MM6100 - C8 - 12/02

INSTALLATION
FOOTE-JONES
LUBRICATION A REGAL-BELOIT Company
OPERATION 2914Industrial Ave. • Aberdeen, SD 57402-1089
MAINTENANCE INSTRUCTIONS 605-225-0360 • 1-800-482-2489 • Fax: 605-225-0567
PRICE $25.00 www.footejones.com
CONCENTRIC SHAFT REDUCER,
COUPLED GEARMOTOR, AND
GEARMOTOR DRIVES - 800 SERIES
TABLE OF CONTENTS APPROXIMATE STORAGE PERIODS
STORAGE CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Type of
Preparation Outdoor* Indoor**
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Normal 2 Months 6 Months
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Long Term 12 Months 24 Months
DISASSEMBLY & ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 6-14
BACKSTOP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 14 * Unit stored on blocks and covered with a tarpaulin in a
PARTS LIST (Gearmotors & Reducers) . . . . . . . . . . . . . 15-18 protected area.
REDUCER (Vertical Flanged) . . . . . . . . . . . . . . . . . . . . . . . 15 ** Dry building with reasonably constant temperature.
PARTS LIST, BACKSTOP . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DOUBLE REDUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 PREPARATION FOR LONG-TERM STORAGE
TRIPLE REDUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 If the storage period provided by normal preparation is not ade-
QUADRUPLE REDUCTION . . . . . . . . . . . . . . . . . . . . . . . . 18 quate, the gear unit must be prepared for long-term storage.
WARNINGS & CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . 19-20
Protection of gear units against corrosion of internal surfaces
ATTENTION: Unit should be inspected immediately on receipt during long-term storage is best accomplished by submerging
of shipment for any indication of rough handling or damage. Any the internals in oil and limiting the entry of air into any remaining
evidence of this should be reported immediately to the carrier space over the oil. The major problem in the preparation of the
and a claim entered. This may show up as scuffed paint, units is to prevent leakage of the oil, which would (1) lower the
broken or cracked castings, bent shafts, metal deformation or a oil level and leave surfaces exposed and (2) contaminate the
shift in alignment of components. storage area. Despite careful preparation by the manufacturer,
some oil seepage can be expected. The gear unit should be
CAUTION Do not operate if mounted on the ceiling, on a located in the storage area so as to avoid damage to other
wall, or on an incline unless the unit has been specifically equipment and the surroundings.
modified for such an installation. Special lubrication
arrangements must be provided when the mounting is other It is preferable that long-term preparation be done at the factory
than standard floor mounting on a level, horizontal surface. but, if this is not possible, the following procedure is recom-
mended:
INTRODUCTION
1. Place the gear unit on wooden blocks.
IMPORTANT - Read the following instructions carefully and use
them as the basis for proper care of your unit. All tags and 2. Tighten all bolts on the housing and all pipe connections
bulletins wired to the unit should be carefully read and filed for such as plugs, standpipes, dipstick caps, and heaters.
future reference. Replace the breather with a pressure-relief valve having a 1
PSI setting.
STORAGE
3. Clean the outside diameter surfaces of the bearing covers
NORMAL PREPARATION and the adjacent surfaces of the bearing blocks with sol-
Prior to shipment, all gear units are tested with a rust inhibiting vent. Apply a fillet of adhesive sealant such as General
oil that covers all interior surfaces. Shaft extensions and Electric RTV-102 around the junction of these surfaces.
external machine surfaces are coated with a drying-film rust-
preventive material. These measures constitute the normal 4. All exposed unpainted parts such as shafts should be
preparation for shipment and for temporary delays during instal- coated thoroughly with a corrosion preventative compound,
lation, and will provide some protection, for some period of time, solvent cut back type, leaving a firm film. Use Nox Rust No.
depending on the ambient conditions. Outdoor, unprotected 369 (Daubert Chemical Co.) or equivalent.
storage is not recommended. The table in the next column
shows approximate storage periods. 5. Completely fill the gear unit with the type of lubricant
specified for operation, and tighten the fill-hole plug.

1
6. Protect other Buyer’s or Seller’s vendor-furnished items in Inspect the seal lips carefully. While in storage, they may have
accordance with the manufacturer’s recommended storage deteriorated, the seal will not perform satisfactorily, and must be
procedures. replaced.

7. Cover the gear unit with tarpaulins. FOUNDATION

The gear unit should be mounted on a rigid foundation such as
8. It is recommended that the input shaft of every reducer be a reinforced concrete pad, a base plate, or a steel structure. An
rotated once a month enough turns to produce one com- inadequate foundation will permit misalignment under load
plete turn on the output shaft to prevent Water Etching or which may result in noise or overloading of elements in the drive
False Brinelling of the bearings and seizure of the train.
Elastomeric Seal Lip Material on the shaft.
Install broad, flat metal shims under the feet to level the gear unit
PROTECTION OF ASSOCIATED and to align it with the motor and the driven equipment. After
EQUIPMENT IN STORAGE bolting the gear unit in place, recheck the alignment; it may be
necessary to modify the heights to the shim packs to compen-
COUPLINGS sate for the effect of torquing the foundation bolts.
Fill with recommended lubricant. Coat the external surfaces
with heavy grease. Wrap plastic film around the coupling and CAUTION Do not mount the gear drive on ceiling, on a
tape the plastic to the shaft. wall, or on an incline unless the unit has been specifically
modified for such an installation. Special lubrication
BACKSTOP arrangements must be provided when the mounting is other
Remove the outer half of the backstop guard (A). While rotating than standard floor mounting on a level, horizontal surface.
the backstop, squirt a rust inhibiting oil such as Mobilarma 523
(Mobil Oil Company) into every open pinhole in the backstop SHAFT CONNECTIONS
housing (C) in a manner that will saturate every component in WHEN GEARING, BELTS OR CHAINS are used to connect the
the backstop assembly. Replace the backstop guard. Wrap gear unit to the prime mover or driven equipment, the pinion,
plastic film around the backstop and tape the plastic to the shaft sheave, or sprocket should be mounted on the shaft as closely
and to the endbell snout. as possible to the bearing cover to minimize shaft deflection and
bearing load. Check the overhung loads to be certain that they
CHAIN DRIVES do not exceed the catalog ratings and that the points of applica-
Remove the chain from the drive, roll it up, coat it with grease, tion are not outboard of the bearing cover by more than one
and wrap it in plastic film. Coat the sprockets with a firm film of shaft diameter. If the overhung load is more than one shaft
a corrosion-preventative compound such as Mobilarma 633. diameter outboard of the bearing cover, the catalog rating will
be reduced. Refer to Catalog PT886, to determine the actual
BELT DRIVES overhung-load rating, or consult the factory.
Remove the belt from the sheaves and wrap it in plastic film.
Coat the sheaves with a firm film of a corrosion preventive com- For satisfactory performance of belt drives and chain drives,
pound such as Mobilarma 633. sheaves and sprockets must be properly aligned. A straight-
edge laid across the sides of sheaves and sprockets, as shown
MOTORS below, will facilitate alignment.
Refer to instructions on storage protection provided by the motor
manufacturer. The bearings are usually prelubricated. Refer to
motor manufacturer for relube period. Use protective cover to
keep out water.

INSTALLATION

SAFETY
It is the purchaser’s responsibility to determine the applicable EXTERNAL GEARING must be adjusted for proper backlash,
local and national safety codes related to speed reducers for the face centering, and alignment. Backlash can best be checked
specific installation involved. Shaft guarding and noise level with a feeler gauge. Face centering can be gauged satis-
requirements particularly should be checked, and any require- factorily by eye–the wider member (usually the pinion) should
ments involving the reducer clearly specified. extend beyond the narrower member approximately equally
on both sides. Alignment can be checked by blueing the teeth,
PREPARING THE GEAR UNIT running the drive under load, and noting the contact pattern.
FOR INSTALLATION Contact should be symmetrical about the center of the gear
face; corner contact is unacceptable. Face pattern and contact
Just prior to installation, remove the protective coatings and pattern are illustrated on the next page.
touch up any rust spots. If the unit was filled with oil suitable for
operation under ambient conditions, it can be drained down to
the recommended operating level. If the oil is not suitable for
operation, the unit must be drained and refilled to the recom-
mended level with the grade and type of oil shown on the name-
plate for the ambient temperature. Reinstall the breather.

2
 sideways and in the vertical direction by shimming. When good
parallel alignment has been obtained, a straight edge at points
IDEAL CONTACT
A, B, C and D will simultaneously contact the outer surfaces of
PATTERN both coupling hubs.

