® Enclosed Gear Drives • Installation & Maintenance Instructions

a good name in industry Type A Series • Sizes 305 thru 585 (Page 1 of 11)

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 Type A Type AB
FREE SERVICE OF YOUR FALK GEAR DRIVE.

Table of Contents
Installation Instructions . . . . . . . . . . . . . . Pages 1-3
Shaft Connections . . . . . . . . . . . . . . . . Pages 3-4
Tightening Torques . . . . . . . . . . . . . . . . . Page 5
Lubrication Recommendations . . . . . . . . . . Pages 5-8
Preventive Maintenance . . . . . . . . . . . . . . . Page 9 Type AXVD Type ABXU
Stored and Inactive Gear Drives . . . . . . . . . . Page 11

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 Type ABR
Type AR
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 Falk for correct oil level, parts,
and application approval.
DISASSEMBLY AND ASSEMBLY — Disassembly & assembly
instructions and parts guides are available from the Factory or
Falk Representatives. When requesting information, please give Type ABRC
complete data from the nameplate on the gear drive; Model,
[Link], Date, RPM, and Ratio. Installation Instructions
WARNING: Consult applicable local and national safety The following instructions apply to standard Falk Type A, AB,
codes for proper guarding of rotating members. Lock out AXV, ABX, AR, ABR, & ABRC (Alignment Free) drives. If a drive
power source and remove all external loads from drive before is furnished with special features, refer to the supplementary
servicing drive or accessories. instructions shipped with the drive.
NOTE: Quadruple Reduction Type “A” Gear Drives:
Warranty Removal of backstop and mounting bracket may be required
The Falk Corporation (the “Company”) warrants that its products for adequate clearance when installing foundation fasteners.
(i) conform to Company’s published specifications, and (ii) are Removal of fan assemblies may be required for adequate
free from defects in material or workmanship. The duration of this clearance when installing foundation fasteners.
warranty is three years from the date of shipment. WELDING — Do not weld on the gear drive or accessories
Company does not warrant any purchased, non-Falk branded without prior approval from The Falk Corporation. Welding on
products or components (manufacturer’s warranty applies) or the drive may cause distortion of the housing or damage to
any defects in, damage to, or failure of products caused by: (i) the bearings and gear teeth. Welding without prior approval
dynamic vibrations imposed by the drive system in which such could void the warranty.
products are installed unless the nature of such vibrations has EFFECTS OF SOLAR ENERGY — If the gear drive operates in
been defined and accepted in writing by Company as a the sun at ambient temperatures over 100°F(38°C), then special
condition of operation; (ii) failure to provide suitable measures should be taken to protect the drive from solar energy.
installation environment; (iii) use for purposes other than those This protection can consist of a canopy over the drive or reflective
for which designed, or other abuse or misuse; (iv) paint on the drive. If neither is possible, a heat exchanger or
unauthorized attachments, modifications or disassembly, or (v) other cooling device may be required to prevent the sump
mishandling during shipping. temperature from exceeding the allowable maximum.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 138-050

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 April 2000
Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link] Supersedes 12-98
Installation & Maintenance Instructions • Enclosed Gear Drives ®

(Page 2 of 11) Sizes 305 thru 585 • Type A Series a good name in industry

MOUNTING POSITION — Standard mounting positions for it becomes the customer’s responsibility to support the rear of
types A, AB, AXV, and ABX are with the base horizontal, and the motor bracket to limit deflection and vibration to within
for types AR, ABR, and ABRC with the input and output shafts satisfactory levels as determined by the customer.
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 Gear Drive Alignment
mount the gear drive in a different position from which it was FOOT MOUNTED DRIVES – Align drive with driven equipment
ordered, refer to Falk for required changes to provide proper by placing broad, flat shims under all mounting pads. Start at the
lubrication. low speed shaft end and level across the length and then the width
FOUNDATION, GENERAL — To facilitate oil drainage, elevate of the drive. Check with a feeler gauge to make certain that all
the gear drive foundation above the surrounding floor level. If pads are supported to prevent distortion of housing when drive is
desired, replace the drive oil bolted down. After drive is aligned with driven equipment and
drain plug with a valve, but bolted down, align prime mover to drive input shaft. Refer to Page
provide a guard to protect 4 for coupling alignment.
the valve from accidental If equipment is received from Falk mounted on a bedplate, the
opening or breakage. components were accurately aligned at Falk with the bedplate
When an outboard mounted on a large, flat assembly plate. Shim under the
bearing is used, mount bedplate foot pads until the gear drive is level and all feet are
drive and outboard in the same plane.
bearing on a continuous Check high speed shaft coupling alignment. If the coupling is
foundation or bedplate, misaligned, the bedplate is shimmed incorrectly. Re-shim
and dowel both in place. bedplate and recheck high speed coupling alignment. If
FOUNDATION, STEEL necessary, realign motor.
— When mounting gear drive on structural steel, it is
recommended that an engineered design be utilized for a Leveling
pedestal, adapter base or bed to provide sufficient rigidity, to Reference
Surfaces
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. Continuous Plate
Shims
FOUNDATION, CONCRETE — If a concrete foundation is
used, allow the concrete to set firmly before bolting down the
gear drive. For the best type of mounting, grout structural steel
mounting pads into the
mounting base, as illustrated, SHAFT MOUNTED DRIVES — Shaft mounted drive
rather than grouting the drive alignment occurs when the gear drive is attached to the driven
directly into the concrete. shaft. The standard hollow low speed shaft is connected to the
driven shaft with a shrink disc connection. Solid low speed
Motors and other shafts are typically connected with an MCF moment type
components mounted on coupling. Refer to the Shaft Connection section for coupling
motor plates or motor brackets may become misaligned installation.
during shipment. ALWAYS check alignment after installation.
Refer to Page 4 for coupling alignment instructions. There may be some visible movement of the drive while
operating due to shaft and coupling runouts. Torque arm
MOTOR BRACKETS — Falk motor brackets provide an assemblies must be aligned such that the gear drive
economical “soft mounting” for standard NEMA and IEC foot movement is not restricted during operation. Refer to torque
mounted AC induction electric motors. The weight, location, arm instructions on Page 3.
and starting torque of the motor will cause cantilevered motor
brackets to deflect downward or to twist to varying degrees. The Alignment Free drive flange motor adapter provides
registration for the motor which eliminates the adjustments
The motor bracket/motor selections are engineered to be normally required for high speed coupling alignment.
within acceptable deflection limits as determined by the Falk
Corporation. Because the bracket is a “soft motor support”,
deflection and vibration magnitude of the bracket may exceed Torque Arms
levels normally considered acceptable for rigidly mounted The torque arm connects a shaft mounted gearbox to the
machinery. foundation. In static condition, it helps to support the weight
For applications using other than standard selections, use of a of the gearbox/motor assembly. In the dynamic condition, it
motor plate is recommended. If a motor bracket is to be used, supports the weight and also transmits the torque reaction to

