Rexnord Falk Quadrive A Series User manual

Rexnord 378-206
3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019
Telephone: [phone] Fax: [phone] www.rexnord.com Supersedes 07-15
(PN-212395)
Falk®Quadrive®Shaft-Mounted Drives Model A •Owners Manual
Sizes 5407-5608 (Page 1 of 53)
TABLE OF CONTENTS
Introduction ....................................2
Drive Identification ...............................3
Section I — Drive Installation
Outfitting.......................................4
Installation .....................................6
Lubrication .....................................8
Start Up .......................................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 ....................15
Bearing Cross Reference Numbers .................16
Seal Cross Reference Numbers....................16
Section III — Drive Reassembly
Drive Reassembly............................ 17-20
Appendix
Appendix A: Lubrication Recommendations...... 22-29
Appendix B: Backstop Installation ............. 30-33
Appendix C: TA Removal Tool ................. 34-35
Appendix D: Motor Mount Installation ........... 36-37
Appendix E: Vertical Standpipe Installation ...... 38-39
Appendix F: Modifications for Non-Standard
Mounting Positions ............... 40-41
Appendix G: Retaining Rings for Bushing Nuts and
Thrust Plates & Tooth Combinations For ...
Vibrations Analysis ..................42
Appendix H: Drive Shaft Recommendations for
Tapered Drive Shafts ................43
Appendix J: Drive Shaft Recommendations
Using TA Taper®Bushing.......... 44-45
Appendix K: Drive Shaft Recommendations
Using (TCB) Kit.................. 46-47
Appendix L: V-Belt Guard Installation........... 48-49
Appendix M: Electric Fan Installation............ 50-51
Appendix N: Reliability Package ............... 52-53

378-206 Rexnord
January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 07-15 Telephone: [phone] Fax: [phone] www.rexnord.com
(PN-212395)
Owners Manual •Falk Quadrive Shaft-Mounted Drives Model A
(Page 2 of 53) Sizes 5407-5608
INTRODUCTION
WARRANTY — Rexnord (the ”Company”) warrants
that Quadrive Shaft Mounted gear drives (I) conform to
Company’s published specifications, and (II) are free
from defects of material for three years from the date of
shipment.
Company does not warrant any non-Company branded
products or components (manufacturer’s warranty applies)
or any defects in , damage to, or failure of products
caused by: (I) dynamic vibrations imposed by the drive
system in which such products are installed unless the
nature of such vibrations has been defined and accepted
in writing by Company as a condition of operation; (II)
failure to provide suitable installation environment; (III)
use for purposes other than those for which designed, or
other abuse or misuse; (IV) unauthorized attachments,
modifications or disassembly, or (V) mishandling during
shipping.
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. 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 — Rexnord wants to
continue to be your primary supplier, and we extend our
service to you if your equipment is in the need of repair or
replacement.
We are able to furnish a fast turnaround on both the
quotation and rebuild. Nobody can do the job better than
Rexnord. If you need repair on Rexnord products, just ask.
Contact your local Rexnord account executive or Rexnord
distributor for more information.

Rexnord 378-206
3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019
Telephone: [phone] Fax: [phone] www.rexnord.com Supersedes 07-15
(PN-212395)
Falk Quadrive Shaft-Mounted Drives Model A •Owners Manual
Sizes 5407-5608 (Page 3 of 53)
Drive Identification
5 407 J 25 A
Size (Series)
Maximum Bushing Bore (4 7/16”)
Drive Type
Ratio (Nominal 25:1)
Model
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 5407 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.
(JR) Shaft-Mounted Drive
1) Drive
2) Torque Arm
3) TA Taper Bushing
(JF) Flange Mounted Drive
1) Drive With Flange
TA Taper Bushing Optional
(JSC) Screw Conveyor Drive (size 5407 only)
1) Drive With Seal Housing
2) Drive Shaft
+ Motor Mounts
+ Backstops
+ Shaft Cooling Fans
+ Electric Cooling Fans
+ Vertical Standpipe
+ Trough Ends
+ Thrust Plate Kits
+ V-Belt Guards
+ TA Removal Tool
NOTE: Use a TA Taper bushing when mounting these drives on a straight driven shaft (hollow shaft is taper bored).