GEAR-FACE PARALLEL
CENTERED MISALIGNMENT
ON PINION

If the gear unit is to be coupling-connected to the prime mover

or the driven equipment, or both, flexible couplings must be
used. Rigid couplings are not suitable. Flexible couplings can
compensate for reasonable amounts of misalignment but it is
good practice to maintain good alignment between the gear unit
and the connected equipment. It is also necessary to adjust the
location of the connected equipment relative to the gear unit to
provide the coupling gap (endwise clearance) between shafts
that is recommended by the coupling manufacturer. After parallel misalignment has been corrected, it is
recommended that the angular alignment be rechecked and
Coupling alignment errors are of two kinds; angular misalign- readjusted as indicated.
ment and parallel misalignment. Satisfactory alignment of the
two shafts is easier to achieve if angular misalignment is The fit of a coupling hub, pinion, sprocket, or sheave on a
corrected first. gear-unit shaft will range from loose to heavy interference.
Heavy hammer blows must never be used to mount any of these
Angular misalignment is illustrated below. It is most easily components on the shaft because the bearings in the gear unit
corrected using a feeler gauge equal in thickness to the recom- may be damaged. If the component at the ambient temperature
mended coupling gap. When good angular alignment has been cannot be mounted with light tapping, it must be expanded by
obtained, the gap measurement at points A, B, C and D will be heating until it can. Heating will also facilitate the removal of
all equal. these components, reducing the likelihood of damaging the gear
unit.

CAUTION When mounting heated components on a

gear-unit shaft, take care to protect the oil seal from heat
damage. Use wet rags or an air hose to cool the shaft.

LUBRICATION
ANGULAR CAUTION Gear units are shipped without oil.
MISALIGNMENT
Before startup, fill the unit to the indicated level with the grade
and type of oil shown on the nameplate for the ambient temper-
ature range.

Suitable oils are listed on Page 4 in this manual. If the unit will
be operated at ambient temperatures outside the range shown
on the nameplate, consult the factory for recommendations.

COUPLING CAUTION Do not overfill; a high oil level will generate heat
GAP through churning. To ensure proper lubrication of all moving
parts, do not underfill or let the oil level drop more than 1/4 inch
below the indicated level.

The initial oil fill should be changed after two weeks of operation.
Thereafter, the oil should be changed every six months under
Parallel misalignment is illustrated below. It is corrected in the normal operating conditions.
horizontal direction by shifting one of the two connected units

3
 TABLE 1
AGMA LUBRICANT NUMBERS FOR
CONCENTRIC SHAFT REDUCER, COUPLED GEARMOTOR & GEARMOTOR
HELICAL AGMA LUBRICANT NUMBER
GEAR REDUCERS BY AMBIENT TEMPERATURE
T SL, VSL, 15 - 60 DEGREES F 50 - 125 DEGREES F
Y P, K, L,
P VL, GM, NORMAL HEAVY NORMAL HEAVY
E CVC SERVICE DUTY SERVICE DUTY
S 820 - 827
I 831 - 837 4 4 EP 5 5 EP
Z
E 843 - 847
Where the lubricant contains lead naphthenate (an EP additive) the reducer oil sump
temperature should not exceed 160°F (70°C).

TABLE 3

APPROXIMATE OIL CAPACITY (GALLONS)

UNIT REDUCER AND
GEARMOTOR
SIZE COUPLED GEARMOTOR
STD. LEVEL L.S. LEVEL VGM LEVEL STD. LEVEL L.S. LEVEL VSL LEVEL
821 .8 1.0 1.9 .8 1.0 1.9
822 1.1 1.3 2.0 1.1 1.3 2.0
823 2.1 2.5 4.5 2.1 2.5 4.5
824 2.8 3.8 7.5 2.8 3.8 7.5
8245 3.7 5.9 7.5 3.7 5.9 7.5
825 5.5 7.8 16.3 5.5 7.8 16.3
8255 8.4 12.0 18.5 8.4 12.0 18.5
826 11.0 16.0 25.0 11.0 16.0 25.0
8265 – – – 30.0 40.0 –
827 – – – 40.0 50.0 –
831 – 1.4 1.9 – 1.4 1.9
832 – 1.6 2.0 – 1.6 2.0
833 – 3.2 4.5 – 3.2 4.5
834 – 4.6 7.5 – 4.6 7.5
8345 – 6.3 9.7 – 6.3 9.7
835 – 10.2 16.3 – 10.2 16.3
8355 – 14.5 18.5 – 14.5 18.5
836 – 20.5 25.0 – 20.5 25.0
8365 – 26.0 – – 26.0 –
837 – 35.0 – – 35.0 –
843 – 3.6 4.5 – 3.6 4.5
844 – 5.1 7.5 – 5.1 7.5
8445 – 7.5 9.7 – 7.5 9.7
845 _ 11.0 16.3 – 11.0 16.3
8455 – 15.3 18.5 – 15.3 18.5
846 – 21.0 25.0 – 21.0 25.0
8465 _ 47.0 – – 47.0 _
847 – 59.0 – – 59.0 –
NOTE: WITH OUTPUT SHAFT SPEED OF 68 RPM OR LESS, THE LOW SPEED LEVEL (HIGH OIL LEVEL) SHOULD BE USED, DATA
APPLIES TO HORIZONTAL FLOOR MOUNTED GEARMOTORS AND REDUCER MODELS.
* FOR VERTICAL UNITS (LOW SPEED DOWN), USE THE HIGH OIL LEVEL PLUG.
CAUTION These are approximate amounts. Always fill your speed reducer to the oil level indicator for proper lubrication.
The vertical flange mounted drive has a grease fitting at the bottom of the housing at the output shaft. Re-grease with NLFI No. 2 consistency
Lithium Base grease at three month intervals.
The seals at the shaft extensions should be purged periodically with NLGI No. 2 Lithium Base grease. Using a hand gun, pump grease into the
fitting until the grease forced out around the shaft is clean. Pump slowly to avoid forcing grease past the lip seal and into the gear unit.

4
 OPERATION foundation bolts and the external housing bolts conform to the
values shown on Page 13.
PRE-STARTUP
After the installation has been completed, but before the initial WEEKLY CHECK
startup, the following checks should be made: Check the oil level. Check for oil leaks. Check for changes in
temperature, sound level, and vibration. Check the connections
1. Check the foundation bolts and the bolts on the gear-unit to the driver and driven units: adjust belt tension, lubricate
housing for tightness. Recommended torque values are chains and couplings, etc. If the environment is extremely dirty,
shown on Page 13. purge the seals at the shaft extensions in accordance with the
instructions on Page 4.
2. Check to ensure that the unit has been filled to the
indicated level with the proper grade and type of oil. MONTHLY CHECK
Check to ensure that the torques on the foundation bolts con-
3. Check the motor for correct direction of rotation. form to the values shown on Page 13. Purge the seals at the
shaft extensions in accordance with the instruction on Page 4. If
4. Check the alignment of the couplings, sheaves, sprockets, the drive has not been operated within the past month, it should
and open gearing. Check the tension in the belts and be run for a few minutes to recoat the internal surfaces with
chains and the backlash in the gearing. lubricant.

5. Check the nameplate rating on the gear unit to be certain it SEMI-ANNUAL CHECK
exceeds the motor rating. Drain and replace the lubricant with a grade and type appro-
priate for the ambient conditions. Check for gear-tooth wear.
WARNING For safety, purchaser or user should provide pro-
tective guards over all shaft extensions and any moving appara-
tus mounted thereon. The user is responsiblefor checking all CONCENTRIC-SHAFT REDUCER
applicable safety codes in his area and providing suitable CONFIGURATION
guards. Failure to do so may result in bodily injury and/or
damage to equipment. Exploded-view drawings of these gear units in double, triple and
quadruple reduction are shown elsewhere in this manual. The
numbers shown in the descriptions below are the item numbers
in the parts lists on the exploded-view drawings. Refer to the
INITIAL STARTUP appropriate drawing as an aid in understanding the assembly of
After the pre-startup checks have been made and corrections your unit.
completed, the gear unit may be put into operation. It is
advisable to job the motor through a few revolutions while The primary housing (1A) is a footed casting or weldment. The
observing the system. After it has been determined that there housing carriers the low-speed shaft (2) with mounted low-
are no problems, and vibration and noise levels appear to be speed gear (3) and the low-speed pinion (4). The bearings
normal, the drive can be operated continuously at full speed. for these two shafts are carried at the right end by bores in the
During the first few hours of operation, the housing should be primary housing and at the left end by bores in the center-plate
checked frequently for overheating. Depending upon the ratio, (1B). The center-plate is bolted to the housing and located
speed, and load, the oil-sump temperature may rise to as much accurately by means of a pilot diameter and a dowel pin. The
as 100°F (56°C) above ambient. high-speed gear (5) is mounted outside the center-plate on an
extension of the low-speed pinion (4). At both the low-speed
CAUTION Under no circumstances should the oil-sump shaft and the high-speed shaft, a lip seal prevents oil leakage.
temperature exceed 200°F (95°C). If this should occur, notify When furnished, a grease-purged seal prevents the entrance of
the factory. contamination.

