falk Series C,E,F,G,J,P,Q,S,Y Gear Drives_Service Manual

Introduction 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 to 125F(9 to +52C). For drives operating outside the above temperature range refer to Synthetic Lubricants paragraphs. Synthetic lubricants can also be used in normal climates.

VISCOSITY (IMPORTANT) For cold climate conditions refer to Table 4, Page 2, and the Synthetic Lubricant paragraphs. Select a lubricant which has a pour point at least 10F (5.5C) below the expected minimum ambient starting temperature. Usable temperature ranges can sometimes be widened if specific application conditions are known.

If a gear drive (excluding semi-high speed and high speed drives) operates in a typical indoor environment where the ambient temperature is within 70 to 125F (21 to 52C), the oil viscosity may be increased one AGMA grade above that shown for the 50 to 125F(10 to 52C) range. That is, an AGMA Number 6 or 7 should be substituted for a 5 or 6 respectively, under this ambient condition.

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, refer to Factory.

Petroleum Based Lubricants R & O GEAR LUBRICANTS (Table 1 below) Industrial type petroleum based rust and oxidation inhibited (R&O) gear lubricants are the most common and readily available general purpose gear lubricants.

EXTREME PRESSURE (EP) LUBRICANTS (Table 2, Page 2) For highly loaded gear drives or drives loaded in excess of original estimates, industrial type petroleum extreme pressure lubricants are preferred. The EP lubricants currently recommended are of the sulfur-phosphorus type.

WARNING: EP LUBRICANTS IN FOOD PROCESSING INDUSTRY EP lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturers approval. Lubricants which meet USDA H1 classification are suitable for food processing applications.

CAUTION: EP LUBRICANTS & INTERNAL BACKSTOPS Do not use EP lubricants or lubricants with anti-wear additives or lubricant formulations including sulfur, phosphorus, chlorine, lead derivatives, graphite or molybdenum disulfides in drives equipped with internal cartridge type backstops. Some lubricants in Table 1 below, may contain anti-wear additives. Lubricants in Table 2, Page 2, do contain several of these additives.

Synthetic Lubricants Synthetic lubricants of the polyalphaolefin type are recommended for cold climate operation, high temperature applications, extended temperature range (all season) operation and/or extended lubricant change intervals. The proper viscosity grade of synthetic lubricant is given in Table 4, Page 2.

Rexnord 128-010 3001 W. Canal St., Milwaukee, WI 53208-4200 November 2000 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 4-94

Falk Enclosed Gear Drives Lubrication Recommendations All Series C, E, F, G, J, P, Q, S, & Y (Page 1 of 4)

TABLE 1 Petroleum Based R&O Gear Oils (Maximum operating temperature of lubricants 200F (93C) AGMA Viscosity Grade 1 2 3 4 5 6 7

ISO Viscosity Grade 46 68 100 150 220 320 460

ViscositycSt @ 40C 41.4-50.6 61.2-74.8 90-110 135-165 198-242 288-352 414-506

SSU @ 100F 193-235 284-347 417-510 626-765 918-1122 1335-1632 1919-2346

Manufacturer Lubricant Lubricant Lubricant Lubricant Lubricant Lubricant Lubricant

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

Amer. Ind. Oil 46 Turbinol T-46 Hydraulic Oil AW 46 Citgo Pacemaker 46

Amer. Ind. Oil 68 Turbinol T-68 Hydraulic Oil AW 68 Citgo Pacemaker 68

Amer. Ind. Oil 100 Turbinol T-100 Machine Oil AW 100 Citgo Pacemaker 100

Amer. Ind. Oil 150 .... Machine Oil AW 150 Citgo Pacemaker 150

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

Amer. Ind. Oil 320 .... Machine Oil AW 320 Citgo Pacemaker 320

Amer. Ind. Oil 460 .... .... Citgo Pacemaker 460

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

Dectol R&O Oil 46 Teresstic 46 Hydro-Drive HP-200 Teresso 46





Dectol R&O Oil 320 Teresstic 320 .... Teresso 320

DectolR&OOil460 Teresstic 460 .... ....

Kendall Refining Co. Keystone Lubricants Lyondell Petrochemical (ARCO) Mobil Oil Corp.