378-206 Rexnord
January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 07-15 Telephone: [phone] Fax: [phone] www.rexnord.com
(PN-212395)
Owners Manual •Falk Quadrive Shaft-Mounted Drives Model A
(Page 4 of 53) Sizes 5407-5608
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 F,
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. Shaft tolerances
for driven shafts are shown in Table 1. The minimum
and maximum driven shaft engagements, dimension
N in Figure 2, 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).
F
L
REPOSITION PLUGS TO
SUIT REQ’D. MOUNTING
D = DRAIN
F = FILL & VENT
L = OIL LEVEL
(HIGHEST
SIDE PLUG)
F
L
D
3 O’CLOCK
6 O’CLOCK
L
F
D
9 O’CLOCK
D
L
FD
12 O’CLOCK
Figure 1 HORIZONTAL DRIVES
STANDPIPE &
VENTED DIPSTICK
FILL
STANDPIPE &
VENTED DIPSTICK
FILL
DRAIN
INPUT SHAFT UP
INPUT SHAFT DOWN
DRAIN
MAX.
±1°
VERTICAL DRIVES
ANGULAR LIMITS FOR HORIZONTAL MOUNTING
(ALL CLOCK POSITONS)
INCLINE ROTATION
5507 & 5608 - 5° INCLINE
ON DRIVES WITH BACKSTOPS
IN ALL MOUNTING POSITIONS

5407 & 5415 - 0° INCLINE DOWN ON
DRIVES WITH BACKSTOPS IN 9 OR 12
O’CLOCK MOUNTING POSITIONS

20° UP
MAX.
5° DOWN
MAX.


±10° MAX.
Table 1 — Driven Shaft Tolerances 
Shaft Diameter — Inches Max Undersize
(Inches)
Over Thru
2.500 4.000 .006
4.000 6.000 .007
6.000 7.000 .008
cMillimeters - h10 tolerance.
MIN. SPACE
REQUIRED FOR
V-BELT CLEARANCE
NMIN. SPACE
REQUIRED TO SPIN
BUSHING UNIT
BUSHING NUT
DRIVEN SHAFT
BEARING
SUPPORT
SHEAVE
INPUT
SHAFT
THRUST
PLATE
BORE
Figure 2
Table 2 — N Dimension 
Drive Size Minimum
Inches (mm)
Maximum
Inches (mm)
5407 8.38 (213) 12.40 (314)
5415 10.33 (263) 13.44 (341)
5507 10.66 (271) 14.53 (369)
5608 12.75 (324) 16.35 (415)
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.

Rexnord 378-206
3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019
Telephone: [phone] Fax: [phone] www.rexnord.com Supersedes 07-15
(PN-212395)
Falk Quadrive Shaft-Mounted Drives Model A •Owners Manual
Sizes 5407-5608 (Page 5 of 53)
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.
BUSHING
NUT
RETAINING
RING
BUSHING
KEY
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. Insert the drive
key, furnished with the bushing, into the keyway.
Proceed to Step 6.
SEAL HOUSING
HOLLOW SHAFT
KEY
RETAINING
RING
THRUST
PLATE
Figure 3
Figure 4
3. JSC (5407 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 792 lb-ft (1073 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.
DRIVE COVER
DRIVE BASE
DRIVE SHAFT KEY
SEAL HOUSING
HOLLOW SHAFT
COVER
DRIVE SHAFT THRUST
PLATE FASTENER
THRUST PLATE
THRUST PLATE
RETAINING RING
INSERT
TROUGH END
TROUGH
END GASKET
SEAL HOUSING FASTENERS
WITH LOCK WASHERS
TROUGH END
MOUNTING FASTENERS
WASTE PACKING
DRIVE SHAFT
Figure 5
b. LIP SEAL (Figure 6) — Coat outside diameter of
seal with Permatex #3 or equivalent. Coat the seal
lips with bearing grease. 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.
DRIVE COVER
DRIVE BASE
DRIVE SHAFT KEY
SEAL HOUSING
THRUST PLATE
RETAINING RING
THRUST PLATE
HOLLOW SHAFT
COVER
DRIVE SHAFT THRUST
PLATE FASTENER
INSERT
TROUGH END
SEAL HOUSING FASTENERS
WITH LOCK WASHERS
TROUGH END
MOUNTING FASTENERS
LIP SEAL
DRIVE SHAFT
Figure 6

