Falk Ultramite® Installation & Maintenance Instructions
Contents
1. Page 5 Tightening Torques 9 Determine appropriate position that motor conduit box must be in once motor is assembled to basic housing Refer to Figure 4 Page 4 Slide motor shaft into high speed motor adapter aligning key of shaft with keyway in motor adapter bore 10 Align threaded mounting holes of high speed motor adapter with holes of electric motor Secure motor to basic housing using fasteners with copper washers when provided Torque fasteners to the value specified in Table 4 Page 5 Tightening Torques ELECTRIC MOTOR FASTENERS PLASTIC KEY IF PROVIDED FASTENERS MOTOR BUSHING IF PROVIDED HIGH SPEED BASIC HOUSING FIGURE 1 PROCEDURE G amp H Figure 2 Important The high speed motor adapters for drives requiring assembly procedure G amp H will initially be assembled and sealed with Loctite at the Factory unless otherwise specified During assembly Do Not break Loctite Seal 1 Place basic housing on a workbench so that high speed end is facing up as illustrated in Figure 2 If necessary block housing so that it is stable and level 2 Remove high speed motor adapter from basic housing ONLY if replacing 3 Clean mating surfaces of basic housing high speed 288 400 November 2002 Supersedes 10 98 The Falk Corporation P O Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo fa2. FACING L S END D 270 FIGURE 4 B 90 ASSEMBLE OUTPUT FLANGE TO DRIVE 1 Place drive on a workbench so that the side to which the output flange will be installed is facing up If necessary block drive so that it is stable and level DRIVE HOUSING BASE FLANGE FIGURE 5 2 Clean mating surfaces of drive and output flange thoroughly using Loctite 7070 Super Clean or equivalent Check for and remove any burrs from mating surfaces 3 Assemble output flange to drive see Figure 5 and secure using the fasteners furnished Torque fasteners to the value shown in Table 4 Page 5 Tightening Torques Sizes 03 thru 12 e Type UB ASSEMBLE TORQUE ARM BRACKET TO DRIVE 1 Place drive on a workbench so that the side in which the torque arm bracket will be installed is easily accessible If necessary block drive so that it is stable and level 2 Clean mating surfaces of drive and torque arm bracket thoroughly using Loctite 7070 Super Clean or equivalent Check for and remove any burrs from mating surfaces 3 Assemble torque arm bracket to drive in the required position see Figure 6 and secure using the fasteners furnished Torque fasteners to the value shown in Table 4 Page 5 Tightening Torques The support to which the torque arm is to be fastened must sustain the torque reaction listed in Table 2 Torque Arm Load Reaction Use SAE grade 5 minimum
3. bushing is at the 12 o clock position Insert drive key furnished with bushing into bushing keyway FIGURE 9 Proceed to Step 3 3 Using a sling safely lift gear drive so that hollow output shaft is in the horizontal position Rotate hollow shaft so that keyway is aligned with driven shaft bushing key Position and slide drive onto driven shaft taking care that driven shaft key seats into hollow shaft keyway DO NOT hammer or use excessive force 4 Thread bushing nut onto hollow shaft one to two turns Note The bushing nut threads have been coated with an anti seize compound at the Factory This compound should not be removed Before re installing a previously used nut recoat the nut threads only with an anti seize compound KEEP TAPERED SURFACE OF BUSHING AND HOLLOW SHAFT BORE FREE FROM ALL ANTI SEIZE OR LUBRICATING COMPOUNDS 5 Tighten nut as instructed in one of the following methods PREFERRED METHOD Using a spanner Table 7 chain or pipe wrench tighten bushing nut to the torque value specified in Table 7 Note For applications where external vibratory or transient loads may act on drive and cause setscrews to become loose apply Loctite 243 or equivalent to threads of setscrew Tighten setscrew on bushing nut ALTERNATE METHOD Use this method when torque cannot be measured Using a spanner Table 7 chain or pipe wrench tighten bushing nut just until drive can no longer be moved by hand axially on the d
4. greater than the thickness of the drive feet be securely bolted to steel supports and extend under the entire drive FOUNDATION CONCRETE If a concrete foundation is used allow the concrete to set firmly before bolting down the gear drive For the best type of mounting grout structural steel mounting pads into the mounting base as illustrated rather than grouting the drive directly into the concrete Motors and other components mounted on motor plates may become misaligned during shipment ALWAYS check alignment after installation GEAR DRIVE ALIGNMENT Align drive with driven equipment by placing broad flat shims under all mounting pads Start at the low speed shaft end and level across the length and then the width of the drive Check with a feeler gauge to make certain that all pads are supported to prevent distortion of housing when drive is bolted down After drive is aligned with driven equipment and bolted down align prime mover to drive input shaft Refer to Pages 5 and 6 for coupling alignment Check high speed shaft coupling alignment If the coupling is misaligned the drive is shimmed incorrectly Re shim drive and recheck high speed coupling alignment If necessary realign motor The Falk Corporation PO Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com 288 400 November 200
