FALK GHB Series Installation and operating instructions

How to Use This Manual
This manual provides detailed instructions on installation and
maintenance of gear drives and couplings. Use the table of
contents below to locate required information.
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE
FREE SERVICE.
Table of Contents
Installation Instructions.....................Pages 1 & 2
Shaft Connections........................Pages 2 & 3
Tightening Torques...........................Page 3
Lubrication Recommendations..............Pages 3 thru 7
Preventive Maintenance........................Page 8
Stored and Inactive Gear Drives..................Page 8
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 accuratelyaligned 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 horsepower, speed
and ratio shown on 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
Falk Representatives. When requesting information, please give
complete data from the nameplate on the gear drive; Model,
M.O.Number, Date, RPM, and Ratio.
WARNING:Consult applicable local and national safety codes
for proper guarding of rotating members. Lock out power source
and remove all external loads from drive before servicing drive
or accessories.
Warranty
The Falk Corporation (the “Company”) warrants that, for a
period of one year from the date of shipment, the product
described herein will deliver successfully its rated output as
indicated on the nameplate, provided, it is properly installed
and maintained, correctly lubricated, and operated in the
environment and within the limits of speed, torque or other load
conditions for which it was sold. Such product is expressly not
warranted against failure or unsatisfactory operation resulting
from dynamic vibrations imposed upon it by the drive system in
which it is installed unless the nature of such vibrations has been
fully defined and expressly accepted in writing by the Company
as a condition of operation.
Installation Instructions
The following instructions apply to standard Falk Type GHB, Y,
YB & YBXdrives shown above. If a drive is furnished with special
features, refer to the supplementary instructions shipped with the
drive.
WELDING — Do not weld on the gear drive or accessories
without prior approval from The Falk Corporation. Welding on
the drive may cause distortion of the housing or damage to the
bearings and gear teeth. Welding without prior approval could
void the warranty.
EFFECTS OF SOLAR ENERGY —If the gear drive operates in
the sun at ambient temperatures over 100°F(38°C), then special
measures should be taken to protect the drive from solar energy.
This protection can consist of a canopy over the drive or reflective
paint on the drive. If neither is possible, a heat exchanger or other
cooling device may be required to prevent the sump temperature
from exceeding the allowable maximum.
HORIZONTAL MOUNTING —Mount gear drive with base
horizontal, unless it has been specifically ordered for mounting
in another position. If it is necessary to mount the drive in a
different position from that for which it was ordered, consult The
Falk Corporation for changes necessary to provide
proper lubrication.
NON-HORIZONTAL MOUNTING —For gear drives with
non-horizontal mounting, including tilted, vertical and wall
mounted, refer to instructions provided with the drive for oil
levels and bearing lubrication.
The Falk Corporation, a SundstrandCompany, P.O. Box 492, Zip 53201-0492148-050
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone]April 1999
Fax: [phone] e-mail: [e-mail] web: www.falkcorp.comSupersedes 4-89
Enclosed Gear Drives •Installation & Maintenance Instructions
Types GHB, Y, YB & YBX
•Sizes 1080–1195 & 2050–2235(Page 1of 8)
Type YType YBX
Type YBType GHB

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
bedplateand 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 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 3 for coupling alignment instructions.
MOTOR BRACKETS —The weight, location and starting torque
of the motor will cause some brackets to deflect downward and
to twist. This movement is within allowable engineered limits for
motor-drive selections from the Falk bulletin. If the customer
considers the movement excessive, jackscrew supports for the
bracket extension are available from Falk. To compensate for
deflection caused by heavy motors AND to get CORRECT
COUPLING ALIGNMENT, use more shims under the rear motor
feet than the front feet.
GEAR DRIVE ALIGNMENT —Align drive with driven equipment
by placing broad, flat shims under all mounting pads. Start at the low
speed shaft end and level across the length and then the width of the
drive. Check with a feeler gauge to make certain that all pads are
supported to prevent distortion of housing when drive is bolted down.
After drive is aligned with driven equipment and bolted down, align
prime mover to drive input shaft. Refer to Page 3 for coupling
alignment.
If equipment is received from Falk mounted on a bedplate, the
components were accurately aligned at Falk with the bedplate
mounted on a large, flat assembly plate. Shim under the
bedplatefoot 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 bedplateis shimmed incorrectly. Re-shim
bedplateand recheck high speed coupling alignment. If
necessary, realign motor.
