizontal
of the
square.belt
tighteningleg
belts
shortens
and bearing life. Keep belts free
from foreign material which may
LEVEL
cause slippage. Inspect the V–belt
GEAR DRIVE WALL
periodically; tighten
the
belts if
SQUARE
AND
they are slipping.
PARALLEL
138-050
January 2010SQUARE AND
PARALLEL
Supersedes 11-09
138-050
138-050
June 2015
January 2010
Supersedes 01-10
Supersedes 11-09
LEVEL
frequently during the first 24 to 48 hours of run-in operation.
Over tightening
belts shortens
beltthe
and
bearing bearing
life. Keep belts
OUTBOARD
BEARING
— Mount
outboard
DO
NOT
over
tighten
belts
or
chains.
Adjust
chains
to will
free
from
foreign
material
which
may
cause
slippage.
Inspect
and gear drive on a common foundation so that they
manufacturers’
specifications.
Adjust
as
follows:
theas
V–belt
periodically;
tighten
the belts
if they
are slipping.
shift
an assembly
if settling
should
occur.
Bring
the
outboard
bearing
the
correct
horizontal
position
The
ideal tension
isto
the
lowest
tension
at which
the bearing
beltwith
will and
not
OUTBOARD
BEARING
— Mount
the
outboard
broad
flat
shims
the foundation
mounting
Align
accurately
slip
under
peak
conditions.
Checkpad.
thethat
belt
tension
gear
drive
on load
aunder
common
so
they
will shift as
soan
that
theduring
loadif is
equally
between
theoutboard
two
drive
frequently
the
first should
24divided
to 48
hours
of run-in
operation.
assembly
settling
occur.
Bring
the
bearings
and
the
outboard
bearing.
Mount
a stop
bar
Over
tightening
belts
shortens
belt and
bearing
life.
Keep
bearing
to the
correct
horizontal
position
with
broad
flatbelts
shims
against
pillow
block
foot
on may
the
load
when
large
free
fromthe
foreign
material
which
causeside
slippage.
under
the
mounting
pad.
Align
accurately
so that
theInspect
load is
horizontal
load components
on the
pillow
the
V–belt divided
periodically;
tighten
theexerted
belts
they
areand
slipping.
equally
between
theare
two
drive ifbearings
the
block.
outboard bearing.
Mount
a stop the
bar outboard
against the
pillow and
block
OUTBOARD
BEARING
— Mount
bearing
PINION
Mount
pinion
to components
the
footdrive
onMOUNTING
the
side—when
large
horizontal
load
gear
on load
a common
foundation
so as
thatclose
they
will
shift as
drive
as
possible
to pillow
avoid
undue
load
and
are
exerted
the
block.
an
assembly
ifon
settling
should
occur.bearing
Bring the
outboard
shaft
deflection.
Refer
to
Factory
for
pinion
alignment
bearing
to the
correct horizontal
position
broadtoflat
PINION
MOUNTING
— Mount
pinionwith
as close
theshims
drive
instructions.
under
the mounting
pad.
Alignbearing
accurately
thatshaft
the deflection.
load is
as possible
to avoid
undue
loadsoand
NON
FALK
COUPLINGS
Refer
manufacturer’s
equally
divided
between
the—two
drivetobearings
and the
Refer
to Factory
for pinion
alignment
instructions.
installation
and maintenance
instructions.
outboard
bearing.
Mount a stop
bar against the pillow block
Non
Falk™ Couplings
— Refer to manufacturer’s
foot
on the load—side
when
large
horizontal
load components
BACKSTOPS
prevent
damage
to backstops
due
installation
andTo
maintenance
instructions.
are
exerted
on
the
pillow
block.
to incorrect motor shaft rotation at start up, couplings
— To when
prevent
damage
to as
backstops
areBACKSTOPS
NOT MOUNTING
assembled
gear
drives
areclose
furnished
PINION
— Mount
pinion
todue
thetodrive
incorrect
motor
shaftundue
at
startload
up,
couplings
NOT
with
backstops
for
allrotation
types
except
ABRC.
For are
type
as
possible
to avoid
bearing
and shaft
deflection.
assembled
when
gear
drives
are
furnished
with
backstops
for all
ABRC
drives,
remove
the
backstop
before
electrically
Refer to Factory for pinion alignment instructions.
types exceptthe
ABRC.
For AB,
type ABR,
ABRC drives,
remove
the backstop
connecting
motor.
and ABRC
backstops
are
Non
Couplings
toAB,
manufacturer’s
before
electrically
theRefer
motor.
ABR, and ABRC
held
inFalk™
place
by
a connecting
retaining —
ring
on the
intermediate
shaft.
installation
andheld
maintenance
backstops are
in place by a instructions.
retaining ring on the intermediate
After completing electrical connections, check motor and
shaft.
BACKSTOPS
—
To
prevent
damage
to backstops
due complete
to
gear drive shaft rotations. If rotations
are correct,
incorrect
motor
rotationofatconnections,
start up, couplings
NOT
After completing
electrical
checkare
motor
alignment
andshaft
assembly
coupling
or re-install
the and gear
assembled
when
gear drives
are furnished
with backstops
for all
drive shaft
rotations.
If rotations
are correct,
complete
backstop.
types
except ABRC.
For type ABRC
drives, remove
the backstop
alignment
and assembly
of coupling
or re-install
the backstop.
before electrically connecting the motor. AB, ABR, and ABRC
backstops are held in place by a retaining ring on the intermediate
shaft.
After completing electrical connections, check motor and gear
drive shaft rotations. If rotations are correct, complete
alignment and assembly of coupling or re-install the backstop.
Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: 414-342-3131 Fax: 414-937-4359
e-mail: info@rexnord.com web: www.rexnord.com
Rexnord
Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
e-mail: info@rexnord.com web: www.rexnord.com
Falk™ Enclosed Gear Drives • Installation and Maintenance
®
Gear
Drives
Sizes 305
thru
585 • Installation and Maintenance
(Page 5 of 11)
Type AFalk
SeriesEnclosed
•
Type A Series • Sizes 305 thru 585
(Page 5 of 17)
Fastener Tightening Torques
Water Cooling
Use the tightening
torque valuesTORQUES
specified in Table 1 for
FASTENER
TIGHTENING
fastening Falk™ gear drives, motors and accessories to
Use
tightening
torquewith
values
specified infasteners.
Table 1 for
their the
mounting
surfaces
un-lubricated
DO
fastening Falk gear drives, motors and accessories to
NOT
use
these
values
for
“torque
locking”
fasteners
or
their mounting surfaces with un-lubricated fasteners. DO
for fastening
components
with aluminum
feet or softor for
NOT
use these
values for “torque
locking” fasteners
gaskets orcomponents
vibration dampeners
on the
mounting
surface.
fastening
with aluminum
feet
or soft gaskets
or
vibration
dampeners
the mounting
surface.
If the
If the
tightening
torque on
exceeds
the capacity
of the
torque
tightening
torque
exceeds
the capacity
of fasteners,
the torqueuse
wrench, use
a torque
multiplier.
For inch
wrench,
torque multiplier.
For inchinch
fasteners,
use A
Grade 5use
for adiameters
though 1.500
and ASTM
Grade 5 for diameters though 1.500 inch and ASTM A 354
354 grade
BC
for larger
diameter
fasteners.
Useproperty
ISO
grade
BC for
larger
diameter
fasteners.
Use ISO
property
class
8.8
for
metric
fasteners.
class 8.8 for metric fasteners.
WATER
COOLING
or control valve
in the water line to the heat exchanger to
TABLE 1 — Tightening Torques: +/-5%
DO NOT Lubricate Fasteners
Inch Fasteners – Grade 5
Metal to Metal
Metal to Concrete
Fastener
Size
lb-ft
Nm
lb-ft
Nm
.250-20
.3125-18
.375-16
.500-13
.625-11
.750-10
.875-9
1.000-8
1.125-7
1.250-7
1.375-6
1.500-6
1.750-5
2.000-4.5
2.250-4.5
2.500-4
2.750-4
3.000-4
7
15
27
67
134
242
395
590
740
1060
1360
1840
3900
5900
8600
11800
14600
19400
10
21
37
91
184
330
530
800
1000
1420
1860
2480
5300
7900
11800
16000
19800
26400
6
12
22
54
108
194
315
475
590
840
1100
1460
2700
4100
6000
8300
10200
13600
8
16
30
73
146
265
425
640
800
1140
1480
1980
4240
6300
9400
12800
15800
21100
TABLE 1A — Tightening Torques: +/-5%
DO NOT Lubricate Fasteners
WATER COOLED HEAT EXCHANGERS — Install a shut-off
WATER
HEAT
EXCHANGERS
— Install
a shutregulate COOLED
the water flow
through
the exchanger.
Also install
a
off
or flow
control
valve
in the water
line tovalve
the heat
exchanger
water
gauge
between
the control
and the
to
regulatetothe
water flow
through
Also to
exchanger
determine
actual
flow the
rate.exchanger.
Discharge water
install
a water
flow
the control valve and
an OPEN
DRAIN
to gauge
preventbetween
back pressure.
the exchanger to determine actual flow rate. Discharge
INTERNAL
TUBES
— Refer
to Manual
138-310
water
to an COOLING
OPEN DRAIN
to prevent
back
pressure.
for installation, operation, and maintenance of internal
INTERNAL COOLING TUBES — Refer to Manual 138-310
cooling tubes.
for installation, operation, and maintenance of internal
cooling tubes.
Lubrication Systems
SPLASH LUBRICATED DRIVES — Standard type A, AR, AB,
ABR, and ABRC 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 AXV and ABX 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, oil filter, flow indicator with
switch, 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 2 for electrical
requirements. Wire the motor for correct rotation as indicated
by the rotation arrow. 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.