138-050 The Falk Corporation, P.O. Box 492, Zip 53201-0492

April 2000 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 12-98 Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link]
 ® Enclosed Gear Drives • Installation & Maintenance Instructions
a good name in industry Type A Series • Sizes 305 thru 585 (Page 3 of 11)

the foundation. The torque arm may be loaded in CORRECT METHOD

compression or tension. Maximum torque arm loads should Heat interference fitted
be considered when designing the foundation for the torque hubs, pinions, sprockets or
arm anchor. pulleys to a maximum of
TORQUE ARM ASSEMBLY — The torque arm components 275°F (135°C) and slide
are to be assembled according to the following illustration. A onto gear drive shaft.
plain spherical bearing is fitted into the gearbox housing or
bedplate. A pin engages the spherical bearing and connects it
to the torque arm. Spacers center the bearing on the pin. The INCORRECT METHOD
pin is retained by a snap ring. A similar connection is made DO NOT drive coupling
between the torque arm and anchor bracket. In operation, the hub, pinion, sprocket or
torque arm is to be perpendicular to the edge of the gear pulley onto the shaft. An
drive. endwise blow on the
shaft/coupling may
Warning: Angular misalignment of the torque arm may restrict – CAUTION – damage gears and
gear drive gear drive movement and cause excessive loading DO NOT HAMMER bearings.
on the low speed shaft and driven equipment.
FLANGED MOTOR ADAPTERS — Accurate axial positioning
SPACER (4) of the coupling hub on the motor shaft is required to ensure
proper coupling gap. To establish the correct overhang on the
TORQUE ARM (1) motor shaft, measurements are required. Refer to Figure 1
TORQUE below. First measure the distance from the motor mounting
ARM PIN (2) face of the motor to the end of the motor shaft (A). Then
measure the distance from the motor mounting face of the
EXTERNAL TUBE FITTING (2) motor adapter to the face of the gear drive hub (B). Refer to
RETAINING RING (2) the coupling installation and maintenance instructions to
determine the desired coupling gap. The coupling overhang is
determined from the following equation:
RADIAL SPHERICAL
PIPE PLUG BEARING (2) Overhang = A + Gap - B
SQUARE HEAD (2)
If the calculated overhang is a positive value, the motor shaft
ANCHOR extends beyond the hub by that amount.
BRACKET (1)
NOTE: For couplings where the coupling gap does not occur
at the end of the motor hub, an additional adjustment must be
made. See dimension C in Figure 1 below.

TORQUE ARM MOVEMENT — Movement of the gear drive FLANGE

while operating is natural. The movement is due to shaft and MOTOR
ADAPTER
coupling runouts. The standard torque arm is designed to
accommodate this movement. It allows the gearbox to move
MOTOR
slightly with the driven shaft. This prevents transmitting MOUNTING
unnecessary additional loads to the driven shaft through the FACE
gearbox. DO NOT restrain free movement of the gear drive,
to do so will adversely load the low speed shaft and driven
shaft and may result in shaft or hub failure. Recheck torque C
arm movement during regular maintenance intervals. MOTOR

Shaft Connections
WARNING: Provide suitable guards in accordance with local
COUPLING HUBS
and national standards. A B
Figure 1 OVERHANG
SHRINK DISC CONNECTIONS — Shrink disc assemblies
used on hollow low speed shafts and on some MCF coupling FALK COUPLINGS — (Except fluid type) Detailed installation
hubs require special installation procedures. Refer to the manuals are available from Falk, your local Falk
following Falk bulletins for detailed instructions: Representative or Distributor—just provide size and type
designations stamped on the coupling. For lubricant
Shrink Discs 138-850 requirements and a list of typical lubricants meeting Falk
MCF couplings 458-862 specifications, refer to appropriate coupling service manual.
Flanged Type Rigid Couplings are typically used on drives with
COUPLING CONNECTIONS — The performance and life vertical output shafts. The low speed shaft extension ends of the
of any coupling depends largely upon how well the coupling is solid vertical shaft drives are drilled and tapped to accommodate
installed and serviced. Refer to the coupling manufacturer’s coupling keeper plates. Tightening torques for fasteners,
manual for specific instructions. including keeper plate fasteners are listed in Table 1, Page 5.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 138-050

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 April 2000
Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link] Supersedes 12-98
Installation & Maintenance Instructions • Enclosed Gear Drives ®

