Rexnord Falk A User manual

Table of Contents
Introduction ...................................2
Drive Identification ...............................3
SECTION I— DRIVE INSTALLATION
Outfitting ...................................4
Installation ...................................7
Lubrication ...................................9
Startup ...................................9
SECTION II — DRIVE SERVICE & REPAIR
Preventive Maintenance .......................... 10
Oil Changes ..................................10
Stored & Inactive Drives .......................... 10
Removal of Drive ...............................10
Drive Disassembly ..............................12
Identifying & Ordering Parts .......................14
Recommended Spare Parts ........................14
Parts List of Falk Part Numbers......................16
Bearing Cross Reference Numbers...................17
Seal Cross Reference Numbers .....................17
SECTION III — DRIVE REASSEMBLY
Drive Reassembly ...............................18
APPENDICES
Appendix A: Lubrication Recommendations............23
Appendix B: Backstop Installation ...................27
Appendix C: TA Removal Tool......................29
Appendix D: Motor Mount Installation ................31
Appendix E: Vertical Standpipe Installation............ 33
Appendix F: Modifications for Non-Standard
Mounting Positions ....................34
Appendix G: Retaining Rings for Bushing Nuts and Thrust
Plates, Tooth Combinations for Vibration Analysis
& JSC Lip Seal Accessory ...............36
Appendix H: Drive Shaft Recommendations for Tapered
Drive Shafts .........................37
Appendix J: Drive Shaft Recommendations Using
TA Taper Bushing..................... 38
Appendix K: Drive Shaft Recommendations Using (TCB) Kit 40
Appendix L: V-Belt Guard Installation ................42
Appendix M: Electric Fan Installation.................44
Rexnord Industries, LLC 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA (PN-2128394)378-200
Telephone: [phone] Fax: [phone] November 2010
e-mail: [e-mail] web: www.rexnord.com Supersedes 6-07
Falk™
Quadrive
Shaft Mounted Drives Model A
•
Owners Manual
Sizes 5107-5315 (Page 1of 44)

Introduction
WARRANTY — Rexnord Industries (the “Company”) warrants
that, for a period of three years from the date of shipment, the
product described herein will deliver successfully its rated output
as indicated on the nameplate, provided, it is properly installed
and maintained, correctly lubricated, and operated in the
environment and within the limits of speed, torque or other load
conditions for which it was sold. Such product is expressly not
warranted against failure or unsatisfactory operation resulting
from dynamic vibrations imposed 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 Rexnord Geared Products. 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 for the application. Refer
to the nameplate for drive size, ratio, and data.
FACTORY REPAIR AND REBUILD — Falk/Renew wants to
continue to be your primary supplier, and extend our service to you
if your equipment is in 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 Rexnord account executive or Rexnord-Falk
Distributor for more information.
Rexnord Industries, LLC 3001 W. Canal St., Milwaukee, WI 53208-4200 USA378-200 (PN-2128394)
Telephone: [phone] Fax: [phone]November 2010
e-mail: [e-mail] web: www.rexnord.comSupersedes 6-07
Owners Manual
•
Falk™
Quadrive
Shaft Mounted Drives Model A
(Page 2of 44) Sizes 5107-5315

Drive Identification
J is the basic drive identification. It can be outfitted for use as a shaft mounted drive JR; a flange mounted drive JF; or a screw
conveyor drive JSC, 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. The prefix “M” identifies a drive that features a nominal metric
high speed shaft.
Rexnord Industries, LLC 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA (PN-2128394)378-200
Telephone: [phone] Fax: [phone] November 2010
e-mail: [e-mail] web: www.rexnord.com Supersedes 6-07
Falk™
Quadrive
Shaft Mounted Drives Model A
•
Owners Manual
Sizes 5107-5315 (Page 3of 44)
5107 J25 A
Size (Series)
Maximum Bushing Bore (1 7/16")
Drive Type
Ratio (Nominal 25:1) Model
Basic “J”
(JR) Shaft Mounted Drive
1) Basic Drive
2) Torque Arm
3) TA Taper Bushing
(JSC) Screw Conveyor Drive
1) Basic Drive
2) Seal Housing
3) Drive Shaft
+ Motor Mounts
+ Backstops
+ Shaft Fans
(5215 thru 5315 only)
+ TA Removal Tool
+ Vertical Standpipe
+ Trough Ends
+ Thrust Plate Kits
+ V-Belt Guards
(JF ) Flange Mounted Drive
1) Basic Drive
TA Taper Bushing Optional
+ Electric Fans
(5307 & 5315 only)
NOTE: Use a TA-Taper bushing when mounting these drives on a straight driven shaft. (Hollow shaft is taper bored.)