TABLE 2 — Oil Pump Electrical Specifications
DRIVE
SIZE
HP
Cycles, Hz
RPM
Voltage
405 & 425
1
50
1425
60
1725
208220/380/440
230/460
445-485
505-535
2
3
60
50
60
1725
1425
1725
208208220/380/440
220/380/440
230/460
230/460
50
1425
Metric Fasteners – Property Class 8.8
Fastener
Size
M4 x .7
M5 x .8
M6 x 1.0
M8 x 1.25
M10 x 1.5
M12 x 1.75
M16 x 2
M20 x 2.5
M30 x 3.5
M36 x 4
M42 x 4.5
M48 x 5
M56 x 5.5
Metal to Metal
Metal to Concrete
lb-ft
Nm
lb-ft
Nm
2
4.5
7.5
18
36
62
56
305
1060
1680
3000
4500
7300
3
6
10
24
50
84
210
415
1 440
2 520
4 050
6 100
9 850
1.5
3.5
6
14
29
50
126
246
850
1500
2400
3600
5800
2
5
8
19
39
68
170
330
1 150
2 030
3 250
4 880
7 860
Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: 414-342-3131 Fax: 414-937-4359
e-mail: info@rexnord.com web: www.rexnord.com
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
Other types of gear drives may also be equipped with oil
pumps for special lubrication considerations or external
cooling.
Caution: Refer to Factory for drives that use pumps to
distribute lubricants with temperatures below 30°F (-1°C).
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 sulfur-phosphorus extreme
pressure (EP) gear lubricants are the recommended lubricants
for ambient temperatures of 15°F to 125°F(-9°C to +50°C).
For drives operating outside the above temperature range
refer to “Synthetic Lubricants” paragraphs, Page 7. Synthetic
lubricants can also be used in normal climates.
138-050
January 2010
Supersedes
11-09
138-050
June 2015
Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance
(Page 6 of 17)
Type A Series • Sizes 305 thru 585
Lubrication Recommendations
INTRODUCTION
LUBRICANT TYPES
Carefully follow instructions on the drive nameplate, warning
tags and installation manuals furnished with the drive.
PETROLEUM-BASED LUBRICANTS (TABLES 6A, 6B &
6C) — Industrial type petroleum-based rust and oxidation
inhibited (R & O) gear lubricants are the most common
and readily available general purpose gear lubricants.
Lubricants listed in this manual are typical products
ONLY and should not be construed as exclusive
recommendations. Industrial type petroleum-based rust
and oxidation inhibited (R & O), industrial type extreme
pressure (EP) or industrial type micropitting resistant gear
lubricants are the recommended gear lubricants. They can
be formulated using petroleum or synthetic base stocks.
The section on food grade lubricants provides guidance
selecting lubricants for applications needing this class of
lubricants. Food grade lubricants are formulated using
petroleum or different types of synthetic base stocks.
LUBRICANT SELECTION PROCESS
1. Refer to Table 3 or 4 for proper lubricant viscosity
grade based on ambient temperature range. See Falk
GMax 6000 paragraph on this page for ambient air
temperature range if using this lubricant.
2. Refer to Table 2 for summary of lubricant type.
3. Using proper lubricant table and viscosity grade, select
desired lubricant manufacturer name.
4. Refer to Table 9 or 10 for approximate oil capacity to
purchase.
TABLE 2 — S
ummary of Lubricant Type and
Greases
Petroleum-Based
R & O Inhibited
See Table 6A
Extreme Pressure (EP)
See Table 6B
Micropitting Resistant
See Table 6C
Synthetic Lubricant, Polyalphaolefin Type (PAO)
R & O Inhibited
See Table 7A
Extreme Pressure (EP)
See Table 7B
Micropitting Resistant
See Table 7C
Synthetic Lubricant, Polyalkylene Glycol Type (PAG)
See Falk GMax 6000 (Paragraph to Right)
Conventional Grease
See Table 8
Food Grade Lubricant & Grease
See Page 14
VISCOSITY (IMPORTANT)
The proper viscosity grade for petroleum-based lubricant
is found in Table 3. For synthetic lubricant viscosity grades,
refer to Table 4 and the “Synthetic Lubricants” paragraphs.
Viscosity grade is determined by ambient air temperature
in immediate vicinity of gear drive. Lubricant selections
must have a pour point at least 10°F (5.5°C) below the
expected minimum ambient starting temperature.
If a gear drive operates in a typical indoor environment
where the ambient temperature is within 70°F to 125°F (21°C
to 52°C), the oil viscosity may be increased one ISO grade
above that shown for the 50°F to 125°F (10°C to 52°C) range.
That is, an ISO VG 320 (AGMA 6) or ISO VG 460 (AGMA 7)
may be substituted for an ISO VG 220 (AGMA 5) or ISO VG
320 (AGMA 6) respectively, under this ambient condition.
138-050
June 2015
Supersedes 01-10
SYNTHETIC LUBRICANTS (TABLES 7A, 7B & 7C) —
Synthetic lubricants of the polyalphaolefin (PAO) 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 4.
Polyalkylene glycols (PAG) are another class of synthetic
lubricants. They have similar performance properties
as PAO synthetics - low pour point, stable at elevated
temperatures, and high viscosity index. PAG's have
exceptional tolerance to water contamination.
WARNING: Polyalkylene glycols (PAG’s) are not
compatible with petroleum mineral oil or PAO synthetic
lubricants and must not be topped off with either lubricant.
In addition, petroleum mineral oils or PAO synthetic
lubricants must not be used to top off systems containing
PAG’s. Do not use PAG’s in gear drives with painted interior
housing walls unless paint compatibility is checked.
Compatibility with oil seals and gasket materials must be
checked prior to use. PAG lubricants are not compatible
with polycarbonate sight glass. Use glass sight glass.
Falk GMax 6000 – Rexnord markets Falk GMax 6000, a
polyalkylene glycol lubricant. It is available in ISO VG 135
and covers ambient air temperature range -30° to +125°F
(-34° to +52°C).
WARNING: GMax 6000 is not compatible with petroleum
mineral oil or PAO synthetic lubricants and must not be
topped off with either lubricant. In addition, petroleum
mineral oils or PAO synthetic lubricants must not be used
to top off systems containing GMax 6000. Do not use
GMax 6000 in gear drives with painted interior housing
walls unless paint compatibility is checked. Compatibility
with oil seals and gasket materials must be checked prior
to use. GMax 6000 is not compatible with polycarbonate
sight glass. Use glass sight glass.
ANTI-WEAR (AW) LUBRICANTS — For moderately
loaded gear drives or operating conditions challenging
for conventional R & O oils, industrial type anti-wear (AW)
lubricants are suggested. These lubricants contain antiwear additives that provide stronger thicker lubricant film
to help maintain surface separation. Synthetic lubricants
by inherent nature of base stock properties provide antiwear performance.
EXTREME PRESSURE (EP) LUBRICANTS (TABLES 6B
& 7B) — For highly loaded drives or for drives loaded in
excess of original estimates, industrial-type petroleum EP
lubricants are preferred. EP lubricants are manufactured
from petroleum or synthetic base lubricants. Anti-scuff is
another term used to describe EP lubricants.
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
Falk® Enclosed Gear Drives • Installation and Maintenance
Type A Series • Sizes 305 thru 585
(Page 7 of 17)
MICROPITTING RESISTANT LUBRICANTS (TABLES 6C & 7C)
OIL PUMPS — When selecting a lubricant for a gear drive
— Micropitting resistant lubricants are specially developed
equipped with an oil pump, cold temperature oil viscosity is
for surface hardened gearing commonly used in modern
important. Lubricant viscosity at start-up generally should not
industrial gear drives. These lubricants contain additives to
exceedDrives
1725 cSt (8,000
SSU). When exceeding
this viscosity,
Installation
and Maintenance
Falk™ Enclosed Gear
Gear
Drives is•
Installation
Maintenance
•possible,
resist formation of micropitting and other conventional forms
pump cavitation
preventingand
oil circulation.
A sump
of gear wear. Highly loaded gear drives or applications
heater may be required or it may be possible to use a lower
305
thru
585
(Page
Type
A
Sizes
305 oil
thru
585 pump cavitation.
(Page 5
5 of
of 11)
11)
Type
A Series
Series
• Sizes
where operating loads are not well defined may
benefit
from •
viscosity
to minimize
this type of lubricant. Generally lubricants are available in
Drives with Oil Pumps Types AXV and occasionally other
limited number of viscosity grades.
types
of gear drives will be equipped with oil pumps for
Fastener
Tightening
Torques
Water
Fastener LUBRICANTS
Tightening IN
Torques
WaterorCooling
Cooling
WARNING:
FOOD PROCESSING
cooling
special lubrication considerations. If a drive is
WATER
HEAT
EXCHANGERS
Install
shut-off
Use
torque
values
in
for
WATER COOLED
COOLED
HEAT
EXCHANGERS
—the
Install
amarked
shut-off
INDUSTRY
— Generally
gear lubricants
equipped
with an oil
pump,
fill the drive to—
levela
Use the
the tightening
tightening
torqueconventional
values specified
specified
in Table
Table 1
1are
for
or
valve
in
water
line
heat
exchanger
fastening
Falk™
gear
motors
and
or control
control
valve Run
in the
thethe
water
line to
to the
the
heat for
exchanger
to
classified
H2 by
NSFdrives,
(National
Sanitation
Foundation)to
on
the dipstick.
lubrication
system
several to
fastening as
Falk™
gear
drives,
motors
and accessories
accessories
to
regulate
the
flow
the
Also
install
a
regulate to
thefillwater
water
flow through
through
the exchanger.
exchanger.
Alsothe
install
a
since
they contain
harmfulwith
substances
and should
not be
minutes
the system
components.