The housing in the vicinity of the high-speed oil seal may reach The number of reductions in a unit is determined by the attach-
a temperature significantly above 200°F. This will diminish as ments mounted upon the primary housing as follows:
the seal and shaft wear in.
For DOUBLE REDUCTION, an endbell (13) carrying the high-
MAINTENANCE speed shaft (12) with integral high-speed pinion is bolted to the
primary housing (1A). The high-speed pinion meshes with the
WARNING Before starting to work on the gear unit, turn off high-speed gear (5).
the power and disconnect the reducer from the connected
equipment. For TRIPLE REDUCTION, a reduction-bracket (6) carrying the
countershaft (7) with integral reduction-bracket pinion is bolted
Good maintenance will prolong the life of the gear unit, help to to the primary housing (1A) and located accurately by means
detect trouble before serious damage can occur, and provide a of pilot diameter and dowel pin. The high-speed gear (8) is
safer working environment for operating personnel. It is recom- mounted on an extension of the countershaft (7). The reduction-
mended that the drive be inspected at intervals as follows: bracket pinion meshes with the intermediate gear (5). An
endbell (13) carrying the high-speed shaft (12) with integral
DAILY CHECK (First Week Only) high-speed pinion is bolted to the reduction-bracket (6) and
Check for oil leaks. Check the oil level. Check for changes in located accurately by means of a pilot diameter. The high-speed
temperature, sound level, and vibration. At the end of the pinion meshes with the high-speed gear (8).
first week of operation, check to ensure that the torques on the

5
For QUADRUPLE REDUCTION, a first reduction-bracket (9) shafts. For the replacement of either of these two parts, an
carrying the first intermediate countershaft (10) with integral assembly must be ordered. Bearings can be installed or
pinion is bolted to the second reduction-bracket (6) and located removed in the field from these assemblies.
accurately by means of a pilot diameter and dowel pin. The
high-speed gear (11) is mounted on an extension of the first
intermediate countershaft (10). The first intermediate pinion DISASSEMBLY AND REASSEMBLY
meshes with the first intermediate gear (8). An endbell (13)
carrying the high-speed shaft (12) with integral high-speed Standard machine shop practices should be used in the disas-
pinion is bolted to the first reduction-bracket and located sembly and reassembly of these gear units. Work should be
accurately by means of a pilot diameter. The high-speed pinion done in a clean, dry area where the likelihood of dirt or other
meshes with the high-speed gear (11). contamination entering the open housing or adhering to the
exposed components is nil. When components are removed
VERTICAL CONCENTRIC SHAFT REDUCERS are standard from the gear unit, they should be carefully cleaned and then
units except that the end surface of the primary housing (1A) placed on clean wooden boards or pallets and covered with
has been machined to provide a mounting surface for a plate paper or plastic sheets.
that will permit vertical installation of the unit. A motor-driven
lube pump is always furnished with vertical units to supply
lubricant to bearings and gearing located above the oil in the PRIMARY HOUSING DISASSEMBLY
primary housing. REASSEMBLY
Disassembly and reassembly will be greatly facilitated by posi-
PINIONS tioning the housing (1A) vertically on blocks spread apart to
clear the low-speed shaft extension (2).
LOW-SPEED PINIONS
Low-speed pinions are cut integrally onto the countershaft (4). 1. Remove the grease-purge cover (26), where applicable,
from the end of the housing.
REDUCTION-BRACKET PINIONS
Reduction-bracket pinions are permanently mounted on their 2. Remove the bolt, washer and retainer plate (40)(41)(42).
shafts (7)(10). For the replacement of either of these two parts, Heat the hub of the high-speed gear (5) to about 300°F
an assembly must be ordered. (150°C) to soften the Loctite. Pull the high-speed gear off
the low-speed pinion (4) with a suitable puller.
HIGH-SPEED PINIONS
There are two types of bearing arrangement for high-speed
pinions in Concentric Shaft Reducers. In the smaller endbells,
direct-mounted bearing are used; in the larger endbells, indirect
mounted bearings are used.

DIRECT MOUNT INDIRECT MOUNT

HIGH-SPEED PINIONS WITH

DIRECT-MOUNTED BEARINGS 3. Remove the bolts and lift out the center-plate (1B).
The sizes that use this configuration in the endbell are as
follows: 820, 821, 831, 832, 833, 843, 844, 8445, and 845. 4. Using eyebolts screwed into the ends of the shafts, gently
raise the shaft assemblies starting with the low-speed shaft.
Depending upon the ratio of the high-speed gearset, the pinion Take care not to strike components together.
may be larger than the bore of the inboard bearing. In this case,
the inboard bearing cone must be mounted on the shaft before 5. Remove the bearing cones from the low-speed pinion and
the pinion is permanently mounted. For the replacement of any the low-speed gear and bearing cones from the low-speed
of these parts, an assembly of the shaft, bearings, and pinion shaft.
must be ordered.
6. Remove the low-speed shaft bearing-plate (21) and the low-
HIGH-SPEED PINIONS WITH speed pinion bearing-plate (35) from the center-plate.
INDIRECT-MOUNTED BEARINGS
The sizes that use this configuration in the endbell are as 7. Remove the bearing cups from the bores in the housing and
follows: 822, 823, 824, 8245, 825, 8255, 826, 8265, 827, 834, center-plate.
8345, 835, 8355, 836, 8365, 837, 8455, 846, 8465, and 847.
8. Remove the oil seal.
These high-speed pinions are permanently mounted on their

6
PRIMARY HOUSING REASSEMBLY NUMBER OF TEETH SPACER USED ON SPACER
LOW-SPEED SHAFT SIZE IN COUNTERSHAFT SHAFT EXTENSION USED ON
PINION END BLIND END
1. Heat the low-speed gear (3) to about 250°F (120°C) to 821, 831 16 YES NO
expand the bore.
8255, 8355, 17 YES NO
8455
2. Insert the key (15) into the keyway on the low-speed shaft
826, 836, 846 17 YES NO
(2). Place the hot gear on the shaft. Before it can shrink,
position the gear firmly against the shaft shoulder. If when 8265, 8365,
8465 17 YES NO
cool, a gap remains between the gear and the shoulder,
place the assembly in a press and close the gap. 2. Heat the bearing cones (30)(33) to about 250°F (120°C) to
expand the bore. Heating can be done with a heat lamp, oil
WARNING Handle the hot gear with insulated gloves. bath, or oven.
3. Install the spacer (18) on the low-speed shaft behind the CAUTION Heat uniformly; do not place the bearing in an
gear. area of localized high temperature. Do not exceed 250°F to
avoid drawing back the bearing hardness.
NOTE: This spacer is not used on the following sizes: 820,
821, 824, 831, 834, and 844. 3. Place the hot bearing cones on the low-speed pinion (4)
with the wider shoulders inward. Before they can shrink,
4. Heat the bearing cones (16)(19) to about 250°F (120°C) to position each cone firmly and squarely against the shaft
expand the bores. Heating can be done with a heat lamp, shoulder or spacer. If when cool, a gap remains between
oil bath, or oven. the bearing and the shoulder, place the assembly in a press
and close the gap.
CAUTION Heat uniformly; do not place the bearing in an
area of localized high temperature. Do not exceed 250°F to WARNING Handle the hot bearings with insulated gloves.
avoid drawing back the bearing hardness.

5. Place the hot bearing cones on the shaft with the wider PRIMARY HOUSING
shoulder inward. Before they can shrink, position each
cone firmly and squarely against the shaft shoulder, spacer, 1. Place the bearing cups (17)(20) in the bearing bores in the
or gear hub as the case may be. If when cool, a gap primary housing (1A) with the wider shoulder contacting the
remains between the bearing and the shoulder, place the housing shoulders. Tap the cups with a piece of hard wood
assembly in a press and close the gap. to seat them firmly.
WARNING Handle the hot bearings with insulated gloves. 2. Using eyebolts screwed into the ends of the shafts, lower
the two shaft assemblies into place starting with the low-
speed pinion (4). Gently guide the teeth in the low-speed
pinion into mesh with the low-speed gear (3).

LOW-SPEED PINION

1. Determine the number and location of low-speed pinion 3. Lower the center-plate (1B) into position slightly above the
spacers (32) to be used from the table below. Units with primary housing. Guiding it to avoid bumping the bearings
combinations of size and number of teeth not appearing in as they are enveloped by the bearing bores, continue to
the table do not use low-speed pinion spacers. lower the center-plate until the pilot diameter and dowel pin
are properly engaged with the housing.