(Page 4 of 11) Sizes 305 thru 585 • Type A Series a good name in industry

FALK FLUID COUPLINGS — Refer to the installation manual DO NOT over tighten belts or chains. Adjust chains to
furnished with the Falk fluid coupling for installation and manufacturers’ specifications. Adjust belts as follows:
startup instructions. The ideal tension is the lowest tension at which the belt will not
Type ABRC — The Alignment Free flange motor adapter has slip under peak load conditions. Check the belt tension
two side inspection openings. On solid shaft gear drives, the frequently during the first 24 to 48 hours of run-in operation.
opening opposite the low speed shaft extension has been Over tightening belts shortens belt and bearing life. Keep belts
marked to indicate the vertical midpoint of the adapter. On free from foreign material which may cause slippage. Inspect
hollow shaft gear drives, the opening on the shrink disk side of the V–belt periodically; tighten the belts if they are slipping.
the gear drive has been marked to indicate the vertical OUTBOARD BEARING — Mount the outboard bearing and
midpoint of the adapter. These marks are used to establish the gear drive on a common foundation so that they will shift as
proper fill angle for the fluid coupling. an assembly if settling should occur. Bring the outboard
The fluid coupling outside diameter has been marked with two bearing to the correct horizontal position with broad flat shims
separate match marks. The recommended fill can be obtained under the mounting pad. Align accurately so that the load is
by lining up the correct match mark on the fluid coupling with equally divided between the two drive bearings and the
the mark in the inspection opening and filling the fluid outboard bearing. Mount a stop bar against the pillow block
coupling until fluid appears at the lip of the fill hole. To determine foot on the load side when large horizontal load components
the correct mark on the fluid coupling begin by aligning the fill are exerted on the pillow block.
hole with the match mark in the inspection opening. For fill PINION MOUNTING — Mount pinion as close to the drive
angles less than 90°, rotate the fill plug upward till the match as possible to avoid undue bearing load and shaft deflection.
marks line up. For fill angles greater than 90°, rotate the fill plug Refer to Falk for pinion alignment instructions.
downward till the match marks line up.
GAP AND ANGULAR ALIGNMENT — If possible, after
Non Falk Couplings — Refer to manufacturers’
mounting coupling hubs, position the driving and driven installation and maintenance instructions.
equipment so that the distance between shaft ends is equal to BACKSTOPS — To prevent damage to backstops due to
the coupling gap. Align the shafts incorrect motor shaft rotation at start up, couplings are NOT
by placing a spacer block, equal in assembled when gear drives are furnished with backstops for all
thickness to required gap, between types except ABRC. For type ABRC drives, remove the backstop
hub faces, as shown at right, and before electrically connecting the motor. AB, ABR, and ABRC
also at 90° intervals around the backstops are held in place by a retaining ring on the intermediate
hub. Check with feelers. shaft.
OFFSET ALIGNMENT — Align STEELFLEX ILLUSTRATED After completing electrical connections, check motor and gear
driving and driven shafts so that a drive shaft rotations. If rotations are correct, complete
straight edge will rest squarely on alignment and assembly of coupling or re-install the backstop.
both couplings hubs as shown to
the right and also at 90° intervals.
Tighten foundation bolts of the
connected equipment and recheck
alignment and gap.
SPROCKETS, PULLEYS OR STEELFLEX ILLUSTRATED
SHEAVES — Mount power
take-offs as close to the gear drive
housing as possible to avoid undue bearing load and shaft
deflection.
Align the output shaft of the gear drive square and parallel
with the driven shaft by placing a straightedge across the face
of the sprockets or sheaves as [Link] horizontal
shaft alignment by placing one leg
of a square against the face RIGHT WRONG
of the sheave or sprocket with
the spirit level on the
horizontal leg of the square.

GEAR DRIVE WALL

LEVEL

SQUARE AND
PARALLEL

138-050 The Falk Corporation, P.O. Box 492, Zip 53201-0492

April 2000 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 12-98 Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link]
 ® Enclosed Gear Drives • Installation & Maintenance Instructions
a good name in industry Type A Series • Sizes 305 thru 585 (Page 5 of 11)

