Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

(Page 1 of 52)

TABLE OF CONTENTS
Introduction 2
Drive Identification
3
SECTION I DRIVE INSTALLATION
Outfitting 4
Installation 7
Lubrication 9
Start-up 9
SECTION II DRIVE SERVICE & REPAIR
Preventive Maintenance . . . . . . . . . . . . . . . . . .10
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . 10
Stored & Inactive Drives . . . . . . . . . . . . . . . . . .10
Repair & Replacement . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . 32
Appendix C: TA Removal Tool . . . . . . . . . . . . . . .34
Appendix D: Motor Mount Installation . . . . . . . . . . .36
Appendix E: Vertical Standpipe Installation . . . . . . . 38
Appendix F: Modifications for Non-Standard

Mounting Positions . . . . . . . . . . . . . 40
Appendix G: Retaining Rings for Bushing Nuts and

Thrust Plates, Tooth Combinations for

Vibration Analysis & JSC Lip Seal
Accessory . . . . . . . . . . . . . . . . . .42
Appendix H: Drive Shaft Recommendations for

Tapered Drive Shafts . . . . . . . . . . . .43
Appendix J: Drive Shaft Recommendations Using

TA Taper Bushing . . . . . . . . . . . . . 41
Appendix K: Drive Shaft Recommendations Using

(TCB) Kit . . . . . . . . . . . . . . . . . . .46
Appendix L: V-Belt Guard Installation . . . . . . . . . . 48
Appendix M: Electric Fan Installation . . . . . . . . . . .50
Appendix N: Reliability Package . . . . . . . . . . . . . 51

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 2 of 52)

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.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Sizes 5107-5315
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.
FALK 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 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 distributor
for more information.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

(Page 3 of 52)

Drive Identification
5

107

25

Size (Series)

Maximum Bushing Bore (1 7/16)

Drive Type

Ratio (Nominal 25:1)

Model

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.
(JR) Shaft-Mounted Drive

+ Motor Mounts

1) Basic Drive
2) Torque Arm
3) TA Taper Bushing
+ Backstops

+ Shaft Fans
(5215 thru 5315 only)
Basic J

JF Flange Mounted Drive

1) Basic Drive
TA Taper Bushing Optional

+ Electric Fans
(5307 & 5315 only)

+ Vertical Standpipe

JSC Screw Conveyor Drive

+ Trough Ends

+ Thrust Plate Kits

+ V-Belt Guards
1) Basic Drive
2) Seal Housing
3) Drive Shaft

+ TA Removal Tool

NOTE: Use a TA Taper bushing when mounting these drives on a straight driven shaft (hollow shaft is taper bored).

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 4 of 52)

Sizes 5107-5315

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.
Figure 1

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).

Figure 2

HOUSING FLANGE
FASTENERS

ANCHOR
BRACKET

HORIZONTAL DRIVES
F

REPOSITION PLUGS TO
SUIT REQD MOUNTING

SIZES 5203 THRU 5315

L
5:1 RATIO ONLY: RELOCATE
AIRVENT ON OUTPUT SIDE
FOR 9 OCLOCK MOUNTING

D = DRAIN
F = Fill & Vent
L = OIL LEVEL
(HIGHEST INPUT
SIDE PLUG)
D
12 O CLOCK

F
L

F
L

D
9 O CLOCK

D
3 O CLOCK

D
6 O CLOCK

VERTICAL DRIVES
STANDPIPE &
VENTED DIPSTICK
FILL

FILL VENT &

STANDPIPE
OIL LEVEL

1 MAX

510 7 & 5115

ALTERNATE
LOCATION
TORQUE ARM
PREFERRED
FASTENER 5203 THRU 5315 LOCATION

TABLE 1 Housing Flange Fastener Size

and Tightening Torque
(Non-Lubricated Fasteners)
DRIVE SIZE

Fastener Size

Tightening Torque lb-ft

(Nm)

5107
5115
5203

.312-18
.312-18
.375-16

19 (26)
19 (26)
28 (37)

5207
5215
5307
5315

.500-13
.500-13
.500-13
.500-13

69 (94)
69 (94)
69 (94)
69 (94)

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).

TABLE 1A Driven Shaft Tolerances

DRAIN
INPUT SHAFT DOWN

Shaft Diameter Inches

Maximum Under-size Inches

Up to 1.500
1.500 - 2.500 incl.
2.500 - 4.000 incl.

.004
.005
.006

DRAIN
INPUT SHAFT UP

ANGULAR LIMITS FOR HORIZONTAL MOUNTING

(ALL CLOCK POSITIONS)

cc Millimeters = h10 tolerance.

Figure 3
THRUST
PLATE

INCLINE

HOLLOW
SHAFT
COVER

ROTATION
30 UP
(20 FOR
5315)

HIGH-SPEED
SHAFT
SHEAVE
MINIMUM SPACE REQUIRED
FOR V-BELT CLEARANCE

5 DOWN

0 Incline down on drives

with backstop in 9 or 12
oclock mounting position.

5
MAX

(5107 & 5115)

378-200 (PN-2128394)
May 2015
Supersedes 01-15

10
MAX

10
MAX

5
MAX

(5203 THRU 5315)

MINIMUM SPACE REQUIRED

DRIVEN
SHAFT
BUSHING
NUT
BEARING
SUPPORT

TORQUE
ARM
CLEVIS
BRACKET

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

TABLE 2 N Dimension Inches (mm)

DRIVE SIZE

Minimum

Maximum

5107
5115
5203

5.00 (127)
5.55 (141)
5.53 (140)
6.11 (155)
7.08 (180)
7.39 (188)
7.92 (201)

7.19 (183)
8.05 (204)
7.78 (198)
8.72 (221)
10.15 (258)
10.69 (272)
10.74 (273)

5207
5215
5307
5315

cc The minimum engagement is necessary for full bushing

engagement; the maximum engagement is only required if a
thrust plate will be++oyed to remove the drive from the driven
shaft.

a. THIN WALL BUSHING (with keyway slot through

the bushing wall) With the driven shaft keyway
at the 12 oclock 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.

(Page 5 of 52)

4107 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.
Figure 5

HOLLOW
SHAFT

RETAINING
RING

OUTPUT
SIDE

THRUST
PLATE

Figure 6

DRIVE

SHAFT

MECHANICAL LIP SEAL

DRIVESHAFT

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 oclock position. Then insert
the drive key, furnished with the bushing, into
the keyway. Proceed to Step 7.
Figure 4

THROUGH END SPACER

(SIZE 5107 WITH 2.437 (61.9 mm)
& 3.000 (76.2 mm) DRIVE SHAFTS ONLY)

GASKET
TROUGH END

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.

TABLE 3 JR & JSC Thrust Plate Fastener

Data (Non-Lubricated Fasteners)
DRIVE
SIZE
5107
5115
5203

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

5207
5215
5307
5315

Fastener Size
& Grade

Torque
lb-ft (Nm)

Min Thread
Depth Inches
(mm)

.500-13UNC x 3.25, GR. 8

.500-13UNC x 3.25, GR. 8
.625-11UNC x 3.50, GR. 8
.625-11UNC x 3.50, GR. 8
.875-9UNC x 3.50, GR. 8
1.00-8UNC x 4.00. GR. 5
1.00-8UNC x 4.00. GR. 8

92 (125)
92 (125)
183 (248)
183 (248)
533 (723)
567 (769)
792 (1074)

2.00 (50.8)
2.00 (50.8)
2.00 (50.8)
2.00 (50.8)
2.50 (63.5)
2.75 (69.8)
2.75 (69.8)

cc 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.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 6 of 52)

Sizes 5107-5315

Figure 7
TROUGH END GASKET
TROUGH END

SEAL HOUSING FASTENERS

WITH LOCK WASHERS

SEAL HOUSING

BASIC DRIVE

TROUGH END
MOUNTING FASTENERS

DRIVE SHAFT KEY

HOLLOW SHAFT COVER

THRUST PLATE
RETAINING RING

WASTE PACKING

THRUST PLATE
DRIVE

SHAFT

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 .500-13 .625-11 .750-10 .875-9 1.000-8 1.000-8 1.000-8

Fasteners
69 (94) 137 (186) 245 (332) 380 (515) 567 (769) 792 (1074) 792 (1074)
lb-ft (Nm)

Trough End
Fasteners
lb-ft (Nm)

DRIVE SHAFT THRUST

PLATE FASTENER

INSERT

1.500 Diameter Drive Shaft

.500-13 Fasteners
69 (94)
2.000 & 2.437 Diameter Drive Shafts
.625-11 Fasteners with Nuts 137 (186)
3.000 & 3.437 Diameter Drive Shafts
.750-10 Fasteners with Nuts 245 (332)

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 lightweight 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.

Figure 8
Figure 9
CUT

TROUGH END GASKET

SEAL HOUSING

TROUGH END
TROUGH END
MOUNTING FASTENERS

PACKING GLAND RING

AFTER CUTTING
(TWO REQUIRED)
SHAFT
BUTT JOINT
PACKING GLAND ROPE

Figure 10
DRIVE

SHAFT

INSERT

PACKING GLAND (TWO RINGS)

DRIVE

SHAFT

INSERT

TROUGH END

MECHANICAL LIP SEAL

TROUGH END GASKETS
(SIZE 5107 WITH 2.437 &
3.000 DRIVE SHAFTS ONLY)

TROUGH END SPACER

(SIZE 5107 WITH 2.437 &
3.000 DRIVE SHAFTS ONLY)
COMPRESSION RING

COMPRESSION RING
FASTENER WITH
FLAT WASHER

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 shafts seal surface.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

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.

TABLE 5 Flange-Mounted Drive Foundation

Fastener Size & Tightening
Torque (Non-Lubricated Fasteners)
DRIVE
SIZE

Fastener Size and Grade

5107
5115
5203

5207
5215
5307
5315

.500-13UNC, GR.5
.625-11UNC, GR.5
.750-10UNC, GR.5
.875-9UNC, GR.5
1.000-8UNC, GR.5
1.000-8UNC, GR.8
1.000-8UNC, GR.8

Torque
lb-ft
(Nm)

Min Fastener
Engagement
Into Drive
Housing
Inches (mm)

69 (94)
.76 (19.3)
137 (186)
.94 (23.9)
245 (332)
.76 (19.3)
380 (515)
.88 (22.4)
567 (769)
1.00 (25.4)
792 (1074)
1.24 (31.5)
792 (1074)
1.24 (31.5)

INSTALLATION

(Page 7 of 52)
Figure 11
SLING FROM
LONG FASTENER
WITH NUT

SLING AROUND
SEAL HOUSING
AND INPUT SHAFT

SLING FROM
EYEBOLTS

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 Rexnord. 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.

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 4107 and 4115, 3/8 for 4203 and
1/2 for 4207 thru 4315. 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.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 8 of 52)

Sizes 5107-5315

Figure 12
HOUSING FLANGE
FASTENERS

HIGHSPEED
SHAFT

TORQUE ARM
FASTENER
2
30

MA

M
AX

CLEVIS
BRACKET

ANCHOR BRACKET
5107 & 5115

HIGHSPEED
SHAFT

ANCHOR
BRACKET
TORQUE ARM
FASTENER

30

MA

5203 THRU 5315

PREFERRED MOUNTING

CLEVIS
BRACKET

HIGHSPEED
SHAFT

30

AX

5203

5207

5215

5307

5315

cc Load includes moment due to motor and motor mount with torque arm at
maximum angle.

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, 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.

5203 THRU 5315

ALTERNATE MOUNTING

TABLE 6 Spanner Wrench Type &

Spanner Nut Tightening Torque
Adjustable Hook Spanner Wrench
Armstrong Tools

Williams

Spanner Nut
Tightening Torque
lb-ft (Nm)

5107
5115
5203

34-307 (2-4 )
34-307 (2-4 )
34-307 (2-4 )

474
474
474

83 (113)
83 (113)
167 (226)

5207
5215
5307
5315

34-310 (4 -6 )
34-310 (4 -6 )
34-310 (4 -6 )
34-313 (6 1/8- 8 )

474A
474A
474A
474B

167 (226)
250 (339)
250 (339)
250 (339)

TABLE 6A Bushing Nut Setscrew

Tightening Torque
DRIVE SIZE

Setscrew Size

Tightening Torque lb-ft (Nm)

5107
5115-5207
5215-5315

.250-20
.312-18
.375-16

5 (7)
11 (15)
19 (26)

TABLE 7 Torque Arm Clevis Bracket

Fastener Tightening Torque
Fastener
Size

Tightening Torque lb-ft (Nm)

Steel Foundation

Concrete Foundation

5107
5115
5203

.375-16UNC
.375-16UNC
.500-13UNC

28 (38)
28 (38)
69 (94)

21 (28)
21 (28)
53 (72)

5207
5215
5307
5315

.500-13UNC
.625-11UNC
.750-10UNC
1.000-8UNC

69 (94)
137 (186)
245 (332)
567 (769)

53 (72)
107 (145)
191 (259)
467 (633)

cc Grade 5 fasteners required.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

5115

ANCHOR
BRACKET
TORQUE ARM
FASTENER

CLEVIS
BRACKET

DRIVE
SIZE

5107

DO NOT apply ANTI-SEIZE

on these areas.

DRIVE
SIZE

DRIVE
SIZE

Load
2440
3810
4680
6750
9160
12963
15890
lb (N) (10850) (16940) (20810) (27790) (40720) (57660) (70700)

30

TABLE 8 Load Reaction Through Torque Arm

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
(90CCW 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.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

13. JSC Assemble drive to trough and install drive shaft

coupling bolts per screw conveyor manufacturers
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.

(Page 9 of 52)

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.
Figure 14

HIGH-SPEED SHAFT

Figure 13

START UP

BELT TENSION ADJUSTED

WITH TORQUE ARM

PARALLEL

BELT TENSION ADJUSTED

WITH MOVABLE MOTOR

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 100F (38C) 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.

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.

TABLE 9 Approximate Oil Capacity

Quarts (Liters)
DRIVE SIZE

JR, JF, & JSC

5107
5115
5203

2 (1.9)
3 (2.8)
3.5 (3.3)
5.5 (5.2)
9 (8.5)
13 (12.3)
15 (14.2)

5207
5215
5307
5315

JRV & JFV

3 (2.8)
4.5 (4.3)
5 (4.7)
7.5 (7.1)
13 (12.3)
18 (17)
21 (19.9)

cc Quantities are approximate. Always fill drive to specified level.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 10 of 52)

Sizes 5107-5315

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
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 vaporphase 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.

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 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.

cc Product of the Daubert Chemical Company, Chicago, Illinois.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

2. JR Refer to Appendix C for instructions on 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 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
pry bar 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
or Step 9 for drive disassembly procedure.
3. JF & JSC Remove the cover from the input end of
the hollow shaft.

JF Remove the bolts which fasten the drive to the
driven equipment.

JSC (a) If the drive is to be removed from the drive
shaft, remove the seal housing fasteners (Figure 7,
Section I), or (b) if the drive is to be removed with the
drive shaft attached, remove the trough end mounting
fasteners and drive shaft coupling bolts. Remove the
assembly from the trough.

JF & JSC Remove the thrust plate, fastener and
retaining ring 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 15. The
head of the backing bolt 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
screwdriver 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 re-torque the bolt
if separation of the drive from the shaft did not occur.
Repeat this procedure, re-torquing the bolt after each
blow, until separation occurs.

TABLE 10 Removal & Backing Bolt Size &

Length
DRIVE SIZE
5107
5115
5203
5207
5215
5307
5315

Removal Bolt
Size & Minimum
Length - Inches

Maximum
Tightening
Torque
lb-ft (Nm)

Backing Bolt
Size & Maximum
Length - Inches

0.625-11UNC x 1.75
0.625-11UNC x 1.75
0.750-10UNC x 2.00
0.750-10UNC x 2.00
1.000-8UNC x 2.50
1.125-7UNC x 3.00
1.125-7UNC x 3.00

133 (180)
133 (180)
242 (328)
242 (328)
567 (769)
742 (1006)
742 (1006)

0.500-13UNC x 1.25
0.500-13UNC x 1.25
0.625-11UNC x 1.75
0.625-11UNC x 1.75
0.875-9UNC x 2.25
1.000-8UNC x 2.50
1.000-8UNC x 2.50

(Page 11 of 52)

Figure 15

BACKING BOLT

TAPPED HOLE
IN DRIVE SHAFT

REMOVAL
BOLT

THRUST
PLATE
RETAINING
RING

DRIVE SHAFT

HOLLOW
SHAFT
FLAT WASHER

CAUTION: Failure to follow this procedure may result

in the destruction of the threads in the thrust plate
(if the retaining ring becomes damaged, refer to
Appendix G, for replacement information).
Proceed as follows:
JF to Step 5 for replacement of Quadrive seals only OR
Step 9 for drive disassembly procedure.
4. JSC If the drive was removed with the seal housing
and the drive shaft attached, remove the seal housing
fasteners to separate the seal housing and drive
shaft from the drive. 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 (Figure 7, Section I), a packing gland seal
(Figure 10, Section I) or a lip seal (Figure 8, Section I),
proceed as follows for removal of the drive shaft from
the seal housing:
a. PACKING GLAND SEAL Remove the key from
the drive shaft keyway. Loosen the compression
ring fasteners. Remove the seal housing toward the
tapered end of the drive shaft.
b.
LIP SEAL Remove the key from the drive shaft
keyway. Remove any burrs from the tapered end
of the shaft and wrap the entire length with masking
tape or a lightweight Kraft paper to protect the
seal lips during removal. Carefully remove the seal
housing toward the tapered end of the drive shaft.
For replacement of Quadrive seals only proceed to
Step 5, otherwise to Step 9.
c. WASTE PACKING SEAL Remove the key from
the drive shaft keyway. Remove the waste packing
material and remove the seal housing toward the
tapered end of the drive shaft.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 12 of 52)

Sizes 5107-5315

DRIVE DISASSEMBLY (Refer to Parts Drawing

Figure 19)
Prior to initiating any disassembly or repair, clean
accumulated dirt and grime from the surface of the drive
housing. Clean the exposed portion of the input and
output shafts with a solvent and a non-abrasive cloth. If
only the seals are being replaced, proceed to Step 5. If
the drive will be disassembled for inspection or repair,
remove input side seal covers, Ref. #13 & 15, as illustrated
in Figure 16, then skip to Step 9.
CAUTION: Do not damage shaft. New seals will leak if seal
contacting surface is marred. Do not use abrasive material
on shaft seal contacting surface.
5. SEAL REMOVAL The input side low-speed and
high-speed shaft seals, Ref. #19 & 20, respectively,
can be replaced without removing drive from the
driven shaft. Remove input side seal covers, Ref. #13 &
15, as illustrated in Figure 16.

Figure 17

RIGHT WAY

WRONG WAY

Figure 16

REF # 13

REF # 15

a. Remove all sharp edges from shaft extension. Use

a sharp center punch to lightly punch the seal
case as a guide for drill bit. NOTE: Seals are not
axially restrained. DO NOT drive seal into bore too
deep, or disassembly of drive may be required to
extract seal.
b. Wrap several turns of tape around the drill bit
approximately .250 (6 mm) from the drill point to
prevent the drill bit from entering too deeply into
the housing and damaging the bearing. Grease
or magnetize the drill bit to help retain the chips.
Drill two .125 (3 mm) diameter holes in the seal
case 180 apart. Control the angle of the drill as
illustrated in Figure 17 to prevent damage to the
shaft.
c. Insert two #10-.750 (M5 x 20) sheet metal screws
into the seal case leaving .5 (13 mm) of the screw
protruding above the seal face. DO NOT drive the
screw more than .25 (6 mm) beyond seal face or
bearing damage may occur. Use a claw type pry
bar under the screw head as shown in Figure 17 to
lift seal out. Remove all metal chips. Use a magnet
to remove the metal chips that fall into the bore.
Flush the drive to remove chips from the bearing.
Remove Permatex from the housing bore.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

6. SEAL SURFACE CONDITION Carefully inspect

polished surface of shaft where the seal makes
contact. If the seal surface shows any sign of a nick,
scratch, spiral swirl or groove, the shaft should be
replaced or refurbished to prevent leakage of the
lubricant. (In many instances, the seal surface can be
restored by use of a thin wall wear sleeve. Check with
your local seal supplier and follow the manufacturers
instructions for installing the wear sleeve.)