Verify that
pump
their
surfaces
un-lubricated
fasteners.
DO
their mounting
mounting
surfaces
with
un-lubricated
fasteners.
DO
water
flow
gauge
between
the
control
valve
and
the
water
flow
gauge
between
the
control
valve
and
the
used
in
the
food
processing
industry.
Lubricants
registered
is
circulating
oil
properly,
then
recheck
oil
level.
If
necessary,
NOT
use
these
values
for
“torque
locking”
fasteners
or
NOT use these values for “torque locking” fasteners or
exchanger
to
actual
rate.
Discharge
exchanger
to determine
determinefor
actual
flow
rate.
Discharge water
water to
to
as
by NSF components
are suitable for
food
processing
add
oil to compensate
filterflow
and/or
cooler.
forH1
fastening
with
aluminum
feetapplications.
or soft
soft
for
fastening
components
with
aluminum
feet
or
an
an OPEN
OPEN DRAIN
DRAIN to
to prevent
prevent back
back pressure.
pressure.
CLIMATE
— Ambient
temperature
gaskets orCONDITIONS
vibration dampeners
on the
mounting in
surface.
Before starting the gear drive, rotate the input shaft to check
INTERNAL
COOLING
TUBES
—
to Manual
138-310
INTERNAL
COOLING
TUBES
— Refer
Refer
Manual
138-310
IfIf the
torque
exceeds
the
capacity
of
immediate
vicinity
of gear
drive is
important
for
obstructions.
Then start
the drive
andto
allow
it to run
without
the tightening
tightening
torque
exceeds
thevery
capacity
of the
thefortorque
torque
for
installation,
operation,
and
maintenance
of
internal
for
installation,
operation,
and
maintenance
of
internal
determining
viscosity
grade.
Table
3
provides
viscosity
load
for
several
minutes.
Shut
down
and
recheck
oil
level.
If
wrench,
use
a
torque
multiplier.
For
inch
fasteners,
use
wrench, use a torque multiplier. For inch fasteners, use
cooling
cooling tubes.
tubes.
grade
for petroleum-based
See A
everything
is satisfactory, the drive is ready for operation.
Grade
5
though
inch
Gradeselections
5 for
for diameters
diameters
though 1.500
1.500 lubricants.
inch and
and ASTM
ASTM
A
Table
4 for synthetic
lubricants.
354 grade
BC for larger
diameter fasteners. Use ISO
354 grade BC for larger diameter fasteners. Use ISO
property
property class
class 8.8
8.8 for
for metric
metric fasteners.
fasteners.
OIL LEVELS
Types A & AB Prior to filling gear drive or after storage, remove
the
inspection
and flood the
oil troughs +/-5%
with oil. The
TABLE
1
Tightening
Torques:
TABLE
1—
—cover
Tightening
Torques:
+/-5%
oil troughs sit directly
beneath
the inspection
cover and can
DO
NOT
Lubricate
Fasteners
DO NOT Lubricate Fasteners
be filled to flooding, typically with a volume of approximately
Fasteners
–– Grade
55 to the bearings. Fill
Inch
Fasteners
Gradeoil
10% of the sump lube.Inch
This
will provide
theFastener
drive with oil to the
level
indicated
on
the Metal
oil dipstick.
The
Metal
to
Metal
to
Metal to Metal
Metal
to Concrete
Concrete
Fastener
approximate
oil capacity
is given
on the gear
drive nameplate.
Size
lb-ft
Nm
lb-ft
Nm
Size
lb-ft
Nm
lb-ft
Nm
For reference, approximate capacities are also given in Table 9.
.250-20
77
10
66
88
.250-20
10
Always
fill to proper15
level indicated
.3125-18
21 on the dipstick.
12
16
.3125-18
15
21
12
16
1.375-6
1360
1860
1100
1480
.375-16
37
30
.375-16 that have27
27been inactive
37 for greater22
22than 1 month,
30
For drives
.500-13
67
91
54
73
.500-13
67
91
54
73oil.
remove
the
inspection
cover
and
flood
the
oil
troughs
with
.625-11
134
184
108
146
.625-11
134
184
108
146
The .750-10
oil troughs sit directly
beneath
the
inspection
cover
and
242
330
194
265
.750-10
242
330
194
265
can be
filled to flooding.
This will
.875-9
395
530
315
425
.875-9
395
530ensure proper
315 lubrication
425 of
800
640
the 1.000-8
bearings. After590
filling the unit
starting, ensure
1.000-8
590
800and before475
475
640
1.125-7
740
1000
590
800
740not exceed
1000
800
that1.125-7
the oil levels do
those on the590dipstick. Always
1.250-7
1060
1420
840
1140
fill to1.375-6
proper level indicated
on 1860
the dipstick.1100
1360
1480
1.500-6
1840
2480
1460
1.500-6
1840and AR Fill
2480the drive with
1460 oil to the1980
1980
Types
ABR, ABRC,
level
1.750-5
3900
5300
2700
4240
1.750-5
3900
5300
2700
4240
indicated
on the oil
dipstick. Approximate
oil capacities
are
2.000-4.5
5900
7900
4100
6300
2.000-4.5
5900
7900
4100
6300
given
on the nameplate
and in
Table 10. 6000
2.250-4.5
8600
11800
9400
2.250-4.5
8600
11800
6000
9400
2.500-4
2.500-4
2.750-4
2.750-4 3
TABLE
3.000-4
3.000-4
—
Output
11800
11800
14600
14600
Viscosity
19400
19400
16000
16000
19800
19800
Grade
26400
26400
8300
12800
8300
12800
15800
10200
15800
Recommendations
13600
21100
13600
21100
For All Petroleum Lubricants
Ambient Temperature Range
TABLE
Torques:
+/-5%
1A —
TABLE
— Tightening
Torques:+50°
+/-5%
RPM
+15°Lubricate
to +60°F Fasteners
to +125°F
DO
DO NOT
NOT
Lubricate
Fasteners
(–9° to +16°C)
(+10° to +52°C)
Fastener
Fastener
Below
Size
Size80
80
M4
.7
M4&xx Above
.7
M5
M5 xx .8
.8
M6
M6 xx 1.0
1.0
M8
TABLE
M8 xx 1.25
1.25 4
M10
M10 xx 1.5
1.5
M12
M12 xx 1.75
1.75
M16
xx 22
Output
M16
M20
xx 2.5
RPM
M20
2.5
M30
M30 xx 3.5
3.5
M36
M36 xx 44
M42
4.5
Below
M42 xx 80
4.5
M48
55
80
& xxAbove
M48
M56
x
M56 x 5.5
5.5
Metric
Metric Fasteners
Fasteners –– Property
Property Class
Class 8.8
8.8
ISO-VG
AGMA
ISO-VG
AGMA
Metal to
to Metal
Metal
Metal to
Metal
Metal
to Concrete
Concrete
150
4
320
6
lb-ft
Nm
lb-ft
Nm
Lubrication
Lubrication Systems
Systems
LUBRICATION
SYSTEMS
SPLASH
——
Standard
typetype
A, AR,
SPLASH LUBRICATED
LUBRICATED
DRIVES
SPLASH
LUBRICATEDDRIVES
DRIVES
Standard
A, AB,
ABR,
and
ABRC
drives
are
splash
lubricated.
lubricant
ABR,AB,
andABR,
ABRCand
drives
are drives
splash are
lubricated.
The
lubricant is
is
AR,
ABRC
splash The
lubricated.
picked
up
revolving
and
to
picked
up by
by the
the
revolving
elements
and distributed
distributed
to the
the
The
lubricant
is picked
upelements
by the revolving
elements
and
bearings
meshes.
bearings and
and
gear
meshes. and gear meshes.
distributed
to gear
the bearings
OIL
PUMP
LUBRICATED
—
Types
AXV
and
ABX
OIL
PUMP
LUBRICATED
DRIVES
——
Types
AXVAXV
and and
ABX are
are
OIL PUMP LUBRICATEDDRIVES
DRIVES
Types
equipped
with
oil
pump
provide
the
equipped
with an
an external
external
oilexternal
pump to
tooil
provide
oil
toprovide
the upper
upper
ABX
are equipped
with an
pumpoil
toto
bearings
gear
meshes.
The
system
is
of
bearings
and
gear
meshes.and
The gear
system
is composed
composed
of an
an
oil
to the and
upper
bearings
meshes.
The system
electric
motor
driven
gear
oil
filter,
indicator
electric
motor of
driven
gear pump,
pump,
oil driven
filter, flow
flow
indicator
with
is
composed
an electric
motor
gear
pump, with
oil
switch,
and
an
distribution
network
with
valve
switch,
andindicator
an internal
internal
distribution
network
with relief
relief
valve (set
(set
filter,
flow
with
switch, and
an internal
distribution
at
The
pump
system
may
be
a
or
at 30
30 psi).
psi).
Therelief
pumpvalve
system
may
be furnished
furnished
with
a 50
50
or
network
with
(set
at 30
psi). The with
pump
system
60Hz,
phase
based
the
Refer
60Hz,be3
3 furnished
phase electrical
electrical
motors
based on
on
the selection.
selection.
Refer to
to
may
with amotors
50 or 60Hz,
3 phase
electrical
the
motor
and
for
electrical
the pump
pump
motoronnameplate
nameplate
and Table
Table
2 to
forthe
electrical
motors
based
the selection.
Refer2
pump motor
requirements.
Wire
the
for
rotation
requirements.
Wire
the 5motor
motor
for correct
correct
rotation as
as indicated
indicated
nameplate
and
Table
for electrical
requirements.
