FALK UltraMax FC 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 ....................Pages1&2
Shaft Connections .......................Pages2&3
Tightening Torques...........................Page3
Lubrication Recommendations .............Pages 3thru 7
Preventive Maintenance .......................Page7
Stored and Inactive Gear Drives .................Page7
Introduction
Credit for long service and dependable operation of a gear
drive is often given to the engineers who designed it, or the
craftsmen who constructed it, or the sales engineer who
recommended the type and size. Ultimate credit belongs to the
mechanic on the job who worked to make the foundation rigid
and level, who accurately aligned the shafts and carefully
installed the accessories, and who made sure that the drive
received regular lubrication. The details of this important job
are the subject of this manual.
NAMEPLATE — Operate Falk gear drives only at 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 & ASSEMBLY — Disassembly and 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.
Falk Factory Warranty
We’re so confident in the performance and reliability of our
latest generation of Falk heavy-duty products that we’re
backing this comprehensive offering with the best standard
warranty in the business. Our full, 3-year Heavy-Duty Warranty
provides “shaft-to-shaft” protection on all Falk Components —
including bearings and seals. It’s an industry first. . .and one
more powerful reason why Falk is your ultimate bottom-line
drive and coupling value. H
HWarranty extends for 3 years from date of shipment. Does not apply to Falk
Omnibox®, Fluid Couplings, Renew® and spare parts. Warranty applies to
Steelflex® and Lifelign® couplings with the use of Falk Long Term Grease.
Installation Instructions
The following instructions apply to standard Falk Type FC & FZ
drives 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 80°F(27°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.
LIFTING INSTRUCTIONS — Lift UltraMax drives by means of
a sling (with adequate lifting capacity) wrapped around the
high speed and low speed shaft extensions for drive Sizes 2040
through 2090 and Sizes 2100 through 2130 when equipped
with an electric fan. Standard drive Sizes 2100 through 2130
are equipped with lifting lugs welded to the side of the drive.
Refer to Figure 1. When lifting adrive with asling,make certain
that the shaft extension keyways do not come in contact with
the sling as the sharp corners could cut the sling.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 318-100
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone] May 2001
Fax: [phone] e-mail: [email protected] web: www.falkcorp.com Supersedes 12-99
®
UltraMax® Gear Drives •Installation & Maintenance Instructions
Types FC & FZ •Sizes 2040 thru 2130 (Page 1 of 7)
Type FZ
LIFTING
LUGS
SLING
SIZES 2040 - 2090 SIZES 2100 - 2130
Figure 1
Type FC

FOUNDATION, GENERAL — To facilitate oil drainage, elevate
the gear drive foundation above the surrounding floor level. If
desired, replace the drives
oil drain plug with a valve,
but provide a guard to
protect the valve from
accidental opening or
breakage.
When an outboard
bearing is used, mount
drive and outboard
bearing on a continuous
foundation or bedplate
and dowel both in place.
FOUNDATION, STEEL — When mounting gear drive on
structural steel, it is recommended that an engineered design
be utilized for a pedestal, adapter base or bed to provide
sufficient rigidity, to prevent
induced loads from distorting
the housing and causing gear
misalignment. In the absence
of an engineered design, it is
recommended that a base
plate, with thickness equal to
or greater than the thickness
of the drive feet, be securely
bolted to steel supports and
extend under the entire drive
as illustrated.
FOUNDATION, CONCRETE — If a concrete foundation is
used, allow the concrete to set 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.
MOTOR BRACKETS — Falk motor brackets provide an
economical “soft mounting” for standard NEMA T & U frame
AC induction type electric motors. The weight, location, and
starting torque of the motor will cause cantilevered motor
brackets to deflect downward or twist to varying degrees.
The drive/coupling/motor selections found in the Falk selection
guide are engineered to be within acceptable deflection limits
as determined by the Falk Corporation. However, because the
bracket is a “soft motor support”, deflection and vibration
magnitude of the bracket may exceed levels normally
considered acceptable for rigidly mounted machinery.
For applications using other than standard selection guide
drive/coupling/motor selections, the use of a motor plate is
recommended. If a motor bracket is to be used, it becomes the
customer’s responsibility to support the rear of the motor bracket
as necessary to diminish motor bracket deflection and vibration
to within satisfactory levels as determined by the customer.
When using other than standard T-frame motors refer to
Manual 317-315.
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 3for 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
bedplate foot pads until the gear drive is level and all feet are
in the same plane.
Check high speed shaft coupling alignment. If the coupling is
misaligned, the bedplate is shimmed incorrectly. Re-shim
bedplate and recheck high speed coupling alignment. If
necessary, realign motor.
