es f INTRODUCTION Fie otowing intrcions apy to oll stondord Fok Speed Reducers © > SIZES 1080 theu 1195 © © SIZES 2050 thru 2225 © Soar Stiighe fa unis fernshed with special features, eafer tothe © Siplamantary structions shipped withthe unit *. pes E. Po + ‘Gees for long service ond deperdable operation of a gear drive is Geen given to the engineers who designed for the craftsmen who Gonsracted it or tne soles engineer who recommended the type ond ‘Sze. Ultimate crecit belongs fo the mechanic on the job who worked So mote the foundation rigid and level, who accurately aligned the | Sats ond carefully installed the accessories, and who made sure that the drive received regular lubriction. The details ofthis important ob fe the sublec of ths manucl. : WARRANTY —The Folk Corporation (the “Company” warrants tht, for 2 period of one yeor from the dote of shipment, the produc! Goscrbed herein wil deliver succotstlly# coled output os indicated | onthe nameplate, provided, its propery installed ond maintained, Gorreaily lubricoted, ond opercted in the environment and within the _ lms of speed, torque or other ood conditions for which t was sold. ‘Such product expresly not wortonted ogcinst file or unsatisfactory ‘aperation esuting from dynamic vibrations imposed upon it by the ‘system in which fis installed unless the nature of such vibrations for been fully defined and expreisly accepted in writing by the ‘Company of 9 condition of operation. CAUTION ‘Consult applicable local and national safety codes for proper, ‘guarding of rotoing members. Lock dut power source and remove all external loads from Unit before servicing unit or accessories. INSTALLATION INSTRUCTIONS FOR SATISFACTORY PERFORMANCE, ‘CAREFULLY FOLLOW THESE INSTRUCTIONS WELDING — Do not weld the geor unithousing or accessories without prior approval from the Folk Corporation. Welding on the unit may Couse distortion of tha housing or damoge to he bearings and gear feeth, Welding without prior opprovel could void the warranty NNAMEPLATE—Operate unit only at horsepower, speed ond ratio shown on nomepiote. Before chonging any one of these, submit Complete nomepiate dota and new application conditions to the Facory for correct ol evel, ports and application approval. TIGHTENING TORQUES Fasteners Soo Page 2. GREASE LUBRICATED BEARINGS —Soo Page 3. ‘STORED AND INACTIVE UNITS—See Page 4. MOUNT HORIZONTALLY —CAUTION: Mount unit with base hort Zonta, unless it has been specifically ordered fer mounting in another postion. ft is necessary fo mount the unit in a different position From thot for which f wos ordared, consult The Falk Corporation for changes necessary 10 provide proper lubrication. FOUNDATION, GENERAL — To facilitate oil drainage, elevate the unit foundation above tha surrounding foo level os ilstrated. If desired, replace the unit ol drain plug with 0 valve, but ; provide a guard fo protect the valve from_ f= ‘ccidentol breakoge. oie When an outboard bear Oe os ing suse, movnt on ond 4 outboord bearing ona. EQ ahh continuous foundoton ory Sedelae nd dowel both in place. ‘ ine Types GHB, ¥, YB & YBX Subject to change without notice © April 1989 Ssupsteades 8.8 FOUNDATION, STEEL—When mounting unit fn structure steel its recommended that on tengineered design be vilized for o bose- plate or bed to provide sufficient rigidity 10 prevent induced loads from distoning the housing and causing geor mis alignment. Ia the absence of on engineered design, itis recom: ended that 2 baseplate, with thickness equal to or greater than the thickness of the unit feet, be securely bolted to steel supports ‘ond extended under the ene uni or ilustroted. FOUNDATION, CONCRETE —f« concrete foundation is used, allow the concrete 10 set fitmly before baiting down the unit. For the best typeof mounting, grout sructrel Steel movating pads into the mounting bose, 0 iustrated, Tother than grouting the unit di rectly into the concrete. ‘Motors and other components (whether mounted on motor plates ‘or motor brackets) may become misaligned during shipment. ALWAYS. check