378-206 Rexnord
January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 07-15 Telephone: [phone] Fax: [phone] www.rexnord.com
(PN-212395)
Owners Manual •Falk Quadrive Shaft-Mounted Drives Model A
(Page 6 of 53) Sizes 5407-5608
4. JSC — Fasten the trough end to the seal housing using
the hex head cap screws included in the drive shaft kit.
Refer to Table 3 for torque value. Proceed to Step 6.
Table 3 — 5407JSC Trough End Fastener
Size & Tightening Torque
(Non-lubricated Fasteners)
Drive Shaft Diameter 3.000 & 3.437
Fastener Size .750-10UNC
Tightening Torque, lb-ft (Nm) 245 (332)
5. JF — (NOTE: If the driven shaft has not been machined
to Falk’s taper bore specifications per Manual 377-140
and a straight shaft is to be utilized, refer to Manual
377-144 for instructions).
Install backstop prior to installation of drive (refer to
Appendix B). Installation of internal backstops NOT
Factory-installed may require removal of mounting
flange, Ref. #12. Remove cover from input end of hollow
shaft bore and save. Install the thrust plate and retaining
ring in the hollow shaft (refer to Figure 4). Proceed to
Step 6.
INSTALLATION
6. JR, JF & JSC — Refer to Figure 7 for recommended
lifting method. In order to sling JR & JF drives as
illustrated, install the torque arm fastener in the torque
arm anchor brackets. Sling the drive from the fastener
as shown. For vertical installation, use (3) eyebolts as
illustrated. Eyebolt sizes are 1/2” for 5407 thru 5507
and 3/4” for 5608. 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 11; JSC to Step 12.
SLING FROM
LONG FASTENER
WITH NUT
SLING AROUNG
SEAL HOUSING
AND INPUT SHAFT
Figure 7
7. JR — If the drive was received with a backstop
installed, the backstop must be temporarily removed
to facilitate mounting. Refer to Section II, Step 10 for
backstop removal instructions. Proceed to Step 8.
8. 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 8 for installation of the torque arm.
The exact position of the torque arm may vary within
the range shown. For torque arm mountings other than
shown, refer to Factory. If it is necessary to shorten the
torque arm assembly, cut the excess from either tie rod
end.
The support to which the clevis bracket is to be
fastened must sustain the torque reaction shown
in Table 4. The maximum load reaction through the
torque arm occurs when the torque arm is located in
the extreme off angle position. Use Grade 5 fasteners
to anchor the clevis bracket; refer to Table 5 for the
fastener size and tightening torque.
Bolt the torque arm 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.
A
A
2°
2°
CLEVIS
BRACKET
TIE ROD
AND
TURNBUCKLE
Figure 8 — Torque Arm Mounting Positions
6 O’Clock Mounting Position Shown
Drive Size A
5407-5507 30°
5608 25°
Table 5 — Tie Rod Clevis Bracket Fastener
Tightening Torque
Drive
Size
Fastener 
Size
Tightening Torque — lb-ft (Nm)
Steel
Foundation
Concrete
Foundation
5407 1.000-8UNC 567 (768) 467 (633)
5415 1.250-7UNC 1050 (1424) 867 (1175)
5507 1.250-7UNC 1050 (1424) 867 (1175)
5608 1.250-7UNC 1050 (1424) 867 (1175)
Grade 5 fasteners required.
Table 4 — Load Reaction Through Tie Rod
Drive Size 5407 5415 5507 5608
Load , lb 21840 26120 32940 40930
Load , (N) (97130) (116170) (146500) (182060)
cLoad includes moment due to motor and motor mount with torque arm at
maximum angle.

