Falk® Enclosed Gear Drives • Installation and Maintenance

Type A Series • Sizes 305 thru 585 (Page 1 of 17)

HOW TO USE THIS MANUAL

This manual provides detailed instructions on installation
and maintenance of parallel shaft Types A, AR, AXV and
right angle Types AB, ABR, ABX, and ABRC gear drives.
Use the table of contents below to locate required information.
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND Type A Type AB
TROUBLE FREE SERVICE OF YOUR FALK GEAR DRIVE.

TABLE OF CONTENTS
Installation Instructions..........................................Pages 1-3
Shaft Connections.................................................Pages 3-4
Tightening Torques.....................................................Page 5
Installation Instructions..........................................Pages 1-3
Shaft Connections.................................................Pages 3-4 Type AXVD Type ABXU
Tightening Torques.....................................................Page 5
Lubricant Recommendations..............................Pages 6-13
Lubricant Selection Process...................................Page 6
Preventative Maintenance......................................Page 8
Lubricant Analysis and Changes...........................Page 8
Stored and Inactive Gear Drives..........................Page 13
Food Grade Lubricants.....................................Pages 14-17
Food Grade Lubricant Selection Process............Page 14
Preventative Maintenance....................................Page 15 Type AR Type ABR
Lubricant Analysis and Changes.........................Page 15
Stored and Inactive Gear Drives..........................Page 17

INTRODUCTION
Credit for long service and dependable operation of a
gear drive is often given to the engineers who designed it,
or the craftsmen who constructed it, or the sales engineer
who recommended the type and size. Ultimate credit
belongs to the mechanic on the job who worked to make
the foundation rigid and level, who accurately aligned the
shafts and carefully installed the accessories, and who
made sure that the drive received regular lubrication. The
details of this important job are the subject of this manual.
NAMEPLATE — Operate Falk gear drives only at power,
speed and ratio shown on the nameplate. Before changing
any one of these, submit complete nameplate data and
new application conditions to the Factory for correct oil
level, parts, and application approval.
DISASSEMBLY AND ASSEMBLY — Disassembly &
assembly instructions and parts guides are available
from the Factory or Rexnord Account Executive. When
requesting information, please give complete data from the
nameplate on the gear drive; Model, M.O.Number, Date,
RPM, and Ratio.
WARNING: Consult applicable local and national safety
codes for proper guarding of rotating members. Lock out
power source and remove all external loads from drive
before servicing drive or accessories.
WARRANTY
WARRANTY — Rexnord Industries (the “Company”)
warrants that, for a period of three years from the
date of shipment, the product described herein will
deliver successfully its rated output as indicated on
the nameplate, provided, it is properly installed and
maintained, correctly lubricated, and operated in the
environment and within the limits of speed, torque or other
load conditions for which it was sold. Such product is
expressly not warranted against failure or unsatisfactory
operation resulting from dynamic vibrations imposed
Type ABRC
upon it by the drive system in which it is installed unless
the nature of such vibrations has been fully defined
and expressly accepted in writing by the Company as a
condition of operation.
INSTALLATION INSTRUCTIONS
The following instructions apply to standard Falk Type A,
AB, AXV, ABX, AR, ABR, & ABRC (Alignment Free) drives.
If a drive is furnished with special features, refer to the
supplementary instructions shipped with the drive.
NOTE: Quadruple Reduction Type “A” Gear Drives:
Removal of backstop and mounting bracket may be
required for adequate clearance when installing foundation
fasteners. Removal of fan assemblies may be required for
adequate clearance when installing foundation fasteners.
WELDING — Do not weld on the gear drive or accessories
without prior approval from Rexnord Industries, LLC.
Welding on the drive may cause distortion of the housing
or damage to the bearings and gear teeth. Welding without
prior approval could void the warranty.
EFFECTS OF SOLAR ENERGY — If the gear drive
operates in the sun at ambient temperatures over
100°F(38°C), then special measures should be taken to
protect the drive from solar energy. This protection can
consist of a canopy over the drive or reflective paint on
the drive. If neither is possible, a heat exchanger or other
cooling device may be required to prevent the sump
temperature from exceeding the allowable maximum.

Rexnord 138-050
3001 W. Canal St., Milwaukee, WI 53208-4200 USA June 2015
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance

(Page 2 of 17) Type A Series • Sizes 305 thru 585

MOUNTING POSITION — Standard mounting positions GEAR DRIVE ALIGNMENT

for types A, AB, , and ABX are with the base horizontal, and
for types AR, ABR, and ABRC with the input and output
shafts horizontal. If a gear drive is ordered for non-standard
mounting positions, refer to the instructions provided with the
drive for oil levels and bearing lubrication. If it is necessary to
mount the gear drive in a different position from which it was
ordered, refer to Falk for required changes to provide proper
lubrication.
FOUNDATION, GENERAL — To facilitate oil drainage,
elevate the gear drive foundation above the surrounding floor
level. If desired, replace the drive oil drain plug with a valve,
but provide a guard to protect the valve from accidental
opening or breakage.
When an outboard
bearing is used, mount
drive and outboard
bearing on a continuous
foundation or bedplate,
and dowel both in place.
FOOT MOUNTED DRIVES – Align drive with driven
equipment by placing broad, flat shims under all mounting
pads. Start at the low speed shaft end and level across
the length and then the width of the drive. Check with a
feeler gauge to make certain that all pads are supported
to prevent distortion of housing when drive is bolted down.
After drive is aligned with driven equipment and bolted
down, align prime mover to drive input shaft. Refer to Page
4 for coupling alignment.
If equipment is received from Rexnord mounted on a
bedplate, the components were accurately aligned at
the Factory with the bedplate mounted on a large, flat
assembly plate. Shim under the bedplate foot pads until
the gear drive is level and all feet are in the same plane.
Check high speed shaft coupling alignment. If the
coupling is misaligned, the bedplate is shimmed
incorrectly. Re-shim bedplate and recheck high speed
coupling alignment. If necessary, realign motor.

FOUNDATION, STEEL — SHAFT MOUNTED DRIVES — Shaft mounted drive

When mounting gear drive alignment occurs when the gear drive is attached to
on structural steel, it is the driven shaft. The standard hollow low speed shaft
recommended that an is connected to the driven shaft with a shrink disc
engineered design be utilized for a pedestal, adapter base connection. Solid low speed shafts are typically connected
or bed to provide sufficient rigidity, to prevent induced loads with an MCF moment type coupling. Refer to the Shaft
from distorting the housing and causing gear misalignment. Connection section for coupling installation.
In the absence of an engineered Leveling
design, it is recommended that a Reference
base plate, with thickness equal Surfaces
to or greater than the thickness
of the drive feet, be securely
bolted to steel supports and
extend under the entire drive as
illustrated.
FOUNDATION, CONCRETE —
If a concrete foundation is
used, allow the concrete to set Continuous Plate
firmly before bolting down the
gear drive. For the best type
of mounting, grout structural steel mounting pads into the Shims
mounting base, as illustrated, rather than grouting the drive
directly into the concrete.
Motors and other components There may be some visible movement of the drive
mounted on motor plates or while operating due to shaft and coupling . Torque arm
motor brackets may become assemblies must be aligned such that the gear drive
misaligned during shipment. movement is not restricted during operation. Refer to
ALWAYS check alignment after installation. Refer to Page 4 for torque arm instructions on Page 3.
coupling alignment instructions. The Alignment Free drive flange motor adapter provides
MOTOR BRACKETS — Falk motor brackets provide an registration for the motor which eliminates the adjustments
economical “soft mounting” for standard NEMA and IEC foot normally required for high speed coupling alignment.
mounted AC induction electric motors. The weight, location,
and starting torque of the motor will cause cantilevered motor
brackets to deflect downward or to twist to varying degrees.
TORQUE ARMS
The torque arm connects a shaft mounted gearbox to
The motor bracket/motor selections are engineered to the foundation. In static condition, it helps to support the
be within acceptable deflection limits as determined by weight of the gearbox/motor assembly. In the dynamic
Rexnord.. Because the bracket is a “soft motor support”, condition, it supports the weight and also transmits the
deflection and vibration magnitude of the bracket may torque reaction to the foundation. The torque arm may
exceed levels normally considered acceptable for rigidly be loaded in compression or tension. Maximum torque
mounted machinery. arm loads should be considered when designing the
For applications using other than standard selections, use foundation for the torque arm anchor.
of a motor plate is recommended. If a motor bracket is to be TORQUE ARM ASSEMBLY — The torque arm
used, it becomes the customer’s responsibility to support the components are to be assembled according to the
rear of the motor bracket to limit deflection and vibration to following illustration. A plain spherical bearing is fitted
within satisfactory levels as determined by the customer.