alignment offer instllation. Refer to Page 2 for coupling alignment instructions. UNIT ALIGNMENT Align unit with driven equipment by placing brood, et shims under all maunting pads. Start at the low speed sha side ond level acros the length and then the width of the unit. Check ‘with fesler gauge 10 make certin that all pads ere supported to Prevent citorion of housing when unit bolted down. After unit is ligned with drwven machine and bolted down, align prime mover 10 Unit input shof. See Page 2 for coupling alignment. shims iF equipment i received from Falk mounted on a bedplate, the ‘Conponans wee cual clgnedat ok wh ne bedpots nowt Gnd lorge, ft essemby pits. Sim under the bedplte foot pods rh he bedplowe level On ol fet or in the some pone. Check the high speed shaft coupling aignment. if he coupling is ‘scligned, the be plot's shined incorrect Reshim bedpote ond ‘Diheas highspeed couping slgrment. If racesoy, ecign moterMOTOR BRACKETS —The weight, location ond starting rave ofthe ‘motor wll cause some brockelsfo defect Gownword ond totwist. This, ‘moverea!'s win alowabie engineered ifs for unttmotr selections from the Falk bulletin, he cestomer considers the mowemant excessive, jedlsctew suppons for the bracket extension are ovalable fom Falk teethe the motor wes mounted by Falko he cusiomer. To compensate for deflection caused by heovy motors AND to get CORRECT COUPLING ALIGNMENT, use more shim under the rear motor feet thon the front fet. Motors and ether components (whether mounted on motor plates ‘or motor brackets) may become misaligned during shipment. ALWAYS, heck alignment ofr instlltion. Refer to coupling alignment instructions below. ‘SHAFT CONNECTIONS COUPLING CONNECTION — The performance and fe of any coupling depends largely upon how well he coupling is installed and serviced. Refer to the coupling manufacturer's manual for specific instructions CORRECT METHOD Heot interference fitted coup, ling hubs, pinions, sprockets or pulleys to1amaximum of 275°F (738%C) ond side orto unt shaft INCORRECT METHOD. DO NOT drive coupling hub, pinion, sprocket or pulley onto fhe shat An endwite blow on the shaft may damage gears ‘ond bearings 4 ee —CAUTION— DO NOT HAMMER table guard accordance with OSHA standards. BACKSTOP—To prevent damage to backstops due to incorrect motor shot rotation at star up, couplings are NOT assembled when units fre furnished with backstops. After completing the electrical con- nection, check motor and unit shaft rotations. Then complete align- ‘ment and assembly of coupling. FALK COUPLINGS —Detciled installation monvols are available from the Foctory ond your local Folk Represeniative or Distributor —just provide size and type designations Stomped on the coupling. Refer to ‘Manual428-010forSteellex couplings ‘and Manval 458-010 for Gear coup" Tings for lubricant requirements and @ Tisting of typical lubricants meeting Falk specifications. The following instructions opply to coupling alignment: Stoelfe ilustrated Gap and Angular Alignment if posible, ofter mounting coupling hubs, postion the driving and driven units 0 that he dstonce between shaft ends is equal o the coupling gap. Aligh the shafts by placing @ “Spocer block, equalin thickness to required gap, between hub faces, os shown above, and also at 90° intervals around the hub. Check with Teles. Offset Alignment—Align shots of 7 driving and driven units 30 that © Qn ‘Sroightedge wil est squarely on both Q ‘coupling hubs as shown to the ight fond clio ot 90° intervals. Tighten foundation bolls of the connected ‘equipment and recheck alignment ‘ond gop. tuerated 2 © SERVICE MANUAL 148-050 the Factory for pinion alignment instructions. ‘OUTBOARD BEARING — Mount the outboard bearing and wnil on o common foundation so thot they will shift as an ossembly if setting should occur Bring the outboard bearing fo [Link] horizontal ‘postion with brood fat shims Under the mounting pod. Align accurtely 40 thatthe lood ' equally divided between the two unit Bearings ond the outboard bearing, Mount a stop bar against