Motors and other components mounted on motor plates or
motor brackets may become misaligned during shipment.
ALWAYS check alignment after installation. Refer to Page 3for
coupling alignment instructions.
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 — 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.
®
The Falk Corporation, P.O. Box 492, Zip 53201-0492318-100
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]May 2001
Fax: [phone] e-mail: [email protected] web: www.falkcorp.comSupersedes 12-99
Installation & Maintenance Instructions •UltraMax® Gear Drives
(Page 2 of 7) Types FC & FZ •Sizes 2040 thru 2130
CONTINUOUS
PLATE
MOTOR
PLATE SHIMS
— CAUTION —
DO NOT HAMMER

Flanged Type Rigid Couplings are typically used on drives
with vertical output shafts. The low speed shaft extension ends
of the solid vertical shaft drives are drilled and tapped to
accommodate coupling keeper plates. Tightening torques for
fasteners, including keeper plate fasteners are listed in Table 1.
GAP & 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 to manufacturers’
specifications. Adjust belts as follows:
The ideal tension is the lowest tension at which the belt will not
slip under peak load conditions. Check the belt tension
frequently during the first 24 to 48 hours of run-in operation.
Over tightening belts shortens belt and bearing life. Keep belts
free from foreign material which may cause slippage. Inspect
the V–belt periodically; tighten the belts if they are slipping.
OUTBOARD BEARING — Mount the outboard bearing and
gear drive on a common foundation so that they will shift as an
assembly if settling should occur. Bring the outboard bearing to
the correct horizontal position with broad flat shims under the
mounting pad. Align accurately so that the load is equally divided
between the two drive bearings and the outboard bearing. Mount
a stop bar against the pillow block foot on the load side when
large horizontal load components are exerted on the pillow block.
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, 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 5 fasteners for diameters through 1.50", for larger diameter
fasteners, use ASTM 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 sulphur-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.
VISCOSITY (IMPORTANT) — The proper grade forR&O,EP,
or lubricants is found in Table 2, Page 4.Select alubricant
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.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 318-100
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone] May 2001
Fax: [phone] e-mail: [email protected] web: www.falkcorp.com Supersedes 12-99
®
UltraMax® Gear Drives •Installation & Maintenance Instructions
Types FC & FZ •Sizes 2040 thru 2130 (Page 3 of 7)
TABLE 1 — Tightening Torques (lb-ft) 5% –
(DO NOT Lubricate Fasteners)
Thread
Dia-UNC
Metal to
Metal
Metal to
Concrete
Thread
Dia-UNC
Metal to
Metal
Metal to
Concrete
.250-20 761.250-7 1060 840
.312-18 15 12 1.375-6 1360 1100
.375-16 27 22 1.500-6 1840 1460
.500-13 67 54 1.750-5 3900 2700
.625-11 134 108 2.000-4.5 5900 4100
.750-10 242 194
.875-9 395 315
1.000-8 590 475
1.125-7 740 590
STEELFLEX ILLUSTRATED
RIGHT WRONG
GEAR DRIVE WALL
LEVEL
SQUARE AND
PARALLEL
STEELFLEX ILLUSTRATED

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 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 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 Falk.
Petroleum Based Lubricants
R & O GEAR LUBRICANTS (Table 6) —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 4) — 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 disulfides in drives
equipped with internal cartridge type backstops. Some lubricants
in Table 6 may contain anti-wear additives. Lubricants in Table
4do 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 3.
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 SHC 624 and SHC 626 provide proper
backstop action under these conditions. Other synthetic
lubricants may also be acceptable.
Oil Levels
Fill the drive with oil to the level indicated on the oil dipstick.
Approximate oil capacities are given on the drive nameplate
and in Table 8, Page 7.
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. Change oil more frequently when
gear drives operate in extremely humid, chemical or dust laden
atmospheres. In these cases, R & O and EP lubricants should
be changed every 3 to 4 months or 1500 to 2000 hours. If the
drive is operated in an area where temperatures vary with the
seasons, change the oil viscosity grade to suit the temperature,
refer to Table 2. Lubricant suppliers can test oil from the
drive periodically and recommend economical
change schedules.
The Falk Corporation, P.O. Box 492, Zip 53201-0492
318-100
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]May 2001
Fax: [phone] e-mail: [e-mail] web: www .falkcorp.comSupersedes 12-99
Installation & Maintenance Instructions •UltraMax® Gear Drives
(Page 4of 7) Types FC & FZ •Sizes 2040 thru 2130
TABLE 2 — Viscosity Grade Recommendations H
Output
RPM
Synthetic Lubricants R & O or EP Lubricants
Cold Climates Normal 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)
ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA
Below 80 32 0S 68 2S150 4320 6
80 & Above 32 0S 68 2S 150 4220 5
HWhen ambient temperatures are higher than 125°F (52°C), or when drives
are operating in extremely humid, chemical, or dust laden atmospheres, it is
recommended that the lubricant be changed more frequently. See
lubricant changes.