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

7. SEAL INSTALLATION
CAUTION: Protect seal lips from sharp edges of
the keyway by wrapping thin, strong paper around
the shaft and coating the paper and seal lips with
grease before sliding the seal on or off the shaft. Do
not expand the seal lips more than .030 (0.75 mm)
diameter.
a. Coat O.D. of seal with #3 Permatex or equivalent
sealant. Position seal squarely in seal bore with
the garter spring toward bearing. Place a square
ended cylindrical tool against seal and press or
lightly tap tool (not seal) until seal outer wall is
seated .14 (3.5 mm) inside the seal bore outer
wall.
CAUTION: A shaft shoulder is NOT provided for
stopping seal. DO NOT seat seal against bearing.
b. Measure seal axial run-out with a dial indicator
mounted on the shaft. If the seal axial run-out is
more than .010 (0.25 mm), tap high side of seal
with installation tool until seal axial run-out is .010
(0.25 mm) or less.
c. Remove shaft wrapping and reinstall the input side
seal covers, Ref. #13 and 15.
8. DRIVE REPAIR IS COMPLETE Review instructions
in Section I for reassembly of drive onto driven shaft.
9. When seals, Ref. #19 & #20, are to be reused
(replacement is recommended), wrap the input shaft
keyway and output shaft threads with masking tape
or lightweight Kraft paper to protect seal lips during
disassembly. Cover wrapping with a light coat of
grease.
10. If drive is equipped with a backstop, remove output
side end cover Ref. #16, gasket Ref. #23, backstop
Ref. #5A1, and key Ref. #5A4 from output housing Ref.
#11 (note the direction of rotation of the input shaft for
proper reassembly).
11. Lay drive on bench with input shaft down. Remove
housing flange fasteners, Ref. #25. Tap out dowel pins.

SIZE 5115J05 Remove fasteners from retaining
plate, Ref. #3A6.

SIZES 5203 THRU 5315 Use one of the housing
flange fasteners as a jackbolt to separate input and
output housing halves using the tapped hole on input
housing flange provided for this purpose. Carefully lift
off output housing, Ref. #11.
12. Remove the shaft assemblies (J05 - 3A & 4A; J09, J14
or J25 -1A, 2A, & 4A) from input housing, Ref. #10.
13. Drive seals out from input and output housing bores
if replacement is indicated. Remove gasket material,
seal compound and any accumulated foreign matter
from seal joints, bores and adjacent sealing surfaces.
Use a solvent to clean housing and shaft assemblies.

(Page 13 of 52)

CAUTION: On sizes 5203 thru 5315, tapered roller

bearing cups are assembled in input housing with
a slight clearance fit. In addition, metal shims for
adjusting bearing preload and axial float are installed
behind bearing cups in housing. When handling input
housing, be careful that bearing cups and shims do
not fall out of input housing.
14. If drive is equipped with a backstop, check the shaft
surface and backstop sprags (inside diameter) for
signs of wear. If either component shows evidence
of wear, both should be replaced (Ref. #1A and 5A or
Ref. #3A and 5A assemblies). Also refer to Step 6 for
inspection of seal surfaces.
15. Inspect gear teeth for wear or indications of fatigue
e.g. hairline cracks at root of tooth. If one element has
undergone severe wear or broken teeth, replace the
mating element also.
16. Clean and inspect bearings for wear. Lubricate with
light oil before spinning to avoid scoring of working
surfaces. Remove any worn bearings with a wheel
puller. When replacing tapered roller bearings,
replace both cups and cones. DO NOT use new cone
assemblies with worn (old) cups.
17. Use a wheel puller or press to remove gears Ref.
#1A4 or 4A4 from the shaft. Exercise caution to avoid
scoring shaft seal diameter with the keyway of gear.
18. Inspect all fasteners for damage or wear and replace
with fasteners of equal grade. Grade 5
fasteners have three (3) radial lines on the
head. Fasteners are available in kit form,
Ref. #80.
19. If the shaft assemblies can be reused intact (no new
parts required), refer to Section III, Steps 6 thru 9, for
reassembly procedure. Replace all shim-gaskets with
new parts, Kit Ref. #100. On sizes 5107 and 5115, use
the same thicknesses as removed during disassembly.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 14 of 52)

Sizes 5107-5315

IDENTIFYING & ORDERING PARTS

RECOMMENDED SPARE PARTS

1. Refer to the drive component diagram, Figure 18, and

exploded parts diagram, Figure 19, and make a list
of the parts required by part reference number. For
example, Ref. #15, 20 100, 1A, 2A1, and 2A2. When a
gasketed joint is separated, always replace with new
shim-gaskets. Order Ref. #100 shim-gasket kit.
2. Now refer to the parts list, Table 11, and determine the
part description and Falk part number using the part
reference number (Step 1) and the drive identification
(e.g. 5107J25) in the column headers of the parts list.
3. Use the part description and Falk part number to order
the required parts. In the examples in steps 1 and
2, Ref. #15, 20, 100, 1A, 2A1 and 2A2 for a 5107J25
would be ordered as follows:
Seal cover . . . . . . . . . . . 4723094
Seal . . . . . . . . . . . . . . 2921419
Shim-gasket kit . . . . . . . . 4729429
Shaft assembly with gear . . . 4729373
Bearing . . . . . . . . . . . . 2926359
Bearing . . . . . . . . . . . . 2926359
4. Table 12 and 13 convert Falk part numbers to
bearing and seal manufacturers part numbers. Tooth
combinations are listed in Appendix G.
5. Place your order with your local Rexnord distributor. If
you need to locate a distributor, phone (414)342-3131
in the United States or Canada.

1. For non-critical drive applications, a complete set of

bearings, seals and shim-gaskets is recommended.
If stored in their original packaging in a dry, cool
location, these parts have a minimum shelf life of
five years.
2. For critical drive applications (where an outage would
create a major production loss), a complete drive is
recommended.
Figure 18

INPUT HOUSING HALF

AIR VENT

OUTPUT HOUSING HALF

LOW-SPEED
SHAFT COVER

LOW-SPEED
GEAR

HIGH-SPEED GEAR
METAL SHIMS

HIGH-SPEED
SEAL COVER

HIGH-SPEED
SHAFT ASSEMBLY
GASKET
ELIMINATOR

378-200 (PN-2128394)
May 2015
Supersedes 01-15

LOW-SPEED
PINION
ASSEMBLY
LOW-SPEED
PINION
HIGH-SPEED
SHAFT COVER
(BACKSTOP COVER)
BACKSTOP
GASKET
HIGH-SPEED PINION

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Figure 19

Sizes 5107-5315

(Page 15 of 52)

4A5

4A2

4A1

4A5

4A2

4A1
4A3

4A3

4A4
2A4

2A2

2A5

4A4

2A1
3A2
3A1

3A4

2A6

2A3
1A4

3A3

1A2
TYPE
J09, J14 & J25

1A1
1A5

TYPE J05

1A3

25

11

4A ASSY.

19

30
10
27
16

23

25

4A ASSY
.
5A5

5107J &
5115J ONLY

31

2A ASSY
.

17 23
5A ASSY.

1 ASSY.

29

19

22

13

3A ASSY
.
24

5A4

6A1
5A2

5A6

5115 J25
ONLY

5A1

5A3

15

29

6A4

23

20

6A3
6A ASSY.
5215 THRU 5315

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 16 of 52)

Sizes 5107-5315

TABLE 11 Parts List of Falk Part Numbers

Ref.
No

Part Description

DRIVE SIZE
5107

5115

5203

5207

5215

5307

5315

Housing Components
13
15
16
16
17

Shaft Cover-LS
Seal Cover
Shaft Cover
Shaft Cover W/BKSP
Cover Spacer BKSP

2109906
4723094
1161865
1243290
1243292

1164350
4723095
1161866
1161866
1243296

1164353
4723096
1238030
1238019

2110134
4723097
2119130
2119130
2119132

1164359
4723098
1161870
1219342

2110504
4723099
1161870
1237944

2110779
4723109
1161870
1219342

19
20
30
80
100

Seal,
Seal, HS
Air Vent
Fastener Kit
Shim & Gasket Kit

2916797
2921419
0914088
4729000
4729429

2921425
2921416
0914088
4729000
4729430

2921422
2902929
0914088
4729032
0786836

2921421
2921417
0914088
4729049
0786837

2904606
2921420
0914088
4729064
0786838

2921423
2916797
0914088
4729082
0786839

2922295
2920669
0914088
4729100
0786840

3A
3A1
3A2
3A3

Shaft Ass'y-Inc 3A1-3A4

Bearing
Bearing
Pinion & Shaft-Inc 3A4

4729363
2926357
2926357
4729364

4729377
2926361
2919340
4729378

4729045
2919339
2919340
4729046

4729061
2918700
0921521
4729062

4729076
2919359
2919360
4729077

4729094
0921354
2916263
4729095

4729112
2919215
0921853
4729113

4A
4A1
4A2

Shaft Ass'y-Inc 4A1-4A5

Bearing
Bearing

4729365
4729014
4729014

4729033
4720891
4720891

4729047
2911822
2911822

4729063
2905191
2905191

4729078
0921778
0921778

4729096
0921727
0921727

4729114
0921366
0921366

4A3
4A4
5A

Hollow Shaft w 4A5 Key

Gear
Backstop Ass'y

4729016
1242585
0795654

4723015
1238105
0793995

4723028
1242878
0785596

4723039
1237897
0783905

4723050
1242848
0785610

4723061
1242860

4723073
1237763

Rotating Elements J05

Rotating Elements J09

1A
1A
1A1
1A2

Shaft Ass'y W/O 1A4 Gear

Shaft Ass'y With 1A4 Gear
Bearing
Bearing

4729366
4729367
2926357
2926357

4729380
4729381
2926361
2919340

4729037
4729034
2919339
2919340

4729053
4729050
2918700
0921521

4729068
4729065
2919359
2919360

4729086
4729083
0921354
2916263

4729104
4729101
2919215
0921851

1A3
1A4
5A

Pinion & Shaft w 1A5 Key

Gear
Backstop Ass'y

4729368
1242532
0795654

4729382
1242536
0793995

4729041
1242834
0785596

4729056
1242842
0783905

4729071
1242849
0785610

4729089
1242857
0785529

4729107
1242861
0757183

1A
1A
1A1
1A2

Shaft Ass'y W/O 1A4 Gear

Shaft Ass'y With 1A4 Gear
Bearing
Bearing

4729369
4729370
2926357
2926357

4729383
4729384
2926361
2919340

4729038
4729035
2919339
2919340

4729054
4729051
2918700
0921521

4729069
4729066
2919359
2919360

4729087
4729084
0921354
2916263

4729105
4729102
2919215
0921851

1A3
1A4
1A5

Pinion & Shaft w 1A5 Key

Gear
Backstop Ass'y

4729371
1242533
0795654

4729385
1242537
0793995

4729042
1242833
0785596

4729057
1242843
0783905

4729072
1242850
0785610

4729090
1242858
0785529

4729108
1237856
0757183

1A
1A
1A1
1A2

Shaft Ass'y W/O 1A4 Gear

Shaft Ass'y With 1A4 Gear
Bearing
Bearing

4729372
4729373
2926357
2926358

4729386
4729387
2926361
2926359

4729039
4729036
2919339
2919340

4729055
4729052
2918700
0921521

4729070
4729067
2919359
2919360

4729088
4729085
0921354
2916263

4729106
4729103
2919215
0921853

1A3
1A4
1A5

Pinion & Shaft w 1A5 Key

Gear
Backstop Ass'y

4729374
1242534
0795655

4729388
1238106
0795658

4729043
1238017
0785596

4729058
1242844
0783905

4729073
1242851
0785610

4729091
1242859
0785529

4729109
1237764
0757183

2A
2A1
2A2
2A3

Shaft Ass'y-Inc 2A1-2A6

Bearing
Bearing
Pinion & Shaft w 2A4 Key

4729375
2926359
2926359
4729376

4729389
2926360
2926360
4729390

4729040
2919338
2919338
4729044

4729059
2918700
2918701
4729060

4729074
0921350
2916288
4729075

4729092
0921793
0921793
4729093

4729110
0921850
0921850
4729111

2A5
2A6
4A
4A1

Spacer
Spacer
Shaft Ass'y-Inc 4A1-4A5
Bearing

1179876
1161925
4729365
4729014

1179877
1163034
4729033
4720891

1161889
4729047
2911822

1163762
4729063
2905191

21200246
4729078
0921778

4729096
0921727

4729114
0921366

4A2
4A3
4A4

Bearing
Hollow Shaft w 4A5 Key
Gear

4729014
4729016
1242585

4720891
4723015
1238105

2911822
4723028
1242878

2905191
4723039
1237897

0921778
4723050
1242848

0921727
4723061
1242860

0921366
4729115
1237763

Rotating Elements J14

Rotating Elements J25

Rotating Elements J09, J14, & J25

Continued on next page.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

(Page 17 of 52)

TABLE 11 Parts List of Falk Part Numbers (Continued from Page 16)
Ref.
No.

DRIVE SIZE

Part Description

5107

5115

5203

5207

5215

5307

5315

...
...
...
...

0785611
4729079
4729080
4729081

0785530
4729097
4729098
4729099

0785432
4729116
4729117
4729118

Shaft Fan Assembly All Ratios

6A
6A1
6A3
6A4

Shaft Fan Ass'y Inc 6A1-6A4

Fan
Guard
Backplate

...
...
...
...

...
...
...
...

...
...
...
...

cc For sizes 5107J 5203J, 4000J/5000J, revolving parts not necessarily interchangeable. Consult Service Parts Department.
For size 5315J05 only; use P/N 1161869.

TABLE 12 Bearing Cross Reference Numbers

Falk Part Number

Manufacturers Number

Tapered Roller Bearings

0921350
0921354
0921366
0921521

HM804843/HM804810
475/472
48393/48320
19138/19283-B

0921727
0921778
0921793
0921850

68462/68712
JM822049/JM822010
HM803149/HM803110
JHM807045/HM807010

0921851
0921853
2905191
2911822

46176/46368
46162/46368
497/492A
34478/34300

2916263
2916288
2918700
2918701

418/414
3879/3820
350A/352
339/332

2919215
2919338
2919339
2919340

HM813841A/HM813810
26112/26283-S
LM48548A/LM48510
17098/17244-B

2919359
2919360
2926357
2926358

386A/382A
3379/3320-B
30205M
30303M

2926359
2926360
2926361
4720891
4729014

30304M
30305M
30206M
29675/29620
JLM506810/JLM506849

TABLE 13 Viton Seal Cross Reference

Numbers
Falk Part Number

Manufacturers Number
Chicago Rawhide

National

2902929
2904606
2916797
2920669

13661
42433
21091
23843

...
...
...
...

2921416
2921417
2921419
2921420

11207
15138
8704
18582

470712V
...
481570V
...

2921421
2921422
2921423
2921425
2922295

33699
29912
46155
27324
52498

...
415995V
...
455315V
...

cc Subject to substitution of equivalent seals without notice.

cc 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.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 18 of 52)

Sizes 5107-5315

Section III
DRIVE REASSEMBLY
REFER TO PARTS DRAWING FIGURE 19
1. GENERAL
a. Clean all parts to be reassembled and coat all
tapered roller bearing cups and pinion teeth with
an SAE 20 (or heavier) oil. DO NOT lubricate gear
teeth prior to assembly on shaft.
b. Heat all ball bearings and tapered roller bearing
cones in an oven to 275F (135C).
CAUTION: Do not apply flame directly to bearings
or rest bearings directly on a heated surface.
c. Slide or press all ball bearings and bearing cones
tight against the shoulder.
CAUTION: Do not apply force to the bearing rollers
or roller cage. Apply force against the inner race
only.
2. ASSEMBLY OF TAPERED ROLLER BEARING CUPS
a. SIZE 5107 THRU 5315 Drive high-speed
bearing cup, Ref. #1A2 or 3A2, intermediate-speed
bearing cup Ref. 2A2, and low-speed bearing cup
4A2 squarely into their respective bearing bores of
output housing Ref. #11, with a press or steel bar
as shown in Figure 20

Figure 20

3. High-speed SHAFT ASSEMBLY Ref. #1A or

3A Assembly.

Seat heated bearings cones, Ref. #1A1, 1A2
or 3A1 & 3A2, firmly against shaft shoulder or
retaining ring.

CAUTION: Allow bearings to cool. Apply a
coat of oil to the cooled bearings to lubricate
and avoid scoring of working surfaces.

Figure 21

SHAFT
EXTENSION

1A1 BEARING
RETAINING
RING 5107
THRU 5215
J25 ONLY
PINION

1A2 BEARING

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

4. INTERMEDIATE SHAFT ASSEMBLY Ref. #2A

Assembly - Type J09, J14 and J25 - Figure 22. Prepare
bearings per Steps 1b and c on Page 18.
Figure 22

2A1 BEARING

1A4
GEAR

2A5 SPACER

2A6 SPACER

2A2 BEARING

a. ALL SIZES Heat gear Ref. #1A4 to 325F (163C)

in an oven. Insert key, Ref. #2A4, in shaft keyway.
Assemble gear onto shaft, with the chamfer toward
pinion, using a press to ensure a tight fit. Allow
gear to cool before proceeding.
b. Assemble spacer, Ref. #2A6, onto intermediate
shaft (except sizes 5307 and 5315). Seat bearings
or cones, Ref. #2A1 & 2A2, on shaft. Seat all
components firmly so spacers do not rotate on
shaft.

CAUTION: Allow assembly to cool. Apply a coat
of oil to the cooled bearings to lubricate and avoid
scoring of the working surfaces.
5. LOW-SPEED SHAFT ASSEMBLY Ref. #4A
Assembly - ALL TYPES - Figure 23. Prepare bearing
cones per Steps 1b and c.
Figure 23

4A1 BEARING

SHAFT SEAL
DIAMETER

(Page 19 of 52)

a. Heat gear, Ref. #4A4, to 325F (163C) in an

oven. Insert gear key, Ref. #4A5, into hollow shaft
keyway. Assemble the gear with the chamfer
toward the shoulder on the shaft using a press to
ensure a tight fit.

WARNING: Exercise care so that the gear keyway
does not contact the shaft seal diameter(s) as
scoring could occur.
b. Seat bearing cones, Ref. #4A1 & 4A2, firmly
against gear and shoulder.
CAUTION: Allow assembly to cool before
proceeding. Apply oil to the cooled bearing rollers
and gear teeth to lubricate and avoid scoring of
the working surfaces.
6. BEARING ADJUSTMENT
a. SIZES 5107 THRU 5315 Bearing adjustment is
made by adjusting thickness of metal shims, Ref.
#24, behind bearing cups in input housing, Ref.
#10.
NOTE: The thickest shim should be located
adjacent to the bearing cup. The thinnest shims
should be located in the center of the shim pack.
(1) Support input housing, such that when highspeed shaft assembly, Ref. #1A or 3A, is
lowered into place there is clearance for shaft
extension end. Install bearing cups in input
housing without any metal shims. Tap dowel
pins into input housing with solid pin nearest
high-speed shaft bore.
(2) Lower low-speed shaft assembly, Ref. #4A,
into input housing, Ref. #10, with threaded
end facing up (DO NOT install Ref. #1A [or 3A]
or 2A shaft assemblies at this time).
(3) Assemble output housing, Ref. #11, to input
housing. Install housing flange fasteners, Ref.
#25, with heads of cap screws against input
housing. Cross tighten fasteners to torque
specified in Table 14.)