Shaft Connections
WARNING:Provide suitable guards in accordance with
OSHA standards.
COUPLING CONNECTIONS — The performance and life of
any coupling depends largely upon how well the coupling is
installed and serviced. Refer to the coupling manufacturer’s
manual for specific instructions.CORRECT METHOD
Heat interference fitted
coupling hubs, pinions,
sprockets or pulleys to a
maximum of 275°F (135°C)
and slide onto gear
drive shaft.
INCORRECT METHOD
DO NOT drive coupling
hub, pinion, sprocket or
pulley onto the shaft. An
endwise blow on the
shaft/coupling may damage
gears and bearings.
FALK COUPLINGS — (Except fluid type) Detailed installation
manuals are available from the Factory, your local Falk
Representative or Distributor—just provide size and type
designations stamped on the coupling. For lubricant requirements
and a list of typical lubricants meeting Falk specifications, refer to
appropriate coupling service manual.
Flanged Type Rigid Couplingsare typically used on drives with
vertical output shafts. The low speed shaft extension ends of the
solid vertical shaft drives are drilled and tapped to accommodate
coupling keeper plates. Tightening torques for fasteners, including
keeper plate fasteners are listed in Table 1, Page 3.
The Falk Corporation, a SundstrandCompany, P.O. Box 492, Zip 53201-0492148-0503001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]April 1999Fax: [phone] e-mail: [e-mail] web: www.falkcorp.comSupersedes 4-89
Installation & Maintenance Instructions •Enclosed Gear Drives
(Page 2of 8)Sizes 1080–1195 & 2050–2235 •Types GHB, Y, YB & YBX
CONTINUOUS PLATE
LEVELING
REFERENCE
SURFACESHIMS
SHIMS
— CAUTION —
DO NOT HAMMER

FALK FLUID COUPLINGS —Refer to the installation manual
furnished with the fluid coupling for installation, alignment and
startup instructions.
GAP AND ANGULAR ALIGNMENT —If possible, after
mounting coupling hubs, position the driving and driven equipment
so that the distance between shaft ends
is equal to the coupling gap. Align the
shafts by placing a spacer block, equal
in thickness to required gap, between
hub faces, as shown above, and also at
90°intervals around the hub. Check
with feelers.
OFFSET ALIGNMENT —Align
driving and driven shafts so that a
straight edge will rest squarely on both
couplings hubs as shown to the right
and also at 90°intervals. Tighten
foundation bolts of the connected
equipment and recheck alignment
and gap.
SPROCKETS, PULLEYS OR SHEAVES —Mount power
take-offs as close to the gear drive housing as possible to
avoid undue bearing load and shaft deflection.
Align the output shaft of the gear drive square and parallel with
the driven shaft by placing a
straightedge across the face of the
sprockets or sheaves as illustrated.
Check horizontal shaft alignment
by placing one leg of a square
against the face of the sheave or
sprocket with the spirit level on
the horizontal leg of the square.
DO NOT over tighten belts or chains. Adjust chains to
manufacturers’ specifications. Adjust belts as follows:
The ideal tension is the lowest tension at which the belt will not
slip under peak load conditions. Check the belt tension
frequently during the first 24 to 48 hours of run-in operation.
Over tightening belts shortens belt and bearing life. Keep belts
free from foreign material which may cause slippage. Inspect
the V–belt periodically; tighten the belts if they are slipping.
OUTBOARD BEARING —Mount the outboard bearing and
gear drive on a common foundation so that they will shift as an
assembly if settling should occur. Bring the outboard bearing to the
correct horizontal position with broad flat shims under the mounting
pad. Align accurately so that the load is equally divided between
the two drive bearings and the outboard bearing. Mount a stop bar
against the pillow block foot on the load side when large horizontal
load components are exertedon the pillow block.
PINION MOUNTING —Mount pinion as close to the unit as
possible to avoid undue bearing load and shaft deflection. Refer
to the Factory for pinion alignment instructions.
BACKSTOPS —To prevent damage to backstops due to
incorrect motor shaft rotation at start up, couplings are NOT
assembled when gear drives are furnished with backstops. After
completing the electrical connection, check motor and gear
drive shaft rotations. Then complete alignment and assembly
of coupling.