5. high speed motor adapter with threaded holes of basic housing while assembling motor adapter to basic housing Secure high speed motor adapter to basic housing using fasteners with copper washers when provided Torque fasteners to value specified in Table 4 Page 5 Tightening Torques The Falk Corporation PO Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com 288 400 November 2002 Supersedes 10 98 Installation amp Maintenance Instructions Ultramite Page 4 of 12 9 Install studs provided into motor flange face 10 Attach adapter ring to motor aligning holes in adapter ring with studs mounted in motor 11 Determine appropriate position that motor conduit box must be in once motor is assembled to basic housing Refer to Figure 4 below Slide motor shaft into high speed motor adapter aligning key of shaft with keyway in motor adapter bore 12 Align mounting holes of high speed motor adapter with studs of motor Secure motor to the basic housing assembly using fasteners with copper washers when provided Torque fasteners to the value specified in Table 4 Page 5 Tightening Torques IMPORTANT CIRCLE EACH FASTENER HOLE WITH A CONTINUOUS AND UNBROKEN BEAD OF LOCTITE 518 OR EQUIVALENT THEN CONNECT EACH ADJACENT FASTENER HOLE WITH A CONTINUOUS AND UNBROKEN FIGURE 3 VIEW
6. or sheaves as illustrated i A GEAR DRIVE WALL Check horizontal shaft alignment by placing one leg of a square against the face of the sheave or sprocket with the spirit level on the horizontal leg of the square LEVEL SQUARE AND PARALLEL DO NOT over tighten belts or chains Adjust chains to manufacturer s specifications Adjust belts as follows The ideal tension is the lowest tension at which the belt will not slip under peak load conditions Check the belt tension frequently during the first 24 to 48 hours of run in operation Over tightening belts shortens belt and bearing life Keep belts free from foreign material which may cause slippage Inspect the V belts periodically tighten the belts if they are slipping PINION MOUNTING Mount pinion as close to the drive as possible to avoid undue bearing load and shaft deflection Refer to the Factory for pinion alignment instructions Retaining Methods for Shaft Mounted Drives The following illustrates methods for retaining shaft mounted drives DRIVE RETAINED WITH LOCKNUT DRIVE RETAINED WITH RETAINING RING Ih il DRIVE RETAINED WITH DRIVE RETAINED WITH PLATE AND FASTENER COLLAR AND SETSCREW FIGURE 8 DRIVE RETAINED WITH RECESSED PLATE AND FASTENER INSTALLATION AND REMOVAL OF TYPE TA TAPER BUSHING Installation 1 The tapered bore hollow output shaft is designed for use with a tapered bushing for mounting on a
7. pry bar into split of bushing and pry split open slightly to loosen bushing and remove from shaft SHAFT MOUNTED DRIVES USING A SHRINK DISC DEVICE Installation Shrink discs can be supplied with shaft mounted drives The following procedures should be followed when fitting or removing drives from the driven shaft 1 Release locking screws gradually and in succession Initially a quarter of a turn on each screw will avoid tilting and jamming do not remove locking bolts completely 2 Remove shrink disc from gear drive hollow shaft a eee LOCKING Poor SCREW lt nE DRIVEN MACHINE i PLATE Fra CUSTOMER S SHAFT FIGURE 10 NOTE ONLY AVAILABLE AS STANDARD IN THIS HANDING CONTACT FALK FOR OPPOSITE HANDING 3 Clean and degrease locating diameters of gear drive hollow shaft driven shaft and shrink disc locating diameter on hollow shaft extension 4 Draw the gear drive onto the driven shaft See Figure 10 5 Grease tapered surfaces of outer ring and inner ring with Molykote 321R or similar Table 8 Tightening Torque lb in F Locking Screws Torque Ib in DRIVE Adjustable Hook Spanner Wrench Spanner Nut Tightening g que SIZE Armstrong Tools Williams Torque lb ft Nm 04 275 05UB 34 307 2 00 4 75 474 83 WE 05 257 06UB 34 307 2 00 4 75 474 83 113 06 257 07UB 34 307 2 00 4 75 474 16
8. with only one type of oil The initial oil should be changed in a new gear drive after 1000 hours of operation or one year or half the above life whichever occurs first Preventive Maintenance AFTER FIRST WEEK Check alignment of the total system and realign where necessary Also tighten all external bolts and plugs where necessary DO NOT readjust the internal gear or bearing settings in the drive these were permanently set Falk PERIODICALLY Carefully check the oil level of the drive when it is stopped and at ambient temperature add oil if needed If the oil level is ABOVE the oil level plug have the oil analyzed for water content If moisture content exceeds 500 ppm change the oil DO NOT fill above the oil level plug as leakage or undue heating may result Grease drives with grease lubricated bearings monthly refer to Table 13 Typical Greases Recommendations amp Specifications Check coupling alignment to make certain that foundation settling has not caused excessive misalignment Bearing Greases Some Ultramite gear drives have one or more grease lubricated bearings Whenever changing oil in the drive grease the bearings with one of the greases listed in Table 13 Typical Grease Recommendations amp Specifications Regrease these bearings as part of the standard maintenance program Before installing a drive note the location of all of the bearing grease fittings and grease labels for future maintenance r