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 basic 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 F, to determine modifications necessary within the
limits illustrated therein. DO NOT fill drive with lubricant at this
time. Oil plugs are located on input housing half.
2. JR — Remove anchor brackets, housing flange fasteners
and rod end fasteners from tie rod kit and assemble to
drive as illustrated in Figure 2. Refer to Table 1 for
tightening torque. (Original fasteners may be discarded).
3. 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. Shaft tolerances for the driven shaft are given in
Table 1A. The minimum and maximum driven shaft
engagements, dimension “N” in Figure 3, are shown in Table 2.
The minimum engagement is necessary for full bushing
engagement; the maximum engagement is only required if a
thrust plate will be employed to remove the drive from the driven
shaft (See Appendix C for preferred removal method).
Rexnord Industries, LLC 3001 W. Canal St., Milwaukee, WI 53208-4200 USA378-200 (PN-2128394)
Telephone: [phone] Fax: [phone]November 2010
e-mail: [e-mail] web: www.rexnord.comSupersedes 6-07
Owners Manual
•
Falk™
Quadrive
Shaft Mounted Drives Model A
(Page 4of 44) Sizes 5107-5315
12 O’CLOCK
D
L
F
F
L
D
3 O’CLOCK
F
L
D
6 O’CLOCK
F
L
D
9 O’CLOCK
REPOSITION PLUGS TO
SUIT REQ’D. MOUNTING
D = DRAIN
F = FILL & VENT
L = OIL LEVEL
(HIGHEST INPUT
SIDE PLUG)
SIZES 4203 THRU 4315
5:1 RATIO ONLY: LOCATE
AIR VENT ON OUTPUT SIDE
FOR 9 O’CLOCK MOUNTING
Figure 1 HORIZONTAL DRIVES
NMINIMUM SPACE REQUIRED
TO SPIN BUSHING NUT
DRIVEN
SHAFT
BEARING
SUPPORT
CLEVIS
BRACKET
TORQUE
ARM
MINIUM SPACE REQUIRED
FOR V-BELT CLEARANCE
SHEAVE
HIGH SPEED
SHAFT
HOLLOW
SHAFT
COVER
THRUST
PLATE
BORE
BUSHING
NUT
Figure 3
STANDPIPE &
VENTED DIPSTICK
FILL 1° MAX.
DRAIN DRAIN
OIL LEVEL
FILL VENT &
STANDPIPE
INPUT SHAFT UPINPUT SHAFT DOWN
+
–
VERTICAL DRIVES
10
MAX.
°
5°
MAX.
30 UP
(20° FOR
5315)
°
5 DOWN°
0° Incline down on drives
with backstop in 9 or 12
o'clock mounting position.
INCLINE ROTATION
5°
MAX.
10°
MAX.
(5107 & 5115) (5203 THRU 5315)
ANGULAR LIMITS FOR HORIZONTAL MOUNTING
(ALL CLOCK POSITIONS)
HOUSING FLANGE
FASTENERS
ANCHOR
BRACKET
TORQUE ARM
FASTENER
ALTERNATE
LOCATION
PREFERRED
LOCATION
5107 & 5115 5203 THRU 5315
Figure 2
TABLE 1 — Housing Flange Fastener Size and
Tightening Torque
(Non-Lubricated Fasteners)
DRIVE SIZE Fastener Size Tightening Torque lb-ft(Nm)
5107 .312-18 19(26)
5115 .312-18 19(26)
5203 .375-16 28(37)
5207 .500-13 69(94)
5215 .500-13 69(94)
5307 .500-13 69(94)
5315 .500-13 69(94)
TABLE 1A — Driven Shaft Tolerances H
Shaft Diameter - Inches Maximum Undersize - Inches
Upto1.500 .004
1.500- 2.500incl. .005
2.500- 4.000incl. .006
HMillimeters = h10 tolerance.

