FALK QUADRIVE JR User manual

QUADRIVE OWNERS
PRICE $2.00
PN - 2109326
Manual
CAUTION!
Drives are shipped
without oil.
Sizes 4407/M4407
thru 4608/M4608
JR, JF & JSC
®
a good name in industry

Gear Drive Identification
J is the basic drive identification. It can be furnished as a shaft mounted drive JR; a flange mounted drive JF; or a screw conveyor
drive JSC(Size 4407 only), as illustrated below. These unique identifiers, JR, JF, & JSC, are used throughout this manual to assist you
in identifying the instructions which apply to your drive arrangement.
NOTE: Use a TA-Taper bushing when mounting these drives on a straight driven shaft (Hollow shaft is taper bored).
The Falk Corporation, P.O. Box 492, Zip 53201-0492378-102
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]August 2004
Fax: [phone] e-mail: [email protected] web: www.falkcorp.comSupersedes 6-92
®
a good name in industry
Owners Manual •Quadrive Shaft Mounted Drives
(Page 2 of 56) Sizes 4407/M4407-4608/M4608
M 4 407 J 25
Size (Series)
Max Bushing Bore (4 7/16")
Drive Type
Ratio (Nominal 25:1)
Blank - Inch
M - Metric
+ TA Removal Tool
(JSC) Screw Conveyor Drive (Size 4407 only)
1) Drive With Seal Housing
2) Drive Shaft
+ Motor Mounts
+ Backstops
+ Cooling Fans
+ Vertical Breathers
+ Trough Ends
+ Thrust Plate Kits
+ V-Belt Guards
(JF) Flange Mounted Drive
1) Drive With Flange
TA Taper Bushing Optional
(JR) Shaft Mounted Drive
1) Basic Drive
2) Tie Rod
3) TA Taper Bushing

Introduction
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 condition of
operation.
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.
CAUTION: Do not weld the drive housing 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 will
void the warranty.
DRIVE RATING — Operate the drive only within the
horsepower and output speed for which it was selected and
specified in Selection Guide 371-110 (M371-110) for the
application. Refer to the nameplate for drive size, ratio and
data.
FALK FACTORY REPAIR AND REBUILD — Falk wants to
continue to be your primary supplier, and extend our service
to you if your equipment is in the need of repair or
replacement.
We are able to furnish a fast turn-around on both the quotation
and rebuild. Nobody can do the job better than Falk. If you
need repair on Falk products...just ask.
Contact your local Falk Representative or Falk Distributor for
more information.
Table Of Contents
Section I — Drive Installation
Outfitting ········································4
Installation ·······································6
Lubrication ·······································8
Startup ·········································8
Section II — Drive Service & Repair
Preventive Maintenance ·································9
Stored & Inactive Drives ·································9
Removal Of Drive····································9
Drive Disassembly ...................................11
Identifying & Ordering Parts ...............................13
Recommended Spare Parts ...............................13
Parts List Of Falk Part Numbers .............................16
Bearing Cross Reference Numbers............................18
Seal Cross Reference Numbers .............................18
Section III — Drive Reassembly
Drive Reassembly ....................................19
Appendix
Appendix A: Lubrication Recommendations .......................26
Appendix B: Backstop Installation ............................29
Appendix C: TA Removal Tool .............................33
Appendix D: Motor Mount Installation..........................35
Appendix E: Vertical Standpipe Installation .......................37
Appendix F: Modification For Non-Standard Mounting Positions .............39
Appendix G: Parts Interchangeability 3000 vs 4000 Series ................41
Appendix H: Retaining Rings For Bushing Nuts and Thrust Plates &
Tooth Combinations For Vibrations Analysis.................43
Appendix J: Drive Shaft Recommendations for Tapered Drive Shafts ............44
Appendix K: Drive Shaft Recommendations Using TA Taper Bushing ............45
Appendix L: Drive Shaft Recommendations Using (TCB) Kit ................47
Appendix M: V-Belt Guard Installation ..........................49
Appendix N: Electric Fan Installation ..........................51
The Falk Corporation, P.O. Box 492, Zip 53201-0492 378-102
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone] August 2004
Fax: [phone] e-mail: [email protected] web: www.falkcorp.com Supersedes 6-92
®
a good name in industry
Quadrive Shaft Mounted Drives •Owners Manual
Sizes 4407/M4407-4608/M4608 (Page 3 of 56)
© The Falk Corporation, 1992, 2004. All Rights Reserved. Litho in U.S.A. FALK, EQUI-POISED, QUADRIVE, STEELFLEX, TA TAPER, and TORUS are registered trademarks.
The Contents of this manual are subject to change without notice or obligation. Information contained herein should be confirmed before placing orders.