138-050 Rexnord
June 2015 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 01-10 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
 are to be assembled according to the following illustration. A CORRECT METHOD
plain spherical bearing is fitted into the gearbox Typehousing
A Series or Sizes 305 thru 585 (Page 3fitted of 11)
bedplate. A pin engages the spherical bearing and connects
•
it Heat interference
Falk® Enclosed Gear Drives • Installation hubs, and Maintenance
pinions, sprockets or
to the torque arm. Spacers center the bearing on the pin. The
pin is retained by a snap ring. A similar connection isType made A Series • Sizes 305 thru 585 pulleys to a maximum of
TORQUE ARM ASSEMBLY — The torque arm components 275°F (135°C) (Page and 3 slide
of 17)
between the torque arm and anchor bracket. In operation, the
are to be assembled according to the following illustration. A onto
CORRECT METHODgear drive shaft.
torque arm is to be perpendicular to the edge of the gear
plain spherical bearing is fitted into the gearbox housing or
drive. Heat interference fitted
bedplate.
into A pin engages
the gearbox housing theor spherical
bedplate. bearing
A pinandengagesconnects it INCORRECT METHODor
Warning:
tothethespherical Angular
torque arm. misalignment
Spacers of the torque arm may restrict hubs,
INCORRECTpinions, sprockets
METHOD
bearing andcenter
connects the bearing
it to theontorque
the pin. arm. The DO NOT
pulleys to drive
a coupling
maximum of
pingear
Spacers drivecenter
is retained gear by drive
athe
snap movement
ring. Aonsimilar
bearing and
the pin.cause excessive
connection
The pin is loading
is retained
made DO NOT
hub, pinion, drive coupling
sprocket
on
between the low speed
the ring.
torque shaft and driven equipment. 275°F (135°C) and slide
by a snap A arm anchor bracket.
similar connection is made In operation,
between the the or
onto
hub,pulleypinion,
gear onto
drive
sprocket
the
shaft.
or
shaft.
TORQUE
torque
torque arm ARM
armis to be
and MOVEMENT
perpendicular
anchor bracket.— to Movement
Inthe edge of
operation, of the
thegear
the gear
torque drive Anpulley
endwiseonto the
blow shaft.
on An
whileisoperating
drive.
arm is natural. The
to be perpendicular to movement
the edge ofis the due gear
to shaft drive.and endwise
the blow on the
shaft/coupling may
coupling Angular runouts. misalignment
The standard of torque arm isarm designed to – CAUTION – damage
shaft/coupling
INCORRECT gears and
may
METHOD
Warning:
WARNING: Angular misalignment the torque
of the torque may restrict – CAUTION –
accommodate
gear this movement. Itandallows gearboxarm
theexcessive to move DO NOT HAMMER
DO NOT HAMMER bearings.
damage gears and
maydrive restrictgeargear drive movement
drive gear drive cause
movement and causeloading DO NOT drive coupling
onexcessive
the low speed loading shaftonand the driven
low speed shaft and driven
equipment. bearings.
hub, pinion, sprocket or
equipment.
TORQUE ARM MOVEMENT — Movement
SPACER (4) of the gear drive FLANGED MOTOR ADAPTERSpulley — Accurate onto theaxial shaft. An
while operating FLANGED MOTOR ADAPTERS hub — Accurate axial positioning
TORQUE ARMis MOVEMENT
natural. The movement — Movement is due oftothe shaft
gear and positioning of the coupling endwise
on the motor blow on the
shaft is
coupling runouts. The standard torque arm is designed to –of the coupling
CAUTION – hub proper
on the motor shaft is required
shaft/coupling mayto ensure
drive while operating is natural. The movement
TORQUE ARM (1) is due to required to ensure coupling gap. To establish
accommodate this movement. It allows the gearbox to move DOproperNOTcoupling
HAMMERgap. To establishdamage theshaft,
correctgears overhang
and on the
shaft and coupling runouts. The standard torque arm is the correct overhang on the motor measurements
TORQUE motor shaft, measurements are1 required. Refer to Figure
designed to accommodate this movement. It allows the
ARM PIN (2)
are required. Refer to Figure below.
bearings. First measure the1
below. First measure the distance
distance from the motor mounting face of the motor to the from the motor mounting
face of
end of the
the motor
motor to the(A). end Thenof themeasuremotor shaft (A). Then
MOTORshaft — Accurate the axialdistance
SPACER (4)
TUBE FITTING (2) FLANGED ADAPTERS positioning
EXTERNAL measure
from the the distance
motor mounting fromface the motor
of the mounting
motor face oftothe
adapter
RETAINING RING (2) of the coupling hub on the motor shaft is required to ensure
TORQUE ARM (1) the
motor
proper face of theto
adapter
coupling gear
the drive
gap.
face of hub
To establish
the(B).gearRefer
the correcttooverhang
drive hub the(B).
coupling
Refer to
on the
TORQUE installation
the coupling and maintenance
installation and instructions
maintenance
motor shaft, measurements are required. Refer to Figure 1 to determine
instructions to
ARM PIN (2)
RADIAL SPHERICAL the desired
determine thecoupling
desired gap.
couplingThe coupling
gap. The overhang
coupling is
overhang is
below. First measure the distance from the motor mounting
PIPE PLUG BEARING (2) determined
determined from from the thefollowing
followingequation:equation:
face of the motor to the end of the motor shaft (A). Then
SQUARE HEAD (2)
EXTERNAL TUBE FITTING (2) measure Overhang=A+Gap-B
the distance from the motor mounting face of the
RETAINING RING (2) ANCHOR Overhang = A + Gap - B
motor
IfIf the adapter
calculated to the face of the
overhang gear drivevalue,
hub (B). Refer to
BRACKET (1) the calculated overhang isisa apositive
positive value, thethe motor
motor shaft
the
shaft coupling
extends installation
beyond andhub
the maintenance
by that instructions to
amount.
extends beyond the hub by that amount.
RADIAL SPHERICAL determine the desired coupling gap. The coupling overhang is
NOTE:
NOTE: For
determined couplings
Forfrom
couplings where
where the
the following the couplinggap
coupling
equation: gapdoesdoesnot notoccur
PIPE PLUG BEARING (2)
SQUARE HEAD (2) occur
at the at end theofendthe of the hub,
motor motoranhub, an additional
additional adjustmentadjustment
must be
must
made.be Seemade. See dimension
dimension C in Figure C in Figure 1 below.
slightly with the driven shaft. This prevents transmitting ANCHOR Overhang =A+ Gap - B 1 below.
unnecessary additional loads to the driven shaftBRACKET through(1)the If the calculated overhang isFLANGE a positive value, the motor shaft
MOTOR
gearbox. DO NOT restrain free movement of the gear drive, extends beyond the hub by that ADAPTERamount.
to do so will adversely load the low speed shaft and driven NOTE: For couplings where the coupling gap does not occur
shaft and may result in shaft or hub failure. Recheck torque at the end of the motor MOTOR hub, an additional adjustment must be
arm movement
gearbox to move during
slightlyregular
with maintenance
the driven intervals.
shaft. This prevents made. See dimension MOUNTINGC in Figure 1 below.
slightly with the driven shaft. This prevents transmitting FACE
transmittingadditional
unnecessary unnecessary loadsadditional
to the driven loads
shaftto through
the driven the FLANGE
shaft through the restrain
gearbox. DO NOT restrain of thefree movement MOTOR
Shaft
gearbox.
of the
Connections
DO NOT
gear drive, to do so
free
will
movement
adversely load
gear
the low
drive, ADAPTER
toWARNING:
do so will adversely suitable load the low speed shaft and driven C
speed shaft Provide and driven shaftguards and may result in shaft
in accordance withor local
shaft and may result in shaft or hub failure. Recheck torque MOTOR
hub failure. Recheck
and national standards. torque arm movement during regular MOTOR
arm movement during regular maintenance intervals.
maintenance
MOUNTING
SHRINK DISCintervals. CONNECTIONS — Shrink disc assemblies FACE
used on hollow low speed shafts and on some MCF coupling
Shaft
SHAFT
hubs requireConnections
CONNECTIONS
special installation procedures. Refer to the
C
following Falk™ Provide bulletins
suitable for guards
detailedininstructions: COUPLING HUBS
WARNING:
WARNING: Provide suitable guardsaccordancein accordance with with
local
MOTOR
A B
and national standards.
local and national standards. Figure 1 OVERHANG
Shrink Discs . . . . . . . . 138-850
SHRINK
SHRINK DISC
DISC CONNECTIONS
CONNECTIONS — Shrink disc assemblies
MCF couplings . . . . . .—. Shrink 458-862 disc assemblies FALK™ COUPLINGS — (Except fluid type) Detailed
used
used onon hollow
hollow lowlow speedspeed shafts and and
shafts on someon some MCFMCF coupling FALK COUPLINGS — (Except fluid type) Detailed
installation manuals are available from Rexnord, your local
hubs
couplingrequirehubs special installation
require special procedures.
installationRefer to the
procedures. installation manuals are available from Rexnord, your local
COUPLING CONNECTIONS — The performance and life Rexnord Account
Rexnord AccountExecutive oror Distributor—just provide size
following Falk™ bulletins for detailed
Refer to the following Falk bulletins for detailed instructions:instructions: AExecutive B
Distributor—just
COUPLING HUBS provide
of any coupling depends largely upon how well the coupling is and type designations
size and typeOVERHANG stamped on
designations stamped on the coupling. the coupling. For lubricant
Figure 1
requirements and a list of typical
installed and Discs
Shrink serviced. . . Refer
. . .to. the . .coupling
138-850manufacturer’s For lubricant requirements and alubricants
list of typical meeting Rexnord
lubricants
manual Shrink
for Discs
specific ........138-850
instructions. specifications,
meeting Rexnord refer to appropriate
specifications, coupling
refer to service
appropriate manual.
MCF couplings . . . . . . . 458-862 FALK™ COUPLINGS — (Except fluid type) Detailed
MCF couplings .......458-862 coupling
Flanged Type
installation service
manuals Rigidmanual. availableare
Couplings
are from typically
Rexnord, usedyouron drives
local with
COUPLING CONNECTIONS — The performance and life vertical Account
Rexnord
Flanged output
Typeshafts. Executive
Rigid The low
Couplings speed areshaft
or Distributor—just extension
typically ends
provide
used of the
onsize
ofCOUPLING
any couplingCONNECTIONS depends largely — upon Thehow performance
well the coupling and is solid vertical shaft drives are
stamped drilled
drives with vertical output shafts. The low speed shaft
and type designations on and
the tapped
coupling. to accommodate
For lubricant
life of any
installed andcoupling
serviced.depends Refer to the largely
coupling uponmanufacturer’s
how well the coupling keeper
extension
requirements endsand plates.
of theofTightening
a list solid
typicalverticaltorques
lubricants shaftfor fasteners,
drives
meeting are drilled
Rexnord
coupling
manual for is installed
specific and serviced. Refer to the coupling
instructions. including
and tapped
specifications, keeper
to
refer plate
accommodate
to fasteners
appropriate are listed
coupling
coupling in Table
keeper
service 1, Page 5.
plates.
manual.
manufacturer’s manual Tightening
Flanged Typetorques for fasteners,
Rigid Couplings including
are typically used keeper
on drivesplate with
for specific instructions. fasteners
vertical output areshafts.
listedThe in Table
low speed1, Page shaft5.extension ends of the
Rexnord Industries,
CORRECT METHOD LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 solid FALK FLUID
vertical COUPLINGS
shaft drives are drilled — Referand tapped to the installation 138-050
to accommodate
Telephone:
Heat 414-342-3131
interference fitted Fax: 414-937-4359 manual keeper
coupling furnished with
plates. the Falk torques
Tightening fluid coupling for January
for fasteners, installation2010
hubs,
e-mail:pinions, sprockets
info@rexnord.com web: www.rexnord.com and startup
including keeper instructions.
plate fasteners are listed in Table Supersedes 1, Page 5. 11-09
or pulleys to a maximum Type ABRC — The Alignment Free flange motor adapter
of 275°F (135°C) and has two side inspection openings. On solid shaft gear
slide onto gear drive
Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 drives, the opening opposite the low speed shaft extension
138-050
shaft.
Telephone: 414-342-3131 Fax: 414-937-4359 January 2010
e-mail: info@rexnord.com web: www.rexnord.com Supersedes 11-09
Rexnord 138-050
3001 W. Canal St., Milwaukee, WI 53208-4200 USA June 2015
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 01-10
Falk Enclosed Gear Drives • Installation and Maintenance
® ™FLUID COUPLINGS — Refer to the installation
FALK DO NOT over tighten belts or chains. Adjust chains to
Installation and
manual furnished Maintenance
with • Falk™
the Falk fluid coupling Enclosed Gear
for installation Drives specifications. Adjust belts as follows:
manufacturers’
and startup
(Page instructions.
4 of 17) Type A Series • Sizes 305 thru The585
ideal tension is the lowest tension at which the belt will not
(Page
Type 4 of 11)
ABRC — The Alignment Free flange Sizes 305
motor adapter 585 • Type
thru has A Series
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.
has opening
been marked oppositetothe low speed
indicate the shaft
vertical extension
midpoint hasofbeen the Over tightening
OUTBOARD BEARINGbelts shortens
— Mount beltthe
and bearing bearing
outboard life. Keep belts
FALKmarked
adapter. ™FLUIDOn to indicate COUPLINGS
hollow the vertical
shaft gear Refer
—drives,
midpoint tothethe of installation
the adapter.
opening on the On DO NOT
free from over tighten
foreign belts
material or chains.
which
and gear drive on a common foundation so that they may Adjust
cause chains
slippage. to willInspect
manual
hollow
shrink furnished
disk shaft side gear with
of the the
drives, gear Falk
thedrivefluidhas
opening couplingon thefor
been markedinstallation
shrink disk
to side of manufacturers’
theas
shift V–belt specifications.
periodically;
an assembly tighten
if settling Adjustthe belts
should as follows:
if they
occur. are slipping.
Bring the
indicate
and thestartup
gear the vertical
instructions.
drive has been midpoint marked of the adapter.the
to indicate Thesevertical marks outboard
The bearing
ideal tension
OUTBOARD isto
the
BEARING the correct
lowest horizontal
tension
— Mount at which
the position
outboard beltwith
the bearing will and
not
are
Type used
midpoint
ABRC toof —establish
the
Theadapter. the proper
Alignment These fill
Freemarks angle
flange are for
used
motor the tofluid
adapter establish has the broad
slip under
gear flat shims
peak
drive aunder
on load the foundation
conditions.
common mounting
Checkpad.sothethatAlign
belt accurately
tension
they will shift as
coupling.
proper fill angle for the fluid
two side inspection openings. On solid shaft gear drives, the coupling. soanthat
frequently theduring
assembly loadif is equally
the 24divided
first should
settling to 48 between
hours
occur. theoutboard
of run-in
Bring the two drive
operation.
opening
The The fluid opposite
fluid coupling
coupling the low speed
outside
outside diameter
diametershaft extension
has
has been beenhas marked
marked beenwith withtwo bearings
Over
bearing and
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to thethe outboard
belts
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horizontal belt and Mount
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position witha stop
life.
broad bar
Keep flatbelts
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marked separate
separate to indicate
match match themarks.
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free fromthe
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foreign
the mounting block
materialpad.foot
which on may
Align the load
causeside
accurately when
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so that large
theInspect
load is
obtained
hollow
by liningshaft by up lining
gear up the
the drives,
correct the correct
match opening markmatchononthe mark
the shrink
fluid oncoupling
the fluid
disk side with
of horizontal
the load components
V–belt divided
equally periodically;
between tightentheare theexerted
two belts on the
drive ifbearings
they areand pillow
slipping.
the
coupling
the gear
the mark with
drive in the theinspection
has mark marked
been in the inspection
opening to indicate
and fillingopening
the verticalthe fluidand filling block.
outboard bearing. Mount a stop the bar outboard
against the pillow and block
OUTBOARD BEARING — Mount bearing
thecoupling
fluid coupling
midpoint ofuntil fluiduntil
the adapter. appearsfluid
These appears
at marks
the lip are ofatthe the
usedfillliphole.
toofestablish
the fill the
To determine PINION onMOUNTING
footdrive
gear the
on load
a commonside—when Mount large
foundation pinion so asthatclose
horizontal load
they to components
will theshift as
hole.
proper Tofilldetermine
the correct angle mark the
foronthe correct
thefluid
fluidcoupling. mark on
coupling begin theby fluid coupling
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fluidby
with aligning
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in the
diameter with the
has match
inspection been opening. markFor
marked inwith the
fill two shaft
bearing deflection.
to the Refer to
correct horizontal Factory for
positionpinion alignment
PINION MOUNTING — Mount pinionwith broadtoflat
as close theshims
drive
inspection
angles match lessopening.
than 90°,For fill angles
rotate the fill plug lessupward
than 90°, tillbe rotate
the match the instructions.
separate marks. The recommended fill can obtained under the mounting
as possible to avoid pad.undueAlignbearing
accuratelyloadsoand thatshaft
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fillmarks
plug upward
line up. till the
For fill matchgreater
angles marksthan line 90°,up. For rotate fill the
angles fill plug
by liningthan up the correct match NON FALK COUPLINGS the—two Refer
drivetobearings
manufacturer’s
greater
downward 90°,
till therotate
match the marks fillmark
plug
lineand
on
up.
the fluid coupling
downward till the match with equally
Refer divided
to Factory between
for pinion alignment instructions.and the
the mark in the inspection opening filling the fluid installation
outboard and maintenance
bearing. Mount a stop instructions.
bar against the pillow block
marks line up. Non Falk™ Couplings — Refer to manufacturer’s
coupling
GAP AND until fluidANGULAR appearsALIGNMENT at the lip of the—fillIfhole. possible, To determine
after foot on the load—side
BACKSTOPS when
prevent large horizontal
damage load components
to backstops due
GAP
the ANDmark
correct
mounting ANGULAR
couplingon thehubs, ALIGNMENT
fluid coupling
position the —driving
begin Ifbypossible,
aligning
and driven after
the fill areinstallation
exerted on andTo
the maintenance
pillow block. instructions.
to incorrect motor shaft rotation at start up, couplings
mounting coupling hubs, in position the driving shaft and Fordriven — To whenprevent damage to as
backstops
hole with the
equipment
equipment
match
so thatmark
so that
the distance the inspectionbetween opening. ends isfillequal to areBACKSTOPS
NOT MOUNTING
PINION assembled — Mount gear drives
pinion areclose todue
furnished thetodrive
angles less than
the coupling 90°,the
gap. rotate
Align distance
the fillshaftsplug upward till the match as incorrect
with backstops
possible motor
to avoid shaftundue
for allrotation
types at
bearing startload
except up,
ABRC.couplingsFor are
and shaft type NOT
deflection.
between shaft ends is equal to the assembled when gear drives are furnished with backstops for all
marks line up.aFor
by placing fill angles
spacer block, greater
equal than
in 90°, rotate the fill plug ABRC drives, remove the backstop
Refer to Factory for pinion alignment instructions. before electrically
coupling gap. Align the shafts linebyup.
downward
thicknesstilltothe match
required marks
gap, between connecting
types exceptthe ABRC.motor.For AB,
type ABR, and ABRC
ABRC drives, remove backstops
the backstop are
placing a spacer block, equal in Non
GAP hubAND faces, as
ANGULAR shown gap, at right,
ALIGNMENT and — If possible, after held inFalk™
before place Couplings
by
electrically retaining —
a connecting theRefer
ring on the
motor. toAB,manufacturer’s
intermediate
ABR, and ABRC shaft.
thickness to required between installation
backstops are andheld maintenance
in place by a instructions.
retaining ring on the intermediate
hub also
mounting at 90°
faces, asintervals
coupling shown hubs, around
at right,
position the
andthe driving and driven After completing electrical connections, check motor and
hub. shaft.
also
equipmentat Check
90°so with the
intervals
that feelers.
around
distancethe hub. shaft ends is equal to
between — To prevent
gear drive shaft rotations. If rotations
BACKSTOPS damage to backstops
are correct, due complete
to
Check
the coupling
OFFSET withALIGNMENT
feelers.
gap. Align the —shaftsAlign alignment
incorrect andshaft
motor
After completing assembly
rotationofatconnections,
electrical coupling or re-install
start up, couplings checkare motor the and gear
NOT
Steelflex Illustrated backstop.
assembled
drive shaft when gear drives
rotations. are furnished
If rotations with backstops
are correct, complete for all
by placingand
driving
OFFSET a spacer
ALIGNMENT drivenblock, shafts —equalso
Alignthatina
thickness
straight toedgerequired will rest gap, between
squarely types except ABRC.
alignment For type ABRC
and assembly drives, remove
of coupling or re-installthe backstop
the backstop.
driving and driven shafts so thatona
hub both
straightfaces, as shown
couplings
edge willhubs
restat as right,
shown
squarely andto on before electrically connecting the motor. AB, ABR, and ABRC
also
boththeatcouplings
90° and
right intervals also
hubs around
atas 90°shown the to
intervals. backstops are held in place by a retaining ring on the intermediate
hub. Check
theTighten
right with
foundation
and also feelers.
at bolts of the
90° intervals. shaft.
connected
Tighten
OFFSET foundation
ALIGNMENT equipment bolts — andof
Alignrecheck
the After completing electrical connections, check motor and gear
connected equipment Steelflex Illustrated
alignment
driving and driven and gap. shaftsand so that recheck a drive shaft rotations. If rotations are correct, complete
alignment
straight
SPROCKETS, and
edge willPULLEYS gap.
rest squarely OR on alignment and assembly of coupling or re-install the backstop.
Steelflex Illustrated
both couplings
SHEAVES
SPROCKETS, —hubs Mount
PULLEYS as power
shown ORto
SHEAVES
the right and—
take-offs asalso Mount
close at 90°topower intervals.
the take-offs
gear drive as close to the gear
drive
Tighten housing
housing foundation as possible
as possible boltstoofavoid to avoid
the undue undue bearing bearing loadload andand shaft
shaft
connected deflection.
deflection. equipment and recheck
alignment
Align
Align the and
theoutput
output gap. shaft
shaftofofthe the geargear drive drive square
square and andparallelparallel
with the
SPROCKETS,
with thedriven
driven shaft
PULLEYSshaftby byORplacing
placing aa straightedge
straightedge acrossthe face
across
Steelflex Illustrated
theofface
SHEAVES of—the
the sprockets Mount sprockets
or power
sheaves or sheaves as illustrated.Check
as illustrated.Check horizontal
horizontal
take-offs asshaft
shaft alignment close alignment
to placing
by the gear byone placing
driveleg one leg of a square
against
housing
of a square the face
as possible againstof the tothe sheave
avoid
face undue or sprocket
bearing RIGHTwith loadthe and spiritshaft
WRONG
level on sheave
deflection.
of the the horizontal or sprocket leg of with the square.
DO theNOT
Align spirit
the overleveltighten
output on theofbelts
shaft the gearor chains. drive squareAdjust and chains to
parallel
withhorizontal
manufacturers’
the driven legshaftof the by square.
specifications.
placing aAdjust straightedge belts as follows:
across the face
of
The theideal
sprocketstension or issheaves
the lowest as illustrated.Check
tension at which horizontal
the belt
shaft
will not alignment
slip under by placing
peak load one leg
of a square against
conditions. Check the the beltface tension RIGHT GEAR DRIVE WALL WRONG
of the sheave
frequently duringor sprocket
the firstwith 24 to 48
the
hours spiritof level
run-in onoperation.
the Over
tighteningleg
horizontal belts of theshortens
square.belt
and bearing life. Keep belts free
from foreign material which may LEVEL
cause slippage. Inspect the V–belt GEAR DRIVE WALL
periodically; tighten SQUARE the AND belts if
they are slipping. PARALLEL