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 pried open
slightly). Insert the drive, key furnished with the bushing,
into the shaft keyway. Proceed to Step 7.
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 4, 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 pried open slightly). 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 7.
4. JSC — NOTE: See Appendix K for non-tapered drive
shafts. Remove the hollow shaft 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 5. When the drive is a Size 5107 and
will employ a 2.437”(61,9 mm) or 3.000” (76,2 mm)
diameter drive shaft, place the (2) gaskets and trough end
spacer, packaged separately, over the trough end surface
of the seal housing, Figure 6. Continue outfitting based on
the type of trough end seal to be installed: (a) Waste
Packing Seal; (b) Lip Seal or; (c) Packing Gland Seal.
a. WASTE PACKING SEAL (Figure 7) — Slide drive shaft
thru seal housing. Insert key into drive shaft and slide
drive shaft into hollow shaft. The seal housing registers
into the basic drive seal bore. Install the drive shaft thrust
plate fastener thru thrust plate and torque to the value
specified in Table 3. Use the seal housing fasteners to
secure the seal housing to the basic drive housing. Refer
to Table 4 for proper torque value. Reinstall hollow shaft
cover. Pack seal housing with waste packing and
proceed to Step 5.
Rexnord Industries, LLC 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA (PN-2128394)378-200
Telephone: [phone] Fax: [phone] November 2010
e-mail: [e-mail] web: www.rexnord.com Supersedes 6-07
Falk™
Quadrive
Shaft Mounted Drives Model A
•
Owners Manual
Sizes 5107-5315 (Page 5of 44)
TABLE 2 — N Dimension Inches (mm) H
DRIVE SIZE Minimum Maximum
5107 5.00(127) 7.19(183)
5115 5.55(141) 8.05(204)
5203 5.53(140) 7.78(198)
5207 6.11(155) 8.72(221)
5215 7.08(180) 10.15(258)
5307 7.39(188) 10.69(272)
5315 7.92(201) 10.74(273)
HThe minimum engagement is necessary for full bushing engagement; the
maximum engagement is only required if a thrust plate will be employed to
remove the drive from the driven shaft.
HThe minimum engagement is necessary for full bushing engagement; the
maximum engagement is only required if a thrust plate will be employed to
remove the drive from the driven shaft.
Figure 4
RETAINING
RING
THRUST
PLATE
HOLLOW
SHAFT
OUTPUT
SIDE
Figure 5
DRIVE SHAFT
DRIVE SHAFT
GASKET
TROUGH END
MECHANICAL LIP SEAL
TROUGH END SPACER
(SIZE 4107 WITH 2.437" (61,9 mm)
& 3.000" (76,2 mm) DRIVE SHAFTS ONLY)
Figure 6
TABLE 3 — JF & JSC Thrust Plate Fastener
Data (Non-Lubricated Fasteners)
DRIVE SIZE Fastener Size & Grade †Torque
lb-ft (Nm)
Min. Thread Depth
Inches (mm)
5107 .500-13UNCx3.25, GR.8 92(125) 2.00(50,8)
5115 .500-13UNCx3.25, GR.8 92(125) 2.00(50,8)
5203 .625-11UNCx3.50, GR.8 183(248) 2.00(50,8)
5207 .625-11UNCx3.50, GR.8 183(248) 2.00(50,8)
5215 .875-9UNCx 3.50,GR.8 533(723) 2.50(63,5)
5307 1.00-8UNCx4.00.GR.5 ‡567(769) 2.75(69,8)
5315 1.00-8UNC x 4.00.GR.8 792 (1074) 2.75(69,8)
†Fastener lengths given are for applications using tapered drive shafts. Other
lengths may be needed for applications using tapered bushings.
‡1.00-8UNC x 3.50, GR. 5 for 5307JF.

b. LIP SEAL (Figure 8) — Coat outside diameter of seal
with Permatex #3 or equivalent. Drive seal into seal
housing with the spring loaded seal lip away from the
driver. Wrap the keyway on tapered shank of drive shaft
with masking tape or light weight Kraft paper to protect
against damaging the seal lips. Coat the seal lips and
straight portion of the drive shaft with bearing grease.
Line up the keyway in the drive shaft with the hollow shaft
keyway and insert the drive shaft into the seal housing.