Section I
Drive Installation
Outfitting
1. JR, JF & JSC — Find the desired mounting position in Figure
1 and install air vent and magnetic drain plug (packaged
separately with drive). Also note and/or mark the oil level
plug location OR in the case of a vertical mounting, refer to
Appendix E, for installation of vertical stand pipe. If the
mounting angle exceeds the limitations shown in Figure 1,
refer to Appendix E, to determine modifications necessary
within the limits illustrated therein. DO NOT fill drive with
lubricant at this time.
2. JR — The tapered bore hollow shaft is designed for use with
a TA Taper bushing for mounting on a driven shaft with a
straight outside diameter. The minimum and maximum
driven shaft engagement, dimension N in Figure 2, are
shown in Table 2. The minimum engagement is necessary
for full bushing engagement; the maximum engagement is
only if a thrust plate will be employed to remove the drive
from the driven shaft (See Appendix C for preferred removal
method). Shaft tolerances for driven shafts are shown in
Table 1.
The Falk Corporation, P.O. Box 492, Zip 53201-0492378-102
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: [phone]August 2004
Fax: [phone] e-mail: [email protected] web: www.falkcorp.comSupersedes 6-92
®
a good name in industry
Owners Manual •Quadrive Shaft Mounted Drives
(Page 4 of 56) Sizes 4407/M4407-4608/M4608
F
L
9O'CLOCK
F
F
L
L
D
D
D
12 O'CLOCK
6O'CLOCK
REPOSITION PLUGS TO
SUIT REQ'D. MOUNTING
3O'CLOCK
D=DRAIN
F=FILL&VENT
L=OILLEVEL
(HIGHEST
SIDE PLUG)
F
L
D
Figure 1 HORIZONTAL DRIVES
MIN. SPACE
REQUIRED FOR
V-BELT CLEARANCE
THRUST
PLATE
BORE
INPUT
SHAFT
MIN. SPACE
REQUIRED TO SPIN
BUSHING UNIT
BUSHING NUT
DRIVEN SHAFT
BEARING
SUPPORT
SHEAVE
N
Figure 2
STANDPIPE &
VENTED DIPSTICK STANDPIPE &
VENTED DIPSTICK
FILL FILL
DRAIN DRAIN
INPUT SHAFT DOWN INPUT SHAFT UP
±1°
MAX.
VERTICAL DRIVES
20 UP
MAX.
5 DOWN
MAX.
°
°
±10 MAX.°
ANGULAR LIMITS FOR HORIZONTAL MOUNTING
(ALL CLOCK POSITIONS)
TABLE 2 — N Dimension – Inches (mm) H
Drive Size Minimum Maximum
4407 8.38 (212,9) 12.40 (315,0)
4415 10.33 (262,4) 13.44 (341,4)
4507 10.66 (270,8) 14.53 (369,1)
4608 13.03 (331,0) 17.56 (446.0)
HThe minimum engagement is necessary for full bushing engagement, the
maximum engagement is only if a thrust plate will be employed to remove the
drive from the driven shaft.
TABLE1—DrivenShaft Tolerances – In
(mm)
Shaft Diameter Max Undersize
Over Thru
2.500 (63,5) 4.000 (101,6) .006 (0,15)
4.000 (101,6) 6.000 (152,4) .007 (0,18)
6.000 (152,4) 7.000 (177,8) .008 (0,20)