Rexnord 378-206
3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019
Telephone: [phone] Fax: [phone] www.rexnord.com Supersedes 07-15
(PN-212395)
Falk Quadrive Shaft-Mounted Drives Model A •Owners Manual
Sizes 5407-5608 (Page 7 of 53)
9. 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, re-coat the nut threads only with an anti-seize
compound.
NOTE: In extremely severe or corrosive environments,
additional anti-seize compound MUST be applied to the
threads of the TA bushing nut.
WARNING: DO NOT apply anti-seize or lubricant
to bushing or shaft surfaces. Use of anti-seize may
prevent secure connection of the drive to the shaft and
cause the drive to move.
WARNING: Overtightening can fail the internal retaining
ring. (See Appendix G, for listing of retaining rings).
DO NOT apply ANTI-SEIZE
on these areas.
a. PREFERRED METHOD — Use a spanner, chain
or pipe wrench to tighten the bushing nut to the
torque value indicated in Table 6. Apply Loctite
243 or equivalent to threads of setscrews. Tighten
the setscrew on the bushing nut to 19 lb-ft (26 Nm)
torque.
b. ALTERNATE METHOD (TO BE USED WHEN
EXACT TORQUE CAN NOT 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 bushing nut. Next mark a
spot on the driven shaft 180° from the first mark. Use
the spanner wrench to tighten the nut until the two
marks are aligned i.e., one half turn. Apply Loctite
243 or equivalent to threads of setscrews. Tighten
the setscrew on the bushing nut to 19 lb-ft (26 Nm)
torque.
Table 6 — Spanner Wrench Type & Spanner
Nut Tightening Torque
Drive
Size
Adjustable Hook Spanner Wrench Spanner Nut
Tightening Torque
lb-ft (Nm)
GearWrench Williams
5407 81858 (6-1/8" to 8-3/4") 474B 333 (452)
5415 81858 (6-1/8" to 8-3/4") 474B 333 (452)
Ridgid Tool Williams
5507 92685  (2" to 12") CT-15 400 (542)
5608 92685  (2" to 12") CT-15 400 (542)
cThese are chain wrenches where standard spanner wrenches are not
available.
10. 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 13.
11. 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 foundation
with fasteners using torque values shown in Table 7.
Next, secure the drive to the shaft with the thrust plate
fastener. Refer to Table 8 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 14.
12. JSC (5407 ONLY) — Assemble drive to trough and
install drive shaft 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 14.
13. 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 input
shaft and hollow shaft as shown in Figure 9. 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. Proceed to Step 14.
Table 7 — JF & JSC Drives – Foundation
Fastener & Tightening Torques
(Non-Lubricated Fasteners)
Drive Size Fastener Size & Grade Torque lb-ft (Nm)
5407 .750-10UNC, Gr. 5 245 (323)
5415 1.250-7UNC, Gr. 5 1050 (1424)
5507 1.250-7UNC, Gr. 5 1050 (1424)
5608 1.500-6UNC, Gr. 5 1842 (2497)
Table 8 — Thrust Plate Fastener Data
(Non-Lubricated Fasteners)
Drive
Size Fastener Size & Grade Torque lb-ft (Nm)
Minimum Thread
Depth-Inches (mm)
5407 1.000-8UNC x 4.00, Gr. 8 792 (1073) 2.75 (69.8)
5415 1.250-7UNC x 4.00, Gr. 8 1596 (2164) 2.50 (63.5)
5507 1.250-7UNC x 4.00, Gr. 8 1596 (2164) 2.50 (63.5)
5608 1.250-7UNC x 4.00, Gr. 8 1596 (2164) 3.00 (76.2)
Fastener lengths given are for applications using tapered drive shafts.
Other lengths may be needed for applications using tapered bushings.