LEVEL
138-050 Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200
January 2010SQUARE AND Telephone: 414-342-3131 Fax: 414-937-4359
PARALLEL
Supersedes 11-09 e-mail: info@rexnord.com web: www.rexnord.com

138-050
138-050 Rexnord
Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200
June 2015 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
January 2010 Telephone: 414-342-3131 Fax: 414-937-4359
Supersedes 01-10 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
Supersedes 11-09 e-mail: info@rexnord.com web: www.rexnord.com
 Falk™ Enclosed Gear Drives • Installation and Maintenance

Type AFalk
SeriesEnclosed Gear Drives
585 • Installation and Maintenance
®
•Sizes 305 thru (Page 5 of 11)
Type A Series • Sizes 305 thru 585 (Page 5 of 17)
Fastener Tightening Torques Water Cooling
Use the tightening torque valuesTORQUES
specified in Table 1 for WATER COOLED HEAT EXCHANGERS — Install a shut-off
FASTENER TIGHTENING WATER COOLING
or control valve in the water line to the heat exchanger to
fastening Falk™ gear drives, motors and accessories to
Use
their the tightening
mounting torquewith
surfaces values specified infasteners.
un-lubricated Table 1 forDO WATER
regulate COOLED HEAT
the water flow EXCHANGERS
through the exchanger. — Install a shut-
Also install a
fastening Falk gear drives, motors and accessories to off
wateror flow
control valve
gauge in the water
between line tovalve
the control the heat exchanger
and the
NOT use these values for “torque locking”
their mounting surfaces with un-lubricated fasteners. DO fasteners or to regulatetothe water flow through
exchanger determine actual flow the
rate.exchanger. Also to
Discharge water
for fastening
NOT use these components with aluminum
values for “torque feet or softor for
locking” fasteners install
an OPEN a water flow
DRAIN to gauge
preventbetween the control valve and
back pressure.
gaskets orcomponents
fastening vibration dampeners on the
with aluminum mounting
feet surface.
or soft gaskets the exchanger to determine actual flow rate. Discharge
or vibration
If the dampeners
tightening torque on the mounting
exceeds surface.
the capacity If the
of the torque INTERNAL
water to an COOLING
OPEN DRAIN TUBES — Refer
to prevent to Manual
back 138-310
pressure.
tightening torque exceeds the capacity of fasteners,
the torqueuse for installation, operation, and maintenance of internal
wrench, use a torque multiplier. For inch INTERNAL COOLING TUBES — Refer to Manual 138-310
wrench, cooling tubes.
Grade 5use for adiameters
torque multiplier. For inchinch
though 1.500 fasteners,
and ASTMuse A for installation, operation, and maintenance of internal
Grade 5 for diameters though 1.500 inch and ASTM A 354 cooling tubes.
354 grade
grade BC for BC for larger
larger diameter
diameter fasteners.
fasteners. Use ISO Useproperty
ISO
property class 8.8 for
class 8.8 for metric fasteners.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
.875-9 395 530 315 425 by the rotation arrow. The flow indicator has a single pole,
1.000-8 590 800 475 640 double throw switch rated at 15A, 125V/7A, 250V maximum.
1.125-7 740 1000 590 800 Connect the flow indicator switch with the prime mover control
1.250-7 1060 1420 840 1140
circuitry to prevent drive operation without the lubrication
1.375-6 1360 1860 1100 1480 system.
1.500-6 1840 2480 1460 1980
1.750-5 3900 5300 2700 4240
2.000-4.5 5900 7900 4100 6300 TABLE 2 — Oil Pump Electrical Specifications
2.250-4.5 8600 11800 6000 9400
DRIVE
2.500-4 11800 16000 8300 12800 SIZE 405 & 425 445-485 505-535
2.750-4 14600 19800 10200 15800
3.000-4 19400 26400 13600 21100 HP 1 2 3
Cycles, Hz 50 60 50 60 50 60
RPM 1425 1725 1425 1725 1425 1725
TABLE 1A — Tightening Torques: +/-5% Voltage 208- 208- 208-
220/380/440 220/380/440 220/380/440
DO NOT Lubricate Fasteners 230/460 230/460 230/460
Metric Fasteners – Property Class 8.8
Fastener Metal to Metal Metal to Concrete
Other types of gear drives may also be equipped with oil
Size lb-ft Nm lb-ft Nm pumps for special lubrication considerations or external
M4 x .7 2 3 1.5 2 cooling.
M5 x .8 4.5 6 3.5 5
M6 x 1.0 7.5 10 6 8 Caution: Refer to Factory for drives that use pumps to
M8 x 1.25 18 24 14 19 distribute lubricants with temperatures below 30°F (-1°C).
M10 x 1.5 36 50 29 39
M12 x 1.75 62 84 50 68
M16 x 2 56 210 126 170 Lubrication Recommendations
M20 x 2.5 305 415 246 330 Carefully follow lubrication instructions on the gear drive
M30 x 3.5 1060 1 440 850 1 150
M36 x 4 1680 2 520 1500 2 030 nameplate, warning tags, and installation manuals furnished
M42 x 4.5 3000 4 050 2400 3 250 with the gear drive.
M48 x 5 4500 6 100 3600 4 880 Lubricants listed in this manual are typical ONLY and should
M56 x 5.5 7300 9 850 5800 7 860
not be construed as exclusive recommendations. Industrial
type petroleum based rust and oxidation inhibited (R & O)
gear lubricants or industrial type sulfur-phosphorus extreme
pressure (EP) gear lubricants are the recommended lubricants
for ambient temperatures of 15°F to 125°F(-9°C to +50°C).
For drives operating outside the above temperature range
refer to “Synthetic Lubricants” paragraphs, Page 7. Synthetic
lubricants can also be used in normal climates.

Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200 138-050

Telephone: 414-342-3131 Fax: 414-937-4359 January 2010
Rexnord
e-mail: info@rexnord.com web: www.rexnord.com 138-050
Supersedes 11-09
3001 W. Canal St., Milwaukee, WI 53208-4200 USA June 2015
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance
(Page 6 of 17) Type A Series • Sizes 305 thru 585
Lubrication Recommendations
INTRODUCTION
Carefully follow instructions on the drive nameplate, warning
tags and installation manuals furnished with the drive.
Lubricants listed in this manual are typical products
ONLY and should not be construed as exclusive
recommendations. Industrial type petroleum-based rust
and oxidation inhibited (R & O), industrial type extreme
pressure (EP) or industrial type micropitting resistant gear
lubricants are the recommended gear lubricants. They can
be formulated using petroleum or synthetic base stocks.
The section on food grade lubricants provides guidance
selecting lubricants for applications needing this class of
lubricants. Food grade lubricants are formulated using
petroleum or different types of synthetic base stocks.
LUBRICANT SELECTION PROCESS
1. Refer to Table 3 or 4 for proper lubricant viscosity
grade based on ambient temperature range. See Falk
GMax 6000 paragraph on this page for ambient air
temperature range if using this lubricant.
2. Refer to Table 2 for summary of lubricant type.
3. Using proper lubricant table and viscosity grade, select
desired lubricant manufacturer name.
4. Refer to Table 9 or 10 for approximate oil capacity to
purchase.
TABLE 2 — S
 ummary of Lubricant Type and
Greases
Petroleum-Based
R & O Inhibited Extreme Pressure (EP) Micropitting Resistant
See Table 6A See Table 6B See Table 6C
Synthetic Lubricant, Polyalphaolefin Type (PAO)
R & O Inhibited Extreme Pressure (EP) Micropitting Resistant
See Table 7A See Table 7B See Table 7C
Synthetic Lubricant, Polyalkylene Glycol Type (PAG)
See Falk GMax 6000 (Paragraph to Right)
Conventional Grease
See Table 8
Food Grade Lubricant & Grease
See Page 14
VISCOSITY (IMPORTANT)
The proper viscosity grade for petroleum-based lubricant
is found in Table 3. For synthetic lubricant viscosity grades,
refer to Table 4 and the “Synthetic Lubricants” paragraphs.
Viscosity grade is determined by ambient air temperature
in immediate vicinity of gear drive. Lubricant selections
must have a pour point at least 10°F (5.5°C) below the
expected minimum ambient starting temperature.
If a gear drive operates in a typical indoor environment
where the ambient temperature is within 70°F to 125°F (21°C
to 52°C), the oil viscosity may be increased one ISO grade
above that shown for the 50°F to 125°F (10°C to 52°C) range.
That is, an ISO VG 320 (AGMA 6) or ISO VG 460 (AGMA 7)
may be substituted for an ISO VG 220 (AGMA 5) or ISO VG
320 (AGMA 6) respectively, under this ambient condition.
138-050
June 2015
Supersedes 01-10
LUBRICANT TYPES
PETROLEUM-BASED LUBRICANTS (TABLES 6A, 6B &
6C) — Industrial type petroleum-based rust and oxidation
inhibited (R & O) gear lubricants are the most common
and readily available general purpose gear lubricants.
SYNTHETIC LUBRICANTS (TABLES 7A, 7B & 7C) —
Synthetic lubricants of the polyalphaolefin (PAO) type
are recommended for cold climate operation, high
temperature applications, extended temperature range
(all season) operation and/or extended lubricant change
intervals. The proper viscosity grade of synthetic lubricant
is given in Table 4.
Polyalkylene glycols (PAG) are another class of synthetic
lubricants. They have similar performance properties
as PAO synthetics - low pour point, stable at elevated
temperatures, and high viscosity index. PAG's have
exceptional tolerance to water contamination.
WARNING: Polyalkylene glycols (PAG’s) are not
compatible with petroleum mineral oil or PAO synthetic
lubricants and must not be topped off with either lubricant.
In addition, petroleum mineral oils or PAO synthetic
lubricants must not be used to top off systems containing
PAG’s. Do not use PAG’s in gear drives with painted interior
housing walls unless paint compatibility is checked.
Compatibility with oil seals and gasket materials must be
checked prior to use. PAG lubricants are not compatible
with polycarbonate sight glass. Use glass sight glass.
Falk GMax 6000 – Rexnord markets Falk GMax 6000, a
polyalkylene glycol lubricant. It is available in ISO VG 135
and covers ambient air temperature range -30° to +125°F
(-34° to +52°C).
WARNING: GMax 6000 is not compatible with petroleum
mineral oil or PAO synthetic lubricants and must not be
topped off with either lubricant. In addition, petroleum
mineral oils or PAO synthetic lubricants must not be used
to top off systems containing GMax 6000. Do not use
GMax 6000 in gear drives with painted interior housing
walls unless paint compatibility is checked. Compatibility
with oil seals and gasket materials must be checked prior
to use. GMax 6000 is not compatible with polycarbonate
sight glass. Use glass sight glass.
ANTI-WEAR (AW) LUBRICANTS — For moderately
loaded gear drives or operating conditions challenging
for conventional R & O oils, industrial type anti-wear (AW)
lubricants are suggested. These lubricants contain anti-
wear additives that provide stronger thicker lubricant film
to help maintain surface separation. Synthetic lubricants
by inherent nature of base stock properties provide anti-
wear performance.
EXTREME PRESSURE (EP) LUBRICANTS (TABLES 6B
& 7B) — For highly loaded drives or for drives loaded in
excess of original estimates, industrial-type petroleum EP
lubricants are preferred. EP lubricants are manufactured
from petroleum or synthetic base lubricants. Anti-scuff is
another term used to describe EP lubricants.
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
 Falk® Enclosed Gear Drives • Installation and Maintenance

Type A Series • Sizes 305 thru 585 (Page 7 of 17)