Fastener Tightening Torques Water Cooling

Use the tightening torque values specified in Table 1 for WATER COOLED HEAT EXCHANGERS — Install a shut-off
fastening Falk gear drives, motors and accessories to or control valve in the water line to the heat exchanger to
their mounting surfaces with un-lubricated fasteners. DO regulate the water flow through the exchanger. Also install a
NOT use these values for “torque locking” fasteners or water flow gauge between the control valve and the
exchanger to determine actual flow rate. Discharge water to
for fastening components with aluminum feet or soft an OPEN DRAIN to prevent back pressure.
gaskets or vibration dampeners on the mounting surface.
If the tightening torque exceeds the capacity of the torque INTERNAL COOLING TUBES — Refer to Manual 138-310
for installation, operation, and maintenance of internal
wrench, use a torque multiplier. For inch fasteners, use cooling tubes.
Grade 5 for diameters though 1.500 inch and ASTM A
354 grade BC for larger diameter fasteners. Use ISO
property class 8.8 for metric fasteners. Lubrication Systems
SPLASH LUBRICATED DRIVES — Standard type A, AR, AB,
ABR, and ABRC drives are splash lubricated. The lubricant is
TABLE 1 — Tightening Torques: +/-5% picked up by the revolving elements and distributed to the
DO NOT Lubricate Fasteners bearings and gear meshes.
OIL PUMP LUBRICATED DRIVES — Types AXV and ABX are
Inch Fasteners – Grade 5
equipped with an external oil pump to provide oil to the upper
Fastener Metal to Metal Metal to Concrete bearings and gear meshes. The system is composed of an
Size lb-ft Nm lb-ft Nm electric motor driven gear pump, oil filter, flow indicator with
.250-20 7 10 6 8 switch, and an internal distribution network with relief valve (set
.3125-18 15 21 12 16 at 30 psi). The pump system may be furnished with a 50 or
.375-16 27 37 22 30 60Hz, 3 phase electrical motors based on the selection. Refer to
.500-13 67 91 54 73 the pump motor nameplate and Table 2 for electrical
.625-11 134 184 108 146 requirements. Wire the motor for correct rotation as indicated
.750-10 242 330 194 265 by the rotation arrow. The flow indicator has a single pole,
.875-9 395 530 315 425 double throw switch rated at 15A, 125V/7A, 250V maximum.
1.000-8 590 800 475 640 Connect the flow indicator switch with the prime mover control
1.125-7 740 1000 590 800
1.250-7 1060 1420 840 1140
circuitry to prevent drive operation without the lubrication
system.
1.375-6 1360 1860 1100 1480
1.500-6 1840 2480 1460 1980 Other types of gear drives may also be equipped with oil
1.750-5 3900 5300 2700 4240 pumps for special lubrication considerations or external
2.000-4.5 5900 7900 4100 6300 cooling.
2.250-4.5 8600 11800 6000 9400
2.500-4 11800 16000 8300 12800
2.750-4 14600 19800 10200 15800 TABLE 2 — Oil Pump Electrical Specifications
3.000-4 19400 26400 13600 21100 DRIVE
405 & 425 445-485 505-535
SIZE
HP 1 2 3
Cycles, Hz 50 60 50 60 50 60
RPM 1425 1725 1425 1725 1425 1725
TABLE 1A — Tightening Torques: +/-5% 208- 208- 208-
DO NOT Lubricate Fasteners Voltage 220/380/440
230/460
220/380/440
230/460
220/380/440
230/460
Metric Fasteners – Property Class 8.8
Caution: Refer to Falk for drives that use pumps to distribute
Fastener Metal to Metal Metal to Concrete lubricants with temperatures below 30°F (-1°C).
Size lb-ft Nm lb-ft Nm
M4 x .7 2 3 1.5 2 Lubrication Recommendations
M5 x .8 4.5 6 3.5 5
M6 x 1.0 7.5 10 6 8 Carefully follow lubrication instructions on the gear drive
M8 x 1.25 18 24 14 19 nameplate, warning tags, and installation manuals furnished
M10 x 1.5 36 50 29 39 with the gear drive.
M12 x 1.75 62 84 50 68 Lubricants listed in this manual are typical ONLY and should
M16 x 2 56 210 126 170
M20 x 2.5 305 415 246 330 not be construed as exclusive recommendations. Industrial
M30 x 3.5 1060 1 440 850 1 150 type petroleum based rust and oxidation inhibited (R & O)
M36 x 4 1680 2 520 1500 2 030 gear lubricants or industrial type sulfur-phosphorus extreme
M42 x 4.5 3000 4 050 2400 3 250 pressure (EP) gear lubricants are the recommended lubricants
M48 x 5 4500 6 100 3600 4 880 for ambient temperatures of 15°F to 125°F(-9°C to +50°C).
M56 x 5.5 7300 9 850 5800 7 860 For drives operating outside the above temperature range
refer to “Synthetic Lubricants” paragraphs, Page 7. Synthetic
lubricants can also be used in normal climates.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 138-050

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 April 2000
Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link] Supersedes 12-98
Installation & Maintenance Instructions • Enclosed Gear Drives ®