Remove the protective wrap and install the drive shaft
key. Insert the drive shaft into the hollow shaft. The seal
housing registers into the basic drive seal bore. Use the
thrust plate fastener Figure 7, to secure the drive shaft.
Refer to Table 3 for proper torque value. Install the seal
housing fasteners to secure the seal housing to the basic
drive. Refer to Table 4 for proper torque value. Reinstall
hollow shaft cover and proceed to Step 5.
c. PACKING GLAND SEAL (Figure 10) — First, wrap the
packing around the drive shaft adjacent to the tapered
portion of the drive shaft as shown in Figure 9. Cut the
packing to produce two complete split seal rings.
CAUTION: Do not mar the shaft’s seal surface.
Rexnord Industries, LLC 3001 W. Canal St., Milwaukee, WI 53208-4200 USA378-200 (PN-2128394)
Telephone: [phone] Fax: [phone]November 2010
e-mail: [e-mail] web: www.rexnord.comSupersedes 6-07
Owners Manual
•
Falk™
Quadrive
Shaft Mounted Drives Model A
(Page 6of 44) Sizes 5107-5315
TROUGH END
TROUGH END
MOUNTING FASTENERS
WASTE PACKING
DRIVE SHAFT
TROUGH END GASKET
SEAL HOUSING
INSERT
SEAL HOUSING FASTENERS
WITH LOCKWASHERS
BASIC DRIVE
DRIVE SHAFT KEY
HOLLOW SHAFT COVER
THRUST PLATE
RETAINING RING
THRUST PLATE
DRIVE SHAFT THRUST
PLATE FASTENER
Figure 7
TABLE 4 — Seal Housing & Trough End Fastener
Size – UNC & Tightening Torque –
(Non-Lubricated Fasteners)
Fastener
Location
DRIVE SIZE
5107 5115 5203 5207 5215 5307 5315
Seal Housing
Fasteners
lb-ft (Nm)
.500-13
69 (94) .625-11 137(186) .750-10 245(332) .875-9 380(515) 1.000-8 567(769) 1.000-8 792(1074) 1.000-8 792(1074)
Trough End
Fasteners
lb-ft (Nm)
1.500"Diameter DriveShaft
.500-13Fasteners
69 (94)
2.000" & 2.437" Diameter Drive Shafts
.625-11FastenerswithNuts —137(186)
3.000" & 3.437" Diameter Drive Shafts
.750-10FastenerswithNuts —245(332)
TROUGH END
TROUGH END
MOUNTING FASTENERS
TROUGH END GASKET
SEAL HOUSING
DRIVE SHAFT INSERT
MECHANICAL LIP SEAL
TROUGH END SPACER
(SIZE 5107 WITH 2.437" &
3.000" DRIVE SHAFTS ONLY
TROUGH END GASKETS
(SIZE 5107 WITH 2.437" &
3.000" DRIVE SHAFTS ONLY
Figure 8 PACKING GLAND RING
AFTER CUTTING
(TWO REQUIRED)
SHAFT
BUTT JOINT
PACKING GLAND ROPE
CUT
Figure 9
PACKING GLAND (TWO RINGS)
DRIVE SHAFT
TROUGH END
COMPRESSION RING
INSERT
COMPRESSION RING
FASTENER WITH
FLAT WASHER
Figure 10

Remove packing rings from the drive shaft and slide the
drive shaft through the seal housing. Install seal rings into
the seal housing. Stagger the seal joints approximately 90°
apart. Slip the compression ring into place. Use fasteners
with flat washers to hold the ring but DO NOT tighten at
this time. Install key in the drive shaft keyway and then
install the drive shaft into the hollow shaft. Use the thrust
plate fastener, Figure 7, to secure the drive shaft. Refer to
Table 3 for torque value. Use the seal housing fasteners to
secure the seal housing to the basic drive. Refer to Table 4
for the torque value. Reinstall the hollow shaft cover. To
adjust packing seal, rotate input shaft to test the
resistance. Tighten the compression ring fasteners evenly
until an additional resistance can be detected when the
high speed shaft is rotated. DO NOT OVERTIGHTEN -
this can cause premature seal wear and possible
overheating. Proceed to Step 5.
5. JSC — Fasten the trough end to the seal housing using the
hex head cap screws included in the drive shaft kit. Refer to
Table 4 for torque value. Proceed to Step 7.
