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Rexnord Falk Quadrive A Owner's Manual

Shaft mounted drives, sizes 5107-5315
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TABLE OF CONTENTS
Introduction
Drive Identification
SECTION I — DRIVE INSTALLATION
Outfitting
Installation
Lubrication
Start-up
SECTION II — DRIVE SERVICE & REPAIR
Preventive Maintenance
Oil Changes
Stored & Inactive Drives
Repair & Replacement
Drive Disassembly
Identifying & Ordering Parts
Recommended Spare Parts
Parts List of Falk Part Numbers
Bearing Cross Reference Numbers
Seal Cross Reference Numbers
SECTION III — DRIVE REASSEMBLY
Drive Reassembly
APPENDICES
Appendix A: Lubrication Recommendations
Appendix B: Backstop Installation
Appendix C: TA Removal Tool
Appendix D: Motor Mount Installation
Appendix E: Vertical Standpipe Installation
Appendix F: Modifications for Non-Standard
Mounting Positions
Appendix G: Retaining Rings for Bushing Nuts and
Thrust Plates, Tooth Combinations for
Vibration Analysis & JSC Lip Seal
Accessory
Appendix H: Drive Shaft Recommendations for
Tapered Drive Shafts
Appendix J: Drive Shaft Recommendations Using
TA Taper Bushing
Appendix K: Drive Shaft Recommendations Using
(TCB) Kit
Appendix L: V-Belt Guard Installation
Appendix M: Electric Fan Installation
Appendix N: Reliability Package
Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com
Falk
®
Quadrive
®
Shaft Mounted Drives Model A • Owners Manual
Sizes 5107-5315
2
3
4
7
9
9
10
10
10
10
12
14
14
16
17
17
18
23
32
34
36
38
40
42
43
41
46
48
51
52
(Page 1 of 52)
378-200
(PN-2128394)
January 2019
Supersedes 04-17

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  • Page 1 Appendix K: Drive Shaft Recommendations Using (TCB) Kit Appendix L: V-Belt Guard Installation Appendix M: Electric Fan Installation Appendix N: Reliability Package 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 2: Introduction

    FALK FACTORY REPAIR AND REBUILD — Rexnord wants the nameplate, provided it is properly installed and to continue to be your primary supplier, and we extend our...

  • Page 3: Drive Identification

    NOTE: Use a TA Taper bushing when mounting these drives on a straight driven shaft (hollow shaft is taper bored) 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 4: Installation

    0° Incline down on drives with backstop in 9 or 12 (5107 & 5115) (5203 THRU 5315) o’clock mounting position. CLEVIS BRACKET 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 5 Figure 5 When the drive is a size  1 00-8UNC x 3 50, GR 5 for 5307JF 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 6 Figure 9 Cut the packing to produce two complete split seal rings CAUTION: Do not mar the shaft’s seal surface. 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 7 TABLE 5 — Flange-Mounted Drive – Foundation vary within the range shown For torque arm mountings other than shown, refer to Rexnord If it is necessary Fastener Size & Tightening to shorten the torque arm, cut the excess from either...
  • Page 8 Refer c Grade 5 fasteners required to Appendix D for motor mount installation instructions Proceed to Step 15 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...

  • Page 9: Lubrication

    Input Shaft UP — Remove the oil level and fill plugs and fill until oil shows in the oil level hole 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 10: Oil Changes

    Refer to Manual 128-014 for "Start-up after Storage" instructions c Product of the Daubert Chemical Company, Chicago, Illinois 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...

  • Page 11: Drive Disassembly

    0.875-9UNC x 2.25 5307 1.125-7UNC x 3.00 742 (1006) 1.000-8UNC x 2.50 5315 1.125-7UNC x 3.00 742 (1006) 1.000-8UNC x 2.50 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 12 Flush the drive to remove chips from the bearing Remove Permatex from the housing bore 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 13 Use a solvent to clean housing and shaft assemblies 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 14: Identifying & Ordering Parts

    Tooth HIGH-SPEED GEAR combinations are listed in Appendix G METAL SHIMS LOW-SPEED Place your order with your local Rexnord distributor If PINION you need to locate a distributor, phone (414)342-3131 ASSEMBLY in the United States or Canada...
  • Page 15 5107J & 5A ASSY. 5115J ONLY 1 ASSY. 3A ASSY . 6A ASSY . 5115 J25 5215 THRU 5315 ONLY 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 16: Parts List Of Falk Part Numbers

    Hollow Shaft w 4A5 Key 4729016 4723015 4723028 4723039 4723050 4723061 4729115 Gear 1242585 1238105 1242878 1237897 1242848 1242860 1237763 Continued on next page 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...