(Page 6 of 11) Sizes 305 thru 585 • Type A Series a good name in industry

VISCOSITY (IMPORTANT) — The proper grade for R & O and highly loaded gear drives or drives loaded in excess of
EP lubricants is found in Table 3. For cold climate conditions refer original estimates, industrial type petroleum extreme pressure
to Table 6, Page 7 and the “Synthetic Lubricant” paragraphs. lubricants are preferred. The EP lubricants currently
If a gear drive operates in a typical indoor environment where recommended are of the sulfur-phosphorus type.
the ambient temperature is within 70°F to 125°F (21°C to
52°C), the oil viscosity should be increased one AGMA grade
above that shown for the 50°F to 125°F(10°C to 52°C) range.
That is, an AGMA Number 6 or 7 should be substituted for a TABLE 5 — Extreme Pressure Lubricants †
5 or 6 respectively, under these ambient conditions. Maximum Operating Temperature
200°F(93°C)
OIL PUMPS — When selecting a lubricant for a gear drive
equipped with an oil pump, cold temperature oil viscosity is Manufacturer Lubricant
important. Lubricant viscosity at start-up generally should not
exceed 1725 cSt (8,000 SSU). When exceeding this viscosity, Amoco Oil Co. Permagear/Amogear EP
pump cavitation is possible, reducing oil circulation and BP Oil Co. Energear EP
Chevron U.S.A. Inc. Gear Compounds EP
possibly damaging the pump. A sump heater may be required Citgo Petroleum Corp. Citgo EP Compound
or it may be possible to use a lower viscosity oil to minimize
pump cavitation, refer to Falk. Conoco Inc. Gear Oil
Exxon Co. U.S.A. Spartan EP
E.F. Houghton & Co. MP Gear Oil
TABLE 3 — Viscosity Grade Recommendations Imperial Oil Ltd. Spartan EP
for Petroleum Based R & O or EP Lubricants Kendall Refining Co. Kendall NS-MP
Normal Climates Keystone Div. Pennwalt Corp. Keygear
Lyondell Petrochemical (ARCO) Pennant NL
15° to 60°F 50° to 125°F Mobil Oil Corp. Mobilgear
Output RPM Petro–Canada Products Ultima EP
(-9° to +16°C) (10° to 52°C)
ISO-VG AGMA ISO-VG AGMA Phillips 66 Co. Philgear
Output RPM Below 80 150 4 320 6 Shell Oil Co. Omala Oil
Output RPM 80 & Above 150 4 220 5 Shell Canada Limited Omala Oil
Sun Oil Co. Sunep
Texaco Lubricants Meropa
Petroleum Based Lubricants Valvoline Oil Co. AGMA EP
R & O GEAR LUBRICANTS (Table 4) — Industrial type
† Minimum viscosity index of 90.
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 5) — For
TABLE 4 — Petroleum Based R & O Gear Oils † Maximum operating temperature of lubricants 200°F (93°C)
AGMA Viscosity Grade 4 5 6 7
ISO Viscosity Grade 150 220 320 460
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632 1919-2346
Viscosity cSt @ 40°C 135-165 198-242 288-352 414-506
Manufacturer Lubricant Lubricant Lubricant Lubricant
Amoco Oil Co. [Link]. Oil 150 [Link]. Oil 220 Amer. Ind. Oil 320 Amer. Ind. Oil 460
BP Oil Co. ..... Energol HLP-HD 220 ..... .....
Chevron U.S.A., Inc. Machine Oil AW 150 Machine Oil AW 220 Machine Oil AW 320 .....
Citgo Petroleum Corp. Citgo Pacemaker 150 Citgo Pacemaker 220 Citgo Pacemaker 320 Citgo Pacemaker 460
Conoco Inc. Dectol R&O Oil 150 Dectol R&O Oil 220 Dectol R&O Oil 320 Dectol R&O Oil 460
Exxon Company, U.S.A. Teresstic 150 Teresstic 220 Teresstic 320 Teresstic 460
Houghton International, Inc. Hydro–Drive HP 750 Hydro–Drive HP 1000 ..... .....
Imperial Oil Ltd. Teresso 150 Teresso 220 Teresso 320 .....
Kendall Refining Co. Four Seasons AW 150 ..... ...... .....
Keystone Lubricants KLC–40 KLC-50 ..... .....
Lyondell Petrochemical (ARCO) Duro 150 Duro 220 Duro 32 .....
Mobil Oil Corp. DTE Oil Extra Heavy DTE Oil BB DTE Oil AA DTE Oil HH
Pennzoil Products company Pennzbell AW Oil 150 Pennzbell AW Oil 220 Pennzbell AW Oil 320 Pennzbell AW Oil 460
Petro–Canada Products Premium R & O 150 Premium R & O 220 Premium R & O 320 .....
Phillips 66 Co. Magnus Oil 150 Magnus Oil 220 Magnus Oil 320 .....
Shell Oil Co. Morlina 150 Morlina 220 Morlina 320 Morlina 460
Shell Canada Limited Tellus 150 Tellus 220 Tellus 320 .....
Sun Oil Co. Sunvis 9150 Sunvis 9220 ..... .....
Texaco Lubricants Regal Oil R&O 150 Regal Oil R&O 220 Regal Oil R&O 320 Regal Oil R&O 460
Unocal 76 (East) Unax RX 150 Unax RX 220 Unax AW 320 Turbine Oil 460
Unocal 76 (West) Turbine Oil 150 Turbine Oil 220 Turbine Oil 320 Turbine Oil 460
Valvoline Oil Co Valvoline AW ISO 150 Valvoline AW ISO 220 Valvoline AW ISO 320 .....
† Minimum viscosity index of 90.

138-050 The Falk Corporation, P.O. Box 492, Zip 53201-0492

April 2000 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 12-98 Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link]
 ® Enclosed Gear Drives • Installation & Maintenance Instructions
a good name in industry Type A Series • Sizes 305 thru 585 (Page 7 of 11)

WARNING: EP LUBRICANTS IN FOOD PROCESSING Synthetic Lubricants

INDUSTRY — EP lubricants may contain toxic substances and
Synthetic lubricants of the polyalphaolefin type are
should not be used in the food processing industry without the
recommended for cold climate operation, high temperature
lubricant manufacturers’ approval. Lubricants which meet USDA
applications, extended temperature range (all season)
“H1” classification are suitable for food processing
operation, and/or extended lubricant change intervals. The
applications.
proper viscosity grade of synthetic lubricant is given in Table 6
Refer to Table 7 for Synthetic lubricants.
TABLE 6 — Viscosity Grade Recommendations for Synthetic Lubricants H
Cold Climates Normal Climates
Output –30° to +10°F –15° to +50°F 0° to +80°F +10° to +125°F +20° to +125°F
RPM (–34° to –12°C) (–26° to +10°C) (–18° to +27°C) (–12° to +52°C) (–7° to +52°C)
ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA
Below 80 32 0S 68 2S 150 4S 320 6S 320 6S
80 & Above 32 0S 68 2S 150 4S 220 5S 320 6S
H Refer to Falk for viscosity recommendations when ambient temperatures are below –30°F (–34°C) or above 125°F (52°C).