6. JF — Install backstops prior to installation of the drive
(Refer to Appendix B). If an adapter flange is provided,
assemble it to the drive using fasteners provided with the
flange. Refer to Table 5 for fastener selection and torque
value. Remove the input side hollow shaft cover. The
standard method for connecting a flange mounted drive to
the driven shaft is to prepare the driven shaft per Appendix
H and mount the drive to the tapered shaft using a thrust
plate kit with fastener as shown in Table 3. An optional
method of connection should be used when replacing
existing drives with special shafts or when producing
tapered shafts is impractical. This optional method uses a
TA tapered bushing as outlined in Appendix J.
Installation
7. JR, JF & JSC — Refer to Figure 11 for recommended lifting
method. In order to sling JR & JF as illustrated, remove a
housing flange fastener and install a long fastener with nut. For
vertical installation, use (3) eye bolts as illustrated. Eyebolt sizes
are 5/16" for 5107 and 5115, 3/8" for 5203 and 1/2" for
5207 thru 5315. DO NOT remove sling until drive is secured
to shaft. Before lifting the drive into position, rotate the high
speed shaft until the hollow shaft keyway will be in position to
line-up with the driven shaft key. JF proceed to Step 12; JSC to
Step 13.
8. JR — If the drive was received with a backstop installed,
the backstop must be temporarily removed to facilitate
mounting.
Refer to Section II, Figure 19 and remove cover Ref.
#16 and backstop Ref. #5A1.
9. JR — Lift the drive into position and slide onto the drive
shaft taking care that the driven shaft key seats into the
hollow shaft keyway. DO NOT hammer or use excessive
force. Refer to Figure 12 for installation of the torque arm.
The exact position of the tie rod may vary within the range
shown. For torque arm mountings other than shown, refer
to Falk. If it is necessary to shorten the torque arm, cut the
excess from either threaded end.
The support to which the clevis bracket is to be fastened must
sustain the torque reaction shown in Table 8. The maximum
load reaction through the torque arm occurs when the
torque arm is located in the extreme (30°) off angle position.
Use Grade 5 fasteners to anchor the clevis bracket; see
Table 7 for the fastener diameter and tightening torque.
Bolt the tie rod to both the clevis bracket and the drive
anchor bracket and tighten the bolts until seated against the
brackets. DO NOT bend the bracket as clearance between
the clevis brackets and tie rod is necessary.
Rexnord Industries, LLC 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA (PN-2128394)378-200
Telephone: [phone] Fax: [phone] November 2010
e-mail: [e-mail] web: www.rexnord.com Supersedes 6-07
Falk™
Quadrive
Shaft Mounted Drives Model A
•
Owners Manual
Sizes 5107-5315 (Page 7of 44)
TABLE 5 — Flange Mounted Drive – Foundation
Fastener Size & Tightening Torque
(Non-Lubricated Fasteners)
DRIVE
SIZE Fastener Size and Grade Torque lb-ft (Nm)
Min Fastener
Engagement
Into Drive
Housing
Inches (mm)
5107 .500-13UNC,GR.5 69(94) .76 (19,3)
5115 .625-11UNC,GR.5 137 (186) .94 (23,9)
5203 .750-10UNC,GR.5 245 (332) .76 (19,3)
5207 .875-9UNC,GR.5 380 (515) .88 (22,4)
5215 1.000-8UNC,GR.5 567 (769) 1.00(25,4)
5307 1.000-8UNC,GR.8 792 (1074) 1.24(31,5)
5315 1.000-8UNC,GR.8 792 (1074) 1.24(31,5)
SLING FROM
LONG FASTENER
WITH NUT
SLING AROUND
SEAL HOUSING
AND INPUT SHAFT
Figure 11
SLING FROM
EYEBOLTS

10. JR — Thread the bushing nut onto the 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 THE TAPERED SURFACE OF
THE BUSHING AND HOLLOW SHAFT BORE FREE FROM
ALL ANTI-SEIZE OR LUBRICATING COMPOUNDS.