Wire
by
rotation
arrow.
flow
has
pole,
by the
the
rotation
arrow. The
The
flow indicator
indicator
has a
abysingle
single
pole,
the
motor
for correct
rotation
as indicated
the rotation
double
throw
switch
rated
15A,
125V/7A,
maximum.
doubleThe
throw
switch
rated at
at
15A,
125V/7A,
250V
maximum.
arrow.
flow
indicator
has
a single
pole,250V
double
throw
Connect
the
indicator
switch
with
the
control
Connect
the flow
flow
indicator
switch250V
with maximum.
the prime
prime mover
mover
control
switch
rated
at 15A,
125V/7A,
Connect
the
circuitry
to
prevent
drive
operation
without
the
lubrication
circuitry
to
prevent
drive
operation
without
the
lubrication
flow indicator switch with the prime mover control circuitry
system.
system.
to
prevent drive operation without the lubrication system.
TABLE
Oil Pump
PumpElectrical
ElectricalSpecifications
Specifications
TABLE 2
2
TABLE
5 — Oil
DRIVE
DRIVE
405
405 &
& 425
425
SIZE
SIZE
HP
1
1
HP
Cycles, Hz
Hz
50
60
Cycles,
50
60
RPM
1425
1725
RPM
1425
1725
Voltage
208Voltage
220/380/440 208220/380/440
230/460
230/460
445-485
445-485
505-535
505-535
22
33
60
50
60
60
50
60
1725
1425
1725
1725
1425
1725
208208208208220/380/440
220/380/440
220/380/440
230/460 220/380/440 230/460
230/460
230/460
50
50
1425
1425
Other types of gear drives may also be equipped with oil
Other
of
drives
also
with
pumps
for special
lubrication
considerations
or external
cooling.
Other types
types
of gear
gear
drives may
may
also be
be equipped
equipped
with oil
oil
pumps
for
special
lubrication
considerations
or
external
pumps
for
special
lubrication
considerations
or
external
CAUTION:
Refer to Factory for drives that use pumps to
cooling.
cooling. lubricants with temperatures below 30°F (-1°C).
distribute
Caution:
Caution: Refer
Refer to
to Factory
Factory for
for drives
drives that
that use
use pumps
pumps to
to
lubricants
with
distribute
lubricants Lubricants
with temperatures
temperatures below
below 30°F
30°F (-1°C).
(-1°C).
fordistribute
All Synthetic
150
4
52
22
1.5220
33
66
3.5
55
4.5
3.5
7.5
10
66
88
7.5
10
18
24
14
19
— Viscosity
Grade
Recommendations
18
24
14
19
36
50
29
39
36
50
29
39
Cold
Climates
Normal Climates
62
84
50
68
62
84
50
68
Lubrication
Recommendations
Lubrication
Recommendations
56
210
126
170
–30°
to
+10°F
–15°
to
+50°F
0°
to
+80°F
+10° to +125°F
+20° to +125°F
56
210
126
170
305
246
(–34°
(–26°
(–18°Carefully
to +27°C) follow lubrication
(–12° to +52°C)
(–7°
to +52°C)
305 to –12°C)415
415
246 to +10°C) 330
330
instructions
on
the
gear
drive
Carefully
follow
lubrication
instructions
on
the
gear
drive
1060
11 440
850
11 150
1060
440
850
150
nameplate,
warning
tags,
and
installation
manuals
furnished
ISO-VG
AGMA
ISO-VG
AGMA
ISO-VG
AGMA
ISO-VG
AGMA
ISO-VG
AGMA
nameplate, warning tags, and installation manuals furnished
1680
22 520
1500
22 030
1680
520
1500
030
with
the
gear
drive.
with
the
gear
drive.
3000
4
050
2400
3
250
32
04 050
682400
2 3 250
150
4
320
6
320
6
3000
4500
32
066 100
683600
2 44 880
150 Lubricants
4 listed
5 typical
320
6
this
and
4500
100
3600
880
Lubricants
listed in
in 220
this manual
manual are
are
typical ONLY
ONLY
and should
should
7300
9
850
5800
7
860
7300
9 850
5800
7 860
not be construed as exclusive recommendations. Industrial
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
not be construed as exclusive recommendations. Industrial
type
type petroleum
petroleum based
based rust
rust and
and oxidation
oxidation inhibited
inhibited (R
(R &
& O)
O)
gear
extreme
gear lubricants
lubricants or
or industrial
industrial type
type sulfur-phosphorus
sulfur-phosphorus 138-050
extreme
pressure
pressure (EP)
(EP) gear
gear lubricants
lubricants are
are the
the recommended
recommended lubricants
lubricants
June 2015
for
to
+50°C).
for ambient
ambient temperatures
temperatures of
of 15°F
15°F to
to 125°F(-9°C
125°F(-9°C
to
+50°C).
Supersedes 01-10
For
For drives
drives operating
operating outside
outside the
the above
above temperature
temperature range
range
refer to “Synthetic Lubricants” paragraphs, Page 7. Synthetic
Falk® Enclosed Gear Drives • Installation and Maintenance
(Page 8 of 17)
Type A Series • Sizes 305 thru 585
PREVENTIVE MAINTENANCE
LUBRICANT ANALYSIS AND CHANGES
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.
OIL ANALYSIS REPORT — Checking oil condition at
regular intervals is recommended. Analyze oil samples
approximately every 1000 hours for petroleum lubricants
or every 3000 hours for synthetic lubricants. In the
absence of more specific limits, the guidelines listed below
may be used to indicate when to change petroleum or
polyalphaolefin type synthetic lubricants:
1. Water content is greater than 500 ppm (parts per
million) (0.05%).
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. TAN (Total Acid Number) 50% increase above reference
sample from new oil container.
6. Viscosity changes more than ±15%.
7. Solid particle contamination code exceeds 25/22/18 for
particle sizes ≥4/≥6/≥14 microns, respectively per ISO
4406.
Guidelines for when to change Falk GMax 6000
polyalkylene glycol type lubricant are:
1. Water content is greater than 3%.
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. Viscosity changes more than ±15%.
6. Solid particle contamination code 25/22/18 per ISO
4406.
Laboratory analysis is recommended for optimum lubricant
life and gear drive performance.
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 100°F (38°C) 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. C
lose the drain and refill the drive to the correct level with
new oil of the correct type and viscosity.
PERIODICALLY —
1. C
heck 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. C
heck 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.
5. P
urge grease from grease lubricated seals WITH HAND
GREASE GUN. Regrease those bearings requiring
grease lubrication.
138-050
June 2015
Supersedes 01-10
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
Falk® Enclosed Gear Drives • Installation and Maintenance
Type A Series • Sizes 305 thru 585
(Page 9 of 17)
TABLE 6A — Petroleum Based R & O (Rust & Oxidation) Inhibited Lubricants s
Maximum Operating Temperature of Lubricants 200°F (93°C)
ISO Viscosity Grade
AGMA Viscosity Grade
Viscosity cSt @ 40°C 
Viscosity SSU @ 100°F
Manufacturer
Castrol Industrial Lubricants
Chevron / Texaco / Caltex
Citgo Petroleum Corp.
Exxon Mobil / Esso
Petro-Canada Lubricants
Phillips 66 / Conoco / 76 Lubricants / Kendall
Shell Oil Co.
Total Lubricants USA / Keystone Div. Penwalt Corp.
Whitmore Manufacturing Company
150
4
135-165
626-765
Lubricant Name
Hyspin AWS 150
Castrol Paradene R&O 150
Castrol Paradene AW 150
Rando HD 150
Pacemaker T 150
DTE Oil Extra Heavy
Vacuoline 528
TurboFlo R&O 150
Multipurpose R&O 150
Morlina S2 B 150
Morlina S2 BA 150
Cirkan ZS 150
Hyperion 150
220
5
198-242
918-1122
Lubricant Name
Hyspin AWS 220
Castrol Paradene R&O 220
Castrol Paradene AW 220
Rando HD 220
Pacemaker SD 220
DTE Oil BB
Vacuoline 533
TurboFlo R&O 220
Multipurpose R&O 220
Morlina S2 B 220
Morlina S2 BA 220
Cirkan ZS 220
Hyperion 220
320
6
288-352
1335-1632
Lubricant Name
--Castrol Paradene R&O 320
Castrol Paradene AW 320
Rando HD 320
Pacemaker SD 320
DTE Oil AA
Vacuoline 537
TurboFlo R&O 320
Multipurpose R&O 320
Morlina S2 B 320
Morlina S2 BA 320
Cirkan ZS 320
Hyperion 320
cc Minimum viscosity index of 90.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
TABLE 6B — Petroleum Based EP (Extreme Pressure) Lubricants s
Maximum Operating Temperature of Lubricants 200°F (93°C)
ISO Viscosity Grade
AGMA Viscosity Grade
Viscosity cSt @ 40°C 
Viscosity SSU @ 100°F
Manufacturer
Castrol Industrial Lubricants
Chevron / Texaco / Caltex
Citgo Petroleum Corp.
Exxon Mobil / Esso
Fuchs Lubricants Company
Kluber Lubrication
Petro-Canada Lubricants
Phillips 66 / Conoco / 76 Lubricants / Kendall
Shell Oil Co.
Total Lubricants USA / Keystone Div. Penwalt Corp.