TABLE 14 Housing Flange Fastener Size &

Tightening Torque 5%
(Non-Lubricated Fasteners)

4A4 GEAR

4A2 BEARING

SHAFT SEAL
DIAMETER

DRIVE SIZE

Fastener Size

5107
5115
5203
5207
5215
5307
5315

.312-18
.312-18
.375-16
.500-13
.500-13
.500-13
.500-13

Tightening Torque
lb-ft (Nm)
19 (26)
19 (26)
27 (37)
67 (91)
67 (91)
67 (91)
67 (91)

(4) Measure low-speed shaft axial float with a

dial indicator, in accordance with method
described on the following page.

4A3 HOLLOW SHAFT

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 20 of 52)

Sizes 5107-5315

(5) Low-speed shaft axial float measurement Ref.

#4A Assembly For drives equipped with TA
Taper bushing, carefully thread bushing nut onto
hollow low-speed shaft threads. Rotate shaft to
seat cone assemblies in bearing cups. Set up a
dial indicator on output housing as illustrated in
Figure 24. Indicator tip must rest on low-speed
shaft and not on nut surface. Rotate and oscillate
shaft with axial force applied in both directions to
obtain axial float measurement.
DIAL INDICATOR TIP MUST
REST ON QUILL SHAFT AND
NOT ON NUT SURFACE
10
2
345

12
4 3

DIAL INDICATOR
WITH STAND
BUSHING NUT
THREADED ON
QUILL SHAFT

PRY BAR

Figure 24

For drives without the TA Taper bushing, insert

hollow shaft thrust plate and secure with retaining
ring as illustrated in Section I, Figure 5. Thread
a bolt into the thrust plate. Set up a dial indicator
on output housing, as illustrated in Figure 24, with
the indicator tip on end of hollow shaft. Rotate
and oscillate shaft with axial force applied in
both directions to obtain axial float measurement
(upward force can be applied by applying upward
force on head of thrust plate bolt).
Refer to Table 15 and note the preload specified
for bearings 4A1 and 4A2. Add to upper and
lower limits shown, the axial float measured.
This will indicate thickness of metal shim(s), Ref.
#31, to be added behind input housing bearing
cup to obtain the specified preload. Table 16
provides shim thickness for each shim pack to
assist in obtaining the desired results.

produce the desired preload.

(6) With drive resting on input housing cover, Ref.
#10, tap the dowel pins out of the housing,
remove flange fasteners and set output housing
aside. Remove low-speed shaft assembly
and bearing cups. Install metal shim(s), as
determined in Step 6b5, behind bearing cup in
input housing.
Reinstall dowels, shims and output housing
cover & torque housing flange fasteners, Ref.
#25, to value in Table 14. Proceed to Step 7.
(7) Lower low-speed, Ref. #4A, high-speed, Ref.
#1A (or 3A), and intermediate, Ref. #2A shaft
assemblies into input housing. Reinstall dowels
and output housing and torque flange fasteners
to value listed in Table 14. Recheck low-speed
shaft with dial indicator to ensure that no float is
present. Measure intermediate and high-speed
shaft float with a dial indicator in accordance
with methods described below.
(8) INTERMEDIATE SHAFT AXIAL FLOAT
MEASUREMENT Ref. #2A Assembly
Figure 25. Remove pipe plug from output
housing cover. Install a .375-16 x 2 size bolt
through hole in housing and turn by hand until
snug. Set up a dial indicator on output housing
with the indicator tip on bolt head as illustrated
in Figure 26. While turning bolt in a clockwise
direction, lift upward to measure axial float.
Subtract from this reading the axial float for the
Ref. #2A shaft assembly shown in Table 15.
This indicates the thickness of metal shim(s),
Ref. #22 to be added behind the input housing
bearing cup to obtain the specified axial float.
Figure 25
TURN AND MOVE
BOLT TO CHECK
FLOAT

TABLE 15 Preload & Axial Float Settings

Ref. # 4A1 & 4A2
Bearing Preload
Inches (mm)

DRIVE
SIZE

Ref. #2A3
Assembly
Intermediate
Shaft
Axial Float
Inches (mm)

Ref. # 1A3 or 3A3

Assembly
High-speed Shaft
Axial Float
Inches (mm)

5107
5115
5203

0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08)

0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08)
0.001-0.004 (0.00-0.10) .001-.003 (0.03-0.08) .001-.003 (0.03-0.08)

5207
5215
5307
5315

0.001-0.004 (0.00-0.10)
0.001-0.004 (0.00-0.10)
0.001-0.004 (0.00-0.10)
0.001-0.004 (0.00-0.10)

.001-.003 (0.03-0.08)
.001-.003 (0.03-0.08)
.001-.003 (0.03-0.08)
.001-.003 (0.03-0.08)

.001-.003 (0.03-0.08)
.001-.003 (0.03-0.08)
.001-.003 (0.03-0.08)
.001-.003 (0.03-0.08)

For example, from Table 15 the desired bearing

preload for the size 5203 low-speed shaft
bearings, Ref. #4A1 & 4A2, is .002 to .004
(0.05 mm to 0.10 mm) tight. If the measured
axial float is .039 (0.99 mm) then addition of
metal shims with a total thickness between
.041 to .043 (1.04 mm to 1.09 mm) behind
the low-speed input housing bearing cup will

378-200 (PN-2128394)
May 2015
Supersedes 01-15

For example, from Table 15 the desired axial

float for the size 5307 intermediate shaft
assembly, Ref. #2A, is .001 to .003 (0.03 mm
to 0.08 mm). If the measured axial float is .039
(0.99 mm) then addition of metal shims with
a total thickness between .036 to .038 (0.91
mm to 0.96 mm) behind the intermediate-speed
input housing bearing cup will produce the
desired axial float.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

Figure 26

(Page 21 of 52)

Figure 27

BEAD OF
LOCTITE 515

INPUT
HOUSING

1A/3A SHAFT
ASSEMBLY

9) High-speed Shaft Axial Float Measurement

Ref. #1A or 3A Assembly Figure 26. Set
up a dial indicator as illustrated in Figure 26
to measure axial float of output end of shaft.
Push upward on shaft extension end with a
twisting motion to obtain reading. Subtract
from this reading the axial float for the Ref. #1A
(or 3A) shaft assembly shown in Table 15. This
indicates the thickness of metal shim(s), Ref.
#24, to be added behind the input housing
bearing cup to obtain the specified axial float.
WARNING: Cover shaft extension end keyway
with tape to avoid lacerations to the hand.
(10) Disassemble drive once more to add metal
shim(s) behind input intermediate and highspeed housing bearing cups to obtain the
specified axial float shown in Table 15.
(11) Apply a bead of Loctite 515 to input housing
flange as shown in Figure 27. Assemble output
housing to input housing and install dowels.
Install and cross tighten flange fasteners to
torque specified in Table 14.

(12) Check intermediate and high-speed shaft

axial floats with dial indicator to ensure they
are within specified limits. If necessary,
disassemble drive. Clean Loctite 515 from
housing flanges. Readjust metal shims behind
input housing bearing cups, reapply Loctite
515, and reassemble. Repeat until specified
float is achieved.
7. BACKSTOP INSTALLATION

If drive will be installed on the driven equipment
using a TA tapered bushing, do not install backstop
at this time. If not, refer to Appendix B, for installation
instructions.
8. SHAFT COVER INSTALLATION

Assemble output side high-speed shaft cover, Ref.
#16, and gasket, Ref. #23 (Table 16). Cross tighten
fasteners to 3.5 lb-ft (4,7 Nm) torque.
9. SEAL INSTALLATION

Refer to Section II, Step 7. Position input end lowspeed and high-speed shaft covers, Ref. #13 & 15,
respectively, over housing bore and tap lightly until
cover is fully seated into bore.

DRIVE IS READY TO INSTALL Refer To Section I.

TABLE 16 Individual Shim-Gasket Part Numbers

DRIVE SIZE

Ref.
No.

Shim Thickness
Inch (mm)

5107

5115

5203

5207

5215

5307

5315

100

...
.002 (0.05)
.005 (0.13)
.010 (0.25)
.030 (0.76)

4729429
793762
793763
1242592
793764

4729430
793770
793771
1242594
793772

0786836
0787097
0787098
1238022
0787099

0786837
0781116
0781117
1237213
0781118

0786838
0787109
0787110
1238062
0787111

0786839
0787080
0787081
1237946
0787082

0786840
0785034
0785035
1237766
0785036

.031 (0.79)
.031 (0.79)
.002 (0.05)
.005 (0.13)
.010 (0.25)
.030 (0.76)

1243291
1243291
793762
793763
1242592
793764

1243297
1243297
793770
793771
1242594
793772

2120198
1238020
0787100
0787101
1238023
0787102

2119131
2119131
0781116
0781117
1237213
0781118

1161876
1189882
0787106
0787107
1238061
0787108

1161876
2120077
0787083
0787084
1237947
0787085

1161876
1189882
0785037
0785038
1237767
0785039

.002 (0.05)
.005 (0.13)
.010 (0.25)
.030 (0.76)

793758
793759
1242591
793760

793766
793767
1242593
793768

0787094
0787095
1238021
0787096

0781113
0781114
1237212
0781115

0787112
0787113
1238063
0787114

0787077
0787078
1237945
0787079

0785031
0785032
1237765
0785033

22
23 (w/o backstop)
23 (with backstop)
24

31

cc Ref. Number 23 Gasket compresses to .028 (0.71); all others are metal shims.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Owners Manual Falk Quadrive Shaft Mounted Drives Model A

(Page 22 of 52)

Sizes 5107-5315

TABLE OF CONTENTS
Appendix A: Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . . . . 23
Appendix B: Backstop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Appendix C: TA Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Appendix D: Motor Mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Appendix E: Vertical Standpipe Installation . . . . . . . . . . . . . . . . . . . . . . . . 38
Appendix F: Modifications for Non-Standard Mounting Positions . . . . . . . . . . . . . 40
Appendix G: Retaining Rings for Bushing Nuts and Thrust Plates, Tooth Combinations

for Vibration Analysis & JSC Lip Seal Accessory . . . . . . . . . . . . . . 42
Appendix H: Drive Shaft Recommendations for Tapered Drive Shafts . . . . . . . . . . 43
Appendix J: Drive Shaft Recommendations Using TA Taper Bushing . . . . . . . . . . 44
Appendix K: Drive Shaft Recommendations Using (TCB) Kit . . . . . . . . . . . . . . . 46
Appendix L: V-Belt Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Appendix M: Electric Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Appendix N: Reliability Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix A

Sizes 5107-5315

(Page 23 of 52)

Lubrication Recommendations
INTRODUCTION
Carefully follow instructions on the drive nameplate,
warning tags and installation manuals furnished with the
drive.
Lubricants listed in this manual are typical products
ONLY and should not be construed as exclusive
recommendations. Industrial type petroleum-based rust
and oxidation inhibited (R & O), industrial type extreme
pressure (EP) or industrial type micropitting resistant gear
lubricants are the recommended gear lubricants. They can
be formulated using petroleum or synthetic base stocks.
The section on food grade lubricants provides guidance
selecting lubricants for applications needing this class of
lubricants. Food grade lubricants are formulated using
petroleum or different types of synthetic base stocks.
LUBRICANT SELECTION PROCESS
1. Refer to Table 3 or 4 for proper lubricant viscosity
grade based on ambient temperature range. See Falk
GMax 6000 paragraph on this page for ambient air
temperature range if using this lubricant.
2. Refer to Table 1 for summary of lubricant type.
3. Using proper lubricant table and viscosity grade,
select desired lubricant manufacturer name.
4. Refer to Table 2 for approximate oil capacity to
purchase.

TABLE 1 Summary of Lubricant Type and

Greases
Petroleum-Based
R & O Inhibited
See Table 5A

Extreme Pressure (EP)

See Table 5B

Micropitting Resistant
See Table 5C

Synthetic Lubricant, Polyalphaolefin Type (PAO)

R & O Inhibited
See Table 6A

Extreme Pressure (EP)

See Table 6B

Micropitting Resistant
See Table 6C

Synthetic Lubricant, Polyalphaolefin Glycol Type (PAG)

See Falk GMax 6000 (Paragraph to Right)
Conventional Grease
See Table 7
Food Grade Lubricant & Grease
See Page 28
DO NOT use in drives equipped with internal backstop.

VISCOSITY (IMPORTANT)
The proper viscosity grade for petroleum-based lubricant
is found in Table 3. For synthetic lubricant viscosity grades,
refer to Table 4 and the Synthetic Lubricants paragraphs.
Viscosity grade is determined by ambient air temperature
in immediate vicinity of gear drive. Lubricant selections
must have a pour point at least 10F (5.5C) below the
expected minimum ambient starting temperature.

LUBRICANT TYPES
PETROLEUM-BASED LUBRICANTS (TABLEs 5A, 5B &
5C) Industrial type petroleum-based rust and oxidation
inhibited (R & O) gear lubricants are the most common and
readily available general purpose gear lubricants.

SYNTHETIC LUBRICANTS (TABLES 6A, 6B & 6C)

Synthetic lubricants of the polyalphaolefin (PAO) type
are recommended for cold climate operation, high
temperature applications, extended temperature range
(all season) operation and/or extended lubricant change
intervals. The proper viscosity grade of synthetic lubricant
is given in Table 4.
Polyalkylene glycols (PAG) are another class of synthetic
lubricants. They have similar performance properties
as PAO synthetics low pour point, stable at elevated
temperatures, and high viscosity index. PAG's have
exceptional tolerance to water contamination.
WARNING: Polyalkylene glycols (PAGs) are not
compatible with petroleum mineral oil or PAO synthetic
lubricants and must not be topped off with either lubricant.
In addition, petroleum mineral oils or PAO synthetic
lubricants must not be used to top off systems containing
PAGs. Do not use PAGs in gear drives with painted interior
housing walls unless paint compatibility is checked.
Compatibility with oil seals and gasket materials must be
checked prior to use. PAG lubricants are not compatible
with polycarbonate sight glass. Use glass sight glass.
Falk GMax 6000 Rexnord markets Falk GMax 6000, a
polyalkylene glycol lubricant. It is available in ISO VG 135
and covers ambient air temperature range -30 to +125F
(-34 to +52C). Gear drives equipped with internal
backstop can use GMax in ambient temperatures above
-20F (-29C).
WARNING: GMax 6000 is not compatible with petroleum
mineral oil or PAO synthetic lubricants and must not be
topped off with either lubricant. In addition, petroleum
mineral oils or PAO synthetic lubricants must not be used
to top off systems containing GMax 6000. Do not use
GMax 6000 in gear drives with painted interior housing
walls unless paint compatibility is checked. Compatibility
with oil seals and gasket materials must be checked prior
to use. GMax 6000 is not compatible with polycarbonate
sight glass. Use glass sight glass.
ANTI-WEAR (AW) LUBRICANTS For moderately
loaded gear drives or operating conditions challenging
for conventional R & O oils, industrial type anti-wear (AW)
lubricants are suggested. These lubricants contain antiwear additives that provide stronger thicker lubricant film
to help maintain surface separation. Synthetic lubricants
by inherent nature of base stock properties provide antiwear performance.
EXTREME PRESSURE (EP) LUBRICANTS (TABLES 5B
& 6B) For highly loaded drives or for drives loaded in
excess of original estimates, industrial-type petroleum EP
lubricants are preferred. EP lubricants are manufactured
from petroleum or synthetic base lubricants. Anti-scuff is
another term used to describe EP lubricants.
CAUTION: EP LUBRICANTS & INTERNAL BACKSTOPS
Do not use EP lubricants or lubricant formulations
including sulfur-phosphorus (EP), chlorine, lead
derivatives, graphite or molybdenum disulfides in drives
equipped with internal cartridge type backstops. Lubricant
formulations may change over time. Some lubricants in
Tables 5A & 6A may contain higher amounts of additives
to reduce friction, resulting in lubricant properties

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix A Falk Quadrive Shaft Mounted Drives Model A

(Page 24 of 52)

Sizes 5107-5315

approaching that of extreme pressure (EP) lubricants; end

user should consult lubricant manufacturer/supplier and
Rexnord as necessary. Typically EP lubricants in Tables 5B
& 6B contain these additives.
MICROPITTING RESISTANT LUBRICANTS (TABLES 5C
& 6C) Micropitting resistant lubricants are specially
developed for surface hardened gearing commonly used
in modern industrial gear drives. These lubricants contain
additives to resist formation of micropitting and other
conventional forms of gear wear. Highly loaded gear
drives or applications where operating loads are not well
defined may benefit from this type of lubricant. Generally
lubricants are available in limited number of viscosity
grades.
CAUTION: MICROPITTING RESISTANT LUBRICANTS
& INTERNAL BACKSTOPS Do not use micropitting
resistant lubricants in drives equipped with internal
cartridge type backstops. These lubricants are listed in
Tables 5C & 6C.
WARNING: LUBRICANTS IN FOOD PROCESSING
INDUSTRY Generally conventional gear lubricants are
classified as H2 by NSF (National Sanitation Foundation)
since they contain harmful substances and should not
be used in the food processing industry. Lubricants
registered as H1 by NSF are suitable for food processing
applications.
CLIMATE CONDITIONS Ambient temperature in
immediate vicinity of gear drive is very important for
determining viscosity grade. Table 3 provides viscosity
grade selections for petroleum-based lubricants. See
Table 4 for synthetic lubricants.

OIL LEVELS
Fill the drive with lubricant to pipe plug level indicated in
illustrations in Section 1. Approximate oil capacities are
given in Table 2 below.

TABLE 2 Approximate Oil Capacity

Quarts (Liters)
DRIVE SIZE

JR, JF & JSC

JRV & JFV

5107
5115
5203

2 (1.9)
3 (2.8)
3.5 (3.3)

3 (2.8)
4.5 (4.3)
5 (4.7)

5207
5215
5307
5315

5.5 (5.2)
9 (8.5)
13 (12.3)
15 (14.2)

7.5 (7.1)
13 (12.3)
18 (17)
21 (19.9)

TABLE 3 Viscosity Grade Recommendations

For Petroleum-Based Lubricants
Ambient Temperature
Range

+30 to +90F
(-1 to +32C)

+70 to +125F
(+21 to +52C)

ISO Viscosity Grade

220

320

AGMA Viscosity Grade

LUBRICANT ANALYSIS AND CHANGES

OIL ANALYSIS REPORT Checking oil condition at
regular intervals is recommended. Analyze oil samples
approximately every 1000 hours for petroleum lubricants
or every 3000 hours for synthetic lubricants. In the
absence of more specific limits, the guidelines listed below
may be used to indicate when to change petroleum or
polyalphaolefin type synthetic lubricants:
1. Water content is greater than 500 ppm (parts per
million) (0.05%).
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. TAN (Total Acid Number) 50% increase above
reference sample from new oil container.
6. Viscosity changes more than 15%.
7. Solid particle contamination code exceeds 25/22/18
for particle sizes 4/6/14 microns, respectively per
ISO 4406.
Guidelines for when to change Falk GMax 6000
polyalkylene glycol type lubricant are:
1. Water content is greater than 3%.
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. Viscosity changes more than 15%.
6. Solid particle contamination code 25/22/18 per ISO
4406.
Laboratory analysis is recommended for optimum lubricant
life and gear drive performance.

cc Quantities are approximate. Always fill drive to specified level.

TABLE 4 Viscosity Grade Recommendations For Synthetic Lubricants

Ambient
Temperature
Range

Cold Climates

Normal Climates

30 to +10F
(34 to 12C)

15 to +50F
(26 to +10C)

0 to +80F
(18 to +27C)

+10 to +125F
(12 to +52C)

+20 to +125F
(7 to +52C)

ISO Viscosity Grade

32

68

150

220

320

AGMA Viscosity Grade

cc Gear drives NOT equipped with internal backstop may widen the ambient temperature range to -18 to +125F (-28 to +52C).