MICROPITTING RESISTANT LUBRICANTS (TABLES 6C & 7C) OIL PUMPS — When selecting a lubricant for a gear drive
— Micropitting resistant lubricants are specially developed equipped with an oil pump, cold temperature oil viscosity is
for surface hardened gearing commonly used in modern important. Lubricant viscosity at start-up generally should not
industrial gear drives. These lubricants contain additives to exceedDrives1725 cSt (8,000 SSU). When exceeding this viscosity,
Falk™ Enclosed Gear
resist formation of micropitting and other conventional forms Gear Drives is•
pump cavitation
Installation
Installation
•possible, preventingand
and Maintenance
Maintenance
oil circulation. A sump
of gear wear. Highly loaded gear drives or applications heater may be required or it may be possible to use a lower
where operating loads are not well defined may
Type
Type A
A Series
benefit • Sizes
from •
Series Sizes 305
305 oil
viscosity
thru
thru 585
585 pump cavitation.
to minimize
(Page
(Page 5 5 of
of 11)
11)
this type of lubricant. Generally lubricants are available in
Drives with Oil Pumps Types AXV and occasionally other
limited number of viscosity grades.
Fastener Tightening Torques types
Water of gear drives will be equipped with oil pumps for
Fastener LUBRICANTS
WARNING: Tightening IN Torques
FOOD PROCESSING WaterorCooling
cooling Cooling
special lubrication considerations. If a drive is
Use
Use the
INDUSTRYthe tightening torque
— Generally
tightening values
values specified
torqueconventional in
in Table
Table 1
gear lubricants
specified for
1are
for WATER
WATER COOLED
equipped with an oil
COOLED HEAT
HEATpump,EXCHANGERS
fill the drive to—
EXCHANGERS —theInstall
levela
Install shut-off
amarked
shut-off
classified
fastening as
fastening H2 by
Falk™
Falk™ NSFdrives,
gear
gear (National
drives, Sanitation
motors
motors and Foundation)to
and accessories
accessories to or
or control
on valve
the dipstick.
control valve Runin
in the water
thethe line
line to
lubrication
water to the heat
system
the exchanger
heat for several to
exchanger to
since
their they contain harmfulwith
substances and should not be regulate
minutes
regulate to the
thefillwater flow
flow through
the system the
the exchanger.
components. Verify that Also
Alsotheinstall
pump a
their mounting
mounting surfaces
surfaces with un-lubricated
un-lubricated fasteners.
fasteners. DO
DO water flow
water
gauge between
through
the
exchanger.
control valve and the
install a
used
NOT in the
use food
these processing
values for industry.
“torque Lubricants
locking”
NOT use these values for “torque locking” fasteners or registered
fasteners or is circulating
water flow oil
gauge properly,
between then
the recheck
control oil
valve level.
and If
thenecessary,
as exchanger to
to determine actual
filterflow rate. Discharge
Discharge water water to
forH1
for by NSF components
fastening
fastening are suitable for
components with
withfood processing
aluminum
aluminum feetapplications.
feet or soft
or soft add
an
oil to compensate
exchanger determinefor actual and/or
flow cooler.
rate. to
an OPEN
OPEN DRAINDRAIN to to prevent
prevent back
back pressure.
pressure.
CLIMATE
gaskets orCONDITIONS — Ambient
vibration dampeners on thetemperature
mounting in surface. Before starting the gear drive, rotate the input shaft to check
immediate
IfIf the vicinity
the tightening
tightening of gear
torque
torque drive is
exceeds
exceeds thevery
the important
capacity
capacity of thefortorque
of the torque
INTERNAL
INTERNAL
for obstructions.
COOLING
COOLINGThen start
TUBES
TUBES — Refer
—
the drive Refer
andto
to Manual
Manual
allow
138-310
138-310
it to run without
determining viscosity grade. Table 3 provides viscosity for
for installation,
installation, operation,
operation, and
and maintenance
maintenance of
of internal
internal
wrench, use a torque multiplier. For inch fasteners,
wrench, use a torque multiplier. For inch fasteners, use use load for several minutes. Shut down and recheck oil level. If
grade cooling
cooling tubes.
tubes.
Gradeselections
Grade 5
5 for for petroleum-based
for diameters
diameters though 1.500 lubricants.
though 1.500 inch
inch and
and ASTMSee A
ASTM A everything is satisfactory, the drive is ready for operation.
Table
354 grade 4 for synthetic lubricants.
BC for larger diameter fasteners. Use ISO
354 grade BC for larger diameter fasteners. Use ISO
property
property class
class 8.8
8.8 for
for metric
metric fasteners.
fasteners. Lubrication
Lubrication Systems
LUBRICATION SYSTEMS
Systems
OIL LEVELS SPLASH
SPLASH LUBRICATED
SPLASH LUBRICATEDDRIVES
LUBRICATED DRIVES
DRIVES —— Standard
Standard typetype A, AR,
A, AB,
Types A & AB Prior to filling gear drive or after storage, remove ABR,
ABR,AB,
AR, and
andABR,ABRC
ABRCand drives
drives
ABRC are splash
are drives lubricated.
splash are splash The
lubricated. The lubricant
lubricant is
lubricated. is
the
TABLE
TABLE inspection 1
1— —cover and flood the
Tightening
Tightening oil troughs +/-5%
Torques:
Torques: with oil. The
+/-5% picked
picked
The up
up by
lubricantby the
the revolving
revolving
is picked upelements
elements and
and distributed
by the revolving distributed
elements to
to the
the
and
oil troughs sit directly DO beneath
NOT the inspection
Lubricate cover and can
Fasteners bearings
bearings and
distributed andto gear
gear meshes.
meshes. and gear meshes.
the bearings
DO NOT Lubricate Fasteners
be filled to flooding, typically with a volume of approximately
OIL PUMP LUBRICATEDDRIVES
OIL
OIL PUMP
PUMP LUBRICATED
LUBRICATED DRIVES
DRIVES —
—— Types
Types
Types AXV
AXVAXV and
and andABX
ABX are
are
10% of the sump lube.Inch This
Inch Fasteners
Fasteners –– Grade
will provide 55 to the bearings. Fill
Gradeoil equipped with
with an an external oil pump
pump to provide
ABX are equipped
equipped with an
external oilexternal tooil pumpoil
provide toto
oil the
the upper
toprovide upper
theFastener
drive with oil to the Metallevel
to indicated
Metal on the Metal
oil dipstick.
to The
to Concrete bearings
Fastener Metal to Metal Metal Concrete oil to the and
bearings upper
and gear
gear meshes.
bearings
meshes.and The system
The gear
system is
is composed
meshes.composed of
of an
The system an
approximate
Size oil capacity is given on the gear drive nameplate. electric motor driven gear
gear pump, oil filter,
filter, flow indicator
Size lb-ft
lb-ft Nm
Nm lb-ft
lb-ft Nm
Nm is composed
electric motor of an electric
driven motor
pump, oil driven gear
flow pump, with
indicator oil
with
For reference, approximate capacities are also given in Table 9. switch, and an
an internal distribution network with
with relief valve
valve (set
.250-20 77 10 66 88 filter,
switch,flow
andindicatorinternalwith switch, and
distribution an internal
network distribution
relief (set
Always fill to proper15
.250-20 level indicated 21 on the dipstick.
10 at
at 30
30 psi). The pump system may be
be furnished
.3125-18
.3125-18 15 21 12 12 16 16 network psi).with
Therelief
pumpvalvesystem(set at 30
may psi). The with
furnished pump
with a
a 50
50 or
system
or
.375-16
.375-16 that have27 37
37 for greater22 30 60Hz,
60Hz,be3 phase
phase electrical
For drives
.500-13
27been inactive
67 91
22than 1 month,
54
30
73 may 3 furnished with amotors
electrical motors based
based on
50 or 60Hz, the
the selection.
3 phase
on electrical
selection. Refer
Refer toto
.500-13 67 91 54 73oil. the
the pump motor
motoronnameplate and
and Table
remove .625-11
.625-11
the inspection
134
134
cover and 184
184
flood the oil
108
108
troughs with
146
146 motorspump based the selection.
nameplate Refer2
Table for
2 to
fortheelectrical
pump motor
electrical
The .750-10
oil troughs sit directly beneath the inspection cover and requirements.
nameplate
requirements. andWire
WireTablethe
the 5motor for
for correct
for electrical
motor correct rotation
rotation as
requirements. as indicated
Wire
indicated
.750-10 242
242 330
330 194
194 265
265
can be filled to flooding. This will by
by the rotation arrow.
arrow. The flow
flow indicator has
has a abysingle pole,
.875-9
.875-9 395
395 530ensure proper
530 315 lubrication
315 425 of
425 the motor
the for correct
rotation rotation
The as indicated
indicator the rotation
single pole,
the 1.000-8
bearings. After590
1.000-8 filling the unit
590 800
800and before475
475 640
starting, ensure
640 double
arrow.
doubleThe throw
throwflowswitch rated
rated at
indicator
switch has
at 15A, 125V/7A,
a single
15A, 125V/7A, pole,250V double
250V maximum.
throw
maximum.
1.125-7 740 1000 590 800 Connect the
that1.125-7
the oil levels do 740not exceed those on the590dipstick. Always
1000 800 switch
Connect the flow
rated at 15A,
flow indicator
125V/7A,
indicator switch with
switch250V the
the prime
with maximum. prime mover Connect
mover control
controlthe
1.250-7 1060 1420 840 1140 circuitry to prevent drive operation without the lubrication
fill to1.375-6
proper level indicated
1360 on 1860
the dipstick.1100 1480 flow indicator switch with the prime mover control circuitry
circuitry to prevent drive operation without the lubrication
1.375-6 1360 1860 1100 1480 system.
1.500-6
Types ABR, ABRC,
1.500-6 1840
1840and AR Fill2480 1460
1460 oil to the1980
2480the drive with level
1980 to prevent drive operation without the lubrication system.
system.
1.750-5
1.750-5 3900
3900 5300
5300 2700
2700 4240
4240
indicated
2.000-4.5on the oil
5900dipstick. Approximate
7900 oil capacities
4100 are
6300 TABLE
TABLE 2
TABLE 5 — Oil
2 Oil Pump
PumpElectrical
ElectricalSpecifications
Specifications
2.000-4.5 5900 7900 4100 6300
given on the nameplate
2.250-4.5
2.250-4.5 8600
8600 and in Table 10. 6000
11800
11800 6000 9400
9400 DRIVE
DRIVE
2.500-4
2.500-4 11800
11800 16000
16000 8300
8300 12800
12800 SIZE 405
405 &
& 425
425 445-485
445-485 505-535
505-535
2.750-4 14600 19800 15800 SIZE
TABLE
2.750-4 3
3.000-4
3.000-4
— Viscosity
14600
19400
19400
Grade
19800
26400
26400
Recommendations
10200
13600
13600
15800
21100
21100 HP
HP 1
1 22 33
For All Petroleum Lubricants Cycles, Hz
Cycles, Hz 50
50 60
60 50
50 60
60 50
50 60
60
Output Ambient Temperature Range RPM
RPM 1425
1425 1725
1725 1425
1425 1725
1725 1425
1425 1725
1725
TABLE
TABLE
RPM 1A —
— Tightening Torques: +/-5%
Torques:+50°
+/-5% Voltage
Voltage 208- 208- 208-
+15°Lubricate
to +60°F Fasteners
to +125°F 220/380/440 208-
220/380/440 220/380/440
220/380/440
208- 220/380/440 208-
DO
DO NOT
NOT Lubricate Fasteners 230/460
230/460 230/460 220/380/440 230/460
230/460 230/460
(–9° to +16°C) (+10° to +52°C)
Metric
Metric Fasteners
Fasteners –– Property
Property Class
Class 8.8
8.8
ISO-VG AGMA ISO-VG AGMA Other types of gear drives may also be equipped with oil
Fastener Metal to
Metal to Metal
Metal Metal to
Metal to Concrete
Concrete
Fastener Other
Other types
pumps of
of gear
for special
types gear drives
drives may
lubrication also
also be
be equipped
considerations
may with
with oil
or external
equipped cooling.
oil
Below
Size80
Size 150 4 320 6
lb-ft Nm lb-ft Nm pumps
pumps for
for special
special lubrication
lubrication considerations
considerations or
or external
external
80 CAUTION: Refer to Factory for drives that use pumps to
M4&xx Above
M4 .7
.7 22 150 33 4 1.5220 52 cooling.
cooling. lubricants with temperatures below 30°F (-1°C).
distribute
M5
M5 xx .8
.8 4.5 66 3.5
3.5 55
M6
M6 xx 1.0
1.0 7.5
7.5 10
10 66 88 Caution: Refer
Caution: Refer to
to Factory
Factory for
for drives
drives that
that use
use pumps
pumps toto
TABLE
M8 1.25 4
M8 xx 1.25 — Viscosity
18
18 Grade
24
24 Recommendations
14
14 19
19 fordistribute
All Synthetic
distribute lubricants Lubricants
lubricants with
with temperatures
temperatures below
below 30°F
30°F (-1°C).
(-1°C).
M10
M10 xx 1.5
1.5 36
36 50
50 29
29 39
39
M12
M12 xx 1.75
1.75 62
62 Cold 84
84 Climates 50
50 68
68 Normal Climates
Output
M16
M16 xx 22 –30°
56
56 to +10°F 210
210 –15°
126
126 to +50°F 170
170 0° Lubrication
Lubrication
to +80°F Recommendations
Recommendations
+10° to +125°F +20° to +125°F
RPM
M20
M20 xx 2.5
2.5 (–34°
305 to –12°C)415
305 415 (–26°
246 to +10°C) 330
246 330 (–18°Carefully
to +27°C) follow lubrication
(–12° to +52°C)
instructions on (–7°
the to +52°C)
gear drive
M30 Carefully follow lubrication instructions on the gear drive
M30 xx 3.5
3.5 1060
1060
ISO-VG AGMA
11 440
440 ISO-VG
850
850 AGMA
11 150
150 ISO-VG AGMA
nameplate, warningISO-VG
tags, and AGMA
installationISO-VG
manuals AGMA
furnished
M36
M36 xx 44 1680
1680 22 520
520 1500
1500 22 030
030 nameplate, warning tags, and installation manuals furnished
Below
with
with the
the gear
gear drive.
drive.
M42 xx 80
M42 4.5
4.5 32
3000
3000 04 050
4 050 682400
2400 2 3 250
3 250 150 4 320 6 320 6
80 & xxAbove
M48
M48 55 32
4500
4500 066 100
100 683600
3600 2 44 880
880 150 Lubricants 4 listed
Lubricants in 220
listed in this
this manual
manual are5 typical
are 320
typical ONLY
ONLY and 6
and should
should
M56
M56 x 5.5
x 5.5 7300
7300 9 850
9 850 5800
5800 7 860
7 860 not be construed as exclusive recommendations. Industrial
not be construed as exclusive recommendations. Industrial
type
type petroleum
petroleum based
based rust
rust and
and oxidation
oxidation inhibited
inhibited (R
(R && O)
O)
gear
gear lubricants
lubricants or
or industrial
industrial type
type sulfur-phosphorus extreme
sulfur-phosphorus 138-050
extreme
Rexnord pressure
3001 W. Canal St., Milwaukee, WI 53208-4200 USA pressure (EP)
(EP) gear
gear lubricants
lubricants are
are the
the recommended
recommended lubricants
lubricants
June 2015
for
for ambient
ambient temperatures
temperatures of of 15°F
15°F to
to 125°F(-9°C
125°F(-9°C to
to +50°C).
+50°C).
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 01-10
For
For drives
drives operating
operating outside
outside the
the above
above temperature
temperature range
range
refer to “Synthetic Lubricants” paragraphs, Page 7. Synthetic
Falk® Enclosed Gear Drives • Installation and Maintenance
(Page 8 of 17) Type A Series • Sizes 305 thru 585
PREVENTIVE MAINTENANCE
AFTER FIRST WEEK — Check alignment of total system
and realign where necessary. Also tighten all external
bolts and plugs where necessary. DO NOT readjust the
internal gear or bearing settings in the drive, these were
permanently set at the Factory.
AFTER FIRST MONTH — Proceed as follows:
1. Operate drive until old sump oil reaches normal
operating temperature. Shut down drive and drain
immediately.
2. Immediately flush drive with an oil of the same type
and viscosity grade as the original charge (warmed to
approximately 100°F (38°C) in cold weather) by rapidly
pouring or pumping a charge equal to 25 -100% of the
initial fill volume or until clean oil flows through the drain.
3. C
 lose the drain and refill the drive to the correct level with
new oil of the correct type and viscosity.
PERIODICALLY —
1. C
 heck the oil level of the drive when it is stopped and at
ambient temperature. Add oil if needed. If the oil level is
ABOVE the high oil level mark on the dipstick, have the
oil analyzed for water content. Moisture in the oil may
indicate that a seal or the heat exchanger is leaking. If
so, replace the defective part immediately and change
the oil. DO NOT fill above the mark indicated as leakage
or undue heating may result.
2. C
 heck coupling alignment to make certain that
foundation settling has not caused excessive
misalignment.
3. If drive is equipped with a fan, periodically clean
accumulated foreign matter from the fan, guard, and
deflector.
4. If drive is equipped with a torque arm, check for free
movement.
 urge grease from grease lubricated seals WITH HAND
5. P
GREASE GUN. Regrease those bearings requiring
grease lubrication.
138-050
June 2015
Supersedes 01-10
LUBRICANT ANALYSIS AND CHANGES
OIL ANALYSIS REPORT — Checking oil condition at
regular intervals is recommended. Analyze oil samples
approximately every 1000 hours for petroleum lubricants
or every 3000 hours for synthetic lubricants. In the
absence of more specific limits, the guidelines listed below
may be used to indicate when to change petroleum or
polyalphaolefin type synthetic lubricants:
1. Water content is greater than 500 ppm (parts per
million) (0.05%).
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. TAN (Total Acid Number) 50% increase above reference
sample from new oil container.
6. Viscosity changes more than ±15%.
7. Solid particle contamination code exceeds 25/22/18 for
particle sizes ≥4/≥6/≥14 microns, respectively per ISO
4406.
Guidelines for when to change Falk GMax 6000
polyalkylene glycol type lubricant are:
1. Water content is greater than 3%.
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. Viscosity changes more than ±15%.
6. Solid particle contamination code 25/22/18 per ISO
4406.
Laboratory analysis is recommended for optimum lubricant
life and gear drive performance.
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
 Falk® Enclosed Gear Drives • Installation and Maintenance

Type A Series • Sizes 305 thru 585 (Page 9 of 17)

TABLE 6A — Petroleum Based R & O (Rust & Oxidation) Inhibited Lubricants s

Maximum Operating Temperature of Lubricants 200°F (93°C)
ISO Viscosity Grade 150 220 320
AGMA Viscosity Grade 4 5 6
Viscosity cSt @ 40°C  135-165 198-242 288-352
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name
Hyspin AWS 150 Hyspin AWS 220 ---
Castrol Industrial Lubricants Castrol Paradene R&O 150 Castrol Paradene R&O 220 Castrol Paradene R&O 320
Castrol Paradene AW 150 Castrol Paradene AW 220 Castrol Paradene AW 320
Chevron / Texaco / Caltex Rando HD 150 Rando HD 220 Rando HD 320
Citgo Petroleum Corp. Pacemaker T 150 Pacemaker SD 220 Pacemaker SD 320
DTE Oil Extra Heavy DTE Oil BB DTE Oil AA
Exxon Mobil / Esso Vacuoline 528 Vacuoline 533 Vacuoline 537
Petro-Canada Lubricants TurboFlo R&O 150 TurboFlo R&O 220 TurboFlo R&O 320
Phillips 66 / Conoco / 76 Lubricants / Kendall Multipurpose R&O 150 Multipurpose R&O 220 Multipurpose R&O 320
Morlina S2 B 150 Morlina S2 B 220 Morlina S2 B 320
Shell Oil Co. Morlina S2 BA 150 Morlina S2 BA 220 Morlina S2 BA 320
Total Lubricants USA / Keystone Div. Penwalt Corp. Cirkan ZS 150 Cirkan ZS 220 Cirkan ZS 320
Whitmore Manufacturing Company Hyperion 150 Hyperion 220 Hyperion 320
cc Minimum viscosity index of 90.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).