Fastener Tightening Torques
Use the tightening torque values specified in Table 1,for
fastening Falk gear drives, motors, keeper plates and accessories to
their mounting surfaces with non-lubricated fasteners. DO NOT use
these values for “torque locking” fasteners or for fastening
components with aluminum feet or with soft gaskets or vibration
dampers on the mounting surface. If the tightening torque exceeds
the capacity of the torque wrench, use a torque multiplier. Use
Grade 5fasteners for diameters through 1.50", for largerdiameter
fasteners,useASTM A-354 Grade BC.
Water Cooling
WATER COOLED HEAT EXCHANGERS— Install a shut-off or
control valve in the water line to the heat exchanger to regulate
the water flow through the exchanger. Also install a water flow
gauge between the control valve and the exchanger to
determine actual flow rate. Discharge water to an OPEN DRAIN
to prevent back pressure.
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 +52°C).
For drives operating outside the above temperature range refer
to “Synthetic Lubricants” paragraphs, Page 4. Synthetic
lubricants can also be used in normal climates.
The Falk Corporation, a SundstrandCompany, P.O. Box 492, Zip 53201-0492148-050
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone]April 1999
Fax: [phone] e-mail: [e-mail] web: www.falkcorp.comSupersedes 4-89
Enclosed Gear Drives •Installation & Maintenance Instructions
Types GHB, Y, YB & YBX
•Sizes 1080–1195 & 2050–2235(Page 3of 8)
TABLE 1 —Tightening Torques – lb-in
DO NOT LUBRICATE FASTENERS
Thread
Dia-UNCMetal to MetalMetal to ConcreteThread Dia-UNCMetal to MetalMetal to Concrete
.250-2090701.250-71260010000
.3125-181851451.375-61650013000
.375-163302551.500-62210017500
.500-138256401.750-52370018700
.625-11164012802.000-4.53700029000
.750-10294022902.250-4.55200041000
.875-9456037502.500-47200056000
1.000-8680056002.750-49800077000
1.125-7890070003.000-412500099000
STEELFLEX ILLUSTRATED

STEELFLEX ILLUSTRATED

VISCOSITY (IMPORTANT) —The proper grade for R & O and
EP lubricants is found in Table 2. For cold climate conditions refer
to Table 4, Page 5 and the “Synthetic Lubricant” paragraphs. Select
a lubricant which has a pour point at least 10°F (5.5°C) below the
expected minimum ambient starting temperature. Usable
temperature ranges can sometimes be widened if specific
application conditions are known.
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 should be increased one AGMAgrade
above that shown for the 50°F to 125°F(10°C to 52°C) range.
That is, an AGMANumber 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, consult the Factory.
Petroleum Based Lubricants
R & O GEAR LUBRICANTS (Table 5) —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 3) —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 sulphur-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 disulfidesin units
equipped with internal cartridge type backstops. Some lubricants
in Table 5 may contain anti-wear additives. Lubricants in Table 3
do contain several of these additives.
Synthetic Lubricants
Synthetic lubricants of the polyalphaolefintype 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.
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 +50°F
(-34°to +10°C). Mobil SHC624 and SHC626 provide proper
backstop action under these conditions. Other synthetic
lubricants may also be acceptable. DO NOT use synthetic
lubricants in units with backstops operating in ambient
temperatures above 50°F (10°C).
Oil Levels
Prior to filling gear drives, remove the inspection cover 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. Approximate
oil capacities are given on the drive nameplate.
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 6 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 thetemperature, refer to Table 2.
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.