378-206 Rexnord
January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 07-15 Telephone: [phone] Fax: [phone] www.rexnord.com
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Owners Manual •Falk Quadrive Shaft-Mounted Drives Model A
(Page 8 of 53) Sizes 5407-5608
90 °
BELT TENSION ADJUSTED
WITH TORQUE ARM
BELT TENSION ADJUSTED
WITH MOVABLE MOTOR
PARALLEL
Figure 9
LUBRICATION
CAUTION: DRIVES SHIPPED WITHOUT OIL.
14. JR, JF & JSC — Refer to Appendix A for selection of
lubricant. Refer to Table 9 for approximate oil capacity
of drives.
15. 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 Permatex #3 or equivalent
thread sealant before replacing.
JRV, JFV & JSCV — (VERTICAL MOUNTING) Refer to
Figure 1, Step 1.
Remove the fill plug and fill with oil to level marked on
the dipstick.
Coat the plug threads with Permatex #3 or equivalent
thread sealant before replacing.
If stand pipe is used as oil fill, the intermediate cover
plug must be removed to eliminate entrapped air.
16. JR, JF & JSC — Where applicable, WITH A HAND
GREASE GUN, pump grease into the input seal cover,
Figure 10, until the grease appears at 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
17. JR, JF & JSC — Before operating the drive, check
for 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. Check correct rotation
of motor & backstop and be sure drive is properly
lubricated. After one week of operation repeat check
of all external fasteners and pipe plugs.
18. 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 oil of the correct type and viscosity.
Table 9 — Approximate Oil Capacity 
Drive
Size
JR, JF & JSC
Gallons (Liters)
JRV & JFV
Gallons (Liters)
5407 4.3 (16.3) 6.3 (23.8)
5415 7.0 (26.5) 9.5 (36.0)
5507 10.3 (39.0) 13.3 (50.3)
5608 12.0 (45.4) 19.5 (73.9)
cQuantities are approximate. Always fill drive to specified level.
Figure 10

Rexnord 378-206
3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019
Telephone: [phone] Fax: [phone] www.rexnord.com Supersedes 07-15
(PN-212395)
Falk Quadrive Shaft-Mounted Drives Model A •Owners Manual
Sizes 5407-5608 (Page 9 of 53)
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. On vertical shaft drives, remove
fill plug before filling or checking oil level. 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 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.
OIL CHANGES
Refer to the Lubrication Recommendations Section in
Appendix A.
STORED & INACTIVE GEAR DRIVES
Each drive is protected with a rust preventive that will
protect 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 gear drive is to be stored, or is inactive after installation
beyond the above periods, add Nox-Rust VCI-10 vapor-
phase rust inhibitor. For drives that have oil installed, add
Nox-Rust VCI-10 vaper-phase rust inhibitor at the rate of
2% of sump capacity. For drives without oil, add Nox-Rust
VCI-10 vapor-phase rust inhibitor at the rate of one ounce
per cubic foot of internal drive space. Rotate the shafts
several times by hand. Before operating, drives which have
been stored or inactive must be filled to the proper level
with oil meeting the specifications given in this manual.
Refer to Manual 128-014 for "Start-up after Storage"
instructions.
cProduct of the Daubert Chemical Company, Chicago, Illinois.
Periodically inspect stored or inactive gear drives and
add Nox-Rust VCI-10 every six months, or more often if
necessary. Indoor dry storage is recommended.
The air breather should be replaced with a plug (air
breather should be attached to gear drive for future use)
so that the protective rust inhibiting atmosphere is sealed
inside the drive. Install air breather when preparing drive
for operation.
WARNING: The rust preventative oil from the factory
and Nox-Rust VCI-10 are not H1 registered with the NSF
(National Sanitation Foundation) as suitable for food
processing applications. When Food Grade Lubricants are
to be used, it is the end users responsibility to properly
flush and prepare the drive for Food Grade service.
Contact the lubricant manufacturer for specific information
and flushing procedures.
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 (See Figure 12) of
5407-5507 drives and high-speed shaft seals of the 5608
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 OF DRIVE
See note above if only seal replacement is intended.
1. JR, JF & JSC — Drain the lubricant at this time.
Remove safety guards and belts (motor and motor
mount, optional). Remove backstop. 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 6. Take up the slack in
the sling before proceeding.