9. 2 Supersedes 10 98 Installation amp Maintenance Instructions Ultramite Page 2 of 12 Sizes 03 thru 12 e Type UB Drive Assembly Instructions Refer to Table 1 to determine the appropriate assembly procedure G G amp R or G amp H for the type of drive motor combination being assembled Then refer to the appropriate assembly procedure Table 1 Motor Adapter Fitting Prodecures NEMA MOTORS PROCEDURE G G amp R OR G amp H ARE USED FOR ALL DRIVE SIZES SUMMARY OF MOTOR ADAPTER FITTING SEQUENCES G Fit motor adapter to basic housing and then attach motor G amp R Attach motor adapter to basic housing then fit adapter ring to motor before attaching motor to assembly G amp H Attach motor adapter to basic housing then fit adapter extension to motor before attaching motor to assembly PROCEDURE G Figure 1 Important The high speed motor adapters for drives requiring assembly procedure G will initially be assembled and sealed with Loctite at the Factory unless otherwise specified During assembly Do Not break Loctite Seal 1 Place basic housing on a workbench so that high speed end is facing up as illustrated in Figure 1 If necessary block housing so that it is stable and level 2 Remove high speed motor adapter from basic housing ONLY if replacing 3 Clean mating surfaces of basic housing high speed motor adapter and electric motor use Loctite 7070 Super C
10. 20 C 302 F 150 C Texaco LTD Multifax EP2 32 F 0 C 248 F 120 C Greases are suitable for use with lubricant oil Types M A and H Type G lubricant is also suitable however the oil must be changed when the amount of grease re lubrication exceeds 10 of the drive s oil fill quantity t Consult Falk Application Engineering Department if 1 Drive has grease lubricated bearings and Type G oil is to be used 2 Drive operates in ambient temperatures outside of range 22 F to 122 F 30 C to 50 C The Falk Corporation PO Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com 288 400 November 2002 Supersedes 10 98 Installation amp Maintenance Instructions Ultramite Sizes 03 thru 12 e Type UB Page 12 of 12 Stored amp Inactive Gear Drives Each gear drive is protected with rust preventive that will protect parts against rust for a period of 6 months in an indoor dry shelter If a gear drive is to be stored or is inactive after installation beyond the above periods drain oil from housing and spray all internal parts with a rust preventive oil that is soluble in lubricating oil or add Motorstor vapor phase rust inhibitor at the rate of one ounce per cubic foot of internal drive space or 5 of sump capacity and rotate the shafts several times by hand Befor
11. 7 226 07 310 08UB 34 310 4 50 6 25 474A 167 226 08 515 09UB 34 310 4 50 6 25 474A 250 339 09 515 10UB 34 310 4 50 6 25 474A 250 339 10 385 12UB 34 313 6 125 8 75 4748 250 339 12 1415 The Falk Corporation PO Box 492 Zip 53201 0492 288 400 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 November 2002 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Supersedes 10 98 Installation amp Maintenance Instructions Ultramite Page 8 of 12 Sizes 03 thru 12 e Type UB 6 Fit shrink disc on gear drive hollow shaft to position shown on in Figure 10 on Page 7 7 Tighten all locking screws gradually and in succession Do not tighten in a diametrically opposite sequence Several passes are required until all screws are tightened Ensure that all inner and outer ring faces are in line and he torque values show in Table 8 on Page 7 are achieved 8 Fit protective cover Note When the hollow output shaft is to operate in a vertical position it is essential that the shaft of the driven machine is provided with a shoulder When the thrust load is not taken by the shoulder on the driven shaft an end plate a shown in Figure 10 must be fitted It is recommended that customers shafts at the non clamped end of the sleeve should be coated with Molykote 321R or equivalent Removal 1 Removal procedure is similar to the reverse of installation Note D
12. ALL SOLID OUTPUT SHAFT 1 Place drive on a workbench so that the hollow shaft is horizontal If necessary block drive so that it is stable and level 2 Clean surfaces of hollow shaft and solid output shaft thoroughly using Loctite 7070 Super Clean or equivalent Check for and remove any burrs from mating surfaces 3 Install key into keyway of solid output shaft Apply Anti fretting compound Dow Corning G n or equivalent to bore of low speed shaft 4 Slide solid output shaft into bore of low speed shaft aligning key with keyway in bore of low speed shaft Note For single extension solid output shaft viewing from low speed end of drive confirm right or left hand extension Refer to Figure 7 5 Install retaining ring into groove of solid output shaft Install end cover single ended solid output shaft applications only 6 Install extension key into extension keyway in solid output shaft SOLID END OUTPUT COVER SHAFT RETAINING RING RETAINING RING DOUBLE ENDED SOLID OUTPUT SHAFT SINGLE ENDED SOLID OUTPUT SHAFT LEFT HAND RIGHT HAND FIGURE 7 VIEW FACING L S END Fastener Tightening Torques Use the tightening torque values specified in Table 4 for fastening Falk gear drives motors and accessories to their mounting surfaces with non lubricated fasteners DO NOT use these values for torque locking fasteners or for fastening components with aluminum feet or with soft gasket