†Refer to Table 3 for proper synthetic lubricant viscosity grades for normal climates.
TABLE 3 — Viscosity Grade Recommendations for Synthetic Lubricants H
Output
RPM
Cold Climates Normal Climates
–30° to +10°F
(–34° to –12°C)
–15° to +50°F
(–26° to +10°C)
0° to +80°F
(–18° to +27°C)
+10° to +125°F
(–12° to +52°C)
+20° to +125°F
(–7° to +52°C)
ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA
Below 80 32 0S 68 2S 150 4S 320 6S 320 6S
80 & Above 32 0S 68 2S 150 4S 220 5S 320 6S
HRefer to Falk for viscosity recommendations when ambient temperatures are below –30°F (–34°C) or above 125°F (52°C).

SYNTHETIC LUBRICANTS — Synthetic lube change intervals
can be extended to 8000-10,000 hours depending upon
operating temperatures and lubricant contamination. Change
oil more frequently when gear drives operate in extremely
humid, chemical or dust laden atmospheres. In these cases
synthetic lubricants should be changed every 4 to 6 months or
4,000 to 6,000 hours. Laboratory analysis is recommended for
optimum lubricant life and gear drive performance. Change
lube with change in ambient temperature, if required. Refer to
Table 5.
Lubrication Systems
SPLASH LUBRICATED DRIVES — Standard Type FC & FZ gear
drives 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:Refer to Falk for drives that use pumps to distribute
lubricants with temperatures below 30°F(-1°C).
The Falk Corporation, P.O. Box 492, Zip 53201-0492 318-100
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone] May 2001
Fax: [phone] e-mail: [email protected] web: www.falkcorp.com Supersedes 12-99
®
UltraMax® Gear Drives •Installation & Maintenance Instructions
Types FC & FZ •Sizes 2040 thru 2130 (Page 5 of 7)
TABLE 4 — Extreme Pressure Lubricants †
Maximum Operating Temperature
200°F(93°C)
Manufacturer Lubricant
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.
Petro–Canada Products
Kendall NS-MP
Keygear
Pennant NL
Mobilgear
Ultima EP
Phillips 66 Co.
Shell Oil Co.
Shell Canada Limited
Sun Oil Co.
Texaco Lubricants
Philgear
Omala Oil
Omala Oil
Sunep
Meropa
Valvoline Oil Co. AGMA EP
†Minimum viscosity index of 90.
DIP
STICK
STAND
PIPE
TABLE 5 — Synthetic Lubricants –
Polyalphaolefin Type H
AGMA Viscosity Grade 0S 2S 4S 5S 6S
ISO Viscosity Grade 32 68 150 220 320
Viscosity SSU @ 100°F 134–164 284–347 626–765 918–1122 1335–1632
Viscosity cSt @ 40°C 28.8–35.2 61.2–74.8 135–165 198–242 288–352
Manufacturer Lubricant
Chevron U.S.A., Inc.
... ... ... Clarity Synthetic
PM Oil 220 ...
... ... ...
Syn. Gear
Lube Tegra
220 ‡
...
Conoco, Inc.
Syncon 32 Syncon 68 . . . . . . . . .
... Syncon
EP 68 ‡... Syncon
EP 220 ‡...
Dryden Oil Co. Drydene SHL
Lubricant 32
Drydene SHL
Lubricant 68
Drydene SHL
Lubricant 150
Drydene SHL
Lubricant 220
Drydene SHL
Lubricant 320
Exxon Co. U.S.A.
Teresstic
SHP 32
Teresstic
SHP 68
Teresstic
SHP 150
Teresstic
SHP 220
Teresstic
SHP 320
... ...
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 ‡
Pennziol Products Co.
Pennzgear
SHD 32
Pennzgear
SHD 68
Pennzgear
SHD 150
Pennzgear
SHD 220
Pennzgear
SHD 320
... Super Maxol
“S” 68 ‡
Super Maxol
“S” 150 ‡
Super Maxol
“S” 220 ‡
Super Maxol
“S” 320 ‡
Petro-Canada Products . . . . . . Super Gear
Fluid 150EP ‡
Super Gear
Fluid 220EP ‡
Super Gear
Fluid 320EP ‡
Shell Oil Co. . . . . . . . . . Hyperia 220 Hyperia 320
. . . . . . . . . Hyperia S220 ‡Hyperia S320 ‡
Sun Co.