150
4
135-165
626-765
Lubricant Name
Alpha SP 150
Meropa 150
Ultra Gear 150
EP Compound 150
Mobilgear 600 XP 150
--Kluberoil GEM 1 N 150
Enduratex EP 150
Extra Duty Gear Oil 150
Omala S2 G 150
Carter EP 150
220
5
198-242
918-1122
Lubricant Name
Alpha SP 220
Meropa 220
Ultra Gear 220
EP Compound 220
Mobilgear 600 XP 220
GearMaster CLP Oils 220
--Enduratex EP 220
Extra Duty Gear Oil 220
Omala S2 G 220
Carter EP 220
320
6
288-352
1335-1632
Lubricant Name
Alpha SP 320
Meropa 320
Ultra Gear 320
EP Compound 320
Mobilgear 600 XP 320
----Enduratex EP 320
Extra Duty Gear Oil 320
Omala S2 G 320
Carter EP 320
cc Minimum viscosity index of 90.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
TABLE 6C — Petroleum Based Micropitting Resistant Lubricants s
Maximum Operating Temperature of Lubricants 200°F (93°C)
ISO Viscosity Grade
AGMA Viscosity Grade
Viscosity cSt @ 40°C 
Viscosity SSU @ 100°F
Manufacturer
Kluber Lubrication
150
4
135-165
626-765
Lubricant Name
---
220
5
198-242
918-1122
Lubricant Name
Kluberoil GEM 1 N 220
320
6
288-352
1335-1632
Lubricant Name
Kluberoil GEM 1 N 320
cc Minimum viscosity index of 90.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
138-050
June 2015
Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance
(Page 10 of 17)
Type A Series • Sizes 305 thru 585
TABLE 7A — Synthetic PAO (Polyalphaolefin) R & O (Rust & Oxidation) Inhibited Lubricants s
ISO Viscosity Grade
AGMA Viscosity Grade
Viscosity cSt @ 40°C 
Viscosity SSU @ 100°F
Manufacturer
Castrol Industrial Lubricants
Chevron / Texaco / Caltex
Citgo Petroleum Corp.
Exxon Mobil / Esso
Kluber Lubrication
Petro-Canada Lubricants
Phillips 66 / Conoco / 76
Lubricants / Kendall
Shell Oil Co.
32
0
28.8-35.2
134-164
Lubricant Name
Alphasyn T 32
Castrol Isolube 32
Cetus HiPerSYN Oil 32
--Mobil SHC 624
--Synduro SHB 32
68
2
61.2-74.8
284-347
Lubricant Name
150
4
135-165
626-765
Lubricant Name
220
5
198-242
918-1122
Lubricant Name
320
6
288-352
1335-1632
Lubricant Name
Alphasyn T 68
Alphasyn T 150
Alphasyn T 220
Alphasyn T 320
Castrol Isolube 68
Castrol Isolube 150
Castrol Isolube 220
Castrol Isolube 320
Cetus HiPerSYN Oil 68
Cetus HiPerSYN Oil 150
Cetus HiPerSYN Oil 220
Cetus HiPerSYN Oil 320
CITGEAR Synthetic HT 68 CITGEAR Synthetic HT 150 CITGEAR Synthetic HT 220 CITGEAR Synthetic HT 320
Mobil SHC 626
Mobil SHC 629
Mobil SHC 630
Mobil SHC 632
Klubersynth G 4 68
Klubersynth G 4 150
Klubersynth G 4 220
--Synduro SHB 68
Synduro SHB 150
Synduro SHB 220
---
---
Syncon R&O 68
Syncon R&O 150 
Syncon R&O 220 
Syncon R&O 320 
---
Morlina S4 B 68
Morlina S4 B 150
Morlina S4 B 220
Morlina S4 B 320
cc Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
zz Minimum viscosity index of 120.
TABLE 7B — Synthetic PAO (Polyalphaolefin) EP (Extreme Pressure) Lubricants s
ISO Viscosity Grade
AGMA Viscosity Grade
Viscosity cSt @ 40°C 
Viscosity SSU @ 100°F
Manufacturer
32
0
28.8-35.2
134-164
Lubricant Name
68
2
61.2-74.8
284-347
Lubricant Name
150
4
135-165
626-765
Lubricant Name
220
5
198-242
918-1122
Lubricant Name
320
6
288-352
1335-1632
Lubricant Name
Castrol Industrial Lubricants
---
--Castrol Isolube EP 68
Alphasyn EP 150
Castrol Isolube EP 150
Alphasyn EP 220
Castrol Isolube EP 220
Alphasyn EP 320
Castrol Isolube EP 320
Chevron / Texaco / Caltex
---
---
Citgo Petroleum Corp.
---
Exxon Mobil / Esso
Fuchs Lubricants Company
Kluber Lubrication
Petro-Canada Lubricants
Phillips 66 / Conoco / 76
Lubricants / Kendall
Shell Oil Co.
Whitmore Mfg. Company
---------
CITGEAR Synthetic
EP Gear 68
---------
Tegra Synthetic Gear
Tegra Synthetic Gear
Tegra Synthetic Gear
Lubricant 150
Lubricant 220
Lubricant 320
CITGEAR Synthetic
CITGEAR Synthetic
CITGEAR Synthetic
EP Gear 150
EP Gear 220
EP Gear 320
Mobil SHC Gear 150
Mobil SHC Gear 220
Mobil SHC Gear 320
--Renolin Unisyn CLP 220
Renolin Unisyn CLP 320
Klubersynth EG 4 150
Klubersynth EG 4 220
Klubersynth EG 4 320
Enduratex Synthetic EP 150 Enduratex Synthetic EP 220 Enduratex Synthetic EP 320
---
---
Syncon EP Plus Gear Oil 150 Syncon EP Plus Gear Oil 220 Syncon EP Plus Gear Oil 320
-----
Omala S4 GX 68
---
Omala S4 GX 150
Decathlon HD 150
Omala S4 GX 220
Decathlon HD 220
Omala S4 GX 320
Decathlon HD 320
cc Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
TABLE 7C — Synthetic PAO (Polyalphaolefin) Micropitting Resistant Lubricants s
ISO Viscosity Grade
AGMA Viscosity Grade
Viscosity cSt @ 40°C 
Viscosity SSU @ 100°F
Manufacturer
Chevron / Texaco / Caltex
Exxon Mobil / Esso
Kluber Lubrication
Petro-Canada Lubricants
Phillips 66 / Conoco / 76 Lubricants / Kendall
Whitmore Manufacturing Company
32
68
0
2
28.8-35.2
61.2-74.8
134-164
284-347
Lubricant Name Lubricant Name
-------------
-------------
150
4
135-165
626-765
Lubricant Name
220
5
198-242
918-1122
Lubricant Name
320
6
288-352
1335-1632
Lubricant Name
----Pinnacle WM 320
----Mobil SHC Gear 320 WT
Klubersynth GEM 4 N 150 Klubersynth GEM 4 N 220 Klubersynth GEM 4 N 320
----Harnex 320
----Syncon WTL 320
Decathlon F 150
Decathlon F 220
Decathlon F 320
cc Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
138-050
June 2015
Supersedes 01-10
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
Falk® Enclosed Gear Drives • Installation and Maintenance
Type A Series • Sizes 305 thru 585
(Page 11 of 17)
Installation and Maintenance • Falk™ Enclosed Gear Drives
PETROLEUM LUBRICANTS — In the absence of oil
analysis, change gear oils every 6 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,
lubricants should be changed every 3 to 4 months or
1500 to 2000 hours. If the drive is operated in an area
where temperatures vary with the seasons, change the oil
viscosity grade to suit the temperature, refer to Table 3.
Lubricant suppliers can test oil from the drive periodically
and recommend economical change schedules.
SYNTHETIC LUBRICANTS — In the absence of oil
analysis, synthetic lube change intervals can be extended
to 8000 hours depending upon operating temperatures.
Laboratory analysis is recommended for optimum lubricant
life and drive performance. Change lube with change in
ambient temperature, if required. Refer to Table 5.
Falk GMax 6000 change interval can be up to 15,000
hours. It has broad temperature range so seasonal oil
changes are generally not needed. The condition of
GMax must be monitored to maintain lubricant properties
and cleanliness.
GREASE-LUBRICATED SEALS AND
BEARINGS
All drives and some backstops are furnished with grease
purged seals which minimize the entry of contaminants
and abrasive dusts. Some vertical shaft and specially
mounted drives have grease lubricated bearings. Drives
are shipped with NLGI #2 grade grease in the seal housing
cavities unless otherwise specified.
Whenever changing oil in the drive, purge the seals with
one of the NLGI #2 grade greases listed in Table 8.
Depending upon the degree of contamination, periodically
(at least every six months), purge contaminated grease
from seals by slowly pumping fresh bearing grease
through the seal, WITH HAND GREASE GUN, until fresh
grease flows out along the shaft. Wipe off purged grease.
CAUTION: Rapid greasing with a power grease gun
can force grease inward past the seals and plug the oil
drainback system causing seal leaks.
TABLE 8 — Conventional NLGI #2 Grade Grease s for
0° to +200°F (-18° to +93°C)
(Page 8 of 11)
Sizes 305 thru 585 • Type A Series
WARNING: Greases in Table 8 contain harmful substances
not allowed in the food processing industry. If grease could
GREASE LUBRICATED
SEALS
gear drives
and industries,GREASE LUBRICA
contaminate
the product,
as—inMost
the food
and drug
backstops
furnishedsupplied
with grease
purged
which
with hollow shaft
the
greaseare
originally
with
gearseals
drive
must be
minimize and
the entry
of contaminants
into the
driveinorTable
backstop.
removed
replaced
with grease
listed
19. Simplylubricated lower
Gear drives and backstops are shipped with #2 grease in the
purging
grease
withunless
grease
gun will
not remove
all grease lubricated at the
seal housing
cavities
otherwise
specified.
If grease
to the preventive
and
cross-contamination
will
likely
occur.
Remove
could contaminate the product, as in the food and drug end cover
and
manually
remove
grease.AGrease
registered
as H1 by instructions.
industries,
it should
be removed.
grease that
meets USDA
BACKSTOPS — F
“H1”National
classification
is suitable
for food processing
applications.
NSF,
Sanitation
Foundation,
is suitable
for food
later, backstops ar
processing applications.