13. OEP 7EP 8EP ISO Viscosity Grade 220 320 460 680 Nameplate Designation 5E 6E 7E 8E Ambient Temperature Range F 23to 32to 50to 68 to 77 104 122 122 Mineral Lubricants Extreme Pressure Manufacturer Lubricant Chevron USA Inc Gear Compound EP Exxon Co USA Spartan EP 220 320 460 680 Mobil Oil Corp Mobilgear 630 632 634 os Shell Oil Co Omala Oil 220 320 460 680 AGMA Viscosity Grade 5S 6S 7S 8s ISO Viscosity Grade 220 320 460 680 Nameplate Designation 5H 6H 7H 8H Ambient Temperature Range F 14to 32to 50to 68 to 86 113 122 122 Synthetic Lubricants Extreme Pressure Except where noted t Manufacturer Lubricant Conoco Inc Syncon R amp 0 Exxon Co USA Teresstic SHP Spartan Synthetic EP SHC Mobil Oil Corp Mobil SHC Mobilgear SHC 220 320 460 680 220 320 460 680 630 632 634 636 220 320 460 680 Pennzoil Products Co Pennzgear SHD 220 320 460 680 Super Maxol S 220 320 460 i t Consult lubricant supplier manufacturer for maximum operating temperature Lubricant does not contain EP extreme pressure additives Consult your lubricant supplier for additional lubricant recommendations The Falk Corporation RO Box 492 Zip 53201 0492 288 400 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 November 2002 Fax 414 937 4359 e mail fa
14. Type UB e Sizes 03 thru 12 Ultramite Installation amp Maintenance Instructions Page 1 of 12 How to Use This Manual This manual provides detailed instructions on installation and maintenance of gear drives and couplings Use the table of contents below to locate required information CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE Table of Contents Drive Assembly Instructions 22000 Page 2 Fastener Tightening Torques 00 Page 5 Shaft Conmeetions 2s lt hc052ieasehuveeieass Page 5 Retaining Methods for Shaft Mounted Drives Page 6 Installation amp Removal of TA Taper Bushing Page 6 Installation amp Removal of Shrink Discs Pages 7 8 Lubrication Recommendations Page 8 Extreme Pressure EP Lubricants Page 8 CHIMES aioe ah ade ewe dew edo o Page 10 Mounting Positions 25 00 0202s eae ob pa nih Page 10 lobre Changes fucked oon PARKS ESE Ces Page 11 Preventive Maintenance 220005 Page 11 Bearing Greags s nce eee ee ene Page 11 Stored and Inactive Gear Drives Page 12 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 found
15. ation rigid and level who accurately aligned the shafts and carefully installed the accessories and who made sure that the drive received lubrication at prescribed intervals The details of this important job are the subject of this manual NAMEPLATE Operate Falk gear drives only at horsepower speed and ratio shown on nameplate and in the mounting position for which it was ordered 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 WARNING Consult applicable local and national safety codes for proper guarding of rotating members Lock out power source and remove all external loads from drive before servicing drive or accessories Warranty The Falk Corporation the Company warrants that for a period of one year from the date of shipment the product described herein will deliver successfully its rated output as indicated on the nameplate provided it is properly installed and maintained correctly lubricated and operated in the environment and within the limits of speed torque or other load conditions for which it was sold Such product is expressly not warranted against failure or unsatisfactory operation resulting from dynamic vibrations imposed upon it by the drive system in which it is installed unless the nature of such vibrations has been fully defined and expressly accepted in writing by the Company as a co
16. driven shaft with a straight outside diameter Refer to Table 6 for driven shaft tolerances TABLE 6 Driven Shaft Tolerances Shaft Diameter Inches Maximum Undersize Inches Up to 1 500 1 500 2 500 incl 005 2 500 3 000 incl 006 Millimeters h 10 tolerance 2 Rotate driven shaft so that keyway is in the 12 o clock position THIN WALL BUSHING with keyway slot through bushing wall With driven shaft keyway at the 12 o clock position slide bushing assembly onto driven shaft nut end first and position keyway slot over shaft keyway bushing may have to be pried open slightly Insert drive key furnished with bushing into shaft keyway Proceed to Step 3 THICK WALL BUSHING with separate internal and external keyways Insert driven shaft key into driven shaft keyway If driven shaft has an open ended keyway stake keyway as illustrated in Figure 9 to prevent axial dislocation of shaft key under operating conditions Slide bushing assembly onto driven shaft bushing may have to 288 400 November 2002 Supersedes 10 98 The Falk Corporation P O Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Type UB e Sizes 03 thru 12 Ultramite Installation amp Maintenance Instructions Page 7 of 12 be pried open slightly Rotate shaft so that external keyway in
17. e operating drives which have been stored or inactive must be filled to the proper level with oil meeting the specifications given in this manual Refer to Manual 128 014 or Start up atter Storage instructions Periodically inspect stored or inactive gear drives and spray or add rust inhibitor every six months or more often if necessary ndoor dry storage is recommended Gear drives ordered for extended storage can be treated at Falk with a special preservative and sealed to rust proof parts or periods longer than those cited previously Material Safety Data For material safety data sheets pertaining to products used in the manufacture of the Falk Ultramite contact The Falk Corporation Customer Service Department 3001 W Canal Street Milwaukee WI 53208 4200 Phone 414 342 3131 288 400 November 2002 Supersedes 10 98 The Falk Corporation P O Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com