WARNING: Overtightening can fail the internal retaining
ring. (See Appendix G, for listing of retaining rings).
a. PREFERRED METHOD — Apply Loctite 243 or
equivalent to threads of setscrew. Tighten the setscrew on
the bushing nut to torque value indicated in Table 6A.
b. ALTERNATE METHOD — (To be used when torque
cannot be measured.) Use a spanner (Table 6), chain or
pipe wrench to tighten the bushing nut just until the drive
can no longer be moved by hand axially on the driven
shaft. Loosen nut ONLY until it can be turned by hand but
do not unseat the taper. Retighten the nut hand tight. Now
mark a spot on the top of the driven shaft. Next mark a
spot on the bushing nut 180° from the driven shaft mark
(90° CCW for Sizes 5107 & 5115). Use the spanner
wrench to tighten the nut CW one half turn until the two
marks are aligned (one quarter turn for Sizes 5107 &
5115). Apply Loctite 243 or equivalent to threads of
setscrew. Tighten the setscrew on the bushing nut to torque
value indicated in Table 6A.
11. JR — Install backstop, motor mount, motor, sheaves
(mount sheaves as close to the drive and motor housing as
possible), belts and guard. Refer to Appendix D for motor
mount installation instructions. Proceed to Step 14.
12. JF (USING TAPERED DRIVE SHAFT) — Put key into the
driven shaft. Lift drive into position and slide onto the
driven shaft taking care that the driven shaft key seats into
the hollow shaft keyway. DO NOT hammer or use
excessive force. Secure the drive to the shaft with the thrust
plate fastener. Refer to Table 3 for torque value. Reinstall
the hollow shaft cover. Install motor mount, motor,
sheaves, belts and guard. Refer to Appendix D for motor
mount installation instructions. Proceed to Step 15.
13. JSC — Assemble drive to trough and install drive shaft
Rexnord Industries, LLC 3001 W. Canal St., Milwaukee, WI 53208-4200 USA378-200 (PN-2128394)
Telephone: [phone] Fax: [phone]November 2010
e-mail: [e-mail] web: www.rexnord.comSupersedes 6-07
Owners Manual
•
Falk™
Quadrive
Shaft Mounted Drives Model A
(Page 8of 44) Sizes 5107-5315
2°2°
TORQUE ARM
FASTENER
HIGH
SPEED
SHAFT
HOUSING FLANGE
FASTENERS
CLEVIS
BRACKET
ANCHOR BRACKET
5107 & 5115
TABLE 6 — Spanner Wrench Type & Spanner
Nut Tightening Torque
DRIVE
SIZE
Adjustable Hook Spanner Wrench Spanner Nut
Tightening Torque
lb-ft (Nm)
Armstrong Tools Williams
5107 34-307(2"-4¾”) 474 83(113)
5115 34-307(2"-4¾”) 474 83(113)
5203 34-307(2"-4¾”) 474 167 (226)
5207 34-310(4 ½"-6¼”) 474A 167 (226)
5215 34-310(4 ½"-6¼”) 474A 250 (339)
5307 34-310(4 ½"-6¼”) 474A 250 (339)
5315 34-313(61/8"-8 ¾”) 474B 250 (339)
TABLE 7 — Torque Arm Clevis Bracket
Fastener Tightening Torque
DRIVE
SIZE FastenerH Size
Tightening Torque — lb-ft (Nm)
Steel Foundation Concrete Foundation
5107 .375-16UNC 28(38) 21(28)
5115 .375-16UNC 28(38) 21(28)
5203 .500-13UNC 69(94) 53(72)
5207 .500-13UNC 69(94) 53(72)
5215 .625-11UNC 137 (186) 107 (145)
5307 .750-10UNC 245 (332) 191 (259)
5315 1.000-8UNC 567 (769) 467 (633)
HGrade 5 fasteners required.
TABLE 8 — Load Reaction Through Torque
Arm
DRIVE
SIZE 5107 5115 5203 5207 5215 5307 5315
Load
lb (N) †2440 (10850) 3810 (16940) 4680 (20810) 6250 (27790) 9160 (40720) 12963 (57660) 15890 (70700)
†Load includes moment due to motor and motor mount with torque arm at
maximum angle.