FOR GREASING
SEAL
SEAL DRAIN
CAVITY
SEAL DRAIN
CAVITY
PLUG
(BUNA-N)
Oil Levels
Types A & AB Prio
of the drive for grea
cover and flood the
LOW OIL LEVEL
HIGH OIL LEVEL
Sizes 385 & 405 thru 585
Sizes 385 & 405 thru 585
beneath the inspec
Inner Bush Seal and Outer
Two Lip Type Oil Seals
typically with a volu
Lip Type Seal
This will provide oil
level indicated on t
given on the gear d
FOR
capacities are also
FOR
GREASING
GREASING
high oil levels. Act
SEAL
SEAL
depending on the
SEAL
SEAL
COVER
Always fill to prope
COVER
BUSH
BUSH
Types ABR, ABRC
SEAL
SEAL
indicted on the oil
SEAL
SEAL
DRAIN
DRAIN
given on the name
CAVITY
CAVITY
Drives with Oil P
types of gear drive
cooling or special
equipped with an
SEAL GAGE PLUG
on the dipstick. Ru
BASE PLUG
BASE PLUG
to fill the system co
circulating oil prop
oil to compensate
HIGH OIL LEVEL
LOW OIL LEVEL
Sizes 305 thru 365 & 395
Sizes 305 thru 365 & 395
Before starting the
Inner Bush Seal and Outer
Inner Bush Seal and Outer
for obstructions. T
Lip Type Seal
Lip Type Seal
without load for se
If everything
Grease Lubricated Bearings & Grease Purged Sealslevel.
operation.
Manufacturer
EP Grease n
Multifak EP 2
Lithoplex RT 2
Premium Lithium EP 2
Mobilith SHC 460 l
Mobilux EP 2
Citgo Petroleum Corp.
ExxonMobil / Esso
Petro-Canada Lubricants
s Not suitable for food grade applications.
n Caution: Do not use EP grease in backstop seals.
zz High performance synthetic alternate.
FOR GREASING
SEAL
THROTTLING
BUSH SEAL
Chevron / Texaco / Caltex
Phillips 66 / Conoco / 76 Lubricants / Kendall
Shell Oil Co.
Total Lubricants USA / Keystone Div. Penwalt Corp.
top of backstop an
Earlier models had
not use greases wi
additives.
Type “A” and “AR” d
or a Falk™ PRT we
backstops are prelu
no future lubricatio
purgeable seals (se
seals).
Falk™ PRT backst
from top of backst
arm.
TYPICAL SEAL ASSEMBLIES
Precision General Purpose EP2
138-050
Multiplex Red
Gadus S1 V220-2
Multis EP 2
Rexnord Industries, LLC,
January 2010
Supersedes 11-09
e
Grease application or re-lubrication should be done at temperatures above 20°F (-7°C). If grease must be applied at cooler temperatures consult factory or
lubricant supplier for recommendations.
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
138-050
June 2015
Supersedes 01-10
mal operating
mmediately.
e type and
rmed to
her) by
ual to 25 an oil flows
Refer to Table 8 for NLGI #2 greases. Some of these greases are
of the EP type and may contain toxic substances not allowed in
the® food
processingGear
industry.
A grease•that
meets the USDA
“H1”
Falk
Enclosed
Drives
Installation
and
Maintenance
classification is suitable for food processing applications.
CAUTION:
Rapid greasing with a power
grease
gun can •force
(Page
12 of 17)
Type
A Series
Sizes 305 thru 585
grease inward past the seals and plug the oil drainback system
causing seal leaks.
GREASE
LUBRICATED BEARINGS
(TYPES
AXVAXV
ANDAND
ABX)
BACKSTOPS — For types AB, ABR, and ABX model C
GREASE
LUBRICATED
BEARINGS
(TYPES
ect level with
— All hollow and most solid vertical low speed shaft drives
and later, backstops are furnished filled with oil. Remove
ABX) — All hollow and most solid vertical low speed shaft
have a grease lubricated lower low speed bearing. Grease
plug from top of backstop and replace with vent wired to
drives
have during
a grease
lubricated
lowofspeed
bearings
oil changes
or atlower
intervals
every 6bearing.
months
torque arm. Refer to the supplemental backstop installation
Theorbearing
is lubricated
at the
factoryis with
NLGI
ped and at
2500 hours
of operation
whichever
less. an
Table
11 #2
If the oil level grade
and maintenance instructions provided with the drive for
grease.
bearing
during
oil changes or at
contains
low Grease
speed bearing
grease
capacities.
dipstick, have
recommended lubricants. It is recommended to lubricate
intervals of every 6 months or 2500 hours of operation
HOLLOW SHAFT DRIVES — Remove the pressure relief plug
re in the oil
backstops during regular drive lubrication intervals. Earlier
whichever
is less. Refer
to
Table
8 for
NLGIcage
#2 grade
before
greasing.
Pump
grease
into
bearing
until
fresh
anger is
models had backstops that are grease lubricated, do
greases.
Table
11atcontains
low
speed
bearing
grease
grease
appears
the
plug.
Replace
the
pressure
relief
plug
mmediately
not use greases with molybdenum disulfide or other EP
capacities.
when
finished.
See
Figure
2
below.
he mark
additives.
Refer to
8 for NLGI
greases.
Some
of thesePump
greases
ay result.
Remove
theTable
pressure
relief#2
plug
before
greasing.
are
of
the
EP
type
and
may
contain
toxic
substances
not
Type “A” and “AR” drives may have a Falk pawl type
at foundation grease into bearing cage until fresh grease appears at the
allowed
in the
food
processing
industry.
A grease
that meets
backstop or a Falk PRT wedge ramp type backstop. Falk
plug.
Replace
the
pressure
relief
plug when
finished.
See
nment.
the USDA
“H1” classification is suitable for food processing
pawl backstops are prelubricated and sealed at assembly
2 below.
n accumulated Figure
applications.
and require no future lubrication. These backstops also
flector.
contain grease purgeable seals (see paragraph above for
for free
grease lubricated seals).
on at regular
e specific
indicate
m).
ng conditions,
g hours,
when gear
t laden
nts should be
urs. If the drive
with seasons,
icant suppliers
al change
Falk PRT backstops are shipped filled with oil. Remove plug
from top of backstop and replace with vent wired to torque
arm. Follow lubrication recommendations as outlined in the
supplemental backstop instructions furnished with the drive.
Installation and Maintenance • Falk™ Enclosed Gear Drives
(Page
Figure
2
10 of 11)
BACKSTOPS
BEARING GREASE FITTING
Sizes 305RELIEF
thru
585 • Type A Series
PLUG
— For types AB, , and ABX refer to the
supplemental
backstop
installation
and maintenance
TABLE
9 — Types
A&
AB Approximate
Oil Capacities ‡
instructions provided with the drive for recommended
Type A
lubricants. It is recommended to lubricate
backstops
DRIVE
during
regular
drive
lubrication
intervals.
If backstops
A1
A2
A3
A4
SIZE
are grease
do not use
Gallons lubricated,
Liters
Gallons
Litersgreases
Gallonswith Liters
Gallons
molybdenum disulfide or other EP additives.
305
3
11
4
15
4
15
Type “A” and
drives may
325
5 “AR” 19
6 have a23Falk™ pawl
6 type23
345
23 PRT wedge
8
30 type backstop.
9
34Falk™
backstop 6or a Falk™
ramp
365
10
38 prelubricated
13
49 sealed13at assembly
49 and
pawl backstops
are
and
385
10 future lubrication.
38
10 These 38
10 also contain
38
10
require no
backstops
395
12
45
16 paragraph
61 above
17 for grease
64
grease purgeable
seals (see
405
10 seals). 38
15
57
15
57
14
lubricated
425
14
53
20
76
21
79
20
Falk™ PRT
are 22a wedge83ramp type
445
22 backstops
83
29 and are
110 oil
28
lubricated.
in38
465
29 Follow110lubrication
30 recommendations
114
39 as outlined
148
485
32
121
144 furnished
57 with216
56
the supplemental
backstop38instructions
the
505
159
50
189
78
295
77
drive. 42
525
53
201
59
223
95
360
93
545
...
...
115
435
135
511
...
565
...
...
130
492
160
606
...
585
...
...
215
814
250
946
...
ge intervals
ng upon
n. Change oil
mely humid,
s, synthetic
or 4000 to
or optimum
Liters
AB2
Gallons
Liters
Type AB
AB3
Gallons
Liters
AB4
Gallons
Liters
38
11
42
11
42
11
42
53
76
106
144
212
291
352
...
...
...
11
14
22
30
31
39
48
...
...
...
42
53
83
114
117
148
182
...
...
...
15
20
29
39
52
70
87
111
142
220
57
76
110
148
197
265
329
420
538
833
15
22
30
39
58
80
100
138
170
275
57
83
114
148
220
303
379
522
644
1 041
DRIVE
SIZE
305
325
345
365
385
395
425
405
445
465
485
505
525
545
565
585
‡
‡ Capacities
Capacities vary
vary with
with ratio,
ratio, speed
speed and
and type
type of
of cooling.
cooling. Follow
Follow values
values on
on the
the gear
gear drive
drive nameplate.
nameplate. Always
Always fill
fill to
to proper
proper level
level indicated
indicated on
on the
the dipstick.
dipstick.