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix A

Sizes 5107-5315

(Page 25 of 52)

TABLE 5A Petroleum Based R & O (Rust & Oxidation) Inhibited Lubricants

Maximum Operating Temperature of Lubricants 200F (93C)

ISO Viscosity Grade

AGMA Viscosity Grade
Viscosity cSt @ 40C
Viscosity SSU @ 100F
Manufacturer
Castrol Industrial Lubricants
Chevron / Texaco / Caltex
Citgo Petroleum Corp.
Exxon Mobil / Esso
Petro-Canada Lubricants
Phillips 66 / Conoco / 76 Lubricants / Kendall
Shell Oil Co.
Total Lubricants USA / Keystone Div. Penwalt Corp.
Whitmore Manufacturing Company

220
5
198-242
918-1122
Lubricant Name
Hyspin AWS 220
Castrol Paradene R&O 220
Castrol Paradene AW 220
Rando HD 220
Pacemaker SD 220
DTE Oil BB
Vacuoline 533
TurboFlo R&O 220
Multipurpose R&O 220
Morlina S2 B 220
Morlina S2 BA 220
Cirkan ZS 220
Hyperion 220

320
6
288-352
1335-1632
Lubricant Name
--Castrol Paradene R&O 320
Castrol Paradene AW 320
Rando HD 320
Pacemaker SD 320
DTE Oil AA
Vacuoline 537
TurboFlo R&O 320
Multipurpose R&O 320
Morlina S2 B 320
Morlina S2 BA 320
Cirkan ZS 320
Hyperion 320

cc Minimum viscosity index of 90.

Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).

TABLE 5B Petroleum Based EP (Extreme Pressure) Lubricants

Maximum Operating Temperature of Lubricants 200F (93C)

ISO Viscosity Grade

AGMA Viscosity Grade
Viscosity cSt @ 40C n
Viscosity SSU @ 100F
Manufacturer
Castrol Industrial Lubricants
Chevron / Texaco / Caltex
Citgo Petroleum Corp.
Exxon Mobil / Esso
Fuchs Lubricants Company
Petro-Canada Lubricants
Phillips 66 / Conoco / 76 Lubricants / Kendall
Shell Oil Co.
Total Lubricants USA / Keystone Div. Penwalt Corp.

220
5
198-242
918-1122
Lubricant Name
Alpha SP 220
Meropa 220
Ultra Gear 220
EP Compound 220
Mobilgear 600 XP 220
GearMaster CLP Oils 220
Enduratex EP 220
Extra Duty Gear Oil 220
Omala S2 G 220
Carter EP 220

320
6
288-352
1335-1632
Lubricant Name
Alpha SP 320
Meropa 320
Ultra Gear 320
EP Compound 320
Mobilgear 600 XP 320
--Enduratex EP 320
Extra Duty Gear Oil 320
Omala S2 G 320
Carter EP 320

cc Minimum viscosity index of 90.

Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
DO NOT use in drives equipped with internal backstop.

TABLE 5C Petroleum Based Micropitting Resistant Lubricants

Maximum Operating Temperature of Lubricants 200F (93C)

ISO Viscosity Grade

AGMA Viscosity Grade
Viscosity cSt @ 40C n
Viscosity SSU @ 100F
Manufacturer
Kluber Lubrication

220
5
198-242
918-1122
Lubricant Name
Kluberoil GEM 1 N 220

320
6
288-352
1335-1632
Lubricant Name
Kluberoil GEM 1 N 320

cc Minimum viscosity index of 90.

Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
DO NOT use in drives equipped with internal backstop.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix A Falk Quadrive Shaft Mounted Drives Model A

(Page 26 of 52)

Sizes 5107-5315

TABLE 6A Synthetic PAO (Polyalphaolefin) R & O (Rust & Oxidation) Inhibited Lubricants
ISO Viscosity Grade
AGMA Viscosity Grade
Viscosity cSt @ 40C
Viscosity SSU @ 100F
Manufacturer
Castrol Industrial Lubricants
Chevron / Texaco / Caltex
Citgo Petroleum Corp.
Exxon Mobil / Esso
Kluber Lubrication
Petro-Canada Lubricants
Phillips 66 / Conoco / 76
Lubricants / Kendall
Shell Oil Co.

32
0
28.8-35.2
134-164
Lubricant Name
Alphasyn T 32
Castrol Isolube 32
Cetus HiPerSYN Oil 32
--Mobil SHC 624
--Synduro SHB 32

68
2
61.2-74.8
284-347
Lubricant Name

150
4
135-165
626-765
Lubricant Name

220
5
198-242
918-1122
Lubricant Name

320
6
288-352
1335-1632
Lubricant Name

Alphasyn T 68
Alphasyn T 150
Alphasyn T 220
Alphasyn T 320
Castrol Isolube 68
Castrol Isolube 150
Castrol Isolube 220
Castrol Isolube 320
Cetus HiPerSYN Oil 68
Cetus HiPerSYN Oil 150
Cetus HiPerSYN Oil 220
Cetus HiPerSYN Oil 320
CITGEAR Synthetic HT 68 CITGEAR Synthetic HT 150 CITGEAR Synthetic HT 220 CITGEAR Synthetic HT 320
Mobil SHC 626
Mobil SHC 629
Mobil SHC 630
Mobil SHC 632
Klubersynth G 4 68
Klubersynth G 4 150
Klubersynth G 4 220
--Synduro SHB 68
Synduro SHB 150
Synduro SHB 220
---

---

Syncon R&O 68

Syncon R&O 150

Syncon R&O 220

Syncon R&O 320

---

Morlina S4 B 68

Morlina S4 B 150

Morlina S4 B 220

Morlina S4 B 320

cc Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
zz Gear drives NOT equipped with internal backstop may widen the ambient tempeature range to -18 to +125F (-28 to +52C).
++ Minimum viscosity index of 120.

TABLE 6B Synthetic PAO (Polyalphaolefin) EP (Extreme Pressure) Lubricants

ISO Viscosity Grade
AGMA Viscosity Grade
Viscosity cSt @ 40C
Viscosity SSU @ 100F
Manufacturer

32
0
28.8-35.2
134-164
Lubricant Name

68
2
61.2-74.8
284-347
Lubricant Name

150
4
135-165
626-765
Lubricant Name

Castrol Industrial Lubricants

---

Castrol Isolube EP 68

Chevron / Texaco / Caltex

---

---

Citgo Petroleum Corp.

---

Exxon Mobil / Esso

Fuchs Lubricants Company
Kluber Lubrication
Petro-Canada Lubricants
Phillips 66 / Conoco / 76
Lubricants / Kendall
Shell Oil Co.
Whitmore Mfg. Company

---------

CITGEAR Synthetic
EP Gear 68
---------

Alphasyn EP 150
Alphasyn EP 220
Alphasyn EP 320
Castrol Isolube EP 150
Castrol Isolube EP 220
Castrol Isolube EP 320
Tegra Synthetic Gear
Tegra Synthetic Gear
Tegra Synthetic Gear
Lubricant 150
Lubricant 220
Lubricant 320
CITGEAR Synthetic
CITGEAR Synthetic
CITGEAR Synthetic
EP Gear 150
EP Gear 220
EP Gear 320
Mobil SHC Gear 150
Mobil SHC Gear 220
Mobil SHC Gear 320
--Renolin Unisyn CLP 220
Renolin Unisyn CLP 320
Klubersynth EG 4 150
Klubersynth EG 4 220
Klubersynth EG 4 320
Enduratex Synthetic EP 150 Enduratex Synthetic EP 220 Enduratex Synthetic EP 320

---

---

Syncon EP Plus Gear Oil 150 Syncon EP Plus Gear Oil 220 Syncon EP Plus Gear Oil 320

-----

Omala S4 GX 68
---

Omala S4 GX 150
Decathlon HD 150

220
5
198-242
918-1122
Lubricant Name

Omala S4 GX 220
Decathlon HD 220

320
6
288-352
1335-1632
Lubricant Name

Omala S4 GX 320
Decathlon HD 320

cc Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
zz Gear drives NOT equipped with internal backstop may widen the ambient tempeature range to -18 to +125F (-28 to +52C).
DO NOT use in drives equipped with internal backstop.

TABLE 6C Synthetic PAO (Polyalphaolefin) Micropitting Resistant Lubricants

ISO Viscosity Grade
AGMA Viscosity Grade
Viscosity cSt @ 40C
Viscosity SSU @ 100F
Manufacturer
Chevron / Texaco / Caltex
Exxon Mobil / Esso
Kluber Lubrication
Petro-Canada Lubricants
Phillips 66 / Conoco / 76 Lubricants / Kendall
Whitmore Manufacturing Company

32
68
0
2
28.8-35.2
61.2-74.8
134-164
284-347
Lubricant Name Lubricant Name
-------------

-------------

150
4
135-165
626-765
Lubricant Name

220
5
198-242
918-1122
Lubricant Name

320
6
288-352
1335-1632
Lubricant Name

----Pinnacle WM 320
----Mobil SHC Gear 320 WT
Klubersynth GEM 4 N 150 Klubersynth GEM 4 N 220 Klubersynth GEM 4 N 320
----Harnex 320
----Syncon WTL 320
Decathlon F 150
Decathlon F 220
Decathlon F 320

cc Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).
zz Gear drives NOT equipped with internal backstop may widen the ambient tempeature range to -18 to +125F (-28 to +52C).
DO NOT use in drives equipped with internal backstop.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix A

Sizes 5107-5315

(Page 27 of 52)

PETROLEUM LUBRICANTS In the absence of oil

analysis, change gear oils every 6 months or 2500 operating
hours, whichever occurs first. Change oil more frequently
when gear drives operate in extremely humid, chemical or
dust laden atmospheres. In these cases, lubricants should
be changed every 3 to 4 months or 1500 to 2000 hours. If
the drive is operated in an area where temperatures vary
with the seasons, change the oil viscosity grade to suit the
temperature, refer to Table 3. Lubricant suppliers can test
oil from the drive periodically and recommend economical
change schedules.

WARNING: Greases in Table 7 contain harmful substances

not allowed in the food processing industry. If grease
could contaminate the product, as in the food and drug
industries, the grease originally supplied with gear drive
must be removed and replaced with grease listed in Table
14. Refer to gear drive assembly/disassembly instructions.
Simply purging grease with grease gun will not remove all
grease and cross-contamination will likely occur. Grease
registered as H1 by NSF, National Sanitation Foundation, is
suitable for food processing applications.

SYNTHETIC LUBRICANTS In the absence of oil

analysis, synthetic lube change intervals can be extended
to 8000 hours depending upon operating temperatures.
Laboratory analysis is recommended for optimum lubricant
life and drive performance. Change lube with change in
ambient temperature, if required. Refer to Table 4.

STORED & INACTIVE GEAR DRIVES

Refer to Section II (Drive Service and Repair) for details on
stored & inactive gear drives.

Falk GMax 6000 change interval can be up to 15,000

hours. It has broad temperature range so seasonal oil
changes are generally not needed. The condition of
GMax must be monitored to maintain lubricant properties
and cleanliness.

GREASE-LUBRICATED SEALS
All drives are furnished with grease purged seals which
minimize the entry of contaminants and abrasive dusts into
the drive. Drives are shipped with NLGI #2 grade grease in
the seal housing cavities unless otherwise specified.
Whenever changing oil in the drive, purge the seals
with one of the NLGI #2 grade greases listed in Table 7.
Depending upon the degree of contamination, it may be
necessary to purge contaminated grease from seals more
often (at least every 3 to 6 months). Slowly pump fresh
bearing grease through the seal, WITH HAND GREASE
GUN, until fresh grease flows out along the shaft. Wipe off
purged grease.

TABLE 7 Conventional NLGI #2 Grade

Grease for Grease Purged Seals
0 to +200F (-18 to +93C)
Manufacturer
Chevron / Texaco /
Caltex
Citgo Petroleum Corp.
ExxonMobil / Esso
Petro-Canada
Lubricants
Phillips 66 / Conoco /
76 Lubricants / Kendall
Shell Oil Co.
Total Lubricants USA /
Keystone Div. Penwalt Corp.

EP Grease n

Grease Without
EP Additives

Multifak EP 2

---

Lithoplex RT 2
Premium Lithium EP 2

---

Mobilux EP 2

Unirex N2

Precision General
Purpose EP2

Precision XL EMB Grease

Precision Synthetic EMB

Multiplex Red

---

Gadus S1 V220-2

Gadus S2 V100 - 2

Multis EP 2

Multis 2

s Not suitable for food grade applications.

n Caution: Do not use EP grease in external backstop purged seals.
Grease application or re-lubrication should be done at temperatures
above 20F (-7C). If grease must be applied at cooler temperatures
consult lubricant supplier for recommendations.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix A Falk Quadrive Shaft Mounted Drives Model A

(Page 28 of 52)

Sizes 5107-5315

FOOD GRADE LUBRICANTS

Guidance for selecting petroleum-based and syntheticbased food grade lubricants are shown below in Table 8.
For general lubrication guidelines, refer to the first part of
the "Lubrication Recomendation" Section.
FOOD GRADE LUBRICANT SELECTION PROCESS
1. Refer to Table 9 or 10 for proper lubricant viscosity
grade based on ambient temperature range.
2. Refer to Table 8 for summary of food grade lubricant
type.
3. Using proper food grade lubricant table and viscosity
grade, select desired lubricant manufacturer name.
4. Refer to Table 2 for approximate oil capacity to
purchase.

TABLE 8 Summary of Food Grade

Lubricants and Greases
Petroleum-Based
R & O Inhibited
Extreme Pressure (EP)
See Table 11A
See Table 11B
Synthetic Lubricant, Polyalphaolefin Type (PAO)
R & O Inhibited
Extreme Pressure (EP)
See Table 12A
See Table 12B
Synthetic Lubricant, Polyalkylene Glycol Type (PAG)
Extreme Pressure (EP)
See Table 13
Food Grade Grease
See Table 14
DO NOT use in drives equipped with internal backstop.

FOOD GRADE LUBRICANTS (TABLES 11A, 11B, 12A,

12B, 13 & 14) Food grade lubricants are a class of
lubricants registered as H1 by NSF, National Sanitation
Foundation. They contain base stock and additives which
comply with Food and Drug Administration Title 21 CFR
178.3570 regulations for lubricants with incidental food
contact. Base stock can be petroleum oil or different types
of synthetic lubricant. Food grade lubricants are not same
as biodegradable or environmentally friendly lubricants.
Rust and corrosion inhibitors used to protect gear drive
during shipment are not qualified as food grade fluids. Flush
out inhibitor oil before filling with food grade lubricant.
Tables 11A, 11B, 12A, 12B, 13 & 14 list food grade
lubricants that have performance properties meeting
Rexnord/Falk specifications. They are not exclusive
recommendations but serve as a guide for making proper
lubricant selections.
CLIMATE CONDITIONS Ambient temperature in
immediate vicinity of gear drive is very important for
determining viscosity grade. Table 9 provides viscosity
grade selections for petroleum-based lubricants. See
Table 10 for synthetic lubricants.

TABLE 9 Viscosity Grade Recommendations

For Food Grade Petroleum-Based
Lubricants
Ambient Temperature
Range

+30 to +90F
(-1 to +32C)

+70 to +125F
(+21 to +52C)

ISO Viscosity Grade

220

320

AGMA Viscosity Grade

Polyalkylene glycols (PAG) are another class of synthetic

lubricants. They have similar performance properties
as PAO synthetics low pour point, stable at elevated
temperatures, and high viscosity index. PAG's have
exceptional tolerance to water contamination.
WARNING: Polyalkylene glycols (PAGs) are not
compatible with petroleum mineral oil or PAO synthetic
lubricants and must not be topped off with either lubricant.
In addition, petroleum mineral oils or PAO synthetic
lubricants must not be used to top off systems containing
PAGs. Do not use PAGs in gear drives with painted interior
housing walls unless paint compatibility is checked.
Compatibility with oil seals and gasket materials must be
checked prior to use. PAG lubricants are not compatible
with polycarbonate sight glass. Use glass sight glass.
CAUTION: EXTREME PRESSURE (EP) LUBRICANTS &
INTERNAL BACKSTOPS Do not use EP lubricants in
drives equipped with internal cartridge type backstops.
These lubricants are listed in Tables 11B, 12B & 13.

LUBRICANT ANALYSIS AND CHANGES

OIL ANALYSIS REPORT (FOOD GRADE) Checking oil
condition at regular intervals is recommended. Analyze oil
samples approximately every 1000 hours for food grade
petroleum lubricants or every 3000 hours for food grade
synthetic lubricants. In the absence of more specific limits,
the guidelines listed below may be used to indicate when
to change food grade lubricants:
1. Water content is greater than 500 ppm (parts per
million) (0.05%).
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. TAN (Total Acid Number) 50% increase above
reference sample from new oil container.
6. Viscosity changes more than 15%.
7. Solid particle contamination code exceeds 25/22/18
for particle sizes 4/6/14 microns, respectively per
ISO 4406.

TABLE 10 Viscosity Grade Recommendations for Food Grade Synthetic Lubricants

Ambient
Temperature
Range

Cold Climates

Normal Climates

30 to +10F
(34 to 12C)

15 to +50F
(26 to +10C)

0 to +80F
(18 to +27C)

+10 to +125F
(12 to +52C)

+20 to +125F
(7 to +52C)

ISO Viscosity Grade

32

68

150

220

320

AGMA Viscosity Grade

cc Gear drives NOT equipped with internal backstop may widen the ambient temperature range to -18 to +125F (-28 to +52C).

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix A

Sizes 5107-5315

(Page 29 of 52)

TABLE 11A Food Grade Petroleum-Based R & O (Rust & Oxidation) Inhibited Lubricants
NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200F (93C)

ISO Viscosity Grade

220

320

AGMA Viscosity Grade

Viscosity cSt @ 40C

198-242

288-352

Viscosity SSU @ 100F

Manufacturer
Bel-Ray Company, Inc.

918-1122

1335-1632

Lubricant Name

Lubricant Name

No-Tox Gear Oil ISO 220

No-Tox Gear Oil ISO 320

---

---

Lubriplate FMO 1100-AW

Lubriplate FMO 1700-AW

Kluber Lubrication
Lubriplate Lubricants Co.

cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes)

TABLE 11B Food Grade Petroleum-Based EP (Extreme Pressure) Lubricants

NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200F (93C)

ISO Viscosity Grade

220

320

AGMA Viscosity Grade

Viscosity cSt @ 40C

198-242

288-352

Viscosity SSU @ 100F

918-1122

1335-1632
Lubricant Name

Manufacturer

Lubricant Name

Petro-Canada

Purity FG EP 220

Purity FG EP 320

Total Lubricants USA, Inc.

Nevastane EP 220

Nevastane EP 320

cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes)

DO NOT use in drives equipped with internal backstop.

TABLE 12A Food Grade Synthetic PAO (Polyalphaolefin) R & O (Rust & Oxidation) Inhibited
Lubricants NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200F (93C)

ISO Viscosity Grade

32

68

150

220
5

320

AGMA Viscosity Grade

Viscosity cSt @ 40C
Viscosity SSU @ 100F

28.2-35.2

61.2-74.8

135-165

198-242

288-352

Manufacturer

134-164

284-347

626-765

918-1122

1335-1632

Lubricant Name

Lubricant Name

Lubricant Name

Lubricant Name

Lubricant Name

ExxonMobil

Mobil SHC Cibus 32

Mobil SHC Cibus 68

Mobil SHC Cibus 150

Mobil SHC Cibus 220

Mobil SHC Cibus 320

Kluber Lubrication

Kluberoil 4 UH1 N 32

Kluberoil 4 UH1 N 68

Kluberoil 4 UH1 N 150

Kluberoil 4 UH1 N 220

Kluberoil 4 UH1 N 320

Lubriplate Lubricants Co.

Lubriplate SFGO Ultra 32

Lubriplate SFGO Ultra 68

Lubriplate SFGO Ultra 150

Lubriplate SFGO Ultra 220

Lubriplate SFGO Ultra 320

Total Lubricants USA, Inc.

Nevastane SL 32

Nevastane SL 68

Nevastane SL 150

Nevastane SL 220

Nevastane SL 320

cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes)

Gear drives NOT equipped with internal backstop may widen ambient temperature range to -18 to +125F (-28 to +52C).