TABLE 7 — Synthetic Lubricants – WARNING: SYNTHETIC LUBRICANTS IN FOOD

Polyalphaolefin Type H PROCESSING INDUSTRY — Synthetic lubricants may contain
toxic substances and should not be used in the food
AGMA Viscosity Grade 0S 2S 4S 5S 6S processing industry without the lubricant manufacturers’
ISO Viscosity Grade 32 68 150 220 320 approval. Lubricants which meet USDA “H1” classification are
Viscosity SSU @ 100°F 134–164 284–347 626–765 918–1122 1335–1632 suitable for food processing applications.
Viscosity cSt @ 40°C 28.8–35.2 61.2–74.8 135–165 198–242 288–352
Manufacturer Lubricant Bearing and Seal Greases
Clarity Synthetic All drives and some backstops have grease lubricated seals.
... ... ... ...
PM Oil 220 Some vertical shaft and specially mounted drives have grease
Chevron U.S.A., Inc. Syn. Gear lubricated bearings. Drives are shipped with NLG1 or #2
... ... ... Lube Tegra ... grease in the seal housing cavities unless otherwise specified.
220 ‡ Refer to Table 8 for grease recommendations.
Syncon 32 Syncon 68 ... ... ...
Conoco, Inc. Syncon Syncon
... ... . ..
EP 68 ‡ EP 220 ‡ TABLE 8 — Greases for Bearings and Seals
Drydene SHL Drydene SHL Drydene SHL Drydene SHL Drydene SHL (0° to 200°F(-18° to +93°C)
Dryden Oil Co.
Lubricant 32 Lubricant 68 Lubricant 150 Lubricant 220 Lubricant 320
Teresstic Teresstic Teresstic Teresstic Teresstic Manufacturer Lubricant
SHP 32 SHP 68 SHP 150 SHP 220 SHP 320 Amoco Oil Co. Amolith Grease No. 2
Exxon Co. U.S.A. Spartan Spartan Spartan BP Oil Co. Energrease LS–EP2
... ... Synthetic Synthetic Synthetic Chevron U.S.A., Inc. Industrial Grease Medium
EP 150 ‡ EP 220 ‡ EP 320 ‡ Citgo Petroleum Corp. Premium Lithium Grease No. 2
SHC 624 SHC 626 SHC 629 SHC 630 SHC 632 Conoco Inc. EP Conolith Grease No. 2
Mobil Oil Corp. Mobilgear Mobilgear Mobilgear Exxon Company, U.S.A. Unirex N2
... ... E.F. Houghton & Co. Cosmolube 2
SHC 150 ‡ SHC 220 ‡ SHC 320 ‡
Imperial Oil Ltd. Unirex N2L
Pennzgear Pennzgear Pennzgear Pennzgear Pennzgear
SHD 32 SHD 68 SHD 150 SHD 220 SHD 320 Kendall Refining Co. Multi–Purpose Lithium Grease
Pennziol Products Co. Keystone Div. Pennwalt Corp. L421
Super Maxol Super Maxol Super Maxol Super Maxol
... Lyondell Petrochemical (ARCO) Zeniplex 2
“S” 68 ‡ “S” 150 ‡ “S” 220 ‡ “S” 320 ‡
Mobil Oil Corp. Litholine H EP 2 Grease
Super Gear Super Gear Super Gear Mobil Oil Corp Mobilith 22
Petro-Canada Products ... ...
Fluid 150EP ‡ Fluid 220EP ‡ Fluid 320EP ‡ Petro–Canada Products Mobilith SHC 460 H
... ... ... Hyperia 220 Hyperia 320 Multipurpose EP2
Shell Oil Co. Hyperia S320 Phillips 66 Co. Philube Blue EP
... ... ... Hyperia S220 ‡ ‡ Shell Oil Co. Alvania Grease 2
Shell Canada Limited Alvania Grease 2
Sunoco Sun Oil Co. Ultra Prestige EP2
Sunoco
... ... ... Challenge Texaco Lubricants Premium RB Grease
Challenge 220
320
Sun Co. Unocal 76 (East & West) Unoba EP2
Sunoco Sunoco
... ... ... Challenge Challenge Valvoline Oil Co. Multilube Lithium EP Grease
EP 220 ‡ EP 220 ‡ H High performance synthetic alternate.
Pinnacle 32 Pinnacle 68 Pinnacle 150 Pinnacle 220 Pinnacle 320
Texaco Lubricants Co. Pinnacle Pinnacle
... ... ...
EP 150 ‡ EP 220 ‡
Decathlon Decathlon Decathlon
Whitmore Mfg. Co. ... ...
4EP ‡ 5EP ‡ 6EP ‡
H Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for
maximum operating temperature.
‡ Extreme Pressure EP lubricant (contains sulphur phosphorus ).

The Falk Corporation, P.O. Box 492, Zip 53201-0492 138-050

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 April 2000
Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link] Supersedes 12-98
Installation & Maintenance Instructions • Enclosed Gear Drives ®

(Page 8 of 11) Sizes 305 thru 585 • Type A Series a good name in industry

GREASE LUBRICATED SEALS — Most gear drives and GREASE LUBRICATED BEARINGS — Vertical shaft drives
backstops are furnished with grease purged seals which with hollow shafts or with drywells have grease
minimize the entry of contaminants into the drive or backstop. lubricated lower low speed bearings. These bearings are
Gear drives and backstops are shipped with NLGI #2 grease lubricated at the Factory with an NLGI#2 grease. Refer
in the seal housing cavities unless otherwise specified. If
grease could contaminate the product, as in the food and
to the preventive maintenance instructions for greasing
drug industries, it should be removed. A grease that meets instructions.
USDA “H1” classification is suitable for food processing BACKSTOPS — For types AB, ABR, and ABX model C and
applications. later, backstops are furnished filled with oil. Remove plug from
top of backstop and replace with vent wired to torque arm.
TYPICAL SEAL ASSEMBLIES Earlier models had backstops that are grease lubricated, do
not use greases with molybdenum disulfide or other EP
FOR GREASING additives.
SEAL Type “A” and “AR” drives may have a Falk pawl type backstop or
FOR GREASING
SEAL a Falk PRT wedge ramp type backstop. Falk pawl backstops are
prelubricated and sealed at assembly and require no future
THROTTLING lubrication. These backstops also contain grease purgeable
BUSH SEAL
seals (see paragraph above for grease lubricated seals).
SEAL DRAIN Falk PRT backstops are shipped filled with oil. Remove plug
CAVITY
from top of backstop and replace with vent wired to torque
arm.
SEAL DRAIN
CAVITY Oil Levels
PLUG
(BUNA-N) Types A & B Prior to filling gear drive, remove the inspection
cover and flood the oil troughs with oil. This will provide oil to the
bearings. Fill the drive with oil to the level indicated on the oil
LOW OIL LEVEL HIGH OIL LEVEL dipstick. Approximate oil capacities are given on the drive
Sizes 385 & 405 thru 585 Sizes 385 & 405 thru 585 nameplate and in Table 9.
Inner Bush Seal and Outer Two Lip Type Oil Seals Types ABR, ABRC, and AR Fill the drive with oil to the level
Lip Type Seal
indicted on the oil dipstick. Approximate oil capacities are
given on the nameplate and in Table 10.
FOR FOR Drives with Oil Pumps Types ABX, AXV, and occasionally
GREASING GREASING other types of gear drives will be equipped with oil pumps for
SEAL SEAL
cooling or special lubrication considerations. If a drive is
SEAL
SEAL
COVER equipped with an oil pump, fill the drive to the level marked
COVER
BUSH BUSH on the dipstick. Run the lubrication system for several minutes
SEAL SEAL to fill the system components. Verify that the pump is
SEAL SEAL circulating oil properly, then recheck oil level. If necessary, add
DRAIN DRAIN
CAVITY CAVITY oil to compensate for filter and/or cooler.
Before starting the gear drive, rotate the input shaft to check
for obstructions. Then start the drive and allow it to run
without load for several minutes. Shut down and recheck oil
SEAL GAGE PLUG level. If everything is satisfactory, the drive is ready for
BASE PLUG BASE PLUG operation.