... ... ... Sunoco
Challenge 220
Sunoco
Challenge 320
... ... ...
Sunoco
Challenge
EP 220 ‡
Sunoco
Challenge
EP 220 ‡
Texaco Lubricants Co.
Pinnacle 32 Pinnacle 68 Pinnacle 150 Pinnacle 220 Pinnacle 320
... ... Pinnacle
EP 150 ‡
Pinnacle
EP 220 ‡...
Whitmore Mfg. Co. . . . . . . Decathlon
4EP ‡
Decathlon
5EP ‡
Decathlon
6EP ‡
HMinimum viscosity index of 130. Consult lubricant supplier/manufacturer for
maximum operating temperature.
‡Extreme Pressure EP lubricant (contains sulphur phosphorus ).

Bearing & Seal Greases
All Type FC & FZ gear drives have grease purged seals, and
some specially mounted gear drives have one or more grease
lubricated bearings. Whenever changing oil in the drive, grease
the bearings where appropriate and purge the seals with one of
the NLGI #2 greases listed in Table 7.
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 SEALS — Most gear drives and
external 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. 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 regreasing with a power grease gun can force
grease inward past the seals and plug the oil drain back system
causing seal leaks.
®
The Falk Corporation, P.O. Box 492, Zip 53201-0492318-100
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]May 2001
Fax: [phone] e-mail: [email protected] web: www.falkcorp.comSupersedes 12-99
Installation & Maintenance Instructions •UltraMax® Gear Drives
(Page 6 of 7) Types FC & FZ •Sizes 2040 thru 2130
TABLE 7 — Greases for Grease Lubricated
Bearings & Grease Purged Seals
0° to 200°F(-18° to +93°C)
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
Kendall Refining Co.
Keystone Div. Pennwalt Corp.
Lyondell Petrochemical (ARCO)
Mobil Oil Corp.
Mobil Oil Corp
Petro–Canada Products
Multi–Purpose Lithium Grease
L421
Zeniplex 2
Litholine H EP 2 Grease
Mobilith 22
Mobilith SHC 460 H
Multipurpose EP2
Phillips 66 Co.
Shell Oil Co.
Shell Canada Limited
Sun Oil Co.
Texaco Lubricants
Philube Blue EP
Alvania Grease 2
Alvania Grease 2
Ultra Prestige EP2
Premium RB Grease
Unocal 76 (East & West)
Valvoline Oil Co.
Unoba EP2
Multilube Lithium EP Grease
HHigh performance synthetic alternate.
TABLE 6 — Petroleum BasedR&OGearOils†Maximum operating temperature of lubricants 200°F (93°C)
AGMA Viscosity Grade 4567
ISO Viscosity Grade 150 220 320 460
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632 1919-2346
Viscosity cSt @ 40°C 135-165 198-242 288-352 414-506
Manufacturer Lubricant Lubricant Lubricant Lubricant
Amoco Oil Co.
BP Oil Co.
Chevron U.S.A., Inc.
Citgo Petroleum Corp.
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 Company, U.S.A.
Houghton International, Inc.
Imperial Oil Ltd.
Dectol R&O Oil 150
Teresstic 150
Hydro–Drive HP 750
Teresso 150
Dectol R&O Oil 220
Teresstic 220
Hydro–Drive HP 1000
Teresso 220
Dectol R&O Oil 320
Teresstic 320
.....
Teresso 320
Dectol R&O Oil 460
Teresstic 460
.....
.....
Kendall Refining Co.
Keystone Lubricants
Lyondell Petrochemical (ARCO)
Mobil Oil Corp.
Pennzoil Products Co.
Petro–Canada Products
Four Seasons AW 150
KLC–40
Duro 150
DTE Oil Extra Heavy
Pennzbell AW Oil 150
PremiumR&O150
.....
KLC-50
Duro 220
DTE Oil BB
Pennzbell AW Oil 220
PremiumR&O220
.....
.....
Duro 320
DTE Oil AA
Pennzbell AW Oil 320
PremiumR&O320
.....
.....
.....
DTE Oil HH
Pennzbell AW Oil 460
.....
Phillips 66 Co.
Shell Oil Co.
Shell Canada Limited
Sun Oil Co.
Texaco Lubricants
Magnus Oil 150
Morlina 150
Tellus 150
Sunvis 9150
Regal Oil R&O 150
Magnus Oil 220
Morlina 220
Tellus 220
Sunvis 9220
Regal Oil R&O 220
Magnus Oil 320
Morlina 320
Tellus 320
.....