7
 CAUTION Alignment between the pinion shank and the
shaft must be maintained while the pinion is being pressed into
the shaft.

CAUTION No heat is required during the installation of the

pinion.

REDUCTION-BRACKET AND SECOND

REDUCTION-BRACKET DISASSEMBLY
The construction and the disassembly and reassembly
procedures are identical for the reduction-bracket and the
second-reduction-bracket. Therefore, the item numbers used
below will refer to the reduction-bracket. When working on the
second-reduction-bracket, item numbers corresponding to those
below can be determined from the exploded-view drawing for
the quadruple reduction unit.

4. Install the bolts and lockwashers on the center-plate and 1. Remove the bolt and retainer plate (55)(54). Heat the hub
torque them to the value shown in the table on Page 13. of the first intermediate gear (8) to about 300°F (150°C) to
soften Loctite. Pull gear off the shaft (7) with a suitable
5. Install the bearing cups (17)(31) in the center-plate and puller.
adjust the bearing endplay following Instruction I in the
Bearing Adjustment section on Pages 11 and 12. 2. Place the reduction-bracket in a hydraulic press and free the
shaft by pressing it out of the left-hand bearing cone (50).
6. Heat the high-speed gear (5) to about 250°F (120°C) to
expand the bore. Clean then coat the spline on the low- CAUTION Do not support the reduction-bracket on its
speed pinion with Loctite Retaining Compound RC-609. flange surface. Take the thrust directly on the bearing-carrier hub.
CAUTION Do not exceed 250°F because the high temper-
ature will have a detrimental effect on the Loctite.

7. After installing the spacer (39) on the shaft, align the

splines and slip the hot gear onto countershaft. Before the
gear can shrink, install the bolt (41), lockwasher (42), and
retainer plate (40) in the end of the countershaft and torque
the bolt to the value shown in the table on Page 13. If when
cool, a gap remains between the bearing and the shoulder,
place the assembly in a press and close the gap.

WARNING Handle the hot gear with insulated gloves.

8. Install the oil seal (25), following the instructions on Pages

12 and 13 and the grease-purge cover (26).

PINION AND SHAFT DISASSEMBLY 3. Remove the right-hand bearing cone (52) from the shaft
Pinions are permanently mounted into the shafts. When using a bearing puller or a hydraulic press.
replacing one member, both members must be replaced.
4. Remove the bearing cups (51)(53) from the bearing-carrier
hub in the reduction-bracket.
PINION AND SHAFT ASSEMBLY
1. Clean the surface of the pinion shank and the shaft bore
thoroughly with an oil-free cleaner. REDUCTION-BRACKET AND SECOND-
REDUCTION-BRACKET REASSEMBLY
2. Apply Loctite Primer 7649 to the pinion shank and allow to Reassembly will be greatly facilitated by blocking up the reduc-
cure for approximately 5 minutes. tion-bracket (6) so that the second intermediate countershaft (7)
is horizontal.
3. Apply Loctite Maximum Strength Retaining Compound
RC/635 to the pinion shank. NOTE: If the shaft was removed from the reduction-bracket, it is
recommended that new bearings be used in the reassembly.
4. Hand insert the pinion shank into the bore of the shaft.
1. Place the bearing cups (51)(53) in the bearing bores in the
5. Using a hydraulic press, press the pinion completely into the reduction-bracket with the wider shoulders contacting the
shaft bore until the shoulder on the pinion bottoms out on bracket shoulders. Tap the cups with a piece of hard wood
the end of the shaft. to seat them firmly.

8
2. Heat the two bearing cones (50)(52) to 250°F (120°C). 821, 831, 832, 833, 843, 844, 8445, and 845.
Heating can be done with a heat lamp, oil bath, or oven.
1. After removing the key (80) from the high-speed shaft (12),
CAUTION Heat uniformly; do not place the bearing in an remove the bearing cone (14).
area of localized high temperature. Do not exceed 250°F to
avoid drawing back the hardness. 2. Pull the high-speed shaft with integral pinion and mounted
bearings (70)(71) out of the endbell (13). Remove the cup
WARNING Handle the hot bearings with insulated gloves. of the right-hand bearing from the bore.

3. Assemble the hot right-hand bearing cone (52) on the

second intermediate countershaft (7), seating the wider
shoulder firmly against the shaft shoulder.

4. From pipe or tubing with inside diameter a little larger than

the splined portion of the shaft, cut a temporary spacer a
little longer than the width of the first intermediate gear (8).

5. Insert the shaft/bearing assembly into the bearing-carrier

hub and slip the hot left-hand bearing cone (50) onto its end
of the shaft leaving about .010 inches endplay in the
bearings.

CAUTION Do not seat the cone so as to remove all endplay.

6. Quickly slip the temporary spacer onto the splined shaft

extension and thread the bolt (55) and retainer plate (54)
assembly into the end of the shaft. 3. Remove the oil seal (75) from the bearing cover.

7. While the bearing cone is still hot, tighten the bolt to adjust 4. Remove the snap ring (72) from the bearing carrier hub in
the bearing endplay following Instruction II in the Bearing the endbell.
Adjustment section on Page 11.

8. After the endplay has been properly established and the ENDBELLS WITH INDIRECT-
bearing has cooled down, remove the bolt, retaining plate, MOUNTED BEARINGS
and temporary spacer. This instruction applies to endbells for the following sizes: 822,
823, 824, 8245, 825, 8255, 826, 8265, 827, 834, 8345, 835,
9. Heat the first intermediate gear to 250°F (120°C) to expand 8355, 836, 8365, 837, 8455, 846, 8465, and 847.
the bore.
1. After removing the key (80) from the high-speed shaft (12),
CAUTION Do not exceed 250°F because the high temper- remove the bearing cover (14).
ature will have a detrimental effect on the Loctite.
2. Bend up the locking tang on the bearing lockwasher (84)
10. Clean, then coat the splined surfaces in the gear bore and and remove the bearing locknut (83) and lockwasher (84).
on the shaft with Loctite Retaining Compound RC-609.
Align the splines, slip the hot gear onto the shaft and posi- 3. Place the endbell in a hydraulic press and free the shaft by
tion it snugly against the bearing cone. pressing it out of the left-hand bearing cone (81).

WARNING Handle the hot gear with insulated gloves. CAUTION Do not support the endbell on its flange surface.
Take the thrust directly on the bearing-carrier hub.
11. Slip the bolt into the retainer plate, coat the threads with
Loctite Threadlock 242, and screw the bolt into the end of
the shaft. Torque the bolt to the value shown in the table on
Page 13.

CAUTION Do not overtorque the bolt because this could

affect the bearing endplay.

ENDBELL DISASSEMBLY
The disassembly will be greatly facilitated by clamping the
flange in a vise so that the shaft is in a horizontal position.

ENDBELLS WITH DIRECT-

MOUNTED BEARINGS
This instruction applies to endbells for the following sizes: 820,

9
4. Remove the right-hand bearing cone (81) from the shaft. 3. Assemble the hot right-hand bearing cone onto the high-
Remove the bearing cups (82) from the bearing-carrier hub speed shaft (12), seating the wider shoulder firmly against
in the endbell. the shaft shoulder. If, when cool, a gap remains between
the bearing and the shoulder, place the assembly in a press
5. Remove the oil seal (87) from the bearing cover. and close the gap.

WARNING Handle the hot bearings with insulated gloves.

ENDBELL REASSEMBLY
The reassembly will be greatly facilitated by clamping the flange 4. Insert the shaft/bearing assembly into the bearing-carrier
in a vise so that the shaft is in a horizontal position. hub and slip the hot left-hand bearing cone onto its end of
the shaft leaving about .010 inches endplay in the bearings.

ENDBELLS WITH DIRECT- CAUTION Do not seat the cone so as to remove all endplay.
MOUNTED BEARINGS
This instruction applies to endbells for the following sizes: 820, 5. Quickly install the bearing locknut (83) onto the threaded
821, 831, 832, 833, 843, 844, 8445, and 845. shaft extension.

1. Install the snap ring (72) in the bearing-carrier hub of the 6. While the bearing cone is still hot, tighten the locknut to
endbell (13). Install the right-hand bearing cup (71) in the adjust the bearing endplay following Instruction IV in the
bearing bore with the wider shoulder contacting the snap Bearing Adjustment section in the next column.
ring. Tap the cup with a piece of hard wood to seat it firmly.
7. After the correct bearing endplay has been achieved,
2. Insert the assembly consisting of high-speed shaft (12), remove the bearing locknut (83).
pinion, and bearing cones (70) into the endbell. Install the
left-hand bearing cup (71) in the bearing bore with the wider 8. Apply Loctite Primer 7649 to the threaded portion of the
shoulder outward. Tap the cup with a piece of hard wood to input shaft and allow the primer to cure for approximately 5
seat it firmly. minutes.