The Falk Corporation, a SundstrandCompany, P.O. Box 492, Zip 53201-0492148-0503001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]April 1999Fax: [phone] e-mail: [e-mail] web: www.falkcorp.comSupersedes 4-89
Installation & Maintenance Instructions •Enclosed Gear Drives
(Page 4of 8)Sizes 1080–1195 & 2050–2235 •Types GHB, Y, YB & YBX
TABLE 2 — Viscosity Grade Recommendations
for R & O or EP Lubricants
Output RPM
Normal Climates
15°to 60°F
(-9°to +16°C)50°to 125°F (10°to 52°C)
ISO-VGAGMAISO-VGAGMA
Output RPM Below 8015043206
Output RPM 80 & Above15042205

®
The Falk Corporation, P.O. Box 492, Zip 53201-0492 148-050
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone] (.pdf revision) April 1999
Fax: [phone] e-mail: [email protected] web: www.falkcorp.com Supersedes 4-89
Enclosed Gear Drives •Installation & Maintenance Instructions
Types GHB, Y, YB & YBX •Sizes 1080–1195 & 2050–2235 (Page 5 of 8)
TABLE 5 — Petroleum BasedR&OGearOils(Maximum operating temperature of lubricants 200°F (93°C)
AGMA Viscosity Grade 1 2 3 4 5 6 7
ISO Viscosity Grade 46 68 100 150 220 320 460
Viscosity cSt@40°C41.4-50.6 61.2-74.8 90-110 135-165 198-242 288-352 414-506
SSU @ 100°F193-235 284-347 417-510 626-765 918-1122 1335-1632 1919-2346
Manufacturer Lubricant Lubricant Lubricant Lubricant Lubricant Lubricant Lubricant
Amoco Oil Co. Amer. Ind. Oil 46 Amer. Ind. Oil 68 Amer. Ind. Oil 100 Amer. Ind. Oil 150 Amer. Ind. Oil 220 Amer. Ind. Oil 320 Amer. Ind. Oil 460
BP Oil Co. Turbinol T-46 Turbinol T-68 Turbinol T-100 .... Energol HLP-HD 220 .... ....
Chevron U.S.A., Inc. Hydraulic Oil AW 46 Hydraulic Oil AW 68 Machine Oil AW 100 Machine Oil AW 150 Machine Oil AW 220 Machine Oil AW 320 ....
Citgo Petroleum Corp. Citgo Pacemaker 46 Citgo Pacemaker 68 Citgo Pacemaker 100 Citgo Pacemaker 150 Citgo Pacemaker 220 Citgo Pacemaker 320 Citgo Pacemaker 460
Conoco Inc. DectolR&OOil46 DectolR&OOil68 DectolR&OOil100 DectolR&OOil150 DectolR&OOil220 DectolR&OOil320 DectolR&OOil460
Exxon Co., U.S.A. Teresstic 46 Teresstic 68 Teresstic 100 Teresstic 150 Teresstic 220 Teresstic 320 Teresstic 460
Houghton International Inc. Hydro-Drive HP-200 Hydro-Drive HP-300 Hydro-Drive HP-500 Hydro-Drive HP-750 Hydro-Drive HP-1000 .... ....
Imperial Oil Ltd. Teresso 46 Teresso 68 Teresso 100 Teresso 150 Teresso 220 Teresso 320 ....
Kendall Refining Co. KenoilR&OAW46 KenoilR&OAW68 KenoilR&OAW100 Four Seasons AW 150 .... .... ....
Keystone Lubricants KLC-15 KLC-20 KLC-30 KLC-40 KLC-50 .... ....
Lyondell Petrochemical (ARCO) Duro 46 Duro 68 Duro 100 Duro 150 Duro 220 Duro 320 ....
Mobil Oil Corp. DTE Oil Medium DTE Oil Heavy Medium DTE Oil Heavy DTE Oil Extra Heavy DTE Oil BB DTE Oil AA DTE Oil HH
Petro-Canada Prod. Harmony 46 Harmony 68 Harmony 100 Harmony 150 or150D Harmony 220 Harmony 320 ....
Phillips 66 Co. Magnus Oil 46 Magnus Oil 68 Magnus Oil 100 Magnus Oil 150 Magnus Oil 220 Magnus Oil 320 ....
Shell Oil Co. Turbo T46 Turbo T68 Morlina 100 Morlina 150 Morlina 220 Morlina 320 Morlina 460
Shell Canada Ltd. Tellus 46 Tellus 68 Tellus 100 Tellus 150 Tellus 220 Tellus 320 ....
Texaco Lubricants Regal OilR&O46 Regal OilR&O68 Regal OilR&O100 Regal OilR&O150 Regal OilR&O220 Regal OilR&O320 Regal OilR&O460
Unocal 76 (East) Unax RX 46 Unax RX 68 Unax RX 100 Unax RX 150 Unax RX 220 Unax AW 320 Turbine Oil 460
Unocal 76 (West) Turbine Oil 46 Turbine Oil 68 Turbine Oil 100 Turbine Oil 150 Turbine Oil 220 Turbine Oil 320 Turbine Oil 460
Valvoline Oil Co. Valvoline AW ISO 46 Valvoline AW ISO 68 Valvoline AW ISO 100 Valvoline AW ISO 150 Valvoline AW ISO 220 Valvoline AW ISO 320 ....