18. eference Note that some fittings may be above the oil level line and others below If a grease fitting will become inaccessible after drive is installed replace the fitting with a pipe extension and the fitting so that the grease fitting will be in an accessible location after the drive is installed Always remove the purge plug when provided when greasing bearings so that the old grease can escape Wipe off purged grease and replace the plug after greasing bearings Some of the greases listed in Table 13 may contain toxic substances and should not be used in the food processing industry without the grease manufacturer s approval A grease that meets the USDA H1 classification is suitable for food processing applications TABLE 13 Typical Grease Recommendations amp Specifications Allowable Operating Temperature Manufacturer Grease t Range Above To Applied Chemicals LTD 4020 220 2 32 F 0 C 248 F 120 C BP Oil LTD LS EP2 22 F 30 C 266 F 130 C Century Oils LTD Lupus A3 22 F 30 C 257 F 125 C Esso Petroleum Co LTD Exxon Beacon EP2 13 F 25 C 257 F 125 C Chevron Gulf Oil GB LTD Crown EP 22 F 30 C 248 F 120 C Kluber Lubrication Centoplex 2 4 F 20 C 266 F 130 C Koolex International Q8 Rembrandt EP2 22 F arg 248 F tH a Lubrication Engineering Almaplex 1275 22 F 30 C 320 F 160 C Mobil Oil Co LTD Mobilux EP2 4 a 266 F 130 C Shell Oils Albida R2 4
19. fasteners for anchoring torque arm to support structure refer to Table 3 Torque Arm Anchoring Fasteners for recommended fastener diameter Fastener length is dependent on support structure Bolt the torque arm to supporting structure and tighten bolt provided by others until it is seated against brackets Do not bend the support clevis bracket Clearance between the clevis bracket and torque arm is required TORQUE ARM BRACKET FIGURE 6 TABLE 2 Torque Arm Load Reaction Ib x DRIVE SIZE Maximum Load Ib 03UB 715 04UB 1215 05UB 1515 06UB 1810 07UB 2910 08UB 3985 09UB 5430 10UB 7160 12UB 10 010 Based on worst case loading conditions consult Falk for loads based on specific application data TABLE 3 Torque Arm Anchoring Fasteners DRIVE SIZE Metric Fastener t Inch Fastener t 03UB M10 375 16 UNC 04UB M10 375 16 UNC 05UB M16 625 11 UNC 06UB M16 625 11 UNC 07UB M24 875 9 UNC 08UB M24 875 9 UNC 09UB M24 875 9 UNC 10UB M24 875 9 UNC 12UB M36 1 375 6 UNC t Standard fastener sizes are given Use of a fitted pin is recommended 288 400 November 2002 Supersedes 10 98 The Falk Corporation P O Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Type UB e Sizes 03 thru 12 Ultramite Installation amp Maintenance Instructions Page 5 of 12 INST
20. grades of EP Mineral and EP synthetic lubricants are found in Table 12 Page 9 Typical Lubricants For cold climates refer to EP Synthetic Lubricant paragraphs Select a lubricant which has a pour point at least 10 F 5 5 C below the expected minimum ambient starting temperature Usable temperature ranges can sometimes be widened if specific applications are known Extreme Pressure EP Mineral Lubricants Mineral EP Lubricants Table 12 Industrial type petroleum based extreme pressure lubricants are preferred The EP lubricants currently recommended are of the sulfur phosphorus type WARNING EP LUBRICANTS IN FOOD PROCESSING INDUSTRY EP lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturer s approval Lubricants which meet USDA H1 classification are suitable for food processing applications Extreme Pressure EP Synthetic Lubricants Synthetic EP Lubricants Table 12 Polyalphaolefin type extreme pressure lubricants are recommended for cold climate operation high temperature applications extended temperature range all season operation and or extended lubricant change intervals WARNING SYNTHETIC LUBRICANTS IN FOOD PROCESSING INDUSTRY Synthetic lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturer s approval Lubricants which meet USDA H1 clas
21. ic motor use Loctite 7070 Super Clean or equivalent Check for and remove any FIGURE 2 7 burrs from mating surtaces Fill basic housing with quantity of oil specified in Table 9 Page 8 Approximate Oil Quantities Apply Anti fretting compound Dow Corning G n or equivalent to bore of high speed motor adapter Depending upon motor shaft diameter either a plastic key or motor bushing will be furnished Refer to the appropriate instructions following Plastic Key If installed remove the metal key from the motor shaft this key will not be used For motor shafts with a closed ended full depth keyway IEC motors shorten plastic key to fit keyway Note plastic key should be the same length as the metal key just removed Motor Bushing Install motor bushing into bore of high speed motor adapter Fit metal key into keyway of motor shaft This will assemble into the motor bushing and drive through it Apply Anti fretting compound Dow Corning G n or equivalent to motor shaft ELECTRIC MOTOR PLASTIC KEY IF PROVIDED MOTOR STUDS ADAPTER EXTENSION RING MOTOR BUSHING HIGH SPEED IF PROVIDED MOTOR ADAPTER FASTENERS BASIC ala a HOUSING Apply liquid gasket material Loctite 518 Falk Part 2918376 furnished to flange face of basic housing as illustrated in Figure 3 Page 4 Caution This step must be followed to prevent leakage Align mounting holes of