3. Adjust the bearing endplay following Instruction III in the 9. Apply Loctite Maximum Strength Retaining Compound
Bearing Adjustment section on Page 12. RC/635 to the threaded portion of the input shaft.

4. Remove the bearing cover (14). Install the oil seal (75) in 10. Install bearing lockwasher (84) and locknut (83) onto the
the bearing cover following the instructions in the Oil Seal threaded shaft extension.
section on Pages 12 and 13.
CAUTION Do not overtighten bearing locknut. Locknut
5. Coat the shimpack on both sides with a very thin film of should only be snugged against the bearing cone.
General Electric RTV-102. Before the sealant begins to set,
bolt the assembly together, torquing the bolts to the value 11. Bend the appropriate lockwasher tang to lock the locknut.
shown in the table on Page 13.
12. Tighten the bearing locknut setscrew. NOTE: Not all lock-
CAUTION Take care to align the slot in the bearing-cover nuts are equipped with setscrews.
hub with the cored oil-drain hole in the endbell and to keep
sealant from preventing drain-back of the oil. 13. Install the oil seal (87) in the bearing cover (14) following the
instruction in the Oil Seal section on Pages 12 and 13.

ENDBELLS WITH INDIRECT- 14. Apply a small bead of General Electric RTV-102 to the
MOUNTED BEARINGS flange surface of the bearing cover, circling each bolt hole.
This instruction applies to endbells for the following sizes: 822,
823, 824, 8245, 825, 8255, 826, 8265, 827, 834, 8345, 835, CAUTION Do not permit sealant to block the drain-back
8355, 836, 8365, 837, 8455, 846, 4865, and 847. slot of hole.

If the high-speed shaft was removed from the endbell, it is 15. Install the bearing cover on the endbell, torquing the bolts to
recommended that new bearings be used in the reassembly. the value shown in the table on Page 13.

1. Place the bearing cups (82) in the bearing bores in the CAUTION If the bearing cover has a slot in the hub, align it
endbell with the wider shoulders contacting the endbell with the cored drain-back hole in the endbell.
shoulders. Tap the cups with a piece of hard wood to seat
them firmly.

2. Heat the two bearing cones (81) to 250°F (120°C). Heating REJOINING THE REASSEMBLED MODULES
can be done with a heat lamp, oil bath, or oven. Gear-unit modules are joined to each other with gaskets
(46)(56)(66) at the mating surfaces. All interfaces use pilot
CAUTION Heat uniformly; do not place the bearing in an diameters to maintain concentricity between the modules.
area of localized high temperature. Do not exceed 250°F to Reduction-brackets also use dowel pins (59) to (69) establish
avoid drawing back the hardness. the correct radial relationship with the modules to which they are

10
joined. Bolts must be torqued to the values shown in the table 3. Rotate both shafts to check for free movement, install a
on Page 13. magnetic base dial indicator to the machined surface of the
housing with the point of the dial indicator contacting the
Endbells are constructed with a heavy lug at one point between end of the low speed shaft. Pull or push on the low speed
the hub and the flange. This lug carries an oil drain-back hole. shaft and read and record the total indicator movement,
then move the dial indicator to the low speed pinion shaft
CAUTION For proper lubrication of the high-speed end and, pull and push on the low speed pinion shaft, read
bearings, the endbell must be mounted on the gear unit in its and record the total indicator movement. Remove center-
original position (with the lug down). plate ie. say the low speed shaft value is .016 and low speed
pinion shaft value is .020, the recommended end play is
On vertical concentric-shaft reducers, any location of the lug is .002” - .004” for both the low speed shaft and low speed pin-
acceptable. On integral gearmotors or vertical integral motors, ion shaft. Then you would put .014 shims in low speed shaft
the motor may be mounted to obtain the best location for the bore of the centerplate, and put .018 shims in the low speed
conduit box. pinion shaft bore of the centerplate. Then re-install the cen-
ter in the housing with ALL the fasteners. See page 13 for
the appropriate bolt tightening torques. Re-install dial indi-
RETURNING THE GEAR-UNIT TO SERVICE cator and recheck the end plays to see if they are within the
specifications, if not then add or subtract the appropriate
After the reassembly has been completed, turn the input shaft shims to be within the recommendation of .002” - .004” end
by hand. Rotation should be smooth with no noise or indications play.
of binding or scraping.

When reinstalling the unit, follow the instructions in the sections

on Installation, Pages 2 and 3, and Operation, Page 5.

BEARING ADJUSTMENT

All bearings in Foote-Jones/Illinois Gear Series 800 concentric-

shaft reducers are single-row tapered-roller bearings. These
bearings must be adjusted at assembly to obtain the proper
axial clearance or endplay. The three methods used for adjust-
ing endplay are:

SHIM ADJUSTMENT
BOLT ADJUSTMENT
LOCKNUT ADJUSTMENT

For each type of shaft, the method of adjustment, the amount of

bearing endplay required and the designation of the applicable
instruction are given in the table below.

METHOD OF BEARING
SHAFT ADJUSTMENT ENDPLAY INSTRUCTION
INSTRUCTION II
Low-Speed Shaft
Sizes: All Shim .001” - .003” I (Reduction-Bracket Countershaft)
Low-Speed Pinion
Sizes: All Shim .001” - .003” I 1. Attach a dial indicator to the reduction-bracket with the point
Reduction-Bracket Countershaft contacting the end face of the pinion.
Sizes: All Bolt .002” - .004” II
High-Speed Shaft (Direct Mounted)
Sizes: 820, 821, 831, 832, 833, 843, 2. While holding the pinion to prevent rotation, tighten the bolt
844, 8445, 845 Shim .003” - .005” III in steps of a few degrees of rotation. While rotationally
High-Speed Shaft (Indirect Mounted) oscillating the shaft to seat the rollers, check the bearing
Sizes: 822, 823, 824, 8245, 825,
8255,826, 8265, 827, 834, 8345,
endplay frequently. The steps should become smaller and
835, 8355, 836, 8365, 837, smaller as the endplay approaches the recommended
8455, 846, 8465, 847 Locknut .002” - .004” IV upper value of .004”. Continue tightening until the endplay
is within the range of .002” - .004”.

3. If the bolt is tightened too far (the endplay is found to be less

INSTRUCTION I than .002”), quickly, while the bearing cone is still hot,
(Low-Speed Shaft and Low-Speed Pinion) loosen the bolt one turn and strike the bolt head with a
rawhide mallet to move the cone and increase the endplay.
1. Place bearing cups on the appropriate bearing cones. Then repeat the above procedure until the proper endplay is
obtained.
2. Assemble centerplate over these cups (slip fit) to inside of
housing, use all the fasteners to secure centerplate to housing.
See page 13 for the appropriate bolt tightening torques.

11
 1. Attach a dial indicator to the endbell (13) with the point con-
tacting the end face of the pinion.

2. While holding the pinion to prevent rotation, tighten the

bearing locknut (83) in steps of a few degrees of rotation.
While rotationally oscillating the shaft (12) to seat the
bearing rollers, check the bearing endplay frequently. The
steps should become smaller and smaller as the endplay
approaches the recommended upper value of .004”.
Continue tightening until the endplay is within the range of
.002” - .004”.

INSTRUCTION III
(High-Speed Shaft in Sizes: 820, 821, 831, 832, 833, 843, 844,
8445, and 845)

1. Mount the bearing cover (14) on the endbell (13) with two
bolts (77) 180° apart. While rotationally oscillating the shaft
(12) to seat the bearing rollers, uniformly tighten the bolts to
about 10 foot-pounds torque.

2. With a feeler gauge or taper gauge, measure the gap

between the bearing cover and the endbell at four places 3. If the locknut is tightened too far (the endplay is found to be
about 90° apart. less than .002”), quickly, while the bearing cone is still hot,
loosen the locknut one turn and strike the end of the shaft
with a rawhide mallet to move the cone and increase the
endplay. Then repeat the tightening procedure until the
proper endplay is obtained.

BOLT TORQUES

To prevent loosening under operating conditions, all bolts must

be tightened, unless otherwise specified, to the torque values
given in table.

SHAFT SEALS

LIP SEALS
The oil seals used in these units have lips of synthetic-elastomer
materials. They are constructed with a spring behind the inner
3. Assemble a shimpack (76) equal in thickness to the average lip which exerts constant pressure to keep the lip in contact with
of the gap reading plus. 004”. the shaft.