a) THIN WALL BUSHING (with keyway slot through the
bushing wall) — With the driven shaft keyway at the 12
o’clock position, slide bushing assembly onto the driven
shaft, nut end first, and position the keyway slot over the
shaft keyway. The bushing may have to be opened slightly
to assist in installation. Insert a screwdriver into the slot in
the bushing and very lightly pry open until the bushing
slides onto the shaft. Insert the drive key furnished with
the bushing into the shaft keyway. Proceed to Step 6.
b) THICK WALL BUSHING (with separate internal and
external keyways) — Insert the driven shaft key into the
driven shaft keyway. If the driven shaft has an
open-ended keyway, stake the keyway, Figure 3, to
prevent axial dislocation of the shaft key under operating
conditions. Slide the bushing assembly onto the driven
shaft. The bushing may have to be opened slightly to
assist in installation. Insert a screwdriver into the slot in
the bushing and very lightly pry open until the bushing
slides onto the shaft. Rotate the shaft so the external
keyway in the bushing is at the 12 o’clock position. Then
insert the drive key, furnished with the bushing, into the
keyway. Proceed to Step 6.
3. JSC(4407 only) — Remove the output cover from the input
side of the hollow shaft bore and save. Separate contents from
the drive shaft kit. Install thrust plate and retaining ring in the
hollow shaft, Figure 4. Insert key into drive shaft. Slide drive
shaft thru the seal housing into the hollow shaft and insert the
thrust plate fastener thru the thrust plate into the drive shaft.
Tighten fastener to 9500 lb-in. (1 073 Nm) Reinstall hollow
shaft cover. Continue outfitting based on the type of trough end
seal to be installed: (a) Waste Packing Seal; or (b) Lip Seal.
a) WASTE PACKING SEAL (Figure 5) — Pack seal housing
with waste packing and proceed to Step 4.
b) LIP SEAL (Figure 6) — Coat outside diameter of seal
with Permatex #3 or equivalent. Carefully slide seal over
drive shaft extension taking care to not damage the seal
lips. Drive seal into seal housing with the spring loaded
seal lip toward the trough end side of the seal housing,
flush with the seal housing. Proceed to Step 4.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 378-102
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : [phone] August 2004
Fax: [phone] e-mail: [email protected] web: www.falkcorp.com Supersedes 6-92
®
a good name in industry
Quadrive Shaft Mounted Drives •Owners Manual
Sizes 4407/M4407-4608/M4608 (Page 5 of 56)
THRUST
PLATE
RETAINING
RING KEY
SEAL HOUSING
HOLLOW SHAFT
Figure 4
Figure 3
DRIVE COVER
THRUST PLATE
RETAINING RING
THRUST PLATE
HOLLOW SHAFT
COVER
DRIVE SHAFT THRUST
PLATE FASTENER INSERT
DRIVE BASE
DRIVE SHAFT KEY
SEAL HOUSING
TROUGH END
TROUGH
END GASKET
TROUGH END
MOUNTING FASTENER
S
WASTE PACKING
DRIVE SHAFT
SEAL HOUSING FASTENERS
WITH LOCK WASHERS
Figure 5
DRIVE COVER
THRUST PLATE
RETAINING RING
THRUST PLATE
HOLLOW SHAFT
COVER
D
RIVE SHAFT THRUST
P
LATE FASTENER
INSERT
DRIVE BASE
DRIVE SHAFT KEY
SEAL HOUSING
TROUGH END
SEAL HOUSING FASTENERS
WITH LOCK WASHERS
TROUGH END
MOUNTING FASTENERS
LIP SEAL
DRIVE SHAFT
Figure 6
KEY
BUSHING
NUT
RETAINING
RING
BUSHING