Regal Oil R&O 320
.....
Morlina 460
.....
.....
Regal Oil R&O 460
Unocal 76 (East)
Unocal 76 (West)
Valvoline Oil Co
Unax RX 150
Turbine Oil 150
Valvoline AW ISO 150
Unax RX 220
Turbine Oil 220
Valvoline AW ISO 220
Unax AW 320
Turbine Oil 320
Valvoline AW ISO 320
Turbine Oil 460
Turbine Oil 460
.....
†Minimum viscosity index of 90.
FOR GREASING
SEAL
OIL LUBRICATED BEARINGS
TYPICAL BEARING & SEAL ASSEMBLIES

BACKSTOP EQUIPPED DRIVES — Sizes 2040 thru 2090,
Types FC & FZ drives, use an internal/cartridge type backstop
which is continuously lubricated. 50% or more of the backstop is
immersed in oil at all times. Sizes 2100 thru 2130, Types FC &
FZ drives, use a self contained, wedge ramp type, externally
mounted backstop which is prelubricated and sealed at
assembly. The external backstops (Type PRT) do require
additional lubrication at specific intervals. Refer to Manual
568-810 for details. These backstops also contain grease
purgeable seals. See paragraph on Page 6, for grease
lubricated seals.
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.
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.
SEAL GREASES —Refer to Page 6.
Stored & Inactive Gear Drives
NEW DRIVES WHICH HAVE NOT BEEN OPERATED — Each
gear drive has been spin tested with a rust preventative oil that
will protect internal parts against rust for a period of 4 months
in an outdoor shelter for 12 months in a dry building after
shipment from the Factory.
If a drive is to be stored or inactive beyond the above periods:
1. Spray all internal parts with a rust preventative oil that is
soluble in lubricating oil or add recommended amounts of
“Motorstor” ™ vapor phase rust inhibitor oil as shown in
Table 9.
2. Seal air vent and the area around the dipstick immediately
with pressure sensitive tape.
SHUT DOWN OF DRIVES WHICH HAVE BEEN
OPERATED — If a drive is to be stored or inactive for more
than two months:
1. Drain oil from the drive and water from any attached cooling
system. Check for damage if water was present in the drive.
2. Add the recommended amounts of “Motorstor” as shown in
Table 9.
3. Seal the drive completely be tightening all gauges and
plugs. Seal air vents and the area around the dipstick with
pressure sensitive tape.
4. Pack grease around the shafts near the contact seals and
into the seal retainers, then tape the shaft areas near the
seals and wrap tape against the seals.
5. For external surfaces, inspect and protect scratched surfaces
as required.
6. If the drive is stored outdoors, position it on blocks. Build a
frame around it if possible and cover it with a tarpaulin left
open on the bottom for ventilation. Do not use a plastic cover.
7. Inspect the drive every three months and add vapor phase
rust inhibitor as outlined in paragraph 2.
START-UP AFTER STORAGE
1. Remove all tape applied in storage preparation.
2. Drain all moisture that may have accumulated in the sump
and thoroughly check for damage.
3. Fill the cooling system (if applicable) and check for leaks.
4. Fill the drive to the proper level with oil meeting
specifications given in the Lubrication Recommendation
Section.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 318-100
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone] May 2001
Fax: [phone] e-mail: [email protected] web: www.falkcorp.com Supersedes 12-99
®
UltraMax® Gear Drives •Installation & Maintenance Instructions
Types FC & FZ •Sizes 2040 thru 2130 (Page 7 of 7)
TABLE 8 — Types FC & FZ
Approx. Oil Capacities H—Gallons
DRIVE
SIZE
Standard – Types FZ & FC – Horizontal
Double Triple Quadruple
2040 2.4 2.4 2.4
2050 3.5 3.5 3.5
2060 4.4 4.8 4.8
2070 6.5 7.0 7.0
2080 9.0 10.0 10.0
2090 14.0 15.5 15.5
2100 20.0 21.0 21.0
2110 27.0 30.0 30.0
2120 36.0 39.0 39.0
2130 48.0 54.0 54.0
HOil capacities are approximate. Exact quantities vary with ratio and input speed.
Always fill drive to level indicated on the dipstick.
TABLE 9 — Recommended Quantity of
Motorstor to Add to Stored or
Inactive Drives
DRIVE SIZE Motorstor Ounces Per Drive
2040 thru 2060 1
2070 2
2080 3
2090 4
2100 6
2110 8
2120 10
2130 14
Product of Daubert Chemical Company, Chicago, IL . (Formerly known as
“Nucle Oil”).