138-050
e, WI 53208-4200
TABLE 10 — Types AR, AVX, ABR,
DRIVE SIZE
Vertical Output
ABX4, AXV3, & AXV4
ABX3 & AXV2
Gallons
Liters
405
425
445
465
485
505
535
555
January 2010
and
ABX Approximate
Supersedes 11-09
10
15
25
30
40
50
70
100
Gallons
10
15
25
30
45
60
80
120
38
57
95
114
151
189
265
379
Oil Capacities
Horizontal Output
ABR3 & AR2
ABR4, AR3, & AR4 Gallons
Liters
Gallons
Liters
Liters
38
57
95
114
170
227
303
454
14
19
35
40
50
65
95
130
53
72
132
151
189
246
360
492
14/18
19/27
35/50
40/55
60/80
80/100
110/140
160/220
53/68
72/102
132/189
151/208
227/303
303/379
416/530
606/833
DRIVE
SIZE
405
425
445
465
485
505
535
555
Values
Values to
to right
right of
of slash
slash mark
mark are
are for
for type
type AR4
AR4 drives
drives when
when HS
HS Shaft
Shaft is
is above
above drive
drive center
center line.
line.
TABLE 11 — Types AXV and ABX – LS Shaft Lower Bearing Grease Capacity
Solid Shaft
DRIVE SIZE
138-050
June 2015
Supersedes
405 01-10
425
445
Hollow Shaft
Down
oz
8
12
12
Up
mL
237
355
355
oz
12
18
18
DRIVE
SIZE
Rexnord
oz
mL
mL
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone:
www.rexnord.com
355 414-342-3131
12 Fax: 414-937-4359
355
405
532
12
355
425
532
24
710
445
465
485
505
535
555
30
40
50
70
100
114
151
189
265
379
30
45
60
80
120
114
40
170
50
®
Falk227Enclosed65Gear
303
95
454
130
151
189
Drives
246
360
492
•
40/55
60/80
Installation
80/100
110/140
160/220
Type A Series • Sizes 305 thru 585
151/208
465
227/303
485
and
Maintenance
303/379
505
416/530
535
606/833
555
Values to right of slash mark are for type AR4 drives when HS Shaft is above drive center line.
(Page 13 of 17)
TABLE 11 — Types AXV and ABX – LS Shaft Lower Bearing Grease Capacity
Solid Shaft
DRIVE SIZE
Hollow Shaft
Down
405
425
445
465
485
505
535
555
Up
oz
mL
oz
mL
8
12
12
30
30
40
50
50
237
355
355
890
890
1180
1480
1480
12
18
18
40
40
50
50
60
355
532
532
1180
1180
1480
1480
1770
STORED & INACTIVE GEAR DRIVES
oz
mL
12
12
24
30
60
60
80
80
355
355
710
890
1770
1770
2370
2370
DRIVE SIZE
405
425
445
465
485
505
535
555
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.
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.
Gear drives ordered for extended storage can be treated at
the Factory with a special preservative and sealed to rustproof parts for periods longer than those cited previously.
CAUTION: Drives are not to be stored outdoors without
shelter. Standing water on drives significantly increases
risk of water ingression and rust. Installer assumes risk.
If a gear drive is to be stored, or is inactive after installation
beyond the above periods, add Nox-Rust VCI-10s vaporphase rust inhibitor. For drives that have oil installed, add
Nox-Rust VCI-10 vapor-phase rust inhibitor at the rate of 2%
of sump capacity as shown in Table 12. For drives without
oil , add Nox-Rust VCI-10 vapor-phase rust inhibitor at the
rate of one ounce per cubic foot of internal drive space.
Rotate the shafts several times by hand. Before operating,
138-050
drives which have been stored or inactive must be filled to
January 2010
the proper level with oil meeting the specifications given
Supersedes 11-09
in the manual. Refer to manual 128-014 for "Start-up after
Storage" instructions.
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.
WARNING: The rust preventative oil from the factory
and Nox-Rust VCI-10 are not H1 registered with the NSF
(National Sanitation Foundation) as suitable for food
processing applications. When Food Grade Lubricants are
to be used, it is the end users responsibility to properly
Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200
flush and prepare the drive for Food Grade service.
Telephone:
414-342-3131
Fax: information
414-937-4359
Contact the lubricant
manufacturer
for specific
e-mail:
info@rexnord.com
web:
www.rexnord.com
and flushing procedures.
TABLE 12 — N
ox-Rust VCI-10 s
Add to Stored or Inactive Drives with Conventional Gear Lubricants
Unit Size
Oil Capacity
Gallons
305
325
345
365
385
405
425
445
465
485
505
525
545
565
585
6
8
13
17
11
15
22
30
39
58
80
100
138
170
275
NOX-RUST VCI-10
2% of Sump Capacity
Gallons
2% of Sump Capacity
Quarts
2% of Sump Capacity
Ounces
0.12
0.17
0.26
0.34
0.22
0.30
0.44
0.60
0.78
1.16
1.60
2.00
2.76
3.40
5.50
0.5
0.7
1.0
1.4
0.9
1.2
1.8
2.4
3.1
4.6
6.4
8.0
11.0
13.6
22.0
15.4
21.1
33.3
43.5
28.2
38.4
56.3
76.8
99.8
148.5
204.8
256.0
353.3
435.2
704.0
s Product of Daubert Chemical Company, Chicago, IL.
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
138-050
June 2015
Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance
(Page 14 of 17)
Type A Series • Sizes 305 thru 585
FOOD GRADE LUBRICANTS
Rust and corrosion inhibitors used to protect gear drive
during shipment are not qualified as food grade fluids. Flush
out inhibitor oil before filling with food grade lubricant.
Tables 16A, 16B, 17A, 17B, 18 & 19 list food grade
lubricants that have performance properties meeting
Rexnord/Falk specifications. They are not exclusive
recommendations but serve as a guide for making proper
lubricant selections.
CLIMATE CONDITIONS — Ambient temperature in
immediate vicinity of gear drive is very important for
determining viscosity grade. Table 14 provides viscosity
grade selections for petroleum-based lubricants. See
Table 15 for synthetic lubricants.
Guidance for selecting petroleum-based and syntheticbased food grade lubricants are shown below in Table 13.
For general lubrication guidlines, refer to the first part of
the "Lubrication Recomendation" Section.
FOOD GRADE LUBRICANT SELECTION
PROCESS
1. Refer to Table 14 or 15 for proper lubricant viscosity
grade based on ambient temperature range.
2. Refer to Table 13 for summary of food grade lubricant
type.
3. Using proper food grade lubricant table and viscosity
grade, select desired lubricant manufacturer name.
4. Refer to Table Table 9 or 10 for approximate oil capacity
to purchase.
TABLE 14 — Viscosity Grade Recommendations
For All Food Grade PetroleumBased Lubricants
Output
RPM
TABLE 13 —Summary of Food Grade
Lubricants and Greases
Ambient Temperature Range
+15° to +60°F
(–9° to +16°C)
Petroleum-Based
R & O Inhibited
Extreme Pressure (EP)
See Table 16A
See Table 16B
Synthetic Lubricant, Polyalphaolefin Type (PAO)
R & O Inhibited
Extreme Pressure (EP)
See Table 17A
See Table 17B
Synthetic Lubricant, Polyalkylene Glycol Type (PAG)
Extreme Pressure (EP)
See Table 18
Food Grade Grease
See Table 19
+50° to +125°F
(+10° to +52°C)
ISO-VG
AGMA
ISO-VG
AGMA
Below 80
150
4
320
6
80 & Above
150
4
220
5
Polyalkylene glycols (PAG) are another class of synthetic
lubricants. They have similar performance properties
as PAO synthetics - low pour point, stable at elevated
temperatures, and high viscosity index. PAG's have
exceptional tolerance to water contamination.
WARNING: Polyalkylene glycols (PAG’s) are not
compatible with petroleum mineral oil or PAO synthetic
lubricants and must not be topped off with either lubricant.
In addition, petroleum mineral oils or PAO synthetic
lubricants must not be used to top off systems containing
PAG’s. Do not use PAG’s in gear drives with painted interior
housing walls unless paint compatibility is checked.
Compatibility with oil seals and gasket materials must be
checked prior to use. PAG lubricants are not compatible
with polycarbonate sight glass. Use glass sight glass.
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, preventing oil
circulation. A sump heater may be required or it may be
possible to use a lower viscosity oil to minimize pump
cavitation.
FOOD GRADE LUBRICANTS (TABLES 16A, 16B, 17A,
17B, 18 & 19) — Food grade lubricants are a class of
lubricants registered as H1 by NSF, National Sanitation
Foundation. They contain base stock and additives which
comply with Food and Drug Administration Title 21 CFR
178.3570 regulations for lubricants with incidental food
contact. Base stock can be petroleum oil or different types
of synthetic lubricant. Food grade lubricants are not same
as biodegradable or environmentally friendly lubricants.
TABLE 15 — Viscosity Grade Recommendations For Food Grade Synthetic Lubricants
Cold Climates
–30° to +10°F
–15° to +50°F
(–34° to –12°C)
(–26° to +10°C)
Output
RPM
Below 80
80 & Above
0° to +80°F
(–18° to +27°C)
Normal Climates
+10° to +125°F
(–12° to +52°C)
+20° to +125°F
(–7° to +52°C)
ISO-VG
AGMA
ISO-VG
AGMA
ISO-VG
AGMA
ISO-VG
AGMA
ISO-VG
AGMA
32
32
0
0
68
68
2
2
150
150
4
4
320
220
6
5
320
320
6
6
138-050
June 2015
Supersedes 01-10
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
Falk® Enclosed Gear Drives • Installation and Maintenance
Type A Series • Sizes 305 thru 585
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.
AFTER FIRST MONTH — Proceed as follows:
1. O
perate 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 100°F (38°C) 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. C
lose the drain and refill the drive to the correct level with
new oil of the correct type and viscosity.
PERIODICALLY —
1. C
heck 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. C
heck coupling alignment to make certain that
foundation settling has not caused excessive
misalignment.
(Page 15 of 17)
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.
5. Refer to Section on Grease-Lubricated Seals and
Bearings.