378-206 Rexnord
January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Supersedes 07-15 Telephone: [phone] Fax: [phone] www.rexnord.com
(PN-212395)
Owners Manual •Falk Quadrive Shaft-Mounted Drives Model A
(Page 10 of 53) Sizes 5407-5608
2. JR — Refer to Appendix C, for instructions for using the
TA torque assist removal tool.
ALTERNATE METHOD — Loosen the setscrew on the
bushing nut which is located at the output end of the
hollow shaft. Use a spanner, pipe or chain wrench to
loosen the bushing nut (Section I, Table 6). Initially, the
nut will freely rotate counter clockwise approximately
180° as the nut moves from the locked position to the
removal position. At this point anticipate resistance
which indicates unseating of the bushing. Continue to
turn the nut until it is free from the hollow shaft. Prepare
drive for lifting (Figure 7) by disconnecting the torque
arm at the drive end. Slide the drive from the bushing.
The bushing can be left in place or removed, as
required. If bushing will not slide off of the shaft, insert
a small prybar into the split of the bushing and pry the
split open slightly to loosen the bushing and remove
from the shaft. Proceed to Step 5 for replacement of
seals only or Step 9 for drive disassembly procedure.
3. JF — Remove the hollow shaft cover, Ref. #14 (Figure
12), from the input end of the hollow shaft. Remove the
bolts which fasten the mounting flange to the driven
equipment.
Remove the fastener, retaining ring, and thrust plate
from the hollow shaft. Refer to Table 10 and select
a backing bolt and flat washer and install them into
the drive shaft as illustrated in Figure 11. The bolt
head provides a working surface for the removal bolt.
Reinsert the thrust plate and retaining ring into the
hollow shaft and select a removal bolt from Table 10.
Thread the removal bolt into the thrust plate until it
contacts the backing bolt head. Torque the removal
bolt to the value shown in Table 10. (If the thrust plate
rotates in the shaft, align the slot in the plate with the
hollow shaft keyway and insert a screw driver or piece
of key stock to prevent rotation of the plate.) After
torquing the bolt, as instructed, strike the bolt, sharply
with a hammer and retorque the bolt if separation
of the drive from the shaft did not occur. Repeat this
procedure, retorquing the bolt after each blow, until
separation occurs.
Table 10 — Removal & Backing Bolt Size and
Length
Drive
Size
Removal Bolt
Size & Minimum
Length – Inches
Maximum
Tightening
Torque – lb-ft (Nm)
Backing Bolt
Size & Maximum
Length – Inches
5407 1.125-7UNC x 3.00 742 (1006) 1.000-8UNC x 2.75
5415 1.500-6UNC x 3.75 1842 (2497) 1.250-7UNC x 2.50
5507 1.500-6UNC x 3.75 1842 (2497) 1.250-7UNC x 2.50
5608 1.500-6UNC x 3.75 1842 (2497) 1.250-7UNC x 3.00
HOLLOW
SHAFT
BACKING BOLT
REMOVAL
BOLT
THRUST
PLATE
RETAINING
RING
TAPPED HOLE
IN DRIVE SHAFT
DRIVE SHAFT
FLAT WASHER
CAUTION: Failure to follow this procedure may result
in the destruction the threads in the thrust plate. (If the
retaining ring becomes damaged, refer to Appendix G,
for replacement information.)
Proceed to Step 5 for replacement of seals only OR
Step 9 for drive disassembly procedure.
4. JSC (5407 ONLY) — Remove drive from driven
equipment trough end by removing the trough end
mounting screws from seal housing. Remove coupling
bolts from drive shaft and slide drive with drive shaft
away from the driven equipment.
To remove drive shaft from the drive, remove the hollow
shaft cover, Ref. #14 (Figure 12), from the input end of
the hollow shaft and then refer to Step 3 above. The
procedure to separate the JSC drive from the shaft is
the same as for separation of a JF drive from driven
equipment shaft.
After separation of the drive and shaft has been
achieved, determine the type of seal equipped in the
seal housing. If it is a waste packing seal, remove the
waste packing material and then remove the loosened
drive shaft from the seal housing side of the drive.
If equipped with a lip seal, first remove the lip seal
following the removal instructions from Step 5. After seal
is removed from seal housing, remove the loosened
drive shaft from the seal housing side of the drive.
CAUTION: The seal housing acts as the bearing
cage, therefore, DO NOT remove from the drive unless
complete drive disassembly is anticipated. Removal of
the seal housing will require readjustment of the L.S.
bearings, Section III.
Figure 11