the pillow block foot ‘on the load side when large horizontal load components are exerted ‘onthe pillow block SPROCKET, PULLEY OR SHEAVE CONNECTION—Mount power ‘oke-offs as close fo the unit housing as possible to avoid undue bearing load and shaft deflection. Align the output shalt ofthe unit square und parallel with the driven shaft by placing a svoightedge ‘ac1055 the foce ofthe sprockets oF Keerce erases MMT WROHo zontal shaft alignment by placing tt prep ers eee eames Se cure atc Se eames odes G SQUARE AND PARALLEL DO NOT overtighten belts or chains. Adjust chins to manufacturer's specifications, Adjust bets 05 follows: ‘The ideal tension isthe lowes! tension of which the bell will not slip under peak load conditions. Check the bel tension frequently during, the fist 24 10 48 hours of runin operation. Overtightening belts will shorten belt and bearing ite. Keep bells free from foreign material “which may cause slippage. Inspect the drive periodically; tighten the belts if they ore sipping, TIGHTENING TORQUES Use the volues specified inthe tabla below for fastening motors and Folk unis and accessories to their mounting surfaces with SAE Grode 5 oF ASTM A9 non lubricated fosteners. DO NOT use these values for “torque locking” fasteners or for fastening components with aluminum feat or with sof gasket or vibration dampers on the mounting surface Ifthe rightening torque exceeds the capacity of he torque wrench, use 2 torque multiplier Tightening Torques—Ib-In.—00 NOT LUBRICATE FASTENERS. Tread | Metal | Metste || thecd |] met | Meri eunc | maa | consi || viene | so Mel | Concvte 250.20 Cy 3 | 1207 | \zea0 | 0000 ioste | as | 4s) rays | tesco | sooo aw | so | 5 ff isms | mio | i730 srr | es | oo |] szsns | 2m | 18700 msn | io | se |] zim | son | 2000 Tso10 | 2 | x0 |} 228048 | S200 | st000 79 | 45s | 750 |} 2sa04 | 72000 | seoo0 vows | a0 | 300 ff 27504 | 92000 | 77000 thas | 00 | tooo |] S004 | vzsomn | se000 LUBRICATION ‘and carry out all instructions on lubrication plate and heed oll warning tags. Determine minimum ‘ond maximum ambient temperatures in which the drive isto operote ‘and read the SAE or AGMA lubricant number for those temperature Conditions from the lubrication plate on the unit. Select o lubricant from Manual 128-010 corresponding fo the SAE or AGMA lubricant umber UNIT LUBRICATION — Re:= ‘if. unit operates in the sun af ambient temperatures over 10°F (38°C) men specie! measures should be token fo protect the unit rom "Solar energy. This protection can consst of @ canopy over the unit or reflective point on the unit neither is possible, a heat exchanger or ther cooling device may be required 10 prevet the sump temperature _ from exceeding the olowable maximum of 200°F (93°C). EXTREME PRESSURE LUBRICANT—DO NOT use extreme prossure “lubricant in units equipped with an internal backstop. Unis some: times ore severely overloaded due to 0 change in design of the driven machine, oF@ change in the nature ofthe material thas being [procested. This alio occurs when power requirements are in excess of that originally esimated. As 9 retll the gear teeth may show signs ‘of distress in the nature of scuffing, scoring or pitting. For opplications ‘Of this nature, an extreme pressure lubricant is racommended. This gives added protection to the gear teeth ond moy retard scoring Gnd scuffing. However this 's Not 9 cure-all. Applications which ‘re severely cverioaded should be referred tothe Factory for Further study and recommendations. Extreme pressure lubricants ore listed in ‘Manual 128-010. SYNTHETIC LUBRICANTS — Synthetic lubriconts of the polyalphaclefin type have been used successfully in geor drives to provide certain ‘advantages beyond that avaliable with Mineral Oi or Extreme Pressure ll, Depending upon operating conditions, these advantages may Include: longer service Iie between lubricant chonges, elimination (of need to change lubricant fo suit the season, operating eapobiites beyond the high and low temperature limits of Mineral or EP oi, Select synthetic ubricans in accordance