LUBRICANT ANALYSIS AND CHANGES
OIL ANALYSIS REPORT (FOOD GRADE) — Checking oil
condition at regular intervals is recommended. Analyze oil
samples approximately every 1000 hours for food grade
petroleum lubricants or every 3000 hours for food grade
synthetic lubricants. In the absence of more specific limits,
the guidelines listed below may be used to indicate when
to change food grade lubricants:
1. Water content is greater than 500 ppm (parts per
million) (0.05%).
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. TAN (Total Acid Number) 50% increase above
reference sample from new oil container.
6. Viscosity changes more than ±15%.
7. Solid particle contamination code exceeds 25/22/18 for
particle sizes ≥4/≥6/≥14 microns, respectively per ISO
4406.
TABLE 16A — Food Grade Petroleum-Based R & O (Rust & Oxidation) Inhibited Lubricants –
NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
ISO Viscosity Grade
150
220
AGMA Viscosity Grade
4
5
6
Viscosity cSt @ 40°C s
Viscosity SSU @ 100°F
135-165
198-242
288-352
Manufacturer
Bel-Ray Company, Inc.
Kluber Lubrication
Lubriplate Lubricants Co.
320
626-765
918-1122
1335-1632
Lubricant Name
Lubricant Name
Lubricant Name
No-Tox Gear Oil ISO 150
No-Tox Gear Oil ISO 220
No-Tox Gear Oil ISO 320
Paraliq P 150
---
---
Lubriplate FMO 900-AW
Lubriplate FMO 1100-AW
Lubriplate FMO 1700-AW
cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes).
TABLE 16B — Food Grade Petroleum-Based EP (Extreme Pressure) Lubricants – NSF (National
Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
ISO Viscosity Grade
150
220
AGMA Viscosity Grade
4
5
320
6
Viscosity cSt @ 40°C s
Viscosity SSU @ 100°F
135-165
198-242
288-352
626-765
918-1122
1335-1632
Manufacturer
Lubricant Name
Lubricant Name
Lubricant Name
Petro-Canada
Purity FG EP 150
Purity FG EP 220
Purity FG EP 320
Total Lubricants USA, Inc.
Nevastane EP 150
Nevastane EP 220
Nevastane EP 320
cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes).
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
138-050
June 2015
Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance
(Page 16 of 17)
Type A Series • Sizes 305 thru 585
TABLE 17A — Food Grade Synthetic PAO (Polyalphaolefin) R & O (Rust & Oxidation) Inhibited
Lubricants – NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
ISO Viscosity Grade
32
68
150
220
AGMA Viscosity Grade
0
2
4
5
6
Viscosity cSt @ 40°C s
28.2-35.2
61.2-74.8
135-165
198-242
288-352
134-164
284-347
626-765
918-1122
1335-1632
Lubricant Name
Lubricant Name
Lubricant Name
Lubricant Name
Lubricant Name
Viscosity SSU @ 100°F
Manufacturer
320
ExxonMobil
Mobil SHC Cibus 32
Mobil SHC Cibus 68
Mobil SHC Cibus 150
Mobil SHC Cibus 220
Mobil SHC Cibus 320
Kluber Lubrication
Kluberoil 4 UH1 N 32
Kluberoil 4 UH1 N 68
Kluberoil 4 UH1 N 150
Kluberoil 4 UH1 N 220
Kluberoil 4 UH1 N 320
Lubriplate SFGO Ultra 32
Lubriplate SFGO Ultra 68
Lubriplate SFGO Ultra 150
Lubriplate SFGO Ultra 220
Lubriplate SFGO Ultra 320
Nevastane SL 32
Nevastane SL 68
Nevastane SL 150
Nevastane SL 220
Nevastane SL 320
Lubriplate Lubricants
Co.
Total Lubricants USA,
Inc.
cc Kinematic viscosity in units of
mm2/S
is equivalent to cSt (centistokes).
TABLE 17B — Food Grade Synthetic PAO (Polyalphaolefin) EP (Extreme Pressure) Lubricants –
NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
ISO Viscosity Grade
32
68
150
220
AGMA Viscosity Grade
0
2
4
5
320
6
Viscosity cSt @ 40°C s
28.2-35.2
61.2-74.8
135-165
198-242
288-352
134-164
284-347
626-765
918-1122
1335-1632
Manufacturer
Lubricant Name
Lubricant Name
Lubricant Name
Lubricant Name
Lubricant Name
Petro-Canada
---
---
---
Purity FG Synthetic EP 220
---
Viscosity SSU @ 100°F
cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes).
TABLE 18 — Food Grade Synthetic PAG (Polyalkylene Glycol) EP (Extreme Pressure)
Lubricants – NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
See Warning Note below.
ISO Viscosity Grade
32
68
150
220
320
AGMA Viscosity Grade
0
2
4
5
6
Viscosity cSt @ 40°C s
28.2-35.2
61.2-74.8
135-165
198-242
288-352
Viscosity SSU @ 100° F
134-164
284-347
626-765
918-1122
1335-1632
Manufacturer
Lubricant Name
Lubricant Name
Lubricant Name
Lubricant Name
Lubricant Name
Exxon Mobil
---
---
Glygoyle 150
Glygoyle 220
Glygoyle 320
Kluber Lubrication
---
---
Klubersynth UH1 6-150
Klubersynth UH1 6-220
Klubersynth UH1 6-320
Lubriplate
---
---
PGO-FGL Synthetic Gear Oil 150 PGO-FGL Synthetic Gear Oil 220 PGO-FGL Synthetic Gear Oil 320
WARNING: Polyalkylene glycol (PAG) lubricants are not compatible with petroleum mineral oils or PAO synthetic lubricants. PAG’s must not
be mixed or used to top off either petroleum mineral oils or PAO synthetic lubricants.
cc Kinematic viscosity in units of mm 2/S is equivalent to cSt (centistokes).
Guidelines for when to change food grade polyalkylene
glycol type lubricant are:
1. Water content is greater than 3%.
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. Viscosity changes more than ±15%.
6. Solid particle contamination code 25/22/18 per ISO 4406.
Laboratory analysis is recommended for optimum lubricant
life and gear drive performance.
PETROLEUM LUBRICANTS (FOOD GRADE) — In the
absence of oil analysis, change gear oils every 6 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, lubricants should be changed every 3 to 4 months
or 1500 to 2000 hours. If the drive is operated in an area
where temperatures vary with the seasons, change the oil
viscosity grade to suit the temperature, refer to Table 14.
Lubricant suppliers can test oil from the drive periodically
and recommend economical change schedules.
138-050
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
June 2015
Supersedes 01-10
SYNTHETIC LUBRICANTS (FOOD GRADE) — In the
absence of oil analysis, synthetic lube change intervals
Falk® Enclosed Gear Drives • Installation and Maintenance
Type A Series • Sizes 305 thru 585
(Page 17 of 17)
can be extended to 8000 hours depending upon operating
temperatures. Laboratory analysis is recommended for
optimum lubricant life and drive performance. Change lube
with change in ambient temperature, if required. Refer to
Table 15.
STORED & INACTIVE GEAR DRIVES
GREASE-LUBRICATED SEALS
AND BEARINGS
WARNING: Rust preventative oil or vapor-phase inhibitors
are not H1 registered with the NSF (National Sanitation
Foundation) as suitable for food processing applications.
When Food Grade Lubricants are to be used, it is the end
users responsibility to properly flush and prepare the drive
for Food Grade service. Contact the lubricant manufacturer
for specific information and flushing procedures.
All drives and some backstops are furnished with grease
purged seals which minimize the entry of contaminants
and abrasive dusts. Some vertical shaft and specially
mounted drives have grease lubricated bearings. Drives
are shipped with NLGI #2 grade grease in the seal housing
cavities unless otherwise specified.
Prior to shipment from the factory, all Rexnord enclosed
gear drives are protected internally against corrosion with
a rust preventative oil. A vapor phase rust inhibitor may
also be added.
Whenever changing oil in the drive, purge the seals
with one of the NLGI #2 grade greases listed in Table
19. Depending upon the frequency and degree of
contamination, purge contaminated grease from seals by
slowly pumping fresh bearing grease through the seal,
WITH HAND GREASE GUN, until fresh grease flows out
along the shaft. Wipe off purged grease.
Greases in Table 8 contain harmful substances not
allowed in the food processing industry. If grease
could contaminate the product, as in the food and drug
industries, the grease originally supplied with gear drive
must be removed and replaced with grease listed in
Table 19. Simply purging grease with grease gun will not
remove all grease and cross-contamination will likely occur.
Remove end cover and manually remove grease. Grease
registered as H1 by NSF, National Sanitation Foundation, is
suitable for food processing applications.
CAUTION: Rapid greasing with a power grease gun
can force grease inward past the seals and plug the oil
drainback system causing seal leaks.
TABLE 19 —Food Grade Grease s for Grease
Lubricated Bearings & Grease
Purged Seals, NLGI #2 Grade
0° to +200°F(-18° to +93°C)
Manufacturer
Lubricant
Bel-Ray Company, Inc.
No-Tox HD Grease 2
Chevron USA, Inc. (Texaco/
Caltex)
Chevron FM ALC EP 2
Exxon Mobil
Mobil SHC Polyrex 462
Kluber Lubrication
Klubersynth UH1 14-222
Lubriplate
Lubriplate FGL-2
Total Lubricants USA, Inc.
Nevastane HT/AW 2
Petro-Canada
Purity FG
Phillips 66 / Conoco / 76
Lubricants / Kendall
Food Machinery Grease 2
cc NSF (National Sanitation Foundation) H1 Registered.
Grease application or re-lubrication should be done at temperatures
above 20°F (-7°C). If grease must be applied at cooler temperatures consult factory or lubricant supplier for recommendations.
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
138-050
June 2015
Supersedes 01-10