Kenoil R&O AW 46 KLC-15 Duro 46 DTE Oil Medium

Kenoil R&O AW 68 KLC-20 Duro 68 DTE Oil Heavy Medium

Kenoil R&O AW 100 KLC-30 Duro 100 DTE Oil Heavy

Four Seasons AW 150 KLC-40 Duro 150 DTE Oil Extra Heavy

....KLC-50 Duro 220 DTE Oil BB

.... .... Duro 320 DTE Oil AA

.... .... ....DTE Oil HH

Petro-Canada Prod. Phillips 66 Co. Shell Oil Co. Shell Canada Ltd.

Harmony 46 Magnus Oil 46 Turbo T46 Tellus 46

Harmony 68 Magnus Oil 68 Turbo T68 Tellus 68

Harmony 100 Magnus Oil 100 Morlina 100 Tellus 100

Harmony 150 or 150D Magnus Oil 150 Morlina 150 Tellus 150



.... ....Morlina 460 ....

Texaco Lubricants Unocal 76 (East) Unocal 76 (West) Valvoline Oil Co.

Regal Oil R&O 46 Unax RX 46 Turbine Oil 46 Valvoline AW ISO 46





Regal Oil R&O 320 Unax AW 320 Turbine Oil 320 Valvoline AW ISO 320

Regal Oil R&O 460 Turbine Oil 460 Turbine Oil 460 ....

COLD CLIMATE CONDITIONS The proper viscosity grade of synthetic lubricant is given in Table 4 below. Usable temperature ranges can sometimes be widened if specific application conditions are known. Synthetic lubricants may be used in gear drives with internal backstops operating in cold temperatures (30 to +50F or 34 to +10C). Select proper lubricant grade from Table 4 below. Mobil 624 and SHC 626 provide proper backstop action under these conditions. Other synthetic lubricants may also be acceptable. DO NOT use synthetic lubricants in drives with backstops operating above +50F (10C). NORMAL CLIMATE CONDITIONS For temperatures of 15F (9C) and above, use viscosity grades as recommended in Table 5, Page 4. Select a lubricant from Table 1, Page 1. Usable temperature ranges can sometimes be widened if specific application conditions are known. WARNING: SYNTHETIC LUBRICANTS IN FOOD PROCESSING INDUSTRY Synthetic lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturers approval. Lubricants which meet USDA H1 classification are suitable for food processing applications.

CAUTION: SYNTHETIC LUBRICANTS & INTERNAL BACKSTOPS Synthetic lubricants may be used in gear drives with internal backstops operating only in cold temperatures 30 to +50F (34 to +10C). Mobil SHC 624 and SHC 626 provide proper backstop action under these conditions. Other synthetic lubricants may also be acceptable. DO NOT use synthetic lubricants in drives with backstops operating in ambient temperatures above 50F (10C).

TABLE 2 Extreme Pressure Lubricants Maximum Operating Temperature 200F (93C)

Lubrication Recommendations Falk Enclosed Gear Drives

All Series C, E, F, G, J, P, Q, S, & Y (Page 1 of 4)

TABLE 3 Greases for Grease Lubricated Bearings & Grease Purged Seals (0 to 200F (-18 to +93C)

High performance synthetic alternate.

TABLE 4 Polyalphaolefin Type Synthetic Lubricants

Minimum viscosity index of 130 (consult lubricant supplier/manufacturer for maximum operating temperature). Viscosity grade selections are not applicable to semi-high speed and high speed drives. With complete application information, temperature range can sometimes be extended, refer to Factory. Extreme pressure EP lubricants (contains sulfur phosphorus).

Manufacturer Lubricant

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

Amolith Grease No. 2 Energrease LS-EP2 Industrial Grease Medium Premium Lithium Grease No. 2

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

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

Kendoll Refining Co. Keystone Div., Penwalt Corp. Lyondell Petrochemical (ARCO)Mobil Oil Corp.

Multi-Purpose Lithium Grease L421 Zeniplex 2 Litholine H EP 2 Grease Mobilith 22

Mobil Oil Corp. Petro-Canada Products Phillips 66 Co. Shell Oil Co.

Mobilith SHC 460 Mulipurpose EP2 Philube Blue EP Alvania Grease 2

Shell Canada Limited Sun Oil Co. Texaco Lubricants

Alvania Grease 2 Ultra Prestige EP2 Premium RB Grease

Unocal 76 (East & West) Valvoline Oil Co.

Unoba EP2 Multilube Lithium EP Grease

AGMA ViscosityGrade

... 2 4 5 6

ISO Viscosity Grade 32 68 150 220 320

ViscositycSt @ 40C 28.835.2 61.274.8 135165 198242 288352

SSU @ 100F 135164 284347 626765 9181122 13351632

AmbientTemperature

RangeF30to+10 15to+50 0to+80 +10 to+125 +20to+125


Chevron U.S.A., Inc. . . . . . . . . .Syn. GearLube Tegra

220 ...