22. lean or equivalent Check for and remove any burrs from mating surfaces 4 Fill basic housing with quantity of oil specified in Table 9 Page 8 Approximate Oil Quantities 5 Apply Anti fretting compound Dow Corning G n or equivalent to bore of high speed motor adapter 6 Depending upon motor shaft diameter either a plastic key or motor bushing will be furnished Refer to the appropriate instructions following Plastic Key If installed remove the metal key from the motor shaft this key will not be used For motor shafts with a closed ended full depth keyway IEC motors shorten plastic key to fit keyway Note plastic key should be the same length as the metal key just removed Motor Bushing Install motor bushing into bore of high speed motor adapter Fit metal key into keyway of motor shaft This will assemble into the motor bushing and drive through it Apply Anti fretting compound Dow Corning G n or equivalent to motor shaft 7 Apply liquid gasket material Loctite 518 Falk Part 2918376 furnished to flange face of basic housing as illustrated in Figure 3 Page 4 Caution This step must be followed to prevent leakage 8 Align mounting holes of high speed motor adapter with threaded holes of basic housing while assembling motor adapter to basic housing Secure high speed motor adapter to basic housing using fasteners with copper washers when provided Torque fasteners to value specified in Table 4
23. lkcorp com web www falkcorp com Type UB e Sizes 03 thru 12 Ultramite Installation amp Maintenance Instructions Page 3 of 12 11 12 motor adapter and electric motor use Loctite 7070 Super Clean or equivalent Check for and remove any burrs from mating surfaces Fill basic housing with quantity of oil specified in Table 9 Page 8 Approximate Oil Quantities Apply Anti fretting compound Dow Corning G n or equivalent to bore of high speed motor adapter Depending upon motor shaft diameter either a plastic key or motor bushing will be furnished Refer to the appropriate instructions following Plastic Key If installed remove the metal key from the motor shaft this key will not be used For motor shafts with a closed ended full depth keyway IEC motors shorten plastic key to fit keyway Note plastic key should be the same length as the metal key just removed Motor Bushing Install motor bushing into bore of high speed motor adapter Fit metal key into keyway of motor shaft This will assemble into the motor bushing and drive through it Apply Anti fretting compound Dow Corning G n or equivalent to motor shaft Apply liquid gasket material Loctite 518 Falk Part 2918376 furnished to flange face of basic housing as illustrated in Figure 3 Page 4 Caution This step must be followed to prevent leakage Align mounting holes of high speed motor adapter with threaded holes of basic h
24. lkinfo falkcorp com web www falkcorp com Supersedes 10 98 Installation amp Maintenance Instructions Ultramite FALK Page 10 of 12 Sizes 03 thru 12 e Type UB position for which it was ordered See below for the placement of the vent drain and oil level plugs based on drive size and mounting position If it is necessary to mount the drive in a special orientation not shown below including rotated and tilted drives consult the Falk Corporation for changes necessary to provide proper lubrication Refer to Table 9 for approximate quantities of oil by the drive mounting position Oil Levels Drives Sizes 03 07 are furnished filled with oil determined by the Drive Mounting Position Refer to Table 12 for a list of typical lubricants meeting Falk specifications Refer to Table 9 for appropriate quantities of oil based on mounting position shown below MOUNTING CAUTION Mount drive unit only in the MOUNTING 1 MOUNTING 2 SYMBOL KEY AIR VENT Q orru ep OIL LEVEL CP OIL DRAIN MOUNTING 3 MOUNTING 4 MOUNTING 5 MOUNTING 6 288 400 The Falk Corporation P O Box 492 Zip 53201 0492 November 2002 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 S
25. ndition of operation TYPE UB General Information The following instructions apply to standard Falk Type UB drives shown above If a drive is furnished with special features refer to the supplementary instructions shipped with the drive WELDING Do not weld on the gear drive or accessories without prior approval from The Falk Corporation Welding on the drive may cause distortion of the housing or damage to the bearings and gear teeth Welding without prior approval could void the warranty EFFECTS OF SOLAR ENERGY If the gear drive operates in the sun at ambient temperatures over 1 00 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 refer to Falk 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 FOUNDATION STEEL When mounting gear drive on structural steel it is recommended that an engineered design be utilized for a pedestal adapter base or bed to provide sufficient rigidity to prevent induced loads from distorting the housing and causing gear misalignment In the absence of an engineered design it is recommended that a base plate with thickness equal to or
26. o not remove shrink disc locking screws completely 2 Remove any rust and dirt from gear drive hollow shaft 3 Withdraw gear drive from driven shaft Note Shrink disc should be removed and cleaned horoughly and Molykote 321R or similar applied to the tapered surfaces of inner ring and locking collar before re use Note Protective covers are supplied with all shrink discs Assembly or removal kits and thrust plates are not provided by the Falk Corporation Lubrication Recommendations Caretully follow lubrication instructions on warning tags and installation manuals furnished with the gear drive Nameplates are stamped with a designation for recommended lubricant standard is 6E for triple reduction ratios of 0 45 1 7E for all other triple and quintuple ratio drives For selection of oil grade based on actual operating conditions refer to Table 11 Page 9 Series UB Oil Grades Lubricants listed in this manual are typical ONLY and should not be construed as exclusive recommendations Refer to your lubricant supplier for additional lubricants meeting the indicated specifications Industrial type extreme pressure EP gear lubricants are the recommended lubricants for ambient temperatures of 15 F to 125 F 9 C to 52 C For drives operating outside the above temperature range refer to Synthetic Lubricants paragraphs Synthetic lubricants can also be used in normal climates VISCOSITY IMPORTANT The proper