TABLE 3 — Extreme Pressure Lubricants
Maximum Operating Temperature 200°F (93°C)
Manufacturer Lubricant
Amoco Oil Co. Permagear/Amogear EP
BP Oil Co. Energear EP
Chevron U.S.A. Inc. Gear Compounds EP
Citgo Petroleum Corp. Citgo EP Compound
Conoco Inc. Gear Oil
Exxon Co. U.S.A. Spartan EP
E.F. Houghton & Co. MP Gear Oil
Imperial Oil Ltd. Spartan EP
Kendall Refining Co. Kendall NS-MP
Keystone Div., Pennwalt Corp. Keygear
Lyondell Petrochemical (ARCO) Pennant NL
Mobil Oil Corp. Mobilgear
Petro-Canada Products Ultima EP
Phillips 66 Co. Philgear
Shell Oil Co. Omala Oil
Shell Canada Limited Omala Oil
Sun Oil Co. Sunep
Texaco Lubricants Meropa
Unocal 76 (East & West) Extra Duty NL Gear Lube
Valvoline Oil Co. AGMA EP
TABLE 4 — Polyalphaolefin Type
Synthetic Lubricants †
AGMA Viscosity Grade . . . 245 6
ISO Viscosity Grade 32 68 150 220 320
Viscosity cSt@40°C28.8–35.2 61.2–74.8 135–165 198–242 288–352
SSU @ 100°F135–164 284–347 626–765 918–1122 1335–1632
Ambient Temperature
Range°F‡
–30to
+10
–15to
+50
0to
+80
+10 to
+125
+20to
+125
Manufacturer Lubricant
Chevron U.S.A., Inc. . . . . . . . . .
Syn. Gear
Lube Tegra
220 •
...
Conoco, Inc. Syncon 32 Syncon 68 . . . . . . . . .
CPI Engineering
Services, Inc.
CP–4620–
32
CP–4620–
68
CP–4620–
150
CP–4620–
220 ...
CP–4630–
32 •
CP–4630–
68 •
CP–4630–
150 •
CP–4630–
220 •...
Exxon Co. U.S.A. . . . . . .
Spartan
Synthetic
EP 150 •
Spartan
Synthetic
EP 220 •
Spartan
Synthetic
EP 320 •
Mobil Oil Corp.
SHC 624 SHC 626 SHC 629 SHC 630 SHC 632
... ... Mobilgear
SHC 150
Mobilgear
SHC 220 •
Mobilgear
SHC 320 •
†Minimum viscosity index of 130 (consult lubricant supplier/manufacturer for
maximum operating temperature). Vixcosity grade selections are not applicable
to semi-high speed and high speed drives.
‡With complete application information, temperature range can sometimes be
extended, consult Factory.
•Extreme pressure EP lubricants (contains sulphur phosphorus).

Lubrication Systems
SPLASH LUBRICATED UNITS —Standard Type GHB, Y, YB &
YBXdrives are splash lubricated. The lubricant is picked up by the
revolving elements and distributed to all bearings and gear meshes.
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: Consult the Factory for drives that use pumps to
distribute lubricants with temperatures below 30°F(-1°C).
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 6.
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 hollow shaft drives.
Pump grease into bearing cage until it appears at the plug.
Replace pressure relief plug.
GREASE LUBRICATED SEALS —Most gear drives and
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: Rapid regreasingwith a power grease gun can force
grease inward past the seals and plug the oil drain back system
causing seal leaks.
BACKSTOP EQUIPPED DRIVES —Type “Y”, gear drives, use a
self contained, pawl type, backstop externally mounted on an
intermediate shaft. The backstop is furnished filled with grease
suitable for operation in an ambient temperature range of -20°F to
+125°F(-29°C to +52°C). Relubricatethe backstop every 3
months (2 weeks in severe operating condition). To relubricate,
select and clean one grease fitting and pump grease into the
backstop until fresh grease appears at both seals. Refer to the
backstop manufacturer’s service manual (supplied with the drive)
for detailed maintenance instructions and recommended greases.
DO NOT use greases with molybdenum disulfide or other
EP additives.