4. Install the shimpack between the bearing cover and the In any disassembly of the gear unit that involves withdrawing a
endbell. Install the full complement of bolts and torque them shaft from an oil seal, it is recommended that oil seal be
to the value shown in the table on Page 13. replaced. If a groove has been worn in the shaft where it con-
tacts the seal lip, it may be possible to shift the seal axially in the
5. Check the resulting bearing endplay with a dial indicator. If seal bore to avoid the groove. If not, the area should be care-
it is not .003” - .005”, modify the thickness of the shimpack fully polished or plunged ground (.003” deep maximum) to
as indicated and repeat the checking procedure. remove the imperfection, or a seal wear-sleeve may be installed.

INSTRUCTION IV
(High-Speed Shaft in Sizes: 822, 823, 824, 8245, 825, 8255,
826, 8265, 827, 834, 8345, 835, 8355, 836, 8365, 837, 8455,
846, 8465, and 847).

12
 RECOMMENDED BOLT TIGHTENING TORQUES* (lb-ft) V-RING SEALS
A dual-seal arrangement is used on the low-speed shaft in ver-
BOLT GRADES GRADE VIII, STUDS,
tical gear-units. The second seal is a V-ring. It is slipped onto
SIZE III & V & SOC. HD. SCREWS
the low-speed shaft outboard of the bearing cone, and its lip
contacts the shell of the standard lip seal.
1/4 9 13
5/16 18 28
3/8 31 46
7/16 50 75 GREASE-PURGED SEALS
1/2 75 115 Where applicable, these seals are furnished for both shaft
9/16 110 165 extensions. The exceptions are the high-speed shaft on integral
5/8 150 225 gearmotors and the low-speed shaft on vertical gear-units.
3/4 250 370
7/8 380 590
1 585 895

1-1/8 780 1410 RATCHET-TYPE BACKSTOP

1-1/4 1100 1960
1-3/8 1460 2630
1-1/2 1750 3150 Pawls are carried in a rotating housing mounted on the high-
1-5/8 2390 4310 speed shaft. These pawls engage a ratchet wheel, preventing
1-3/4 3110 5610 rotation in one direction. The backstop can be assembled to
1-7/8 4190 7550 permit free rotation of the high-speed shaft in either direction.
2 4500 8100
2-1/4 6500 11,700
2-1/2 7140 16,200 At a rotational speed of about 600 RPM, centrifugal force lifts
*Maximum torque values are shown. Use 90% to 100% of these values. the pawls off the ratchet wheel. When rotation drops below this
speed, springs on the pawls force the pawls into contact with the
ratchet wheel. The exploded-view drawing of this device
Before installing a new seal, carefully examine it for imperfec- shown elsewhere in this manual can be used as an aid in under-
tions. The lips should have smooth, uninterrupted edges free standing the disassembly and reassembly instructions below.
of molding flash. The shell O.D. should be free of dents,
scratches, and burrs.
BACKSTOP DISASSEMBLY
1. Clean the seal bore in the bearing cover (14) or primary If the purpose of the disassembly is to reverse the direction of
housing (1A) and apply a thin coating of sealant to the seal rotation, perform only steps 1 through 4 below.
bore.
1. Remove the outer half of the dust cover (A).
2. Mount the seal in the seal bore with the spring side inboard.
Use a piece of hard wood to drive the seal flush with the
surface.

3. Wipe a liberal amount of NLGI No. 2 Lithium Base grease

into the seal and onto the lips and shaft as an aid in instal-
lation and for lubrication at startup.

2. Loosen the set screw in the housing (C) and pull the
housing off the shaft (12). Lay the housing, open-side up,
on a table.

3. Drive out the roll pins (B) upon which the pawls pivot and
the stop pins (K).

CAUTION Care must be taken to prevent damaging the 4. Remove the socket-head screws (L) from the ratchet wheel
seal lip on the edges of the keyway or on shaft shoulders. (E), and remove the ratchet wheel.
Plastic electrical tape wrapped around the shaft starting at the
seal area and working toward the end of the shaft will protect the 5. Remove the inner half of the dust cover and the key (D).
lips during installation.
NOTES: If the backstop will not be remounted, fasten the
bearing cover to the endbell with hex-head bolts of proper
size and length.

13
BACKSTOP REASSEMBLY

1. Coat all surfaces of the pawl (F) assemblies lightly with

grease. With the housing (C) laying on a table, open-side
up, lay the pawls in the housing, orienting them properly for
the desired direction of rotation.

2. Align the holes in the pawls with the holes of the same size
in the housing. Drive roll pins (B) through the pawl and both
sides of the housing.

3. Coat the ratchet wheel (E) lightly with grease. Mount the
ratchet wheel and the inner half of the dust cover (A) on the
bearing cover (14), orienting the ratchet wheel to permit
high-speed shaft (12) rotation in the desired direction.
Torque the socket-head screws (L) to the value shown in the
table on Page 13.

4. Move each pawl outward against its stop. Insert a small

dowel pin or nail into the appropriate hole in the housing
under the pawl to hold the pawl clear of the ratchet wheel
during assembly.

5. Heat the housing/pawl assembly in an oven to about 250°F

(120°C). After placing the key (D) in the keyway in the shaft,
slide the hot housing assembly onto the shaft. Position the
housing with about .06” between its hub and the end-sur-
face of the bearing cover (14). In this position, the pawls
should fully engage the ratchet wheel and there should be
no other contact between moving and stationary parts.

6. When it has been determined that the housing is positioned

correctly, tighten the set screw in the housing hub.

7. Remove the pins or nails from the housing to permit the

pawls to drop into operating positions.

8. Install the outer half of the dust cover, taking care to provide
adequate clearance between it and the housing. Fasten the
two cover pieces together with sheet-metal screws.

14
 12 HIGH-SPEED SHAFT / 12A PINION
13 ENDBELL
14 BEARING COVER
70 HIGH-SPEED BEARING – LEFT AND RIGHT
71 HIGH-SPEED BEARING – LEFT AND RIGHT
72 HIGH-SPEED BEARING SNAP RING
73 ENDBELL MOUNTING BOLT
74 ENDBELL MOUNTING LOCKWASHER
V1 HOUSING & CENTER PLATE 75 HIGH-SPEED LIP SEAL
V2 OUTPUT SHAFT 76 GASKET
V3 MOUNTING FLANGE 77 BEARING-COVER BOLT
V4 V RING SEAL 78 BEARING-COVER LOCKWASHER
V5 SLINGER 79 HIGH-SPEED GREASE-PURGE FITTING
V6 MOTORIZED PUMP 80 HIGH-SPEED SHAFT KEY
V7 PUMP MOUNTING PLATE
V8 MOUNTING FLANGE LOCKWASHER High-Speed Shaft (Direct Mounted)
V9 MOUNTING FLANGE BOLT Sizes: 820, 821, 831, 832, 833
843, 844, 8445, 845
For other reducer parts See pages 16, 17, or 18

PARTS LIST
BACKSTOP
LOCKING OPTION
12 HIGH-SPEED SHAFT
13 ENDBELL
14 BEARING COVER
80 HIGH-SPEED SHAFT KEY
A DUST COVER
B PIVOT PIN
C HOUSING
D KEY
E RATCHET WHEEL
F PAWL
G BUSHING
H FLAT-HEAD RIVET
I SPRING STIFFENER
J PAWL SPRING
K STOP PIN
L SOCKET-HEAD SCREW