  • Page 17: Bearing Cross Reference Numbers

    Other Falk suppliers of bearings that are considered equal to those listed are: TRW, Fafnir, FAG and BCA  Falk suppliers of Tapered Roller Bearings are: Timken, Bower, and Tyson 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 18 Ref #11, with a press or steel bar RING 5107 as shown in Figure 20 THRU 5215 J25 ONLY PINION Figure 20 1A2 BEARING 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 19 (4) Measure low-speed shaft axial float with a dial indicator, in accordance with method SHAFT SEAL described on the following page 4A2 BEARING DIAMETER 4A3 HOLLOW SHAFT 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 20 041” to 043” (1 04 mm to 1 09 mm) behind the low-speed input housing bearing cup will 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 21 0787096 0781115 0787114 0787079 0785033 c Ref Number 23 Gasket compresses to 028 (0 71); all others are metal shims 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 22: Table Of Contents

    Appendix K: Drive Shaft Recommendations Using (TCB) Kit Appendix L: V-Belt Guard Installation Appendix M: Electric Fan Installation Appendix N: Reliability Package 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...

  • Page 23: Appendix A: Lubrication Recommendations

    Use glass sight glass. Refer to Table 1 for summary of lubricant type Falk GMax 6000 — Rexnord markets Falk GMax 6000, a Using proper lubricant table and viscosity grade, polyalkylene glycol lubricant It is available in ISO VG 135 select desired lubricant manufacturer name and covers ambient air temperature range -30°...
  • Page 24 TABLE 3 — Viscosity Grade Recommendations approaching that of extreme pressure (EP) lubricants; end user should consult lubricant manufacturer/supplier and For Petroleum-Based Lubricants Rexnord as necessary. Typically EP lubricants in Tables 5B Ambient Temperature +30° to +90°F +70° to +125°F &...
  • Page 25  Kinematic viscosity in units of mm /s is equivalent to cSt (centistokes)  DO NOT use in drives equipped with internal backstop 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 26  Gear drives NOT equipped with internal backstop may widen the ambient tempeature range to -18° to +125°F (-28° to +52°C)  DO NOT use in drives equipped with internal backstop 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 27 Grease application or re-lubrication should be done at temperatures above 20°F (-7°C) If grease must be applied at cooler temperatures consult lubricant supplier for recommendations 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 28 Tables 11A, 11B, 12A, 12B, 13 & 14 list food grade lubricants that have performance properties meeting Copper content exceeds 75 ppm Rexnord/Falk specifications They are not exclusive TAN (Total Acid Number) 50% increase above recommendations but serve as a guide for making proper...
  • Page 29  Gear drives NOT equipped with internal backstop may widen ambient temperature range to -18° to +125°F (-28° to +52°C)  DO NOT use in drives equipped with internal backstop 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 30 STORED & INACTIVE GEAR DRIVES GREASE-LUBRICATED SEALS Prior to shipment from the factory, all Rexnord enclosed All drives are furnished with grease purged seals which gear drives are protected internally against corrosion with minimize the entry of contaminants and abrasive dusts into...
  • Page 31 Falk Quadrive Shaft Mounted Drives Model A • Appendix A Sizes 5107-5315 (Page 31 of 52) THIS PAGE LEFT INTENTIONALLY BLANK 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 32: Appendix B: Backstop Installation

    #16, Figure 1 Keep size 5115J and 5207J end covers, bore as instructed size 5207J fasteners and all lock washers for reuse, all other parts may be discarded 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 33 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 34: Appendix C: Ta Removal Tool