The Falk Corporation, a SundstrandCompany, P.O. Box 492, Zip 53201-0492148-0503001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]April 1999Fax: [phone] e-mail: [e-mail] web: www.falkcorp.comSupersedes 4-89
Installation & Maintenance Instructions •Enclosed Gear Drives
(Page 6of 8)Sizes 1080–1195 & 2050–2235 •Types GHB, Y, YB & YBX
TABLE 6 —Greases for Grease Lubricated
Bearings & Grease Purged Seals
(0°to 200°F (–18°to +93°C)
ManufacturerLubricant
AmocoOilCo.AmolithGrease No. 2
BPOilCo.EnergreaseLS-EP2
ChevronU.S.A.,Inc.IndustrialGreaseMedium
CitgoPetroleumCorp.PremiumLithiumGreaseNo. 2
ConocoInc.EP ConolithGrease No. 2
Exxon Company, U.S.A.UnirexN2
E.F.Houghton&Co.Cosmolube2
ImperialOilLtd.UnirexN2L
KendollRefiningCo.Multi-PurposeLithiumGreaseL421
KeystoneDiv., PenwaltCorp.Zeniplex2
LyondellPetrochemical (ARCO)LitholineHEP2Grease
MobilOilCorp.Mobilith22
MobilOilCorp.MobilithSHC460★
Petro-CanadaProductsMulipurposeEP2
Phillips66Co.PhilubeBlueEP
ShellOilCo.AlvaniaGrease2
ShellCanadaLimitedAlvaniaGrease2
SunOilCo.UltraPrestigeEP2
Texaco LubricantsPremiumRBGrease
Unocal76(East&West)UnobaEP2
ValvolineOilCo.MultilubeLithiumEPGrease
HHigh performance synthetic alternate.
DipstickTYPICAL SEAL ASSEMBLIES
FOR
GREASING
SEALSEAL
COVER
SEALGAGEPLUG
BASEPLUG
BUSH
SEAL
SEAL
DRAIN
CAVITY
FOR
GREASING
SEALSEAL
COVER
BASEPLUG
BUSH
SEAL
SEAL
DRAIN
CAVITY

The Falk Corporation, a SundstrandCompany, P.O. Box 492, Zip 53201-0492148-050
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone]April 1999
Fax: [phone] e-mail: [e-mail] web: www .falkcorp.comSupersedes 4-89
Enclosed Gear Drives •Installation & Maintenance Instructions
Types GHB , Y, YB & YBX•Sizes 1080–1195 & 2050–2235(Page 7of 8)
TABLE 7 —Viscosity Recommendations ★
Drive DescriptionClassification Symbol
(Drive Type)Drive
Size
Synthetic LubricantsR & O Petroleum Oils
Cold ClimatesNormal Climates
–30°to +10°F
(–34°to –12 °C)–15°to +50°F (–26°to +10 °C)15°to 60 °F (–9°to +16 °C)50°to 125 °F (10 °to 52°C)
IS0-VGAGMAISO-VGAGMAISO-VGAGMAISO-VGAGMA
Parallel Shaft and Horizontal
Right Angle
•
Roller Bearings
Fabricated Steel Housings
Y150-135,2050-213532...6821003 2205
YF11080-113532...6821003 2205
Y1140-195, 2140-216532...6821504 2205
YF11140-119532...6821504 2205
Y2&YB250-19532...6821504 2205
Y2&YB22050-224532...6821504 2205
Y3,YB3&450-135,2050-213532...6821504 2205
Y3,YB3&4140-195, 2140-224532...6822205 3206
Vertical Right Angle
•
Fabricated Steel Housings
YBX250-135,2070-213532...6821003 2205
YBX350-135,2070-213532...6821504 2205
YBX2140-195, 2140-219532...6821504 2205
YBX3140-195, 2140-219532...6822205 3206
Parallel Shaft
•
Sleeve and Roller Bearings
Cast Iron Housings
GHC,GHF
GDA,GDF
GRA,GRF










5
6-9
10-13
32
32
32
...
...
...
68
68
68
2
2
2
100
150
150
3
4
4
220
220
220
5
5
5
Right Angle
•
Horizontal and Vertical
Cast Iron Housings
2000GHB12050-212032...6821003 2205
GHB
GDB
GRB










3-5
6-9
10-12
32
32
32
...
...
...