TABLE 6B — Petroleum Based EP (Extreme Pressure) Lubricants s

Maximum Operating Temperature of Lubricants 200°F (93°C)
ISO Viscosity Grade 150 220 320
AGMA Viscosity Grade 4 5 6
Viscosity cSt @ 40°C  135-165 198-242 288-352
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name
Castrol Industrial Lubricants Alpha SP 150 Alpha SP 220 Alpha SP 320
Meropa 150 Meropa 220 Meropa 320
Chevron / Texaco / Caltex
Ultra Gear 150 Ultra Gear 220 Ultra Gear 320
Citgo Petroleum Corp. EP Compound 150 EP Compound 220 EP Compound 320
Exxon Mobil / Esso Mobilgear 600 XP 150 Mobilgear 600 XP 220 Mobilgear 600 XP 320
Fuchs Lubricants Company --- GearMaster CLP Oils 220 ---
Kluber Lubrication Kluberoil GEM 1 N 150 --- ---
Petro-Canada Lubricants Enduratex EP 150 Enduratex EP 220 Enduratex EP 320
Phillips 66 / Conoco / 76 Lubricants / Kendall Extra Duty Gear Oil 150 Extra Duty Gear Oil 220 Extra Duty Gear Oil 320
Shell Oil Co. Omala S2 G 150 Omala S2 G 220 Omala S2 G 320
Total Lubricants USA / Keystone Div. Penwalt Corp. Carter EP 150 Carter EP 220 Carter EP 320
cc Minimum viscosity index of 90.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).

TABLE 6C — Petroleum Based Micropitting Resistant Lubricants s

Maximum Operating Temperature of Lubricants 200°F (93°C)
ISO Viscosity Grade 150 220 320
AGMA Viscosity Grade 4 5 6
Viscosity cSt @ 40°C  135-165 198-242 288-352
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name
Kluber Lubrication --- Kluberoil GEM 1 N 220 Kluberoil GEM 1 N 320
cc Minimum viscosity index of 90.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).

Rexnord 138-050
3001 W. Canal St., Milwaukee, WI 53208-4200 USA June 2015
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance

(Page 10 of 17) Type A Series • Sizes 305 thru 585

TABLE 7A — Synthetic PAO (Polyalphaolefin) R & O (Rust & Oxidation) Inhibited Lubricants s
ISO Viscosity Grade 32 68 150 220 320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C  28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
Alphasyn T 32 Alphasyn T 68 Alphasyn T 150 Alphasyn T 220 Alphasyn T 320
Castrol Industrial Lubricants
Castrol Isolube 32 Castrol Isolube 68 Castrol Isolube 150 Castrol Isolube 220 Castrol Isolube 320
Chevron / Texaco / Caltex Cetus HiPerSYN Oil 32 Cetus HiPerSYN Oil 68 Cetus HiPerSYN Oil 150 Cetus HiPerSYN Oil 220 Cetus HiPerSYN Oil 320
Citgo Petroleum Corp. --- CITGEAR Synthetic HT 68 CITGEAR Synthetic HT 150 CITGEAR Synthetic HT 220 CITGEAR Synthetic HT 320
Exxon Mobil / Esso Mobil SHC 624 Mobil SHC 626 Mobil SHC 629 Mobil SHC 630 Mobil SHC 632
Kluber Lubrication --- Klubersynth G 4 68 Klubersynth G 4 150 Klubersynth G 4 220 ---
Petro-Canada Lubricants Synduro SHB 32 Synduro SHB 68 Synduro SHB 150 Synduro SHB 220 ---
Phillips 66 / Conoco / 76 --- Syncon R&O 68 Syncon R&O 150  Syncon R&O 220  Syncon R&O 320 
Lubricants / Kendall
Shell Oil Co. --- Morlina S4 B 68 Morlina S4 B 150 Morlina S4 B 220 Morlina S4 B 320
cc Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
zz Minimum viscosity index of 120.

TABLE 7B — Synthetic PAO (Polyalphaolefin) EP (Extreme Pressure) Lubricants s

ISO Viscosity Grade 32 68 150 220 320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C  28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
--- Alphasyn EP 150 Alphasyn EP 220 Alphasyn EP 320
Castrol Industrial Lubricants --- Castrol Isolube EP 68 Castrol Isolube EP 150 Castrol Isolube EP 220 Castrol Isolube EP 320
Tegra Synthetic Gear Tegra Synthetic Gear Tegra Synthetic Gear
Chevron / Texaco / Caltex --- --- Lubricant 150 Lubricant 220 Lubricant 320
CITGEAR Synthetic CITGEAR Synthetic CITGEAR Synthetic CITGEAR Synthetic
Citgo Petroleum Corp. --- EP Gear 68 EP Gear 150 EP Gear 220 EP Gear 320
Exxon Mobil / Esso --- --- Mobil SHC Gear 150 Mobil SHC Gear 220 Mobil SHC Gear 320
Fuchs Lubricants Company --- --- --- Renolin Unisyn CLP 220 Renolin Unisyn CLP 320
Kluber Lubrication --- --- Klubersynth EG 4 150 Klubersynth EG 4 220 Klubersynth EG 4 320
Petro-Canada Lubricants --- --- Enduratex Synthetic EP 150 Enduratex Synthetic EP 220 Enduratex Synthetic EP 320
Phillips 66 / Conoco / 76 --- --- Syncon EP Plus Gear Oil 150 Syncon EP Plus Gear Oil 220 Syncon EP Plus Gear Oil 320
Lubricants / Kendall
Shell Oil Co. --- Omala S4 GX 68 Omala S4 GX 150 Omala S4 GX 220 Omala S4 GX 320
Whitmore Mfg. Company --- --- Decathlon HD 150 Decathlon HD 220 Decathlon HD 320
cc Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).

TABLE 7C — Synthetic PAO (Polyalphaolefin) Micropitting Resistant Lubricants s

ISO Viscosity Grade 32 68 150 220 320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C  28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
Chevron / Texaco / Caltex --- --- --- --- Pinnacle WM 320
Exxon Mobil / Esso --- --- --- --- Mobil SHC Gear 320 WT
Kluber Lubrication --- --- Klubersynth GEM 4 N 150 Klubersynth GEM 4 N 220 Klubersynth GEM 4 N 320
Petro-Canada Lubricants --- --- --- --- Harnex 320
Phillips 66 / Conoco / 76 Lubricants / Kendall --- --- --- --- Syncon WTL 320
Whitmore Manufacturing Company --- --- Decathlon F 150 Decathlon F 220 Decathlon F 320
cc Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
„„ Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).

138-050 Rexnord
June 2015 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 01-10 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
 Falk® Enclosed Gear Drives • Installation and Maintenance

Type A Series • Sizes 305 thru 585 (Page 11 of 17)

Installation and Maintenance • Falk™ Enclosed Gear Drives

(Page 8 of 11) Sizes 305 thru 585 • Type A Series

PETROLEUM LUBRICANTS — In the absence of oil WARNING: Greases in Table 8 contain harmful substances
analysis, change gear oils every 6 months or 2500 not allowed in the food processing industry. If grease could
operating hours, whichever occurs first. Change oil more contaminate the product,
GREASE LUBRICATED SEALSas—inMost
the food and drug
gear drives and industries,GREASE LUBRICA
frequently when gear drives operate in extremely humid, backstops
the greaseare furnishedsupplied
originally with grease purged
with gearseals
drive which
must be with hollow shaft
chemical or dust laden atmospheres. In these cases, minimize and
removed the entry of contaminants
replaced with greaseinto the driveinorTable
listed backstop.
19. Simplylubricated lower
Gear drives and backstops are shipped with #2 grease in the
lubricants should be changed every 3 to 4 months or purging grease
seal housing withunless
cavities grease gun will
otherwise not remove
specified. all grease lubricated at the
If grease
1500 to 2000 hours. If the drive is operated in an area and
could contaminate the product, as in the food and drug end cover
cross-contamination will likely occur. Remove to the preventive
where temperatures vary with the seasons, change the oil and manually
industries, remove
it should grease.AGrease
be removed. grease thatregistered
meets USDA as H1 by instructions.
viscosity grade to suit the temperature, refer to Table 3. NSF,
“H1”National Sanitation
classification Foundation,
is suitable is suitable
for food processing for food
applications. BACKSTOPS — F
Lubricant suppliers can test oil from the drive periodically processing applications. later, backstops ar
and recommend economical change schedules. top of backstop an
TYPICAL SEAL ASSEMBLIES Earlier models had
SYNTHETIC LUBRICANTS — In the absence of oil not use greases wi
analysis, synthetic lube change intervals can be extended FOR GREASING additives.
SEAL Type “A” and “AR” d
to 8000 hours depending upon operating temperatures. FOR GREASING
Laboratory analysis is recommended for optimum lubricant SEAL or a Falk™ PRT we
backstops are prelu
life and drive performance. Change lube with change in THROTTLING no future lubricatio
ambient temperature, if required. Refer to Table 5. BUSH SEAL
purgeable seals (se
SEAL DRAIN seals).
Falk GMax 6000 change interval can be up to 15,000 CAVITY
hours. It has broad temperature range so seasonal oil Falk™ PRT backst
from top of backst
changes are generally not needed. The condition of arm.
GMax must be monitored to maintain lubricant properties SEAL DRAIN
CAVITY
and cleanliness.
PLUG Oil Levels
(BUNA-N)
Types A & AB Prio
GREASE-LUBRICATED SEALS AND of the drive for grea
BEARINGS LOW OIL LEVEL HIGH OIL LEVEL cover and flood the
Sizes 385 & 405 thru 585 Sizes 385 & 405 thru 585 beneath the inspec
All drives and some backstops are furnished with grease Inner Bush Seal and Outer Two Lip Type Oil Seals typically with a volu
purged seals which minimize the entry of contaminants Lip Type Seal This will provide oil
and abrasive dusts. Some vertical shaft and specially level indicated on t
mounted drives have grease lubricated bearings. Drives given on the gear d
are shipped with NLGI #2 grade grease in the seal housing FOR FOR capacities are also
GREASING GREASING
high oil levels. Act
cavities unless otherwise specified. SEAL SEAL
depending on the
SEAL SEAL
Whenever changing oil in the drive, purge the seals with COVER COVER Always fill to prope
BUSH BUSH
one of the NLGI #2 grade greases listed in Table 8. SEAL SEAL Types ABR, ABRC
SEAL SEAL indicted on the oil
Depending upon the degree of contamination, periodically DRAIN
CAVITY
DRAIN
CAVITY
given on the name
(at least every six months), purge contaminated grease Drives with Oil P
from seals by slowly pumping fresh bearing grease types of gear drive
through the seal, WITH HAND GREASE GUN, until fresh cooling or special
grease flows out along the shaft. Wipe off purged grease. SEAL GAGE PLUG equipped with an
BASE PLUG BASE PLUG on the dipstick. Ru
CAUTION: Rapid greasing with a power grease gun to fill the system co
can force grease inward past the seals and plug the oil circulating oil prop
oil to compensate
drainback system causing seal leaks. LOW OIL LEVEL HIGH OIL LEVEL
Sizes 305 thru 365 & 395 Sizes 305 thru 365 & 395 Before starting the
Inner Bush Seal and Outer Inner Bush Seal and Outer for obstructions. T
Lip Type Seal Lip Type Seal
without load for se
TABLE 8 — Conventional NLGI #2 Grade Grease s for Grease Lubricated Bearings & Grease Purged Sealslevel. If everything
operation.
0° to +200°F (-18° to +93°C)
Manufacturer EP Grease n
Chevron / Texaco / Caltex Multifak EP 2
Citgo Petroleum Corp. Lithoplex RT 2
Premium Lithium EP 2
ExxonMobil / Esso Mobilith SHC 460 l
Mobilux EP 2
Petro-Canada Lubricants Precision General Purpose EP2
Phillips 66 / Conoco / 76 Lubricants / Kendall Multiplex Red
Shell Oil Co. Gadus S1 V220-2
Total Lubricants USA / Keystone Div. Penwalt Corp. 138-050 Multis EP 2 Rexnord Industries, LLC,
January 2010
s Not suitable for food grade applications.
n Caution: Do not use EP grease in backstop seals. Supersedes 11-09 e
zz High performance synthetic alternate.
Grease application or re-lubrication should be done at temperatures above 20°F (-7°C). If grease must be applied at cooler temperatures consult factory or
lubricant supplier for recommendations.