2°
HIGH
SPEED
SHAFT
ANCHOR
BRACKET
TORQUE ARM
FASTENER
5203 THRU 5315
PREFERRED MOUNTING CLEVIS
BRACKET
2°
HIGH
SPEED
SHAFT
ANCHOR
BRACKET
TORQUE ARM
FASTENER
5203 THRU 5315
ALTERNATE MOUNTING
CLEVIS
BRACKET
Figure 12
TABLE 6A — Bushing Nut Setscrew
Tightening Torque
DRIVE SIZE Setscrew Size Tightening Torque
lb-ft(Nm)
5107 .250-20 5(7)
5115-5207 .312-18 11(15)
5215-5315 .375-16 19(26)

coupling bolts per screw conveyor manufacturer’s
instructions. Install motor mount, motor, sheaves, belts
and guard. Refer to Appendix D for motor mount
installation instructions. Proceed to Step 15.
14. JR — When the torque arm turnbuckle is used for belt
tension adjustment, position the motor so that the belt pull
will be about 90° to a line through the drive high speed
shaft and hollow shaft as shown in Figure 13. For drives
where the motor is moved to adjust belt tension, mount
the motor slide base so that the belt tension adjustment is
approximately parallel to the belt centers. Refer to
Appendix D, for instructions relative to alignment of
sheaves and belts.
Lubrication
CAUTION: Drives shipped without oil.
15. JR, JF & JSC— Refer to Appendix A for selection of
lubricant. Refer to Table 9 at right for approximate oil
capacity of drives.
16. JR, JF & JSC — HORIZONTAL MOUNTING
Remove air vent and oil level plug (Refer to Step 1). Fill the
drive until oil shows in the oil level hole. Coat the air vent
and plug threads with #3 Permatex or equivalent thread
sealant before replacing.
JRV, JFV & JSCV — (VERTICAL MOUNTING) - Refer to
Figure 1, Step 1.
Input Shaft DOWN — Remove the fill plug and fill with
oil to level marked on the dipstick.
Input Shaft UP — Remove the oil level and fill plugs
and fill until oil shows in the oil level hole.
Coat the plug threads with #3 Permatex or equivalent
thread sealant before replacing.
17. JR, JF & JSC — Where applicable, pump grease into the
high speed shaft seal cover WITH A HAND GREASE
GUN, Figure 14, until fresh grease flows out along the
shaft. Wipe off excess grease from the shaft. DO NOT use
grease where it could contaminate the product e.g. foods,
drugs, etc.
Start Up
18. JR, JF & JSC — Before operating the drive, check any
fasteners, pipe plugs, air vent, etc. which may have been
loosened in the course of Outfitting, Installing and Lubricating
the drive, to be sure that they have been properly retightened.
If a long fastener was used to lift the drive into place, reinstall
the housing flange fastener and torque to the value shown in
Table 1. After one week of operation repeat check of all
external fasteners and pipe plugs.
19. AFTER ONE MONTH OF OPERATION:
a. Operate the drive until the sump oil reaches normal
operating temperature. Shut the drive down and
drain immediately.
b. Immediately flush the drive with an oil of the same type
and viscosity grade as the original charge (warmed to
approximately 100°F[38°C] in cold weather). Rapidly
pour or pump a charge equal to 25-100% of the initial
fill thru the drive, or until clean oil flows thru the drain.
c. Close the drain and refill the drive to the correct level
with new or reclaimed oil of the correct type and
viscosity. If determined to be in good condition by the
supplier, drain oil may be reused if it is filtered thru a
100 micron or finer filter.
Rexnord Industries, LLC 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA (PN-2128394)378-200
Telephone: [phone] Fax: [phone] November 2010
e-mail: [e-mail] web: www.rexnord.com Supersedes 6-07
Falk™
Quadrive
Shaft Mounted Drives Model A
•
Owners Manual
Sizes 5107-5315 (Page 9of 44)
BELT TENSION ADJUSTED
WITH TORQUE ARM
Figure 13
BELT TENSION ADJUSTED
WITH MOVABLE MOTOR
PARALLEL
HIGH SPEED SHAFT
Figure 14
TABLE 9 — Approximate Oil Capacity –
Quarts (Liters) H
DRIVE SIZE JR, JF & JSC JRV & JFV
5107 2(1,9) 3(2,8)
5115 3(2,8) 4.5 (4,3)
5203 3.5 (3,3) 5(4,7)
5207 5.5 (5,2) 7.5 (7,1)
5215 9(8,5) 13(12,3)
5307 13(12,3) 18(17)
5315 15(14,2) 21(19,9)
HQuantities are approximate. Always fill drive to specified level.