27. ousing while assembling motor adapter to basic housing Secure high speed motor adapter to basic housing using fasteners with copper washers when provided Torque fasteners to value specified in Table 4 Page 5 Tightening Torques Install studs provided into motor flange face Attach adapter extension to motor aligning holes in adapter extension with studs mounted in motor Determine appropriate position that motor conduit box must be in once motor is assembled to basic housing Refer to Figure 4 Page 4 Slide motor shaft into high speed motor adapter aligning key of shaft with keyway in motor adapter bore Align mounting holes of high speed motor adapter with studs of motor Secure motor to the basic housing assembly using fasteners with copper washers when provided Torque fasteners to the value specified in Table 4 Page 5 Tightening Torques PROCEDURE G amp R Figure 2 Important The high speed motor adapters for drives requiring assembly procedure G amp R will initially be assembled and sealed with Loctite at the Factory unless otherwise specified During assembly Do Not break Loctite Seal 1 Place basic housing on a workbench so that high speed end is facing up as illustrated in Figure 2 If necessary block housing so that it is stable and level Remove high speed motor adapter from basic housing ONLY if replacing Clean mating surfaces of basic housing high speed motor adapter and electr
28. p 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com FALK Ultramite Installation amp Maintenance Instructions Type UB e Sizes 03 thru 12 Page 9 of 12 TABLE 10 Oil Change Intervals Based on Operating Temperature Operating Oil Change Intervals Temperature Mineral Oil Synthetic Oil 150 F 66 C or less 17000 Hours or 3 Years 26000 Hours or 3 Years 158 F 70 C 12000 Hours or 3 Years 26000 Hours or 3 Years 167 F 75 C 8500 Hours or 3 Years 21000 Hours or 3 Years 176 F 80 C 6000 Hours or 2 Years 15000 Hours or 3 Years 185 F 85 C 4200 Hours or 17 Months 10500 Hours or 3 Years 194 F 90 C 3000 Hours or 12 Months 7500 Hours or 2 1 2 Years 203 F 95 C 2100 Hours or 8 Months 6200 Hours or 2 Years 212 F 100 C 1500 Hours or 6 Months 5200 Hours or 18 Months TABLE 11 Series UB Oil Grades Ambient Temperature Range t DRIVE Ratio TYPE Range 23 F to 68 F 22 F to 68 F 32 F to 95 F 68 F to 122 F 5 C to 20 C 30 C to 20 C 0 C to 35 C 20 C to 50 C maa 0 45 SE SH 6 F JE gi riple 50 160 6 5H 7E 6H BE 7H Quintuple Al 6E SH 7E 6H BE 7H Consult Falk representative for other ambient temperatures Consult Falk representative for input speeds below 500 rpm TABLE 12 Typical Lubricants Recommendations amp Specifications AGMA Vixcosity Grade SEP
29. riven shaft Loosen nut ONLY until it can be turned by hand but do not unseat the taper Retighten nut hand tight Mark a spot on top of driven shaft Mark a spot on bushing nut 180 from the driven shaft mark 90 CCW for Sizes O5UB amp O6UB Using a spanner wrench tighten nut CW one half turn until the two marks are aligned one quarter turn for Sizes O5UB amp O6UB Note For applications where external vibratory or transient loads may act on drive and cause setscrew to become loose apply Loctite 243 or equivalent to threads of setscrew Tighten setscrew on bushing nut TABLE 7 Spanner Wrench Type amp Spanner Nut Tightening Torque Removal WARNING Drive must be supported during removal process Use a sling around the gear drive and take up slack before proceeding 1 Loosen setscrew on bushing nut located at output end of hollow shaft 2 Use a spanner Table 7 pipe or chain wrench to loosen bushing nut Initially bushing nut will freely rotate counter clockwise approximately 180 as the nut moves from the locked position to the removal position At this point anticipate resistance which indicates unseating of the bushing Continue to turn bushing nut until it is free from the hollow shaft 3 Prepare drive for lifting by disconnecting torque arm at drive end Slide drive from bushing Note Bushing can be left in place or removed as required If bushing will not slide off of shaft insert a small
30. s or vibration dampers on the mounting surface If the tightening torque exceeds the capacity of the torque wrench use a torque multiplier Use Grade 5 fasteners for diameters through 1 50 For assembling motors high speed adapters output flanges or torque arm brackets to drives refer to the tightening torque values listed in Table 4 for metric fasteners Use ISO grade 8 8 minimum fasteners for securing output flanges and or torque arms to drives TABLE 4 Tightening Torques lb in Nm 5 Thread Dia UNC DO NOT Lubricate Fasteners Metal to Concrete 250 20 90 10 70 7 3125 18 185 20 145 16 375 16 330 37 255 28 500 13 825 93 640 72 625 11 1640 185 1280 i 750 10 2940 332 2290 258 Metric Fasteners Output Flange Feet and Torque Arm Bracket Electric Motor and High Speed Motor Adapter 88 7 3 88 7 3 M8 220 18 3 160 M10 450 37 5 325 27 0 M12 750 62 5 570 47 0 M16 1770 147 5 1330 110 0 M20 3100 258 3 2300 190 0 M24 5400 450 es M30 10800 900 M36 19000 1585 Shaft Connections WARNING Provide suitable guards in accordance with OSHA standards Input and output shaft extension diameter tolerance is 0000 to 0005 for shafts up to 1 750 diameter and 0000 to 0010 for shafts larger than 1 750 diameter The fitted component must be machined to ensure proper fit DO NOT drive coupling hub pinion sprocket or pulley on