Conoco, Inc. Syncon 32 Syncon 68 ... ... ...

CPI EngineeringServices, Inc.

CP462032

CP462068

CP4620150

CP4620220 ...

CP463032

CP463068

CP4630150

CP4630220 ...

Exxon Co. U.S.A. ... ...Spartan

SyntheticEP 150

SpartanSyntheticEP 220

SpartanSyntheticEP 320

Mobil Oil Corp.

SHC 624 SHC 626 SHC 629 SHC 630 SHC 632

. . . . . .MobilgearSHC 150

MobilgearSHC 220

MobilgearSHC 320


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

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

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

Gear Oil Spartan EP MP Gear Oil Spartan EP

Kendall Refining Co. Keystone Div., Pennwalt Corp. Lyondell Petrochemical (ARCO)Mobil Oil Corp.

Kendall NS-MP Keygear Pennant NL Mobilgear

Petro-Canada Products Phillips 66 Co. Shell Oil Co. Shell Canada Limited

Ultima EP Philgear Omala Oil Omala Oil

Sun Oil Co. Texaco Lubricants Unocal 76 (East & West) Valvoline Oil Co.

Sunep Meropa Extra Duty NL Gear Lube AGMA EP

128-010 RexnordNovember 2000 3001 W. Canal St., Milwaukee, WI 53208-4200 Supersedes 4-94 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com

Oil Levels Prior to filling gear drives, remove the inspection cover (on drives so equipped) and flood the oil troughs with a generous flow of oil to the bearings. Fill the drive with oil to the level indicated on the oil dipstick or appropriate plug.

Lubricant Changes OIL ANALYSIS REPORT Checking oil condition at regular intervals is recommended. In the absence of more specific limits, the guidelines listed below may be used to indicate when to change oil: 1. Water content is greater than 0.05% (500 ppm). 2. Iron content exceeds 150 ppm. 3. Silicon (dust/dirt) exceeds 25 ppm. 4. Viscosity changes more than 15%.

PETROLEUM LUBRICANTS For normal operating conditions, change gear oils every six months or 2500 operating hours, whichever occurs first. If the drive is operated in an area where temperatures vary with the seasons, change the oil viscosity grade to suit the temperature, refer to Table 1, Page 1. Lubricant suppliers can test oil from the drive periodically and recommend economical change schedules. SYNTHETIC LUBRICANTS Synthetic lube change intervals can be extended to 8000-10,000 hours depending upon operating temperatures and lubricant contamination. Laboratory analysis is recommended for optimum lubricant life and gear drive performance. Change lube with change in ambient temperature, if required. Refer to Table 4, Page 2.

Lubrication Systems OIL PUMPS Occasionally gear drives are equipped with oil pumps, either for special lubrication considerations or for external cooling. When so equipped, run the lubrication system for several minutes to fill the system components. Verify that the pump is circulating oil properly then recheck the oil level. Before starting the gear drive, rotate the input shaft by hand to check for any obstruction. Then start the drive and allow it to run without a load for several minutes. Shut down and recheck oil level. Add oil to compensate for cooler, filter, etc., oil capacities. If everything is satisfactory, the drive is ready for operation.

CAUTION: Refer to Factory for drives that use pumps to distribute lubricants with temperatures below 30F(1C).

Bearing & Seal Greases Some gear drives have one or more grease lubricated bearings and grease purged seals. Whenever changing oil in the drive, grease the bearings and purge the seals with one of the NLGI #2 greases listed in Table 3, Page 2.

Some of these greases are of the EP type and may contain toxic substances not allowed in the food processing industry. A grease that meets the USDA H1 classification is suitable for food processing applications.

GREASE LUBRICATED BEARINGS Remove pressure relief plug when greasing bearing on vertical shaft drives. Pump grease into bearing cage until it appears at the plug. Replace pressure relief plug.

GREASE LUBRICATED SEALS Most gear drives and all BIF pawl type backstops are furnished with grease purged seals which minimize the entry of contaminants and abrasive dusts into the drive or backstop. Gear drives and backstops are shipped with NLGI #2 grease in the seal housing cavities unless otherwise specified. If grease could contaminate the product, as in the food and drug industries, it should be removed. A grease that meets USDA H1 classification is suitable for food processing applications.