    5107 thru 5315 The kit can be ordered from your DO NOT USE THIS HOLE Rexnord distributor by specifying “TA Removal Kit - Part FOR SIZES 5107 & 5115 0769406” NOTE: Use of this tool requires a minimum axial SETSCREW clearance “M”...
  • Page 35 133 (181) 5307 762 (1033) 405 (549) 278 (377) 150 (203) 5315 813 (1102) 432 (585) 283 (384) 160 (217) 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 36: Appendix D: Motor Mount Installation

    WHEN USING TORQUE ARM 5115J-2-A6S 6.12 (2.92) and touch up 5203J-1-A6C 8.00 (2.26) the paint 5203J-2-A6C 8.00 (2.26) 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 37 Inspect the V-belt drive Long ..periodically; re-tighten belts if they are slipping 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 38: Appendix E: Vertical Standpipe Installation

    X + B equals oil level “Low” mark the vented filler plug in the standpipe X + C equals dipstick length 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 39 ® Shaft Mounted Drives Model A • Owners Manual Sizes 5107-5315 (Page 39 of 52) THIS PAGE LEFT INTENTIONALLY BLANK 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 40: Appendix F: Modifications For Non-Standard Mounting Positions

    (C), discard the pipe plug Kits consist of parts for an drawings below (6 o’clock illustrated) oil expansion chamber Pipe fittings and kits tabulated on CODE Page 35 are available from Rexnord Pipe fittings may also B — Bushing N — Nipple be purchased locally Use galvanized pipe fittings C —...
  • Page 41 4 This oil level applies when only a street elbow with a pipe plug is used L — Always locate at high side plug KIT — Install at standard air vent location 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 42: Accessory

    5207 0912835 Chicago Rawhide 29865 5215 2911957 Chicago Rawhide 34861 5307 0912741 Chicago Rawhide 34886 5315 0912741 Chicago Rawhide 34886 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...

  • Page 43: Appendix H: Drive Shaft Recommendations For Tapered Drive Shafts

    1 16” (29 5 mm) inside end of hollow shaft (not near the end of the hollow shaft as shown) 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 44: Appendix J: Drive Shaft Recommendations Using Ta Taper Bushing

    1.000- 8UNC, GR. 8 792 (1074) 1.24 (31.5) key, and slide the bushing and drive shaft into the hollow shaft bore 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 45 N9 tolerances Inch keyway depth tolerance is + 010”, - 000” Refer to ISO 773 or DIN 6885 sheet 1 for metric keyway depth tolerances 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 513-455-5030 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 46 Install the retaining ring into the groove 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...

  • Page 47: Appendix K: Drive Shaft Recommendations Using (Tcb) Kit

    Inch keyway width tolerances are as follows: over 312” to & including 500” = + 0025”, - 0000”; over 500” to & including 1 000” = + 0030”, - 0000”; 1 000” Inch keyway depth tolerance is + 010”, - 000” y Maximum for use with packing gland seal 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 48 2 PL DEC. = .030 3 PL DEC. = .010 ANGLES = 1 no screws with screws with cover plate with pulleys with cover 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...
  • Page 49 6. MOUNT COVER AND APPLY WARNING LABEL with fan cover and plate with fan with sheaves ith hardware with belt guard cover 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...

  • Page 50: Appendix M: Electric Fan Installation

    Finish installing V-belt guard assembly per installation instruction in Appendix L Connect electric fan to power source per local and national electrical codes 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...

  • Page 51: Appendix N: Reliability Package

    #1 & #2 of the gearbox as shown in Figure 2 Figure 3 — Sight Glass Subassembly 378-200 Rexnord (PN-2128394) 3001 W. Canal St., Milwaukee, WI 53208-4200 USA January 2019 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com Supersedes 04-17...
  • Page 52 Page 23 for Lubrication Recommendations; DO AirMax Plus HG-1 Breather 10097978 NOT USE GMAX 6000 or other types of polyalkylene 378-200 (PN-2128394) Rexnord January 2019 3001 W. Canal St., Milwaukee, WI 53208-4200 USA Supersedes 04-17 Telephone: 414-342-3131 Fax: 414-937-4359 www.rexnord.com...

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