NOTE: BEARING ARRANGEMENT IS

NOT AS SHOWN FOR ALL SIZES

15
16
DOUBLE REDUCTION
1. HOUSING (1A) AND CENTERPLATE (1B) 26. LOW-SPEED GREASE PURGE COVER 45. CENTERPLATE DOWEL PIN
2. LOW-SPEED SHAFT 27. LOW-SPEED GREASE PURGE COVER SCREW 46. RTV
3. LOW-SPEED GEAR 28. LOW-SPEED GREASE PURGE FITTING 47. EYEBOLT
4. LOW-SPEED PINION 29. LOW-SPEED SHAFT KEY 48. DYNA-SEAL WASHER
5. HIGH-SPEED GEAR 30. LOW-SPEED PINION BEARING–CONE, LEFT 49. BREATHER
12. HIGH-SPEED SHAFT / 12A PINION 31. LOW-SPEED PINION BEARING–CUP, LEFT 80. HIGH-SPEED SHAFT KEY
13. ENDBELL 32. LOW-SPEED PINION BEARING–SPACER 81. HIGH-SPEED CONE, LEFT AND RIGHT
14. BEARING COVER 33. LOW-SPEED PINION BEARING–CONE, RIGHT 82. HIGH-SPEED BEARING CUP, LEFT AND RIGHT
15. LOW-SPEED GEAR KEY 34. LOW-SPEED PINION BEARING–CUP, RIGHT 83. HIGH-SPEED BEARING LOCKNUT
16. LOW-SPEED BEARING–CONE, LEFT 36. LOW-SPEED PINION BEARING SHIMPACK 84. HIGH-SPEED BEARING LOCKWASHER
17. LOW-SPEED BEARING–CUP, LEFT 37. LOW-SPEED PINION BEARING PLATE BOLT 85. ENDBELL MOUNTING BOLT
18. LOW-SPEED BEARING SPACER 38. LOW-SPEED PINION BEARING PLATE LOCKWASHER 86. ENDBELL MOUNTING LOCKWASHER
19. LOW-SPEED BEARING–CONE, RIGHT 39. HIGH-SPEED GEAR SPACER 87. HIGH-SPEED LIP SEAL
20. LOW-SPEED BEARING–CUP, RIGHT 40. HIGH-SPEED GEAR RETAINER PLATE 88. BEARING COVER MOUNTING BOLT
22. LOW-SPEED BEARING SHIMPACK 41. HIGH-SPEED GEAR RETAINER PLATE BOLT 89. BEARING COVER MOUNTING LOCKWASHER
23. LOW-SPEED BEARING PLATE BOLT 42. HIGH-SPEED GEAR RETAINER PLATE LOCKWASHER 90. HIGH-SPEED GREASE-PURGE FITTING
24. LOW-SPEED BEARING PLATE LOCKWASHER 43. CENTERPLATE MOUNTING BOLT
25. LOW-SPEED SHAFT LIP SEAL 44. CENTERPLATE MOUNTING LOCKWASHER
WARNING Use a bead of adhesive sealant such as General Electric RTV-102 on part #13 before final assembly to part #1, otherwise the gear reducer
will leak hot oil.
17
TRIPLE REDUCTION
1. HOUSING (1A) AND CENTERPLATE (1B) 27. LOW-SPEED GREASE PURGE COVER SCREW 50. COUNTERSHAFT BEARING–CONE, LEFT
2. LOW-SPEED SHAFT 28. LOW-SPEED GREASE PURGE FITTING 51. COUNTERSHAFT BEARING–CUP, LEFT
3. LOW-SPEED GEAR 29. LOW-SPEED SHAFT KEY 52. COUNTERSHAFT BEARING–CONE, RIGHT
4. LOW-SPEED PINION 30. LOW-SPEED PINION BEARING–CONE, LEFT 53. COUNTERSHAFT BEARING–CUP, RIGHT
5. INTERMEDIATE GEAR 31. LOW-SPEED PINION BEARING–CUP, LEFT 54. HIGH-SPEED GEAR RETAINER–PLATE
6. REDUCTION BRACKET 32. LOW-SPEED PINION BEARING–SPACER 55. HIGH-SPEED GEAR RETAINER–PLATE BOLT
7. COUNTERSHAFT / 7A PINION 33. LOW-SPEED PINION BEARING–CONE, RIGHT 56. RTV
8. HIGH-SPEED GEAR 34. LOW-SPEED PINION BEARING–CUP, RIGHT 57. REDUCTION-BRACKET MOUNTING BOLT
12. HIGH-SPEED SHAFT / 12A PINION 36. LOW-SPEED PINION BEARING SHIMPACK 58. REDUCTION-BRACKET MOUNTING LOCKWASHER
13. ENDBELL 37. LOW-SPEED PINION BEARING PLATE BOLT 59. REDUCTION-BRACKET DOWEL PIN
14. BEARING COVER 38. LOW-SPEED PINION BEARING PLATE LOCKWASHER 81. HIGH-SPEED BEARING CONE
15. LOW-SPEED GEAR KEY 39. INTERMEDIATE GEAR SPACER 82. HIGH-SPEED BEARING CUP
16. LOW-SPEED BEARING–CONE, LEFT 40. INTERMEDIATE GEAR RETAINER PLATE 83. HIGH-SPEED BEARING LOCKNUT
17. LOW-SPEED BEARING–CUP, LEFT 41. INTERMEDIATE GEAR RETAINER PLATE BOLT 84. HIGH-SPEED BEARING LOCKWASHER
18. LOW-SPEED BEARING SPACER 42. INTERMEDIATE GEAR RETAINER PLATE LOCKWASHER 85. ENDBELL MOUNTING BOLT
19. LOW-SPEED BEARING–CONE, RIGHT 43. CENTERPLATE MOUNTING BOLT 86. ENDBELL MOUNTING LOCKWASHER
20. LOW-SPEED BEARING–CUP, RIGHT 44. CENTERPLATE MOUNTING LOCKWASHER 87. HIGH-SPEED LIP SEAL
22. LOW-SPEED BEARING SHIMPACK 45. CENTERPLATE DOWEL PIN 88. BEARING COVER MOUNTING BOLT
23. LOW-SPEED BEARING PLATE BOLT 46. RTV 89. BEARING COVER MOUNTING LOCKWASHER
24. LOW-SPEED BEARING PLATE LOCKWASHER 47. EYEBOLT 90. HIGH-SPEED GREASE-PURGE FITTING
25. LOW-SPEED SHAFT LIP SEAL 48. DYNA-SEAL WASHER
26. LOW-SPEED GREASE PURGE COVER 49. BREATHER
WARNING Use a bead of adhesive sealant such as General Electric RTV-102 on parts #6, 13 & 14 before final assembly to part #1, otherwise the gear
reducer will leak hot oil.
 QUADRUPLE REDUCTION

18
1. HOUSING (1A) AND CENTERPLATE (1B) 28. LOW-SPEED GREASE PURGE FITTING 54. FIRST INTERMEDIATE GEAR RETAINER–PLATE
2. LOW-SPEED SHAFT 29. LOW-SPEED SHAFT KEY 55. FIRST INTERMEDIATE GEAR RETAINER–PLATE BOLT
3. LOW-SPEED GEAR 30. LOW-SPEED PINION BEARING–CONE, LEFT 56. RTV
4. LOW-SPEED PINION 31. LOW-SPEED PINION BEARING–CUP, LEFT 57. REDUCTION-BRACKET MOUNTING BOLT
5. SECOND INTERMEDIATE GEAR 32. LOW-SPEED PINION BEARING–SPACER 58. REDUCTION-BRACKET MOUNTING LOCKWASHER
6. SECOND REDUCTION BRACKET 33. LOW-SPEED PINION BEARING–CONE, RIGHT 59. REDUCTION-BRACKET DOWEL PIN
7. SECOND INTERMEDIATE COUNTERSHAFT / 7A PINION 34. LOW-SPEED PINION BEARING–CUP, RIGHT 60. FIRST INTERMEDIATE BEARING–CONE, LEFT
8. FIRST INTERMEDIATE GEAR 36. LOW-SPEED PINION BEARING SHIMPACK 61. FIRST INTERMEDIATE BEARING–CUP, LEFT
9. FIRST REDUCTION BRACKET 37. LOW-SPEED PINION BEARING PLATE BOLT 62. FIRST INTERMEDIATE BEARING–CONE, RIGHT
10. FIRST INTERMEDIATE COUNTERSHAFT / 10A PINION 38. LOW-SPEED PINION BEARING PLATE LOCKWASHER 63. FIRST INTERMEDIATE BEARING–CUP, RIGHT
11. HIGH-SPEED GEAR 39. SECOND INTERMEDIATE GEAR SPACER 64. HIGH-SPEED GEAR RETAINER PLATE
12. HIGH-SPEED SHAFT / 12A PINION 40. SECOND INTERMEDIATE GEAR RETAINER PLATE 65. HIGH-SPEED GEAR RETAINER PLATE BOLT
13. ENDBELL 41. SECOND INTERMEDIATE GEAR RETAINER PLATE BOLT 66. RTV
14. BEARING COVER 42. SECOND INTERMEDIATE GEAR RETAINER PLATE LOCK- 67. REDUCTION-BRACKET MOUNTING BOLT
15. LOW-SPEED GEAR KEY WASHER 68. REDUCTION-BRACKET MOUNTING LOCKWASHER
16. LOW-SPEED BEARING–CONE, LEFT 43. CENTERPLATE MOUNTING BOLT 69. REDUCTION-BRACKET DOWEL PIN
17. LOW-SPEED BEARING–CUP, LEFT 44. CENTERPLATE MOUNTING LOCKWASHER 81. HIGH-SPEED BEARING CONE
18. LOW-SPEED BEARING SPACER 45. CENTERPLATE DOWEL PIN 82. HIGH-SPEED BEARING CUP
19. LOW-SPEED BEARING–CONE, RIGHT 46. RTV 83. HIGH-SPEED BEARING LOCKNUT
20. LOW-SPEED BEARING–CUP, RIGHT 47. EYEBOLT 84. HIGH-SPEED BEARING LOCKWASHER
22. LOW-SPEED BEARING SHIMPACK 48. DYNA-SEAL WASHER 85. ENDBELL MOUNTING BOLT
23. LOW-SPEED BEARING PLATE BOLT 49. BREATHER 86. ENDBELL MOUNTING LOCKWASHER
24. LOW-SPEED BEARING PLATE LOCKWASHER 50. SECOND COUNTERSHAFT BEARING–CONE, LEFT 87. HIGH-SPEED LIP SEAL
25. LOW-SPEED SHAFT LIP SEAL 51. SECOND COUNTERSHAFT BEARING–CUP, LEFT 88. BEARING COVER MOUNTING BOLT
26. LOW-SPEED GREASE PURGE COVER 52. SECOND COUNTERSHAFT BEARING–CONE, RIGHT 89. BEARING COVER MOUNTING LOCKWASHER
27. LOW-SPEED GREASE PURGE COVER SCREW 53. SECOND COUNTERSHAFT BEARING–CUP, RIGHT 90. HIGH-SPEED GREASE-PURGE FITTING
WARNING Use a bead of adhesive sealant such as General Electric RTV-102 on parts #6, 9, 13 & 14 before final assembly to part #1, otherwise the gear
reducer will leak hot oil.
 MECHANICAL WARNINGS AND CAUTIONS