with specifications in Monual 128-010. ‘Splash Lubricated Units Stondord Type Y units ore splosh lubricated, The lubricant picked up by the revolving elements ond distributed ro ‘ll bearings and gear meshes. Unit with Hoot Exchangers—~Check inmediotly afer starting to See that the external pump is circulating oll properly. Insta shut-off or control valve in the waterline into the heat exchar to regulate the water flow through the exchanger. Also install 0 water low gauge between the conrlvlve and he exchange 0 ‘determine oetval flow rate. Discharge water [Link] OPEN DRAIN to prevent back pressure. Preteure Lubricated Units Check immediately after starting o see ‘hat the internal or external pump it cculating oll properly. Refer fo “Manual 148.931 for detailed instructions. OIL LEVELS— Approximate copacties of oll ore shown on the unit omeplate. Friot toiling Types Y ond YB reducers, remove the ‘inspection plate ond FLOOD THE Ol TROUGHS to insure @ generous ow of ol 10 the bearings. For Type YBX, remove sight glass and flood oil postages. This priming ation lubricates and protects the ‘beorings until suffcent of i crevlotad by the rototing gears. After ‘operating unit afew minutes shut down and recheck ollevel. Add oil te compensate for cooley fier etc. ol copacii GREASE LUBRICATED AND GREASE PURGED SEALS—Type Y units tre furnished with grease purged seals which minimize the entry of Yoconile and other abrosive dusts into the unit. Units are shipped with NLGI #2 grease in the seal housing cavities uness otherwise specified. 1f grease could contaminate the product, os in the food and drug Industries, it should be removed. Pociocicolly (ot least every six months) depending upon the frequency ‘ond degree of contamination, pucge contominated greose from seals by slowly pumping fresh bearing grease through the seal with a hand ‘grease gun ntl freth grease flows ov! olong the shaft. Wipe off Purged grease. CAUTION: Rapid regreasing with a power grease gun Enforce geass inword post the Seals ong plug he dremack sytem ‘causing #20 leaks ROOM TEMPERATURE Seal sex. Bean cane sea Ee ewe BASE UG HIGH OIL LEVEL Low ol Lever "Al Sizes val Sizes Inner uth Seal and Outer Inner Bush Seol end Outer pType Seal Up Type Seal GREASE LUBRICATED BEARINGS —When changing oil in the unit, {grease bearings with 0 NIGI #2 beoring grease. Regrease these Bearings ot por of the standord molatenonce program. Before install. ing o uni, note the location of all of the bearing grease fitings ond ‘greote labels for future maintenance reference, Note hat some tings may be ABOVE the ol level line and others BELOW. Ifa grease iting ‘will become inaccessible after the unt installed, replace the fiting ‘witha pipe extension (and the fing) so that the grease fiting will be ivan accessible location after the units installed DO NOT confuse the grease fittings for grease lubricated sels with thos for rai ubnzed ecrngy al inadvry grates {recte wil oppear along the shalt atthe shaft cover, 4 Allow peed shet (bottom) bering of YEX us oe grease bee = ‘Always femove the purge plug [whan provided) when greasing Bear ings ho he old greaue con vcape Wipe of purged root ond replace the plug afer greosing bearings. OIL CAPACITIES ADD OIL TO THE LEVEL MARKED ON ‘THE UNIT DIPSTICK LARGE SPEED REDUCERS —01copacties forthe org speed reducers wa te wat se redacony po pepe ond ae der Focby for si copocly of thes unis. Safe tating ony unt, Al sro fo level insicoted Tor he dive. PREVENTIVE MAINTENANCE Bi [AFTER FIRST WEEK — Check alignment ofthe total system and realign ‘where necessary. Alto, tighten all external bolts end plugs where ‘necessary DO NOT reagjvit the internal geor or bearing sattings inthe reducer these were permanently set t the Factory. AFTER FIRST MONTH'S SERVICE —Praceed os follows: 1. Operate unit untold sump oll reaches normal operating femperature, ‘Shut the unit down ond drain immediately. 