Section II
Drive Service & Repair
Preventive Maintenance
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 specified level, have the oil
analyzed for water content. Moisture in the oil may indicate seal
leakage or condensation. If so, correct the defect immediately
and change the oil. DO NOT overfill or oil leakage may result.
If a drive is equipped with a fan, periodically clean accumulated
foreign matter from the fan and fan guard to allow adequate air
flow.
GREASE PURGED SEALS — Periodically (at least every six
months), depending upon the frequency and degree of
contamination, purge contaminated grease from seal by slowly
pumping fresh bearing grease through the seal cage, WITH A
HAND GREASE GUN, until fresh grease flows out along the
shaft. Wipe off the purged grease. Refer to Appendix A.
PACKING GLAND SEAL — Section I, Step 4(C)
Oil Changes
PETROLEUM LUBRICANTS — For normal operating
conditions, change gear oil every six months or 2500 operating
hours, whichever occurs first. If the drive is operated in an area
where temperatures vary with the seasons, change the oil
viscosity grade to suit the temperature. Where applicable,
grease seals when changing oil. Refer to Appendix A.
SYNTHETIC LUBRICANTS — Synthetic lube change intervals
can be extended to 8000-10,000 hours depending on
operating temperatures and lubricant contamination.
Laboratory analysis is recommended for optimum lubricant life
and drive performance. Change lube with changes in ambient
temperature, if required. Refer to Appendix A.
Stored & Inactive Drives
NEW DRIVES WHICH HAVE NOT BEEN OPERATED — Each
drive is spin tested with a rust preventive oil that will protect
internal parts against rust for a period of 4 months in an
outdoor shelter or 12 months in a dry building after shipment
from the Factory.
If a drive is to be stored or inactive beyond the above periods,
spray all internal parts with a rust preventive oil that is soluble in
lubricating oil or add 1 ounce (23,35 grams) of “Motorstor H”
vapor phase rust inhibitor oil. Seal air vent immediately with
pressure sensitive tape.
Before operating drives which have been stored or inactive,
remove tape and fill to the proper level with oil meeting
specifications given in the Lubrication Recommendation found
in Appendix A.
HProduct of the Daubert Chemical Company, Chicago, Illinois.(Formerly
known as “Nucel Oil.”)
SHUTDOWN OF NEW OR EXISTING DRIVES WHICH
HAVE BEEN OPERATED — If a drive is to be stored or inactive
for more than 2 months after a period of operation, add 1
ounce (23,35 grams) of “Motorstor” to the oil sump and
immediately seal the air vent with pressure sensitive tape. It is
not necessary to drain the oil prior to storage if oil is still
serviceable and not contaminated.
Before operating drive, remove tape and check oil level.
PERIODICALLY INSPECT STORED OR INACTIVE DRIVES AND
SPRAY OR ADD RUST INHIBITOR EVERY SIX MONTHS, OR
MORE OFTEN IF NECESSARY. INDOOR DRY STORAGE IS
RECOMMENDED.
Drives Ordered for Extended Storage can be treated at the
Factory with a special preservative and sealed to rust-proof
parts for periods longer than those stated above, if specified on
the order.
Repair & Replacement
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.
NOTE: Only the seals on the input side of the drive can be
replaced without removing the drive from the driven equipment.
All other repairs require removal of the drive from the driven
equipment. Proceed to Step 1 for drive removal. Proceed to
Step 5 for replacement of seals.
Removal (See above note for seal replacement only)
1. JR, JF & JSC — Drain the lubricant at this time. Remove
safety guards and belts (motor and motor mount, optional).
Remove backstop (if so equipped). Refer to Section II, Step
10, for backstop removal instructions.
WARNING: Drive must be supported during removal process.
Use a sling around the motor mount or as recommended in
Section I, Step 7. Take up the slack in the sling before
proceeding.
Rexnord Industries, LLC 3001 W. Canal St., Milwaukee, WI 53208-4200 USA378-200 (PN-2128394)
Telephone: [phone] Fax: [phone]November 2010
e-mail: [e-mail] web: www.rexnord.comSupersedes 6-07
Owners Manual
•
Falk™
Quadrive
Shaft Mounted Drives Model A
(Page 10 of 44) Sizes 5107-5315