TABLE 12B Food Grade Synthetic PAO (Polyalphaolefin) EP (Extreme Pressure) Lubricants
NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200F (93C)

ISO Viscosity Grade

32

68

150

220

320

AGMA Viscosity Grade

Viscosity cSt @ 40C

Viscosity SSU @ 100F

28.8-35.2

61.2-74.8

135-165

198-242

288-352

134-164

284-347

626-765

918-1122

1335-1632

Manufacturer

Lubricant Name

Lubricant Name

Lubricant Name

Lubricant Name

Lubricant Name

Petro-Canada

---

---

---

Purity FG Synthetic EP 220

---

cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes)

Gear drives NOT equipped with internal backstop may widen ambient temperature range to -18 to +125F (-28 to +52C).
DO NOT use in drives equipped with internal backstop.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix A Falk Quadrive Shaft Mounted Drives Model A

(Page 30 of 52)

Sizes 5107-5315

TABLE 13 Food Grade Synthetic PAG (Polyalkylene Glycol) EP (Extreme Pressure)

Lubricants NSF (National Sanitation Foundation) H1 Registered
Maximum operating temperature of lubricants 200F (93C)
See Warning Note below.

ISO Viscosity Grade

32

68

150

220

320

AGMA Viscosity Grade

28.8-35.2

61.2-74.8

135-165

198-242

288-352

134-164

284-347

626-765

918-1122

1335-1632

Lubricant Name

Lubricant Name

Lubricant Name

Lubricant Name

Lubricant Name

Exxon Mobil

---

---

Glygoyle 150

Glygoyle 220

Glygoyle 320

Kluber Lubrication

---

---

Klubersynth UH1 6-150

Klubersynth UH1 6-220

Klubersynth UH1 6-320

Lubriplate

---

---

PGO-FGL Synthetic Gear Oil 150

PGO-FGL Synthetic Gear Oil 220

PGO-FGL Synthetic Gear Oil 320

Viscosity

cSt @ 40C

Viscosity SSU @ 100 F

Manufacturer

WARNING: Polyalkylene glycol (PAG) lubricants are not compatible with petroleum mineral oils or PAO synthetic lubricants. PAGs must not be mixed or
used to top off either petroleum mineral oils or PAO synthetic lubricants.

cc Kinematic viscosity in units of mm2/S is equivalent to cSt (centistokes).

Gear drives NOT equipped with internal backstop may widen the ambient temperature range to -18 to +125F (-28 to +52C).
DO NOT use in drives equipped with internal backstop.

Guidelines for when to change food grade polyalkylene

glycol type lubricant are:
1. Water content is greater than 3%.
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
4. Copper content exceeds 75 ppm.
5. Viscosity changes more than 15%.
6. Solid particle contamination code 25/22/18 per ISO 4406.
Laboratory analysis is recommended for optimum lubricant
life and gear drive performance.
PETROLEUM LUBRICANTS (FOOD GRADE) In the
absence of oil analysis, change gear oils every 6 months
or 2500 operating hours, whichever occurs first. Change
oil more frequently when gear drives operate in extremely
humid, chemical or dust laden atmospheres. In these
cases, lubricants should be changed every 3 to 4 months
or 1500 to 2000 hours. If the drive is operated in an area
where temperatures vary with the seasons, change the oil
viscosity grade to suit the temperature, refer to Table 9.
Lubricant suppliers can test oil from the drive periodically
and recommend economical change schedules.

SYNTHETIC LUBRICANTS (FOOD GRADE) In the

absence of oil analysis, synthetic lube change intervals
can be extended to 8000 hours depending upon operating
temperatures. Laboratory analysis is recommended for
optimum lubricant life and drive performance. Change lube
with change in ambient temperature, if required. Refer to
Table 10.

GREASE-LUBRICATED SEALS
All drives are furnished with grease purged seals which
minimize the entry of contaminants and abrasive dusts into
the drive. Drives are shipped with NLGI #2 grade grease
in the seal housing cavities unless otherwise specified.
Whenever changing oil in the drive, purge the seals with one
of the NLGI #2 grade greases listed in Table 14. Depending
upon the degree of contamination, it may be necessary to
purge contaminated grease from seals more often (at least
every 3 to 6 months). Slowly pump fresh bearing grease
through the seal, WITH HAND GREASE GUN, until fresh
grease flows out along the shaft. Wipe off purged grease.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

If grease could contaminate the product, as in the food

and drug industries, the grease originally supplied
with gear drive must be removed and replaced with
grease listed in Table 14. Refer to gear drive assembly/
disassembly instructions. Simply purging grease with
grease gun will not remove all grease and crosscontamination will likely occur. Grease registered as H1
by NSF, National Sanitation Foundation, is suitable for food
processing applications.

TABLE 14 Food Grade Grease for Grease

Purged Seals , NLGI #2 Grade
0 to +200F (-18 to +93C)

Manufacturer

Lubricant

Bel-Ray Company, Inc.

No-Tox HD Grease 2

Chevron USA, Inc. (Texaco/

Caltex)

Chevron FM ALC EP 2

Exxon Mobil

Mobil SHC Polyrex 462

Kluber Lubrication

Klubersynth UH1 14-222

Lubriplate

Lubriplate FGL-2

Total Lubricants USA, Inc.

Nevastane HT/AW 2

Petro-Canada

Purity FG

Phillips 66 / Conoco / 76
Lubricants / Kendall

Food Machinery Grease 2

cc NSF (National Sanitation Foundation) H1 Registered.

Grease application or re-lubrication should be done at temperatures
above 20F (-7C). If grease must be applied at cooler temperatures
consult lubricant supplier for recommendations.

STORED & INACTIVE GEAR DRIVES

Prior to shipment from the factory, all Rexnord enclosed
gear drives are protected internally against corrosion with
a rust preventative oil. A vapor phase rust inhibitor may
also be added.
WARNING: These corrosion inhibitors 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.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix A

Sizes 5107-5315

(Page 31 of 52)

THIS PAGE LEFT INTENTIONALLY BLANK

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix B Falk Quadrive Shaft Mounted Drives Model A

(Page 32 of 52)

Sizes 5107-5315

Backstop Installation
INTRODUCTION

Figure 1

The following instructions apply to INSTALLATION ONLY

of internal backstops in horizontal drives, sizes 5107 thru
5215 single and double reduction and size 5307 & 5315
double reduction.
CAUTION: If backstop is to be replaced, the high-speed
shaft must also be replaced. Refer to instructions regarding
high-speed shaft replacement, Section III.
Remove all external loads from system before servicing drive
or accessories, and lock out starting switch of prime mover.

LUBRICANT
PETROLEUM-BASED LUBRICANTS Use R & O type
lubricants which do not contain extreme pressure (EP)
additives if the drive is equipped with an internal backstop.
CAUTION: Do not use EP lubricants, or lubricant
formulations including sulfur, phosphorus, chlorine, lead
derivatives, graphite or molybdenum disulfides in drives
equipped with internal backstops. Refer to Appendix A
for proper selection of lubricants. Use of an improper
lubricant will contribute to premature wear or malfunction
of the backstop.
SYNTHETIC LUBRICANTS Synthetic lubricants of the
polyalphaolefin type may be used in drives with internal
backstops.
Before installing backstop, check direction of free rotation
(overrunning) indicated by the arrow etched on each side
of the backstop.

REF. #23 GASKET

REF. # 27
FASTENERS REF. #16
SHAFT COVER

2. BACKSTOP PREPARATION: Remove backstop Ref.

#5A1 from the kit and wipe off any excess lubricant.
On drive sizes 5107 (all ratios) and 5115 (24.87 ratio),
assemble retaining ring Ref. #5A2 onto one of the
grooves on the backstop OD. On drive size 5115J25,
assemble spacer Ref. #5A6 to backstop OD adjacent
to retaining ring on inboard side. All other size 5115J
and larger drives, insert housing spacer Ref. #5A3
(retaining ring used as housing spacer on drive size
5207J) into housing bore adjacent to bearing cup
(Figure 2). Assemble key Ref.#5A4 to backstop keyway
(spacer Ref. #5A6 is between retaining ring and key on
511J25 backstop).

BACKSTOP APPLICATION
Backstops are designed to prevent reverse rotation
or back-run without backlash in applications such as
conveyors, bucket elevators, fans, rotary pumps and
kilns. Backstops are not approved for use on systems that
are designed for handling of people such as elevators,
manlifts, ski tows and ski lifts. DO NOT use a backstop as a
substitute for a brake.

INDEXING
DO NOT use the backstop for indexing applications.
The backstop is designed to prevent reverse rotation
five times or less in eight hours, with one minute or
more in overrunning direction between backstopping
load applications. If backstopping operations are more
frequent, or the time between operations is less than one
minute, the backstop is classified as an indexing device
and must be referred to the Factory.

INSTALLATION (Backstop Added to Existing Drive

Only)
1. DRIVE PREPARATION: Drain oil from drive. Remove
fasteners Ref. #27, end cover Ref. #23, and gasket Ref.
#16, Figure 1. Keep size 5115J and 5207J end covers,
size 5207J fasteners and all lock washers for reuse, all
other parts may be discarded.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

REF.# 5A4

Figure 1
DRIVE SIDE

SHAFT
COVER
SIDE

REF.# 5A3 SPACER

REF.# 5A1
REF.# 5A2

REF.# 5A6 (5115J25 ONLY)

3. ALL SIZES BACKSTOP INSTALLATION: Apply oil

to the O.D. of the high-speed shaft backstop journal
and the sprags inside of the backstop. Align the
backstop key with the keyway in the exposed housing
bore and carefully slide the backstop into the bore
while slowly rotating the high-speed shaft. The shaft
will only rotate in one direction. DO NOT FORCE OR
HAMMER; this may damage the shaft or misalign the
sprags.

Check operation of backstop by turning high-speed
shaft in required direction of rotation by hand. If the
shaft does not rotate in the required direction, remove
backstop, reverse it, reposition the retaining ring and
spacer (where used) and reinsert it into the housing
bore as instructed.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix B

Sizes 5107-5315

(Page 33 of 52)

Backstop Installation

Rotate high-speed shaft in the required direction

of rotation and then reverse the rotation to lock up
the backstop. Observe the position of the sprags.
All sprags must be engaged and lay in the same
relative position around the shaft. If the sprags are not
uniformly positioned, lightly tap the backstop cage to
centralize all the sprags around the shaft and cage. If
sprags cannot be uniformly positioned in this manner,
remove the backstop and run a finger around the
sprags in the overrunning direction. Reinstall backstop
as instructed in preceding steps.

Check the position of the sprags several times by
overrunning and locking the sprags. If all sprags move
uniformly, hold the backstop in the locked position and
proceed to the next assembly step.
4. FINAL ASSEMBLY EXTERNAL PARTS: On drive
sizes 5107J and 5115J, install one gasket Ref. #23,
cover spacer Ref. #17, spider Ref. #5A5, second
gasket Ref. #23, and backstop end cover Ref. #16
(size 5115J uses stamped end cover removed in Step
1). Oil feed slots in gaskets and cover spacer must
be aligned with the housing backstop oil feed hole to
provide proper lubrication for the backstop. Refer to
figures 3A and 3B. Install fasteners with lock washers
and cross tighten to 3.5 lb-ft (4,7 Nm) torque.

Figure 3A

GASKET

Figure 4
DRIVE EQUIPPED
WITH INTERNAL BACKSTOP

H.S. SHAFT ROTATION

DO NOT USE EXTREME
PRESSURE LUBRICANTS

5107J WITH BACKSTOP

BACKSTOP OIL
FEED HOLE

On drive sizes 5203 thru 5315, install one gasket Ref.

#23 and backstop end cover Ref. #27 to drive housing
(one gasket Ref. #23, cover spacer Ref. #17, second
gasket Ref. #23, and end cover Ref. #16 on drive size
5207J). Size 5207J uses end cover and fasteners
removed in Step 1. Oil feed holes or slots in gaskets,
cover spacer (5207J), and cast shaft covers must
be aligned with the housing backstop oil feed hole
to provide proper lubrication to the backstop. Install
fasteners with lock washers and cross tighten to
8 lb-ft (11 Nm) torque.
Clean housing surface for rotation and WARNING
labels. Affix the rotation indicator label next to
the high-speed shaft extension to indicate the
free direction of rotation (Figure 4). Fill to oil level
specified in Section I with oil specified in Appendix
A. Check motor for correct rotation before completing
connection to drive.

Rexnord Industries, LLC

INSTALLED BACKSTOP
(WITH RETAINING
RING)

SPIDER 5A5
EXTERNAL HOUSING
SPACER WITH GASKET
ON BOTH SIDES REF.#17
END COVER REF.#16

Figure 3B

5115J WITH BACKSTOP

BACKSTOP OIL
FEED HOLE
OIL FEED
SLOT

INSTALLED BACKSTOP
(WITH SPACER AND
RETAINING RING
ON 5115J25)
EXTERNAL HOUSING SPACER
WITH GASKET ON BOTH SIDES
REF.#17
SPIDER 5A5

STAMPED ( REF.#16) END COVER

BACKSTOP REPLACEMENT IN EXISTING

DRIVES WITH DAMAGED BACKSTOPS
5. DISASSEMBLY EXTERNAL PARTS: Drain oil from
drive and remove backstop cover fasteners, backstop
end cover, gasket(s), cover spacer (where used),
and spider (where used). Save all metallic parts for
possible reuse.
6. BACKSTOP REMOVAL: Remove backstop from drive
and discard, keep backstop key, backstop spacer
(5115J25 only), and backstop retaining rings (where
used) for possible reuse. Remove housing spacer
from drive housing backstop bore and keep for reuse.
NOTE: Complete drive disassembly is required to
replace the high-speed shaft, refer to Sections II and
III of this manual for disassembly, parts replacement,
and reassembly of the basic drive.
7. BACKSTOP PREPARATION, BACKSTOP
INSTALLATION AND EXTERNAL PARTS
ASSEMBLY: Refer to Sections 2, 3, and 4 of this
appendix for preparation of the backstop, installation
of the backstop in the rebuilt drive, assembly of the
external parts associated with the backstop to the
drive and preparation of the drive for service.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix C Falk Quadrive Shaft Mounted Drives Model A

(Page 34 of 52)

Sizes 5107-5315

TA Removal Tool
INTRODUCTION
The patented TA removal tool offers a positive method
for removing a TA Taper equipped Quadrive from the
driven shaft. This method uses the torque multiplying
characteristic of the drive to separate the drive from the
bushing and driven shaft.
The removal tool is available in kit form suitable for use with
sizes 5107 thru 5315. The kit can be ordered from your
Rexnord distributor by specifying TA Removal Kit - Part
0769406. NOTE: Use of this tool requires a minimum axial
clearance M shown in Figure 1 and Table 1.
CAUTION: DO NOT modify the tool in any way OR use it
in another manner except to loosen the bushing nut as
instructed herein.
Figure 1

2. Loosen the setscrew on the O.D. of the bushing nut

and select the most convenient of the tapped holes in
the housing face for the threaded adapter. Figure 2.

Figure 2
DO NOT USE THIS HOLE
FOR SIZES 5107 & 5115
SETSCREW
(3) TOOL
ADAPTER HOLES

THREADED
ADAPTER

REMOVAL
TOOL

3. Select the proper adapter from the tool kit (adapters

are marked with the Quadrive Size and part number).
Make sure the tapped hole in the housing face is
clean before inserting the adapter. Apply tightening
torque from Table 2.

TABLE 1 Minimum Tool Clearance

Inches (mm)
DRIVE SIZE

M Dimension

5107
5115
5203

2.62 (67)
2.62 (67)
2.62 (67)
2.62 (67)
3.18 (81)
3.18 (81)
3.18 (81)

5207
5215
5307
5315

TABLE 2 Adapter Tightening Torque

DRIVE SIZE
5107
5115
5203
5207
5215
5307
5315

Adapter
Part Number

Torque
lb-ft (Nm)

2111955
2111956
9111957
2111958
2111959
2111959
2111959

35 (47)
70 (95)
108 (146)
120 (163)
180 (244)
180 (244)
180 (244)

PREPARATION FOR REMOVAL

WARNING: Always lock out prime mover before working
on the Quadrive.
1. Quadrive shafts, input and output, must be free to
rotate.
a) Remove any external load on the driven shaft.
b) Remove belts from input shaft sheave.
c) Remove the backstop (if so equipped). Refer
to Section II Step 10, for backstop removal
instructions.
CAUTION: DO NOT disconnect the drive from its
torque arm until the removal process is completed.
In addition, the drive must be supported during
removal process. Use a sling around the motor
mount or as recommended in Section I, Step 7.
Be sure to take up the slack in the sling before
proceeding.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Mount the removal tool as illustrated in Figure 3 or 4.

It is generally preferable to install the tool in a position
where its weight will tend to keep it engaged into
the nut. Then rotate the input shaft until the tool hook
engages one of the slots in the nut.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix C

Sizes 5107-5315

(Page 35 of 52)

TA Removal Tool
Figure 3

SIZES 5107, 5115, 5203, & 5207

ENGAGE TOOL
IN SLOT

TOOL

USE INNER
HOLE
LOW-SPEED SHAFT
ROTATION

Figure 4

SIZES 5215, 5307, & 4315

REMOVAL OF QUADRIVE
5. Use a spanner wrench to apply torque through the
input shaft keyway (Type J05 clockwise; Types J09,
J14 or J25 counter-clockwise) to loosen the bushing
nut.

CAUTION: Never use the prime mover to produce the
torque needed. This could result in severe personal
injury or damage to the equipment.

To avoid damage to the drive or the removal tool, DO
NOT exceed the H.S. shaft torque values listed in Table
3. NOTE: The nut will rotate freely for approximately
180 as it moves from the locked to the removal
position. Resistance will indicate that unseating
is occurring. Turn until the nut and bushing are
completely free. Now, prepare the drive for lifting by
disconnecting the torque arm at the drive end.
6. ALTERNATE METHOD Torque may be applied to
the sheave or sprocket mounted on the input shaft.

ENGAGE TOOL IN SLOT

TOOL

TABLE 3 Maximum Torque H.S. Shaft

lb-ft (Nm)

USE OUTER
HOLE
LOW-SPEED SHAFT
ROTATION

DRIVE
SIZE
5107
5115
5203
5207
5215
5307
5315

Drive Reduction
J05

J09

J14

J25

164 (223)
248 (336)
406 (550)
493 (668)
677 (917)
762 (1033)
813 (1102)

88 (120)
133 (181)
224 (304)
263 (357)
371(503)
405 (549)
432 (585)

58 (78)
90 (121)
143 (193)
173 (234)
245 (332)
278 (377)
283 (384)

33 (44)
50 (68)
79 (107)
100 (136)
133 (181)
150 (203)
160 (217)

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix D Falk Quadrive Shaft Mounted Drives Model A

(Page 36 of 48)

Sizes 5107-5315

Motor Mount Installation

INTRODUCTION

STANDARD ASSEMBLIES

The Falk Equi-Poised motor mount is an all steel weldment

that bolts directly to the drive housing of Falk Shaft-Mounted
(Type JR), Flange-Mounted (Type JF) and Screw Conveyor
(Type JSC) Drives, as shown in Figure 1.
This modern design provides a simple means of tensioning
V-belts or chains with adjusting screws. Motor baseplates are
available from Factory pre-drilled for NEMA and IEC standard
foot-mounted motors within the rated capacity of the drive.

Figure 1
JAM NUT

Figure 2

D3
(3 o'clock)

B9
(9 oclock)
A6
(6 o'clock)

C12
(12 o'clock)

Letter = Motor Mount Position

Clock = Drive High-speed Shaft Position

MOTOR
BASE PLATE

OPTIONAL ASSEMBLY
The motor mount may be mounted on the highspeed shaft end of FLANGE MOUNTED DRIVES
JF (also SCREW CONVEYOR DRIVES JSC)
if clearance over the trough end permits) when
increased motor mount clearance is required at
the driven machine. Consult Factory for SHAFTMOUNTED DRIVES JR.