LOW OIL LEVEL HIGH OIL LEVEL

Sizes 305 thru 365 & 395 Sizes 305 thru 365 & 395
Inner Bush Seal and Outer Inner Bush Seal and Outer
Lip Type Seal Lip Type Seal

138-050 The Falk Corporation, P.O. Box 492, Zip 53201-0492

April 2000 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 12-98 Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link]
 ® Enclosed Gear Drives • Installation & Maintenance Instructions
a good name in industry Type A Series • Sizes 305 thru 585 (Page 9 of 11)

Preventive Maintenance change in ambient temperature, if required. Refer to Table 6 for

synthetic lubricant viscosity recommendations.
AFTER FIRST WEEK — Check alignment of total system and
realign where necessary. Also tighten all external bolts and GREASE LUBRICATED SEALS — Depending on the frequency
plugs where necessary. DO NOT readjust the internal gear or and degree of contamination (at least every six months), purge
bearing settings in the drive, these were permanently set at contaminated grease from seals by slowly pumping fresh bearing
Falk. grease , WITH A HAND GREASE GUN, through the seal until
AFTER FIRST MONTH — Proceed as follows: fresh grease flows out along the shaft. Wipe off purged grease.
1. Operate drive until old sump oil reaches normal operating Refer to Table 8 for NLGI #2 greases. Some of these greases are
temperature. Shut down drive and drain immediately. of the EP type and may contain toxic substances not allowed in
the food processing industry. A grease that meets the USDA “H1”
2. Immediately flush drive with an oil of the same type and
classification is suitable for food processing applications.
viscosity grade as the original charge (warmed to
approximately 100°F (38°C) in cold weather) by rapidly CAUTION: Rapid greasing with a power grease gun can force
pouring or pumping a charge equal to 25 - 100% of the grease inward past the seals and plug the oil drainback system
initial fill volume or until clean oil flows through the drain. causing seal leaks.
3. Close the drain and refill the drive to the correct level with GREASE LUBRICATED BEARINGS (TYPES AXV AND ABX)
new oil of the correct type and viscosity. — All hollow and most solid vertical low speed shaft drives
PERIODICALLY — have a grease lubricated lower low speed bearing. Grease
1. Check the oil level of the drive when it is stopped and at bearings during oil changes or at intervals of every 6 months
ambient temperature. Add oil if needed. If the oil level is or 2500 hours of operation whichever is less. Table 11
ABOVE the high oil level mark on the dipstick, have the oil contains low speed bearing grease capacities.
analyzed for water content. Moisture in the oil may indicate HOLLOW SHAFT DRIVES — Remove the pressure relief plug
that a seal or the heat exchanger is leaking. If so, replace before greasing. Pump grease into bearing cage until fresh
the defective part immediately and change the oil. DO grease appears at the plug. Replace the pressure relief plug
NOT fill above the mark indicated as leakage or undue when finished. See Figure 2 below.
heating may result. Refer to Table 8 for NLGI #2 greases. Some of these greases
2. Check coupling alignment to make certain that foundation are of the EP type and may contain toxic substances not
settling has not caused excessive misalignment. allowed in the food processing industry. A grease that meets
3. If drive is equipped with a fan, periodically clean accumulated the USDA “H1” classification is suitable for food processing
foreign matter from the fan, guard, and deflector. applications.
4. If drive is equipped with a torque arm, check for free
movement.

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).
Figure 2 BEARING GREASE FITTING
2. Iron content exceeds 150 ppm. RELIEF PLUG

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

BACKSTOPS — For types AB, ABR, and ABX refer to the
4. Viscosity changes more than 15%. supplemental backstop installation and maintenance
PETROLEUM LUBRICANTS — For normal operating conditions, instructions provided with the drive for recommended
change gear oils every 6 months or 2500 operating hours, lubricants. It is recommended to lubricate backstops
whichever occurs first. Change oil more frequently when gear during regular drive lubrication intervals. If backstops
drives operate in extremely humid, chemical or dust laden
atmospheres. In these cases, R & O and EP lubricants should be
are grease lubricated, do not use greases with
changed every 3 to 4 months or 1500 to 2000 hours. If the drive molybdenum disulfide or other EP additives.
is operated in an area where the temperatures vary with seasons, Type “A” and “AR” drives may have a Falk pawl type backstop
change oil viscosity grade to suit temperature. Lubricant suppliers or a Falk PRT wedge ramp type backstop. Falk pawl
can test oil periodically and recommend economical change backstops are prelubricated and sealed at assembly and
intervals. require no future lubrication. These backstops also contain
SYNTHETIC LUBRICANTS — Synthetic lube change intervals grease purgeable seals (see paragraph above for grease
can be extended to 8000 - 10,000 hours depending upon lubricated seals).
operating temperatures and lubricant contamination. Change oil Falk PRT backstops are a wedge ramp type and are oil
more frequently when gear drives operate in extremely humid, lubricated. Follow lubrication recommendations as outlined in
chemical or dust laden atmospheres. In these cases, synthetic the supplemental backstop instructions furnished with the
lubricants should be changed every 4 to 6 months or 4000 to drive.
6000 hours. Laboratory analysis is recommended for optimum
lubricant life and gear drive performance. Change lube with