2, Immediately ush unit wth an ol ofthe some type ond viscosity grade (5 the original charge {warmed to opproximately 100°F (38°C) ‘ncold weather). Rapidly pour or pump acharge equal o 25-10% ‘of the iil fil thru the Unit oF until clean ol Hows thru the drain, [Link] the drain ond ref the unit tothe correct level with new or ‘ecioimed ol of he correct type and viscosity. If determined to be in ‘good condition by the supplier, reclaimed oil may be used i iis tered they a 40 micron or finer fier. SERVICE MANUAL 148-050 «3level matk on the dipstick or the oil lavel have the oi onclyzed for water content. Moisture i the oll y indicate that the heat exchanger or o seal is leaking. If so, lace the defective part immediotely and change the cil. DON | filtebove mark indicated as leakage oF undue heating may result. | Also check coupling alignment fo make ceroin thet foundation | getting has not caused excessive misalignment. f unit is equipped with fon, periodically clean accumulated foreiga matter from the fon, fon guard and deflector to sllow adequate air flow. "OIL. CHANGES For norma! operating concitions, change geor oils ‘every 6 months or 2500 operating hours, whichever occurs fist. Compounded ails may raquire more frequent changes. In dusty areas OF where fomperctures are high, more frequent changes moy be Fequired. Lubricant suppliers can test oll somples from the drive ppotiodically and recammend econominal change periods Dosed on the rote of lubricant contamination and degradation. If the drive is operated in an areo where temperatures vary with the seasons, change the oil vscosly grade to suit the temperature. Refer to Manual 128-010 for vscosty recommendations and typical | [ubriconts meeting Felk specications "GREASE PURGED SEALS—See'Foge 3 BEARINGS — Some units have one or more grease lubricated beorings See GREASE LUBRICATED BEARINGS. When chonging oll n the unt, {grease bearings with 9 NIGI #2 beoring grease. COUPLINGS —Lubricate Falk Steeflex couplings in accordance with instretions in Manu! 428-0 10 and Folk Geor couplings in accordance ‘ith instructions in Manuol 458-010, DISMANTLING —CAUTION: Lock out power source and remove all External loads from unit before servicing unit or accessories. Service manuals and parts guides are available from the Faciory ond Falk Representatives. When writing, please give complete data from the rrameplate on the unt; Model, ™1.0,, Date, RPM, and Ratio. SPARE AND REPAIR PARTS—When ordering ports, always give Complete dota from the nameplate on the Folk drive. This complete emepiate dota will assure you of receiving the correct ports. If new nameplate received wih the new pars (or example, when : ive ratio charged), alac the old nameplate on he deve ‘ath the new nameplate for future reference. . SERVICE MANUAL 148-050 alia months in a dry Bulding offer shipment From the Factory. STORED AND Each drive is spin-tested with rst preventive ofl “ogoinst rust for 9 period of 4 months in on 0 door shelter Io drive is to be stored, or s inactive after installation beyond the howe periods drain olfomovsing and pray allinternalporwth Gros preventive oltetisoldble miuorcating oof 236" Motortor”™ Topo" phase ro? intr inthe amounts fobuated below: Belore + ‘operating, units which have been stored or inactive must be filled to. the proper eel wih i mesing the speahestons vn m Menl 1z8-010. Periodically inspect stored or inactive units ond spray or odd rust Inhibitor, every six months ot more often, it ncessary. Indoor dry storage is recom Units ordered for extended storage can be treated at the Foctory with © spedel preservative ond saoled to rustproof ports for periods Tonger than those cited above, if specified on the erder. ‘The vents replaced with a plug (vent is then attached to the unit) so thatthe protective rust inhibiting atmosphere is seoled inside the unit. Replace plug with vent when preparing unit for operation. MOTORSTOR& —Add fo Stored or Inactive Units wr wr MOTORSTOR am st Ounces PEK UT 1000-109, 2050-2090 2 Vee-1135, 2100-2135 6 MY pes T4114, 240-215 10 ond 1150-1145, 2150-2165 D a, 117-1195, 2002195, a meen 19. “#fradact of Dovow" Chenical Company, heap (Formery brown 22 "Nude OF)