BASE PLATE SUPPORT

ADJUSTING
SCREW

BASE PLATE SUPPORT

FASTENERS
SUPPORT LEG (ATTACHED
TO INPUT SIDE OF DRIVE)
SUPPORT LEG
FASTENERS
JAM NUT

MOTOR
BASE PLATE

BELT GUARD
MOUNTING HOLES

ADAPTER PLATE
ADAPTER FASTENERS

ASSEMBLY INSTRUCTIONS
From Figure 2, determine which assembly is required.
For minimum bearing loads on driven machine, minimum
shaft deflection and the most economical belt selections,
use the 6 oclock mounting position, high-speed shaft
relative to the low-speed shaft, illustrated in Figure
1. The motor/drive assembly can also be mounted in
positions shown in Figure 2. Always locate air vent at the
top of horizontal drives.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

GUARDS
CAUTION: Consult applicable
OSHA type
local and national safety
guard when
codes for proper guarding of
specified.
rotating members.
Dimensions
to suit
Mounting holes located on
components.
the motor mount supports are
provided for installing a belt
guard. Refer to Appendix L
for installation of Falk V-Belt
guards.
WARNING: Remove all external loads from system
before servicing drive or accessories.
1. ASSEMBLE MOTOR MOUNT Loosely assemble
support legs to the base plate support as shown in
Figure 1.

NOTE: Nuts on inside for sizes 5107 thru 5115.

Nuts on outside for sizes 5203 thru 5315.

For NEMA motor frames 254 and larger or IEC motor
frames 160 & larger, fasten adapter plate to base
plate support and tighten adapter fasteners to the
torque specified in Table 1. Assemble adjusting
screws to base plate support (or adapter plate when
used). Assemble motor base plate to adjusting
screws with a jam nut above and below the motor
base plate. Motor base plates on size 5207 and
larger drives with 254 frame and larger motors have
turned down edges. These base plates may be
inverted to improve access to the lower jam nuts
provided the turned up edges do not interfere with
the motor conduit box or electrical wiring.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix D

Sizes 5107-5315

(Page 37 of 52)

Motor Mount Installation

TABLE 1 Motor Mount Fasteners & Torques lb-ft (Nm)
Support Leg to
Baseplate Support

DRIVE
SIZE

Fastener
Size

5107 .375-16UNC x 1.00

5115 .375-16UNC x 1.00
5203 .500-13UNC x 1.25
5207 .500-13UNC x 1.25
5215 .625-11UNC x 1.50
5307 .750-10UNC x 1.75
5315 .750-10UNC x 1.75

Support Let
to Housing

Adapter Plate to
Baseplate Support

Adjusting Screws
(Without Adapter)

Adjusting Screws
(With Adapter)

Tightening
Torque

Fastener
Size

Tightening
Torque

Fastener
Size

Tightening
Torque

Fastener
Size

Tightening
Torque

Fastener
Size

Tightening
Torque

28 (38)
28 (38)
69 (94)
69 (94)
137 (186)
245 (332)
245 (332)

.312-18UNC x 1.50
.312-18UNC x 1.50
.375-16UNC x 2.00
.500-13UNC x 2.25
.500-13UNC x 2.25
.500-13UNC x 2.50
.500-13UNC x 2.50

20 (26)
20 (26)
28 (38)
69 (94)
69 (94)
69 (94)
69 (94)

...
.625-11UNC x 1.00
.625-11UNC x 1.00
.625-11UNC x 1.00
.625-11UNC x 1.00
.625-11UNC x 1.00
.625-11UNC x 1.00

...
60 (81)
60 (81)
60 (81)
60 (81)
60 (81)
60 (81)

.625-11UNC x 5.00
.625-11UNC x 5.00
.625-11UNC x 5.00
.625-11UNC x 5.00
.625-11UNC x 5.00
.625-11UNC x 5.00
.625-11UNC x 5.00

60 (81)
60 (81)
60 (81)
60 (81)
60 (81)
60 (81)
60 (81)

...
.750-10UNC x 6.00
1.000-8UNC x 6.00
1.250-7UNC x 7.00
1.250-7UNC x 7.00
1.250-7UNC x 7.00
1.250-7UNC x 7.00

...
108 (146)
180 (244)
362 (491)
362 (491)
362 (491)
362 (491)

cc All fasteners are Grade 5.

2. ATTACH MOTOR MOUNT TO DRIVE To determine

the number of housing flange fasteners to be removed
for a given shaft center and drive size, refer to Table 2.
Remove and discard appropriate number of housing
flange fasteners, and replace them with the longer
support leg fasteners provided. Attach support legs to
the input side of drive with the hex nuts on output side
of drive. Tighten support leg and base plate support
fasteners to torque values specified in Table 1.

RIGHT

Figure 4

WRONG

GEAR DRIVE WALL

Figure 3

LEVEL
M
MEDIUM
CENTERS

S
SHORT
CENTERS

SQUARE AND
PARALLEL

L
LONG
CENTERS

TABLE 2 Support Leg Fastener Quality

(Each Side)
DRIVE SIZE

Shaft
Centers

5107

5115

5203

5207

5215

5307
5315

Short

NA

NA

Medium

Long

Adjustment of the belt or chain is accomplished

by turning adjusting screws evenly. DO NOT overtighten belts or chains. Over-tightening belts or chains
reduces belt/chain and bearing life. When the required
tension is reached, tighten adjusting screw jam nuts
to torques listed in Table 1. Adjust chain tension to
manufacturers specifications. Adjust belts as follows:
The ideal belt tension is the lowest tension at which
the belt will not slip under peak load conditions. Check
belt tension frequently during the first 24 to 48 hours of
run-in operation. Keep belts free from foreign material
which may cause slippage. Inspect the V-belt drive
periodically; re-tighten belts if they are slipping.

3. MOUNT MOTOR Position motor on motor base

plate so that all mounting holes are in alignment. Install
and tighten motor fasteners.
4. SPROCKET, PULLEY OR SHEAVE CONNECTION
Mount power take-offs as close to drive and motor
housing as possible to avoid undue bearing load
and shaft deflection. Align the high-speed shaft of
drive square and parallel with motor shaft by placing
a straightedge across the face of the sprockets or
sheaves as illustrated in Figure 4. Check horizontal
shaft alignment by placing one leg of a square against
the face of the sheave or sprocket with the spirit level
on the horizontal leg of the square.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix E Falk Quadrive Shaft Mounted Drives Model A

(Page 38 of 52)

Sizes 5107-5315

Vertical Standpipe Installation

INTRODUCTION
The following instructions apply to the installation of
standpipe kits to standard drives mounted for vertical
operation (high-speed shaft up or down). Drawings are
representative of this series of drives and may not agree in
exact detail with all drive sizes.

HIGH-SPEED SHAFT DOWN FIGURE 1

1. After installing the drive per the Owners Manual
installation instructions, determine which of the lower
side plug locations on the drive will provide the best
location for the standpipe, observing clearance
required to remove dipstick (Dimension D, Table 1).
Discard the air vent. When the air vent location is not
used for the standpipe, relocate the pipe plug from the
selected standpipe location to the air vent location. Recoat pipe plug threads with Permatex #3 or equivalent
sealant before reinstalling.

TABLE 1 Dimensions Inches (mm)

DRIVE SIZE

5107
5115
5203

0.90 (23)
0.90 (23)
1.08 (27)
1.14 (29)
1.54 (39)
1.54 (39)
1.70 (43)

1.10 (28)
1.10 (28)
1.28 (33)
1.34 (34)
1.74 (44)
1.84 (47)
2.20 (56)

1.60 (41)
1.60 (41)
1.78 (45)
1.84 (47)
2.24 (57)
2.34 (59)
2.70 (69)

19.2 (488)
18.3 (465)
18.2 (462)
20.4 (518)
22.1 (561)
23.7 (602)
23.1 (587)

5207
5215
5307
5315

2. Coat all pipe threads of kitted parts with Permatex #3

or equivalent sealant.
3. Assemble kitted parts to the drive as illustrated in
Figure 1 and then secure the standpipe with an
external support to maintain its vertical position.
Figure 1

SCALE

STRAIGHT
EDGE
FILLER
PLUG

D
CLEARANCE
FO R DIPSTICK
REMOVAL

Figure 2

VENTED FILLER PLUG

OIL LEVEL

USE REDUCING BUSHING

FOR SIZES 5107 THRU 5207

X+ A
X+B
X+C

FILE SMOOTH

4. Carefully measure Dimension X as illustrated in Figure 1.

5. From Table 1:
X + A equals oil level Full mark.
X + B equals oil level Low mark.
X + C equals dipstick length.

May 2015
Supersedes 01-15

1. After installing the drive per the Owners Manual

installation instructions, determine which of the upper
four side plug locations on the drive will provide the
best location for the standpipe, observing clearance
required to remove dipstick (Dimension D, Table 1).
Discard the air vent. When the air vent location is not
used for the standpipe, relocate the pipe plug from the
selected standpipe location to the air vent location. Recoat pipe plug threads with Permatex #3 or equivalent
sealant before reinstalling.

OIL DRAIN

OIL FULL
LEVEL {
MARKS LOW

378-200 (PN-2128394)

HIGH-SPEED SHAFT UP FIGURE 2

DIPSTICK
CAP

FELT
PAD

USEREDUCING
OIL DRAIN BUSHING FOR
SIZES 5107 THRU 5207

6. Scribe Dimensions X + A and X + B on the dipstick as

illustrated in Figure 1. Make measurements from the
felt pad in the dipstick cap.
7. Lightly chisel permanent oil level marks on the scribed
lines and cut the dipstick to the length marked. File
end of dipstick smooth.
8. Install magnetic drain plug furnished in oil drain
location.
9. Remove the oil filler plug. Add oil until the oil level
reaches the Full mark on the dipstick. Coat the filler
plug (not vented) with Permatex #3 or equivalent
sealant and replace it.
10. Filler plug must always be removed to relieve
entrapped air before checking oil level.

2. Coat all pipe threads of kitted parts with Permatex #3

or equivalent sealant.
3. Assemble kitted parts to drive as illustrated in Figure
2 and then secure the standpipe with an external
support to maintain its vertical position.
4. See Figure 1 and follow steps 4 thru 7.
5. Install magnetic drain plug furnished in oil drain
location.
6. Remove one of the three oil level plugs. Add oil
through the standpipe until the oil level reaches
the plug hole. Coat the plug with Permatex #3 or
equivalent sealant and replace it. Be sure to use only
the vented filler plug in the standpipe.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Owners Manual

Sizes 5107-5315

(Page 39 of 52)

THIS PAGE LEFT INTENTIONALLY BLANK

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix F Falk Quadrive Shaft Mounted Drives Model A

(Page 40 of 52)

Sizes 5107-5315

Modifications for Non-Standard Mounting Positions

INSTRUCTIONS
For non-standard mountings, modify drives as illustrated
below and on Page 38 to assure satisfactory lubrication.
For applications that exceed the limits shown, drives that
are both rotated AND tilted and drives with backstops,
consult Factory.
CAUTION: Inadequate lubrication will cause damage.
When replacing a pipe plug (P) with a street elbow (E),
insert the plug in the elbow (E/P). When replacing a pipe
plug (P) with a street elbow (E), pipe nipple (N) and a pipe
cap (C), discard the pipe plug. Kits consist of parts for an
oil expansion chamber. Pipe fittings and kits tabulated on
Page 35 are available from Rexnord. Pipe fittings may also
be purchased locally. Use galvanized pipe fittings.

Remove all pipe plugs and coat them and the added parts, with
Permatex #3 or equivalent to prevent leakage. Install parts as
illustrated to suit the mounting position. The air vent must be in
the top of the drive or in the kit standpipe. Fill drives with oil to the
level indicated by the letter L in the following drawings.

STANDARD DRIVE MOUNTING

LIMITS
The standard drive rotation limits from the
basic 3, 6, 9 & 12 oclock mounting positions
are given in Section I, Page 4. For higher
limits, follow the instructions at the left and the
drawings below (6 oclock illustrated).

CW

CCW

CODE

B Bushing
N Nipple
C Cap
P Pipe Plug
E Street Elbow STD No Modifications
L Oil Level

HORIZONTAL DRIVE MODIFICATIONS 20 MAX. DRIVE ROTATION

5 to 20 CW Rotation Sizes 5107 & 5115
10 to 20 CW Rotation Sizes 5203 thru 5315

5 to 20 CCW Rotation Sizes 5203 thru 5315

10 to 20 CCW Rotation Sizes 5107 & 5115

3 oclock CW Rotation

3 oClock CCW Rotation

L

5107 = STD

5115 = .375 E/P

5115 = STD

6 oClock CCW Rotation

5115 = .375 E/P

5107 & 5115 = STD

5203 thru 5315 = STD

5203 = .375 E/C & .375 X 1.00N

5207 = .375 E/C & .375 X 1.50N
5215 = .500 E/C & .500 X 1.12N
5307 & 4315 = .500 E/C & .500 X 2.00N

9 oClock CCW Rotation

9 oClock CW Rotation
L

5203 = .375 E/C & .375 X 1.00N

5207 = .375 E/C & .375 X 2.00N
5215 = .500 E/C & .500 X 2.00N
5307 = .500 E/C & .500 X 2.50N
5315 = .500 E/C & .500 X 2.50N

L L

5107 = STD

5107 = KIT 0738540

5203 & 5207 = KIT 0786775

6 oClock CW Rotation

L
L

5107 = 5-12 STD

5107 = 13-20 .375 E/P
5115 = .375 E/P

5203 & 5207 = KIT 0786775

5215 thru 5315 = KIT 0786776

5107 = .375 E/P

5115 = .375 E/P

378-200 (PN-2128394)
May 2015
Supersedes 01-15

5115 = KIT 0786775

5107 = .375 E/C &

.375 X 3.00N

12 oClock CCW Rotation

12 oClock CW Rotation

5203 & 5207 = KIT 0786775

5215 thru 5315 = KIT 0786776

5107 & 5115 = KIT 0738540

5-15 16-20
5203 = .375 E/C & .375 X 1.00N 1.50N
5207 = .375 E/C & .375 X 1.00N 1.50N
5215 = .500 E/C & .500 X 1.12N 1.50N
5307 = .500 E/C & .500 X 1.50N 2.00N
5315 = .500 E/C & .500 X 1.50N 2.00N

L
5203 = .375 E/C & .375 X 1.50N
5207 = .375 E/C & .375 X 2.00N
5215 = .500 E/C & .500 X 2.00N
5307 = .500 E/C & .500 X 2.50N
5315 = .500 E/C & .500 X 2.50N

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix F

Sizes 5107-5315

(Page 41 of 52)

Modifications for Non-Standard Mounting Positions

STANDARD DRIVE
MOUNTING LIMITS

UP
DOWN

Standard Pipe Fittings Inches

The standard drive incline limits from

the basic 3, 6, 9 & 12 oclock mounting
positions are given in Section I, Page 4.
For higher limits, follow the instructions
on Page 38 and the drawings below (6
oclock illustrated).
CODE
C Cap
N Nipple
E Street Elbow P Pipe Plug
L Oil Level
STD No Modifications

.375-18 NPT

Falk No.

.500-14 NPT

Falk No.

.375 Street Elbow

.375 Cap
.375 x 1 Nipple
.375 x 1.5 Nipple
.375 x 2 Nipple
.375 x 3 Nipple

0915252
0914802
0915724
0915725
0915722
0915727

.500 Street Elbow

.500 Cap
.500 x 1.12 Nipple
.500 x 1.5 Nipple
.500 x 2 Nipple
.500 x 2.5 Nipple
.500 x 3 Nipple
.500 x 4 Nipple

0915251
0914803
0915734
0915735
0915736
0915723
0915737
0915739

cc Kits: Falk Nos. 0786775 & 0786776, oil expansion chamber parts. All
pipe fittings are galvanized.

HORIZONTAL DRIVE MODIFICATIONS FOR INCLINED H.S. SHAFT

H.S. Shaft Inclined 20 to 30 Up

H.S. Shaft Inclined 5 to 30 Down

3 oClock H,S,S Up

3 oClock H,S,S Down

5107 THRU 5315 = STD

6 oclock H,S,S Up

6 oClock H,S,S Down

5107 THRU 5315 = STD

5107 = .375 E/P

5115 = .375 E/C & .375 X 2.00N
5203 = .375 E/C & .375 X 1.50N
5207 = .375 E/C & .375 X 2.00N
5215 = .500 E/C & .500 X 2.50N
5307 = .500 E/C & .500 X 2.50N
5315 = .500 E/C & .500 X 2.50N

9 oclock H,S,S Up

9 oClock H,S,S Down

5107 THRU 5307 = STD

5315 = KIT 0786776

12 oClock H,S,S Up

5107 = 5-25 .375 E/P

5107 = 26-30 .375 E/C, .375 X 1.00N & KIT 0786775
5115 = 5-20 .375 E/C & .375 X 1.00N
5115 = 21-30 .375 E/C, .375 X 2.00N & KIT 0786775
5203 = 5-30 .375 E/C & .375 X 1.50N
5207 = 5-15 .375 E/P
5207 = 16-30 .375 E/C & .375 X 2.00N
5215 = 5-30 .500 E/C & .500 X 2.50N
5307 = 5-30 .500 E/C & .500 X 2.50N
5315 = 5-30 .500 E/C & .500 X 2.50N

12 oClock H,S,S Down

5107 THRU 5315 = STD

5107 = 5-15 STD

5107 = 16-30 .375 E/P & KIT 0786775
5115 = 5-15 .375 E/P
4115 = 16-30 .375 E/C, .375 X 2.00N & KIT 0786775
5203 = 5-20 .375 E/P
5203 = 21-30 .375 E/C, .375 X 1.50N & KIT 0786775
5207 = 5-20 .375 E/C
5207 = 21-30 .375 E/C, .375 X 2.00N & KIT 0786775
5215 = 5-15 .500 E/P
5215 = 16-30 .500 E/C, .500 X 2.00N & KIT 0786776
5307 = 5-20 .500 E/P
5307 = 21-30 .500 E/C, .500 X 2.00N & KIT 0738471
5315 = 5-30 .500 E/C, .500 X 4.00N & KIT 0738471
5107 = 5-15 .375 E/P
5107 = 16-30 .375 E/C, .375 X 1.00N & KIT 0786775
5115 = 5-15 .375 E/P
5115 = 16-30 .375 E/C, .375 X 2.00N & KIT 0786775
5203 = 5-30 .375 E/C & .375 X 1.50N
5207 = 5-30 .375 E/C & .375 X 2.00N
5215 = 5-30 .500 E/C & .500 X 2.50N
5307 & 4315= 5-30 .500 E/C & .500 X 2.50N

44 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.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix G Falk Quadrive Shaft Mounted Drives Model A

(Page 42 of 52)

Sizes 5107-5315

Retaining Rings for Bushing Nuts & Thrust Plates

JR Retaining Rings for Bushing Nuts
DRIVE SIZE

Manufacturer Part Number

5107
5115
5203

Truarc N5000-237
Truarc N5000-312
Truarc N5000-334

5207
5215
5307
5315

Eaton IN375
Truarc N5000-462
Eaton IN500
Truarc N5000-575

JF & JSC Retaining Rings for Thrust

Plate Kits
DRIVE SIZE

Manufacturer Part Number

5107
5115
5203

Truarc N5000-165
Eaton IN225
Eaton IN244

5207
5215
5307
5315

Eaton IN281
Eaton IN334
Eaton IN375
Eaton IN433

Tooth Combinations for Vibration Analysis

Type J05 Tooth Combinations

Type J09 Tooth Combinations

DRIVE
SIZE

Exact
Ratio

Pinion
Ref. #3A3

Gear
Ref. #4A4

5107
5115
5203

5.077
5.053
5.071

13
19
14

66
96
71

5207
5215
5307
5315

5.077
4.923
4.857
4.857

13
13
14
14

66
64
68
68

Type J14 Tooth Combinations

DRIVE
SIZE

Exact
Ratio

5107
5115
5203
5207
5215
5307
5315

Input

DRIVE
SIZE

Exact
Ratio

5107
5115
5203
5207
5215
5307
5315

Input

Output

Pinion
Ref. #1A3

Gear
Ref. #1A4

Pinion
Ref. #2A

Gear
Ref. #4A4

9.462
9.357
9.179

22
27
21

41
50
38

13
19
14

66
96
71

9.492
8.997
9.131
9.131

23
29
25
25

43
53
47
47

13
13
14
14

66
64
68
68

Type J25 Tooth Combinations

Output

DRIVE
SIZE

Exact
Ratio

Pinion
Ref. #1A3

Gear
Ref. #1A4

Pinion
Ref. #2A3

Gear
Ref. #4A4

14.43
13.95
14.45

19
21
20

54
58
57

13
19
14

66
96
71

5107
5115
5203

14.47
13.60
14.03
13.91

20
21
18
22

57
58
52
63

13
13
14
14

66
64
68
68

5207
5215
5307
5315

Input

Output

Pinion
Ref. #1A3

Gear
Ref. #1A4

Pinion
Ref. #2A3

Gear
Ref. #4A4

25.81
24.87
26.94

12
13
16

61
64
85

13
19
14

66
96
71

24.99
24.94
25.26
25.26

13
15
15
15

64
76
78
78

13
13
14
14

66
64
68
68

Seal Housing Lip Seals for Types JSC

Type JSC Seal Housing Lip Seals Accessory
DRIVE SIZE

Falk Part No.