The Falk Corporation, P.O. Box 492, Zip 53201-0492 138-050

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 April 2000
Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link] Supersedes 12-98
Installation & Maintenance Instructions • Enclosed Gear Drives ®

(Page 10 of 11) Sizes 305 thru 585 • Type A Series a good name in industry

TABLE 9 — Types A & B Approximate Oil Capacities

Type A Type AB
DRIVE DRIVE
A1 A2 A3 A4 AB2 AB3 AB4
SIZE SIZE
Gallons Liters Gallons Liters Gallons Liters Gallons Liters Gallons Liters Gallons Liters Gallons Liters
305 3 11 4 15 4 15 305
325 5 19 6 23 6 23 325
345 6 23 8 30 9 34 345
365 10 38 13 49 13 49 365
385 10 38 10 38 10 38 10 38 11 42 11 42 11 42 385
395 12 45 16 61 17 64 395
405 10 38 15 57 15 57 14 53 11 42 15 57 15 57 425
425 14 53 20 76 21 79 20 76 14 53 20 76 22 83 405
445 22 83 22 83 29 110 28 106 22 83 29 110 30 114 445
465 29 110 30 114 39 148 38 144 30 114 39 148 39 148 465
485 32 121 38 144 57 216 56 212 31 117 52 197 58 220 485
505 42 159 50 189 78 295 77 291 39 148 70 265 80 303 505
525 53 201 59 223 95 360 93 352 48 182 87 329 100 379 525
545 ... ... 115 435 135 511 ... ... ... ... 111 420 138 522 545
565 ... ... 130 492 160 606 ... ... ... ... 142 538 170 644 565
585 ... ... 215 814 250 946 ... ... ... ... 220 833 275 1 041 585

TABLE 10 — Types AR, AVX, ABR, and ABX Approximate Oil Capacities
Vertical Output Horizontal Output
DRIVE
DRIVE SIZE ABX3 & AXV2 ABX4, AXV3, & AXV4 ABR3 & AR2 ABR4, AR3, & AR4 H
SIZE
Gallons Liters Gallons Liters Gallons Liters Gallons Liters
405 10 38 10 38 14 53 14/18 53/68 405
425 15 57 15 57 19 72 19/27 72/102 425
445 25 95 25 95 35 132 35/50 132/189 445
465 30 114 30 114 40 151 40/55 151/208 465
485 40 151 45 170 50 189 60/80 227/303 485
505 50 189 60 227 65 246 80/100 303/379 505
535 70 265 80 303 95 360 110/140 416/530 535
555 100 379 120 454 130 492 160/220 606/833 555
H Values to right of slash mark are for type AR4 drives when HS Shaft is above drive center line.

TABLE 11 — Types AXV and ABX – LS Shaft Lower Bearing Grease Capacity
Solid Shaft Hollow Shaft
DRIVE SIZE Down Up DRIVE SIZE
oz mL
oz mL oz mL
405 8 237 12 355 12 355 405
425 12 355 18 532 12 355 425
445 12 355 18 532 24 710 445
465 30 890 40 1180 30 890 465
485 30 890 40 1180 60 1770 485
505 40 1180 50 1480 60 1770 505
535 50 1480 50 1480 80 2370 535
555 50 1480 60 1770 80 2370 555

138-050 The Falk Corporation, P.O. Box 492, Zip 53201-0492

April 2000 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131
Supersedes 12-98 Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link]
 ® Enclosed Gear Drives • Installation & Maintenance Instructions
a good name in industry Type A Series • Sizes 305 thru 585 (Page 11 of 11)

Stored & Inactive Gear Drives

Each gear drive is protected with a rust preventative that will
protect parts against rust for a period of 4 months in an
outdoor shelter or 12 months in a dry building after shipment
from Falk.
If a gear drive is to be stored, or in inactive after installation
beyond the above periods, drain oil from housing and spray
all internal parts with a rust preventative oil that is soluble in
lubricating oil or add “Motorstor”™ vapor phase rust inhibitor
at the rate of one ounce per cubic foot (1.05 liters per cubic
meter) of internal drive space (5% of sump capacity). Refer to
Table 12 for Motorstor quantities. Rotate the shafts several
times by hand. Before operating, drives which have been
stored or inactive must be filled to the proper level with oil
meeting the specifications given in this manual. Refer to
Manual 128-014 for “Start-up after Storage” instructions.
Periodically inspect stored or inactive gear drives and spray or
add rust inhibitor every six months, or more often if necessary.
Indoor dry storage is recommended.
Gear drives ordered for extended storage can be treated at
Falk with a special preservative and sealed to rust-proof parts
for periods longer than those cited previously.
The vented dipstick should be replaced with a plug (vented
dipstick should be attached to gear drive for future use) so
that the protective rust inhibiting atmosphere is sealed inside
the drive. Install vented dipstick when preparing drive for
operation.

TABLE 12 — Motorstor/VCI–10H
(Add to stored or inactive drives)
Motorstor
DRIVE SIZE
Ounces Per Drive Milliliters Per Drive
305 thru 425 2 60
445 thru 485 6 180
505 thru 535 10 300
545 thru 585 30 890
H Product of Daubert Chemical Company, Chicago, IL.

The Falk Corporation, P.O. Box 492, Zip 53201-0492 138-050

3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 April 2000
Fax: 414-937-4359 e-mail: falkinfo@[Link] web: [Link] Supersedes 12-98