Rexnord 138-050
3001 W. Canal St., Milwaukee, WI 53208-4200 USA June 2015
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 01-10
mal operating
Refer to Table 8 for NLGI #2 greases. Some of these greases are
mmediately.
of the EP type and may contain toxic substances not allowed in
e type and Falk Enclosed
the® food processingGear Drives
industry. A grease•thatInstallation
meets the USDA and Maintenance
“H1”
rmed to classification is suitable for food processing applications.
her) by
ual to 25 -
(Page 12 of 17)
CAUTION: Rapid greasing with a power Type A Series
grease gun can •force
Sizes 305 thru 585
grease inward past the seals and plug the oil drainback system
an oil flows
causing seal leaks.
GREASE
GREASE LUBRICATED BEARINGS
LUBRICATED BEARINGS (TYPES
(TYPESAXVAXV ANDAND ABX) BACKSTOPS — For types AB, ABR, and ABX model C
ect level with — All hollow and most solid vertical low speed shaft drives
ABX) — All hollow and most solid vertical low speed shaft and later, backstops are furnished filled with oil. Remove
have a grease lubricated lower low speed bearing. Grease
drives have during
bearings a grease lubricated
oil changes or atlower lowofspeed
intervals every 6bearing.
months plug from top of backstop and replace with vent wired to
ped and at Theorbearing
2500 hours is lubricated
of operationat the factoryis with
whichever less. an NLGI
Table 11 #2 torque arm. Refer to the supplemental backstop installation
If the oil level grade grease.
contains low Grease bearing
speed bearing during
grease oil changes or at
capacities. and maintenance instructions provided with the drive for
dipstick, have intervals of every 6 months or 2500 hours of operation recommended lubricants. It is recommended to lubricate
HOLLOW SHAFT DRIVES — Remove the pressure relief plug
re in the oil whichever
before is less. Refer
greasing. Pump to Table
grease 8 for
into NLGIcage
bearing #2 grade
until fresh backstops during regular drive lubrication intervals. Earlier
anger is greases. Table 11atcontains low speed bearing grease models had backstops that are grease lubricated, do
mmediately grease appears the plug. Replace the pressure relief plug
capacities.
when finished. See Figure 2 below. not use greases with molybdenum disulfide or other EP
he mark additives.
ay result. Remove
Refer totheTablepressure relief#2
8 for NLGI plug before
greases. greasing.
Some of thesePump
greases
at foundation grease into bearing cage until fresh grease appears at the
are of the EP type and may contain toxic substances not Type “A” and “AR” drives may have a Falk pawl type
nment. allowed
plug. Replace in thethefood processing
pressure industry.
relief A grease
plug when that meets
finished. See backstop or a Falk PRT wedge ramp type backstop. Falk
the USDA “H1” classification is suitable for food processing pawl backstops are prelubricated and sealed at assembly
n accumulated Figure 2 below.
flector.
applications. and require no future lubrication. These backstops also
contain grease purgeable seals (see paragraph above for
for free grease lubricated seals).
Falk PRT backstops are shipped filled with oil. Remove plug
from top of backstop and replace with vent wired to torque
arm. Follow lubrication recommendations as outlined in the
on at regular supplemental backstop instructions furnished with the drive.
e specific
indicate Installation and Maintenance • Falk™ Enclosed Gear Drives
m). (Page
Figure 2 10 of 11) BEARING GREASE FITTING Sizes 305RELIEF
thru 585 • Type A Series
PLUG

BACKSTOPS — For types AB, , and ABX refer to the

supplemental
TABLE backstop
9 — Types A& installation and maintenance
AB Approximate Oil Capacities ‡
instructions provided with the drive for recommended
ng conditions, Type A Type AB
g hours, lubricants. It is recommended to lubricate backstops
DRIVE
during regular drive lubrication intervals. If backstops DRIVE
when gear SIZE A1 A2 A3 A4 AB2 AB3 AB4
SIZE
t laden are grease
Gallons lubricated,
Liters do not use
Gallons Litersgreases
Gallonswith Liters Gallons Liters Gallons Liters Gallons Liters Gallons Liters
nts should be molybdenum disulfide or other EP additives.
305 3 11 4 15 4 15 305
urs. If the drive Type “A” and
325 5 “AR” 19 drives may 6 have a23Falk™ pawl 6 type23 325
with seasons, 345
backstop 6or a Falk™ 23 PRT wedge 8 30 type backstop.
ramp 9 34Falk™ 345
icant suppliers 365 10
pawl backstops are38 prelubricated
13 and49 sealed13at assembly49 and 365
al change 385 10 future lubrication.
require no 38 10 These 38backstops 10 also contain
38 10 38 11 42 11 42 11 42 385
395 12
grease purgeable 45
seals (see16 paragraph
61 above 17 for grease
64 395
405 10 seals). 38
lubricated 15 57 15 57 14 53 11 42 15 57 15 57 425
ge intervals 425 14 53 20 76 21 79 20 76 14 53 20 76 22 83 405
ng upon are 22a wedge83ramp type
Falk™ PRT
445 22 backstops83 29 and are
110 oil 28 106 22 83 29 110 30 114 445
n. Change oil lubricated.
465 29 Follow110lubrication30 recommendations
114 39 as outlined
148 in38 144 30 114 39 148 39 148 465
mely humid, the supplemental
485 32 backstop38instructions
121 144 furnished57 with216 the 56 212 31 117 52 197 58 220 485
s, synthetic 505
drive. 42 159 50 189 78 295 77 291 39 148 70 265 80 303 505
or 4000 to 525 53 201 59 223 95 360 93 352 48 182 87 329 100 379 525
or optimum 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
‡
‡ Capacities
Capacities vary
vary with
with ratio,
ratio, speed
speed and
and type
type of
of cooling.
cooling. Follow
Follow values
values on
on the
the gear
gear drive
drive nameplate.
nameplate. Always
Always fill
fill to
to proper
proper level
level indicated
indicated on
on the
the dipstick.
dipstick.
e, WI 53208-4200 138-050
January 2010
TABLE 10 — Types AR, AVX, ABR, and ABX Approximate
Supersedes 11-09
Oil Capacities
Vertical Output Horizontal Output
DRIVE SIZE ABX3 & AXV2 ABX4, AXV3, & AXV4 ABR3 & AR2 ABR4, AR3, & AR4 
DRIVE
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

 Values
Values to
to right
right of
of slash
slash mark
mark are
are for
for type
type AR4
AR4 drives
drives when
when HS
HS Shaft
Shaft is
is above
above drive
drive center
center line.
line.

TABLE 11 — Types AXV and ABX – LS Shaft Lower Bearing Grease Capacity
Solid Shaft Hollow Shaft

138-050
DRIVE SIZE Down Up
oz mL
DRIVE SIZE
Rexnord
June 2015 oz mL oz mL 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes
405 01-10 8 237 12 Telephone: 12 Fax: 414-937-4359
355 414-342-3131 355 www.rexnord.com
405
425 12 355 18 532 12 355 425
445 12 355 18 532 24 710 445
 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 Falk227Enclosed65Gear
®
Drives
246 • Installation
80/100 and Maintenance
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
Type A Series • Sizes 305 thru 585 (Page 13 of 17)
 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

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 the Factory.
CAUTION: Drives are not to be stored outdoors without
shelter. Standing water on drives significantly increases
risk of water ingression and rust. Installer assumes risk.
If a gear drive is to be stored, or is inactive after installation
beyond the above periods, add Nox-Rust VCI-10s vapor-
phase rust inhibitor. For drives that have oil installed, add
Nox-Rust VCI-10 vapor-phase rust inhibitor at the rate of 2%
of sump capacity as shown in Table 12. For drives without
oil , add Nox-Rust VCI-10 vapor-phase rust inhibitor at the
rate of one ounce per cubic foot of internal drive space.
Rotate the shafts several times by hand. Before operating,
138-050
drives which have been stored or inactive must be filled to
January 2010
the proper level with oil meeting the specifications given
Supersedes 11-09
in the manual. Refer to manual 128-014 for "Start-up after
Storage" instructions.
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 vented dipstick should be replaced with a plug (vented
dipstick should be attached to gear drive for future use)
so that the protective rust inhibiting atmosphere is sealed
inside the drive. Install vented dipstick when preparing
drive for operation.
WARNING: The rust preventative oil from the factory
and Nox-Rust VCI-10 are not H1 registered with the NSF
(National Sanitation Foundation) as suitable for food
processing applications. When Food Grade Lubricants are
to be used, it is the end users responsibility to properly
Rexnord Industries, LLC, 3001 W. Canal St., Milwaukee, WI 53208-4200
flush and prepare the drive for Food Grade service.
Contact the lubricant Telephone: 414-342-3131
manufacturer Fax: information
for specific 414-937-4359
e-mail:
and flushing procedures. info@rexnord.com web: www.rexnord.com

TABLE 12 — N
 ox-Rust VCI-10 s
Add to Stored or Inactive Drives with Conventional Gear Lubricants

NOX-RUST VCI-10
Oil Capacity
Unit Size
Gallons 2% of Sump Capacity 2% of Sump Capacity 2% of Sump Capacity
Gallons Quarts Ounces
305 6 0.12 0.5 15.4
325 8 0.17 0.7 21.1
345 13 0.26 1.0 33.3
365 17 0.34 1.4 43.5
385 11 0.22 0.9 28.2
405 15 0.30 1.2 38.4
425 22 0.44 1.8 56.3
445 30 0.60 2.4 76.8
465 39 0.78 3.1 99.8
485 58 1.16 4.6 148.5
505 80 1.60 6.4 204.8
525 100 2.00 8.0 256.0
545 138 2.76 11.0 353.3
565 170 3.40 13.6 435.2
585 275 5.50 22.0 704.0
s Product of Daubert Chemical Company, Chicago, IL.

Rexnord 138-050
3001 W. Canal St., Milwaukee, WI 53208-4200 USA June 2015
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance

(Page 14 of 17) Type A Series • Sizes 305 thru 585

FOOD GRADE LUBRICANTS
Guidance for selecting petroleum-based and synthetic-
based food grade lubricants are shown below in Table 13.
For general lubrication guidlines, refer to the first part of
the "Lubrication Recomendation" Section.
FOOD GRADE LUBRICANT SELECTION
PROCESS
1. Refer to Table 14 or 15 for proper lubricant viscosity
grade based on ambient temperature range.
2. Refer to Table 13 for summary of food grade lubricant
type.
3. Using proper food grade lubricant table and viscosity
grade, select desired lubricant manufacturer name.
4. Refer to Table Table 9 or 10 for approximate oil capacity
to purchase.
TABLE 13 — Summary of Food Grade
Lubricants and Greases
Petroleum-Based
R & O Inhibited Extreme Pressure (EP)
See Table 16A See Table 16B
Synthetic Lubricant, Polyalphaolefin Type (PAO)
R & O Inhibited Extreme Pressure (EP)
See Table 17A See Table 17B
Synthetic Lubricant, Polyalkylene Glycol Type (PAG)
Extreme Pressure (EP)
See Table 18
Food Grade Grease
See Table 19
OIL PUMPS — When selecting a lubricant for a gear drive
equipped with an oil pump, cold temperature oil viscosity
is important. Lubricant viscosity at start-up generally
should not exceed 1725 cSt (8,000 SSU). When exceeding
this viscosity, pump cavitation is possible, preventing oil
circulation. A sump heater may be required or it may be
possible to use a lower viscosity oil to minimize pump
cavitation.
FOOD GRADE LUBRICANTS (TABLES 16A, 16B, 17A,
17B, 18 & 19) — Food grade lubricants are a class of
lubricants registered as H1 by NSF, National Sanitation
Foundation. They contain base stock and additives which
comply with Food and Drug Administration Title 21 CFR
178.3570 regulations for lubricants with incidental food
contact. Base stock can be petroleum oil or different types
of synthetic lubricant. Food grade lubricants are not same
as biodegradable or environmentally friendly lubricants.
Rust and corrosion inhibitors used to protect gear drive
during shipment are not qualified as food grade fluids. Flush
out inhibitor oil before filling with food grade lubricant.
Tables 16A, 16B, 17A, 17B, 18 & 19 list food grade
lubricants that have performance properties meeting
Rexnord/Falk specifications. They are not exclusive
recommendations but serve as a guide for making proper
lubricant selections.
CLIMATE CONDITIONS — Ambient temperature in
immediate vicinity of gear drive is very important for
determining viscosity grade. Table 14 provides viscosity
grade selections for petroleum-based lubricants. See
Table 15 for synthetic lubricants.
TABLE 14 — Viscosity Grade Recommendations
For All Food Grade Petroleum-
Based Lubricants
Output Ambient Temperature Range
RPM
+15° to +60°F +50° to +125°F
(–9° to +16°C) (+10° to +52°C)
ISO-VG AGMA ISO-VG AGMA
Below 80 150 4 320 6
80 & Above 150 4 220 5
Polyalkylene glycols (PAG) are another class of synthetic
lubricants. They have similar performance properties
as PAO synthetics - low pour point, stable at elevated
temperatures, and high viscosity index. PAG's have
exceptional tolerance to water contamination.
WARNING: Polyalkylene glycols (PAG’s) are not
compatible with petroleum mineral oil or PAO synthetic
lubricants and must not be topped off with either lubricant.
In addition, petroleum mineral oils or PAO synthetic
lubricants must not be used to top off systems containing
PAG’s. Do not use PAG’s in gear drives with painted interior
housing walls unless paint compatibility is checked.
Compatibility with oil seals and gasket materials must be
checked prior to use. PAG lubricants are not compatible
with polycarbonate sight glass. Use glass sight glass.

TABLE 15 — Viscosity Grade Recommendations For Food Grade Synthetic Lubricants

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 0 68 2 150 4 320 6 320 6

80 & Above 32 0 68 2 150 4 220 5 320 6

138-050 Rexnord
June 2015 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 01-10 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
 Falk® Enclosed Gear Drives • Installation and Maintenance

Type A Series • Sizes 305 thru 585 (Page 15 of 17)

PREVENTIVE MAINTENANCE 3. If drive is equipped with a fan, periodically clean

AFTER FIRST WEEK — Check alignment of total system
and realign where necessary. Also tighten all external
bolts and plugs where necessary. DO NOT readjust the
internal gear or bearing settings in the drive, these were
permanently set at the Factory.
AFTER FIRST MONTH — Proceed as follows:
1. O
 perate drive until old sump oil reaches normal
operating temperature. Shut down drive and drain
immediately.
2. Immediately flush drive with an oil of the same type
and viscosity grade as the original charge (warmed to
approximately 100°F (38°C) in cold weather) by rapidly
pouring or pumping a charge equal to 25 -100% of the
initial fill volume or until clean oil flows through the drain.
3. C
 lose the drain and refill the drive to the correct level with
new oil of the correct type and viscosity.
PERIODICALLY —
1. C
 heck the oil level of the drive when it is stopped and at
ambient temperature. Add oil if needed. If the oil level is
ABOVE the high oil level mark on the dipstick, have the
oil analyzed for water content. Moisture in the oil may
indicate that a seal or the heat exchanger is leaking. If
so, replace the defective part immediately and change
the oil. DO NOT fill above the mark indicated as leakage
or undue heating may result.
2. C
 heck coupling alignment to make certain that
foundation settling has not caused excessive
misalignment.
accumulated foreign matter from the fan, guard, and
deflector.
4. If drive is equipped with a torque arm, check for free
movement.
5. Refer to Section on Grease-Lubricated Seals and
Bearings.
LUBRICANT ANALYSIS AND CHANGES
OIL ANALYSIS REPORT (FOOD GRADE) — Checking oil
condition at regular intervals is recommended. Analyze oil
samples approximately every 1000 hours for food grade
petroleum lubricants or every 3000 hours for food grade
synthetic lubricants. In the absence of more specific limits,
the guidelines listed below may be used to indicate when
to change food grade lubricants:
1. Water content is greater than 500 ppm (parts per
million) (0.05%).
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. TAN (Total Acid Number) 50% increase above
reference sample from new oil container.
6. Viscosity changes more than ±15%.
7. Solid particle contamination code exceeds 25/22/18 for
particle sizes ≥4/≥6/≥14 microns, respectively per ISO
4406.

TABLE 16A — Food Grade Petroleum-Based R & O (Rust & Oxidation) Inhibited Lubricants –
NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
ISO Viscosity Grade 150 220 320
AGMA Viscosity Grade 4 5 6
Viscosity cSt @ 40°C s 135-165 198-242 288-352
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name
Bel-Ray Company, Inc. No-Tox Gear Oil ISO 150 No-Tox Gear Oil ISO 220 No-Tox Gear Oil ISO 320
Kluber Lubrication Paraliq P 150 --- ---
Lubriplate Lubricants Co. Lubriplate FMO 900-AW Lubriplate FMO 1100-AW Lubriplate FMO 1700-AW
cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes).

TABLE 16B — Food Grade Petroleum-Based EP (Extreme Pressure) Lubricants – NSF (National
Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
ISO Viscosity Grade 150 220 320
AGMA Viscosity Grade 4 5 6
Viscosity cSt @ 40°C s 135-165 198-242 288-352
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name
Petro-Canada Purity FG EP 150 Purity FG EP 220 Purity FG EP 320
Total Lubricants USA, Inc. Nevastane EP 150 Nevastane EP 220 Nevastane EP 320
cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes).

Rexnord 138-050
3001 W. Canal St., Milwaukee, WI 53208-4200 USA June 2015
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 01-10
Falk® Enclosed Gear Drives • Installation and Maintenance

(Page 16 of 17) Type A Series • Sizes 305 thru 585

TABLE 17A — Food Grade Synthetic PAO (Polyalphaolefin) R & O (Rust & Oxidation) Inhibited
Lubricants – NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
ISO Viscosity Grade 32 68 150 220 320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C s 28.2-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
ExxonMobil Mobil SHC Cibus 32 Mobil SHC Cibus 68 Mobil SHC Cibus 150 Mobil SHC Cibus 220 Mobil SHC Cibus 320
Kluber Lubrication Kluberoil 4 UH1 N 32 Kluberoil 4 UH1 N 68 Kluberoil 4 UH1 N 150 Kluberoil 4 UH1 N 220 Kluberoil 4 UH1 N 320
Lubriplate Lubricants
Lubriplate SFGO Ultra 32 Lubriplate SFGO Ultra 68 Lubriplate SFGO Ultra 150 Lubriplate SFGO Ultra 220 Lubriplate SFGO Ultra 320
Co.
Total Lubricants USA,
Nevastane SL 32 Nevastane SL 68 Nevastane SL 150 Nevastane SL 220 Nevastane SL 320
Inc.
cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes).

TABLE 17B — Food Grade Synthetic PAO (Polyalphaolefin) EP (Extreme Pressure) Lubricants –
NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
ISO Viscosity Grade 32 68 150 220 320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C s 28.2-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
Petro-Canada --- --- --- Purity FG Synthetic EP 220 ---
cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes).

TABLE 18 — Food Grade Synthetic PAG (Polyalkylene Glycol) EP (Extreme Pressure)

Lubricants – NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200°F (93°C)
See Warning Note below.
ISO Viscosity Grade 32 68 150 220 320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C s 28.2-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100° F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
Exxon Mobil --- --- Glygoyle 150 Glygoyle 220 Glygoyle 320
Kluber Lubrication --- --- Klubersynth UH1 6-150 Klubersynth UH1 6-220 Klubersynth UH1 6-320
Lubriplate --- --- PGO-FGL Synthetic Gear Oil 150 PGO-FGL Synthetic Gear Oil 220 PGO-FGL Synthetic Gear Oil 320

WARNING: Polyalkylene glycol (PAG) lubricants are not compatible with petroleum mineral oils or PAO synthetic lubricants. PAG’s must not
be mixed or used to top off either petroleum mineral oils or PAO synthetic lubricants.
cc Kinematic viscosity in units of mm 2/S is equivalent to cSt (centistokes).

Guidelines for when to change food grade polyalkylene PETROLEUM LUBRICANTS (FOOD GRADE) — In the
glycol type lubricant are: absence of oil analysis, change gear oils every 6 months
1. Water content is greater than 3%. or 2500 operating hours, whichever occurs first. Change
oil more frequently when gear drives operate in extremely
2. Iron content exceeds 150 ppm. humid, chemical or dust laden atmospheres. In these
3. Silicon (dust/dirt) exceeds 25 ppm, above reference cases, lubricants should be changed every 3 to 4 months
sample from new oil container. or 1500 to 2000 hours. If the drive is operated in an area
4. Copper content exceeds 75 ppm. where temperatures vary with the seasons, change the oil
viscosity grade to suit the temperature, refer to Table 14.
5. Viscosity changes more than ±15%.
Lubricant suppliers can test oil from the drive periodically
6. Solid particle contamination code 25/22/18 per ISO 4406. and recommend economical change schedules.
Laboratory analysis is recommended for optimum lubricant
SYNTHETIC LUBRICANTS (FOOD GRADE) — In the
life and gear drive performance.
absence of oil analysis, synthetic lube change intervals

138-050 Rexnord
June 2015 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 01-10 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
 Falk® Enclosed Gear Drives • Installation and Maintenance

Type A Series • Sizes 305 thru 585 (Page 17 of 17)

can be extended to 8000 hours depending upon operating STORED & INACTIVE GEAR DRIVES
temperatures. Laboratory analysis is recommended for
Prior to shipment from the factory, all Rexnord enclosed
optimum lubricant life and drive performance. Change lube
gear drives are protected internally against corrosion with
with change in ambient temperature, if required. Refer to
a rust preventative oil. A vapor phase rust inhibitor may
Table 15.
also be added.
WARNING: Rust preventative oil or vapor-phase inhibitors
GREASE-LUBRICATED SEALS are not H1 registered with the NSF (National Sanitation
AND BEARINGS Foundation) as suitable for food processing applications.
All drives and some backstops are furnished with grease When Food Grade Lubricants are to be used, it is the end
purged seals which minimize the entry of contaminants users responsibility to properly flush and prepare the drive
and abrasive dusts. Some vertical shaft and specially for Food Grade service. Contact the lubricant manufacturer
mounted drives have grease lubricated bearings. Drives for specific information and flushing procedures.
are shipped with NLGI #2 grade grease in the seal housing
cavities unless otherwise specified.
Whenever changing oil in the drive, purge the seals
with one of the NLGI #2 grade greases listed in Table
19. Depending upon the frequency and degree of
contamination, purge contaminated grease from seals by
slowly pumping fresh bearing grease through the seal,
WITH HAND GREASE GUN, until fresh grease flows out
along the shaft. Wipe off purged grease.
Greases in Table 8 contain harmful substances not
allowed in the food processing industry. If grease
could contaminate the product, as in the food and drug
industries, the grease originally supplied with gear drive
must be removed and replaced with grease listed in
Table 19. Simply purging grease with grease gun will not
remove all grease and cross-contamination will likely occur.
Remove end cover and manually remove grease. Grease
registered as H1 by NSF, National Sanitation Foundation, is
suitable for food processing applications.
CAUTION: Rapid greasing with a power grease gun
can force grease inward past the seals and plug the oil
drainback system causing seal leaks.

TABLE 19 — Food Grade Grease s for Grease

Lubricated Bearings & Grease
Purged Seals, NLGI #2 Grade
0° to +200°F(-18° to +93°C)
Manufacturer Lubricant
Bel-Ray Company, Inc. No-Tox HD Grease 2
Chevron USA, Inc. (Texaco/
Caltex) Chevron FM ALC EP 2

Exxon Mobil Mobil SHC Polyrex 462

Kluber Lubrication Klubersynth UH1 14-222
Lubriplate Lubriplate FGL-2
Total Lubricants USA, Inc. Nevastane HT/AW 2
Petro-Canada Purity FG
Phillips 66 / Conoco / 76
Food Machinery Grease 2
Lubricants / Kendall
cc NSF (National Sanitation Foundation) H1 Registered.
Grease application or re-lubrication should be done at temperatures
above 20°F (-7°C). If grease must be applied at cooler temperatures con-
sult factory or lubricant supplier for recommendations.

Rexnord 138-050
3001 W. Canal St., Milwaukee, WI 53208-4200 USA June 2015
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 01-10