Manufacturers Part No.

5107
5115
5203

2905318
0912859
2911847

Chicago Rawhide 17271

National 470565
Chicago Rawhide 26153

5207
5215
5307
5315

0912835
2911957
0912741
0912741

Chicago Rawhide 29865

Chicago Rawhide 34861
Chicago Rawhide 34886
Chicago Rawhide 34886

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix H

Sizes 5107-5315

(Page 43 of 52)

Drive Shaft Recommendations for Tapered Drive Shafts

Dimensions Inches (mm)

Keyway
DRIVE
SIZE

LA

LB

Key

LC

T
Min

+.000, .005
(+0.00, 0.13,

DA

.030
(0.76)

+.000, .010
(+0,00,
0.25)

+.040, .000
(+1.02,
0.00)

LD

LE

2.875 (73.02)
3.250 (82.55)
3.750 (95.25)

1.614 (40.996)
2.173 (55.194)
2.425 (61.595)

1.750 (44.45)
2.357 (59.87)
2.620 (66.55)

.437 (11.10)
.500 (12.70)
.500 (12.70)

1.329 (33.76)
1.902 (48.31)
2.153 (54.69)

3.679 (93.45)
5.656 (143.66)
5.286 (134.26)

1.50 (38.1)
2.72 (69.1)
2.13 (54.1)

1.50 (38.1)
1.50 (38.1)
1.50 (38.1)

1.07 (27.2) .500-13 2.00 (50.8)

1.16 (29.46) .500-13 2.00 (50.8)
1.10 (27.9) .625-11 2.00 (50.8)

4.875 (123.82)
4.250 (107.95)
5.875 (149.22)
6.000 (152.40)

2.725 (69.215)
3.258 (82.753)
3.878 (98.501)
4.433 (112.598)

2.920 (74.17)
3.500 (88.90)
4.100 (104.14)
4.664 (118.47)

.625 (15.88)
.750 (19.05)
.875 (22.22)
1.000 (25.40)

2.416 (61.37)
2.923 (74.24)
3.413 (86.69)
3.871 (98.32)

6.218 (157.94)
7.616 (193.45)
8.008 (203.40)
8.398 (213.31)

3.10 (78.7)
3.75 (95.3)
4.46 (113.3)
4.75 (120.7)

2.00 (50.8)
2.00 (50.8)
2.04 (51.8)
2.00 (50.8)

.010
(0.25)

5107
5115
5203

.375 (9.53)
.500 (12.70)
.500 (12.70)

5207
5215
5307
5315

.625 (15.88)
.750 (19.05)
.875 (22.23)
1.000 (25.40)

MD

.375
.500
.500

.375
.375
.375

2.50
2.75
3.25

1.11 (28.2) .625-11 2.00 (50.8) .625

1.19 (30.2) .875-9 2.50 (63.5) .750
1.27 (32.2) 1.000-8 2.75 (69.8) .875
1.27 (32.2) 1.000-8 2.75 (69.8) 1.000

.438
.500
.625
.750

4.25
3.50
5.00
5.00

cc Dimensions are for reference only and are subject to change without notice unless certified.
Inch keyway width tolerances are as follows: over .312 (7.92) to & including .500 (12.70) = +.0025 (+0.064), .0000 (0.000), over .500 (12.70) to &
including 1.000 (25.40) = +.0030(+0.076), .0000(0.000). Keyway depth tolerance is +.010(+0.25), .000(0.00).
Straight diameter is used to aid in measurement and manufacture of the keyway.
zz Dimension MD will vary slightly depending on degree of axial compression during installation and manufacturing tolerances.
44 Dimension LC is a measure of the length of the taper from the basic taper diameter (DA) to the end of the shaft. NOTE: for Drive Size 5107, LC will be
located approximately 1.16 (29.5 mm) inside end of hollow shaft (not near the end of the hollow shaft as shown).

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix J Falk Quadrive Shaft Mounted Drives Model A

(Page 44 of 52)

Sizes 5107-5315

Drive Shaft Recommendations Using TA Taper Bushing

INTRODUCTION These instructions are for use when a
flange-mounted 5107-5315JF drive is to be used and the
manufacture of a tapered drive shaft is not feasible. For
JF tapered drive shaft recommendations, see Appendix
H. Use this appendix to retrofit existing applications or for
outfitting new installations. Parts required are the Basic
drive, TA Taper bushing and a thrust plate kit.
This appendix will allow the use of a straight drive shaft
with the tapered bushing (without spanner nut) on flangemounted applications. Provided are dimensions (Table
4) for shaft recommendations and instructions for the
installation and removal of the assembly. All bushing bore
sizes, which are available in the standard Quadrive, are
possible with this setup.
Drives are provided with tapped holes in the output face of
the housing along with a female register to allow mounting
to the driven equipment. JF drives are mounted to the
equipment without the use of an adapter flange. Optional
adapter flanges are available, consult the Factory.
FIGURE 2 The hollow shaft of the drive has a tapered
bore which accepts the tapered bushing. When the
bushing is drawn into the taper, a clamping force is applied
to the drive shaft. The drive shaft is drawn into the hollow
shaft via a fastener in the thrust plate. The bushing seats
against a shoulder on the driven shaft and is drawn into the
drive with the shaft. Removal is accomplished by using a
jackscrew in the thrust plate and forcing the drive shaft out
of the drive. The retaining ring in the drive shaft assures
that the bushing will be removed along with the shaft.
DRIVE SHAFT RECOMMENDATIONS The
recommendations for the drive shaft consist of two major
features. The first is the shoulder which must be provided
in the location shown in Figure 2. This shoulder provides
the backing necessary to draw the bushing into the
taper. A permanently fixed shoulder must be provided in
order for this design to be effective. The shoulder may
be a welded collar or an integral step. SET COLLARS
ARE NOT ACCEPTABLE. A retaining ring may be used,
in the driven shaft, to provide the shoulder, but stress
concentrations occur at the groove and therefore shaft
stresses must be checked. The second major feature on
the shaft is the retaining ring groove in the shaft end. This
feature is recommended to ensure positive removal of the
bushing when the drive shaft is removed from the drive.
The threaded hole in the end of the drive shaft accepts the
thrust plate fastener.
WARNING: Lock out power source and remove all external
loads from system before servicing drive or accessories.
INSTALLATION PROCEDURE With the drive shaft
manufactured per the recommendations shown, and the
bushing selected for the proper shaft diameter, remove
and discard the retaining ring and spanner nut from the
bushing assembly.
Slide the bushing (flange end first) onto the drive shaft until
it contacts the shoulder on the shaft. Insert the key through
the bushing and into the drive shaft keyway. Install the
retaining ring into the groove in the drive shaft. Bring the
drive into position, line-up the hollow shaft keyway with the
key, and slide the bushing and drive shaft into the hollow
shaft bore.

Attach the drive to the mounting surface with fasteners (not

provided). Refer to Table 1 for fastener size and tightening
torque. Assemble the thrust plate and retaining ring into
the counterbore in the hollow shaft. Insert the thrust plate
fastener through the thrust plate and thread into the drive
shaft end. Tighten to the torque given in Table 2. Install all
covers and guards.
REMOVAL PROCEDURE Remove low-speed shaft
input end cover. Remove the thrust plate fastener, retaining
ring and thrust plate from the hollow shaft. Refer to Table
3 and select a backing bolt and flat washer and install
them into the drive shaft as illustrated in Figure 1. The
head of the backing bolt 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 3. Thread the removal bolt into the thrust plate until
it contacts the backing bolt head. Tighten the removal bolt
to the torque indicated in Table 3 (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, re-torquing the bolt after
each blow, until separation occurs.

378-200 (PN-2128394)

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

May 2015
Supersedes 01-15

Figure 1

BACKING BOLT

TAPPED HOLE
IN DRIVE SHAFT

REMOVAL
BOLT
DRIVE SHAFT

RETAINING
RING

THRUST
PLATE

BUSHING

RETAINING
RING
HOLLOW
SHAFT
FLAT WASHER

TABLE 1 JF Drive Foundation Fastener

& Tightening Torque
(Non-Lubricated Fasteners)
DRIVE
SIZE

Fastener Size
& Grade

Max Tightening
Torque
lb-ft (Nm)

Min. Fastener
Engagement Into
Drive Housing
Inch (mm)

5107
5115
5203

.500-13UNC, GR. 5
.625-11UNC, GR. 5
.750-10UNC, GR. 5

69 (94)
137 (186)
245 (332)

.76 (19.3)
.94 (23.9)
.76 (19.3)

5207
5215
5307
5315

.875- 9UNC, GR. 5

1.000- 8UNC, GR. 5
1.000- 8UNC, GR. 8
1.000- 8UNC, GR. 8

380 (515)
567 (769)
792 (1074)
792 (1074)

.88 (22.4)
1.00 (25.4)
1.24 (31.5)
1.24 (31.5)

Falk Quadrive Shaft Mounted Drives Model A Appendix J

Sizes 5107-5315

(Page 45 of 52)

Drive Shaft Recomendations Using TA Taper Bushing

MOUNTING
SURFACE

Figure 1

FURNISHED
BY CUSTOMER

W (Keyway)

B
A
L (Keyway)

H (Keyway)

DB

DA
0.010 (0.25 mm) R MAX.
IN GROOVE CORNERS

THRUST
PLATE
FASTENER

.06 (1.5 mm) RADIUS

1-S DIA. UNC TAPPED HOLE

T-DEEP

C
MOUNTING
SURFACE

TABLE 3 Removal & Backing Bolt Size

and Tightening Torque

TABLE 2 Thrust Plate Fastener Data

(Non-Lubricated Fasteners)
DRIVE
SIZE

Fastener Size & Grade

Max Tightening
Torque lb-ft (Nm)

Min Thread Depth

Inches (mm)

5107
5115
5203

.500-13UNC x 3.50, GR.8

.500-13UNC x 4.00, GR.8
.625-11UNC x 3.50, GR.8

92 (125)
92 (125)
183 (248)

2.00 (50.8)
2.00 (50.8)
2.00 (50.8)

5207
5215
5307
5315

.625-11UNC x 3.50, GR.8

.875- 9UNC x 5.00, GR.8
1.000- 8UNC x 5.00, GR.5
1.000- 8UNC x 5.00, GR.8

183 (248)
533 (723)
567 (769)
792 (1074)

2.00 (50.8)
2.50 (63.5)
2.50 (63.5)
2.50 (63.5)

cc Fasteners may be hex socket head or hex head except for size 5307,
which must be a hex head to clear input end cover.

DRIVE
SIZE

Removal Bolt Size &

Min Length Inches

Max Tightening
Torque lb-ft (Nm)

Backing Bolt
Size & Max
Length Inches

5107
5115
5203

.625-11UNC x 1.75
.625-11UNC x 1.75
.750-10UNC x 2.00

133 (180)
133 (180)
242 (328)

.500-13UNC x 1.25
.500-13UNC x 1.25
.625-11UNC x 1.75

5207
5215
5307
5315

.750-10UNC x 2.00
1.000- 8UNC x 2.50
1.125- 7UNC x 3.00
1.125- 7UNC x 3.00

242 (328)
567 (769)
742 (1006)
742 (1006)

.625-11UNC x 1.75
.875- 9UNC x 2.25
1.000- 8UNC x 2.50
1.000- 8UNC x 2.50

TABLE 4 Dimensions for Largest Bore Bushing Inches (mm)

Thrust
Plate
Kit

Thrust
Plate
Part
No.

5107

TP4107JF

5115

DRIVE
SIZE

Retaining Ring
A
0.010

DA

(0.250)

0.030
(0.75)

0778773

4.780
(121.41)

5.000 -1.356 (-34.4) 2.500

(127.00) -1.606 (-40.8) (63.50) 1.4375

TP4115JF

0778774

5.330
(135.38)

5203

TP4203JF

0778775

5207

TP4207JF

5215

DB
Min

Groove

Keyway

Spir O Lox
Max
O.D

L
Min

T
Min

Mfg
No.

1.750
(44.45)

1.295
1.287

0.056
0.060

RSN-137

1.500

0.375

0.1875

3.563
(90.50)

2.00
0.500-13 (50.8)

5.500 -1.528 (-38.8) 3.250

(139.70) -1.794 (-45.6) (82.55 1.9375

2.250
(57.15)

1.735
1.725

0.068
0.072

RST-181

2.000

0.500

0.2500

4.000
(101.60)

2.00
0.500-13 (50.8)

5.310
(134.87)

5.625 -1.634 (-41.5) 3.500

(142.88) -1.921 (-48.8) (88.90) 2.1875

2.500
(63.50)

1.952
1.940

0.086
0.091

RSN-206

2.250

0.500

0.2500

4.625
(117.48)

2.00
0.625-11 (50.8)

0778776

5.890
(149.61)

6.250 -1.557 (-39.6) 4.000

(158.75) -1.885 (-47.9) (101.60) 2.4375

2.750
(69.85)

2.290
2.278

0.056
0.060

RS-236

2.500

0.625

0.3125

5.625
(142.88)

2.00
0.625-11 (50.8)

TP4215JF

0778777

6.860
(174.24)

7.125 -1.755 (-44.6) 4.750

(180.98) -2.082 (-52.9) (120.65) 2.9375

3.250
(82.55)

2.728
2.716

0.056
0.060

RS-281

3.062

0.750

0.3750

5.875
(149.22)

2.50
0.875-9 (63.5)

5307

TP4307JF

0778778

7.170
(182.12)

7.500 -1.843 (-46.8) 5.125

(190.50) -2.175 (-55.2) (130.18) 3.4375

3.750
(95.25)

3.172
3.160

0.103
0.108

RSN-334

3.625

0.875

0.4375

6.750
(171.45)

2.50
1.000-8 (63.5)

5315

TP4315JF

0778779

7.700
(195.58)

8.000 -1.840 (-46.7) 6.000

4.250
(203.20) -2.175 (-55.2) (152.40) 3.9375 (107.95)

3.701
3.690

0.120
0.125

RST-387

4.125

1.000

0.5000

7.062
(179.37)

2.50
1.000-8 (63.5)

cc For metric drive shafts or bushing bores smaller than the maximum provide the retaining ring groove per manufacturers recommendations, keyway
appropriate for the shaft diameter, and DB minimum of 0.300 (7.62 mm) larger than the bushing bore to provide adequate backing.
Kit consists of: thrust plate, thrust plate fastener, hollow shaft retaining ring, and drive shaft retaining ring.
The range for C dimensions is the variation which may occur due to axial compression and manufacturing tolerances. Negative C dimensions indicate that
the bushing protrudes beyond the mounting surface.
zz The D dimension is the recommended minimum bore which clears the TA Taper bushing flange.
44 Shaft diameter tolerances are per AGMA as follows: to 1.50 = +.000, -.004; over 1.50 to & including 2.50 = +.000, -.005; over 2.50 to & including
4.00 = +.000, - .006. Metric drive shafts are to be based on h10 tolerances.
ww Smalley retaining rings may be used instead of Spir O Lox by substituting WS for RS. WST for RST or WSM for RSN.
yy Inch keyway width tolerances are as follows: over .312 to & including .500 = +.0025, -.0000; over .500 to & including 1.000 = +.0030, -.0000. Metric keyway
widths are based on class N9 tolerances. Inch keyway depth tolerance is +.010, -.000. Refer to ISO 773 or DIN 6885 sheet 1 for metric keyway depth tolerances

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 513-455-5030 Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix K Falk Quadrive Shaft Mounted Drives Model A

(Page 46 of 52)

Sizes 5107-5315

Drive Shaft Recomendations Using (TCB) Kit

INTRODUCTION These instructions are for use when a
screw conveyor 5107 - 5315JSC drive is to be used and the
following conditions exist: Falk standard or 316 stainless steel
JSC tapered drive shafts can not be used due to special
extension dimensions or materials; or manufacturing a
special tapered drive shaft is not feasible. Use this appendix
to retrofit existing applications or for outfitting new installations
where the above conditions warrant. For tapered shaft
recommendations, see Appendix H.
This appendix will allow the use of a straight (non-tapered)
drive shaft with a special bushing conversion kit on screw
conveyor applications. This kit provides one bushing bore per
drive size as shown in Table 4. Provided in this appendix are
dimensions for drive shaft recommendations and instructions
for the installation and removal of the assembly.
FIGURE 2 The hollow shaft of the drive has a tapered
bore which accepts the tapered bushing. When the
bushing is drawn into the taper, a clamping force is applied
to the drive shaft. The drive shaft is drawn into the hollow
shaft via a fastener in the thrust plate. The bushing seats
against a shoulder on the drive shaft and is drawn into the
drive with the shaft. Removal is accomplished by using a
jackscrew in the thrust plate and forcing the drive shaft out
of the drive. The retaining ring in the drive shaft assures
that the bushing will be removed along with the shaft.
The packing gland sealing option (sizes 5107-5315) is
usable with the bushing kit, but the clamp ring must be
assembled from the extension end of the drive shaft on
sizes 5307 and 5315.
DRIVE SHAFT RECOMMENDATIONS The
recommendations for the drive shaft consist of two major
features. The first is the shoulder which must be provided
in the location shown in Figure 2. This shoulder provides
the backing necessary to draw the bushing into the taper. A
permanently fixed shoulder must be provided in order for this
design to be effective. The shoulder may be a welded collar
or an integral step. SET COLLARS ARE NOT ACCEPTABLE.
A retaining ring may be used in the drive shaft, to provide the
shoulder, but stress concentrations can occur at the groove
and therefore shaft stresses must be checked. The second
major feature on the shaft is the retaining ring groove in the
shaft end. This feature is recommended to ensure positive
removal of the bushing when the drive shaft is removed from
the drive. The threaded hole in the end of the drive shaft
accepts the thrust plate fastener.
WARNING: Lock out power source and remove all external
loads from system before servicing drive or accessories.
INSTALLATION PROCEDURE With the shaft manufactured
per the recommendations shown, proceed as follows:
5107-5215JSC The seal housing may be assembled to
the drive before or after the drive shaft is installed into the
drive, depending on the shaft extension diameter.
5307-5315JSC The seal housing must be assembled
over the drive shaft from the extension end of the shaft, or
the shaft shoulder must be fixed in position after the seal
housing is assembled over the drive shaft (see Figure 2).
ALL JSC DRIVES Slide the bushing (large end first)
onto the drive shaft until it contacts the shoulder on the
shaft. Insert the key through the bushing and into the
drive shaft keyway. Install the retaining ring into the groove

in the drive shaft. Line up the keyway in the drive hollow

shaft with the key in the drive shaft and slide shaft/bushing
assembly into the hollow shaft. Attach the seal housing to
the drive with the fasteners provided.
Tighten fasteners to torque given in Table 1. Assemble the
thrust plate and retaining ring into the counterbore in the
hollow shaft. Insert the thrust plate fastener through the
thrust plate and thread into the drive shaft end. Tighten to
the torque given in Table 2. Install all covers and guards.
REMOVAL PROCEDURE Remove low-speed shaft input
end cover. Remove the thrust plate fastener, retaining ring and
thrust plate from the hollow shaft. Refer to Table 3 and select a
backing bolt and flat washer and install them into the drive shaft
as illustrated in Figure 1. The head of the backing bolt 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 3. Thread the removal bolt into the thrust plate until it
contacts the backing bolt head. Tighten the removal bolt to the
torque indicated in Table 3 (if the thrust plate rotates in the shaft,
align the slot in the plate with the hollow shaft keyway and insert
a screwdriver 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 re-torque the bolt if separation of the drive
from the shaft did not occur. Repeat this procedure, re-torquing
the bolt after each blow, until separation occurs.