31. sedes 10 98 Installation amp Maintenance Instructions Ultramite Page 6 of 12 Sizes 03 thru 12 e Type UB FALK COUPLINGS Except fluid type Detailed installation manuals are available from Falk your local Falk Representative or Distributor just provide size and type designations stamped on the coupling For lubricant requirements and a list of typical lubricants meeting Falk specifications refer to appropriate coupling service manual GAP AND ANGULAR ALIGNMENT If possible after mounting coupling hubs position the driving and driven equipment so that the distance between shaft ends is equal to the coupling gap Align the shatts by placing a spacer block equal in thickness to required gap between hub faces as shown and also at 90 intervals around the hub Check with feelers OFFSET ALIGNMENT Align driving and driven shafts so that a straight edge will rest squarely on both coupling hubs as shown to the right and also at 90 intervals Tighten foundation bolts of the connected equipment and recheck alignment and gap SPROCKETS PULLEYS OR SHEAVES Mount power take offs as close to the gear drive housing as possible to avoid undue bearing load and shaft deflection STEELFLEX ILLUSTRATED STEELFLEX ILLUSTRATED Align the output shaft of the gear drive square and parallel with the driven shaft by placing a RIGHT WRONG straightedge across the face of the ad game Aa m sprockets
32. sification are suitable for food processing applications Table 9 Approximate Oil Quantities Liters x DRIVE SIZE Triple Reduction 03UB3 04UB3 05UB3 06UB3 07UB3 08UB3 09UB3 10UB3 12UB3 Mount ing Position DRIVE SIZE Quintuple Reduction 03UB5 04UB5 05UB5 06UB5 07UB5 Pri Second Pri Second Pri Second Pri Second Pri Second maryt ary maryt ary maryt ary maryt ary maryt ary 201UC2 203UC2 05UB3 203UC2 203UC2 Mounting Position DRIVE SIZE Quintuple Reduction O8UB5 09UB5 10UB5 12UB5 Primaryt Secondary Primaryt Secondary Primaryt Secondary Primaryt Secondary 205UC2 08UB3 205UC2 09UB3 207UC2 10UB3 207UC2 12UB3 Mounting Position 1 1 6 4 5 1 6 8 8 2 8 14 0 2 8 22 0 2 1 6 9 3 1 6 5 0 2 8 24 0 2 8 36 0 3 1 6 6 2 1 6 5 0 2 8 24 0 2 8 36 0 4 1 6 9 1 1 6 1 5 2 8 28 6 2 8 41 0 5 1 9 10 4 1 9 20 9 3 2 33 0 3 2 49 0 6 2 5 9 1 2 5 6 3 4 9 25 6 4 9 35 9 Convert quantities using the following Liters to US Gallons Liters x 0 26 Liters to Imperial Gallons Liters x 0 22 Liters to US Quarts Liters x 1 057 t Primary drives filled with Grade 6E lubricant suitable for all ambient temperatures between 32 C and 95 F 0 C and 35 C 288 400 November 2002 Supersedes 10 98 The Falk Corporation P O Box 492 Zip 53201 0492 3001 W Canal St Zi
33. the shaft An endwise blow on the shaft may damage gears and bearings Coupling hubs pinions sprockets or pulleys must be installed onto the shaft using a screw jack device fitted into the threaded hole provided in the end of the shaft refer to Table 5 TABLE 5 Shaft End Threaded Holes Inches DRIVE SIZE Input Shaft Output Shaft 03UB 250 x 63 UN 375 x 75 UNF 04UB 250 x 63 UN 500 x 1 13 UNF 05UB 250 x 63 UN 625 x 1 50 UNF 06UB 250 x 63 UN 625 x 1 50 UNF 07UB 385 x 63 UN 625 x 1 50 UNF 08UB 375 x 87 UN 750 x 1 65 UNF 09UB 500 x 1 10 UNF 750 x 1 65 UNF 10UB 625 x 1 42 UNF 750 x 1 65 UNF 12UB 750 x 1 65 UNF 1 00 x 2 17 UNF COUPLING CONNECTIONS The performance and life of any coupling depends largely upon how well the coupling is installed and serviced Refer to the coupling manufacturer s manual for specific instructions CORRECT METHOD Heat interference fitted coupling hubs pinions sprockets or pulleys to a maximum of 212 F 100 C and slide onto gear drive shaft INCORRECT METHOD DO NOT drive coupling hub pinion sprocket or pulley onto the shaft An endwise blow on the shaft coupling may damage gears and bearings CAUTION DO NOT HAMMER The Falk Corporation RO Box 492 Zip 53201 0492 3001 W Canal St Zip 53208 4200 Milwaukee WI USA Telephone 414 342 3131 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com 288 400 November 2002 Super
34. upersedes 10 98 Fax 414 937 4359 e mail falkinfo falkcorp com web www falkcorp com Type UB e Sizes 03 thru 12 Ultramite Installation amp Maintenance Instructions Page 11 of 12 Lubricant Changes All drive sizes require regular oil changes as instructed in this manual OIL ANALYSIS REPORT Checking oil condition at regular intervals is recommended In the absence of more specific limits The guidelines listed below may be used to indicate when to change oil Water content is greater than 0 05 500 ppm Iron content exceeds 150 ppm Silicon dust dirt exceeds 25 ppm Viscosity changes more than 15 Oil temperature drive operating under load Lubricant type Operating conditions shock loading etc MOnN A aAABWBN Mineral oil content exceeds 10 of oil fill quantity The effective life of an oil is greatly reduced at elevated temperatures This is most pronounced with oils containing fatty and EP additives To prevent damage to the drive through lubricant breakdown the oil should be changed at the intervals shown in Table 10 Oil Change Intervals Intervals shown are for oil temperatures when the drive has attained normal running temperature when operating under load These intervals are based on normal running Where conditions are particularly severe it may be necessary to change the oil more frequently When changing oil if the same oil is not used flush drive and fill
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