WARNING IMPORTANT INFORMATION CAUTION

PLEASE READ CAREFULLY

The following WARNING and CAUTION information is supplied to you for your protection and to provide you with many
years of trouble free and safe operation of your Foote-Jones/Illinois Gear product:

Read ALL instructions prior to operating reducer. Injury to personnel or reducer failure may be caused by improper installation, maintenance
or operation.

WARNING • Written authorization from Foote-Jones/Illinois Gear is required to operate or use reducers in man lift or people moving devices.

• Check to make certain application does not exceed the allowable load capacities published in the current catalog.

• Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which Buyer shall apply
the product. The application by Buyer shall not be subject to any implied warranty of fitness for a particular purpose.

• For safety, Buyer or User should provide protective guards over all shaft extensions and any moving apparatus mounted
thereon. The User is responsible for checking all applicable safety codes in his area and providing suitable guards. Failure to
do so may result in bodily injury and/or damage to equipment.

• Hot oil and reducers can cause severe burns. Use extreme care when removing lubrication plugs and vents.

• Make certain that the power supply is disconnected before attempting to service or remove any components. Lock out the
power supply and tag it to prevent unexpected application of power.

• Reducers are not to be considered fail safe or self-locking devices. If these features are required, a properly sized,
independent holding device should be utilized. Reducers should not be used as a brake.

• Any brakes that are used in conjunction with a reducer must be sized or positioned in such a way so as to not subject the
reducer to loads beyond the catalog rating.

• Lifting supports including eyebolts are to be used for vertically lifting the gearbox only and no other associated attachments
or motors.

• Use of an oil with an EP additive on units with backstops may prevent proper operation of the backstop. Injury to personnel,
damage to the reducer or other equipment may result.

• Overhung loads subject shaft bearings and shafts to stress which may cause premature bearing failure and/or shaft breakage
from bending fatigue, if not sized properly.

CAUTION • Test run unit to verify operation. If the unit tested is a prototype, that unit must be of current production.

• If the speed reducer cannot be located in a clear and dry area with access to adequate cooling air supply, then precautions
must be taken to avoid the ingestion of contaminants such as water and the reduction in cooling ability due to exterior
contaminants.

• Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation.

In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a conspicuous place and in
a conspicuous manner in a written agreement covering such sale:

The manufacturer makes no warranties or representations, express or implied, by operation of law or otherwise, as to the
merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges that it alone has
determined that the goods purchased hereunder will suitably meet the requirements of their intended use. In no event will the
manufacturer be liable for consequential, incidental or other damages. Even if the repair or replacement remedy shall be deemed
to have failed of its essential purpose under Section 2-719 of the Uniform Commercial Code, the manufacturer shall have no
liability to Buyer for consequential damages.

Resellers/Buyers agree to also include this entire document including the warnings and cautions above in a conspicuous place and in a
conspicuous manner in writing to instruct users on the safe usage of the product.

This information should be read together with all other printed information supplied by Foote-Jones.

19
 ELECTRICAL WARNINGS AND CAUTIONS

WARNING IMPORTANT INFORMATION CAUTION

PLEASE READ CAREFULLY

Appropriate Foote-Jones/Illinois Gear instructions provided with the motor and precautions attached to the motor should be read carefully prior to
installation, operation and/or maintenance of the equipment. Injury to personnel or motor failure may be caused by improper installation, maintenance or
operation.

The following WARNING and CAUTION information is supplied to you for your protection and to provide you with many years
of trouble free and safe operation of your Foote-Jones product:

WARNING • Disconnect power and lock out driven equipment before working on a motor.

• Always keep hands and clothing away from moving parts.

• The lifting support on the motor is not to be used to lift the entire machine. Only the motor attached directly to the support may be
safely lifted by the support.

• Install and ground per local and national codes.

• Discharge all capacitors before servicing a single phase motor.

• Misapplication of a motor in hazardous environment can cause fire or an explosion and result in serious injury. Only the end user,
local authority having jurisdiction, and/or insurance underwriter are qualified to identify the appropriate class(es), group(s), division and
temperature code Foote-Jones/Illinois Gear personnel cannot evaluate or recommend what motors may be suitable for use in hazardous
environments. If a motor is name plated for hazardous locations, do not operate the motor without all of the grease and drain
plugs installed.

• Never attempt to measure the temperature rise of a motor by touch. Temperature rise must be measured by thermometer, resistance,
resistance, imbedded detector or thermocouple.

• Motors with automatic reset thermal protectors will automatically restart when the protector temperature drops sufficiently. Do not use
motors with automatic reset thermal protectors in applications where automatic restart will be hazardous to personnel or equipment.

• Motors with manual reset thermal protectors may start unexpectedly after the protector trips when the surrounding air is at +20˚
Fahrenheit or lower. If the manual reset protector trips, disconnect motor from its power supply. After the protector cools (five minutes
or more), it can be reset and power may be applied to the motor.

• Connect all protective device leads, marked P1, P2, etc., per instructions supplied with the motor.

• Operation of a motor at other than its nameplate rating may result in fire, damage to equipment or serious injury to personnel.

• For safety, Buyer or User should provide protective guards over all shaft extensions and any moving apparatus mounted thereon.
The User is responsible for checking all applicable safety codes in his area and providing suitable guards. Failure to do so may result
in bodily injury and/or damage to equipment.

CAUTION • Consult qualified personnel with questions and all electrical repairs must be performed by trained and qualified personnel only.

• For motors nameplated as “belted duty only”, do not operate the motor without belts properly installed.

• Motors and/or driven equipment should not be operated faster than their rated speed.

• For inverter applications, follow the inverter manufacturer’s installation guidelines.

• Make sure the motor is properly secured and aligned before operation.

In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a conspicuous place and in a
conspicuous manner in a written agreement covering such sale:

The manufacturer makes no warranty or representations, express or implied, by operation of law or otherwise, as to the
merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges that it alone has determined
that the goods purchased hereunder will suitably meet the requirements of their intended use. In no event will the manufacturer be
liable for consequential, incidental or other damages. Even if the repair or replacement remedy shall be deemed to have failed of its
essential purpose under Section 2-719 of the Uniform Commercial Code, the manufacturer shall have no liability to Buyer for
consequential damages.

Resellers/Buyers agree to also include this entire document including the warnings and cautions above in a conspicuous place and in a conspicuous
manner in writing to instruct users on the safe usage of the product.

This information should be read together with all other printed information supplied by Foote-Jones.

For more information contact: Foote-Jones, A REGAL-BELOIT Company, 2914 Industrial Avenue, Aberdeen, SD 57402-1089
Phone: 605-225-0360 • Fax: 605-225-0567

20
NOTES

21
NOTES

22
NOTES

23
 FOOTE-JONES

Custom Gearing
Bevels
Helical
Spurs
Racks
Herringbones
Worm Gearing
Splined Shafts

Enclosed Drives
Concentrics
Parallel Shafts
Spiral Bevels
Worms
Shaft Mounts
Screw Conveyor Drives

P ower
T ransmission
D istributors
Association

FOOTE-JONES
A REGAL-BELOIT Company

2914 Industrial Avenue • Aberdeen SD 57402-1089 • 605-225-0360 • Fax: 605-225-0567

1-800-482-2489 • www.footejones.com

Printed in U.S.A. 3755F/1500/1-03/CONT/BH