378-200 (PN-2128394)

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

May 2015
Supersedes 01-15

BACKING BOLT

Figure 1

TAPPED HOLE
IN DRIVE SHAFT

REMOVAL
BOLT
DRIVE SHAFT

RETAINING
RING

THRUST
PLATE

BUSHING

RETAINING
RING
HOLLOW
SHAFT
FLAT WASHER

TABLE 1 Seal Housing Fastener Tightening

Torque (Non-Lubricated Fasteners)
DRIVE
SIZE

Fastener Size

Max Tightening
Torque lb-ft (Nm)

5107
5115
5203

.500-13UNC
.625-11UNC
.750-10UNC

69 (94)
137 (186)
245 (332)

5207
5215
5307
5315

.875- 9UNC
1.000- 8UNC
1.000- 8UNC
1.000- 8UNC

380 (515)
567 (769)
792 (1074)
792 (1074)

TABLE 2 Thrust Plate Fastener Data

(Non-Lubricated Fasteners)
DRIVE
SIZE

Fastener Grade
& Size

Max Tightening
Torque lb-ft (Nm)

Min Thread Depth

Inches (mm)

5107
5115
5203

.500-13UNC x 3.50, GR.8

.500-13UNC x 4.00, GR.8
.625-11UNC x 3.50, GR.8

92 (125)
92 (125)
183 (248)

2.00 (50.8)
2.00 (50.8)
2.00 (50.8)

5207
5215
5307
5315

.625-11UNC x 3.50, GR.8

.875- 9UNC x 5.00, GR.8
1.000- 8UNC x 5.00, GR.5
1.000- 8UNC x 5.00, GR.8

183 (248)
533 (723)
567 (769)
792 (1074)

2.00 (50.8)
2.50 (63.5)
2.50 (63.5)
2.50 (63.5)

cc Fasteners may be hex socket head or hex head except for size 5307,
which must be a hex head to clear input end cover.

Falk Quadrive Shaft Mounted Drives Model A Appendix K

Sizes 5107-5315

(Page 47 of 52)

Drive Shaft Recommendations Using (TCB) Kit

Figure 2
MOUNTING
SURFACE

MOUNTING
SURFACE
V
U

MOUNTING
SURFACE

THRUST
PLATE
FASTENER

MOUNTING
SURFACE

THRUST
PLATE
FASTENER
A

W (Keyway)

TABLE 3 Removal & Backing Bolt Size

and Tightening Torque

B
A

DRIVE
SIZE

Removal Bolt Size &

Min Length Inches

Max Tightening
Torque lb-ft (Nm)

Backing Bolt Size &

Max Length Inches

5107
5115
5203

.625-11UNC x 1.75
.625-11UNC x 1.75
.750-10UNC x 2.00

133 (180)
133 (180)
242 (328)

.500-13UNC x 1.25
.500-13UNC x 1.25
.625-11UNC x 1.75

5207
5215
5307
5315

.750-10UNC x 2.00
1.000- 8UNC x 2.50
1.125- 7UNC x 3.00
1.125- 7UNC x 3.00

242 (328)
567 (769)
742 (1006)
742 (1006)

.625-11UNC x 1.75
.875- 9UNC x 2.25
1.000- 8UNC x 2.50
1.000- 8UNC x 2.50

L (Keyway)

H (Keyway)
F

DB

DA
0.010 (0.25 mm) R MAX.
IN GROOVE CORNERS
G
.06 (1.5 mm) RADIUS

1-S DIA. UNC TAPPED HOLE

T-DEEP

TABLE 4 Dimensions Inches (mm)

Taper
Conversion
Bushing
Kit

(TCB)
Kit
Part
No.

A
0.010
( 0.25)

B
0.030
( 0.75)

TCB5107J1.438

0766041

4.780
(121.41)

5.000
(127.00)

2.625 (66.68)
2.414 (61.32)

TCB5115J1.938

0766042

5.330
(135.38)

5.500
(139.70)

TCB5203J2.188

0766043

5.310
(134.87)

TCB5207J2.438

0766044

TCB5215J2.938

DA

DB
+0.000, - 0.003
(+0.00, - 0.08)

Keyway

Retaining Ring
Groove
F

Mfg
No.

Max
O.D.

L
Min

T
Min

Weld/Integral
Flange
U

1.4375

1.750
(44.45)

1.295
1.287

0.056 Spir O Lox

3.563
2.00
1.500 0.375 0.1875
0.500-13
0.060 RSN-137
(90.50)
(50.8)

...

...

2.452 (62.28)
2.226 (56.54

1.9375

2.375
(60.33)

1.735
1.725

0.068 Spir O Lox

4.000
2.00
2.000 0.500 0.2500
0.500-13
0.072 RST-181
(101.60)
(50.8)

...

...

5.625
(142.88)

2.346 (59.59)
2.099 (53.31)

2.1875

2.625
(66.68)

1.952
1.940

0.086 Spir O Lox

4.625
2.00
2.250 0.500 0.2500
0.625-11
0.091 RSN-206
(117.48)
(50.8)

...

...

5.890
(149.61)

6.250
(158.75)

2.548 (64.72)
2.260 (57.40)

2.4375

3.000
(76.20)

2.290
2.278

0.056 Spir O Lox

5.625
2.00
2.500 0.625 0.3125
0.625-11
0.060 RS-236
(142.88)
(50.8)

...

...

0766045

6.860
(174.24)

7.125
(180.98)

2.475 (62.87)
2.188 (55.58)

2.9375

3.500
(88.90)

2.728
2.716

0.056 Spir O Lox

5.875
2.50
3.062 0.750 0.3750
0.875-9
0.060 RS-281
(149.22)
(63.5)

...

...

TCB5307J3.438

0766046

6.530
(165.86)

6.860
(174.24)

3.527 (89.59)
3.235 (82.17)

3.4375

3.500
(88.90)

3.172
3.160

0.103 Spir O Lox

6.750
2.50 0.375 4.250
3.625 0.875 0.4375
1.000-8
0.108 RSN-334
(171.45)
(63.5) (9.52) (107.95)

TCB5315J3.438

0785785

7.030
(178.56)

8.500
(215.90)

3.560 (90.42)
3.266 (82.96)

3.4375

3.500
(88.90)

3.263
3.251

0.103 Spir O Lox

0.108 RSN-343

...

0.875 0.4375

8.250
2.50 0.375 4.250
1.000-8
(209.55)
(63.5) (9.52) (107.95)

cc Kit consists of: Bushing, thrust plate, fastener, key, retaining ring, and hardware.
The range of C dimension is the variation which may occur due to axial compression and manufacturing tolerances.
Shaft diameter tolerances are per AGMA as follows: to 1.50 = +.000, -.004; over 1.50 to & including 2.50 = +.000, -.005; over 2.50 to & including 4.00
= +.000, - .006.
zz If a lip type seal is used, a 32rms finish is recommended.
44 Smalley retaining rings may be used instead of Spir O Lox by substituting WS for RS, WST for RST or WSM for RSN.
ww 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.
yy Maximum for use with packing gland seal.

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix L Falk Quadrive Shaft Mounted Drives Model A

(Page 48 of 52)

Sizes 5107-5315

OSHA V-Belt Guard Installation for Drives without Shaft Fan

WARNING: Consult applicable local and national safety
codes for proper guarding of rotating members.

WARNING: Lock out power source and remove all external

loads from drive before servicing drive or accessories.

1. ASSEMBLE MOTOR MOUNT AND MOTOR TO DRIVE AS

INSTRUCTED IN APPENDIX D

4. ASSEMBLE THREADED RODS TO BACKPLATE & MOUNT

SLOT COVER(S) AS REQUIRED

ALLOW FOR
BELT TAKE UP
ALLOW FOR BELT
INSTALLATION

2. ASSEMBLE BELT GUARD BRACKETS TO MOTOR MOUNT

5. MOUNT BELT DRIVE AS INSTRUCTED IN APPENDIX D

GUARD
MOUNTING
BRACKETS

MEDIUM CENTER
POSITION
SHORT & LONG
CENTER POSITION

3. ASSEMBLE BACKPLATE TO BRACKETS

GUARD
BACKPLATE

6. MOUNT COVER AND APPLY WARNING LABEL

LOCKNUT
& FLAT
WASHER

WARNING

CH_930001

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix L

Sizes 5107-5315

(Page 49 of 52)

OSHA V-Belt Guard Installation for Drives with Shaft Fan

WARNING: Consult applicable local and national safety
codes for proper guarding of rotating members.

WARNING: Lock out power source and remove all external

loads from drive before servicing drive or accessories.

1. ASSEMBLE MOTOR MOUNT AND MOTOR TO DRIVE AS

INSTRUCTED IN APPENDIX D

4. ASSEMBLE THREADED RODS TO BACKPLATE & MOUNT

SLOT COVER(S) AS REQUIRED

ALLOW FOR
BELT TAKE UP
ALLOW FOR BELT
INSTALLATION

2. ASSEMBLE GUARD MOUNTING BRACKET & ADAPTER

5. MOUNT BELT DRIVE AS INSTRUCTED IN APPENDIX D

GUARD
BACKPLATE

GUARD
MOUNTING
BRACKET

ADAPTER

3. ASSEMBLE BACKPLATE TO BRACKET & FAN

6. MOUNT COVER AND APPLY WARNING LABEL

LOCKNUT
& FLAT
WASHER

GUARD
BACKPLATE

WARNING

CH_930001

SLOTS

LOCKNUT

HEXNUT

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix M Falk Quadrive Shaft Mounted Drives Model A

(Page 50 of 52)

Sizes 5107-5315

Electric Fan Installation

INTRODUCTION

ASSEMBLY INSTRUCTIONS

The following instructions apply to the installation of electric

fans. Refer to Figure 1 for fan mounting location.

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.
1. Remove V-belt guard assembly.
2. Insert four 1.25 (32 mm) long cap screws through fan
mounting holes in shroud with threaded portion of cap
screw away from drive. Secure cap screws to shroud
with flat washers and hex nut. See Figure 2.
3. Mount shroud to drive using spacers and hardware.
See Figure 1.

Figure 1
MOTOR MOUNT
(SHOWN FOR REFERENCE)

SPACER
.32 LONG
CAP SCREW
.625 x 1.25
LOCK WASHER
V-BELT GUARD BRACKET
(SHOWN FOR REFERENCE)

SPACER
1.45" LONG (4307)
0.62" LONG (4315)
CAP SCREW
.625 x 2.50 (4307)
.625 x 1.50 (4315)
LOCK WASHER

Figure 2
SHROUD

CAP SCREW
.25" x 1.25"
HEX NUT

SHROUD

(2) FLAT WASHERS

LOCKNUT
ELECTRIC FAN

ELECTRIC FAN PANEL

4. Assemble V-belt guard bracket.

5. Position the electric fan panel on the remaining
threaded portion of the cap screws and secure it to the
shroud with four locknuts. See Figure 2.
6. Remove the condensation plug from bottom of the fan.
7. Finish installing V-belt guard assembly per installation
instruction in Appendix L.
8. Connect electric fan to power source per local and
national electrical codes.

378-200 (PN-2128394)
May 2015
Supersedes 01-15

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com

Falk Quadrive Shaft Mounted Drives Model A Appendix N

Sizes 5215-5315

(Page 51 of 52)

Reliability Package
INTRODUCTION

LOCATION #2
(ELBOW SUBASSEMBLY)

The Quadrive Reliability Package shown in Figure 1

includes an enhanced desiccant and particulate filter, antifoam block, oil level sight glass and oil sampling port. The
Reliability Package will be supplied in two subassemblies,
a prebent hydraulic tube and an AirMax Plus breather that
will need to be assembled by the customer.
AIRMAX PLUS
BREATHER

LOCATION #3
(OIL FILL)

OIL LEVEL
SIGHT GLASS

LOCATION #1
(SIGHT GLASS
SUBASSEMBLY)

Figure 2 Pipe Plug Locations

ANTI-FOAM
BLOCK

OIL SAMPLING
PORT

Figure 1 Reliability Package

The Quadrive reliability kit part numbers and

corresponding drive sizes are provided in Table 1.

TABLE 1 Kit Part Numbers for Quadrive

Reliability Package
Drive Size
5215J
5307J
5315J

2. Sight Glass Subassembly Prepare the sight glass

subassembly for installation by applying Loctite joint
compound #1534294 to the male threads as shown in
Figure 3. Install the sight glass subassembly into the
Quadrive housing at location #1 as shown in Figure 2.
The galvanized pipe nipple shown in Figure 3 should
be used to thread the subassembly hand tight. Using
a pipe wrench, turn the pipe nipple an additional 2-3
turns so that it is oil tight. The sight glass should be in
a vertical position when completed as shown in Figure 1.

CAUTION: Do not use the sight glass to thread the
assembly into the housing.

Kit Part Number

7708104
7708105
7708105

PIPE WRENCH

INSTALLATION INSTRUCTIONS
When removing components from the shipping package,
use caution to avoid damaging the oil sight glass.
The sight glass and elbow subassemblies have been
pressure tested in the factory. It will be the installers
responsibility to ensure that the installed fittings are
oil tight. The Reliability Package can be assembled by
following the steps outlined below:
1. Pipe Plugs Remove the two (2) 1.25 NPT pipe
plugs from locations #1 & #2 of the gearbox as shown
in Figure 2.

PIPE NIPPLE

Figure 3 Sight Glass Subassembly

Rexnord (PN-2128394) 378-200

3001 W. Canal St., Milwaukee, WI 53208-4200 USA
May 2015
Telephone: 414-342-3131Fax: 414-937-4359 www.rexnord.com
Supersedes 01-15

Appendix N Falk Quadrive Shaft Mounted Drives Model A

(Page 52 of 52)

Sizes 5215-5315

3. Elbow Subassembly Prepare the elbow

subassembly for installation by applying Loctite joint
compound #1534294 to the male threads as shown
in Figure 4. Install the elbow subassembly into the
Quadrive housing at location #2 as shown in Figure 2.
The galvanized elbow should be used to thread the
subassembly hand tight. Using a pipe wrench, turn
the galvanized elbow an additional 2-3 turns so that it
is oil tight. The elbow should be parallel to the output
shaft when finished as shown in Figure 1.
APPLY LOCTITE
JOINT COMPOUND
#1534294

Figure 4 Elbow subassembly

4. AirMax Plus Prepare the AirMax breather for

installation by removing the two smaller red plastic
plugs from the bottom air vents located 180F apart.
Also, remove the large red plastic plug from the
breather mounting threads. Thread the breather into
the pipe tee of the Reliability Package as shown in
Figure 1. Hand-tighten only to seal o-ring against pipe
tee. For detailed breather installation and maintenance
instructions, refer to the literature included with the
AirMax Plus breather (GR3-002).
5. Lifting The drive can be lifted by using either a
sling with a longer housing flange fastener or a sling
wrapped around the seal housing and input shaft. Lift
and mount the drive by following the drive installation
and lifting instructions provided in Section 1 (page 7)
of this Owners Manual.
CAUTION: To prevent damage to the hydraulic tubing,
it should NOT be installed until after the drive has been
lifted and mounted into position. Prevent debris from
entering the drive by covering the Lenz fittings of the
subassemblies, until the hydraulic tubing can be installed.
6. Hydraulic Tubing Install the hydraulic tubing by
following the steps outlined below:
1. Remove the nut and tapered split ring from the two
Lenz fittings.
2. Slide the nut and the tapered split ring onto the ends
of the hydraulic tubing. The large end of the tapered
ring should face the fitting.
3. Apply oil to the O-ring.
4. Insert the ends of the hydraulic tubing simultaneously
into the appropriate Lenz fittings.Continue to push the
tubing into the Lenz fittings until the tube ends are
past each o-ring for proper sealing.
NOTE: The hydraulic tubing may have to be bent
slightly to install it properly into the Lenz fittings thus
ensuring the tubing extends past the o-rings in the
fittings.
5. Once the hydraulic tube is positioned properly, slide
the tapered spit rings up to the Lenz fittings.
6. Tighten the nut hand tight. Then with a wrench
tighten one turn or until the rear of the tapered ring
is flush with the nut.
7. Oil Fill Remove the oil fill pipe plug from location
#3 as shown in Figure 2. Using a funnel with a flexible
spout, fill the gearbox with an approved lubricant (refer
to Page 23 for Lubrication Recommendations; DO
NOT USE GMAX 6000 or other types of polyalkylene

378-200 (PN-2128394)
May 2015
Supersedes 01-15

glycol (PAG) lubricants which are not compatible with

the polycarbonate sight glass). Once the oil level
reaches the bottom of the fill hole, wait a minimum of 5
minutes for the oil to reach the oil level sight glass. Add
additional oil to the gearbox and repeat the process
until the oil level in the gearbox and sight glass are
constant and the excess runs out. It is recommended
to mark the sight glass with this final oil level.
The oil level sight glass is intended to be used when
the gearbox is not running; in the static condition.
Therefore, the sight glass contains a label that
indicates a static oil level. (oil levels tend to fluctuate
based on oil churning and are dependent on speed
and direction of rotation; for continuous direction, and
continuous speed applications it is recommended that
the oil level sight glass be marked once steady state
operating conditions have been reached).
Prepare the oil fill pipe plug for installation by applying
Loctite joint compound #1534294 to the threads.
Reinstall the elbow subassembly into the Quadrive
housing at location #3 as shown in Figure 2.

MAINTENANCE INSTRUCTIONS
AirMax Breather Falk AirMax Plus breathers have visual
indication when they need to be changed. As the breather
functions, the silica gel material changes color from blue
to pink as it absorbs moisture. When all the material has
turned pink in color, it is time to replace the breather.
Breather life is dependent on operating conditions
and ambient conditions (humidity). Breather should be
changed every twelve (12) months regardless of color
Oil Sampling The oil sampling port that is
included allows users to easily draw oil samples for
lubrication analysis. Refer to the Oil Analysis Report
section in Appendix A of this document for detailed
recommendations on oil content. The oil sample port has
a screw on cover that needs to be unscrewed in order to
access the valve to the sampling port. The valve can then
be actuated by screwing on the threaded oil sample port
adapter included in our Oil Sample Kit (sold separately;
see Table 2). The sampling bottle is composed of PET
(polyethylene terephthalate) which is compatible with
most industrial lubricants; however, user should confirm
compatibility prior to use. It should be noted that the
cleanliness of the bottle can greatly affect the results of an
oil sample analysis; therefore user is cautioned to use care
to avoid contamination of the sample.
The oil sample should be taken shortly after the unit has
been shut down to ensure the oil is properly mixed. It is
important to initially purge some oil from the oil sampling
port and discard this purge, prior to collecting the sample.
Be sure to check the oil level in the drive after the sample
has been collected (additional oil may need to be added to
ensure proper level).

TABLE 2 Sample Port Adapter, Sampling

Kit and Breather for use by
Maintenance Professionals
Part Description
Oil Sampling Kit (includes oil sample
port adapter, case of 12 sample bottles,
vacuum pump, 20' of tubing and labels)
AirMax Plus HG-1 Breather

Part Number
10097025
10097978

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200 USA
Telephone: 414-342-3131Fax: 414-937-4359www.rexnord.com