Periodically (at least every six months) depending upon the frequency and degree of contamination, purge contaminated grease from seals by slowly pumping fresh bearing grease thru the seal, WITH A HAND GREASE GUN, until fresh grease flows out along the shaft. Wipe off purged grease.

CAUTION: For Y-Type drives only, rapid regreasing with a power grease gun can force grease inward past the seals and plug the oil drain back system causing seal leaks.

Rexnord 128-010 3001 W. Canal St., Milwaukee, WI 53208-4200 November 2000 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 4-94

Falk Enclosed Gear Drives Lubrication Recommendations All Series C, E, F, G, J, P, Q, S, & Y (Page 3 of 4)

Drive DescriptionClassification

Symbol(Drive Type)

DriveSize

Synthetic Lubricants R & O Petroleum Oils

Cold Climates Normal Climates

30 to +10F(34 to 12C)

15 to +50F(26 to +10C)

15 to 60F(9 to +16C)

50 to 125F(10 to 52C)

ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG

Parallel Shaft and HorizontalRight Angle

Roller BearingsFabricated Steel Housings

Y1 YF1

Y1 YF1

Y2 & YB2 Y2 & YB2

Y3, YB3 & 4 Y3, YB3 & 4

50-135, 2050-2135 1080-1135

140-195, 2140-2165 1140-

1195

50-195 2050-2245

50-135, 2050-2135 140-195, 2140-2245

32 32

32 32

32 32

32 32

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

68 68 68 68 68 68 68 68

2 2

2 2 2 2

2 2

100 100

150 150 150 150

150 220

3 3

4 4

4 4

4 5

220 220

220 220

220 220

220 320

5 5

5 5

5 5

5 6

Vertical Right Angle

Fabricated Steel Housings

YBX2 YBX3 YBX2 YBX3

50-135, 2070-2135 50-135, 2070-2135 140-195, 2140-2195 140-195, 2140-2195

32 32 32 32

. . .

. . .

. . .

. . .

68 68 68 68

2 2 2 2

100 150 150 220

3 4 4 5

220 220 220 320

5 5 5 6

Parallel ShaftSleeve and Roller Bearings

Cast Iron Housings

GHC, GHF

GDA, GDF

GRA, GRF

56-910-13

323232

. . .

. . . . . .

686868

2 2 2

100150150

3 44

220 220 220

5 55

Right Angle

Horizontal and VerticalCast Iron Housings

2000 GHB1

GHB

GDB

GRB

GDX GDX, GRX

DTC

2050-21203-56-9

10-12

4, 5 6-12 3 & 5

32323232

32 32 32

. . .

. . .

. . .

. . .

. . .

. . .

. . .

68686868

68 68 68

2 222

2 2 2

100100150150

100 150 150

3 344

3 4 4

220220220220 220 220 220

5 555

5 5 5

Parallel Shaft Semi-High Speed

Sleeve, Roller and Ball Bearings

YHF1 YH1 YH2

GHCH GHCH

S Press Lube S Splash Lube

1080-1135 2050-2125 2050-2175

5

6-13

All Sizes

32 32 32

32 32

32 32

. . .

. . .

. . . . . . . . . . . . . . .

68 68 68

68 68

68 68

2 2 2

2 2

2 2

100 100 150

68 100

46 100

3 3 4

2 3

1 3

220 220 220

100 150

68 150

5 5 5

3 4 2 4

Parallel Shaft High Speed

Sleeve Bearings

Q, P, YQA, YPA All Sizes 32 . . . 68 2 46 1 68 2

MotoreducersConcentric Shaft Speed Reducers

Shaft and Flange Mounted Drives

AllF&ETypes All FC & C Types

All J TypesAll Sizes 32 . . . 68 2 150 4 220 5

TABLE 5 Viscosity Recommendations

128-010 RexnordNovember 2000 3001 W. Canal St., Milwaukee, WI 53208-4200 Supersedes 4-94 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com

Lubrication Recommendations Falk Enclosed Gear Drives

All Series C, E, F, G, J, P, Q, S, & Y (Page 4 of 4)

Refer to Factory for viscosity recommendations when ambient temperatures are higher than 125F(52C), or when drives are operating in extremely humid, chemical, or dust laden atmospheres. Lubricant inlet temperature to gear drive must not exceed 100F(38C) when using an AGMA No. 1 oil (193 to 235 SSU at 104F; 41.5-50.6 cSt at 40C) in a pressure lubrication system. Refer to Factory before substituting higher viscosity grades from those indicated in Table 5 above.

falk Series C,E,F,G,J,P,Q,S,Y Gear Drives_Service Manual

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