68
68
68
2
2
2
100
150
150
3
4
4
220
220
220
5
5
5
GDX4, 532...6821003 2205
GDX ,GRX6-1232...6821504 2205
Parallel Shaft Semi-High Speed ‡
•
Sleeve, Roller and Ball Bearings
YHF1
YH1
YH2
1080-1135
2050-2125
2050-2175
32
32
32
...
...
...
68
68
68
2
2
2
100
150
150
3
3
4
220
220
220
5
5
5
GHCH
GHCH5 6-1332 32... ...68 682 268 1002 3100 1503 4
Parallel Shaft High Speed ‡
•
Sleeve BearingsYQA, YPAAllSizes32...68246 †1 †682
HConsult Factory for viscosity recommendations when ambient temperatures are higher than 125°F(52°C), or when drives are operating in extremely humid,
chemical, or dust laden atmospheres.
†Lubricant inlet temperature to gear drive must not exceed 100°F(38°C) when using an AGMANo. 1 oil (193 to 235 SSUat 104°F; 41.5-50.6 cStat 40°C)
in a pressure lubrication system.
‡Consult Factory before substituting higher viscosity grades from those indicated in Table 7 above.

Preventive Maintenance
AFTER FIRST WEEK —Check alignment of the 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 FILTER SERVICE —Record oil pressure at oil filter
indicating gauge with drive at operating temperature, with fresh
oil. Replace oil filter when oil pressure INCREASE reaches 10 psi
with drive at operating temperature. Replacement filter elements
(Falk Part No. 2906540, GresenK-22002 or equivalent 30
micron) are available from the Factory.
AFTER FIRST MONTH’S SERVICE —Proceed as follows:
1.Operate drive until old sump oil reaches normal operating
temperature. Shut the drive down 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). Rapidly pour
or pump a charge equal to 25-100% of the initial fill volume
through the drive or until clean oil flows through the drain.
3.Close the drain and refill the drive to the correct level with
new or reclaimed oil of the correct type and viscosity. If
determined to be in good condition by the supplier,
reclaimed oil may be reused if it is filtered through a 40
micron or finer filter.
PERIODICALLY —Carefully check the oil level of the drive
when it is stopped and at ambient temperature, add oil if
needed. If the oil level is ABOVE the high level mark on the
dipstick, have the oil analyzed for water content. Moisture in the
oil may indicate that the heat exchanger or a seal is leaking. If
so, replace the defective part immediately and change the oil.
DO NOT fill above mark indicated as leakage or undue heating
may result. Also check coupling alignment to make certain that
foundation settling has not caused excessive misalignment. If
drive is equipped with a fan, periodically clean accumulated
foreign matter from the fan, fan guard and deflector to allow
adequate air flow.
LUBRICANT CHANGES —Refer to Page 4.
BEARING & SEAL GREASES —Refer to Page 6.
Stored & Inactive Gear Drives
Each gear drive is protected with rust preventive that will protect
parts against rust for a period of 4 months in an outdoor shelter
or 12 months in a dry building after shipment from
the Factory.
If a gear drive is to be stored, or is inactive after installation
beyond the above periods, drain oil from housing and spray all
internal parts with a rust preventive oil that is soluble in
lubricating oil or add “Motorstor”™vapor phase rust inhibitor at
the rate of one ounce per cubic foot of internal drive space (or
5% of sump capacity) and 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 the
Factory with a special preservative and sealed to rust-proof parts
for periods longer than those cited previously.
The vent cap and vented dipstick should be replaced with a plug
(vented dipstick and vent cap assembly should be attached to
gear drive for future use) so that the protective rust inhibiting
atmosphere is sealed inside the drive. Install vent cap and
vented dipstick when preparing drive for operation.
The Falk Corporation, a SundstrandCompany, P.O. Box 492, Zip 53201-0492148-0503001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]April 1999Fax: [phone] e-mail: [e-mail] web: www.falkcorp.comSupersedes 4-89
Installation & Maintenance Instructions •Enclosed Gear Drives
(Page 8of 8)Sizes 1080–1195 & 2050–2235 •Types GHB, Y, YB & YBX
Motorstor™/VCI–10 (Add to Stored or InactiveUnits)
Drive TypeDrive SizeMotorstor™ Ounces Per Drive
All Types
and
2000 GHB
1080-1090, 2050-20902
1100-1135, 2100-21356
1140-1145, 2140-214510
1150-1165, 2150-216520
1170-1195, 2170-219545
2200-2235130
Product of DaubertChemical Company, Chicago, IL .